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FIELD OF THE INVENTION
This application is a continuation of U.S. patent application Ser. No. 12/639,247 filed Dec. 16, 2009, itself a continuation of U.S. patent application Ser. No. 11/217,688, filed Sep. 2, 2005, which is a continuation in part of U.S. patent application Ser. No. 10/430,298, filed on May 7, 2003 (now U.S. Pat. No. 6,973,756), all of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
This invention relates to a connector for securing veneer to back-up walls.
BACKGROUND OF THE INVENTION
Many construction techniques have been developed for commercial buildings utilizing a back-up wall and a set of thin walled veneer panels that are supported on the back-up wall. Typically, there is a cavity between the veneer panels and the back-up wall to allow for the insertion of insulation and other materials. The veneer panels are connected to the back up wall using any of several different styles of connectors that are currently available. In addition to supporting the veneer panels, these connectors typically withstand various other loads, such as shear and wind loads.
Typically prior art connectors are relatively expensive to manufacture, and offer relatively poor load-bearing capacity for their weight and cost. One such prior art connector consists of an L-shaped member, and a veneer connector plate. The vertical portion of the L-shaped member is mounted to the back-up wall, and the horizontal portion extends outwardly therefrom. The horizontal portion typically includes slotted holes therethrough, for the mounting of the veneer connector plate thereon. The veneer connector plate extends outwards and supports at its outwardmost edge, a portion of a veneer panel.
For several reasons, these connectors are typically relatively expensive, and can add to the overall cost of erecting a building. One reason for their cost is that, to support the required loads during use, such connectors are typically required to be made from relatively thick materials. For example, for some applications, the L-shaped member is made from angle having a ⅜″ wall thickness. Furthermore, many building codes require such connectors to be made from stainless steel, to resist corrosion and subsequent weakening or failure. Because of this materials requirement, the cost of the L-shaped member is increased substantially.
Furthermore, in order to cut ⅜″ thick angle when making the L-shaped member, a sophisticated cutting device may be required, such as, for example, a plasma cutter. Plasma cutters are typically more expensive to operate than other cutting devices, and also, plasma cutter operators are more expensive than other cutting machine operators due to their relatively uncommon expertise.
A further issue driving the cost of prior art connectors is that, typically, they include at least two stainless steel bolts in their assembly, for example, to attach the veneer connector to the L-shaped piece. Stainless steel bolts are relatively expensive and can add significantly to the overall cost of the connector.
Accordingly, there is a need for a connector that is relatively inexpensive to manufacture, for use in supporting veneer panels.
SUMMARY OF THE INVENTION
According to one aspect, a connector for retaining at least one veneer panel on a back up wall is provided. The veneer panel may have a top edge and a bottom edge. The connector comprises a veneer connector and a support member. The support member comprises a mounting flange adapted for securing the support member to the back-up wall, and first and second support member side walls extending outwardly from the mounting flange. The first and second support member side walls define at least one generally horizontal surface when the support member is secured to the back-up wall. The veneer connector is securable to the horizontal surface by a mechanical fastener and is adapted to support a generally horizontal edge of the at least one veneer panel when the support member is secured to the back-up wall and when the veneer connected is supported by the generally horizontal surface. The connector is mountable on the back up wall such that the veneer connector supports one of the top and bottom edges of the at least one veneer panel.
The mounting flange may have an adjustment aperture therethrough. The adjustment aperture may be elongate and may be adapted to adjustably receive a fastener therethrough for mounting the support member to the back-up wall. The adjustment aperture may be generally vertical.
The generally horizontal surface may be provided by an upper surface of the first and second support member side walls.
The connector may further comprise a separate fastener for securing the veneer connector to the generally horizontally extending surface.
The veneer connector may comprise a section that abuts the veneer panel and is adapted to receive fasteners that engage the veneer panel.
According to another aspect, a connector for coupling a veneer panel to a back-up wall is provided. The connector comprises a support member comprising a mounting flange adapted for securing the support member to said back-up wall, and first and second support member side walls extending outwardly from the mounting flange. The first and second support member side walls define at least one generally horizontal slot when the support member is secured to the back-up wall. The connector further comprises a veneer connector configured for non-rotational sliding receipt in the generally horizontal slot and adapted to support a generally horizontal edge of said veneer panel when the veneer connector is received in the generally horizontal slot and when the support member is secured to the back-up wall.
The veneer connector may have a load transfer region for supporting the veneer panel, and the first and second support member side walls may extend outward from the mounting flange sufficiently to support the veneer connector proximate the load transfer region.
The veneer connector may have at least one veneer connector side wall. The veneer connector side wall may be generally vertical and may extend at least along a portion of the veneer connector that is unsupported by the support member.
The veneer connector may have a generally horizontal load transfer region for mounting to a horizontal edge of the veneer panel.
The generally horizontal slot may comprise a generally horizontal lower surface.
The mounting flange may comprise a first mounting flange portion and a second mounting flange portion. Each may have an aperture therethrough for mounting the support member to the back-up wall. At least one of the apertures may be positioned above the slot.
An elongate veneer connector adjustment aperture may be defined in the veneer connector. An elongate support member adjustment aperture may be defined in the support member. The support member adjustment aperture and the veneer connector adjustment aperture may extend generally perpendicularly to each other.
A veneer connector aperture may be defined in the veneer connector. A support member aperture may be defined in the support member. The support member aperture and the veneer connector aperture may be alignable with respect to each other for the pass through of a single mechanical fastener for securing the veneer connector to the support member.
The first and second side walls may be connected to each other by a side wall connecting portion. The first and second side walls may be joined together by a horizontal load support wall. The horizontal load support wall may be positioned at the top of the side walls.
The veneer connector may comprise a section that abuts the veneer panel and is adapted to receive fasteners that engage the veneer panel.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention and to show clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:
FIG. 1 is a perspective view of a system of connectors in accordance with a first embodiment of the present invention, supporting panels of veneer on a back up wall;
FIG. 2 is a magnified plan view of a veneer connector shown in FIG. 1 ;
FIG. 2 a is a plan view of a variant of the veneer connector shown in FIG. 2 ;
FIG. 3 is a perspective view of a portion of the veneer connector shown in FIG. 2 , supporting a panel of veneer;
FIG. 4 is a magnified perspective view of a support member shown in FIG. 1 ;
FIG. 5 is a magnified perspective view of the connector shown in FIG. 1 ;
FIG. 5 a is an end view of the connector shown in FIG. 5 , partially sectioned for greater clarity, with a variant to the fastener shown in FIG. 5 ;
FIG. 6 a is a magnified plan view of the support member shown in FIG. 1 , in a partial state of manufacture;
FIG. 6 b is a perspective view of the support member shown in FIG. 6 a in a further state of manufacture;
FIG. 7 is a magnified perspective view of an alternative veneer connector to that which is shown in FIG. 1 ;
FIG. 8 is a perspective view of a variant of the support member shown in FIG. 4 ;
FIG. 8 a is an end view the support member variant shown in FIG. 8 , supporting a veneer panel;
FIG. 9 is an end view of another variant of the support member shown in FIG. 4 ;
FIG. 10 is an end view of yet another variant of the support member shown in FIG. 4 ;
FIG. 11 is a plan view of a work piece that is in a partial state of manufacture, which can be made into either of the support members shown in FIGS. 9 and 10 ;
FIGS. 12 a and 12 b are perspective views of the work piece shown in FIG. 11 , in a further state of manufacture;
FIG. 13 is a plan view of a system, made up of the connectors shown in FIGS. 9 and 10 , supporting veneer panels to a back-up wall;
FIG. 14 is a top view of a variant of the support member shown in FIG. 4 ;
FIG. 15 is an front view of another variant of the support member shown in FIG. 4 ;
FIG. 16 is a perspective view of a connector in accordance with another embodiment of the present invention;
FIG. 17 is a front view of the connector shown is FIG. 16 ;
FIG. 18 is a perspective view of another variant of the support member shown in FIG. 4 ; and
FIG. 19 is a perspective view of another variant of the support member shown in FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
Reference is made to FIG. 1 , which shows a system of connectors 10 in accordance with a preferred embodiment of the present invention. Each connector 10 includes a veneer connector 12 for connecting with a veneer panel 14 , and a support member 16 adapted for receiving the veneer connector 12 and for securement to a back-up wall 18 . The connectors 10 may be made of any suitable material, such as 10 or 11 gauge stainless steel. The connectors 10 are preferably free of welds and formed from a single sheet of metal manufactured into the desired shape. The veneer panel 14 is may be a natural stone material, such as marble or granite. The veneer panel 14 may be a thin-walled panel, which is typically known as a thin masonry veneer panel, which many building codes require to be individually supported (i.e., each panel must be supported individually). It will be noted that the mortar that would typically exist between adjacent veneer panels 14 has been removed from the Figures for greater clarity.
The back-up wall 18 may be of form-poured concrete construction. Alternatively, the back-up wall 18 may be constructed of any suitable material, such as, for example, metallic studs, or block masonry. The veneer panels 14 may be spaced from the back-up wall 18 to provide a cavity 20 therebetween. Optionally, an insulation material 24 and a vapor barrier 26 may be installed in the cavity 20 .
Reference is made to FIG. 2 , which shows the veneer connector 12 in plan view. The veneer connector 12 may have a generally rectangular shape and has a first edge 28 and a second edge 30 . An adjustment aperture 32 may be positioned adjacent the first edge 28 . Referring to FIG. 5 , the adjustment aperture 32 is used to receive a fastener 65 to join the veneer connector 12 to the support member 16 . Referring to FIG. 2 , the adjustment aperture 32 may be generally elongate to permit adjustment of the position of the veneer connector 12 within the support member 16 , as will be discussed further below.
The veneer connector 12 includes a plurality of veneer connection apertures 34 , which may be positioned proximate the second edge 30 . The veneer connector 12 may include any suitable number of veneer connection apertures 34 , such as, for example, three apertures 34 , as shown in FIG. 2 . Referring to FIG. 3 , the veneer connection apertures 34 permit the pass-through of fastening ties 36 that extend from the edge of the veneer panel 14 . The veneer connection apertures 34 may be generally circular, and may be sized to permit easy pass-through of the fastening ties 36 , but are not required to be so large as to facilitate substantial adjustment of the veneer 14 relative to the veneer connector 12 .
The veneer connection apertures 34 are positioned proximate the second edge 30 of the veneer connector 12 to prevent the unwanted protrusion of the second edge 30 past the outer face of the veneer 14 . Thus, the second edge 30 can be buried in the mortar between vertically adjacent panels of veneer 14 .
Referring to FIG. 2 a , an alternative veneer connector 12 ′ is shown, which has a plurality of veneer connection apertures 34 ′ which are elongate to provide further adjustability of the veneer connector 12 with respect to the fastening ties 36 .
Referring to FIG. 3 , a securing means 40 prevents veneer 14 from disengaging from veneer connector 12 . Securing means 40 may be any suitable means, such as, for example, a mechanical fastener or a weld.
The veneer connector 12 supports the veneer panel 14 ( FIG. 1 ) during use generally in the region of the veneer connection apertures 34 . The load imparted to the veneer connector 12 from the weight of the veneer panel 14 is shown at F.
Reference is made to FIG. 4 , which shows the support member 16 in more detail. The support member 16 includes a mounting flange 42 and a support portion 44 . The mounting flange 42 is adapted for mounting the support member 16 to the back-up wall 18 ( FIG. 1 ). As shown, the mounting flange 42 is formed by a first mounting flange and a second mounting flange 48 (shown in FIG. 4 )
The mounting flange 42 has an adjustment aperture 50 therethrough, which is adapted to receive a fastener 52 , for fastening the support member 16 to the back-up wall 18 ( FIG. 1 ). The adjustment aperture 50 may be generally elongate, as shown in FIG. 4 , to permit adjustment of the support member 16 in the vertical direction. Such vertical adjustment capability facilitates aligning the support members 16 in a row on the back-up wall 18 ( FIG. 1 ).
The mounting flange 42 also includes a securing aperture 54 therethrough, may be positioned on the second mounting flange 48 , generally opposite the adjustment aperture 50 . The securing aperture 54 is adapted for receiving a fastener 56 therethrough to further retain the support member 16 on the back-up wall 18 ( FIG. 1 ), and to fix the position of the support member 16 therewith. Once the desired adjustment to the position of the support member 16 has been made using the fastener 52 and the adjustment aperture 50 , the fastener 56 may be passed through the aperture 54 and into the back up wall 18 ( FIG. 1 ), to fix the position of the support member 16 .
Reference is made to FIG. 5 , which shows the support portion 44 of the support member 16 more clearly. The support portion 44 extends from the mounting flange 42 , and specifically, extends from the first mounting flange 46 and the second mounting flange 48 , in a generally vertical plane denoted by the axes (y) and (z), and joins the first mounting flange 46 and second mounting flange 48 along two generally vertical lines which extend generally in the vertical (y) direction. By extending in a generally vertical plane, the support portion 44 is provided with a generally greater resistance to vertical bending forces, which result from the load F, that arise when the connector 10 supports a veneer panel 14 ( FIG. 1 ). In other words, the configuration of the support portion 44 provides the support member 16 with a relatively high moment of inertia in the vertical (y) direction, compared to a typical L-shaped member used in connectors of the prior art.
The support portion 44 is made up of two spaced apart side walls 58 , which are connected at their respective upper ends by a top portion 59 . The top portion 59 and the spaced configuration of the side walls 58 provide resistance to bending loads that can occur in the lateral (x) direction during use. It is expected that any lateral loads will be smaller than the vertical loads incurred from the weight of the veneer 14 ( FIG. 1 ). As a result, the moment of inertia in the lateral (x) direction may be smaller than that in the vertical (y) direction.
The top portion 59 can thus be referred to as a horizontal load support wall 59 . As such it is not necessary for the horizontal load support wall 59 to be positioned at the top of the support member 16 . For example, referring to FIG. 18 , a support member 16 ″″″ is shown, having a horizontal load support wall 132 positioned at the bottom of the two side walls 58 . The support member 16 ″″″ may otherwise be similar to the support member 16 ( FIG. 5 ).
In the embodiments in FIG. 5 , the horizontal load support wall 59 may be made contiguous such that the adjustment aperture 62 is not provided thereon. Instead the opposing end (i.e. the bottom end) of the side walls 58 , which is not covered, may act as the adjustment aperture in the Z direction. Thus, the fastener 65 could mount between the open bottom end of the side walls 58 and the veneer connector 14 . Similarly, in the embodiment in FIG. 18 , horizontal support wall 132 may be made contiguous such that the adjustment aperture 62 is not provided thereon. Instead the opposing end (i.e. the top end) of the side walls 58 , which is not covered, may act as the adjustment aperture in the Z direction. Thus, the fastener 65 (not shown in FIG. 18 ) 65 could mount between the open top end of the side walls 58 and the veneer connector 14 .
Referring to FIG. 5 , the side walls 58 are advantageously joined together by the horizontal load support wall 59 . However, the horizontal load support wall 59 could be omitted, as shown in the embodiment shown FIG. 19 . FIG. 19 shows a support member 16 ″″″ that has a contiguous flange portion 136 . The side walls 138 extend outwards from the flange portion 136 and are joined to the flange portion along generally vertical, spaced apart lines. The side walls 138 could be joined to the flange portion by any suitable means, such as, for example, welding.
Referring to FIG. 5 , the side walls 58 together define a slot portion 60 , which may extend in a generally horizontal (x-z) plane, for receiving and supporting the veneer connector 12 . The slot 60 permits the lateral adjustment of the veneer connector 12 in both the (x) direction and in the z direction. The slot 60 is made sufficiently deep so that the veneer connector 12 is supported along a substantial portion of its length. More particularly, the support portion 44 extends outwards to support the veneer connector 12 proximate its load supporting region, i.e. the region about the apertures 34 where the load F is imparted to the veneer connector 12 by the veneer panel 14 ( FIG. 1 ). This reduces bending stresses on the veneer connector 12 in use when supporting a veneer panel 14 ( FIG. 1 ).
The slot 60 is preferably positioned proximate the upper ends of the side walls 58 , to reduce its impact on the overall moment of inertia of the support portion 44 in the vertical (y) direction. It will be noted that the slot 60 may extend in a plane that is other than horizontal. For example the slot 60 may be angled generally downwards towards its blind end, so that the veneer connector 12 may be retained in place temporarily without the use of a fastener.
An adjustment aperture 62 may be defined in the upper portion 59 , for receiving the fastener 65 therethrough. The fastener 65 may pass through the adjustment aperture 62 and the adjustment aperture 32 in the veneer connector 12 for fixedly retaining the veneer connector 12 in place in the support member 16 . The adjustment aperture 62 may be generally elongate, and may extend in a direction that is generally perpendicular the aperture 32 in the veneer connector 12 . In this way, the apertures 62 and 32 cooperate to provide adjustment for the veneer connector 12 within the slot 60 in both the (x) and (z) directions.
The fastener 65 may be any suitable type of fastener. For example, the fastener 65 may be made up of a stainless steel hex-head bolt 65 a , a washer 65 b , and a nut 65 c . The hex head bolt 65 a extends upwards from under the veneer connector 12 , and is sized so that the side walls 58 capture the head of the bolt 65 a and prevent it from rotating. The threaded end of the bolt 65 a passes up and through the adjustment aperture 62 on the support member 16 . The washer 65 b and nut 65 c are positioned on the exposed end of the bolt 65 a and are tightened to provide a secure connection between the support member 16 and the veneer connector 12 . By having captured the bolt 65 a between the side walls 58 , the task of installing the fastener 65 is facilitated. It will be noted that other types of bolts and other types of fasteners altogether could alternatively be used to connect the support member 16 and the veneer connector 12 .
Reference is made to FIG. 5 a , which shows an alternative washer 65 b ′ that can be used as part of the connector 65 . The washer 65 b ′ may have a generally arcuate shape in side view and extends downwards to capture the side walls 58 of the support member 16 . When the nut 65 c is tightened, the washer 65 b ′ captures and pushes together the side walls 58 , further strengthening their capture of the head of the bolt 65 a . Thus, as the tightening force on the nut 65 c is increased, the capturing force of the side walls 58 on the bolt 65 a is increased, inhibiting the bolt 65 a from rotating as a result of the increased tightening force.
It will be noted that the washer 65 b ′ may have any suitable shape for pushing the side walls 58 together. For example, the washer 65 b ′ may alternatively have an inverted V-shape in side view instead of an arcuate shape. Furthermore, the washer 65 b ′ may have any shape in plan view. For example, the washer 65 b ′ may have a generally circular shape or may alternatively have a rectangular shape so that it better captures the side walls 58 .
Reference is made to FIG. 6 a , which shows a plate 70 which may be used to manufacture the support member 16 ( FIG. 1 ). The plate 70 may be machined with a plurality of apertures and slots which will ultimately form the slot 60 , the aperture 62 and the mounting apertures 50 and 54 . Furthermore, a slot 72 may be machined into the plates 70 , to remove unnecessary material. Once the plate 70 is machined with the appropriate slots and apertures, it may be bent into the shape of the support member 16 by two primary bending operations. The first bending operation bends the two tabs shown at 74 and 76 along a bend line 78 , resulting in the structure 79 shown in FIG. 6 b . The tabs 74 and 76 will ultimately form the mounting flange 42 ( FIG. 4 ). The second bending operation involves folding the plate 70 generally about a fold line. The folding of the plate 70 may be performed on a radiused surface thereby forming the upper portion 59 and the spaced apart side walls 58 . Manufacturing the support member 16 in this way saves cost and manufacturing time while providing a relatively strong resulting structure. It will be noted that the order of operations described is preferable, but may alternatively be rearranged in any suitable way.
By making the support member 16 by appropriately machining and by applying two simple bends to the single, integral plate 70 , the cost of manufacture for the support member 16 are reduced, relative to complex structures of the prior art which are made from multiple pieces which are welded together.
Reference is made to FIG. 1 , which shows the connector 10 in use. In use, a plurality of connectors 10 are used to support a plurality of panels of veneer 14 in a spaced relationship from the back up wall 18 of a structure such as an office tower. The support members 16 are mounted to the back-up wall, and may be spaced from each other in a generally horizontally and vertically extending array. The veneer connectors 12 are positioned in the slots 60 ( FIG. 5 ), and extend therefrom to support the veneer panels 14 . The fastening ties 36 ( FIG. 3 ) extend between vertically adjacent veneer panels 14 and pass through the veneer connection apertures 34 , which retain the panels 14 in place. Furthermore, mortar may be used to close any air gap adjacent veneer panels 14 , and to assist in retaining the panels 14 in place. The vertical load F that results from the weight of the veneer panels 14 is supported by the veneer connectors 12 , and in turn, by the support members 16 . Because the support members 16 have generally high moments of inertia in the vertical direction, they are able to be made with relatively thin gauge material for supporting the load imposed thereon by the veneer panels 14 . It will be noted that while two connectors 10 are shown along the top edge of each veneer panel 14 , any suitable number of connectors 10 may be used to support each veneer panel 14 , depending on the nature of the specific application.
Reference is made to FIG. 7 , which shows a veneer connector 12 ′″, which may be used alternatively to the veneer connector 12 . The veneer connector 12 ″′ may be similar to the veneer connector 12 ( FIG. 2 ), or the veneer connector 12 ′ ( FIG. 2 a ), except that the veneer connector 12 ″′ has a pair of side webs 84 that extend vertically from the side edges of the veneer connector 12 ″′. The side webs 84 may extend generally along substantially the entire length of the veneer connector 12 ″′, except for the portion 86 of the veneer connector 12 ″′ that will be embedded within the gap between adjacent veneer panels 14 ( FIG. 1 ). The side webs 84 provide increased bending resistance to the veneer connector 12 ″′, relative to the veneer connector 12 ( FIG. 2 ), because the side webs 84 generally increase the moment of inertia of the veneer connector 12 ″′.
Reference is made to FIG. 8 , which shows a support member 16 ′ that maybe used as an alternative to the support member 16 ( FIG. 4 ). The support member 16 ′ may be similar to the support member 16 , except that the support member 16 ′ has a slot 90 that positioned closer to the bottom of the support member 16 ′, relative to the slot 60 on the support member 16 ( FIG. 4 ). The slot 90 may otherwise be similar to the slot 60 , and is for receiving and retaining the veneer connector 12 or 12 ″′ ( FIGS. 2 and 2 a ). Referring to FIG. 8 a , the slot 90 is positioned sufficiently low, so that, when the support member 16 ′ is being mounted to the back-up wall 18 proximate the top edge of a veneer panel 14 , the veneer panel 14 does not completely obstruct access to the adjustment aperture and the securing aperture, which are shown at 92 and 94 respectively. Thus, the relatively lower position of the slot 90 facilitates the mounting of the support member 16 ′.
Reference is made to FIG. 9 , which shows a support member 16 ″, which is another alternative to the support member 16 . The support member 16 ″ may be similar to the support member 16 , except that the support member 16 ″ has an adjustment aperture 98 that is elongate along an angle A from the vertical. The adjustment aperture 98 in the embodiment shown in FIG. 9 provides vertical adjustability for the support member 16 ″, in a similar way to the adjustment aperture 50 on the support member 16 ( FIG. 4 ). During vertical adjustment of the support member 16 ″, however, the support member 16 ″ will be shifted by a certain amount horizontally. Preferably, the angle A from the vertical is small, to reduce the horizontal shift that occurs during vertical adjustment of the support member 16 ″. Referring to FIG. 10 , a support member 16 ″′ may also be made which has an adjustment aperture 98 ′ that is a mirror image of the adjustment aperture 98 ( FIG. 9 ).
The support member 16 , as shown in FIG. 5 , has a support portion 44 that extends generally orthogonally outwards from the plane of the mounting flange 42 . It is, however, possible for the support portion 44 to extend outwards from the mounting flange 42 , at an angle such that it is not orthogonal to the mounting flange 42 , as shown in FIG. 14 . In the support member 16 ″″ of the variant shown in FIG. 14 , the side walls 58 of the support portion 44 are supported along generally vertical lines by the mounting flange 42 and thus have a greater resistance to bending under a vertical load imposed thereupon, relative to a typical L-shaped member used in connectors of the prior art. This is true even though the side walls 58 extend outward from the mounting flange 42 at an angle such that they are not orthogonal to the mounting flange 42 .
The side walls 58 of the support portion 44 are shown in FIG. 5 as being supported along vertical lines by the mounting flange 42 . It is not necessary that the support be provide along strictly vertical lines however. Referring to FIG. 15 , the support member 16 ″″ is advantageous relative to L-shaped members of the prior art, even though the side walls 58 are not strictly vertical, and are supported by the mounting flange 42 along lines that are off of vertical by some small amount. Throughout this disclosure and the accompanying claims, the term “generally vertical” is meant to include lines or planes that are strictly vertical and those that are off of vertical within a selected range. While the selected range is preferably small so that the side walls 58 are relatively close to vertical, the range could alternatively be relatively large while still providing a structure that is advantageous relative to L-shaped connectors of the prior art. For example, the range could be as large as 45 degrees off of vertical in each direction.
Reference is made to FIG. 16 , which shows a connector 110 , in accordance with another embodiment of the present invention. The connector 110 includes a support member 16 ″″″ and a veneer connector 12 ″. The support member 16 ″″″ may be similar to the support member 16 ( FIG. 4 ), except that the support member 16 ″″″ supports the veneer connector on its upper surface, shown at 116 , instead of supporting the veneer connector 12 ″ in a slot.
The upper support wall 116 may be made generally planer to assist in supporting and stabilizing the veneer connector 12 ″. The adjustment aperture 62 is provided in the upper support wall 116 . The upper support wall 116 extends between the two spaced apart side walls 118 . The side walls 118 may be similar to the side walls 58 , shown in the support member 16 , shown in FIG. 5 . The upper support wall 116 , thus acts as the horizontal support for the side walls 118 .
The veneer connector 12 ″ rests on top of the upper support wall 116 . The veneer connector 12 ″ has the adjustment aperture 32 which is alignable with the adjustment aperture 62 on the support member 16 ″″″ when the veneer connector is positioned on the upper support wall 116 . The adjustment aperture 32 is generally perpendicular to the adjustment aperture 62 in order to provide adjustability for the veneer connector 12 ″ on the support member 16 ″″″ in two orthogonal directions in a horizontal plane.
Referring to FIG. 17 , the fastener 65 may be provided for joining the veneer connector 12 ″ to the support member 16 ″″″. The fastener 65 may include the hex head bolt 65 a , the washer 65 b , the nut 65 c , and a washer 65 d . The washers 65 b and 65 d are provided to inhibit the pulling through of the bolt 65 a or nut 65 c through the adjustment apertures 62 and 32 during assembly and use of the connector 110 .
Referring to FIG. 16 , the veneer connector 12 ″ includes the veneer connection apertures 34 , positioned proximate its second, or outside, edge 30 . The veneer connection apertures 34 may include a centre aperture 34 a and two outer apertures 34 b . The centre aperture 34 a may be generally circular while the outer apertures 34 b may be slotted to provide flexibility in receiving imperfectly positioned fastening ties 36 ( FIG. 3 ) on the veneer panels 14 ( FIG. 3 ).
The veneer connector 12 ″ may include a pair of side webs 120 , which may be similar to the side webs 84 on the veneer connector 12 ″′, as shown in FIG. 7 .
The veneer connector 12 ″ may include one or more strengthening ribs 121 on its upper surface 122 . The strengthening ribs 121 provide additional vertical bending resistance for the central region of the veneer connector 12 ″ which is spaced relatively far away from the side webs 120 . By positioning the strengthening ribs 121 on the upper surface 122 , they do not create an interference hazard when mounting the veneer connector 12 ″ on the support member 16 ″″″. Like the side webs 120 , the strengthening ribs 121 must be positioned so as not to obstruct the connection of the veneer connector 12 ″ with the veneer panel 14 that will ultimately sit above it (see FIG. 3 ).
Referring to FIG. 11 , the support members 16 ″ and 16 ″′ may be manufactured from a common plate 100 . The common plate 100 may be similar to the plate 70 ( FIG. 6 a ), except that the common plate 100 has an aperture therein, that will ultimately become the adjustment aperture 98 ( FIG. 9 ), or the adjustment aperture 98 ′ ( FIG. 10 ), depending on which way the plate 100 is folded during manufacture. For example, referring to FIG. 12 a , the tabs on the plate 100 , which are shown at 104 may be folded in a first direction, so that the plate 100 will ultimately form the support member 16 ″. However, referring to FIG. 12 b , the tabs 104 may be folded in a second direction that is opposite the first direction, so that the plate 100 ultimately forms the support member 16 ″′.
Reference is made to FIG. 13 , which shows a system of connectors 106 and 108 , which cooperate in pairs to support veneer panels 14 . The connectors 106 and 108 may be similar to the connector 10 ( FIG. 1 ), and include a suitable veneer connector, such as the veneer connector 12 . However, the connectors 106 and 108 include the support members 16 ″ and 16 ″′ respectively, instead of the support member 16 ( FIG. 1 ).
The top and bottom edges of the panel 14 are supported by at least one of each connector 106 and 108 . As a result, the weight of the panel 14 is prevented from dragging the connectors 106 and 108 down the wall 18 , because the adjustment apertures extend in different directions. Thus, because the adjustment apertures 98 and 98 ′ are not parallel to each other when the connectors 106 and 108 are installed on the back-up wall and are in use, the adjustment apertures 98 and 98 ′ cooperate with their respective fasteners and with each other to prevent the connectors 106 and 108 from being dragged down from their supported load.
It will be noted that more than one of each connector 106 and 108 may be used to support an edge of the veneer panel 14 . For example, several of one type of connector, e.g. connector 106 and one or two of the other type of connector, eg. connector 108 , may be used to support an edge of the veneer panel 14 . At least one of each connector 106 and 108 is used, however.
It will be noted that the features shown in the support members disclosed herein may all be combined into a support member in accordance with the present invention in any desired way. For example, a support member may be provided that includes the basic structure of support member 16 , but that has a low-positioned slot, similar to the slot 90 of support member 16 ′ ( FIG. 8 ), and that also has a slanted adjustment aperture, similar to the adjustment aperture 98 or 98 ′ of support members 16 ″ and 16 ″′ ( FIGS. 9 and 10 ). Similarly, the features shown in the veneer connectors disclosed herein may all be combined into a veneer connector in accordance with the present invention in any desired way.
In the embodiments described above, the side walls of the support members have been described and shown as extending outwardly from the mounting flanges along vertical planes. It will be noted that the vertical planes need not be strictly vertical, but are at least generally vertical. In another alternative, the side walls of the support members need not be strictly planar, and may instead be curved or may have further folds, which are preferably generally vertical.
In the embodiments described above, the veneer connector mounts to the support member using a single fastener, such as a bolt. Using a single fastener instead of a plurality of fasteners can provide a significant cost savings in the overall cost of the connector, particularly in jurisdictions which require the use of stainless steel for connectors supporting veneer panels in a cavity wall.
The connectors of the present invention are able to support the same loads as the L-shaped connectors of the prior art, but can be manufactured from thinner material, with fewer fasteners. As a result the connectors of the present invention can be less expensive than the L-shaped connectors of the prior art.
While what has been shown and described herein constitutes the preferred embodiments of the subject invention, it will be understood that various modifications and adaptations of such embodiments can be made without departing from the present invention, the scope of which is defined in the appended claims.
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A connector for coupling a veneer panel to a back-up comprises a support member comprising a mounting flange adapted for securing the support member to said back-up wall, and first and second support member side walls extending outwardly from the mounting flange. The first and second support member side walls define at least one generally horizontal slot when the support member is secured to the back-up wall. The connector further comprises a veneer connector configured for non-rotational sliding receipt in the generally horizontal slot and adapted to support a generally horizontal edge of said veneer panel when the veneer connector is received in the generally horizontal slot and when the support member is secured to the back-up wall.
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RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 09/483,676, filed Jan. 14, 2000 now U.S. Pat. No. 6,468,289. The aforementioned application Ser. No. 09/483,676 is itself a continuation of U.S. patent application Ser. No. 09/323,326 filed Jun. 1, 1999, (now U.S. Pat. No. 6,174,313). The aforementioned application Ser. No. 09/323,326 is a continuation of U.S. patent application Ser. No. 08/834,835 filed Apr. 11, 1997 (now U.S. Pat. No. 5,935,131). The aforementioned application Ser. No. 08/834,835 is itself a divisional of U.S. patent application Ser. No. 08/695,274 filed Aug. 9, 1996, (now U.S. Pat. No. 5,694,951). The aforementioned application Ser. No. 08/695,274 is itself a divisional of U.S. patent application Ser. No. 08/353,494 filed on Dec. 9, 1994, (now U.S. Pat. No. 5,577,517). The aforementioned application Ser. No. 08/353,494 is itself a divisional of U.S. application Ser. No. 08/134,914 filed Oct. 12, 1993, (now U.S. Pat. No. 5,403,317). The aforementioned application Ser. No. 08/134,914 filed Oct. 12, 1993 is itself a divisional of U.S. application Ser. No. 07/545,908 filed Jun. 28, 1990, (now U.S. Pat. No. 5,269,785). The benefit of the earlier filing dates of the aforementioned application Ser. Nos. 09/483,676; 09/323,326; 08/834,835; 08/695,274; 08/353,494; 08/134,914 and 07/545,908 is hereby claimed.
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to the field of tissue removal and tissue grafting. More particularly, the present invention relates to an apparatus and method for the percutaneous cutting and removal of selected portions of tissue from a patient and the possible harvesting and implantation of the tissue portion in the donor.
2. Description of the Prior Art
There are various known methods and apparatus for the cutting and removal of tissue fragments from a human. Each of these, however, suffers from one or more deficiencies.
U.S. Pat. No. 4,832,683 shows an instrument for ultrasonic cutting of bones, with irrigation or suction. However, there is no suction while cutting, no removal of the cut bone or tissue, and no flexibility in the instrument.
U.S. Pat. No. 4,265,231 shows apparatus for drilling a curved hole having a flexible shaft confined in a rigid tubular sheath, but which shows no removal of cut bone or tissue.
U.S. Pat. No. 4,541,423 shows apparatus for drilling a curved hole having a flexible shaft confined in a semi-rigid tubular sheath, but which shows no removal of cut bone or tissue.
U.S. Pat. No. 4,589,414 shows a surgical cutting instrument with a reciprocatory cutting motion, but which has no removal of cut bone or tissue, and no flexibility in the instrument.
U.S. Pat. No. 4,603,694 shows a rotating arthroscopic shaver with suction, but which is not flexible and which has no removal of cut bone or tissue.
U.S. Pat. No. 4,751,922 shows a flexible medullary reamer with a plastic shaft and a guide rod, but which has no suction and no removal of the cut bone or tissue.
U.S. Pat. Nos. 4,798,213, 4,649,918, and 4,142,517 show various apparatus for bone coring.
SUMMARY OF THE INVENTION
The present invention is a percutaneous tissue removal apparatus including a flexible drill shaft and means for transmitting motion to the shaft. A cutting tip is mounted on the shaft to cut tissue fragments from the tissue. The tissue fragments are removed by suction along the flexible drill shaft to a location outside the body while cutting. One or more selected components of the removed tissue fragments may be collected for implantation, preferably into the body of the patient from whom they were removed. Because the drill shaft is flexible, the surgeon can guide the cutting tip into various locations within the tissue from a small (percutaneous) incision. The surgeon can cut around arcs or angles, rather than only being able to go in a straight line, to reach any desired location, and to avoid vital tissue which would otherwise be in the cutting path. For example, when removing unwanted tissue inside a knee joint the drill shaft can deform, and is therefore less likely to damage normal tissue or joint surfaces. None of these functions is possible with a straight line system.
GENERAL DESCRIPTION OF THE INVENTION
The present invention is a percutaneous tissue removal device and method. In the preferred embodiments described below, the apparatus and method are illustrated as used for removal of bone tissue, but such description is for illustrative purposes only. The invention is not limited to the removal of bone tissue and may be used for removal of cartilage, muscle, fetal tissue, etc. It may be used to break up and remove kidney stones, in the gall bladder for a stone or tumor, in the stomach, in the colon to remove a polyp or tumor, etc. It can reach spaces not currently available with the straight line systems currently available.
A percutaneous tissue removal apparatus in accordance with the present invention includes a flexible drill shaft for insertion inside a tissue. A cutting tip is mounted on the drill shaft for cutting the tissue. Either rotating motion or reciprocating motion is transmitted to the drill shaft to move the cutting tip against the tissue to cut tissue fragments from the tissue. While cutting, the tissue fragments are removed by suction to a location outside the body. The drill shaft and cutting tip are small enough to be usable percutaneously. They may also be used for endoscopic, arthroscopic or fiberoptic or open surgery.
Because the drill shaft is flexible, the surgeon can guide the cutting tip into various locations within the tissue from one percutaneous incision. The surgeon can cut around arcs or angles, rather than only being able to go in a straight line, to reach any desired location, and to avoid vital tissue which would otherwise be in the cutting path. The flexible drill shaft also allows the surgeon when working inside a bone, for example, to keep the cutting tip away from the harder outer cortical bone and to remove only the softer inner cancellous bone. None of these features is available with the current straight line cutting devices.
The drill shaft may be made of metal, of polymeric material to reduce friction, or of a composite material. Extensive use of polymers in the drill shaft, its housing if provided, and the cutting tip area reduces friction substantially, thus requiring less energy and generating less heat within the tissue. The drill shaft is drivable by hand (for improved feel) or by motor, at variable speeds based on the need for the tissue removed.
To provide for the collection of the tissue fragments to be harvested, the removal apparatus has an axially extending suction passage along the drill shaft through which the tissue fragments are removed. The suction passage has a smooth lining to keep the tissue fragments or graft material contained and to reduce friction of the harvested tissue fragments. This lining may be the inside diameter of the flexible drill shaft itself, or may be a separate liner sleeve which can be removed and disposed of when it becomes unsanitary or clogged, without having to remove the drill shaft and cutting tip. Alternatively, if a separate guide sleeve or guide rod is used the suction passage may be formed between the drill shaft and the guide sleeve or guide rod. In such a case, the drill shaft may be solid rather than hollow.
The cutting tip is made of a material which is harder than the material to be cut. The cutting tip may be slightly larger in diameter than the drill shaft. The cutting tip may be made of a polymeric material or a composite material. Alternatively, the cutting tip may be made of a ceramic material. The cutting tip is separable from the drill shaft, and several different cutting tips may be provided in varying hardnesses, so that the surgeon can selectively remove various portions of tissue as desired.
By virtue of its flexibility, the flexible drill shaft, when removing bone tissue, may stay within the cortical confines of the bone. Alternatively, it may work with a guide device to control the location of the cutting tip within the bone. The guide means may be a guide rod extending within the flexible drill shaft, or a hollow guide sleeve outside the flexible drill shaft. The guide rod or guide sleeve may be rigid in a particular shape, to fit a particular application; or it may be bendable into a particular shape which it will hold; or it may be selectively rigidifiable into a particular shape in situ. The guide means may include structure for positioning the tip of the flexible drill shaft. The guide means may also be inserted into a separate flexible tube system to guide it to a specific location, then removed, allowing the flexible drill to be inserted.
Fluid may be injected through the flexible drill shaft to a location adjacent the cutting tip to increase the efficiency of the tissue removal and to limit thermal necrosis. Alternatively, a fluid injection passage may extend axially along the flexible drill shaft, the drill shaft. Alternatively, fluid may be injected through the suction passage, alternating with the suction. The fluid injection may be constant or it may be pulsatile in nature. If fluid injection is used, centrifuging of the harvested material may be performed.
Means for collecting one or more selected components of the harvested tissue fragments may include a known trap or filter connected to the outlet of the suction passage. Removed tissue may be centrifuged to separate its components. Thus, the tissue fragments are not merely removed from the body and may be harvested for implantation of the fragments, preferably into the body of the patient from whom they were removed. In order to maintain the sterility of the tissue removed, the entire suction apparatus including the suction passage and the trap or filter is sterilized, and, if necessary, is disposable.
With the present invention all work is done by going percutaneously through the skin to a specific tissue area to minimize the damage to skin, muscle, and bone. For example, when removing bone tissue, trauma is limited to a small opening in the hard outer structural cortical bone, limiting postoperative bleeding from the bone which is difficult to stop, because the small operative hole can easily be plugged after the grafting procedure is completed, preventing postoperative bleeding into soft tissue. There is only intraosseous bleeding, so that fewer complications, and less pain, are likely to arise. The operation does not create stress risers which would weaken the bone. Thus, the present invention provides a safe and efficient way to collect and reuse a patient's own tissue.
Human tissue grafting works best using the patient's own tissue as donor material. Therefore, the harvested tissue may be implanted in the donor's own body for grafting. To implant one or more selected components of harvested bone fragments, for example, a cannula is inserted through the skin and muscle to the area of the bone where the graft is to be placed. A drill or curette is then used to remove a portion of the outer cortical bone. A curette or probe is inserted through the cannula to clear out the area where the graft is to be placed, either in open surgery or through X-ray guidance in percutaneous surgery. The harvested tissue fragments may be packed or compressed into a plug of tissue graft material, of a specific shape, with or without blood or fibrin for adhesion. Or, a retaining material such as a biodegradable mesh may be used to hold the graft material together as a unit. The graft material and its retaining material are then inserted at the graft location in the bone. Alternatively, the graft material is inserted and then sealed in place with a mass of formable polymeric material inserted over the graft material to hold the graft together in position.
A method of percutaneous tissue removal in accordance with the present invention includes the steps of placing within a tissue mass a flexible drill shaft having mounted thereon a cutting tip for cutting the tissue; transmitting motion to the drill shaft to move the cutting tip against the tissue to cut tissue fragments from the tissue; and removing the tissue fragments by suction to a location outside the tissue mass while cutting the tissue. The method may further include the step of controlling the location of the cutting tip within the tissue with a guide rod, the step of collecting one or more selected components of the harvested tissue fragments, and/or the step of implanting the fragments into the body of the patient from whom they were removed.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features of the present invention will become apparent to those skilled in the art to which the present invention relates from reading the following specification with reference to the accompanying drawings, in which:
FIG. 1 is a schematic view of a tissue removal system in accordance with the present invention and including a flexible drill;
FIG. 2 is a schematic view of a hand-powered flexible drill for use in the system of FIG. 1;
FIG. 3 is a schematic view of a portion of a hollow flexible drive shaft for the flexible drill;
FIG. 4 is a schematic view similar to FIG. 3 and showing a guide rod inside the hollow flexible drive shaft;
FIG. 5 illustrates a portion of a flexible drill including a hollow flexible inner cutting shaft within a flexible outer sleeve and a suction passage between the two shafts;
FIG. 6 is a view similar to FIG. 5 with a suction passage within the inner shaft;
FIG. 7 illustrates a portion of a flexible drill including a solid flexible inner cutting shaft within a flexible outer sleeve and a suction passage between the two shafts;
FIG. 8 illustrates a portion of a flexible drill including a solid formable inner guide rod within a flexible outer cutting sleeve and a suction passage between;
FIG. 9 illustrates a portion of a flexible drill including a hollow flexible inner cutting shaft within a solid formable outer sleeve and a suction passage between;
FIG. 10 is a view similar to FIG. 9 with a suction passage within the inner shaft;
FIG. 11 illustrates a portion of a flexible drill including a solid flexible inner cutting shaft within a solid formable outer sleeve and a suction passage between;
FIG. 12 illustrates a portion of a flexible drill including a relatively flexible portion between two relatively rigid portions;
FIG. 13 illustrates the use of a liner sleeve in a suction passage;
FIGS. 14A-14G are views illustrating a number of different cutting tips usable with the flexible drill;
FIGS. 15 and 16 are schematic views illustrating the provision of a plurality of separately inflatable bladders as a guide mechanism for a flexible structure and the operation of a guidance system for locating the tip of the flexible structure;
FIGS. 17A and 17B are schematic views illustrating the forming of harvested tissue fragments into a compressed plug suitable for implantation;
FIG. 18 is a schematic view illustrating the implantation of harvested bone fragments using a polymeric mesh as a retainer; and
FIGS. 19A and 19B are schematic views illustrating the implantation of harvested tissue fragments using a formable polymeric sealant as a retainer.
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention is described herein with reference to a percutaneous bone removal and harvesting apparatus and method. It should be understood that the present invention is not limited to the removal of bone tissue, but is useful in the removal of any hard or soft tissue in the body such as excess, unwanted, or tumorous tissue or tissue used for reimplantation or grating.
A percutaneous bone removal apparatus 10 (FIG. 1) in accordance with the present invention includes a flexible drill 12 . The flexible drill 12 has a flexible shaft 14 and a cutting tip 16 at the distal end of the shaft 14 . The proximal end of the flexible shaft 14 is connected by a housing 18 to a motor or other power source 20 to provide rotational motion or reciprocating motion in a manner known in the art. Alternatively, the drill 12 may have an angled drive, such as 90° drive or any angle, with the motor drive connected at an angle to the longitudinal extent of the suction and cutting apparatus.
Control means indicated schematically at 21 may include one or more switches or valves to turn on or off the suction, irrigation, and motor drive control A fluid injection source 22 is connected by a fluid injection line 24 to the housing 18 of the flexible drill 12 . A suction source 26 acts through a trap or filter or strainer 28 and a suction line 30 to provide suction capabilities for the flexible drill 12 .
FIG. 2 illustrates a flexible drill 12 a in which the housing 18 a is connected to a hand controller 20 a . The hand controller 20 a allows the surgeon to operate the flexible drill 12 a by hand, imparting either rotational or reciprocating movement to the flexible shaft 14 a and cutting tip 16 a.
FIG. 3 illustrates a portion of a basic version of a flexible drill having a cutting tip 16 mounted on a flexible drive shaft 31 . The drive shaft 31 has an outer surface 32 and an inner surface 34 defining a longitudinally extending suction passage 36 . The cutting tip 16 has a cutting edge 40 and an opening 38 through which tissue fragments cut by the cutting tip 16 may be aspirated. The tissue fragments are drawn through the suction passage 36 in the flexible drive shaft 31 and thence into the suction line 30 (FIG. 1) for collection in the trap or filter or strainer 28 .
FIG. 4 illustrates the use of a pre-inserted guide rod 42 with a flexible drill of the present invention. The guide rod 42 extends through the suction passage 36 of the flexible drive shaft 31 . The guide rod 42 may be any suitable structure including a K-wire or other known device. The cutting tip 16 may have a centrally located opening in its distal end to allow insertion of the flexible drill over the guide rod 42 . The guide rod 42 is first placed in the body, then the flexible drill is inserted over the guide rod 42 and guided to the location from which tissue is to be harvested.
FIG. 5 illustrates an embodiment of a flexible drill having an outer sleeve 44 circumscribing a flexible drill shaft 41 . The flexible outer sleeve 44 may be formed of a metal or composite material or may be formed of a polymeric material which may be the same as or different from the material of the flexible inner cutting shaft 31 . The outer sleeve 44 is fixed (non-moving) to minimize tissue damage. A suction passage 46 is defined between the outer surface of the flexible inner shaft 31 to which the cutting tip is attached, and the inner surface of the flexible outer sleeve 44 . Alternatively, as shown in FIG. 6, a suction passage 48 may be defined within the flexible inner cutting shaft 50 . In this case, the outer surface of the flexible inner shaft 50 is preferably, as illustrated in FIG. 6, in close proximity to the inner surface of the outer sleeve 44 to increase stability. The use of polymeric materials for both the inner shaft 50 and the outer sleeve 44 provides for reduced friction between the sleeve 44 and the shaft 50 for ease of operation and reduced heat generation.
FIG. 7 illustrates an alternate embodiment of the apparatus of FIG. 5 in which the flexible inner cutting shaft 52 is formed as a solid shaft rather than a hollow shaft. The harvested tissue fragments travel through the suction passage 46 between the inner shaft 52 and the outer sleeve 44 .
FIG. 8 illustrates apparatus similar to FIG. 7 in which a fixed (non-moving) inner shaft 54 is made of a solid, formable, material and the cutting tip is mounted on a flexible rotating outer sleeve 56 . Suction is drawn through a suction passage 58 between the shaft 54 and the sleeve 56 . The inner shaft 54 is made from a semi-rigid material which is bendable to a desired curvature, at the use site, to select the curvature of the hole to be drilled, and which is rigid enough to retain that curvature in use while the drill shaft 56 rotates around it. Such material is disclosed in U.S. Pat. No. 4,541,423, the disclosure of which is incorporated herein by reference.
FIGS. 9, 10 and 11 illustrate embodiments of the flexible drill of the present invention in which a flexible inner cutting shaft, which may be hollow or solid, is disposed within a non-moving formable outer sleeve. The formable outer sleeve 60 is made of a semi-rigid bendable shape retaining material as described above with reference to FIG. 8 . In FIG. 9, a hollow flexible inner cutting shaft 62 is disposed within the outer sleeve 60 and defines therebetween a suction passage 64 . In FIG. 10, a hollow flexible inner cutting shaft 66 is disposed in close proximity to and within the outer sleeve 60 , with a suction passage 68 formed within the flexible inner cutting shaft 66 . In FIG. 11, a solid flexible inner cutting shaft 70 is disposed within the outer sleeve 60 , defining therebetween a suction passage 72 .
FIG. 12 illustrates a portion of a flexible drill shaft 80 in accordance with the present invention in which a pair of relatively rigid drill portions 82 and 84 are joined by a relatively flexible drill portion 86 . The relatively rigid drill portion 82 includes an outer sleeve 88 , an inner shaft 90 , and a suction passage 92 therebetween. The relatively rigid drill portion 84 includes an outer sleeve 94 like the outer sleeve 88 , an inner shaft 96 like the inner shaft 90 , and a suction passage 98 therebetween. The drill portion 86 includes a relatively flexible inner shaft portion 100 disposed within a relatively flexible outer sleeve portion 102 , defining therebetween a suction passage 104 . The relatively flexible inner shaft portion 100 connects the relatively rigid inner shaft portions 90 and 96 . The relatively flexible outer sleeve portion 102 connects the relatively rigid outer sleeve portions 88 and 94 . The suction passage 104 in the relatively flexible drill-shaft portion 86 connects the suction passages 92 and 98 . Either the inner shaft or the outer sleeve of the flexible drill 80 may have a cutting tip mounted thereon. Thus, with a flexible drill shaft made in this manner, it is not necessary that the entire drill shaft be made of flexible materials, but rather “joints” such as are formed by the relatively flexible portion 86 may be placed along the longitudinal extent of a relatively rigid drill shaft as desired.
FIG. 13 illustrates how a disposable single-use liner sleeve 110 may be used in a flexible drill of the present invention. The liner sleeve 110 shown in FIG. 13 is located within an outer sleeve 112 and is shown about a guide rod or guide wire 114 . Suction is drawn through a passage 116 within the liner sleeve 110 . The disposable single-use liner sleeve 110 provides an absolutely sterile environment through which harvested tissue fragments may pass. The inner surface 118 of the liner sleeve 110 is extremely smooth in order to facilitate passage of the harvested tissue fragments therethrough. It should be understood that a liner sleeve like the liner sleeve 110 may be used with any suitable flexible drill shaft configuration in accordance with the present invention, and not merely with the configuration shown in FIG. 13 .
FIGS. 14A-14G illustrate several different cutting tips which may be attached in a known manner to a flexible drill shaft in accordance with the present invention. The technology for the cutting tips is not specific to the present invention, but rather the cutting tips may be designed in accordance with known principles.
The cutting tip 120 (FIGS. 14A-14G) has a cutting edge 122 at least partially defining an opening 123 through which suction is drawn. The cutting tip 124 includes a plurality of cutting edges 126 defining a plurality of suction openings 128 disposed along the outer circumferential portion of the cuffing tip 124 . The cutting tip 130 is similar to the cutting tip 124 but includes cutting edges 126 a and suction openings 128 a which extend to the end of the cutting tip 130 . Furthermore, the cutting tip 130 is blunt rather than sharp, to avoid perforation of tissue, such as bones.
The cutting tip 132 has a spiral cutting edge 134 defining a spiral suction opening 136 . The cutting tip 138 has at least one longitudinally extending cutting edge 140 at least partially defining a longitudinally extending suction opening 142 . The cutting tip 143 is formed as a burr with fluted cutting edges 144 and suction openings 145 , and is especially suited for shaving operations such as removal of bone spurs, etc. The cutting tip 146 has twin cutting edges 147 and 148 and a suction opening 149 . The cutting edges 157 and 148 can be configured with the leading edge to grab the tissue and the trailing edge to cut the tissue.
The configuration of a cutting tip for use in accordance with the present invention is a design choice within the skill of the art. The goals to be met are proper cutting and suction capabilities, controllability and shape so as to avoid unwanted damage to areas of tissue not to be cut. For example, when removing the softer cancellous portion of bone, the cutting tip may be made of a material which is harder than the cancellous material of the bone but softer than the cortical portion of the bone to avoid damage thereto. Metal may be useful, and suitable polymers are also readily available. Ceramic materials and composites are also suitable. Also, the cutting tip may be arranged as a rotating flexible shaft within a fixed flexible outer shaft, with a cutting edge on the rotating shaft to cut tissue off against the fixed edge. In such a case, the apparatus may be advantageously configured with one shaft being metal and the other polymeric, to minimize friction and heat buildup.
FIGS. 15 and 16 illustrate an alternate guidance system for positioning a flexible drill shaft 150 and its associated cutting tip. Disposed within the sleeve 150 is a guidance mechanism 152 including a plurality of inflatable elements spaced serially. The inflatable elements, when inflated, rigidify and become straight, while when in the deflated condition they are soft and flexible and may be curved or bent. Thus, as seen in FIG. 15, both the inflatable elements designated 154 and the inflatable elements 156 are curved. In FIG. 16, the inflatable elements 154 have rigidified and straightened, while the inflatable elements 156 remain in their curved position. The inflatable elements may also be accordion shaped, expanding in length as they are inflated. The mechanism 152 may be augmented with a known cable guidance system.
By selectively and individually controlling the rigidification of any or all of the inflatable elements of the mechanism 152 , the inflatable mechanism 152 and its associated outer sleeve 150 may be selectively formed into almost any desired shape or position. Suitable control and valving apparatus is provided for controlling the inflation of the inflatable elements. Such apparatus may be, when only a few elements are present, a simple mechanical valving apparatus. When more elements are present, or more sophisticated or complex control thereof is desired, a microprocessor may be used to control the inflation of each segment. Separate inflation and deflation lines can be used, or one line can, by alternating valving, serve both functions. In such case, the control signals may be multiplexed down the structure via electric wire, optical fiber, or radio control, for example.
At the distal end of the mechanism 152 is a tip guidance mechanism 160 including a plurality of inflatable members 162 . The inflatable members 162 when in a deflated condition are flexible and relatively straight. When inflated, as shown in FIG. 16, the members 162 assume a preformed shape which may be curved or straight and which is illustrated herein as a curved shape, bending radially outwardly to engage the surface of adjacent tissue 164 and curve the end of the device into an appropriate position. The members 162 may be constructed, using known principles, to assume any desired shape. By controlling the positioning of one or more of the elements 162 , the tip portion 168 of the guidance mechanism 152 may be selectively placed in any position relative to the tissue 164 , thus positioning the end of the sleeve 150 . The air bladder guidance system as described may be used in conjunction with a flexible tube separate from the flexible drill shaft, order to guide the flexible tube to a specific location and position it there, thereafter removing the guidance system and allowing a flexible drill to be inserted.
Means for collecting one or more selected components of the harvested tissue fragments includes a mechanism 28 (FIG. 1) which may be a known trap or filter connected to the outlet of the suction passage 30 . Removed tissue may also be centrifuged if necessary or desired, keeping the components such as bone, cells, and blood and discarding fluid. These components and connections, and their uses, are well known in the art and thus are not described herein in greater detail. The harvested tissue fragments are not merely removed from the body of the patient, but are also collected in the structure 28 and thus harvested or saved for later implantation of the fragments, preferably into the body of the patient from whom they were removed. Such harvesting and implantation are desirable because human tissue grafting works best using the patient's own tissue as donor material.
In preparing the harvested graft material for implantation, the tissue fragments alone are spun or compressed (see FIG. 17B) to form them into the desired shape. When the tissue is harvested, blood and blood clots are often drawn along with the tissue fragments. The blood component fibrin is a sticky clotting component, and can be used to aid in holding the tissue fragments together for implantation. Thus, the blood can be separated from the tissue fragments and then spun to separate the fibrin for use with the tissue fragments. Alternatively, the entire mass of tissue fragments and blood is compressed into a specific shape to form the mass into a specific, appropriate shape for implantation into the body.
The surgeon can also place other substances into the graft material to be implanted, such as other tissue graft material, collagen, antibiotics, or ceramic hydroxyapatite or tricalcium phosphate to aid in bone ingrowth. In such a case, when the blood or fibrin is used also, the graft has the adhesive qualities of the blood or fibrin and the biological properties of the bone (or other) tissue, along with the appropriate medical properties of any other material included.
Harvested tissue fragments before implantation are preferably packed or compressed into a plug of tissue graft material. Alternatively, the tissue fragments may be left in a more loose state, or only certain selected cells, components, or tissue fragments are used. Any suitable means of packing or compressing fragments may be used. FIGS. 17A and 17B illustrate schematically a simple apparatus for doing so. As viewed in FIGS. 17A and 17B, the harvested tissue pieces 170 are placed into a form or mold 172 and then compressed by a movable compressor 174 to form a plug 176 of a desired shape or size. Unwanted fluid drains out through one or more fluid outlets 178 , while the graft, cells, fibrin, and blood clot tissues remain within the form 172 .
Referring to FIG. 18, to implant one or more selected components of the harvested tissue fragments, for example in grafting bone tissue onto a bone, a cannula 180 is inserted through the skin 182 and must be 184 to the area of the bone 186 where the graft is to be placed. A curette or probe is then inserted through the cannula 182 to clear out the area 188 where the graft is to be placed.
The harvested tissue fragments are compacted or compressed into a plug 190 of tissue graft material. A retaining material such as a known biodegradable or other polymeric mesh 192 is then used to hold the graft material 190 together as a unit. The retaining material may also be a sac of biodegradable material used to hold the graft material. The sac can be closed by a clamp or by crimping or heat sealing. The graft material 190 and its retaining material 192 are then inserted into the graft area of the bone. The cannula 180 may then be removed. Alternatively, the tissue graft material may be held in place by a mass of biodegradable or other polymeric material used as a sealant for the opening in the bone 186 . The graft material can be compressed or spun into a specific shape. Thus, if an implant is needed to fit a specific shape of bone defect, the graft material can be formed in the shape needed and packed directly into the bone gap.
Referring to FIGS. 19A and 19B, the bone graft material may also be implanted in the loose condition as described above. The bone graft material 194 , if loose, can be inserted through a funnel 196 and a sleeve 198 located within the cannula 180 , to the area 188 to be grafted. It is then packed in place as desired using a suitable instrument. Next, an injector 200 is used to inject a mass of flowable biodegradable or other polymeric material 202 for use as a sealant to seal the bone graft material 194 in position. The use of a flowable biodegradable material is preferable in that it allows the surgeon to form in situ a custom shaped sealant plug to seal the opening in the tissue graft area, which will eventually resorb as new tissue grows into its place.
The apparatus may include, as noted above, fluid injection means 22 and 24 for injecting fluid through the flexible drill to a location adjacent the cutting tip to aid in cutting and removal of the harvested tissue fragments. For example, in the drill shaft structure illustrated in FIG. 5, fluid may be injected through a fluid injection passage 204 within the flexible inner cutting shaft 31 , while suction is drawn in the opposite direction through the suction passage 46 . Alternatively, the suction may be intermittently discontinued and fluid may be injected through the suction passage, alternating with the suction. The fluid injection may be constant or it may be pulsatile in nature.
The present invention thus provides a method of percutaneous tissue removal which includes the steps of placing adjacent to a tissue mass a flexible drill shaft 14 having mounted thereon a cutting tip 16 for cutting the tissue; transmitting motion to the drill shaft 14 to move the cutting tip 16 against the tissue to cut tissue fragments from the tissue; and removing the tissue fragments by suction to a location outside the tissue mass while cutting the tissue. The method may further include the step of controlling the location of the cutting tip within the tissue with a guide mechanism, the step of collecting one or more selected components of the harvested tissue fragments, and/or the step of implanting the fragments into the body of the patient from whom they were removed.
From the above description of the invention, those skilled in the art will perceive improvements, changes and modifications. Such improvements, changes and modifications within the skill of the art are intended to be covered by the appended claims.
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A tissue removal method utilizes a tool having a shaft with a flexible inner member rotatable about the shaft and an outer member extending along the inner member. The inner and outer members are bent to a desired configuration and the inner member rotates relative to the outer member while maintaining the shaft in the desired configuration under the influence of the rigidity of the outer member during rotation of the inner member. A patient's body tissue is cut with a cutting element connected with the inner member during rotation and the body tissue cut from the patient is moved along a passage within the shaft while the shaft is maintained in the desired configuration.
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FIELD OF THE INVENTION
This invention relates to superconductive materials and, more particularly, to a means for determining the superconductive magnetic properties of a sample. The United States Government has non-exclusive license rights to this invention as a result of partial support by a grant from the National Science Foundation.
BACKGROUND OF THE INVENTION
Since the discovery that certain ceramic materials could be superconducting at temperatures significantly higher than that of liquid helium, the research community has embarked on a wide ranging search for other ceramics having higher critical temperatures (Tc). As of this writing, researchers have found that certain ceramic compositions become superconductive at temperatures in excess of the temperature of liquid nitrogen (77° K.). Almost on a weekly basis, papers are being published disclosing new ceramic materials and compositions which exhibit superconducting properties in the liquid nitrogen regime.
One problem which has received little public notice to date, is that it is difficult to characterize the superconducting properties of these new high Tc materials. On presently used test method involves making electrical contact to a sample and taking measurements of electrical resistance. An obstacle to the application of that method is the high contact resistance that often occurs where the contacts attach to the sample. Efforts have been made to overcome this problem but the preparation of the contacts and the subsequent testing of the superconductor, together, are quite complex. (e.g. see "Method for Making Low-Resistivity Contacts to High Tc Superconductors" by Ekin et al, Applied Physics Letters, Volume 52, Number 4, 25 Jan., 1988).
Others have attempted to determine the qualitative superconducting properties of a material by attempting to float a magnet above the sample. It is known, that when a magnet is bought into proximity with a superconducting sample, its magnetic field induces "super-currents" within the sample. The super-currents then generate their own magnetic field which is repulsive to the field created by the magnet. With the discovery of high Tc superconductors, it has been repeatedly shown that a small magnet can be stably levitated over a superconducting disk. What was surprising from those demonstrations was the finding that a small magnet would float above a superconducting disk at an equilibrium position over the disk's center, stable against lateral displacements. This phenomenon, while interesting, does not provide a quantitative characterization of the material other than simply to say that it is superconducting. There is no indication in such a test as to whether the material exhibits either homogeneous or heterogeneous superconducting properties.
Accordingly, it is an object of this invention to provide a system for determining superconductive properties of a sample which is both simple to operate and sophisticated in its measurement technique.
It is another object of this invention to provide a system for determining superconductive properties of a sample which avoids the necessity for making any connections to the sample.
It is a further object of this invention to provide a system which provides quantitative determinations of the magnetic superconducting properties of a sample.
It is still another object to this invention to provide a system for determining superconductive magnetic properties of a sample which is adapted to determine the homogeneity of the sample's superconducting properties.
SUMMARY OF THE INVENTION
The invention comprises cantilever beam means for suspending magnet means in proximity to a sample while the sample is maintained at a superconducting temperature. The magnet means causes the sample, assuming it is superconductive, to itself generate a magnetic field which interacts with the magnet means in a repulsive manner. Means are provided for measuring the movement of the cantilever beam means when the magnet means is in proximity to the sample, the movement of the cantilever beam means being a measure of the interaction of the sample's magnetic field with the magnetic means. Several types of cantilever beam means are disclosed, one of which is adapted to move in a direction orthogonal to the surface of the sample and another of which is adapted to move parallel to the surface of the sample.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a test system which embodies the invention hereof.
FIG. 2 is a side view of a modification to the test system of FIG. 1 which improves it sensitivity.
FIG. 3 shows a modification of the test system of FIG. 1 wherein the cantilever beam means is mounted so that it moves parallel to the surface of the sample.
FIG. 4 is a block diagram of analog circuitry which operates in conjunction with systems shown in FIGS. 1, 2 and 3.
FIG. 5 is a block diagram of a digital system for operation in conjunction with the measurement system shown in FIGS. 1, 2 and 3.
FIG. 6 is a plot for the magnet means of repulsive force versus vertical distance from the superconductor surface.
FIG. 7 is a plot similar to FIG. 6 where the movement of the magnet means is modified so that it oscillates at certain positions.
FIG. 8 is a plot similar to FIG. 6 indicating the measurement of lateral forces on the magnet means when it is moved laterally across the surface of the sample.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, a sample of a high temperatures superconducting ceramic (HTSC) material 10 is mounted on an aluminum block 12 which is immersed in a bath of liquid nitrogen 14 contained within insulated tub 16. Also mounted on block 12 is a thermocouple 15. A Hall probe 13 is mounted on the surface of sample 10.
A motorized stage 18 is provided with a vertical support column 20 attached thereto. Motorized stage 18 is provided with motor drives that enable it to move in either of the X, Y or Z directions, as the case may be (not shown). Movable stages of this type are available commercially and may be obtained from the Newport Corporation, P.O. Box 8020, 18235 Mt. Baldy Circle, Fountain Valley, Calif. 92728.
A horizontal slot 22 in column 20 supports the proximal end of a cantilever support beam 24. At the distal end of beam 24, a bar magnet 26 is attached as is a reflecting strip 28. In addition, a pair of strain gauges 30 and 32 are respectively mounted on the upper and lower surfaces of beam 24 to provide an indication of the flexure thereof.
The aspect ratio of beam 24 is such that it exhibits an anisotropic flexibility characteristic, i.e., a substantial flexibility in its thickness dimension and a substantial inflexibility in its width dimension. Thus, beam 24 will flex in a vertical direction as shown by arrows 34 and 36 but not orthogonally thereto. A preferable material for beam 24 is a high strength aluminum alloy, or a non-magnetic stainless steel. Magnet 26 is shown as oriented over sample 10 such that that the axis between its north and south poles is parallel to the surface of sample 10. The system will also provide acceptable measurements if the magnetic axis of magnet 10 is oriented perpendicular to the surface of sample 10. Magnet 26 is preferably a rare earth magnet which exhibits a substantial field strength, (i.e., on the order of at least 2000-3000 Gauss or better at the pole faces). Preferably, magnet 26 is of the samarium cobalt rare earth type with its dipole or polar axis parallel to surface of the sample. Other rare earth magnets are also acceptable (e.g. Nd, Bo, Fe based magnets). It should also be noted that magnet 26 could be replaced by an electromagnetic coil.
A typical position sensing system comprising collimated light source 40 and photo-electric position sensor 42 is provided to indicate the position of magnet 26. Position sensor 42 comprises a plurality of photocells which are successively illuminated as beam 44 moves up and down and which thereby provide outputs indicative of the position of magnet 26 (to thereby provide a position indication for cantilever beam 24). It should be understood, that any position sensor is acceptable so long as it provides a direct positional change indication as magnet 26 is moved.
Initially, sample 10 is placed on aluminum block 12 and insulated tub 16 (a cryostat) is filled with liquid nitrogen. When sample 10 reaches an equilibrium temperature where it is expected to exhibit superconducting properties, stage 18 moves magnet 26 into proximity with the surface of sample 10. If sample 10 is superconducting, magnet 26 will induce super-currents therein thereby causing sample 10 to produce a magnetic field which opposes the field produced by magnet 26. This interaction causes magnet 26 and beam 24 to deflect in the direction indicated by arrow 34. The deflection of beam 24 results in strain gauges 30 and 32 providing outputs which are a measure of the magnetic force exerted by sample 10. By combining the strain gauge measurements with a measure of the amount of deflection of light beam 24, a plot can be created which shows the variations of magnetic force as the position of magnet 26 is altered. The output from Hall probe 13, which is an indication of the magnetic field strength at the surface of sample 10, can also be plotted against magnetic force. The output from thermocouple 15 provides an indication of temperature and enables a plot of temperature versus force to be produced. The circuitry for providing these measurements and plots is shown in FIGS. 3 and 4 and will be discussed in greater detail hereinbelow.
A modification of the test system of FIG. 1 which increases its sensitivity is shown in FIG. 2. A taller support column 60 is substituted for column 20 and a folded cantilever beam 62 is substituted for beam 24. Folded beam 62 provides a 3 times more sensitive force indication and a 9 times greater deflection per unit of magnetic force.
The measure of maximum repulsive force provided by strain gauges 30 and 32 provides an indication of the superconducting quality of sample 10. It does not, however, provide an indication of the lateral forces exerted by sample 10. Referring to FIG. 2, beam 24 is removed from slot 22, rotated 90° and inserted into slot 50 so that its main axis of flexibility is now parallel with the surface of sample 10. The position sensing elements of the invention i.e. light source 40, reflector 28 and photoconductor 42 are reoriented so that they are adapted to sense movement in a path parallel to the surface of sample 10.
The interaction between magnet 26 and the fields of force generated by the induced super-currents in sample 10, is then measured by moving column 20 in the Y dimension so that cantilever beam 24 moves magnet 26 across the surface of sample 10. This relative movement allows the interaction between the force fields generated by magnet 26 and sample 10 to be sensed and enables flux pinning to be measured. Flux pinning has the effect of modifying the deflection of beam 24 as it traverses across the surface of sample 10. The variation in deflection of beam 24 is sensed by strain gauges 30 and 32 which, in turn, provide appropriate signals to the measurement circuitry.
This invention can also be used to measure Type I or Type II superconducting behavior. In the Type I regime, the magnetic force is not hysteretic. Thus, by cycling the position of magnet 26, while measuring the magnetic field at the surface of sample 10 with Hall probe 13, one can look for the onset of flux penetration and hysteresis in the outputs from strain gauges 30, 32 as an indication of the transition from Type I to Type II behavior.
Referring now to FIG. 4, an analog system is shown which plots the variations in deflection of beam 24 against the variations in stress in beam 24. The outputs from strain gauges 30 and 32 are fed to a bridge 50 which is adjusted to provide a zero output when cantilever beam 24 and magnet are not under the influence of sample 10's magnetic field (if any). The output from bridge 50 is fed to X, Y plotter 52. When an output from one or the other of strain gauges 30 or 32 predominates, the output from bridge 52 to X, Y plotter 52 is similarly modified. Another input to X, Y plotter 52 comes from photosensor 42. Thus, it can be seen that as the position of magnet 26 is modified with respect to the surface of sample 10, X, Y plotter 52 is provided with signals that enable it to provide a plot of the relationship between the stress in beam 24 and the position of magnet 26.
Referring now to FIG. 5, a digital system is shown which enables automatic control of the X, Y and Z motors which control the position of stage 18. In this instance, each of the inputs from photosensor 42 strain gauges 30 and 32, Hall probe 13 and thermocouple 15 are fed to microprocessor 60. In response, microprocessor 60 provides an output to X, Y plotter 52 or any other appropriate display device which is capable of illustrating the relationships indicated by signals from the strain gauges, Hall probe, thermocouple and the position photosensors. In addition, microprocessor 60 can automatically provide signals which operate the X, Y and Z motors to cause the beam 24 to properly move with respect to the face of sample 10 as the measurements are being taken.
EXPERIMENTAL RESULTS
The measurements system described herein, was constructed and used to measure the magnetic forces between a rare earth magnet and a bulk, cylindrically shaped HTSC sample. Cantilever arm 24 was an aluminum alloy and exhibited at least a 8 to 1 aspect ratio in its width to thickness dimensions. The length of the cantilever arm was 32 cm, its width 0.7 cm, and its thickness 0.085 cm. The test magnet was a samarium cobalt rare earth magnet, 6.49 mm long by 6.37 mm in diameter and weighed 1.7 grams. It dipole axis was kept parallel to the surface of the HTSC superconductor.
The superconductor was Y 1 Ba 2 Cu 3 O x and was processed by the free sintering method. The samples were prepared by a solid state reaction of Y 2 O 3 , CuO, and BaCO 3 . Finely ground powders were calcined for 24 hours in an oxygen atmosphere at 920° C., reground, pressed into pellets, and then free sintered at 950° C. for 12 hours. The density of the sample used was 87% of theoretical density. Its shape was in the form of a cylindrical disc, 18.2 mm in diameter and 5.48 mm thick. The liquid nitrogen was kept level with the HTSC surface.
The test magnet's maximum pole strength was measured at approximately 0.3 Tesla. The field strength normal to the HTSC surface ranged from 0 to 0.075 T.
The results from a series of tests are shown in FIGS. 5-7. Those curves show plots of magnetic force versus distance. The data in FIGS. 5 and 6 are for distances normal to the HTSC surface and those in FIG. 7 are for parallel distances measured from the center of the HTSC disk. The distances shown are measured from the superconductor surface to the bottom surface of the magnet. In each case, the HTSC was first warmed until it went normal and then cooled to the superconducting state before any magnet was brought into proximity.
The repulsion force between the magnet and superconductor was near zero when the magnet was one diameter away as shown in FIG. 5. In this experiment, the magnet was continuously moved toward the superconductor surface and then monotonically moved away using the motorized stage. The data shows a large hysteresis loop. This loop was repeatable when the magnet was recycled through the same movements. The magnetic force equaled the weight of the magnet at both 1.3 mm and 0.5 mm. This suggests that if the magnet were free, there would be two levitated equilibrium positions.
The next experiments involved making small cycles of the distance as shown in FIG. 6. The curves exhibited small hysteresis loops. However, all the small loops were contained in the large hysteresis loop. For very small cycles, the force-distance relationship appeared to approach a reversible behavior which might be a measure of flux pinning. The slope of these small loops is not tangential to the main loop and is also a measure of the magnetic stiffness (flux pinning).
Measurements of the lateral magnetic forces are shown in FIG. 7. In those tests, the superconductor was again brought to its normal state with no magnetic field. The magnet was lowered to a height of 2 mm with its dipole axis parallel to the HTSC surface. Beam 24 was oriented so that it was sensitive to lateral bending and was used to measure the force exerted on the magnet. As shown in FIG. 7, the magnet was moved laterally across the surface from the center to the edge of the superconductor. For the same lateral distance, the lateral force could either act towards or away from the center of the superconductor. Small lateral cycles of motion were also made. As in the cases for the normal force test, the loops created were contained in the major hysteresis loop. The slope of those loops was a measure of the lateral magnetic stiffness (flux pinning).
These results show that a small magnet could be stably levitated on a flat HTSC surface depending on the history of the magnetic flux pattern on the superconductor surface. Once levitated, small magnets will exhibit lateral magnetic stiffness for small excursions. The non-uniqueness of the lateral position of a small levitated magnets above an HTSC disc can be observed. For the force history shown in FIG. 7, there are two lateral equilibrium positions which exhibit zero force. If magnets were initially brought in from the edge of the superconducting disc, then the equilibrium positions would be different as has been indicated by the experiment.
The sensitivity of the measurement system was excellent in that it measured force changes in the 1 to 10 dyne range.
It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives modifications and variances which fall within scope of the appended claims.
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A cantilever beam is employed to place a magnet in proximity to a sample while the sample is maintained at a superconducting temperature. The magnet causes the sample, assuming it is superconductive, to itself generate a magnetic field which interacts with the magnet. Means are provided for measuring the movement of the cantilever beam, such movement being a measure of the interaction of the sample's magnetic field with the magnet. Several types of cantilever beams are disclosed, one of which is adapted to move in a direction orthogonal to the surface of the sample and another of which is adapted to move parallel to the surface of the sample. This enables the obtaining of quantitative measurements of the bulk properties of high temperature superconducting materials.
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BACKGROUND OF THE INVENTION
The present invention relates to the container sealing art and more particularly to an improved high speed and easily adjustable straight line container sealing machine.
Straight line sealing machines for sealing containers have been in use for many years. These machines are generally characterized by having a horizontal moving conveyor which carries filled and unsealed containers successively through a cap feeding device, a cap applicator device, and a cap sealing means which may or may not include vacuum sealing means. Although the known machines have proven capable of providing satisfactory sealing operations, these prior machines have had limited speed capabilities and an inability for being readily and simply adjusted for handling differing container and closure cap sizes and shapes. For example, where changes are made in the products being sealed and where these changes require differing closure cap and container sizes and shapes it has required considerable time and usually expert operators to reset the various portions of the sealing machines for the necessary changes. Attempts to run these prior sealing machines at ever increasing speeds have also resulted in tie-ups and breakage resulting from an inability of the machines to adequately control the container and cap feeds and the sealing operations at these higher speeds. The present sealing machine is an improvement, for example, upon earlier sealing machines of the types shown in U.S. Pat. Nos. 3,274,748 and 3,438,174 dated Sept. 27, 1966 and Apr. 15, 1969 respectively and owned by the assignee of the present invention.
In particular, the new machine of this invention has an improved base which provides independently adjustable supports for the vacuum chamber height as well as the heights and spacing of the container controlling side belts. The power feeds for the sealing heads and side belts and other moving parts are also at least partially contained in the machine base and permit all adjustments without affecting the drive synchronization.
The cap feed is improved for higher speed and is characterized by the use of a driven cap feed wheel and the side belts are adapted for improved container gripping and locating.
Accordingly, an object of the present invention is to provide an improved straight line sealing machine.
Another object of the present invention is to provide a straight line sealing machine for use at significantly increased container sealing speeds.
Another object of the present invention is to provide a straight line sealing machine which is easily adjusted by inexperienced personnel for closure cap and container size changes.
Another object of the present invention is to provide an improved high speed cap feed system for a straight line sealing machine.
Another object of the present invention is to provide an improved side belt container control system for a straight line sealing machine.
Another object of the present invention is to provide an improved sealing chamber and related cap feed chute end for a high speed straight line sealing machine.
Another object of the present invention is to provide a sealing machine structure adapted for adjustment using electric or hydraulic powered adjusting drives.
Another object of the present invention is to provide an easily adjustable side belt system for a straight line container sealing machine.
Other and further objects of the present invention will be apparent upon an understanding of the illustrative embodiments about to be described or will be indicated in the appended claims, and various advantages not referred to herein will occur to one skilled in the art upon employment of the invention in practice.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of the improved sealing machine in accordance with the invention.
FIG. 2 is a top plan view of the sealing machine of FIG. 1.
FIG. 3 is an end elevational view of the sealing machine of FIG. 1.
FIG. 4 is a detailed fragmentary rear elevational view of the sealing chamber and the cap chute end mounting.
FIG. 5 is a detailed fragmentary top plan view illustrating the cap feeding end of the cap chute including the cap feeding star wheel.
FIG. 6 is a vertical sectional view of the cap chute end and star wheel taken along line 6--6 on FIG. 5.
FIG. 7 is a detailed fragmentary vertical sectional view of the exit end of the cap feed chute and the adjacent vacuum chamber.
FIG. 8 is a horizontal sectional of the vacuum chamber taken along line 8--8 of FIG. 7.
FIG. 9 is a fragmentary enlarged top plan view illustrating side chains having a pocket in engagement with a container.
FIG. 10 is a fragmentary enlarged top plan view corresponding to FIG. 9 illustrating a differing embodiment of the side chains.
FIG. 11 is a front elevational view of the sealing machine base.
FIG. 12 is a top plan view of the machine base of FIG. 11.
FIG. 13 is a horizontal sectional view of the machine base taken along line 13--13 on FIG. 11.
FIG. 14 is a detailed front elevational view of the side belt support assembly.
FIG. 15 is a top plan view of the support assembly of FIG. 14.
FIG. 16 is a horizontal sectional view taken along the line 16--16 on FIG. 14.
FIG. 17 is an exploded perspective view of the machine base, the side belt support assembly and the sealing chamber of the sealing machine of FIG. 1.
FIGS. 18 through 21 are vertical sectional views of the sealing machine taken along lines 18 through 21 respectively on FIG. 1.
FIG. 22 is a front elevational view of another embodiment of the sealing machine base with powered adjusting means.
FIG. 23 is a top plan view of the machine base of FIG. 22.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The improved sealing machine will first be described generally with particular reference to FIGS. 1, 2 and 3. The sealing machine 1 carries the filled containers 2 on an endless conveyor 3, successively beneath a cap feeder 4, a cap applicator 5 and a cap sealing head 6. At the cap feeder 4, each moving container 2 draws a closure cap 7 from the lower end of a cap chute 8. The moving container 2 then carries the loosely telescoped cap through the cap applicator 5 which lightly coaxes or turns the cap 7 onto the container 2 in the case of a twist cap or levels the closure cap 7 in the case of a press-on type of closure cap. Thereafter the continuously moving container 2 carries the cap 7 further through a sealing chamber 9 where the sealing head 6 twists or presses the closure cap 7 tightly onto the container 2.
For vacuum sealing, a steam atmosphere is maintained at the lower end of the cap chute 8 and within the sealing chamber 9 in such a manner as to direct steam within the headspace of each container 2 before it is sealed resulting in the formation of a vacuum as the container cools after the sealing operation. An encoding device 10 properly synchronized with the sealed and moving containers 2 encodes or labels the closure of the sealed container. As will be more fully described below, with particular reference to FIGS. 5 and 6, the flow of the caps 7 downwardly through the cap feeding chute 8 is controlled by a rotating star wheel 11 which simultaneously controls feed pressure within the chute 8 and synchronizes the cap movements with container movements to the point of cap pickup just in advance of the cap applicator 5.
Moving side belts 12 engage and grip each of the containers 2 as they pass beneath the sealing chamber 9 to properly space and support the moving containers. The side belt 12 height and width adjustments, as will also be more fully described below, are provided in the base 13 which adjusts these belt positions, independently of the sealing chamber height. The height of the chamber 9 is also independently adjustable by means of a separate height adjustment which will be described below.
THE CAP FEED
The sealing machine 1 of the present invention operates at relatively high sealing speeds so that a means is required for feeding the closure caps 7 at a high and controlled feeding rate to the moving containers 2. The closure caps 7 are bed from a cap feeding hopper (not shown) which continuously feeds properly orientated caps into the top of the feed chute 8. The chute 8 confines and supports the caps as they are projected downwardly until they reach a pressure relieving and feed synchronizing cap feed wheel 11. The feed wheel 11 is driven in synchronism with other driven portions of the sealing machine including the container conveyor 3, the container gripping side belts 12, and the sealing head 6. Thus, each of the pockets 14 (FIGS. 5 and 6) in the rotating feed wheel 11 engage a closure cap 7 and carry it around to a release point 15 in the lower portion of the cap feed chute 8. A cap 7 released from the feed wheel 11 moves by gravity and by the momentum provided by the feed wheel 11 to a separately mounted feed shoe 16 (FIG. 7) at the lower end of the cap feeding chute 8 where the cap 7 is positioned to be engaged by and withdrawn from the feed shoe 16 by a container 2 being carried on the conveyor 3. Resilient detents or other release means 17 temporarily holds each cap within the shoe 16 until the cap 7 is engaged by the top of a moving container 2. A suitable feed shoe 16 and related cap applicator 5 are illustrated in copending U.S. application No. 940,554 filed Sept. 8, 1978 and owned by the assignee of the present invention.
A drive means for the rotating cap feed wheel 11 is illustrated in FIGS. 4, 5 and 6.
The feed wheel 11 is mounted on a suitable drive shaft 18 on bearings 19 which is driven through the intermediation of bevel gears 20, pinions 21, and a universal drive shaft 22 connected to a horizontal drive shaft 23 on the sealing chamber. The drive shaft 23 is coupled to the sealing machine drive system in the machine base 13 as will be described below.
The cap feeding wheel 11 provides important improved machine operating results where the caps 7 are being fed at a high feed rate and thus at a relatively high chute feeding pressure. As best illustrated in FIG. 5, the pockets 14 in the feed wheel 11 successively engage and support the endmost cap 7 in the line of caps being fed into the upper portion of the cap feed chute 8 at a relatively high rate and thus at a high feed pressure. The caps 7 are only released from the upper portion by the rotation of the feed wheel 11 which removes the endmost cap 7 from the line and from the chute feed pressure and then releases it for independent sliding movement down the chute 8 and to the cap release means 17 which releasably holds the caps in the feed shoe 16 until the cap 7 is pulled free by a moving container 2.
THE CLOSURE CAP APPLICATOR
The function of the closure cap applicator 5, which is best illustrated in FIG. 7, is to control the release of each cap 7 from the chute 8 onto the top of a moving container 2 and to thereafter lightly coax or position the cap on the container finish preparatory to the final sealing action at the sealing head 6. A variety of applicators may be used with the sealing machine of this invention including those of the above referred to U.S. patents or a preferred form described and illustrated in the above referred to copending patent application.
Briefly, the cap applicator 5 has means for lightly pressing the closure caps 7 onto the finishes of the moving containers 2 and for leveling them and placing them in position for the final sealing action. In the case of press-on closures this means includes a pressure shoe which lightly presses and levels each cap into position on a moving container. For threaded or lugged caps the applicator 5 includes means for simultaneously leveling each closure cap 7 and for lightly twisting it onto cooperating container lugs or threads. The applicator illustrated in FIG. 7, for example, includes a spring mounted leveling plate 24 positioned in advance of an off-center cap drag shoe 25 which lightly turns each cap onto the threads of a moving container by retarding an off-center portion of the cap.
As each container 2 leaves the cap applicator 5 it has a closure cap lightly or initially positioned at its mouth for the final sealing operation for vacuum sealing. The container head space, which is the space between the product and the closure cap is filled with steam injected from the suitable nozzles 26 in the cap chute and the lower portion of the cap chute support as well as outlets (not shown) in the sealing chamber. A vacuum occurs in the sealed containers 2 when the steam condenses as it cools subsequent to the container sealing operation.
THE SEALING HEAD
After each container 2 is moved beyond the cap applicator 5, it next moves beneath the container sealing head 6 mounted on the sealing chamber 9. The function of the sealing head 6 is to either push press-on closures tightly onto the containers 2 or in the case of lugged or threaded closure caps, to twist them tightly onto the containers 2. A known type of sealing head is illustrated at 6 in FIGS. 1 and 7. This may be, for example, sealing heads of the type described in more detail in the above referred to U.S. patents. Briefly, where the sealing head 6 is employed for lugged or threaded caps, it engages them and twists them into sealing engagement with the containers. The rotating action is obtained by retarding an off-center portion of each cap 7 by a slower moving endless sealing belt 27 while turning an opposite off-center portion of each cap by means of a faster moving sealing belt 28. The sealing belts are mounted on a drive pulleys 29 and 30 and a number of idler pulleys 31. The slower moving sealing belt 27 may be replaced by a stationary drag shoe. The drive means for the drive pulleys is synchronized with the other moving portions of the machine by being coupled to the main drive in the machine base 13 as will be further described. Since the sealing head 6 is mounted on the sealing chamber 9, its height is adjusted as the chamber 9 is moved up and down with a corresponding height adjustment of the applicator 5 and cap chute 8 already described. The support which permits these adjustments without changing the synchronization of the driven portions of the sealing chamber is also an integral portion of the improved machine base 13 which will be described below in greater detail.
CONTAINER SIDE BELTS
In order to provide for a higher speed sealing machine operation, the containers 2 are supported on the moving horizontal conveyor 3 and are held by the side belts 12 positioned above the conveyor 3. The container conveyor 3 comprises a conventional metal or plastic endless link conveyor belt driven by spaced and sprockets coupled to the machine drive and synchronized with the other driven portions of the machine. The side belts 12 each comprise an endless roller chain 30 mounted on sprockets 31 on spaced vertical end shafts 32 and 33. As illustrated in FIG. 9 the side belts 12 comprise the roller chains 30 having container spacing pockets 34 provided by plastic spacers 35 attached to the roller chains 30. The end shafts 32 and 33 are coupled to the main machine drive system by a means which permits adjustment of the side belt 12 heights without changing the side belt synchronization and independently of the height of the sealing chamber 9. The drive means for the side belts together with its synchronizing features will also be described below in the description of the improved machine base and drive means. FIG. 10 illustrates another embodiment of the side chains having smooth and resilient container gripping members 36 fastened to the roller chains 37 for feeding randomly spaced containers.
Means is provided for guiding the roller chains 30 and 37 and for causing the moving side belts 12 to tightly grip the containers 2 particularly as they are moved beneath the cap applicator 5 and the sealing head 6. A preferred embodiment of the side belt guide assembly 38 is illustrated in FIGS. 8 and 18. The inner run of each of the two side belts is positioned by elongated backup bars 39 which slidably mount a series of chain guide pads 40. The pads 40 are formed of long wearing, low friction materials such as fiber reinforced phenolic pads or other low friction plastic materials. The guide pads 41 at the exit ends of the side belts 12 comprise fixedly mounted pads with tapered chain guiding surfaces 42. The pads 40 are slidably mounted on guide pins 43 for movement towards each other and in a container gripping direction under the force of compressed coil springs 44 which urge the pads 40 and the belts 12 inwardly towards the moving containers 2. The outer runs of the side belts 12 are slidably supported on suitably shaped flange members 45.
The heights of the exit end drive sprockets 31 are adjustable, as described below, however, the vertical axes of the drive shafts 33 for the exit sprockets 31 are fixed. The remaining elements of the belt guide assembly 38 move laterally for the belt spacing adjustment on the mounting plates 46 (FIG. 18). The roller chains 30 and 37 are kept under the proper tension during the belt width adjustments by the spring 47 and the link pivot 48 mounting for the idler entrance end sprockets 31. The flange members 45 are mounted on a fixed pivot 49 adjacent the drive sprockets 31 at the exit end and on a pivot 50 at the entrance end which moves with the mounting plates 46.
THE IMPROVED MACHINE DRIVE AND SEALING CHAMBER AND SIDE BELT ADJUSTMENTS
Although it is particularly advantageous to use high capacity container sealing machines with simple adjusting means for changing the machine settings for differing cap and container sizes, prior machines have not had this capacity due to the supposed complexity of such a design. The present sealing machine, however, provides for both a high speed sealing capacity as well as for adjustments which must be made for the particular size of the caps and containers being sealed. The improved machine drive and adjusting means will now be described together with its cooperation with the various operating elements of the sealing machine already described.
The improvement will first be described generally, with particular reference to FIGS. 1, 11, 12 and 17.
As already described, the means for moving the containers through the sealing machine 1 includes a conveyor belt 3 mounted on suitable end sprockets at a fixed height on a support frame 40. The cap feeding and sealing elements including the cap chute 8, the cap pickup 5 and the sealing head 6 are mounted on or in fixed relation to the sealing chamber 9 positioned above the conveyor 3. It is desirable that chamber 9 positioned together with the elements mounted thereon be adjustable vertically permitting a rapid adjustment of the sealing machine for handling containers of differing heights. It is also desirable that this adjustment be made without changing the previously set up synchronization between the several elements such as the cap feeder 4, the sealing head 6, and the coder 10 mounted on the sealing chamber 9.
As will be described in greater detail below, the sealing chamber 9 height adjustment is provided by mounting it on a pair of longitudinally spaced support columns 51. The columns 51 are adjustably mounted on the machine base 13 which includes means for raising and lowering the columns 51 together with the sealing chamber 9 supported thereon.
The machine base 13 also includes significant portions of the machine drive assembly as well as means for supporting and adjusting the spacing and height of the container supporting side belts 12. FIGS. 11, 12 and 17 illustrate the machine base 13 which includes a hollow sealed chamber 52 containing the various adjusting and driving elements and adapted for being filled with a lubricating oil for the protection of the adjusting and driving elements. The chamber 52 is supported on four legs 53 at a fixed height. The two sealing chamber support columns are slidably mounted on suitable elongated support bearings 54 with their upper ends being bolted or otherwise attached to the sealing chamber 9. The height of the two support columns 51 is simultaneously adjusted by means of the sealing chamber adjusting wheel 55 which is operatively coupled to the two columns 51 by means of the coupling system illustrated in FIG. 13. The adjusting wheel 55 is attached to a connecting shaft 56 which is in turn connected through an idler shaft 57 and suitable gearing to a column connecting shaft 58. Rotation of the adjusting wheel 55 rotates the connecting shaft 58 in one direction or the other to simultaneously raise or lower the sealing chamber support columns 51 through the intermediation of interconnected racks 59 on the columns 51 and pinions 60 on the connecting shaft 58.
As already indicated, adjusting means are also included in the machine base 13 for adjusting the container side belt 12 heights and spacing. The side belt adjusting means includes a side belt support assembly 61 illustrated in FIGS. 17 and 21. The support assembly 61 is mounted on a pair of assembly mounting columns 62 adjustably positioned on the machine base 13. A side belt height adjusting wheel 63 is coupled to the two columns 62 to raise and to lower the side belt support assembly 61 and to thus raise and lower the side belts 12 themselves. The adjusting wheel 63 is coupled to the two columns 62, as illustrated in FIG. 13, through the intermediation of a lateral connecting shaft 64 which is coupled by suitable gears 65 to a longitudinal coupling shaft 66 having pinions 67 on its opposite ends for engaging suitable racks 68 on the two columns 62. Rotation of the side belt height adjusting wheel 63 in one direction or the other raises or lowers the entire side belt support assembly 61 together with the side belts 12 which are attached thereto by means of the plates 46 and the support arms 69.
The coupling between the side belt support assembly 61 and the side belts 12 includes mens for adjusting the spacing of the side belts 12 for handling containers of differing diameters. Each of the two side belt mounting plates 46 are mounted on two longitudinally spaced support arms 69. Since the arms 69 are fixed vertically with respect to the above described side belt support assembly 61, the heights of the side belts 12 are adjustable as the side belt support assembly 61 is raised and lowered using the adjusting wheel 63 as described below. The arms 69, however, are adjustably mounted for lateral movement towards and away from each other to provide a side belt spacing adjustment. This adjusting means is illustrated in FIGS. 14 through 19. Each of the four arms 69 are attached to the outer end of a slidably mounted horizontal support rack 70 (FIG. 16). The racks 70 are mounted in suitable bearings 71 for horizontal movement under the control of a side belt width adjusting wheel 72. As best seen in FIG. 19, the wheel 72 is mounted on a shaft threadedly connected to the side belt support assembly 61. Turning the wheel 72 in one direction or the other causes a threadedly connected arm 69 to which one rack 70 is connected to move one way or the other laterally of the sealing machine. The movement of the one rack 70 results in a corresponding movement of the other three racks 70 and their attached mounting arms 69 through the intermediation of a pinion 73, an idler shaft 74 (FIG. 19), pinion 75 and rack 76. A corresponding idler shaft and pinions 77 couple the other two racks 70 to the rack 76. The support arms 69 support suitable bearing rods 78 and are spring loaded by coil springs 79 to provide a smooth spacing adjustment.
Suitable steam containing covers 81 are mounted on the side bearing rods 78 and other portions for adjusment therewith so that the covers 81 fit closely for differing size containers.
The above described adjusting means is seen to provide for the necessary sealing chamber and side belt height and spacing adjustments. The machine base 13 also incorporates an important portion of the machine drive system to permit these adjustments to be made independently of the drive and without the sealing machine. The machine drive system will now be described with particular reference to FIGS. 11 through 17 and 20 and 21.
A main drive shaft 82 is mounted in the machine base having a coupling portion 83 extending from the left side of the base 13 as seen in FIGS. 11, 12 and 13 for interconnection to the sealing machine main drive including a suitable electric motor and speed control and reduction devices, not illustrated.
As illustrated in FIG. 13, the main drive shaft 82 extends longitudinally through the hollow oil filled machine base chamber 52. The forward end of the drive shaft 82 is coupled by gears 83' to a drive shaft 84 which extends through the forward end of the base chamber 52 to provide a coupling 85 for the conveyor drive 86 (FIG. 1). The conveyor 3 is driven through the intermediation of horizontal conveyor drive shaft 87 and a right angle drive 88 to turn a conveyor drive sprocket. This positive coupling moves the conveyor 3 at a predetermined speed with respect to the speed of the main drive shaft 82 and the additional drive means coupled thereto. These additional drive means include a first splined vertical drive shaft 89 for coupling drive power to the sealing chamber and its driven elements and a second splined vertical drive shaft 90 for the side belts.
FIGS. 4 and 21 illustrate the drive transmission means whereby the driven elements in the sealing chamber 9 are coupled to the splined vertical drive shaft 89. As seen in FIG. 21, a hollow splined shaft 91 is positioned in telescoping and driven relationship with the splined shaft 89 to transmit the drive power upwardly to the sealing chamber 9 and to permit the chamber 9 to be moved vertically as the pair of splined shafts 89 and 91 slide longitudinally with respect to one another. A gear box 92 is provided on the forward portion of the sealing chamber 9 in which a bevel gear 93 on the upper end of the hollow splined shaft 91 engages a bevel gear 94 on a horizontal idler shaft 95. A bevel gear 96 on the idler shaft 95 drives a bevel gear 97 on the cap feed drive shaft 23 and a pinion 99 on an outer end of the idler shaft 95 engages gear 100 for driving the sealing head 6 pully drive support shaft 101. These positively geared couplings insure a synchronous coupling for their driven elements with respect to all other driven portions of the sealing machine which are a part of the main drive system. Where a coder 10 is used on the sealing machine, a coder drive shaft may also be coupled by means of a bevel gear 102 (FIG. 4) to the bevel gear.
The forward vertical splined drive shaft 90 is used for driving the two side belts 12. This drive coupling also permits a height adjustment of the side belts 12 independently of the drive by including a hollow splined drive shaft 103 slidably engaging the lower splined drive shaft 90 (FIG. 20). The upper portion of the shaft 103 comprises the sprocket drive shaft 33 for driving one side belt 12. The opposite end side belt 12 is driven through the intermediation of a gear train 104 which couples the driven shaft 90 to the opposite support shaft 33 positioned at the exit end of the other side belt 12.
ALTERNATE BASE WITH POWERED ADJUSTMENTS
FIGS. 22 and 23 illustrate an alternate embodiment of the machine base 105 illustrating powered adjustments in place of the above described hand powered adjustments. An adjustment of the sealing chamber height and the side belt height has already been described utilizing hand wheels 55 and 63. The alternate embodiment provides for the substitution of power driven means for these adjustments. In this embodiment, an individual power source is mounted adjacent to the control shafts for the two height adjustments. Such power sources are illustrated at 106 and 107. These may comprise either electric or hydraulic drive motors under the control of suitable switches or other controls mounted in a convenient position on or near the sealing machine. The output of each of the power sources 106 and 107 are coupled to shafts 108 and 109 similar to the shafts 56 and 64 already described by suitable gear trains or other couplings. In the case of both electrical and hydraulic drives, limit stops may be provided to limit the adjustment within a predetermined overall adjustment range. A generally similar power means may also be utilized with the side belt spacing adjustment. The use of powered adjustments adapts the overall sealing machine set up to computer control, as for example, using program cards or other known control means so that the necessary height and belt width adjustments may be automatically and rapidly obtained when the cap and or container sizes are being changed merely by the insertion by the proper machine adjustment card or other prerecorded instructions.
It will be seen that an improved high speed sealing machine has been described in which the improvements are particularly directed to improvements in the cap feed and container control at the higher operating speeds together with significantly improved machine adjustment and drive means. Rapid machine adjustments may be made without disturbing the machine drive synchronization for differing container heights and widths and shapes. A particular improvement in the container feed provides a positive cap drive including a cap star feed wheel, which times the closure cap feed and which also isolates the closure cap pickup area from the necessarily high cap chute feed pressure.
The improved container control provides improved side belts with positive side belt container gripping. The improved machine adjustment features are combined with a compact and fully lubricated machine drive system adapted for full positive drive throughout the machine and for an overall reduced drive rate whereby substantial portions of the drive system operate at approximately the speed or rate required at that operating position. This results in a significant reduction of machine noise and vibration and provides for a smooth overall operation facilitating the higher sealing rates which may be employed.
Other and further advantages of the present invention will become apparent upon an understanding of the illustrative embodiments about to be described or will be indicated in the appended claims, and various advantages not referred to herein will occur to one skilled in the art upon employment of the invention in practice.
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A sealing machine is disclosed of the type which applies closure caps to containers at extremely high speeds by moving filled containers successively through a cap feeding station, a cap applying station, and a cap sealing station. The machine is characterized by improvements in its several sections which permit it to operate effectively at increased speeds, and at the same time provide for an improved adjustability for differing package sizes. The adjustability provides for independently operable adjustments for the sealing chamber height and for the width and height of the side belts which move the containers through the sealing chamber. Additionally, an improved cap feed is described with a cap feeding star wheel and improved container guiding side belts are also disclosed.
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This application is the U.S. national-phase application of PCT International Application No. PCT/EP93/01175.
This application is the U.S. national-phase application of PCT International Application No. PCT/EP93/01175.
BACKGROUND OF THE INVENTION
The present invention relates to a hydraulic pump driven by an internal combustion engine. More particularly, the present invention relates to a hydraulic unit or system including a hydraulic pump driven by a camshaft of an internal combustion engine for providing pressure fluid to engine-compartment consumers in automotive vehicles.
A pump of this type is disclosed in German Patent Publication number DE-OS 40 33 105. According to the system disclosed by this reference an internally pressurized radial piston pump is flanged to the engine housing and has an air-flow sensor flap between the pump housing and the engine housing. The phrase "internally pressurized" means that the pressurization of the fluid occurs radially inward relative to the piston. The airflow sensor flap is provided with a central opening, through which a clutch extends that interconnects the pump motor and the drive shaft of the engine.
Undesirably, this known system requires a large number of component parts and the pump of this system necessitates a relatively large mounting space. In particular, in up-to-date automotive vehicles, it is desirable to reduce the dimensions of the units which are accommodated in the engine compartment to the greatest possible extent.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to provide a generic hydraulic pump which requires only a reduced number of component parts, which affords greater ease of assembly and, in addition, necessitates less mounting space. This object is achieved by providing a hydraulic pump which is an externally pressurized and internally driven radial piston pump, having at least one pump piston, and which is integrated into the cylinder head of the internal combustion engine. The phrase "externally pressurized" means that the pressurization of the fluid occurs radially outward relative to the pump piston. Similarly, the phrase "internally driven" means that the mechanism which drives the piston is radially inward relative to the pump piston.
Designing a hydraulic pump as an internally driven radial piston pump, driven by an eccentric, for example, is inexpensive because a reduced number of component parts is needed, thereby diminishing the assembling effort. In addition, it is possible to use low-cost pump elements of existing series. Further, an externally pressurized pump may have short dimensions in the axial direction. The radial extension of such a pump is dictated by the number and size of the pump pistons used, both of which can be adapted to the demanded pressure fluid requirement. The attachment of the piston may be conformed to the space requirements, in particular, in case only one piston is used.
The system of the present invention permits a particularly short construction of the pump. Integrating the pump into the cylinder head of the internal combustion engine is an economy in overall size as compared to a flanged component part. More specifically, the pump is actually formed within the cylinder head, for example, by being disposed within the axial length of the cylinder head wall of the cylinder head. The cylinder head may be expediently provided with openings and chambers, which can be prepared for the incorporation of the pump elements, in only a few additional machining steps. These machining steps essentially imply the provision of bores. The operating shaft serving to drive the pump may be any desired spacer shaft of the engine, for example a shaft of the distributor drive, or a shaft of the lubrication pump drive.
According to a preferred embodiment of the present invention, the camshaft, or one of the camshafts of the internal combustion engine, is used as the drive shaft. An eccentric or a cam, possibly a valve cam, which is incorporated in the camshaft may serve as a pump drive. Since the eccentric or the cam serving as the pump drive may be arranged on the camshaft at any desired location, it is possible to arrange the pump at any chosen location, such as at an especially suitable position relative to the cylinder head.
According to another embodiment of the present invention, a free end of a camshaft of the internal combustion engine is provided as the pump drive. This free end of the camshaft must be extended appropriately and configured to drive the pump.
According to another embodiment of the present invention, the end of the camshaft is provided with an eccentric on which a ball race is rotatably mounted. The pump piston or pistons take support on the ball race. The eccentric may be provided by the camshaft having an eccentrically arranged section. It may be less expensive to design the camshaft end such that an eccentric component can be fitted thereon. Thus, the boundary surface between the camshaft end and the eccentric may be designed as a toothed truncated cone-shaped surface, for example, which permits ease of assembly and precludes relative rotation between the camshaft and the eccentric. Of course, when the camshaft is supported appropriately, the eccentric surface may also be machined therein. The rotatable ball race may be seated on the eccentric in a friction bearing or a needle bearing.
The mounting support of the camshaft in the cylinder head according to an aspect of the invention is able to absorb forces which are exerted by the pump on the camshaft. This prevents impairment of the functioning of the pump.
Still shorter overall dimensions of the pump and, hence, of the housing of the internal combustion engine, can be achieved if, according to another aspect of the invention, bearings of the camshaft are provided in the cylinder shaft which are able to absorb the forces exerted by the pump on the camshaft. In this event, the area of the cylinder head between the engine compartment and the pump chamber may have a very thin design.
According to a preferred embodiment of the hydraulic pump according to the present invention which lends itself to particular ease of manufacture, an opening leading to the cylinder head is provided in the cylinder head wall, through which the free end of the camshaft extends. This opening is succeeded by a hollow space accommodating the ball race and the eccentric, and the cylinder head wall contains at least one cylinder bore in which each piston is guided. Also, the suction channel and the pressure channel extend through the cylinder head wall.
According to another embodiment of the present invention, the pump chamber is closed towards the outside by a cover, which permits ease of assembly of the pump.
Still another embodiment of the present invention incorporates part of the suction channel of the pump in the cover and provides restrictors in the cover. This embodiment is favorable in that the cover may be machined independently of the cylinder head and delivered in prefabricated condition for the assembly. The restrictor permits operation of the pump with choked suction, which means that no more than the maximum required fluid volume is supplied, even if the camshaft runs at a higher speed than necessary for the maximum fluid flow. Thus, suction throttling economizes energy.
According to another preferred embodiment of the present invention, the cover in the fringe area is round in shape and is furnished with a circumferential annular groove which forms one boundary surface of a suction channel, while the other boundary surface is formed by the cylinder head. The bores leading from the circumferential annular groove to the side of the cover close to the cylinder head are the restrictors, through which pump pistons may aspirate the pressure fluid. The recess provided in the middle of the cover may serve to accommodate attachment means to attach the eccentric of a camshaft.
According to another embodiment of the present invention, the intermediate reservoir is incorporated in the cylinder head wall. The intermediate reservoir may be produced by providing a hole extending towards the annular channel of the cover in a simple manner.
According to another embodiment of the present invention, the lubricating oil of the internal combustion engine, which is delivered into the intermediate reservoir by a lubricating oil pump, is used as the pressure fluid. Advantageously, leakage from the pump to the engine compartment is tolerable, so that there is no need for additional pressure fluid, and fluid return is permitted from the consumer or consumers into the oil pan of the internal combustion engine.
The hydraulic pump according to the present invention is appropriate for supplying pressure fluid to consumers in automotive vehicles. The hydraulic pump of the present invention is particularly appropriate for supplying pressure fluid to either a camshaft adjusting device, an automatic clutch, a differential lock, a slip control system or a power steering system, or any combination of such consumers at the same time. These consumers are arranged close to the internal combustion engine and must be furnished with pressure fluid.
The pump according to the present invention is particularly well suited for supplying a camshaft adjusting device with pressure fluid, since the camshaft adjusting device also may be attached directly to the cylinder head of the internal combustion engine. Various designs are possible and particularly short pressure fluid conduits are required when the camshaft adjusting device and the hydraulic pump are arranged at the inlet camshaft and/or outlet camshaft on the same side of the engine block. Depending on the respective engine construction, the conduits may be cast-in or drilled channels, or part of the conduits may be provided as screwed pipes.
It is possible to adjust several camshafts irrespective of one another when the camshaft adjusting device and the hydraulic pump are attached at the opposed ends of a camshaft. If desired, further camshafts of the internal combustion engine may be equipped with camshaft adjusting devices. Thus, it is possible to adjust also the camshafts which drive the hydraulic pump.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features of the present invention and their operation can be seen in the drawings, in which:
FIG. 1 is a schematic diagram of a hydraulic unit, including a hydraulic pump according to the present invention, and
FIG. 2 is a partial cross-section of the hydraulic pump according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a portion of the lubrication system of an internal combustion engine including an oil pan 1, a lubrication pressure pump 2, a filter 3 and a lubrication pressure line 4. Branching off from the lubrication pressure line 4 is a supply line 5 containing a restrictor 6 which terminates into an intermediate reservoir 7 with an overflow tank 8. The intermediate reservoir 7 is part of a hydraulic unit which comprises a suction-controlled hydraulic pump 9, a pressure-limiting valve 10, an electromagnetically operable control valve 11 and an operating cylinder 12. The operating cylinder 12 may serve to operate a consumer 19, such as a variable camshaft adjusting device. Consumer 19 may represent other consumers, such as an automatic clutch, a differential lock, a slip control system, a power steering system, or combinations thereof.
The suction side of the hydraulic pump 9 is connected to the intermediate reservoir 7 through a restrictor 13 for the purpose of suction control of the delivery rate. The pressure side of the hydraulic pump 9 is in direct connection with the piston rod side of the operating cylinder 12. To perform adjusting movements, the side of the operating cylinder 12 remote from the piston rod is connected, by way of the control valve 11, either with the pressure side of the hydraulic pump 9 or, through a return line 14, with the oil pan 1. In an intermediate position, the control valve 11 is closed, and the piston of the operating cylinder 12 is stopped in a position which it reaches due to the surrounding pressurization. Also, a return line 15 leads from the pressure-limiting valve 10 to the oil pan 1.
Variations in the operating pressure of the lubrication system of an internal combustion engine are substantial due to the rotational speed of the engine and the operating temperature. Nonetheless, the hydraulic unit of the present invention may expediently use the lubrication system of an internal combustion engine in spite of such variations in the operating pressure in order to deliver operating media to the hydraulic pump 9 driven by the internal combustion engine. The unpressurized intermediate reservoir permits suction pressure control of the hydraulic pump 9 so that the delivery rate of the hydraulic pump 9 can easily be limited to an appropriate maximum value, while small losses are involved, despite major rotational speed variations of the pump drive.
FIG. 2 shows an embodiment of the hydraulic pump 9 (shown as pump element 20 in FIG. 2) according to the present invention. On the left side (as shown in FIG. 2) is the cylinder head 27, the right-hand boundary portion of which is a cylinder head wall 17. An opening 18 is contained in the cylinder head wall 17, in which the camshaft 33 (having a cam 34) is seated by way of a bearing 22. Fitted to the right-hand end of the camshaft 33 is a conical section 39, which is of toothed design and on which an eccentric 26 is seated which is toothed as well. The toothed engagement precludes relative rotation between the eccentric 26 and the conical section 39 of the camshaft 33. The eccentric 26 is protected against axial displacement by means of a set-screw 40 fitted to the end of the camshaft 33. A ball race 25 is rotatably mounted on the eccentric 26.
In the cylinder head wall 17, the intermediate reservoir 7 is arranged, into which the supply line 5 from the lubrication pressure pump 2 terminates and which is provided with an overflow tank 8 (not shown in FIG. 2). Channel 41, which extends from the intermediate reservoir 7, forms part of the suction channel 28 which is continued in a circumferential annular groove 32 in the cover 37. Cover 37 confines the hollow space 16, formed in the cylinder head wall 18, towards the outside. Towards the inside, it is furnished with a recess 35, in which the set-screw 40 is arranged, as well as bores, serving as restrictors 13, between the annular groove 32 and the hollow space 16.
A cylinder bore 23 is arranged in the cylinder head wall 17 in which a piston 24 is guided which takes support on the ball race 25 and is urged onto the ball race by a spring 21. On one side, downwardly as viewed in FIG. 2, the piston 24 is open and furnished with intake bores 29 having a throttling effect. In the uppermost possible position of the piston 24, as viewed in FIG. 2, intake bores 29 are in communication with the hollow space 16.
Spring 21 is guided by a guiding means 36 and bears against the attaching element 38. There is a connection between the interior of the piston 24 and the pressure channel 31, in which a check valve 30 is arranged and which extends through the cylinder head wall 17 outwardly.
In operation, the pressure fluid supplied by the lubrication pressure pump 2 of the internal combustion engine into the intermediate reservoir 7 propagates through the suction channel 28, composed of channel 41 and annular groove 32, to the restrictors 13 which allow passage of a reduced fluid volume only. Pressure fluid is conveyed through the restrictors 13 into the hollow space 16. Rotation of the camshaft 33, through the eccentric 26 and the ball race 25, causes the piston 24 to perform upward and downward strokes. Spring 21 is rated such that it prevents the piston 24 from lifting off the ball race 25. When piston 24 is in the aspirating position, which is its uppermost position as viewed in FIG. 2, pressure fluid is aspirated from the hollow space 16 through the intake bore 29 into the interior of the piston 24.
During the downward stroke of the piston 24, the intake bores 29 having a throttling effect are moved away from the area of the hollow space 16 and closed by the cylinder bore 23, thereby pressurizing and pumping the pressure fluid into the pressure channel 31. During the subsequent upward stroke of the piston 24, the check valve 30 prevents return flow of the pressure fluid and, thus, prevents a pressure decrease in the direction of the consumer. As a result, vacuum develops in the interior of the piston 24, whereby the pressure fluid prevailing in the hollow space 16 is aspirated into the interior of the piston 24, as soon as the intake bore 29 is in communication with the hollow space 16 again.
Although illustrated and described herein with reference to certain specific embodiments, the claims are not intended to be limited to the details of the specific embodiments. Rather, the claims should be read to include various modifications of the details of the specific embodiments without departing from the spirit of the invention.
List of Reference Numerals:
1 oil pan
2 lubrication pressure pump
3 filter
4 lubrication pressure line
5 supply line
6 restrictor
7 intermediate reservoir
8 overflow tank
9 hydraulic pump
10 pressure-limiting valve
11 control valve
12 operating cylinder
13 restrictor
14 return line
15 return line
16 hollow space
17 cylinder head wall
18 opening
19 consumer
20 pump element
21 spring
22 bearing
23 cylinder bore
24 piston
25 ball race
26 eccentric
27 cylinder head
28 suction channel
29 intake bore
30 check valve
31 pressure channel
32 annular groove
33 camshaft
34 cam
35 recess
36 guiding means
37 cover
38 attaching element
39 conical section
40 set-screw
41 channel
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A hydraulic pump driven by an internal combustion engine is an externally pressurized radial piston pump, which is internally driven by an eccentric. The hydraulic pump is integrated within the cylinder head of an internal combustion engine.
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This application is a continuation of U.S. patent application Ser. No. 10/811,590 filed on Mar. 29, 2004, now pending.
BACKGROUND
Mats have many residential, commercial and industrial uses. Some of the most demanding uses involve factory applications. Mats are commonly placed around industrial machines. There they are subject to heavy traffic, as well as liquid, solid and chemical contamination.
Most industrial mats are fabricated from rubber. The rubber must be hard for durability. On the other hand, it should be resilient and compressive for the comfort and health of the user. These two properties are significantly incompatible with each other. A hard mat is not resilient and compressive. A soft mat, while resilient and compressive, is not durable.
Most mats are supported by legs. Mats are often placed upon metal gratings surrounding a machine or a work area. The gratings are necessary to receive and contain liquid and solid waste and contaminants. The use of mats with legs on top of metal gratings is problematic because the legs tend to sink into and embed within the gratings.
Many mats are fabricated to have surface drain holes to promote liquid and solid drainage. The holes are typically contained within the horizontal top surface of the mat. The problem with such a drain hole configuration is that the holes easily clog. They readily catch and retain foreign objects. A hard object trapped in an upright position within a drain hole often presents a serious safety hazard. The problem could be alleviated by positioning drain holes within a vertical wall on the top mat surface. Unfortunately, vertical wall drain holes are difficult to cost effectively mold into rubber.
Another problem with mats is that they are often subject to liquid, oily or slippery environments. Such environments constitute serious safety hazards because of the unsafe footing to which users are subjected. This problem can be alleviated by bonding grit to the top surface of a mat. However, it is often not cost-effective to cover a mat with grit. Further, the compressive forces to which a mat is subjected by users causes flexure of the mat which tends to break the bond holding the grit to the mat. As a result, it is difficult to keep sufficient grit bonded to a mat during the life expectancy of the mat.
The manufacturing cost of a grit covered mat could be reduced by only applying grit to selective areas of the mat. This becomes problematic because the adhesives typically used to bond grit to a mat are liquid or semiliquid. The adhesives tend to flow out of any surface area or channel to which they are applied. Further, there are no known methods to easily apply adhesives and grit to selective areas of mats.
There is a need for an improved mat which would have one or more of the following features. It could be manufactured from hard rubber for durability, yet feel compressive and resilient when stepped upon. When placed upon a grating it would not sink into or embed within the grating. It would have drain openings which are positioned within vertical surfaces on top of the mat. It would have areas of selectively placed grit bonded onto its top surface. A substantial portion of the selectively placed grit would be below the mat surface. The selectively placed grit would also have support from underneath to inhibit flexure causing the grit to become unbonded. Additionally, a cost-effective method for applying selectively placed grit to the top of the mat is needed. The tendency of a liquid adhesive to flow away from the area where it is initially placed needs to be minimized.
Because of the difficulty of cost effectively molding drain holes into vertical wall surfaces on top of a mat, there is also a need for a cost-effective process for creating drain holes within a vertical wall surface on top of a mat.
SUMMARY
The present invention provides a solution for these problems. One version of the invention is comprised of a mat base, a plurality of long legs, a plurality of short legs, a plurality of ribs, a plurality of channels, a plurality of grit trenches and grit. The mat base has a top surface and a bottom surface. The long legs are perpendicularly attached to the bottom surface of the mat base. This provides resilient support for the mat base.
The short legs are also perpendicularly attached to the bottom surface of the mat base. The short legs support the mat base and modify the resiliency of the mat. The long legs and the short legs are adapted to provide a selected mat compression when a load is applied to the top surface of the mat.
Each rib connects a pair of legs. The length of each rib, as measured along the dimension perpendicular to the mat when the rib is attached to the legs, is approximately the length of the legs to which it is attached. However, its length is not longer than either of the legs to which it is attached. When the mat is placed on top of a floor grating the rib between the legs tends to prevent the mat from becoming embedded within the grating.
The channels subdivide the mat top surface into mat segments. Each channel has a floor and a lateral wall surface. The lateral wall surface is vertically oriented with respect to the top surface of the mat. The lateral wall surface has a drain opening. The drain opening permits drainage from the top surface of the mat to below the bottom surface of the mat.
The grit trenches are embedded within the top surface of the mat. Each trench has two ends. Each end has a retention lip. The retention lip forms a dam for retaining adhesive and grit. The grit is bonded into the trenches by an adhesive. In order to reduce flexure within the trenches at least one trench is supported by some of the long legs perpendicularly attached to the bottom surface of the mat.
The preferred improved mat is constructed with all of the described features. An improved mat may also be constructed with less than all of the described features.
The invention includes a process for fabricating lateral drain openings into the top surface of a mat. The first step of the process is to mold a mat. The mat has a top surface and a bottom surface. Channels subdivide the mat top surface into mat segments. The channels have a floor and a lateral wall surface. The mat is also constructed to have a rib perpendicularly molded into the bottom surface of the mat below each channel.
The next step of the process is to remove material from the floor of at least one channel, at least one of its lateral wall surfaces and its underlying rib. The material is removed to a depth which is below the bottom surface of the mat base. The removal of the material will cause the formation of a drain opening within the lateral wall of the channel. The material can be removed with a grooving tool such as a tire groover.
Preferably, a programmable Cartesian robot is used to remove the material. A grooving tool, such as a tire groover is attached to the programmable Cartesian robot. The grooving tool has a heated blade. The programmable Cartesian robot is programmed to remove the material from the floor of each channel and its underlying rib. The mat is secured onto the workbed of the programmable Cartesian robot. The programmable Cartesian robot and the attached grooving tool are then used to remove the material from the floor of at least one channel, at least one of its lateral wall surfaces and its underlying rib.
Preferably, a programmable cartesian robot is also used to bond grit into the trenches embedded within the top surface of the mat. An adhesive dispenser is attached to the programmable Cartesian robot. The robot is programmed to fill the trenches with adhesive. The mat is secured onto the workbed of the robot. The robot then fills the trenches with adhesive. After the adhesive is placed, grit is spread over the top surface of the mat. Finally, the excess, non bonded, grit is removed. This may be done by shaking the grit off of the mat.
DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
FIG. 1 is a perspective view of a mat segment of an improved mat.
FIG. 2 is a bottom plan view of an improved mat.
FIG. 3 is a side elevation sectional view of a section of the improved mat of FIG. 2 .
FIG. 4 is a another side elevation sectional view of a section of the improved mat of FIG. 2 .
FIGS. 5 a , 5 b and 5 c are side elevation sectional views of a section of the improved mat of FIG. 2 showing the compression of short legs and long legs of the mat when a compressive load is applied to the top surface of the mat.
FIG. 6 is a perspective view of the mat segment of FIG. 1 after grit has been bonded into the grit trenches of the mat segment.
FIGS. 6 a , 6 b and 6 c are sectional views of a channel of an improved mat showing the process for creating a drain opening within the lateral walls of the channel.
FIG. 7 is a bottom plan view of an improved mat showing drainage paths.
FIG. 8 is a top plan fragmentary view of the mat segment of FIG. 1 showing the application of adhesive to a grit trench.
FIG. 9 is a top plan fragmentary view of the mat segment of FIG. 1 showing the application of grit to a grit trench.
FIG. 10 is a side elevation sectional view of the mat segment of FIG. 9 showing grit bonded by an adhesive into the grit trench of the mat segment.
DESCRIPTION
The preferred embodiment of the improved mat 30 and methods for fabricating it are shown in FIGS. 1 through 10 . Preferably, the mat 30 is molded from a hard rubber. This will promote durability. The mat 30 is comprised of a mat base 32 , long legs 38 , short legs 40 , ribs 44 , channels 52 , grit trenches 64 , adhesive 72 and grit 70 . The mat base 32 has a top surface 34 and a bottom surface 36 .
The long legs 38 are perpendicularly attached to the bottom surface 36 of the mat base 32 . This will provide resilient support for the mat base 32 . The short legs 40 are perpendicularly attached to the bottom surface of the mat base 32 . The long legs 38 and the short legs 40 are adapted to provide a selected mat compression when a load is applied to the top surface 34 of the mat base 32 . The combination of long legs 38 and short legs 40 causes the mat 30 which is constructed from hard rubber to feel and function as if it were constructed from a softer, more compressive rubber.
This function is shown in FIGS. 5 a , 5 b and 5 c . There, a compressive force 42 is applied to the top surface 34 of the mat base 32 . Before the compressive force 42 is applied the long leg 38 is in contact with the ground. The short legs 40 are raised above the ground. The compressive force 42 causes the long leg 38 to compress thereby bringing the short legs 40 closer to the ground. Finally, in FIG. 5 c , the short legs 40 contact the ground and begin to compress. The result is a mat 30 constructed from hard rubber which compresses as if it were constructed from a softer material. We have found that when using a configuration similar to that depicted in FIG. 2 to fabricate an 18 inch by 18 inch by three-quarter inch mat, the combination of 504 long legs and 144 short legs 40 provides the preferred compression of the mat.
The molded mat 30 contains a number of different rib 44 styles. Shorts support ribs 45 are used to provide structural integrity, especially near the drain openings 58 described below. Long ribs 48 are used to connect legs 38 , 40 . Each long rib 48 is approximately the length of the legs 38 , 40 to which it is to be attached. However, the long ribs 48 do not exceed the length of the legs 38 , 40 to which they are attached. A plurality of long ribs 48 are each connected to a pair of legs 38 , 40 . The long ribs 48 will thereby prevent the mat 30 from sinking into and becoming embedded into a grating upon which it is placed. The mat 30 , may also be used on top of a solid floor. If only long ribs 48 were used to connect the legs 38 , 40 , drainage from the top of the mat 30 to the exterior of the mat 30 and air circulation within the mat 30 may be inhibited. Therefore, a plurality of short ribs 46 are used, instead of long ribs 48 , to interconnect some legs 38 , 40 . This will result in expanded gapping between the floor and the short ribs 46 , thereby promoting drainage and circulation, as shown by the drain paths 60 in FIG. 7 .
The channels subdivide the mat top surface 34 into mat segments 62 , as shown in FIG. 1 . Each channel 52 has a floor 54 and a lateral wall surface 56 . Most channels 52 have two lateral wall surfaces 56 . Preferably, the lateral wall surfaces 56 contain drain openings 58 . Such drain openings 58 are positioned upon a vertical lateral wall surface 56 rather than horizontally oriented, as in current mats. Because the drain openings 58 are on vertically oriented surfaces the drain openings are less likely to become clogged by contaminants. The drain openings 58 are also much less likely to trap hard and dangerous objects resulting in safety hazards. Liquids and other contaminants drain through the drain openings 58 to the bottom of the mat 30 and to the exterior of the mat 30 by way of the drain paths 60 .
The grit trenches 64 are embedded within the top surface 34 of the mat base 32 . The grit trenches 64 are intended to hold grit 70 . Each grit trench 64 has two ends 66 . Each end 66 has a retention lip 68 forming a dam for retaining adhesive 72 and grit 70 . The retention lip 68 prevents the adhesive 72 from flowing out of the grit trench 64 , while the adhesive 72 is in a liquid form. This enhances the ability to selectively place grit 70 upon the top surface 34 of the mat 30 .
Grit 70 is securely bonded into the grit trenches 64 with the adhesive 72 . The preferred grit 70 is silicon carbide. The preferred adhesive 72 is cyanoacrylate. In order to minimize the likelihood of mat 30 flexure causing the grit 70 to become unbonded, the grit 70 and adhesive 72 are placed substantially below the top surface 34 of the mat 30 , as shown in FIG. 10 . However, some of the grit 70 must protrude above the top surface 34 of the mat base 32 in order for the grit 70 to increase the coefficient of friction of the top surface 34 of the mat base 32 . To further reduce unbonding of grit 70 by flexure, long legs 38 are perpendicularly attached to the bottom surface 36 of the mat base 32 below the grit trenches 64 in order to provide support for the grit trenches 64 . Because the grit 70 and adhesive 72 are substantially below the top surface 34 of the mat base 32 and because the grit trenches 64 are supported by long legs 38 grit 70 may be selectively placed upon the top surface 34 without significant unbonding being caused by flexure.
Lateral drain openings 58 positioned upon a lateral wall surface 56 are difficult to cost effectively fabricate by molding. Another technique is needed to fabricate the drain openings 58 . First, a mat 30 is molded such that it has a top surface 34 and a bottom surface 36 . It is molded such that channels 52 subdivide the mat top surface 34 into mat segments 62 . As previously described, the channels 52 have a floor 54 and a lateral wall surface 56 . The mat 30 is fabricated such that a rib 48 is perpendicularly molded into the bottom surface 34 of the mat 30 below each channel 52 .
Drain openings 58 may be created within the lateral wall surfaces 56 of each channel 52 by removing material from the floor 54 , at least one lateral wall surface 56 and the underlying rib 48 , 46 of the channel. The material must be removed to a depth which is below the bottom surface 36 of the mat base 32 in order to form a drain opening 58 .
The material may be removed with a grooving tool such as a tire groover. The grooving tool has a heated blade 74 for removing rubber. Preferably, the material is removed from the floor 54 of each channel 52 and its underlying rib 48 , 46 by a process which uses a programmable Cartesian robot. The first step of the process is to attach a grooving tool having a heated blade 74 to the robot. Preferably, the grooving tool is a tire groover. The robot is programmed to remove the material from the floor 54 of each channel 56 and its underlying rib 46 , 48 . After the groover is attached to the robot and the robot is programmed, the mat 30 is secured onto the workbed of the robot. Then, the material is removed from the floor 54 of at least one channel 52 , at least one of its lateral wall surfaces 56 and its underlying rib 46 , 48 with the robot and the attached groover, thereby forming a drain opening 58 .
The robot may also be used to automate the bonding of grit 70 into the trenches 64 embedded within the top surface 34 of a mat 30 . First an adhesive dispenser 76 is attached to the robot. The robot is programmed to fill the trenches 64 with adhesive 72 . The mat 30 is secured onto the workbed of the robot. The robot then fills the trenches 64 with adhesive 72 . Before the adhesive 72 sets grit 70 is spread over it. Finally, the excess grit 70 is removed from the mat 30 . Optionally, the programmable Cartesian robot may be equipped with a grit dispenser 78 for selectively spreading grit 70 , as shown in FIG. 9 .
Although the invention has been shown and described with reference to certain preferred embodiments, those skilled in the art undoubtedly will find alternative embodiments obvious after reading this disclosure. With this in mind, the following claims are intended to define the scope of protection to be afforded the inventor, and those claims shall be deemed to include equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
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An improved mat is disclosed. Long and short legs support the mat and cause it to feel resilient although it is fabricated from hard rubber. The mat has drain holes on vertical surfaces. Ribs prevent the mat from embedding within grating. Grit is selectively placed upon the mat and physically supported. Adhesive for bonding the grit is retained by retention lips. Also disclosed is a process for creating drain holes on vertical surfaces of mats by attaching a grooving tool to a robot and programming the robot to cut through molded mat channels to create the desired drain holes. An additional process uses the robot to selectively place adhesive upon the mat. An adhesive dispenser is attached to the robot and the robot is appropriately programmed.
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CROSS-REFERENCE TO RELATED APPLICATION AND PRIORITY CLAIM
This application is related to and claims priority under 35 U.S.C. §119(a) to European Application No. 13194693.1, filed 27 Nov. 2013, titled “Noble Metal Nanoparticles, Method for Preparing the Same and Their Application”, the entirety of which is hereby incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to noble metal nanoparticles, a method for preparing the same, and their use.
BACKGROUND
Nanoparticles are of great scientific interest as they can be utilized in many industrial or medical applications. Nanoparticles are typically sized between 1 to 100 nm.
In particular, gold nanoparticles have been intensively studied as they are versatile materials having interesting chemical, electronic and optical properties for a broad range of different applications. The properties and applications of gold nanoparticles strongly depend on their respective shape and size.
Possible applications of gold nanoparticles lie, for example, in the fields of nanoelectronics, imaging, sensing, catalysis, optics, environmental industry, energy development and biomedicine. Due to the low oxidation metal potential of gold nanoparticles, they can be used in medical diagnostic tests, such as labeling, X-ray contrasting, immunestrain and phago kinetic tracking studies, in targeted truck delivery techniques, as well as in medical therapies.
Silver nanoparticles have various and important applications. Historically, silver has been known to have a disinfecting effect and has been found in applications ranging from traditional medicines to culinary items. It has been reported that silver nanoparticles (AgNPs) are non-toxic to humans and most effective against bacteria, virus and other eukaryotic micro-organism at low concentrations and without any side effects. Moreover, several salts of silver and their derivatives are commercially manufactured as antimicrobial agents. In small concentrations, silver is safe for human cells, but lethal for microorganisms. Antimicrobial capability of AgNPs allows them to be suitably employed in numerous household products such as textiles, as well as disinfection in water treatment, food storage containers, home appliances and in medical devices. The most important application of silver and AgNPs is in medical industry such as tropical ointments to prevent infection against burns and open wounds.
Several methods for producing noble metal nanoparticles have been developed which utilize harsh conditions. Wet methods often require the application of aggressive reducing agents, for example sodium borohydride, capping agents and may additionally need organic solvents such as toluene or chloroform. Furthermore, often toxic compounds must be employed or are produced during the synthesis of noble nanoparticles. Although known methods may produce successfully noble metal nanoparticles, energy preparation consumption and pollution effects are relatively high, as well as materially and environmental costs. Even the availability of some materials, in particular of biomaterials, as for example plant materials, may be a problem. In consequence, there remains a need for more cost-effective and environmentally benign alternative methods for producing noble metal nanoparticles with improved properties on a large scale. Main criteria for a green chemistry synthesis of stabilized nanoparticles are the choice of eco-friendly and non-hazardous solvents, reducing agents and capping agents, especially for noble metal nanoparticles which shall be utilized in medical treatment.
Biological synthesis of nanoparticles by plant extracts is at present under exploitation as some researchers worked on it and tested then for antimicrobial activities.
Chemical reduction methods are widely used for synthesizing Ag—NPs because of their readiness to generate Ag—NPs under gentle conditions and their ability to synthesize Ag—NPs on a large scale.
US 2010/0055199 A1 discloses systems and methods for synthesizing silver nanoparticles using Trichoderma funghi. In an aspect, Trichoderma reesei was used for extracellular synthesis of silver nanoparticles. In the biosynthesis of metal nanoparticles by a fungus, one or more enzymes or metabolites are produced that reduce the silver ions to its metallic solid nanoparticles through a catalytic process.
US 2010/0200501 A1 relates to methods of making and using as well as compositions of metal nanoparticles formed by green chemistry synthetic techniques. The production of metal nanoparticles of Ag, Au, Pt, Pd, Fe, Mn, Cu and In in a single pot method using plant extracts as coffee and/or tee extract and use of these metal nanoparticles in removing contaminates from soil, groundwater and other contaminated sites are described. The reducing agent used for the preparation of the metal nanoparticles can be among others a phenolic compound or a flavonoid or a combination thereof.
For the last two decades extensive work has been done to develop new drugs from natural products because of the resistance of micro-organisms to the existing drugs. Nature has been an important source of products currently being used in medical practice.
There are various strategies for using gold nanoparticles as a drug delivery vehicle, including systems based on covalent binding or drug encapsulation. Furthermore, it has been reported that antibiotics often disturb the bacterial flora of digestive tract which may develop multiple drug-resistant isolates, hence novel ways of formulating biocide materials is an upcoming field of attraction. For this reason, there is a need for the use of an agent which does not generate resistance and presents a good bactericidal property. Gold nanoparticles have a great bactericidal effect on several ranges of microorganisms.
A number of synthetic methods have been employed for the synthesis of silver-based nanoparticles involving physical, chemical and biochemical techniques. However, these chemical synthesis methods employ toxic chemicals in the synthesis route which may have adverse effect in the medical applications and hazard to environment.
SUMMARY
Therefore, preparation of Ag—NPs by green synthesis approach has advantages over physical and chemical approaches as it is environmental friendly, cost effective and the most significant advantage is that conditions of high temperature, pressure, energy and toxic chemicals are not required in the synthesis protocol.
It is an object of the present invention to provide a method for preparing noble metal nanoparticles using green chemistry synthetic techniques which overcomes the drawbacks of the prior art. Especially, a method shall be provided which allows the use of non-toxic, abundant eco-friendly bioavailable material and which enables saving energy and costs. It is a further object to provide noble metal nanoparticles which show improved medical properties and can be utilized in industrial and medical applications.
The first object is achieved by a method for preparing noble metal nanoparticles, comprising the following steps: a) preparing an Olea Europaea fruit extract; b) preparing an Acacia Nilotica extract; c) mixing the Olea Europaea fruit extract and the Acacia Nilotica extract for preparing a mixed extract; d) providing an aqueous solution containing a noble metal compound dissolved therein; e) mixing the mixed extract obtained in step c) and the aqueous solution of step d) to form noble metal nanoparticles.
By the term “nanoparticle” is meant a microscopic particle with at least one dimension less than 100 nm.
Preferably, the mixed extract obtained in step c) contains flavonoids, phenols and/or pentacyclic triterpenoids as effective group.
Within the present application, the term “effective group” is to be understood, that the effective group containing compound of the mixed extract plays a main role, for example, as reducing and/or stabilizing agent for the inventive noble metal nanoparticles. One or more different effective group(s) may be alone or together responsible for these effects.
It is preferred that the preparation of the Olea Europaea fruit extract is performed by adding deionized or distilled water to Olea Europaea fruit, preferably grinding it and then filtering the extract.
In a preferred embodiment, the preparation of the Acacia Nilotica extract is performed by adding deionized or distilled water to Acacia Nilotica, preferably soaking it and then filtering the extract.
Alternatively, the term “extract” of the present invention means an extract obtained from bioavailable plant and/or fruit materials. The extract may be obtained by using standard extraction techniques, like a separatory funnel, a soxhlet apparatus and so on. Further, the extraction may comprise one or more different extraction steps in which the same or different extraction techniques may be used.
More preferably, the Olea Europaea fruit extract and the Acacia Nilotica extract are mixed in a range of mixing ratios from 5:1 to 1:5, preferably in ratios of 7:3, 3:1, 1:1 or 1:3.
It is also preferred that the mixing in step e) includes stirring at 25° C., putting the mixture into a shaker for 30 min at 145 rpm, shaking the mixture in a water bath at 125 rpm at 60° C. or leaving the mixture for about 3 months at room temperature.
More preferably, the mixing of step e) is preferably at room temperature.
According to the present invention, any mixing technique utilized in the art may be used.
Even preferred, the noble metal is selected from Au or Ag.
It is further preferred that the gold nanoparticles shall be prepared by utilizing an inorganic acid containing Chloroauric Acid (HAuCl 4 ). When silver nanoparticles shall be prepared, a solution of silver nitrate may be utilized and provided in step d).
Most preferably, the aqueous solution provided in step d) also comprises a surfactant, preferably cetyl trimethyl ammonium bromide (CTAB). Especially the noble metal nanoparticles prepared in the presence of a surfactant, which are preferably colloidal noble metal nanorods, are effective as antibacterial agent.
The second object is achieved by noble metal nanoparticles prepared by the inventive method wherein the average particle size is within a range of 10-100 nm, preferably of 20-60 nm, more preferably the average particle size is 40 nm.
It is further preferred that the noble metal nanoparticles are substantially spherical. Even preferred, the noble metal nanoparticles obtained have a smooth surface morphology, i.e. regular shapes and morphology.
In a further embodiment, the noble metal nanoparticles are substantially monodispersed.
More preferably, the gold nanoparticles are colloidal.
In another preferred embodiment, the nanoparticles are in the form of nanorods, having preferably an average size of 96 nm.
A further object is achieved by the use of the inventive noble metal nanoparticles in a catalytic, electronic, imaging, sensing, photonic, energy, optical, environmental, biotechnical or medical application.
More preferably, the noble metal nanoparticles are preferably used in antibacterial and cancer treatment, and more preferably are used with photothermal therapy in treatment of Ehrlich Ascites carcinoma cells.
It was also found that the inventive noble metal nanoparticles can be used in textile fabrication, in food storage containers, as antibacterial agent against Kleb, pseudomonas, salmonella and Escherichia coli bacteria, in nanoelectronics, as biosensors, as biomedical tools, in sustainable energy development, in bioremediation of radioactive wastes, as functional electrical coating, in the synthesis of enzyme electrodes and particularly in medicine, such as for delivery of antigen for vaccination, gene delivery for treatment or prevention of genetic disorder, and drug delivery, in waste water treatment etc.
Surprisingly, it was found that the inventive method provides the possibility to synthesize noble metal nanoparticles in an easy, energy saving and cost-efficient way from non-toxic, abundant natural materials and medical plants. In addition, the synthesis method of the invention is accomplished in a short time and is suitable for large scale preparation. Moreover, it was found that the inventive method allows faster nanoparticle growth, the possibility to achieve a variety of particle shapes and a better control of particle size distribution, compared to the prior art US 2010/0055199A1. The inventive noble metal nanoparticles may have several applications, such as antibacterial and cancer treatment, catalyst in chemical reactions, electrical batteries, in spectrally selective coatings for absorption of solar energy, as optical elements, in pharmaceutical components, chemical sensing, biosensing or in food and water storage.
This invention focuses especially on a new method for synthesis of gold nanorods and nanospheres. The preferred presence of surfactant molecules on the surface of the gold nanorods and nanospheres strongly influences their reactivity and stability. The preparation of Au nanorods and nanospheres according to the invention has advantages over physical and chemical approaches as it is eco-friendly, economical, clean and doesn't involve the use of any toxic chemical, as well as simple application and storage at room temperature and high stability. Further, the antibacterial efficacy of inventive gold nanorods and nanospheres was studied against various strains of Escherichia coli, Staphylococcus aureus, and conjugated with antibiotic ampicillin, and the results shows that eco-friendly gold nanorods and nanospheres showed highly effective antibacterial activity towards Gram-positive and Gram-negative microorganisms and also with antibiotic, examined by the agar-well-diffusion method.
Preparation of Ag—NPs by the inventive method has advantages over physical and chemical approaches as it is environmental friendly, cost effective and the most significant advantage is that conditions of high temperature, pressure, energy and toxic chemicals are not required in the synthesis protocol.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is now further illustrated by the accompanying figures and detailed description from which further features and advantages may be taken. It is to be noted that the following explanations are presented for the purpose of illustration and description only; they are not intended to be exhaustive or to limit the invention to the precise form disclosed.
FIG. 1 shows a graph of UV-Vis spectrum of gold nanoparticles synthesized by the inventive method chemistry synthetic techniques according to example 1.
FIG. 2 shows a graph of Zetasizer® for measuring the average particle size of the gold nanoparticles prepared according to the invention.
FIGS. 3 a, 3 b and 3 c show a graph of transmission electron microscopy (TEM) image of gold nanoparticles synthesized by the inventive method (100 KV) with different shapes and magnifications.
FIG. 4 shows the graph of scanning electron microscopy (SEM) image and elemental analysis by energy-dispersive spectroscopy (EDS) of the inventive gold nanoparticles.
FIG. 5 shows a graph of FTIR spectrum of (A) mixed extract, (B) gold nanoparticles synthesized by the inventive method.
FIG. 6 presents a graph of UV-Vis spectrum of gold nanorods prepared according to the present invention, example 2.
FIG. 7 presents a graph of a Zetasizer® for measuring the average size of nanorods prepared according to the present invention, example 2.
FIGS. 8 a, 8 b and 8 c present a graph of transition electron microscopy (TEM) image of gold nanorods synthesized according to the invention, with different magnifications.
FIG. 9 presents a graph of a scanning electron microscopy (SEM) image and elemental analysis by energy-dispersive spectroscopy (EDS) of gold nanorods prepared according to the present invention, example 2.
FIG. 10 presents a graph of a FTIR spectrum of inventive (A) gold nanorods synthesized by the inventive method, (B) mixed extract.
FIG. 11 presents a graph of Antibacterial activity assay of eco-friendly gold nanorods and with antibiotic (5, 10 μg/ml) respectively against (a) E. coli and (b) Staphylococcus aureus.
FIG. 12 shows a graph of Zetasizer® for measuring the average particle size of the silver nanoparticles prepared according to the present invention.
FIGS. 13 a, 13 b and 13 c show a graph of transmission electron microscopy (TEM) image of silver nanoparticles synthesized by the inventive method (100 KV) with different shapes and magnifications.
FIG. 14 shows the graph of scanning electron microscopy (SEM) image and elemental analysis by energy-dispersive spectroscopy (EDS) of the inventive silver nanoparticles.
FIGS. 15 a, 15 b and 15 c Antibacterial activity assay for green Ag nanoparticles prepared according to the present invention against, (A) E. Coli (B) Staphylococcus aureus, (C) Streptococcus.
DETAILED DESCRIPTION
Example 1
Colloidal gold nanoparticles were synthesized by bioreduction of AuCl 4 − ions. 15 g Olea Europaea fruit was washed carefully and was added to 15 ml deionized water. Then it was grinded, filtered and the extract was kept until it was used. 15 g Acacia Nilotica was added to 15 ml deionized water, soaked all night, filtered and then the extract was kept until it was used. Equal volumes of the Olea Europaea fruit extract and Acacia Nilotica extract were mixed to prepare a mixed extract which preferably contains flavonoids, phenols and/or pentacyclic triterpenoids. 5 ml of the mixed extract was added to 50 ml of an aqueous solution of 0.1M HAuCl 4 . Afterwards, the mixture was stirred for about 10 minutes at 35° C., or put in a shaker for 30 minutes at 145 rpm and 39° C., or put in a water bath shaking at 125 rpm and 60° C. or was left at room temperature for 3 months, approximately. A color change from yellow transparent to black and then to red purple indicated the formation of the respective gold nanoparticles.
A separation process for the extracts of Olea Europaea fruit extract and Acacia Nilotica extract, was carried out by using a reparatory funnel and separated fractions were tested by TLC. It was clearly found that effective groups or preparing the nanoparticles comprise flavonoids, phenols and/or pentacyclic triterpenoids. These effective groups are actually responsible and play main role as reducing and stabilizing agent for the rapid formation of nanorods with high monodispersity.
The formed gold nanoparticles have been analyzed: FIG. 1 shows the absorption peak (SPR) obtained in a visible range at 565.97 nm by UV-visible spectral analysis (Lambda 25, PerkinElmer, United Kingdom). This indicates monodisperse and colloidal gold nanoparticles. FIG. 2 shows that the average particle size of the gold nanoparticle is 40 nm, measured by Zetasizer® (ZEN 3600, MALVERN, United Kingdom). Transmission electron microscopy (TEM) (JEM-1011, JEOL, Japan) images of the prepared gold nanoparticles are shown in FIGS. 3 a, 3 b and 3 c. The inorganic gold nanoparticles are spherical in shape with a smooth surface morphology. EDS spectrum, linked with SEM (JEOL-FE_SEM), was used to analyze the element of gold nanoparticles ( FIG. 4 ), in addition with FTIR spectroscopy (NICOLET 6700, Thermo, USA) ( FIG. 5 ). In this analysis, the electronic beam is focused only on the gold aggregates, so that the results can represent the real composition of a gold suspension. The EDS quantitative analysis confirmed the gold total elementary composition. To understand the above detailed description see graphics and images below.
Inoculation of Mice with Tumor Cells:
Female Swiss mice, 6-7 weeks of age, were obtained from the Laboratory Animal Unit of King Saud University, Research center—Saudi Arabia—Riyadh. Mice were injected subcutaneously in the flank of sub thigh with 200 μL (3×107) Ehrlich Ascites carcinoma cells suspended in 10 mM PBS. Near-infrared (NIR) plasmonic photothermal therapy (PPTT) was performed once tumor burden reached 10-12 mm in diameter (7-9 days).
In Vivo Near-Infrared PPTT:
100 microliters of the inventive gold nanoparticles (Laser OD λ=808 nm =40) were directly injected into the tumor. Mouse tumors were extracorporeally exposed to NIR laser radiation (0.9-1.1 W/cm 2 , 6 mm diameter, 10 min) within 2 min of injection to limit particle diffusion beyond the tumor boundaries. Due to the unusually rapid growth rates observed in the Ehrlich
Ascites model, tumors and vital organs were harvested at days 11-14 for use in separate, ongoing the liver and kidney functions investigations.
Statistical Analysis
The results were expressed as mean (mean±SD), whereas SD is the standard derivation. Data were analyzed statistically using one-way analysis of variance followed by t test. A value of (P<0.05) was considered statistically significant.
Results:
1-Volume of Tumor:
TABLE 1
Average volume change in tumors followed by near-infrared
PPTT at 808 nm irradiation of gold nanoparticles
Time
1
2
3
4
5
First day(mm)
10.8
12.1
5.6
9.7
11.5
Sixth day (mm)
9.6
8.9
1.7
4.1
6.3
The results of Table 1 clearly indicate specificity of near-infrared PPTT by reduction of the tumor volume when the inventive gold nanoparticles are directly injected.
2-Liver Function Changes:
TABLE 2
Liver function changes by treatment with the gold nanoparticles
(NPs) and control group Healthy mice without tumor (Cont).
Number of mice
1
2
3
4
5
GOT (NPs) U/l
453
444
445
444
465
GPT (NPs) U/l
42.7
30.5
46.7
43.2
51.3
GOT (Cont) U/l
445
466
451
447
446
GPT (Cont) U/l
70.7
77.0
59.9
69.8
59.9
GPT and GOT are commonly measured to determine liver health. GPT (Glutamic-pyruvic transaminase), also known as ALT (Alanine aminotransferase), is a cytoplasmic hepatocellular enzyme, whose increase in blood is highly indicative for liver damage, e.g. by hepatitis, cirrhosis or hepatic tumors. GOT (Glutamic oxaloacetic transaminase) is applied as a marker for liver health as well. When measured for clinical data, the values for GPT and GOT are typically stated in units per liter (U/l).
TABLE 3
Unpaired t test (GPT) between two groups
Group
Group (Control)
Group (NPs)
Mean
41.8000
67.4600
SD
13.76989
7.43794
SEM
6.15808
3.32635
N
5
5
TABLE 4
Unpaired t test (GOT) between two groups:
Group
Group (Control)
Group (NPs)
Mean
376.0000
451.0000
SD
115.01739
8.68907
SEM
51.43734
3.88587
N
5
5
In Tables 3 and 4 the data for the unpaired t test for GPT and GOT measurements of Table 2 are shown, whereas SD is the standard derivation, SEM is the standard error of the mean and N is the sample size.
In conclusion, no significant changes of liver function among mice treated with gold nanoparticles (Np) and healthy mice (Cont) have been noticed by determine GPT. Unpaired t test results demonstrate that this difference is considered to be not statistically significant (95%) (t=−0.142−, df=8, standard error of difference=4.79677). Even for the determination of GOT, no significant changes of liver function has been observed. Unpaired t test results show that this difference is considered to be not statistically significant (95%) (t=2.006, df=8, standard error of difference=5.62).
3-Kidney Function Changes:
TABLE 5
Kidney function changes by treatment with the gold nanoparticles
(NPs) and control healthy mice without tumor (Cont).
Number of mice
1
2
3
4
5
Creatinine (NPs)
<0.5
<0.5
<0.5
<0.5
<0.5
mg/dl
Urea (NPs)
61
70
53.2
48.1
118.3
Creatinine mg/dl
<0.5
<0.5
<0.5
<0.5
<0.5
(Cont)
Urea(Cont) mg/dl
38.1
46.4
44.8
46.5
47.3
Urea is a waste product formed of the digestion of proteins. Urea is usually passed in the urine. A high blood level of urea (“ureamia”) indicates that the kidneys may not be working properly or that dehydration may occur (low body water content). Creatinine is a waste product made by the muscles. Creatinine passes into the bloodstream, and is usually passed out in urine. A high blood level of creatinine indicates that the kidneys may not be working properly. Creatinine is usually a more accurate marker of kidney function than urea. Typically, urea and creatinine are reported in milligrams per deciliter (mg/dl).
TABLE 6
Unpaired t test (Urea) between two groups
Group
Group (Control)
Group (NPs)
Mean
66.4200
44.6200
SD
10.05967
3.75593
SEM
4.49882
1.67970
N
5
5
Changes of some kidney functions determined by creatinine and urea showed no differences among mice treated with gold nanoparticles (Np) and healthy mice (Cont), as shown in Tables 5 and 6. For the urea testing, the unpaired t test results of Table 6 demonstrate that this difference is considered to be not statistically significant (95%) (t=2.006, df=8, standard error of difference=12.71239). Table 5 shows the same results for creatinine
From all of these results, the benefit of the inventive method and the inventive nanoparticles prepared by using green chemistry synthetic techniques, comprising the mixed extract of Olea Europaea fruit extract and Acacia Nilotica extract, is demonstrated. The benefit is especially the significant affinity of the inventive nanoparticles towards Ehrlich Ascites carcinoma cell.
Similar studies has been considered by E. B. Dickerson et al., 2008, who presented a work which demonstrates the feasibility of in-vivo PPTT treatment of deep-tissue malignancies using easily-prepared plasmonic gold nanorods and a small, portable, inexpensive near-infrared (NIR) laser. Dramatic size decreases in squamous cell carcinoma xenografts were observed for direct (P<0.0001) and intravenous (P<0.0008) administration of pegylated gold nanorods with resorption of >57% of the directly-injected tumors and 25% of the intravenously-treated tumors. The significant benefit of the present invention compared to these studies is that using green natural material to synthesize gold nanoparticles as anti-cancer agents, yields in a better treatment of Ehrlich Ascites carcinoma cell.
Moo-Sung Kim et al., 2013, reported in-vitro studies for investigating the antioxidative and anti-neuroinflammatory potentials of Olea Europaea Linn. fruit pulp (OFP-EA) extract in LPS-stimulated BV-2 microglial cells. The results indicate that OFP-EA extract exhibited strong antioxidant properties.
Example 2
Noble metal colloidal gold nanorods were synthesized by bioreduction of AuCl 4 − ions. 15 g Olea Europaea fruit was washed carefully and was then added to 15 ml deionized water. Then it was grinded, filtered and kept until used. 15 g Acacia Neurotica was added to 15 ml deionized water, soaked all night, filtered and then the extract was kept until it was used. Equal volumes of the Olea Europaea fruit extract and Acacia Neurotica extract were mixed to prepare a mixed extract which preferably contains flavonoids, phenols and/or pentacyclic triterpenoids. 5 ml of the mixed extract was added to 50 ml of an aqueous solution of 0.09M HAuCl 4 and cetyl trimethylammonium bromide (CTAB) 0.35M. This has been stirred for about 10 minutes at 35° C. When adding the extract the color changed, from orange transparent to colorless, then dropping one or more drop of NaOH 0.5M , these colorless indicated the formation of the respective nanorods. Au antibacterial test of the gold nanorods has been conducted, showing a significant inhibition against both gram-positive and gram-negative bacteria. As a reference, nanoparticles were also prepared by using an organic extract as described in the prior art. The formed nanorods have been analyzed: FIG. 6 shows the absorption peak (SPR) obtained in the visible range at range at 515.04-560 nm by UV-visible spectral analysis (Lambda 25, PerkinElmer, United Kingdom) This indicates mono disperse gold nanorods. FIG. 7 shows that the particles average size is 96 nm, measured by Zetasizer® (ZEN 3600, MALVERN, United Kingdom). Transmission electron microscopy (TEM) (JEM-1011, JEOL, Japan) images of prepared gold nanorods are shown in the FIGS. 8 a, 8 b, 8 c. The gold nanorods are rods in shape with a smooth surface morphology. EDS spectrum, linked with SEM (JEOL-FE_SEM), was used to analyze the element of gold nanoparticles ( FIG. 9 ). In this analysis, the electronic beam is focused only on the gold aggregates, so the results can represent the real composition of a gold suspension. The EDS quantitative analysis confirmed the gold total elementary composition, in addition of FTIR spectroscopy (NICOLET 6700, Thermo, USA), FIG. 10 .
Microorganisms and Antibacterial Activity
Pure culture of Escherichia coli, Staphylococcus aureus, Kleb sp., Pseudomonas sp., Salmonella sp., and Streptococcus of bacteria were used. The antibacterial activities of biosynthesized gold nanorods nanoparticles were carried out by disc diffusion method. Nutrient agar medium plates were prepared, sterilized and solidified. After solidification bacterial cultures were swabbed on these plates. The sterile discs were dipped in gold nanorods nanoparticle solutions (1, 5, 10 μg/ml) and placed in the nutrient agar plate and kept for incubation at 37° C. for 24 hours, upon inhibitory activity a zone of clearing around the wells was observed. The diameter of the clearing zones was measured in mm using the ruler scale. The experiments were repeated 3 times and mean values of zone diameter were presented (N. Savithramma et al., 2011).
Results:
TABLE 7
Zone of inhibition (mm) of gold nanorods prepared according
to example 2, against different bacterial strains.
Reagents
E coli
Staphylococcus aureus
Interpretation
Interpretation
zone diameters
zone diameters
(mm)
(mm)
Concentrations
5 μg/ml
10 μg/ml
5 μg/ml
10 μg/ml
Gold nanorods
15
16
19
24
Gold nanorods
27
30
40
45
antibiotic
Example 3
Colloidal silver nanoparticles were synthesized by bioreduction of Ag + ions. 15 g Olea Europaea fruit was washed carefully and was added to 15 ml deionized water. Then it was grinded, filtered and the extract was kept until it was used. 15 g Acacia Nilotica was added to 15 ml deionized water, soaked all night, filtered and then the extract was kept until it was used. The Olea Europaea fruit extract and Acacia Nilotica extract were mixed to prepare a mixed extract which preferably contains flavonoids, phenols and/or pentacyclic triterpenoids. 5 ml of the mixed extract was added to 50 ml of an aqueous solution of 0.1M Ag(NO 3 ) 2 . Afterwards, the mixture was stirred for about 10 minutes at 35° C., or put in a shaker for 30 minutes at 145 rpm and 39° C., or put in a water bath shaking at 125 rpm and 60° C. or was left at room temperature. The color change from colorless transparent to brown indicated the formation of the respective silver nanoparticles.
A separation process for extracts of Olea Europaea fruit extract and Acacia Nilotica extract, was carried out by using a separatory funnel and separated fractions were tested by TLC. It was clearly found that effective groups or preparing the nanoparticles comprise flavonoids, phenols and/or pentacyclic triterpenoids. These effective groups are actually responsible and play main role as reducing and stabilizing agent for the rapid formation of nanorods with high monodispersity.
The formed silver nanoparticles have been analyzed: FIG. 12 shows that the average particle size of the silver nanoparticle is 83 nm, measured by Zetasizer® (ZEN 3600, MALVERN, United Kingdom). Transmission electron microscopy (TEM) (JEM-1011, JEOL, Japan) images of the prepared silver nanoparticles are shown in FIGS. 13 a, 13 b and 13 c. The inorganic silver nanoparticles have different shapes like spherical, rod and other shapes as shown in FIG. 13 . EDS spectrum, linked with SEM (JEOL-FE_SEM), was used to analyze the element of silver nanoparticles ( FIG. 14 ). The EDS quantitative analysis confirmed the silver total elementary composition.
Microorganisms and Antibacterial Activity
The antibacterial test of silver nanoparticles, prepared using a 1:3 mixture of Olea Europaea fruit extract and Acacia Nilotica extract with silver nitrate under stirring, showed a significant inhibition against both gram-positive and gram-negative bacteria.
Pure culture of Escherichia coli, Staphylococcus aureus, and Streptococcus of bacteria were used. The antibacterial activities of biosynthesized silver nanoparticles were carried out by disc diffusion method. Nutrient agar medium plates were prepared, sterilized and solidified. After solidification bacterial cultures were swabbed on these plates. The sterile discs were dipped in silver nanoparticle solutions (5, 10,15 μg/ml) and placed in the nutrient agar plate and kept for incubation at 37° C. for 24 hours, upon inhibitory activity a zone of clearing around the wells was observed. The diameter of the clearing zones was measured in mm using the ruler scale. The experiments were repeated 3 times and mean values of zone diameter were presented (N. Savithramma et al., 2011).
Results:
TABLE 8
Zone of inhibition (mm) of silver nanoparticles, prepared according
to the present invention, against different bacterial strains.
Reagents
Staphylococcus
E coli
aureus
Streptococcus
Interpretation
Interpretation
Interpretation
zone diameters
zone diameters
zone diameters
(mm)
(mm)
(mm)
Concentrations μg/ml
5
10
15
5
10
15
5
10
15
Silver
10
12
14
12
14
17
12
13
15
Nanoparticles
The features disclosed in the foregoing description, the claims and the drawings may, both separately or in any combination, be material for realizing the invention in diverse forms thereof.
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The present invention discloses a method for preparing noble metal nanoparticles, comprising the following steps: a) preparing an Olea Europaea fruit extract; b) preparing an Acacia Nilotica extract; c) mixing the Olea Europaea fruit extract and the Acacia Nilotica extract for preparing a mixed extract; d) providing an aqueous solution containing a noble metal compound dissolved therein; e) mixing the mixed extract obtained in step c) and the aqueous solution of step d) to form noble metal nanoparticles; noble metal nanoparticles obtained thereby and their use.
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RELATED APPLICATIONS
The present application is a §371 U.S. national stage entry of International Application No. PCT/FR2009/052454, filed Dec. 8, 2009, which claims the priority of France patent application No. 08 58413 filed Dec. 9, 2008, all of which are incorporated herein by reference in its entirety.
FIELD
The present invention relates to a valve for spraying coating material, and to an atomizer including such a valve.
BACKGROUND
EP-A-0 274 322 describes a spraying installation for spraying a coating material onto articles to be coated, in which installation a multi-axis robot moves an atomizer for spraying coating material facing articles to be coated. In the example described below, the coating material is a primer, a paint, or a varnish, and the articles to be coated are motor vehicle bodies transported by a conveyor.
The atomizer is equipped with a reservoir containing the volume of paint that is necessary for performing the stage of spraying paint onto the vehicle body. After that stage, it is necessary to fill the reservoir again by coupling the atomizer to a preselected paint circuit, sometimes referred to as a “circulating” paint circuit. When filling the reservoir again, it is often necessary to change coating material, in particular so as to change the shade of color of the paint. It is therefore necessary to clean the reservoir and the channels of the atomizer, and the coupling zones, by rinsing them with a cleaning material such as a solvent.
That is why a prior art paint spraying installation generally includes at least two distinct coupling means placed respectively between the atomizer and the paint circuit and between the atomizer and the solvent circuit. Those coupling means comprise, amongst others, two distinct valves mounted on and/or in the atomizer for the purpose of controlling, respectively and successively, the flow of solvent and the flow of paint. During the cleaning stage, residual waste solvent and paint must also be collected and then conveyed to a treatment unit, which requires an additional valve. This also requires corresponding additional control members and components for actuating the various valves.
Unfortunately, said juxtaposed valves in the atomizer represent considerable overall size, regardless of their respective dimensions. That overall size increases the overall size of the atomizer and makes its structure more complex. In addition, that overall size reduces access to the other components of the atomizer during maintenance operations.
In addition, those three valves are interconnected via a network of common channels, in particular so as to make it possible to rinse the valve and the ducts for enabling paint to flow towards the reservoir. Unfortunately, the volume of those common channels is filled firstly with paint for the reservoir-filling and spraying stages and secondly with solvent for the cleaning stages, so that that volume gives rise to wastage of paint and to a relatively high consumption of solvent. Paint is also wasted when the reservoir is filled again without changing the shade of paint.
A particular object of the present invention is to remedy those drawbacks by proposing a valve that is compact, that significantly reduces the amount of paint wasted and the solvent consumption, and that simplifies the structure of the atomizer.
SUMMARY
To this end, the invention provides a valve comprising:
a body; at least one first duct for channeling the flow of a fluid; at least one second duct for channeling the flow of a fluid; a first needle mounted to move in translation, in a first direction, between an open position and a closed position for opening and closing the or each first duct, the body forming a first seat for the first needle; and a second needle mounted to move in translation, in a second direction, between an open position and a closed position for opening and closing the or each second duct.
This valve is characterized in that the first direction and the second direction are parallel or coincide, while the first needle defines a recess for receiving the second needle, and while the first needle forms a second seat for the second needle.
According to other advantageous but optional characteristics of the invention, taken in isolation or in any technically feasible combination:
the first needle and the second needle are circularly symmetrical respectively about the first direction and about the second direction, and the first needle and the second needle are arranged coaxially; the body defines the first duct, and the second needle has an internal cavity forming a portion of the second duct; the body has an opening common to the first duct and to the second duct; the first needle and the second needle come flush with said opening; the valve further comprises at least one resilient member for urging the first needle and the second needle back into their respective closed positions in which they close the first duct and the second duct, and the first needle and the second needle have respective thrust surfaces arranged in such a manner as to transmit thrust forces exerted by a thrust fluid, such as compressed air, in the first direction or in the second direction in opposition to the resilient member; at least one resilient member is formed by a crest-to-crest multi-turn spring; the first duct extends substantially transversely to the second duct; the first duct and the second duct are arranged to receive a first type of fluid, such as a cleaning material, or a second type of fluid, such as a coating material; the first seat and the second seat are frustoconical in shape; and the first needle and the second needle present wetted surfaces that are substantially locally tangential to the lines of flow of the fluids, in such a manner as to limit fluid retention.
In addition, the invention provides an atomizer for spraying coating material, said atomizer including a valve as described above.
The invention can be well understood and its advantages also appear from the following description, given merely by way of non-limiting example and with reference to the accompanying drawings, in which:
FIGURES
FIG. 1 is a section view of a first embodiment of a valve of the invention;
FIG. 2 is a section view of a second embodiment of a valve of the invention;
FIG. 3 is a section view similar to FIG. 1 , showing a third embodiment of the invention;
FIGS. 4 and 5 are section views on a smaller scale, showing the FIG. 2 valve placed in opening configurations;
FIGS. 6 and 7 are section views, on a smaller scale, showing the FIG. 3 valve placed in opening configurations; and
FIG. 8 is a fragmentary section view of an atomizer of the invention.
DETAILED DESCRIPTION
FIG. 1 shows a valve 100 comprising a body 101 , a first duct 111 and a distinct second duct 112 , in which duct fluids can flow that are used during filing, spraying, and cleaning stages, e.g. paint, solvent, and compressed air.
The valve 100 further comprises a first needle 130 and a second needle 160 , which needles have the function of allowing or preventing fluid flow. The body 101 houses the first needle 130 and the second needle 160 . In addition, the first needle 130 defines a recess 140 adapted to receive a substantial portion of the second needle 160 .
The body 101 is made up of an upstream half-body 102 and of a downstream half-body 103 . The upstream half-body 102 is formed essentially of an upstream end plate 104 and of an upstream cylindrical wall 105 that are united with each other. The downstream half-body 103 is formed essentially of a downstream end plate 106 and of a downstream cylindrical wall 107 . The upstream and downstream end plates 104 and 106 are generally disk-shaped. The upstream and downstream end plates 104 and 106 are provided respectively with an upstream through opening 104 . 1 and with a downstream through opening 106 . 1 . The upstream opening 104 . 1 and the downstream opening 106 . 1 are of circular shape and make it possible for the fluids to pass through the first duct 111 and the second duct 112 , as described in detail below.
The upstream half-body 102 and the downstream half-body 103 are assembled together by the upstream cylindrical wall 105 and the downstream cylindrical wall 107 being fastened together. The upstream and downstream cylindrical walls 105 and 107 may be fastened together by clip-fastening or by screw-fastening, as in the first and second embodiments shown in FIGS. 1 and 2 , or by any other equivalent fastening means.
In the present patent application, the terms “upstream” and “downstream” are used with reference to the general direction of flow of the fluids through the first duct 111 and through the second duct 112 . These flows are shown in FIGS. 4 to 7 by lines of flow L 211 , L 212 , L 311 , and L 312 .
The first needle 130 is mounted to move in translation in a first direction represented by an axis X 112 that is vertical in FIG. 1 . The second needle 160 is mounted to move in translation in a second direction that is also represented by the axis X 112 . In other words the first direction and the second direction in which the first needle 130 and the second needle 160 respectively move are co-linear and coincide as a common axis X 112 .
The first needle 130 is mounted to move between an open position in which it opens the first duct 111 , and a closed position in which it closes said first duct. The second valve 160 is mounted to move between an open position in which it opens the second duct 112 , and a closed position in which it closes said second duct. FIG. 1 shows the valve 100 as placed in its closure configuration, with the first needle 130 and the second needle 160 being in their respective closed positions. In other words, in FIG. 1 , the first needle 130 and the second needle 160 are in their closed positions in which they close the first duct 111 and the second duct 112 respectively. In the configuration shown in FIG. 1 , no fluid can flow in the first duct 111 or in the second duct 112 .
The first needle 130 is made up of a first upstream end-piece 132 that is frustoconical in shape, of a first upstream cylinder 133 , of a first ring 134 , and of a first downstream cylinder 135 . The axis X 112 is common to the first upstream end-piece 132 , to the first upstream cylinder 133 , to the first ring 134 , and to the first downstream cylinder 135 . The first needle 130 is thus circularly symmetrical about the first translation direction constituted by the axis X 112 . The first needle 130 is hollow. More precisely, the first upstream end-piece 132 , the first upstream cylinder 133 , the first ring 134 , and the first downstream cylinder 135 have hollow central regions that communicate with one another.
The second needle 160 is made up of a second upstream end-piece 162 that is frustoconical in shape, of a second upstream cylinder 163 , of a second ring 164 , and of a second downstream cylinder 165 . The axis X 112 is common to the second upstream end-piece 162 , to the second upstream cylinder 163 , to the second ring 164 , and to the second downstream cylinder 165 . The second needle 160 is thus circularly symmetrical about the second translation direction constituted by the axis X 112 . The second needle 160 is hollow. More precisely, the second upstream end-piece 162 , the second upstream cylinder 163 , the second ring 164 , and the second downstream cylinder 165 have hollow central regions that communicate with one another.
The first needle 130 and the second needle 160 are thus arranged coaxially about the axis X 112 .
In the present patent application, the terms “interconnect”, “connect”, “couple”, and “communicate” refer to fluid communication, i.e. to a link enabling a gaseous or liquid fluid to flow or to circulate between two or more points or parts. Such a link may be direct or indirect, i.e. formed by a duct, by a pipe, or by a channel etc. Similarly, the nouns derived from these verbs, such as “interconnection”, “connection”, and “coupling”, concern such fluid communication.
Close to the upstream opening 104 . 1 , the body 101 forms a first seat 123 for the first needle 130 . More precisely, the first seat 123 is constituted by a frustoconical surface of axis X 112 that is provided in the upstream half-body 102 and that converges towards the axis X 112 going towards the upstream opening 104 . 1 . The first upstream end-piece 132 has an outside radial surface 131 having a frustoconical shape that is complementary to the frustoconical shape of the seat 123 . When the first needle 130 is in the closed position, the outside radial surface 131 bears in leaktight manner against the seat 123 . The first needle 130 thus closes the first duct 111 .
In the present application the adjectives “radial” and “axial” are used with reference to the general orientation of the element they describe. For example, a surface is said to be “radial” or “axial” depending on whether a normal to said surface is oriented perpendicularly or parallel to the axis X 112 .
In the present application, the adjectives “inside” and “outside” respectively designate an element facing towards the axis X 112 and an element facing away from the axis X 112 .
The first needle 130 forms a second seat 136 for the second needle 160 . The seat 136 is formed by an inside radial surface of the second upstream end-piece 132 , which surface is of frustoconical shape. The second needle 160 has a terminal plate 166 situated at the upstream end of the second upstream end-piece 162 .
The terminal plate 166 has terminal axial surface that is disk-shaped, and that closes off a substantial fraction of the upstream opening 104 . 1 . The terminal plate 166 also has an outside radial surface 161 having a frustoconical shape that is complementary to the frustoconical shape of the second seat 136 . When the second needle 160 is in the closed position, the outside radial surface 161 of the second upstream end-piece 162 bears in leaktight manner against the second seat 136 . The second needle 160 thus closes the second duct 112 .
The first needle 130 and the second needle 160 come flush with the upstream opening 104 . 1 . More precisely, the respective terminal axial surfaces of the first upstream end-piece 132 and of the second upstream end-piece 162 come flush with an outer surface 104 . 2 of the upstream end plate 104 . This arrangement makes it possible to minimize the overall size of the valve 100 and to reduce coating material consumption and cleaning material consumption.
The body 101 defines the first duct 111 that is machined in the upstream half-body 102 . The first duct 111 extends rectilinearly along an axis X 111 . A substantial portion of the second duct 112 is formed by an internal cavity 170 formed by a blind and cylindrical recess of axis X 112 that is provided through the second needle 160 . The second duct 112 thus extends essentially along the axis X 112 The axis X 111 of the first duct 111 is substantially transverse to the axis X 112 . The adverb “substantially” indicates that the axis X 111 and the axis X 112 may be disjoint, i.e. non-intersecting. In the plane of FIG. 1 , the axis X 111 and the axis X 112 form an angle A of about 70°.
The first needle 130 can slide inside the body 101 and following a sliding and pivoting connection along and about the axis X 112 . In practice, the outside radial surface of the first upstream cylinder 133 has a diameter D 133.1 that is slightly smaller than the diameter D 102 of the inside radial and cylindrical surface of the upstream half-body 102 . The difference between the diameter D 133.1 and the diameter D 102 corresponds to operating clearance allowing the first upstream cylinder 133 to slide inside the upstream half-body 102 .
Similarly, the diameter D 135 of the outside radial surface of the first downstream cylinder 135 is slightly smaller than the diameter D 105 of the inside radial surface of the upstream cylindrical wall 105 . The difference between the diameter D 105 and the diameter D 135 corresponds to operating clearance that allows the first downstream cylinder 135 to slide in the upstream cylindrical wall 105 .
In analogous manner, the second needle 160 can slide inside the first needle 130 and in the downstream half-body 103 , sliding and pivoting along and about the axis X 112 . For this purpose, the diameter D 163 of the outside radial surface of the first upstream cylinder 163 is slightly smaller than the diameter D 133.2 of the inside radial surface of the first upstream cylinder 133 . The difference between the diameter D 133.2 and the diameter D 163 corresponds to operating clearance that allows the first upstream cylinder 163 of the second needle 160 to slide in the first upstream cylinder 133 of the first needle 130 .
Similarly, the diameter D 164 of the outside radial surface of the first ring 164 is slightly smaller than the diameter D 140 of the inside radial surface of the recess 140 that is defined by the inside radial surface of the first downstream cylinder 135 . The difference between the diameter D 164 and the diameter D 140 corresponds to operating clearance that allows the first ring 164 to slide in the recess 140 . In addition, the diameter D 165 of the outside radial surface of the first downstream cylinder 165 is slightly smaller than the diameter D 108 of the inside radial surface of an inner wall 108 of cylindrical shape that belongs to the downstream half-body 103 . The difference between the diameter D 108 and the diameter D 165 corresponds to operating clearance that allows the first downstream cylinder 165 to slide in the inner wall 108 .
FIG. 8 shows an atomizer 1 having a body 11 housing a reservoir 10 containing the coating material, and a high-voltage unit 12 . The atomizer 1 has a valve 100 described above with reference to FIG. 1 . A connection duct 13 connects the upstream of the reservoir 10 to the upstream opening 104 . 1 of the valve 100 . The connection duct 13 is partially formed by the second duct 112 . The downstream of the reservoir 10 is connected to an atomizer member (not shown) via a feed duct 14 . The body 11 has an outside surface 15 surrounding the upstream opening 104 . 1
As shown in FIG. 1 , the upstream opening 104 . 1 is common to the first duct 111 and to the second duct 112 . When the valve 100 is in the opening configuration, the paint and the solvent can flow successively through the upstream opening 104 . 1 during the stages of cleaning and of filling the reservoir 10 of the atomizer 1 . The second upstream end-piece 162 of the second needle 160 has orifices 172 distributed about the axis X 112 . Via the orifices 172 , the fluids (paint, solvent, and compressed air) can flow from the upstream opening 104 . 1 towards the internal cavity 170 , and thus towards the second duct 112 .
The diameter D 111 of the first duct 111 is about 3 millimeters (mm), because it serves to pass solvent and compressed air for the purpose of cleaning the channels and the atomizer member of the atomizer 1 . The diameter D 112 of the second duct 112 , as measured in its narrowest portion, is about 8 mm, because it serves to pass paint. Thus, the first duct 111 and the second duct 112 are arranged to receive respectively a first type of fluid such as a cleaning material, constituted by solvent and by compressed air, or a second type of fluid such as a coating material constituted by paint.
The valve 100 has a length L 100 , as measured parallel to the axis X 112 , of about 49 mm. The valve 100 has a width W 100 , as measured perpendicularly to the axis X 112 , of about 44 mm. Thus, the valve 100 is particularly compact.
This compactness of the valve 100 facilitates access to the other components of the atomizer 1 during maintenance operations, and it limits wastage of paint and consumption of solvent. In addition, this compactness limits head losses generated by the valve 100 on the flows of paint and of solvent, thereby improving the effectiveness of the cleaning and increasing the flow-rate of filling of the reservoir 10 , and thus reducing the time required for changing shades of paint.
The first needle 130 and the second needle 160 have respective thrust surfaces 137 and 167 that are arranged in such manner as to transmit respective thrust forces F 137 and F 167 exerted by a thrust fluid, which is compressed air in this example. The compressed air is injected onto the first thrust surface 137 via a first thrust chamber 138 and via a first thrust channel 139 . The compressed air is brought onto the second thrust surface 167 via a second thrust chamber 168 and via a second thrust channel 169 , which channel is provided through the upstream cylindrical wall 105 and communicates with the second thrust chamber 168 through the first downstream cylinder 135 . The thrust surfaces 137 and 167 are fainted by respective upstream axial surfaces of the rings 134 and 164 .
The thrust forces F 137 and F 167 are distributed respectively over the set of thrust surfaces 137 and 167 . The resultants of the thrust forces F 137 and F 167 are exerted parallel to the axis X 112 , i.e. in the first translation direction in which the first needle 130 moves in translation, and in the second translation direction in which the second needle 160 moves in translation.
In order to urge the first needle 130 and the second needle 160 back into their respective closed positions in which they close the first duct 111 and the second duct 112 , the valve 100 further includes a first spring 191 and a second spring 192 . The first spring 191 and the second spring 192 respectively constitute a first resilient member and second resilient member for urging the first needle 130 and the second needle 160 back into their respective closed positions in which they close the first duct 111 and the second duct 112 . The first spring 191 and the second spring 192 work in compression in opposition to respective ones of the thrust forces F 137 and F 167 .
The surface areas of the thrust surfaces 137 and 167 are determined as a function of the available thrust fluid pressure and of the return forces exerted by the first spring 191 and by the second spring 192 . The first spring 191 and the second spring 192 are dimensioned as a function of the paint and solvent feed pressures that are exerted on their upstream end-pieces of type 132 . These feed pressures are defined for the paint installation in which the valve 100 is used.
The first spring 191 is a conventional helical wire spring. Alternatively, it may be a crest-to-crest multi-turn spring. For the same length unloaded, a crest-to-crest multi-turn spring offers stiffness greater than the stiffness offered by a conventional helical wire spring. The first spring 191 is flanked laterally by the downstream cylindrical wall 107 and by an inner wall 108 belonging to the downstream half-body 103 . The first spring 191 is in abutment firstly against the downstream end plate 106 and secondly against an upstream axial surface of the first downstream cylinder 135 .
The second spring 192 is a conventional helical wire spring. The second spring 192 is flanked laterally by the downstream cylindrical wall 107 and by the inner wall 108 . The second spring 192 is mounted to bear firstly against the downstream end plate 106 and secondly against an upstream axial surface of the first ring 164 .
The valve 100 also includes a plurality of sealing zones that are arranged between its various components for the purpose of making them leaktight relative to the fluids flowing through the valve 100 , which fluids are constituted by paint, solvent, and compressed air. The first needle 130 and the second needle 160 are sealed by O-ring seals bearing against radial surfaces, thereby increasing the axial compactness of the valve 100 . These radial surfaces correspond to the cylindrical portions of the first needle 130 and of the second needle 160 . Implementing the sealing on radial surfaces rather than on axial surfaces makes it possible to retain fluids while eliminating “dead” zones.
FIG. 2 shows a second embodiment of a valve 200 of the invention. The description of the valve 100 that is given above can be transposed to the valve 200 , except for the significant differences mentioned below. An element of the valve 200 that is identical or that corresponds to an element of the valve 100 bears the same numerical reference plus 100.
This transposition thus defines the valve 200 , a body 201 , an upstream half-body 202 , a downstream half-body 203 , an upstream end plate 204 , an upstream opening 204 . 1 , an upstream cylindrical wall 205 , a downstream end plate 206 , a downstream opening 206 . 1 , a downstream cylindrical wall 207 , a first duct 211 of axis X 211 , and of diameter D 211 , a second duct 212 of axis X 212 and of diameter D 212 , a first seat 223 , a first needle 230 with a first upstream end-piece 232 , a first upstream cylinder 233 , a first ring 234 , a first downstream cylinder 235 , a second seat 236 , a first thrust surface 237 , a first thrust chamber 238 , a recess 240 , a second needle 260 with a second upstream end-piece 262 , a second upstream cylinder 263 , a second ring 264 , a second downstream cylinder 265 , a terminal plate 266 , a second thrust surface 267 , a second thrust chamber 268 , an internal cavity 270 , a first spring 291 , and a second spring 292 .
The valve 200 differs from the valve 100 essentially by the functions of its first and second ducts, i.e. by the geometrical shapes and dimensions of the first duct 211 and of the second duct 212 . The first duct 211 and the second duct 212 extend respectively along an axis X 211 and along an axis X 212 that are perpendicular, i.e. that form an angle of 90° between them in the plane of FIG. 2 . The valve 200 is more compact than the valve 100 , because the length of the valve 200 is 43 mm and its width is 36 mm.
The diameter D 211 of the first duct 211 is about 8 mm, because it serves more particularly to pass paint. The diameter D 212 of the second duct 212 , as measured in its narrowest portion, is about 3 mm because it serves to pass solvent and compressed air for cleaning the channels and the atomizer member of the atomizer 1 . Thus, the second duct 212 and the first duct 211 are arranged to receive respectively a first type of fluid, such as a cleaning material, constituted by solvent and by compressed air, or a second type of fluid, such as a coating material constituted by paint.
In addition, the first upstream end-piece 262 of the second needle 260 is cylindrical in overall shape, unlike the second upstream end-piece 162 of the valve 100 that is frustoconical in shape.
Furthermore, the end-piece 232 of the first needle 230 and the end-piece 262 of the second needle 260 have wetted surfaces that are substantially locally tangential to the lines of flow of the fluids, in such a manner as to limit retention of fluid.
To this end, for example, the valve 200 has a recess 232 . 1 in the shape of a half-torus, which recess is locally tangential to the lines of flow L 211 , as shown in FIG. 5 . The frustoconical shapes of the first and second upstream end-pieces 132 and 162 are also locally tangential to the lines of flow of the fluids, thereby making it possible to limit fluid retention and to improve rinsing of the soiled surfaces.
In addition, the valve 200 also has other structural differences relative to the valve 100 . Insofar as these structural differences do not involve operating differences between the valves 100 and 200 , they are not described in the present application.
FIG. 3 shows a third embodiment of a valve 300 of the invention that is substantially identical to the valve 100 described above with reference to FIG. 1 . The description of the valve 100 that is given above can be transposed directly to the valve 300 , except for the significant differences mentioned below. An element of the valve 300 that is identical or that corresponds to an element of the valve 100 bears the same numerical reference plus 200.
This transposition thus defines the valve 300 , a body 301 , an upstream half-body 302 , a downstream half-body 303 , an upstream opening 304 . 1 , a downstream opening 306 . 1 , a first duct 311 , a second duct 312 of axis X 312 , a first needle 330 with a first thrust surface 337 , and first thrust chamber 338 , a recess 340 , a second needle 360 with a second thrust surface 367 , and a second thrust chamber 368 and an internal cavity 370 .
The valve 300 differs from the valve 100 essentially in that it has a single spring 392 analogous to the second spring 192 . The spring 392 constitutes a resilient member for urging the first needle 330 and the second needle 360 into their respective closed positions in which they close the first duct 311 and the second duct 312 .
In order to maintain the second needle 360 open, during opening of the first needle 330 , the pressure prevailing in the second thrust chamber 368 must be greater than the pressure prevailing in the first thrust chamber 338 .
By mounting a single spring 392 instead of two springs 191 and 192 , it is possible to reduce the manufacturing costs and to increase the compactness of the valve 300 .
Operation of the valve 300 is shown by FIGS. 6 and 7 . Operation of the valve 100 is substantially identical to operation of the valve 300 that is described below. In order to perform the cleaning stage, the valve 300 is placed in a first opening configuration shown by FIG. 6 . The first duct 311 and the second duct 312 are opened as a result of the first needle 330 and of the second needle 360 sliding under the effect of the thrusts exerted on the thrust surfaces 337 and 367 . The solvent then flows in the first duct 311 and in the second duct 312 , thereby cleaning the ducts and all of the downstream elements. The flow of solvent is represented by the lines of flow L 311 and L 312 .
In order to perform the filling stage, the valve 300 is placed in a second opening configuration shown in FIG. 7 . The first duct 311 is closed by the first needle 330 , while the second duct 312 is opened by moving the second needle 360 . The paint then flows into the second duct 312 towards the reservoir 10 . The flow of paint is represented by the line of flow L 312 . No fluid flows into the first duct 211 .
When the valve 300 is in a third opening configuration (not shown), the first duct 211 is open, while the second duct 212 is closed.
Operation of the valve 200 is shown in FIGS. 4 and 5 . In order to perform the cleaning stage, the valve 200 is placed in a first opening configuration shown in FIG. 4 . The first duct 211 and the second duct 212 are opened as a result of the first needle 230 and of the second needle 260 sliding under the effect of the thrusts exerted on the thrust surfaces 237 and 267 . The solvent then flows through the first duct 211 and through the second duct 212 , thereby cleaning these ducts and all of the downstream elements. The flow of solvent is represented by the lines of flow L 211 and L 212 .
In order to perform the filling stage, the valve 200 is placed in a second opening configuration shown in FIG. 5 . The first duct 211 is opened by moving the first needle 230 , while the second duct 212 is closed by the second needle 260 . Paint then flows into the first duct 211 towards the reservoir 10 . The flow of paint is represented by the line of flow L 211 . No fluid then flows in the second duct 212 .
When the valve 200 is in a third opening configuration (not shown), the first duct 211 is closed, while the second duct 212 is open.
In addition to its high compactness, a valve of the invention avoids a mechanically blocked construction that, in the prior art, is made necessary by sealing zones being formed simultaneously for two adjacent ducts.
In a variant (not shown), the first translation direction of the first needle is parallel to, without being co-linear with, the second translation direction of the second needle.
In another variant (not shown), the upstream and downstream half-bodies are assembled together by being fastened together by clipping the upstream cylindrical wall onto the downstream cylindrical wall, instead of by screw-fastening as applies to valves 100 , 200 , and 300 . The assembly clearance resulting from that clip-fastening is taken up by the second spring, because the second spring works in compression and pushes back firstly the downstream half-body and secondly the upstream half-body, via the first needle.
In yet another variant (not shown) the first needle 130 and the second needle 160 project out of the upstream opening 104 . 1 , instead of being flush therewith as in valves 100 , 200 , and 300 . This makes it possible to seal off an upstream cavity whenever necessary.
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This valve ( 100 ) comprises: a body ( 101 ); a first channel ( 111 ) for channelling the flow of a fluid; a second channel ( 112 ) for channelling the flow of a fluid; a first valving element ( 130 ) which is movable translationally in a first direction (X 112 ), between an open position and closed position of the or each first channel ( 111 ), the body ( 101 ) forming a first seat ( 123 ) for the first valving element ( 130 ); and a second valving element ( 130 ) which is movable translationally in a second direction (X 112 ), between an open position and a closed position of the or each second channel ( 112 ); the first direction (X 112 ) and the second direction (X 112 ) being parallel or coinciding with each other. The first valving element ( 130 ) defines a housing ( 140 ) for the second valving element ( 130 ). The first valving element ( 130 ) forms a second seat ( 136 ) for the second valving element ( 130 ).
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BACKGROUND OF THE INVENTION
1. Field of the Invention
In plants, acyl-carrier protein (ACP) exists as a small acidic cofactor protein which participates in at least 12 reactions of fatty acid biosynthesis and metabolism. In recent years, research on this protein has intensified in several laboratories because of the potential of ACP to serve as a representative marker protein for studies of the regulation of plant fatty acid synthetase gene expression. Such studies may eventually have an important practical impact on the selection of genetic engineering strategies used to modify the amount and type of fatty acids produced by oilseed crops. For example, ACP levels have been measured in developing soybean seeds by both enzymic and immunochemical assays [J. B. Ohlrogge et at. I, Plant Physiol. 74: 622-625 (1984)]. A close correlation was found between rates of fatty acid synthesis in vivo and ACP content. These results suggest that levels of fatty acid biosynthetic proteins may be a rate-determining component of the seed's overall lipid biosynthetic capacity. Although other factors such as substrate and cofactor supply may also limit seed oil production, the results with ACP provide encouragement that molecular genetic modification of fatty acid biosynthetic protein levels may provide a means to influence oilseed metabolism.
2. Description of the Prior Art
ACPs have been the first proteins in plant fatty acid biosynthesis to be purified to homogeneity and, to date, the only proteins for which amino acid sequence data are available. Spinach leaf ACP-I has been completely sequenced [T. M. Kuo et al. I, Arch. Biochem. Biophys. 234: 290-296 (1984)], and 72 of 87 residues of the barley leaf ACP-I are known [P. B. Hoj et al., Carlsberg Res. Commun. 48: 284-306 (1983)]. The two plant sequences are 70% homologous, indicating that the ACP structure is highly conserved between monocot and dicot plant species. Comparison with the Escherichia coli ACP sequence reveals 40% homology; whereas, the ACP domain of the rabbit multi-enzyme fatty acid synthetase complex has 25% homology with plant or bacterial ACP sequences. These comparisons suggest that all ACPs evolved from a common ancestor, but, intriguingly, the plant structure has remained closer to its bacterial counterpart than to the corresponding animal structure.
Plants have recently been shown to contain multiple isoforms of ACP [P. B. Hoj et al., Carlsberg Res. Commun. 49: 483-492 (1984); J. B. Ohlrogge et al. II, J. Biol. Chem. 260: 8032-8037 (1985)]. Although the isoforms are clearly closely related in structure, there are significant differences in the amino acid composition and the N-terminal sequences of both barley and spinach ACP isoforms. These differences suggest that the isoforms may be coded by multigene families.
The plant ACP isoforms are expressed differently in different tissues (Ohlrogge et al. II, supra). In spinach leaves we find that ACP-I is present at three- to fourfold higher levels than ACP-II. However, in developing spinach seeds ACP-II is the predominant species, with ACP-I absent or barely detectable. Similar results have been observed with castor oil seed leaves and endosperm and soybean leaves and developing cotyledons.
Studies have revealed that ACP is localized essentially exclusively in the plastids of spinach mesophyll cells, but is probably initially synthesized in the cytoplasm. Reported data also suggest that ACP is a nuclear-encoded protein, which is synthesized as a precursor polypeptide containing a transit peptide that guides its uptake by the plastids.
ACPs constitute less than 0.1% of the total cell protein in most species [T. M. Kuo et al. II, Arch. Biochem. Biophys. 230: 110-116 (1984)]. Therefore, purification of milligram quantities is difficult, and, as a consequence, plant lipid biosynthetic studies have been hampered by the absence of adequate supplies of plant ACP for use as cofactor or substrate.
Expression of a plant ACP gene in a suitable vector such as E. coli might provide a means of providing sufficient ACP for enzymological and other studies. A synthetic gene encoding only a strutural protein is more likely to produce an active ACP when introduced into E. coli than either a genomic clone (with expected intervening sequences, i.e., introns) or a full-length cDNA clone (with an expected transit peptide encoding sequence).
SUMMARY OF THE INVENTION
We have now discovered a strategy for constructing, cloning, and expressing synthetic acyl carrier protein genes. The novel genes contemplated by the invention are designed to have a high level of homology with the naturally occurring ACP genes.
In accordance with this discovery, it is an object of the invention to provide synthetic genes encoding for proteins which are structurally homologous and functionally identical to authentic acyl carrier proteins.
It is also an object of the invention to clone the ACP gene in a standard cloning vector and also to express the ACP gene in high efficiency expression vectors.
It is a further object of the invention to produce and recover ample quantities of synthetic ACP.
It is an object of one particular embodiment of the invention to provide, clone, and express in E. coli a synthetic gene encoding the entire amino acid sequence of spinach ACP-I.
It is another object of the invention to provide a prototype for a synthetic ACP gene designed for expression in plants and animals.
Other objects and advantages of this invention will become readily apparent from the ensuing description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow diagram illustrating the strategy for constructing and cloning the synthetic spinach ACP-I gene described in Example 1.
FIG. 2 illustrates the nucleotide sequences and oligonucleotide fragments employed in the construction of the synthetic spinach ACP-I gene described in Example 1.
GLOSSARY
For purposes of this invention, the following standard abbreviations and terms used herein have been defined below. Also included are a listing of restriction enzymes and an appendix of biological materials mentioned in the specification.
Abbreviations
ACP=acyl carrier protein
ACP-I=acyl carrier protein, isoform I
ACP-II=acyl carrier protein, isoform II
ATP=adenosine triphosphate
bp=base pairs
cDNA=single-stranded DNA complementary to a messenger RNA
DNA=deoxyribonucleic acid
MES=4-morpholineethanesulfonic acid
RNA=ribonucleic acid
trc=a high level promoter derived by fusion of the tryptophan (trp) and β-galactosidase promoter (lac)
YT=yeast extract+tryptone growth medium (8 g/l tryptone, 5 g/l yeast extract, 5 g/l NaCl)
Terms
clone: in reference to DNA, the product or process of isolating a segment of DNA, linking it to a vector, and introducing it into a host for expression
expression: the transcription of a gene into messenger RNA (mRNA) and the subsequent translation of the mRNA into a protein coded by the gene
expression vector: a DNA sequence such as an amplicon, phage, or plasmid which is able to replicate in a host cell and express genes present in the DNA sequence
gene: a segment of DNA which encodes a specific protein or polypeptide, or RNA
hybridization: the pairing together or annealing of single-stranded regions of nucleic acids to form double-stranded molecules
linker: synthetic oligonucleotide containing a site for a restriction enzyme
phage: a bacteriophage; a virus which infects bacteria
plasmid: circular double-stranded DNA capable of autonomous replication within a bacterium
polylinker: array of restriction enzyme recognition sites (each of which is usually 4-8 bases long) linked together
probe: a labelled nucleic acid fragment which will hybridize with complementary nucleic acid sequences, and thereby be useful for detecting specific nucleic acid fragments
promoter: a recognition sequence for binding of RNA polymerase
subclone: in reference to DNA, the product or process of cloning a portion of an already cloned DNA segment
transform: to change in a heritable manner the characteristics of a host cell in response to DNA foreign to that cell
transgenic: relating to new genetic information becoming embedded into a germline
vector: a nucleic acid molecule such as a plasmid or phage and having a site for inserting a gene of interest for cloning, transfer, or expression
______________________________________Restriction Enzyme Cleavage SiteBamHI 5' . . . G↓GATCC . . . 3'HindIII 5' . . . A↓AGCTT . . . 3'HgaI 5' . . . GACGC(N).sub.5 . . . 3' 3' . . . CTGCG(N).sub.10 . . . 5'NcoI 5' . . . C↓CATGg.3'XhoI 5' . . . C↓TCGAg.3'Appendix of Biological MaterialsE. coli cells: SourceDH5 BRLDH5α BRLJM101 ClontechJM103 J. MessingJM109 J. MessingEnzymes:T.sub.4 (polynucleotide kinase) N.E. Biolabs or BRLT.sub.4 (DNA lignase of IBIbacteriophage)calf intestinal phosphatase BoerhingerPlasmids and Phage:M13mp19RFI (M13) PharmaciapPB104 NRRL B-18218pPB269 NRRL B-18219pKK233-2 J. BrosiuspTZ19R Pharmacia______________________________________
DETAILED DESCRIPTION OF THE INVENTION
For purposes of the invention, the expression "synthetic ACP gene" and equivalent expressions are defined to mean any nonnaturally occurring nucleic acid sequence which encodes acyl carrier protein (ACP). As previously discussed, it is recognized that ACP may exist in more than one isoform in a given species, and that the ACP structure varies from species to species. In fact, it is generally known that variations may exist in the amino acid sequence of a protein without any significant effect on its functional characteristics. It is also recognized that the coding sequences and the general construction of the synthetic gene may be varied considerably without altering the amino acid sequence of the encoded protein. The expression "synthetic ACP gene" is intended to encompass all such variations in gene structure.
The expression "plant ACP" refers to any acyl carrier protein having the essential functional characteristics of naturally occurring ACP molecules found in plants. The expressions "procaryotic ACP," "yeast ACP," and "animal ACP" are similarly defined, as are these same expressions when used in conjunction with the term "gene."
The first step in constructing a gene for expressing ACP is to predetermine the amino acid sequence of the specific protein to be encoded. In modeling the protein after an authentic ACP, slight variations may be made in the amino acid sequence without consequential effect on its functionality. Thus, certain amino acid additions, deletions, or substitutions inadvertently introduced or expressly designed into the protein structure would be contemplated as being within the purview of this invention.
The next step in gene construction is to select an appropriate nucleic acid triplet (codon) for encoding each amino acid within the latitude allowed by the redundancy of the genetic code. In order to optimize the synthetic gene as a probe for the naturally occurring homologous gene and mRNA, the gene's codon usage is made to reflect that of sequenced genes for other proteins in homologous systems. Creation of a codon usage table such as that employed in the Example below is a logical approach to this exercise. Unusual or disruptive nucleotide sequences within a codon, or created by adjacent codons, should be avoided. Also to be avoided are direct and inverted repeat sequences which would have a tendency to create undesirable mismatches or secondary structure.
The gene per se will usually be a component of larger synthetic recombinant DNA molecule including other DNA sequences. For example, it would be desirable to flank the gene with restriction endonuclease recognition sites as known in the art and to incorporate the gene into vectors for promoting assembly and expression. Of particular interest as vectors are plasmids and phages which lend themselves to cloning, transfer, and expression of the synthetic gene. Other sequences such as promoters, enhancers, and the like may also be built into the constructions.
While various approaches to construction may be taken, it is preferred to synthesize the complementary strands of the gene from overlapping oligonucleotide fragments ranging in size from about 10-60 nucleotides each. The oligonucleotides may be synthesized using a DNA synthesizer as known in the art, and they are subsequently ligated and annealed together using conventional enzymes and methodology. Depending on the size of the gene, either the complete sequence or parts thereof can be constructed in this manner.
By incorporating the ligation products into a suitable cloning vector, the gene or gene parts can be multiplied and selected by established criteria. If clones of components of the gene are selected, a stategy similar to that employed for assembling the oligonucleotide fragments can be applied to assembling the whole gene.
To achieve expression, the gene is subcloned from the cloning vector into a suitable expression vector. Typically the expression vector will provide both a promoter and a ribosome binding site upstream from the insert site. A start codon must also be provided at an appropriate site in the construction. A preferred expression system for in vitro production of ACP is E. coli. Of course, appropriate design modifications can be made in the synthetic ACP gene to achieve in vivo expression in plant cells.
The full-length synthetic ACP genes contemplated by this invention have utility as sensitive DNA and RNA probes to the ACP gene. In addition, clones partial genes and oligonucleotides such as those used in constructing the ACP-I gene described in the Example, below, have utility as probes for specific portions of the ACP gene. The successful expression of a synthetic plant ACP gene in E. coli or other vector system enables isolation of large quantities of the synthetic protein. This is also a first step toward achieving expression of authentic ACP-I from transformed plant cells or transgenic plants.
The ensuing Example drawn to construction of a synthetic spinach ACP-I gene is intended to illustrate the contruction of similar genes within the compass of the invention. Modifications to the design of the gene and strategy for its assembly and cloning would be obvious to the skilled artisan.
EXAMPLE
Design of a Synthetic Gene for Spinach ACP-I
The design of the 268-base pair, synthetic ACP gene described below was guided by the following 82 amino acid sequence of spinach ACP-I reported in the literature by Kuo et al. I, supra. ##STR1##
Amino acid residue 76 was not identified in the original protein sequencing. Glycine occurs in this position in E. coli ACP, and the plant and bacterial sequences are approximately 50% homologous in this region. In addition, amino acids analysis of spinach ACP-I suggested a glycine residue could have been missed in the sequencing. Therefore, we designed the gene based on a glycine at position 76.
A plant codon usage table (Table I) was constructed using 18 sequences from the "Genbank" data base. The 18 sequences represent 4,478 amino acids. Ten of the sequences are from seed proteins, and there are four sequences for ribulose bisphosphate carboxylase small subunit from different plants. The probability of the occurrence of the third nucleotide for degenerate codons and the optimum codon for arginine, serine, and leucine were calculated as in Lathe [J. Mol. Biol. 183: 1-12 (1985)]. The initial ACP synthetic gene sequence was generated using the most probable codons in cases of degeneracy. In subsequent analyses, the dinucleotide CG was removed wherever possible from the sequence, as this dinucleotide is rare in the structural genes of eucaryotes (Lathe, supra). Codon usage in the gene sequence was further modified to remove direct or inverted repeat sequences greater than eight bases in order to eliminate undesirable mismatches or secondary structure in the oligonucleotides.
TABLE I__________________________________________________________________________Plant Codon UsageU C A G1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5__________________________________________________________________________U 74 0.35 0.78 Phe U 78 0.22 0.57 Ser U 53 0.38 0.79 Tyr U 10 0.19 0.78 Cys U 1390.65 0.88 Phe C 84 0.24 0.60 Ser C 87 0.62 0.87 Tyr C 42 0.81 0.94 Cys C 30 0.07 0.49 Thr A 60 0.17 0.51 Ser A E1 A E3 A 94 0.22 0.55 Thr G 22 0.06 0.47 Ser G E2 G 58 1.0 1.0 Trp GC 96 0.22 0.63 Thr U 63 0.26 0.75 Pro U 35 0.44 0.81 His U 36 0.20 0.55 Arg U 93 0.22 0.63 Thr C 55 0.23 0.74 Pro C 44 0.56 0.85 His C 31 0.17 0.54 Arg C 59 0.14 0.63 Thr A 97 0.40 0.80 Pro A 200 0.64 0.88 Gln A 12 0.06 0.59 Arg A 60 0.14 0.67 Thr G 27 0.11 0.70 Pro G 113 0.36 0.78 Gln G 10 0.05 0.58 Arg GA 83 0.34 0.78 Ile U 73 0.32 0.77 Thr U 77 0.33 0.78 Ash U 39 0.11 0.31 Ser U 1200.49 0.83 Ile C 99 0.43 0.81 Thr C 153 0.67 0.89 Ash C 71 0.20 0.35 Ser C 40 0.16 0.72 Ile A 38 0.17 0.72 Thr A 88 0.38 0.79 Lys A 50 0.27 0.62 Arg A 88 1.0 1.0 Met G 18 0.08 0.69 Thr G 143 0.62 0.87 Lys G 43 0.24 0.60 Arg GG 84 0.27 0.76 Val U 119 0.32 0.77 Ala U 93 0.47 0.81 Asp U 74 0.27 0.75 Gly U 65 0.21 0.73 Val C 123 0.34 0.78 Ala C 106 0.53 0.84 Asp C 94 0.34 0.78 Gly C 42 0.14 0.71 Val A 83 0.23 0.74 Ala A 103 0.43 0.81 Glu A 60 0.22 0.74 Gly A 1170.38 0.79 Val G 41 0.11 0.70 Ala G 137 0.57 0.86 Glu G 44 0.16 0.72 Gly G__________________________________________________________________________ 1. Number of times a particular codon was used out of 4,470 amino acids screened. 2. Probability of usage of particular codon. 3. Certainty factor or overall homology for codon [see Table 5, Lathe, J. Mol. Biol. 183: 1-12 (1985)]. 4. Amino acid, three letter code. 5. Third nucleotide in codon. Sequences used to determine codon usage: Hordeum vulgare amylase (cDNA); Hordeum vulgare B1 hordein (cDNA); Lemna gibba ribulose bisphosphate carboxylase small subunit (cDNA); Zea mays 22 Kd. zein protein (cDNA); Ze mays alcohol dehydrogenase ADH1 (cDNA); Zea mays zein clone A30 (cDNA); Nicotiana sylvestris ribulose bisphosphate carboxylase small subunit (cDNA); Petroselinum hortense chalcone synthase (cDNA); Pisum sativum legumin subunit pair precursor (cDNA); Pisum sativum lectin (alpha and beta subunits) (cDNA); Pisum sativum ribulose biphosphate carboxylase small subunit (cDNA); Pisum sativum vicilin (cDNA) (two separate clones); Phaseolus vulglaris lectin (cDNA); Glycine max 7S seed storage protein α + α.sup.1 (cDNA); Glycine max actin gene; Glycine max lecti gene; Glycine max ribulose bisphosphate carboxylase small subunit gene (cDNA); Triticum aestivum gliadin (cDNA).
The overall strategy for construction and cloning of the synthetic gene is outlined in FIG. 1. Numbers 1-16 refer to the oligonucleotides depicted in FIG. 2.
As shown in FIG. 2, two gene fragments, one encoding the amino-terminal portion (A) and the other the carboxy-terminal portion (B) of the protein, were separately assembled from 16 synthetic oligonucleotides. The numbers correspond to the amino acids of the mature protein. The approach of assembling the oligonucleotide into two gene fragments facilitated cloning.
BamHI sites were positioned at the 3' end of the amino-terminal segment and the 5' of the carboxy-terminal segment as shown in FIG. 1. These sites were designed to facilitate insertion of the respective segments into the cloning plasmids. Because HgaI generates 5' overhangs of five bases outside of its recognition site, HgaI sites were oriented in the segments in a manner such that digestion with the enzyme removed the HgaI and the adjacent BamHI sites from the rest of the construction. This procedure allowed for the generation of unique cohesive ends between the two half-gene clones, which when annealed and ligated, resulted in a full-length ACP coding sequence, without the flanking sites at the junction.
Oligonucleotide Synthesis
The oligonucleotide were synthesized on an Applied Biosystems 381 A DNA synthesizer, using diisopropylmethyl phosphoramidites for the fragments of one strand of each part, and diisopropyl cyanoethylphosphoramidites for the fragments of the other part. The 16 fragements were deblocked and cleared from the solid support by NH 4 OH treatment. After desalting on Sephadex-G50, the fragments were purified by gel electrophoresis in 8M-urea/12% acrylamide gels.
Partial Gene Constructions
Following oligonucleotide purification, all fragments except those with a 5' BamHI site (the 5' ends of the construction) were individually phosphorylated with T 4 polynucleotide kinase. Fragments were annealed in separate reactions containing two or three complementary oligonucleotides.
Oligonucleotides 1 and 10; 2, 3, and 11; 4 and 12 were annealed in separate tubes and then sequentially ligated, yielding the coding sequence for the amino-terminal portion of ACP-I. Similarly, oligonucleotides 5 and 13; 6, 7, and 14; 8 and 15; 9 and 16 were annealed and ligated to yield the coding sequence for the carboxy-terminal portion of the protein. In each case, a small (1-3%) but easily detected portion of the ligation products was found to be of the appropriate size (124 bp and 170 bp) for the desired construction. In a typical reaction the fragments were present at 12 μM in 10 mM Tris-Cl (pH 7.4), 10 mM NaCl, and 10 mM MgCl 2 . After briefly heating to 80° C., the reactions were allowed to cool slowly to room temperature. The annealing reactions were then mixed sequentially and ligated to 14° C. with 1 unit/ml T 4 DNA ligase, in the presence of 667 μM ATP and 4.4 mM dithiothreitol. Each ligation was allowed to proceed 30 min. before the addition of the next annealed set of oligonucleotides. Additional ligase, ATP, and dithiothreitol were added after each addition to maintain the appropriate concentrations. Thirty minutes after the final addition, the reaction was stopped by heating to 70° C. for 5 min.
Cloning of Synthetic DNA
The synthetic DNA ligation products were ethanol precipitated and phosphorylated with T 4 polynucleotide kinase. The phosphorylated synthetic DNA (0.2 pmol) was then mixed with (0.02 pmol) BamHI digested phage M13mp19RFI DNA which had been dephosphorylated with calf intestinal phosphatase to prevent self-ligation. The reactions were carried out at 4° C. for 12 hours, with T 4 DNA ligase present at 0.5 unit/ml, followed by an hour at 4° C. with 7.5 units/ml.
The ligation products were then used to transform competent E. coli cells, strain DH5. The transformed cells were plated in soft agar containing E. coli cells, strain JM109, isopropyl-β-D-thiogalactopyranoside, and 5-bromo-4-chloro-3-indoyl-β-D-galactoside onto B-agar plates. White plaques were picked, and recombinant phage were slot blot screened by preparing single-stranded DNA using the method of Sanger et al. [J. Mol. Biol. 143: 161-178 (1980)], binding the DNA to nitrocellulose, and hybridizing with 32 P-labelled oligonucleotide probes. Oligonucleotides were labelled according to Maxam and Gilbert [Proc. Natl. Acad. Sci. 74: 560-564 (1977)], using [γ 32 P]ATP (Amersham) and T 4 polynucleotide kinase. For both half-gene constructions, a significant number of clones showed positive signals; 19 of 23 analyzed for the first half and 24 of 57 analyzed for the second half. The desired construct should have been the only product that was completely double-stranded, with two BamHI cohesive ends. Thus, ligation to the vector and subsequent transformation of E. coli provided a strong selection for the correct construct. DNA sequencing confirmed that a number of these positive clones did contain the exact sequences which had been synthesized. Some positively hybridizing clones contained deletions or base substitutions.
Construction and Cloning of a Full-Length ACP-I Sequence
M13 clones for both the 3' and 5' ends of the ACP-I gene were propagated on E. coli JM103, and replicative form DNA was prepared from each according to Zoller et al. [DNA 3: 479-488 (1984)]. Equimolar amounts of each replicative form were mixed together and digested to completion with HgaI to eliminate the extraneous bases in the shaded region of FIG. 2.
The digestion products comprising multiple fragments of DNA were adjusted to 2.5M NH 4 OAc and ethanol precipitated. The DNA was resuspended at a final concentration of 0.5 mg/ml and the fragments ligated with 12.5 units/ml ligase at 16° C. for 1 hour. The reaction was then heated to 70° C. for 5 min. to prevent any further reaction. The DNA was again subjected to HgaI digestion followed by BamHI digestion to cut any ligation products which were the result of reformation of the original constructs. Finally, the reaction was extracted with phenol and chloroform, the aqueous phase adjusted to 0.3M NaOAc and 0.01M MgCl 2 , and the DNA precipitated with ethanol. The DNA obtained from this procedure was mixed with T 4 DNA ligase and ligated to pTZ19R DNA, which had been previously digested with BamHI and dephosphorylated with calf intestinal phosphatase. Conditions were as described for cloning into M13, except that 68 ng of pTZ19R and 115 ng of the precipitated DNA were used in a 10-μl reaction.
The ligation products were used to transform competent E. coli cells, strain DH5α. Transformants were selected on 5-bromo-4-chloro-3-indolyl-β-D-galactoside+ampicillin plates. White colonies were picked and their plasmid DNA screened on slot blots. Fifty white colonies were analyzed and eight showed hybridization with probes for both halves of the gene. These eight plasmids were digested with BamHI and the digestion products analyzed on agarose gels. All eight plasmids contained an appropriately sized BamHI insert (268 bp). Two also contained a 170-bp insert, and two apparently contained a 37-bp fragment very likely corresponding to the ligation of the Hga-Bam fragments removed from the ends of each half-gene. Clones containing only the 268-bp insert were sequenced, confirming the proper assembly of the full ACP-I gene as shown in FIG. 2. The plasmid carried by one such clone was designated pPB269. This plasmid has been cloned in E. coli DH5α, and as such has been deposited under the Budapest Treaty with the Agricultural Research Service in Peoria, IL, and has been assigned NRRL Accession No. B-18219. Restriction analysis indicated that the ACP-I gene was oriented within the polylinker as indicated in FIG. 1.
Expression of Spinach ACP-I gene in E. coli
In order to express the synthetic spinach ACP-I gene in E. coli, it was subcloned from pPB269 into the expression vector pKK233-2 [Amann et al., Gene 40: 183-190 (1985)]. This vector provides both a trc promoter and a ribosome binding site upstream from the insert site. In addition, the start codon is optimally spaced relative to the ribosome binding site, and proper positioning of inserts is guaranteed by the presence of an NcoI recognition site at this start codon. An NcoI site at the start codon was designed into the synthetic ACP-I gene to facilitate cloning into this and other similar expression vectors.
The NcoI/HindIII fragment containing the ACP-I gene was ligated into the NcoI and HindIII sites of pKK233-2 and introduced into E. coli cells, strain JM101.
Immunoscreening of Spinach ACP Expressing Colonies
Colonies of recombinant clones were screened for the expression of the spinach ACP-I gene with antibody following their transfer to nitrocellulose and lysis by the method of Helfman et al. [Proc. Natl. Acad. Sci. 80: 31-35 (1983)]. Bound ACP-I antibody (rabbit) was visualized with an alkaline phosphatase linked antirabbit antibody system from Promega Biotec. Controls indicated that E. coli ACP did not give a strong positive signal with the antibody to spinach ACP-I that had been blocked with E. coli lysates. Plasmid DNA was prepared from colonies showing a positive signal. These plasmids were digested with NcoI and HindIII and screened for insert size. Several plasmids with the appropriately sized insert were detected. One, pPB104, has been cloned in E. coli JM109, and as such has been deposited under the Budapest Treaty with the Agricultural Research Service in Peoria, IL, and has been assigned NRRL Accession No. B-18218.
Western Blot Analysis of ACP-I Expression in E. coli
Western blot analysis of spinach ACP-I expression in E. coli JM101 cells containing no plasmid, pKK233-2, or pPB104 were grown to an OD 550 of 0.6 in 3 ml of LB medium. The cells were centrifuged and the pellets resuspended in 5 ml of YT medium. One-half of each plasmid-containing culture was then induced by the addition of isopropyl-β-D-thiogalactoside to 1 mM. All cultures were grown for an additional 3 hours to an OD 550 of 2.3. One milliliter of each culture was centrifuged and the cell pellets boiled for 5 min. in 800 μl of sample buffer. Extracts (2 μl) of JM101, JM101 carrying uninduced pKK233-2, JM101 carrying induced pKK233-2, 10 ng spinach ACP-I, JM101 carrying uninduced pPB104, JM101 carrying induced pPB104, and 20 ng E. coli ACP were applied separately to 15% NaDodSO 4 polyacrylamide gels.
Western blots of these gels were probed with antibody (rabbit) to ACP-I. Proteins binding the anti ACP-I were detected with alkaline phosphatase-linked, antirabbit antibody. The results indicate that E. coli ACP was barely detectable under the conditions employed (antibody blocked with E. coli extracts). Furthermore, crossreacting material was not found in extracts from JM101 cells containing no plasmid or containing pKK233-2 without an insert. However, cells containing pPB104 showed a strongly crossreacting band of protein, with electrophoretic mobility nearly identical to purified spinach ACP-I. This protein was induced by isopropyl-β-D-thiogalactopyranoside approximately fourfold, but it was also present at easily detectable levels in uninduced cultures.
Characterization of the Synthetic Gene Product
A 4-liter culture of JM101 cells containing pPB104 was grown in YT medium to an OD 550 of approximately 10. The harvested cell pellet was extracted by homogenization in 10 vol 0.1M Tris, 0.1M glycine, 25 mM EDTA (pH 8.0). Lysozyme (10 μg/g cell pellet) was added, and the suspension was stirred for 2 hours before passage through a French pressure cell. Ater centrifugation at 4,000 g for 30 min., the supernatant was adjusted to 65% ammonium sulfate, centrifuged as before, and the supernatant adjusted to 2.5% TCA. After standing 1.5 hours at 4° C., the acid pellet was collected by centrifugation, redissolved in 10 ml 10 mM MES (pH 6.1) and dialyzed against 200 vol of 10 mM MES, 0.5 mM dithiothreitol (pH 6.1) overnight. The dialysate was applied to a 2.5×5.0 cm. DE53 column (Whatman) and eluted with a 150 -ml linear salt gradient (0.0 to 0.5M LiCl) in 10 mM MES, 2 mM dithiothreitol (pH 6.1). Fractions were assayed for holo ACP using E. coli acyl-ACP synthetase and for spinach ACP-I using a radioimmunoassay [Kuo et al. III, Anal. Biochem. 136: 479-502 (1984)]. In a competitive binding radioimmunoassay, which is very sensitive to differences in ACP structures [Ohlrogge et al. II and Kuo et al. III supra], the spinach ACP-I produced in E. coli competed completely with ACP-I purified from spinach leaves. From radioimmunoassay of cell extracts, we estimate that approximately 6 mg of ACP-I protein is produced per liter of induced culture or roughly 1% of total cell protein.
The E. coli cells producing spinach ACP-I are able to attach the phosphopantetheine prosthetic group in vivo to the plant protein to form holo ACP-I. This is demonstrated by the ability of the partially purified synthetic gene product to be acylated by E. coli acyl-ACP synthetase. Extracts of E. coli cells expressing the synthetic gene were fractionated by ion exchange chromatography on DEAE-cellulose. During elution with a LiCl gradient, spinach ACP-I elutes before E. coli ACP. Two peaks of activity, measured enzymatically, were eluted from the column but only the first ACP peak was active in a radioimmunoassay for spinach ACP-I. Thus, the first ACP peak is enzymatically active spinach ACP-I produced from the synthetic gene, and the second peak is E. coli ACP. These identifications were confirmed by NaDodSo 4 /PAGE analysis of the separate peaks. The quantity of holo-spinach ACP-I measured by its acylation with [ 3 H]palmitate is similar to the quantity determined by radioimmunoassay. Because acylation by palmitate requires holo ACP, whereas the radioimmunoassay responds to both holo and apo ACP, it appears that most of the spinach ACP-I produced in E. coli contains the phosphopantetheine prosthetic group.
It is understood that the foregoing detailed description is given merely by way of illustration and that modification and variations may be made therein without departing from the spirit and scope of the invention.
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A synthetic gene which encodes for acyl carrier protein (ACP) has been designed. Construction, cloning, and expression in E. coli of spinach ACP-I has been demonstrated. In vitro production of ACP by appropriate expression vectors carrying the synthetic gene will augment the meager supply of this protein. Analogous genes designed for expression of ACP in plants would be a useful tool for controlling fatty acid synthesis and metabolism.
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BACKGROUND
[0001] The invention relates to a variable sensor interface for a control device, comprising a circuit board which is equipped with components for connecting at least one external sensor.
[0002] Control devices are used in automotive technology, receiving signals from a plurality of sensors arranged distributed in motor vehicles. These sensors are guided to a sensor interface inside the control device. A control device in a steering system of a motor vehicle is known from DE 10 2006 046 834 A1, which is connected to a magnetic field sensor to determine a steering angle, which sensor determines the rotor position of the rotor shaft of an electric motor.
[0003] In many cases the control device is not only connected to one sensor but to various sensor types, which require different interface circuits. These interface circuits may represent for example a current interface, a PWM interface, an analog interface, or the like. Furthermore, passive as well as active sensors are connected. This variety of sensor types requires that a specifically defined sensor interface must be provided for each sensor type, which is installed in the control device. Based on this plurality of sensors the interface must be prepared concretely for the sensors to be connected, which largely increases the number of sensor interfaces to be rendered available.
SUMMARY
[0004] The invention is therefore based on the objective to provide a sensor interface for a control device to which various sensor types can be easily connected.
[0005] According to the invention the objective is attained such that the circuit board exhibits a conductive track layout with a plurality of predetermined mounting locations for components, with the mounting locations being allowed to be equipped with sensor specific components. By way of such flexibility, here various configurations of sensors can be connected to a control device without requiring any change of the specifically predetermined conductive track layout. Accordingly, the provision of various interfaces for the respective sensor types can be waived, because the variable sensor interface can be varied by a simple equipment of selected mounting locations with components. This way the interface variety is limited and the production costs are reduced.
[0006] Advantageously, a predetermined number of resistors and/or capacitors can be specifically connected to various mounting locations for each sensor. This variable sensor interface therefore provides a circuit for resistors and capacitors by providing assembly options, which with minimum expense and without changing the conductive track layout of the circuit board is suitable for various sensor types.
[0007] In one embodiment, a protective circuit for transient interferences and/or ESD (electrostatic discharge) can be specifically connected to at least one mounting location for one sensor.
[0008] In one variant, an overcurrent protection circuit can be connected to at least one of the mounting locations. In case of short circuits, such an overcurrent protection circuit limits the amperage and thus protects the control device from damage.
[0009] In one embodiment the overcurrent protection circuit is arranged in one or more current paths of the conductive track layout, which provides the operating voltage or the ground for the external sensor. Here, the arrangement occurs in the supply path for protecting from short circuitry to the ground and/or in the ground path for protecting from short circuitry towards the battery voltage or another voltage.
[0010] A further development of the invention relates to a control device for a motor vehicle, which can be connected to at least one external sensor by the external sensor being connected to a sensor-interface. In a control device to which a plurality of sensor types can be connected the sensor-interface is embodied according to at least one feature of this patent application. Such a control device is provided for connecting various sensor types. Here, it is particularly advantageous that the sensor interface can be embodied according to each sensor type without requiring that any change of the conductive track layout occurs on the circuit board of the sensor interface.
[0011] Advantageously, each input and/or output of the sensor interface can be switched with a protective circuit for transient interferences and/or ESD. This is advantageous in that the electromagnetic interferences are already detected and intercepted at the location of their entering the control device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention allows numerous embodiments. Two of them shall be explained in greater detail based on the figures shown in the drawing.
[0013] Shown are:
[0014] FIG. 1 : a first exemplary embodiment of the control device according to the invention,
[0015] FIG. 2 : a second exemplary embodiment of the control device according to the invention.
[0016] Identical features are marked with the same reference characters.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] FIG. 1 shows a first exemplary embodiment of a control device 1 , as used for example in a motor vehicle. Here, the control device 1 has two outputs 2 , 3 for the energy supply of external sensors, which are not shown in greater detail. The output 2 is switched with a first protective circuit 4 for transient interferences and ESD, which are switched serially with a first overcurrent protection circuit 5 . This overcurrent protective circuit 5 is connected via a first resistor R 1 to a first voltage source 6 of the control device 1 . In case of short circuitry, the overcurrent protection circuit 5 limits the current of the supply voltage 6 at the output 2 and this way prevents any damage of the control device 1 .
[0018] The second output 3 of the control device 1 is also connected via a second protection circuit 7 for transient interferences and ESD, which leads to a second overcurrent protection circuit 8 . This second overcurrent protection circuit 8 is connected via the resistor R 2 to a second voltage source 9 of the control device 1 . A third resistor R 3 is arranged between the first overcurrent protection circuit 5 and the first resistor R 1 as well as the second overcurrent protective circuit 8 and the second resistor R 2 . By the assembly options of the resistors R 1 , R 2 , and R 3 the two supply voltages 6 , 9 of the control device 1 can be combined arbitrarily for the two outputs 2 , 3 . This is shown in greater detail in table 1.
[0000]
TABLE 1
First output 2
Second output 3
R1
R2
R3
Voltage source 6
Voltage source 6
0 Ohm
Not
0 Ohm
equipped
Voltage source 6
Voltage source 9
0 Ohm
0 Ohm
Not
equipped
Voltage source 9
Voltage source 9
Not
0 Ohm
0 Ohm
equipped
[0019] Here, the identification “not equipped” shall indicate an interruption in the conductive track layout 17 . If the resistance amounts to 0 Ohm, a resistor bridge is provided in the conductive track layout 17 .
[0020] FIG. 2 shows a second exemplary embodiment of a control device 10 , which in addition to the output 2 for an external sensor provides two inputs 11 , 12 for the external sensor. The output 2 is connected to the voltage source 6 via the first protection circuit 4 for transient interferences and ESD and via the first overcurrent protection circuit 5 . The inputs 11 and 12 are each connected to a second and/or a third protective circuit 13 , 14 for transient interferences and ESD. The second protective circuit 13 for transient interferences leads via a resistor R 5 and a filter resistor R Filter to an internal input 15 of the control device 10 , at which either an analog/digital converter, now shown in greater detail, can be connected or a digital PWM-input. The filter resistor R Filter is connected via a capacitor C Filter to the ground. The second protective circuit 13 for transient interferences and ESD is connected via a resistor R 6 and the third protection circuit 14 for transient interferences and ESD via a resistor R 7 to an overcurrent protection circuit 16 , which in turn leads to the ground.
[0021] In the case to be discussed further the protective circuits 4 , 13 , 14 for transient interferences and ESD as well as the filter resistor R Filter and the filter capacitor C Filter are mandatory. The filter resistor R Filter and the filter capacitor C Filter are required according to EMC-specifications (EMC-electromagnetic compatibility). However, applications are also possible in which the filter resistor R Filter and the filter capacitor C Filter can be waived. The resistors R 4 to R 7 represent assembly options. Depending on the application, the value of the filter resistance R Filter and/or the filter capacitor C Filter must be adjusted, which occurs depending on the speed the sensor signals change. In table 2 the potential interface types shall be shown, which are realized with the resistors R 4 to R 7 by the various assembly options.
[0000]
TABLE 2
Interface type
R4
R5
R6
R7
Resistance/
Equipped
0 Ohm
Not
0 Ohm
temperature
with 1% R
equipped
sensor (NTC,
PCT, . . . )
2-pin current
Not equipped
0 Ohm
Equipped
Not
interface
equipped
3-pin PWM
Equipped
0 Ohm
Not
0 Ohm
interface (open
equipped
collector)
Passive inductive
Equipped
Equipped
Equipped
0 Ohm
speed sensor
Analog voltage
Not equipped
0 Ohm
Not
0 Ohm
equipped
Analog current
Not
0 Ohm
Equipped
0 Ohm
equipped
[0022] When using resistance and/or temperature sensors the inputs of the external sensor are switched to the inputs 11 and 12 . The output 2 remains open. R 4 represents a reference resistor, here.
[0023] In case of a 2-pin current interference the connection of the external sensor occurs to the output 2 and to the input 11 . The input 12 remains open. R 6 is here a current/voltage converter resistor.
[0024] If a 3-pin PWM-interface is used, the connection of the voltage supply occurs from the external sensor to the output 2 and the input 12 . The input 11 is used as the input for the sensor signal and R 4 is embodied as a pull-up resistor.
[0025] If the external sensor is embodied as a passive inductive speed sensor, the connections of the external sensor occur to the inputs 11 and 12 . The output 2 remains open, while the resistors R 4 and R 5 serve to provide the signal with an offset, in order to allow feeding an analog-digital converter at the inner input 15 . This way it is ensured that the sensor signal is always in the positive voltage range.
[0026] If the external sensor applied at the control device shows an analog voltage the voltage supply of the external sensor occurs by the output 2 and the input 12 . The input 11 is the input for the sensor signal.
[0027] If the external sensor provides an analog current, the connection of the voltage supply of the external sensor occurs at the output 2 and at the input 12 . The input 11 is the input of the sensor signal and the resistor R 6 is a current/voltage converter resistor.
[0028] The variable interface explained is suitable for any type of control device, in which the connection of various sensors is provided. The particular advantage comprises that the circuit can be adjusted to the respective external sensor without any change of the conductive track layout of the circuit board being necessary, but only the assembly of the resistors needs to be adjusted.
LIST OF REFERENCE CHARACTERS
[0029] 1 control device
[0030] 2 output
[0031] 3 output
[0032] 4 protection circuit for transient interferences and ESD
[0033] 5 overcurrent protection circuit
[0034] 6 voltage source
[0035] 7 protection circuit for transient interferences and ESD
[0036] 8 overcurrent protection circuit
[0037] 9 voltage source
[0038] 10 control device
[0039] 11 input
[0040] 12 inlet
[0041] 13 protection circuit for transient interferences and ESD
[0042] 14 protection circuit for transient interferences and ESD
[0043] 15 internal input
[0044] 16 overcurrent protection circuit
[0045] 17 conductive track layout
[0046] R 1 resistor
[0047] R 2 resistor
[0048] R 3 resistor
[0049] R 4 resistor
[0050] R 5 resistor
[0051] R 6 resistor
[0052] R 7 resistor
[0053] R Filter resistor
[0054] C Filter capacitor
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The invention relates to a variable sensor interface for a control unit, this variable sensor interface including a circuit board which is provided with components. In a sensor interface which can easily be used for the use of different sensor types, the circuit board has a predefined conductive track layout having a plurality of predefined mounting locations, the mounting locations being provided with components in a sensor-specific manner.
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BACKGROUND OF THE INVENTION
The present invention relates to a method of and a device for transferring stitches on a knitting machine by transfer elements.
In all known methods for transferring of stitches, the needles which hold the stitches to be transferred are advanced so far that the stitches slide over the open latch; or the slide of the needle until they are placed on the needle shaft. There the stitch is spread by a spreading spring, so that subsequently it can be taken by a needle of the opposite needle bed or also by transfer fingers. Such methods are disclosed for example in German patent document DE-OS. 24 43 231 and European patent document EP 0 103 033 A1.
The known methods have the disadvantage that a great needle advance distance is required. The control curves which are needed for this purpose require correspondingly wide knitting cams. Moreover, the wide needle advance stroke leads to a reduction of the production speed of the knitting products. The main disadvantage of the known methods is however that the stitches, before the transfer to a neighboring needle or a transfer finger, are pulled far from the stitch structure and spread out, so that sensitive yarns are used for splitting the stitches. The transferred stitches moreover are increased by the transfer process, so that this is visible in smooth knitting products in the overall knitting pattern and therefore the quality of the knitted product is limited.
SUMMARY OF THE INVENTION
Accordingly, it is an object of present invention to provide a method of and a device for transferring stitches, which avoid the disadvantages of the prior art.
More particularly, it is an object of the present invention to provide a method of and a device for transferring of stitches, which avoid a high yarn loading and an increase in production time for producing knitted articles.
In keeping with these objects and with others which will become apparent hereinafter, one feature of present invention resides, briefly stated, in a method of transferring stitches on a knitting machine by means of transferring elements, in which a transfer element is associated with all needles on which stitches must be suspended, wherein in accordance with the present invention the stitches held in the needles and to be transferred are placed by needle advance and return movements on the needle ledge or, in case of slide needles, on the closed needle slide, and subsequently the transfer element is inserted into the stitch and the needle is pulled out of the stitch, so that the stitch is suspended alone on the transfer element and is available for transfer on the same or other needle or on another transfer element.
For placing, the stitches on the ledge or on the slide, needle movements are needed as required in normal stitch forming processes. The further advance of the needle to which the stitch is transferred in accordance with the known methods is no longer needed. In the inventive method the stitch is sufficiently clamped by the needle ledge over the needle slide so that the tip of the transfer element can be introduced into the stitch. However, no additional spreading of the stitch when compared with the conventional, not suspended stitch is carried out, so that also no significant increase of the suspended stitch takes place, which can be seen later in the knitted pattern.
For placing of the stitch, different possibilities are provided. The stitch can be placed by a needle advance and subsequent needle return movement on the closed ledge of the needle. It suffices that the needle is advanced so far that the stitch is located behind the open ledge. The stitch can be placed however also by a needle advance movement on the open ledge of the needle. Both, in the case of the open as well as closed ledge, the stitch is sufficiently clamped, so that the transfer element can be inserted into the stitch.
With the use of the slide needles, the stitch can be placed by a needle advance movement with the open slide and a subsequent needle return movement with the closed slide, over the closed slide.
Similar conditions are provided for the transfer process as during placing of the stitch on the closed ledge of a ledge needle. The inventive method for transferring of stitches can be utilized both on flat knitting machines and also on round knitting machines.
The inventive device for transferring stitches on a knitting machine in accordance With the inventive method has an associated transfer element for all needles on which stitches are suspended, and in accordance with the present invention the transfer element has a tip which is formed by at least one plate spring. With the use of the plate spring tip it is possible to provide insertion into stitches which are clampingly held on the ledges or on the slides. The plate spring is introduced in the thread space and runs between the legs of the stitch.
In accordance with a preferable embodiment of the invention, the transfer element cans have a tip formed by two plate springs. One plate spring is displaceable over the left side and the other plate spring is displaceable over the right side of the needle ledge or the needle slide and is insertable between the stitch legs. With such a design, the tip engages with stitch symmetrically left and right of the needle shaft, and the transfer of the stitch to the transfer element is even more reliable. After the return of the needle from the stitch, the both plate spring elements are compressed and together form the tip of the transfer element.
In a transfer device for a flat knitting machine, the transfer element is supported longitudinally displaceably in at least one sinker arranged over the at least one needle bed of the flat knitting machine. For this purpose the at least one sinker is provided with grooves, in which the transfer elements are longitudinal displaceable. The transfer elements have the same distance from one another as the needles of the at least one needle bed. Thereby it is guaranteed that a transfer element is exactly associated with each needle.
When the at least one needle bed of the flat knitting machine is supported not longitudinally displaceably, the at least one sinker is supported longitudinally displaceably on the knitting machine. Thereby a lateral offset of the stitches through the transferring process is possible With the longitudinally displaceable needle beds, the sinker with the transfer elements can be also arranged fixedly.
With a multi-bed knitting machine it is advantageous when for each needle bed of the flat knitting machine at least one sinker with transfer elements is provided. The sinker can be provided over its whole length with transfer elements, or only in its partial regions. Moreover, it is naturally possible, to provide for each needle bed several sinkers in such regions, in which the transfer process must be carried out.
The transfer elements can be controllable preferably similarly as the needles of the flat. knitting machine, in particular by control curves or cams, in which projections arranged on the transfer elements engage. It is advantageous when these control curves are arranged on the slide or slides for needle control of the flat knitting machine. Again, no separate drive for selection of the transfer elements is needed.
The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 a - 1 f are views showing partial sections through front and rear needle beds of a flat knitting machine with an inventive transfer device in different needle and transfer element positions, during transfer of a stitch to the transfer element in accordance with the inventive method;
FIGS. 2 a - 2 c are views showing a partial cross-section through the front needle bed of a flat knitting machine with an inventive transfer device in different needle positions and transfer element positions, during transfer of a stitch on a needle of the front needle bed;
FIGS. 3 a - 3 c are views showing a partial cross-section through the front and rear needle bed of a flat knitting machine with an inventive transfer device in different needle and transfer positions during transfer of a stitch on a needle of the rear needle bed;
FIGS. 4 a - 4 c are views showing a partial cross-section through the front and rear needle bed of a flat knitting machine with an inventive transfer device in different transfer element positions during transfer of a stitch from one transfer element to another transfer element;
FIG. 5 is a view showing a partial cross-section through the front needle bed of a flat knitting machine with slide needles with an inventive transfer device;
FIG. 6 is a view showing a partial cross-section through the front needle bed with a flat knitting machine with an inventive transfer device during transfer of a mesh located on an open latch needle, to a transfer element;
FIGS. 7 a , 7 b are detailed views of a transfer element in accordance with the present invention; and
FIG. 8 is a schematic perspective view of a stitch transfer with the transfer element of FIG. 7 .
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a front needle bed 1 and a real needle bed 2 of a flat knitting machine. Latch needles 3 are longitudinally displaceably supported in the front needle bed 1 and similarly latch needles 4 are longitudinally displaceably supported in the rear needle bed 2 . Transfer elements 5 and 6 are arranged over the needle beds 1 and 2 with the needles 3 and 4 , for transferring of stitches. In the shown example the needle 3 holds a stitch 7 in its thread space 33 which is formed by a needle hook 31 as well as a closed needle latch 32 . The transfer element 5 associated with the needle 3 is a part of a stitch transfer device 150 which is not shown in detail. The transfer element 5 has a tip 51 with a front surface 53 . In FIG. 1 a the needle 3 is located in its basic position, or in other words the stitch 7 abuts against a knocking over base 11 of the front needle bed 1 under the action of the knitting product pull in direction of the arrow 71 .
In FIG. 1 b the needle 3 is driven out or advanced in direction of the arrow 300 . Thereby the needle latch 32 is open through the stitch 7 , and the stitch 7 is now located on the needle shaft behind the open latch 32 .
Subsequently as can be seen from FIG. 1, the needle 2 is pulled back in direction of the arrow 301 until the stitch 7 during a forward sliding on the needle 3 again closes the latch 32 and comes to abutment against the closed latch 32 . This position is shown in FIG. 1 d . The needle 3 is pulled back in the direction of arrow 301 so far that the stitch is located shortly before its knocking off position (transfer position). The stitch 7 is now clamped by the needle head with the closed latch 32 so far, that the transfer element 5 is advanced in direction of the arrow 500 and can be inserted into the stitch 7 . The tip 51 of the transfer element 5 thereby slides laterally on the rear of the latch 32 and so far into the spring thread space 33 (FIG. 1 a ) of the needle 3 that it extends at the inner side of the leg through the stitch 7 .
Subsequently the needle 3 is pulled back in direction of the arrow 301 to its basic position and thereby the stitch 7 is released as shown in FIG. 1 e . Simultaneously, the transfer element 5 is driven so far in direction of the arrow 500 until the stitch 7 abuts against the front region 53 . The stitch 7 is now transferred from the transfer element 5 .
When the stitch 7 , which now is suspended on the transfer element 5 , temporarily must not take part in the knitting process, the stitch transfer element 5 can be pulled back in direction of the arrow 501 , so that the stitch 7 is suspended on the tip 51 , and the tip 51 is however located behind the central axis 100 of the knitting machine. Moreover, the transfer element 5 can be offset laterally via the needle 3 by a half pitch, and the needle 3 can take part in the knitting process so that the stitch 7 located on the transfer element 5 does not hinder the knitting process as shown in FIG. 1 f.
FIGS. 2, 3 and 4 show the transfer of the stitch 7 suspended on the transfer element 5 to the same needle 3 or another needle of the same needle bed 1 as shown in FIG. 2, on the needle 4 on the opposite needle bed 2 as shown in FIG. 3, and on an oppositely located transfer element 6 as shown in FIG. 4 .
In FIG. 2 a the stitch transfer element 5 is driven in direction of the arrow 500 to its transfer position for the needle 3 of the same needle bed 1 . The needle 3 is driven in direction of the arrow 300 so far, until the needle hook 31 is introduced into the stitch transfer element 5 in the region 52 and is located in the region of the tip 51 . With this process the needle hook 31 slides through the legs of the stitch 7 . In accordance with FIG. 2 b , subsequently the stitch. transfer element 5 is completely withdrawn in direction of the arrow 501 , so that the stitch 7 now is suspended on the needle 3 . Then the needle 3 moves in direction of the arrow 301 again to its basic position, so that the stitch 7 is suspended in the needle hook 31 and abuts against the knocking off base 11 shown in FIG. 2 c.
During the transfer process of the stitch 7 to the needle 4 of the opposite needle bed shown in FIG. 3, the needle 4 in accordance with FIG. 3 a is driven in direction of the arrow 400 so far that it is inserted with its needle hook 41 in a section 52 of the stitch transfer element 5 , which is located in the transfer position for needles of the opposite needle bed. During this process the needle hook 40 slides through the legs of the stitch 7 . Subsequently, as shown in FIG. 3 b the transfer element 5 is pulled back in direction of the arrow 501 , so that now the stitch 7 is suspended alone on the needle 4 . The needle 4 is subsequently (FIG. 3 c ) pulled back in direction of the arrow 401 to its basic position, so that the stitch 7 abuts against the knocking off base of the rear needle bed 2 .
During the transfer of the stitch 7 from the transfer element 6 in accordance with FIG. 4, both transfer elements 5 and 6 are advanced in direction of the arrows 500 and 600 so far, that the stitch transfer element 6 with its top 61 is introduced into the section 52 of the stitch transfer element 5 and thereby slides with its tip 61 through the length of the stitch 7 . Subsequently, in accordance with FIG. 4 b the stitch transfer element 5 is completely withdrawn in direction of the arrow 501 so that the stitch 7 now is suspended alone on the transfer element 6 . In accordance with FIG. 4 c , then the transfer element 7 is pulled back in direction of the arrow 601 so far that the stitch 7 is suspended again on the tip 61 , while the tip 61 however is located behind the central axis 100 of the knitting machine. When the needle 4 associated with. the transfer element 6 must take part in a further knitting process but the stitch 7 must be held for a certain time on the transfer element 6 , the needle 4 and the transfer element 6 can be offset relative to one another by a half pitch, so that the stitch 7 releases the advance space of the needle 4 .
FIG. 5 illustrates the transfer of the stitch 7 from a slide needle 30 . The slide 35 of the needle 30 and thereby also the thread space 36 are closed. The needle 30 is pulled back so far in direction of the arrow 331 that it is located in the transfer position, or in other words the stitch 7 is located on the closed slide 35 . The transfer element 5 is driven in the direction of the arrow 500 so far that its tip 51 is introduced in the thread space 36 and thereby between the legs of the stitch 7 . By this introduction of the tip 51 of the transfer element 5 into the thread space 36 , the inventive transfer process and the inventive transfer device can be used both for latch and for slide needles.
FIG. 6 shows a further variant of a transfer of a stitch 7 by the stitch transfer element 5 for latch needles 3 . The needle 3 is driven in direction of the arrow 300 to its stitch transfer position, in which the stitch 7 comes to lie on the open latch 32 . Also, in this position the stitch 7 is clamped. Moreover, a free space between the open latch spoon and the needle shaft is formed. The transfer element 5 is driven in direction of the arrow 500 with its tip 51 into the free space. The tip extends now between the length of the stitch 7 and therefore can take the stitch.
FIGS. 7 a , 7 b and 8 illustrate a preferable embodiment of a transfer element 5 . FIG. 7 a shows the side view and FIG. 7 b the plan view of the transfer element 5 . FIG. 7 b shows that the tip 51 of the transfer element 5 is also a double tip of two plate spring elements 51 and 51 ′. The plate spring element 51 and 51 ′ are located over one another on the tip. In its rear region, a hollow space 52 is enclosed, in which the needle head of a needle 3 , 4 can be inserted, for taking the stitch 7 which is suspended on the transfer element 5 . The stitch 7 is supported on the front face 53 after the transfer. The transfer element 5 also has a massive shaft 54 , which is longitudinally displaceable in a groove of a not shown sinker and can be controlled by a control cam.
FIG. 8 illustrates in a perspective view the transfer of the stitch 7 from the needle 3 by the transfer element 5 . The tip 51 , 51 ′ of the transfer element extends. into the thread space of the needle 3 .
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the invention has been illustrated and described as embodied in method of .and device for transferring stitches on a knitting machine, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims:
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Transferring of stitches on a knitting machine with transfer elements includes associating a transfer element with all needles on which stitches are suspended, placing a stitch which is held in a needle and has to be transferred on a needle element, introducing the transfer element into the stitch, withdrawing the needle from the stitch, so that the stitch is suspended alone on the transfer element and is available for a transfer, and transferring the stitch to a further element.
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BACKGROUND OF THE INVENTION
This invention is generally directed to transmitters having a linear final power amplifier (PA) and more specifically directed to such amplifiers which are corrected for amplitude or phase distortion by predistorting the input signal to the PA.
Linear amplifiers are needed when nonconstant envelope amplitude modulated signals are to be amplified such as in a single sideband transmitter. Even "linear" amplifiers do not provide an output signal which is an amplified exact duplicate of the input signal with regard to magnitude and phase.
In an effort to correct for such nonlinearities, circuits have been devised which "predistort" the input signal to a PA to take into account the nonlinearities of the PA so that its output has increased linearity. Typically the PA output signal is sampled and utilized as a feedback signal by such circuitry to generate the predistorted signal.
Since the PA must be operating in order to generate the feedback signal, problems can occur with regard to off-frequency or other unauthorized transmissions should a phase locked loop (PLL) in the predistortion circuit become unlocked. A temporary unlocked condition could be caused by a change in operating frequency or a transient condition that affects the predistortion circuit or the PA.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a transmitter having a linear power amplifier with a predistortion circuit which provides improved linearity and which inhibits the operation of the PA when such circuit is in an unlocked state.
In one embodiment according to the present invention, a radio frequency (RF) transmitter includes a linear PA and a mean which includes a PLL for generating an input signal to the PA based upon a signal from an exciter and a second signal. The input signal to the PA is predistored to account for nonlinear characteristics of the PA. Another means is provided for generating the second signal so that is is based upon the output of the PA when the PLL is in its locked state and is based upon the input signal to the PA when the PLL is in its unlocked state. The PA is inhibited when the PLL is in its unlocked state thereby minimizing undesired transmissions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a transmitter utilizing a linear PA and circuitry which provides a predistored input signal to the PA.
FIG. 2 is a block diagram of an embodiment of a transmitter according to the present invention.
FIG. 3 is a schematic diagram of an embodiment of an RF switch utilized in the transmitter of FIG. 2.
FIG. 4 is a diagram of a control circuit utilized for controlling the switches of FIG. 3.
DESCRIPTION OF PREFERRED EMBODIMENT
FIG. 1 illustrates a prior art implementation of a transmitter which utilizes a linear PA and circuitry for providing a predistorted signal to the PA. This embodiment illustrates a signal sideband RF transmitter which includes a transmitter exciter 10 and a polar loop circuit 12 which provides a predistorted signal 14 to PA 16. The output 18 of the PA is coupled to antenna 22 by means of an RF coupler 20 which also samples the PA output signal. The sample signal is attenuated by attenuator 24 before being coupled as the feedback input signal 26 to circuit 12.
In circuit 12, an RF splitter 28 splits the input signal from exciter 10 and provides inputs to mixer 30, PLL 32 and envelope detector 34. The output 36 of PLL 32 provides the other input to mixer 30. The output of the mixer consists of a frequency translated signal which is filtered by bandpass filter 38. The amplitude of the signal is controlled by variable attenuator 40. The output of attenuator 40 consists of the predistorted signal 14 which is applied as an input to PA 16.
The variable attenuator is controlled by the output of comparator 42 which compares two inputs. The feedback signal 26 from PA 16 provides an input to mixer 44. The other input to mixer 44 consists of a local oscillator 46. The output of the mixer is coupled to envelope detector 48 and to PLL 32 after being shifted in phase by 90 degrees by phase shifter 47. The PLL includes a voltage controlled oscillator (VCO) 50 which varies in response to phase differencers between the two input signals to the PLL and a conventional circuit which provides a binary signal that corresponds to locked and unlocked states of the PLL. The output of envelope detector 48 provides one input to comparator 42 with the other input being provided by the output of envelope detector 34.
The input signal 36 to mixer 30 includes a phase correction which is intended to provide a predistorted phase signal to PA 16 to minimize phase distortions at its output 18. Variable attenuator 40 modulates the amplitude of the input signal 14 to compensate for nonlinear amplitude variations in PA 16. Thus both amplitude and phase corrections are accomplished.
FIG. 2 illustrates an embodiment of a transmitter according to the present invention which includes a linear PA 16 and a predistortion or polar loop circuit 12. The present invention seeks to minimize undesired or of frequency transmissions by PA 16 which can occur when an unlocked condition exists within polar loop circuit 12. As used herein PA means a power amplifier which includes at least the final stage of amplification.
In accordance with the present invention, two paths exist by which a feedback signal 26 to polar loop circuit 12 can be derived. A short loop path exists by which the predistorted signal 14 is coupled by switch S1 and resonator 60 to constitute feedback signal 26. When the short loop is selected, switch S1 is closed and switches S2, S3 are open. The short loop is engaged when polar loop circuit 12 is unlocked thereby preventing drive signal 14 from reaching the PA 16 and minimizing the transmission of undesired signals. Switch S3 breaks the feedback path from the sampled output signal of the PA.
A long loop path exists whereby input signal 26 is derived from predistorted input signal 14 as coupled through elements S2, PA 16, coupled 20, attenuator 24, and switch S3. The long loop will be active when the polar loop circuit 12 is locked. In this condition switches S2, S3 will be closed and switch S1 will be open. Thus the short loop is effectively decoupled when the long loop is active. A control circuit 62 controls the operation of the switches S1-S3.
Attention should be given to the way in which the transition from the short loop to the long loop is accomplished. Once the polar loop circuit 12 has changed from the unlocked to locked condition, it is desirable that the opening of switch S1 and closing of switches S2, S3 effectuate a graduated attenuation change so as not to introduce a transient which would cause the polar loop circuit to become unlocked. Thus, it is desired that switches S2, S3 provide at least some level of conduction prior to switch S1 becoming nonconductive.
To preclude the possibility of undesired oscillation which could occur when both the long loop and short loop are connected during the switching transition, it is desirable to place at least a single pole resonator in the loop to provide additional attenuation at frequencies outside of the normal frequency band of operation. Use of the resonator is recommended when the switches are implemented by the use of PIN diodes in a switching arrangement which is frequency sensitive such as will be described in regard to FIG. 3. The insertion of the resonator 60 in the short loop is preferred to insertion in the long loop so that it will not add to the substantial delay already present in the long loop.
When the short loop is active during an unlocked condition, it may also be useful to disable the power supply from one or more stages of the PA 16 to provide additional attenuation and further minimize any signal transfer through the PA. In view of the RF environment, switches S1-S3 should be considered as attenuators since some amount of signal transfer will occur with the switch in the off or open position.
FIG. 3 illustrates an embodiment of a PIN diode attenuator or switch which can be utilized in the present invention. The RF input signal is connected at terminal 70 to a transmission line 72 which is preferably 1/4 wavelength at the frequency of operation. A high impedance RF choke 76 provides a DC ground path at terminal 74. PIN diode 78 is connected in series with capacitor 80 to form a series circuit between terminal 74 and ground. The anode of the diode is connected by a high impedance RF choke 82 with terminal 84 which receives a controlled DC current to control the impedance associated with the dioide 78. The value of capacitor 80 is selected to form a series resonant circuit with the inductance associated with the PIN diode so that a very low impedance path is presented to terminal 74 when the diode is ON. The 1/4 wavelength transmission line 72 transforms the low impedance at terminal 74, when the diode is ON, into a high impedance at terminal 70 thereby attenuating the magnitude of signal that can pass from terminal 70 to terminal 74.
It will be apparent to those skilled in the art that a plurality of sections of the switch as shown in FIG. 3 can be connected in series to increase the total attenuation of the signal. Each section can provide attenuation of 20-30 decibels at RF frequencies.
In this particular switch configuration, it will be seen that the switching elements are frequency sensitive and will not provide the same level of attenuation for frequencies outside the desired range of operation. This give rise to the need for additional attenuation provided by resonator 60 as shown in FIG. 2 to prevent undesired oscillations.
FIG. 4 illustrates a diagram of a control circuit 62 which can be utilized to control the switches and DC power to the PA. Waveform 90 illustrates a step voltage (or current) function at time t o which is a command signal generated by the transmitter indicating that the transmitter went from an unlocked to locked state which in turn causes a corresponding transition from the short loop to the long loop. For example, each time the transmitter is keyed it usually takes a finite time for any PPL's in the transmitter to acquire lock. Inverting amplifier 92 provides a corresponding output waveform 94 which is utilized to provide a DC control signal to the PIN diode in switches S2, S3. The input commmand is delayed by RC delay circuit 96 before being amplified by amplifier 98. This results in an output waveform 100 from amplifier 98 which provides an RC time constant rise time beginning at t o . Output waveform 100 is utilized to drive PIN diodes associated with switch S1. It should be remembered that when the PIN diode is conducting, the associated switch is OFF or providing maximum attenuation caused by the shunting of the signal to ground by the diode. Thus, when the short loop is active just before t o , switch S1 is ON which means the associated PIN diode is not conducting.
To effect the desired gradual transition from short loop to long loop, waveform 100 is applied to the diodes associated with switch S1 to provide a gradual change from not conducting to conducting. Relative to time t o , the control signal to the diodes associated with switches S2, S3 is rapidly changed to force the diodes to go as quickly as possible from conducting to nonconducting. However the lifetime of the minority carriers of the PIN diodes is such that it takes longer for the diodes to turn OFF than to be turned ON. The value of the RC delay circuit 96 is selected to match the inherent turn OFF delay associated with diodes in switches S2, S3 so as to provide a gradual change during the transition from short loop to long loop.
Input waveform 90 is amplified by amplifier 102 to provide an output waveform 104 which can be utilized to provide DC bias control to amplifier stages within PA 16. For example, waveform 104 can be applied to the base of a bipolar transistor having its collector and emitter coupled in series between the DC supply voltage and the collector of an amplifier stage. This is utilized to provide additional attenuation in the PA path when the short loop is active.
The transistion from the long loop to the short loop occurs when the polar loop circuit goes from locked to unlocked. Since the polar loop will be unlocked, the method of transition is less critical.
Although an embodiment of the present invention has been described and illustrated in the drawings, the scope of the invention is defined by the claims which follow.
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A linear power amplifier is included in a RF transmitter. A mechanism is provided for generating a predistorted input signal to the PA so that nonlinear phase and amplitude characteristics of the PA will be compensated. Another means is provided for generating a feedback signal to the predistortion generating mechanism so that the feedback signal is based on the output of the PA when the predistortion circuit is locked and is based upon the input signal to the PA when the predistortion generating circuit is unlocked. Undesired emissions from the power amplifier are inhibited when the predistortion mechanism is unlocked.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/984,533, filed on Nov. 1, 2007, which is hereby incorporated in its entirety herein by reference.
FIELD
[0002] The invention relates generally to a multiple speed transmission having a plurality of planetary gear sets and a plurality of torque transmitting devices and more particularly to a transmission having eight or more speeds, three planetary gear sets and a plurality of torque transmitting devices.
BACKGROUND
[0003] The statements in this section merely provide background information related to the present disclosure and may or may not constitute prior art.
[0004] Automatic power transmissions are currently in widespread use in passenger vehicles and trucks. As is well known, the automatic transmission provides a plurality of speed ratios in the forward direction and at least one speed ratio in the reverse direction. The speed ratios are established through the use of a plurality of planetary gearsets. The engagement of the gearsets is controlled by a number of fluid-operated torque transmitting mechanisms, for example clutches and brakes.
[0005] It has become a standard to provide at least four forward speed ratios in automatic transmissions for use in passenger vehicles. More recently, automobile manufacturers have increased the forward speed ratios to six and in some instances seven or eight. This, of course, requires the addition of planetary gearsets. However, it is desirable to minimize the number of torque transmitting mechanisms to reduce cost and overall size of the transmission.
[0006] A number of the currently proposed eight speed planetary transmissions provide three planetary gearsets and six torque-transmitting mechanisms. One problem facing transmission designers and manufacturers is the packaging of the planetary gearsets and the torque-transmitting mechanisms. It is preferable to arrange the gearsets and torque-transmitting mechanisms in a way that minimizes the overall size of the transmission as well as reduces manufacturing complexity.
[0007] Therefore, there is a need for a new and improved multi-speed transmission. The arrangement of the gearsets and the torque-transmitting mechanisms of the transmission should minimize the size and manufacturing complexity of the transmission.
SUMMARY
[0008] In an aspect of the present invention, a multi-speed transmission is provided. The transmission has an input member, an output member, a transmission housing, a first, second and third planetary gear set, five clutches and one brake.
[0009] The transmission housing has a first wall, a second wall, and a third wall extending between the first and second walls. The second planetary gear set is adjacent the first wall, the third planetary gear set is adjacent second wall, and the first planetary gear set is between the second and third planetary gear sets, each planetary gear set having a sun gear member, a ring gear member, and a planet carrier member supporting a plurality of planet gears each configured to intermesh with at least one of the sun gear member and the ring gear member.
[0010] The output member is continuously interconnected with the ring gear member of the third planetary gear set. The input member is continuously interconnected with the sun gear member of the second planetary gear set.
[0011] The sun gear member of the first planetary gear set is permanently coupled to the transmission housing. The planet carrier member of the second planetary gear set is permanently coupled to the planet carrier member of the third planetary gear set.
[0012] The transmission housing has a first area defined radially inward from an outer periphery of the planetary gear sets and axially bounded by the first wall and the second planetary gear set, a second area defined radially inward from the outer periphery of the planetary gear sets and axially bounded by the first and second planetary gear sets, a third area defined radially inward from the outer periphery of the planetary gear sets and axially bounded by the first and third planetary gear sets, a fourth area defined radially inward from the outer periphery of the planetary gear sets and axially bounded by the third planetary gear set and the second wall, and a fifth area defined radially inward from the third wall and radially outward from the outer periphery of the planetary gear sets and axially bounded by the first wall and the second wall.
[0013] The first of the five clutches is selectively engageable to interconnect the input member with the planet carrier member of the first planetary gear set. The second of the five clutches is selectively engageable to interconnect the input member with the ring gear member of the second planetary gear set. The third of the five clutches is selectively engageable to interconnect the planet carrier member of the first planetary gear set with the sun gear member of the third planetary gear set. The fourth of the five clutches is selectively engageable to interconnect the ring gear member of the first planetary gear set with the sun gear member of the third planetary gear set. The fifth of the five clutches is selectively engageable to interconnect the ring gear member of the first planetary gear set with the ring gear member of the second planetary gear set. The brake is selectively engageable to interconnect the planet carrier member of the third planetary gear set to the transmission housing.
[0014] The first of the five clutches is disposed in the second area. The second of the five clutches is disposed in at least one of the first, second and fifth areas. The third of the five clutches is disposed in at least one of the third and fourth areas. The fourth of the five clutches is disposed in at least one of the third and fifth areas. The fifth of the five clutches is disposed in at least one of the second and fifth areas. The brake is disposed in at least one of the fourth and fifth areas.
[0015] The clutches and the brake are selectively engageable to establish at least eight forward speed ratios and at least one reverse speed ratio between the input member and the output member.
[0016] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0017] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0018] FIG. 1 is a diagram of a cross-section of a transmission according to the principles of the present invention.
DETAILED DESCRIPTION
[0019] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
[0020] Referring now to FIG. 1 , an embodiment of a multi-speed transmission is generally indicated by reference number 10 . The transmission 10 includes a transmission housing 11 , an input shaft or member 12 , and an output shaft or member 14 . The input member 12 is preferably connected to an engine (not shown) or to a turbine of a torque converter (not shown). The output member 14 is preferably connected with a final drive unit (not shown) or transfer case (not shown). In the example provided, the output member 14 is located along an axis different from a longitudinal axis defined by the input member 12 . Accordingly, the output member 14 may exit on the same side of the transmission 10 as the input member 12 , thereby providing, for example, a front wheel drive transmission configuration.
[0021] The transmission 10 includes a first planetary gear set 16 , a second planetary gear set 18 , and a third planetary gear set 20 . The planetary gear sets 16 , 18 , and 20 are connected between the input member 12 and the output member 14 . In a preferred embodiment of the present invention, the first planetary gear set 16 is a planetary gear set that includes a sun gear member 22 , a ring gear member 24 and a carrier member 28 that rotatably supports a set of pinion gears 32 , 34 . Pinion gears 32 , 34 are configured to intermesh with each other, sun gear member 22 and ring gear member 24 . Moreover, sun gear member 22 is fixedly connected to the transmission housing 11 of the transmission 10 for preventing rotation of sun gear member 22 . Ring gear member 24 is connected for common rotation with a first interconnecting shaft or member 38 and a second interconnecting shaft or member 39 . Carrier member 28 is connected for common rotation with a third interconnecting shaft or member 40 and a fourth interconnecting shaft or member 45 .
[0022] The second planetary gear set 18 includes a sun gear member 42 , a ring gear member 44 and a carrier member 46 that rotatably supports a set of pinion gears 48 . Pinion gears 48 are each configured to intermesh with both sun gear member 42 and ring gear member 44 . Sun gear member 42 is connected for common rotation with the input member 12 and a fifth interconnecting shaft or member 43 . Carrier member 46 is connected for common rotation with a sixth interconnecting shaft or member 47 . Ring gear member 44 is connected for common rotation with a seventh interconnecting shaft or member 50 .
[0023] The third planetary gear set 20 includes a sun gear member 52 , a ring gear member 54 and a carrier member 56 that rotatably supports a set of pinion gears 58 . Pinion gears 58 are each configured to intermesh with both sun gear member 52 and ring gear member 54 . Sun gear member 52 is connected for common rotation with an eighth interconnecting shaft or member 60 . Ring gear member 54 is connected for common rotation with the output member 14 . Carrier member 56 is connected for common rotation with the sixth interconnecting member 47 .
[0024] The transmission 10 includes a variety of torque-transmitting mechanisms or devices including a first clutch 70 , a second clutch 72 , a third clutch 74 , a fourth clutch 76 , a fifth clutch 78 , and a brake 80 . The first clutch 70 is selectively engagable to connect the fifth interconnecting member 43 with the fourth interconnecting member 45 . The second clutch 72 is selectively engagable to connect the fifth interconnecting member 43 with the seventh interconnecting member 50 . The third clutch 74 is selectively engagable to connect the third interconnecting member 40 with the eighth interconnecting member 60 . The fourth clutch 76 is selectively engagable to connect the second interconnecting member 39 to the eighth interconnecting member 60 . The fifth clutch 78 is selectively engagable to connect the first interconnecting member 38 to the seventh interconnecting member 50 . The brake 80 is selectively engagable to connect carrier member 56 to the transmission housing 11 to restrict rotation of carrier member 56 .
[0025] The transmission 10 is capable of transmitting torque from the input member 12 to the output member 14 in preferably at least eight forward torque ratios and two reverse torque ratios. Each of the forward torque ratios and the reverse torque ratios are attained by engagement of one or more of the torque-transmitting mechanisms (i.e. first clutch 70 , second clutch 72 , third clutch 74 , fourth clutch 76 , fifth clutch 78 , and brake 80 ). Those skilled in the art will readily understand that a different speed ratio is associated with each torque ratio. Thus, eight forward speed ratios may be attained by the transmission 10 .
[0026] The transmission housing 11 includes a first end wall 102 , a second end wall 104 , and a third wall 106 . The third wall 106 interconnects between the first and second end walls 102 and 104 to provide a space or cavity 108 in which the planetary gear sets 16 , 18 , and 20 and the torque-transmitting mechanisms 70 , 72 , 74 , 76 , 78 , and 80 are located. Further, the cavity 108 has a plurality of areas or Zones A, B, C, D, and E in which the plurality of torque transmitting mechanisms 70 , 72 , 74 , 76 , 78 , and 80 are specifically positioned, in accordance with the preferred embodiments of the present invention.
[0027] As shown in FIG. 1 , Zone A is defined by the area or space bounded: axially on the left by the first end wall 102 , on the right by planetary gear set 18 , radially inward by a reference line “L” which is a longitudinal line that is axially aligned with the input shaft 12 , and radially outward by a reference line “M” which is a longitudinal line that extends adjacent an outer diameter or outer periphery of the planetary gear sets 16 , 18 , and 20 . While reference line “M” is illustrated as a straight line, it should be appreciated that reference line “M” follows the outer periphery of the planetary gear sets 16 , 18 , and 20 , and accordingly may be stepped or non-linear depending on the location of the outer periphery of each of the planetary gear sets 16 , 18 , and 20 . Zone B is defined by the area bounded: axially on the left by planetary gear set 18 , axially on the right by planetary gear set 16 , radially outward by reference line “M”, and radially inward by reference line “L”. Zone C is defined by the area bounded: axially on the left by planetary gear set 16 , axially on the right by planetary gear set 20 , radially outward by reference line “M”, and radially inward by reference line “L”. Zone D is defined by the area bounded: axially on the left by planetary gear set 20 , axially on the right by the second end wall 104 , radially outward by reference line “M”, and radially inward by reference line “L”. Zone E is defined by the area bounded: axially on the left by the first end wall 102 , axially on the right by the second end wall 104 , radially inward by reference line “M” and radially outward by the third wall 106 .
[0028] The torque transmitting mechanisms 70 , 72 , 74 , 76 , 78 , and 80 are intentionally located within specific Zones in order to provide advantages in overall transmission size, packaging efficiency, and reduced manufacturing complexity. In the particular example shown in FIG. 1 , the torque transmitting mechanisms 70 , 72 , and 78 are in Zone B, the torque transmitting mechanisms 74 and 76 are in Zone C, and the torque transmitting mechanism 80 is in Zone D.
[0029] However, the present invention contemplates other embodiments where the torque transmitting mechanisms 70 , 72 , 74 , 76 , 78 , and 80 are disposed in the other Zones. The feasible locations of the torque-transmitting devices 70 , 72 , 74 , 76 , 78 , and 80 relative to the Zones are illustrated in Chart 1. An “X” in the chart indicates that the present invention contemplates locating the particular torque transmitting device in the referenced Zones. An “O” in the chart indicates that the present invention contemplates that it is not feasible to locate the particular torque transmitting device in the referenced Zone.
[0000]
CHART 1
TORQUE
TRANSMITTING
ZONE
ZONE
ZONE
DEVICES
A
B
C
ZONE D
ZONE E
80
◯
◯
◯
X
X
78
◯
X
◯
◯
X
76
◯
◯
X
◯
X
74
◯
◯
X
X
◯
70
◯
X
◯
◯
◯
72
X
X
◯
◯
X
[0030] For example, the present invention provides that brake 80 may be located in Zones D or E, but may not be located in Zones A, B, or C. It should be appreciated that each of the torque transmitting devices 70 , 72 , 74 , 76 , 78 , and 80 may be located in a permissible Zone, as indicated in Chart 1, independently of the location of any of the other torque transmitting devices 70 , 72 , 74 , 76 , 78 , and 80 .
[0031] The description of the invention is merely exemplary in nature and variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
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A transmission is disclosed having an input member, an output member, three planetary gear sets, a plurality of coupling members and a plurality of torque transmitting devices. Each of the planetary gear sets includes a sun gear member, a planet carrier member, and a ring gear member. The torque transmitting devices include five clutches and a brake arranged within a transmission housing.
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[0001] This is a continuation application of and claims priority to the U.S. patent application 13/089442 filed Apr. 19, 2011, entitled “Massively Scalable Object Storage System,” and claims benefit of U.S. provisional patent application 61/450,166, filed Mar. 8, 2011, entitled “Massively Scalable File Storage System.” This application is also related to co-pending non-provisional U.S. patent applications 13/______, filed Apr. 19, 2011, and 13/______, filed Apr. 19, 2011. The entirety of these disclosures is hereby incorporated herein by reference.
BACKGROUND
[0002] The present disclosure relates generally to cloud computing, and more particularly to a massively scalable object storage system to provide storage for a cloud computing environment.
[0003] Cloud computing is location-independent computing, whereby shared servers provide resources, software, and data to computers and other devices on demand. As a term, “cloud computing” describes a consumption and delivery model for IT services based on the Internet, and it typically involves over-the-Internet provisioning of dynamically scalable and often virtualized resources. This frequently takes the form of web-based tools or applications that users can access and use through a web browser as if it were a program installed locally on their own computer. Details are abstracted from consumers, who no longer have need for expertise in, or control over, the technology infrastructure “in the cloud” that supports them. Most cloud computing infrastructures consist of services delivered through common centers and built on servers. Clouds often appear as single points of access for consumers' computing needs.
[0004] As the use of cloud computing has grown, cloud service providers such as Rackspace Hosting Inc. of San Antonio, Tex., have been confronted with the need to greatly expand file storage capabilities rapidly while making such expansions seamless to their users. Conventional file storage systems and methods to expand such systems suffer from several limitations that can jeopardize data stored in the object storage system. In addition, known techniques use up substantial resources of the object storage system to accomplish expansion while also ensuring data safety. Finally, the centralization of data storage brings with it issues of scale. A typical local storage system (such as the hard drive in a computer) may store thousands or millions of individual files for a single user. A cloud-computing-based storage system is designed to address the needs of thousands or millions of different users simultaneously, with corresponding increases in the number of files stored.
[0005] Accordingly, it would be desirable to provide an improved scalable object storage system.
SUMMARY
[0006] According to one embodiment, the improved scalable object storage system includes a method for storing data, comprising providing a plurality of physical storage pools, each storage pool including a plurality of storage nodes coupled to a network, each storage node further providing a non-transient computer readable medium for data storage; classifying a plurality of availability zones, wherein the storage nodes within an availability zone are subject to a correlated loss of access to stored data; defining a plurality of abstract partitions, wherein each possible input data management request deterministically corresponds to one of the plurality of abstract partitions; mapping the plurality of abstract partitions to the plurality of physical storage pools such that each mapped physical storage pool includes a replica of the data associated with the associated mapped abstract partition, and each replica for a particular abstract partition is mapped to a physical storage pool in a different availability zone; receiving a data management request over the network, the data management request associated with a data object; identifying a first partition corresponding to the received data management request; and manipulating the data object in the physical storage pools mapped to the first partition in accordance with the data management request.
[0007] According to another embodiment, the improved scalable object storage system includes a distributed storage coupled to a network, the distributed storage including a first storage pool and a second storage pool from a plurality of storage pools, the first storage pool in a first availability zone and the second storage pool in a second availability zone, each storage pool including at least one processor, a computer readable medium, and a communications interface; a director coupled to the network, the director including a processor, a computer readable medium, and a communications interface; a ring structure associated with the director, wherein the ring structure is adapted to associate a storage request with a first abstract partition from a plurality of abstract partitions, and wherein the ring structure is further adapted to selectively associate a first abstract partition with a first fault-tolerant multi-master replication target, the first replication target including the first storage pool and the second storage pool; wherein the director is adapted to route inbound storage requests to the replication target and outbound storage responses from the replication target.
[0008] According to another embodiment, the improved scalable object storage system includes a non-transient computer readable medium containing executable instructions, which when executed on a processor at a first time, initialize a ring by retrieving a set of ring parameters, the ring parameters including a number of abstract partitions, a number of physical storage pools, and a set of performance constraints; performing a consistent hashing function associating a first range of inputs with a first abstract partition and a second range of inputs with a second abstract partition; and allocating the available physical storage pools by mapping each abstract partition to one or more storage pools in accordance with the set of performance constraints; at a second time, opaquely route an input request to a correct storage pool in accordance with the initialized ring; and at a third time, rebalance the ring by retrieving the set of ring parameters, performing a consistent hashing function associating the range of inputs with the first abstract partition and the second range of inputs with the second abstract partition; and allocating the available storage pools mapping each abstract partition to one or more storage pools in accordance with the set of performance constraints such that each abstract partition has zero or one changes in the physical storage pools allocated thereto.
[0009] According to another embodiment, the improved scalable object storage system includes a system for coordinating events in a distributed system, comprising a plurality of subsidiary nodes coupled to a network, each subsidiary node including at least one processor, a computer-readable medium, and a communications interface, wherein information in a first subsidiary node needs to be synchronized with the information in a second subsidiary node in response to a time-varying series of requests; a first gateway, including a first processor, a first local clock, and a first communications interface; a second gateway, including a second processor, a second local clock, and a second communications interface; a timekeeping node coupled to the network, including a master clock; and a synchronization rectifier coupled to the first and second subsidiary nodes; wherein the timekeeping node is operationally coupled to the first and second gateways to reduce clock skew between the master clock, the first local clock and the second local clock below a configurable threshold; wherein the first gateway uses the first processor to timestamp a first request received over the first communications interface according to the time of the first local clock with a granularity at least equal to the configurable threshold; wherein the second gateway uses the second processor to timestamp a second request received over the second communications interface according to the time of the second local clock with a granularity at least equal to the configurable threshold; wherein synchronization between the first subsidiary node and the second subsidiary node is controlled by the later-occurring request if the first request and the second request are separated by a time greater than the configurable threshold; and wherein synchronization between the first subsidiary node and the second subsidiary node is controlled by the synchronization rectifier if the first request and the second request are separated by a time smaller than the configurable threshold.
[0010] According to another embodiment, the improved scalable object storage system includes a method for coordinating events in a distributed system, comprising synchronizing a master clock to coordinated universal time within a master skew threshold; synchronizing a first local clock at a first gateway with the master clock within a system skew threshold, and synchronizing a second local clock at a second gateway with the master clock within the system skew threshold; receiving, at the first gateway, a first request to manipulate a non-volatile data storage, and marking the first request with the time of reception according to the first local clock, with a granularity at least equal to the system skew threshold; receiving, at the second gateway, a second request to manipulate the non-volatile data storage, and marking the second request with the time of reception according to the second local clock, with a granularity at least equal to the system skew threshold; evaluate the first request and the second request to determine if they are unambiguously ordered by determining if the first request and the second request are temporally ordered with a granularity greater than the system skew threshold; if the first request and the second request are unambiguously ordered, modifying the non-volatile data storage as directed in the later request; and if the first request and the second request are not unambiguously ordered, modifying the non-volatile data storage as directed by a deterministic tiebreaker.
[0011] According to another embodiment, the improved scalable object storage system includes a non-transient computer readable medium containing executable instructions, which when executed on a processor synchronize a first local clock with a second local clock within a system skew threshold; receive a first request to manipulate a system resource and marks the first request with the time of reception according to the first local clock, with a granularity at least equal to the system skew threshold; receive a second request to manipulate the system resource and marks the second request with the time of reception according to the second local clock, with a granularity at least equal to the system skew threshold; evaluate the first request and the second request to determine if they are unambiguously ordered by determining if the first request and the second request are temporally ordered with a granularity greater than the system skew threshold; if the first request and the second request are unambiguously ordered, manipulates the system resource as directed in the later request; and if the first request and the second request are not unambiguously ordered, executes tiebreaker instructions controlling the system resource; and returns a success or error depending on the outcome of the tiebreaker instructions.
[0012] According to another embodiment, the improved scalable object storage system includes a method for managing data items in a distributed storage pool, comprising providing a plurality of physical storage pools, each storage pool including a plurality of storage nodes coupled to a network, each storage node further providing a non-transient computer readable medium for data storage; storing a first replica of a data item in a first physical storage pools, and storing a second replica of the data item in a second physical storage pool; in response to receiving a modification instruction for the data item, selectively modifying the first replica of the data item, creating a first modification sentinel file, and storing the first modification sentinel file in the first physical storage pool; in response to encountering the first modification sentinel file during a data item replication process, modifying the second replica of the data item and creating a second modification sentinel file in the second physical storage pool.
[0013] According to another embodiment, the improved scalable object storage system includes a system for out-of-band communication of object storage metadata, the system comprising a distributed storage system coupled to a network, the distributed storage including a first storage pool and a second storage pool from a plurality of storage pools, the first and second storage pools each including at least one processor, a computer readable medium, and a communications interface; wherein the first storage pool includes a first replica of a data item, and the second storage pool includes a second replica of the data; an object service responsive to modification instructions; and a replicator adapted to create a second replica of the data item in the second storage pool; wherein the object service responds to an out-of-band instruction by selectively modifying the first replica of the data item, creating a first modification sentinel file, and storing the first modification sentinel file in the first physical storage pool; and wherein the replicator responds to encountering the first modification sentinel file during a data item replication process by modifying the second replica of the data item and creating a second modification sentinel file in the second physical storage pool.
[0014] According to another embodiment, the improved scalable object storage system includes a non-transient computer readable medium containing executable instructions, which when executed on a processor at a first time, run a replication procedure that takes a first copy of a data item in a first location and makes an identical second copy of the data item in a second location; at a second time, run an out-of-band modification procedure to selectively modify the first copy of the data item, create a first modification sentinel file, and store the first modification sentinel file in the first location; and at a third time, change the execution of the replication procedure to modify a the second copy of the data item and create a second modification sentinel file in the second location.
[0015] According to another embodiment, the improved scalable object storage system includes a non-transient computer readable medium containing executable instructions, which when executed on a processor at a first time, run a replication procedure that takes a first copy of a data item in a first location and makes an identical second copy of the data item in a second location; at a second time, run an out-of-band modification procedure to selectively modify the first copy of the data item, create a first modification sentinel file, and store the first modification sentinel file in the first location; and at a third time, change the execution of the replication procedure to modify a the second copy of the data item and create a second modification sentinel file in the second location.
[0016] According to another embodiment, the improved scalable object storage system includes a distributed information synchronization system, comprising a first subsidiary node coupled to a network, the first subsidiary node including a first non-transitory computer-readable medium wherein the first computer-readable medium includes a first structured information repository, and wherein information in the first structured information repository is subject to internal consistency constraints; a second subsidiary node coupled to a network, the second subsidiary node including a second non-transitory computer-readable medium wherein the second computer-readable medium includes a second structured information repository, and wherein information in the second structured information repository is subject to internal consistency constraints; a repository synchronizer coupled to the first and second structured information repositories; the repository synchronizer further including a consistency evaluation module adapted to evaluate the differences between the first structured information repository and the second structured information repository; an internal modification module adapted to modify the internal structures of a structured information repository; an external replication module adapted to delete a target structured information repository and replace it with a replicated copy of a source structured information repository; and a threshold comparator; wherein the repository synchronizer is adapted to evaluate the first and second structured information repositories and determine a level of difference and compare the level of difference to a configurable threshold using the threshold comparator; if the level of difference is above the configurable threshold, modify the internal structures of a selected structured information repository using the internal modification module; and if the level of difference is below the configurable threshold, delete the selected structured information repository and replace it with a replicated copy of a consistent structured information repository using the external replication module.
[0017] According to another embodiment, the improved scalable object storage system includes a method for synchronizing structured information in a distributed system, comprising storing a first structured information repository on a first non-transitory computer-readable medium, wherein information in the first structured information repository is subject to internal consistency constraints; storing a second structured information repository on a second non-transitory computer-readable medium, wherein information in the second structured information repository is subject to internal consistency constraints; evaluating the differences between the first structured information repository and the second structured information repository to determine a preferred state and a difference measurement quantifying a difference from the preferred state; determining whether the difference measurement exceeds a configurable threshold; modifying a selected structured information repository if the difference measurement for the selected structured information repository is less than the configurable threshold, wherein the modification of the selected structured information repository is subject to the internal consistency constraints of the selected structured information repository, deleting the selected structured information repository if the difference measurement for the selected structured information repository is greater than the configurable threshold, and replacing the selected structured information repository with a replica of a structured information repository in the preferred state, wherein either modifying the selected structured information repository or deleting and replacing the structured information repository changes the non-transitory computer-readable medium storing the selected structured information repository such that the selected structured information repository is both compliant with its internal consistency constraints and in the preferred state. The method may also include determining that both the first structured information repository and the second structured information repository are not in the preferred state; pre-selecting the structured information repository that is closer to the preferred state and modifying the pre-selected structured information repository to bring the pre-selected structured information repository to the preferred state, subject to the internal consistency requirements of the pre-selected structured information repository, regardless of the configurable threshold.
[0018] According to another embodiment, the improved scalable object storage system includes a non-transient computer readable medium containing executable instructions, which when executed on a processor update a first structured information repository on a first non-transitory computer-readable medium, subject to internal consistency constraints; update a second structured information repository on a second non-transitory computer-readable medium, subject to internal consistency constraints; evaluate the differences between the first structured information repository and the second structured information repository to determine a preferred state and a difference measurement quantifying a difference from the preferred state; determine whether the difference measurement exceeds a configurable threshold; modify a selected structured information repository if the difference measurement for the selected structured information repository is less than the configurable threshold, subject to the internal consistency constraints of the selected structured information repository, delete the selected structured information repository if the difference measurement for the selected structured information repository is greater than the configurable threshold, and replace the selected structured information repository with a replica of a structured information repository in the preferred state.
[0019] According to another embodiment, the improved scalable object storage system includes a non-transient computer readable medium containing executable instructions, which when executed on a processor update a first structured information repository on a first non-transitory computer-readable medium, subject to internal consistency constraints; update a second structured information repository on a second non-transitory computer-readable medium, subject to internal consistency constraints; evaluate the differences between the first structured information repository and the second structured information repository to determine a preferred state and a difference measurement quantifying a difference from the preferred state; determine whether the difference measurement exceeds a configurable threshold; modify a selected structured information repository if the difference measurement for the selected structured information repository is less than the configurable threshold, subject to the internal consistency constraints of the selected structured information repository, delete the selected structured information repository if the difference measurement for the selected structured information repository is greater than the configurable threshold, and replace the selected structured information repository with a replica of a structured information repository in the preferred state.
[0020] The specifics of these embodiments as well as other embodiments are described with particularity below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 a is a schematic view illustrating an embodiment of a file storage system.
[0022] FIG. 1 b is a schematic view illustrating an embodiment of an information handling system used in the file storage system of FIG. 1 a.
[0023] FIG. 2 is a schematic view illustrating an embodiment of a logical structure provided by the file storage system of FIG. 1 a.
[0024] FIG. 3 is a schematic view illustrating an embodiment of a user account.
[0025] FIG. 4 is a flow chart illustrating an embodiment of a method for storing an object.
[0026] FIG. 5 is a flow chart illustrating an embodiment of a method for creating a ring
[0027] FIG. 6 flow chart illustrating an embodiment of a method for reassigning partitions in a ring.
DETAILED DESCRIPTION
[0028] Referring now to FIG. 1 a , an embodiment of a file storage system 100 is illustrated. The file storage system 100 includes a user device 102 connected to a network 104 such as, for example, a Transport Control Protocol/Internet Protocol (TCP/IP) network (e.g., the Internet.) A storage management server 106 is connected to the network 104 and to a plurality of storage servers 108 . While only one user device has been illustrated as connected to the network 104 for clarity of discussion, one of skill in the art will recognize that a plurality of user devices may, and typically will, be connected to the network 104 . While only one storage management server coupled to a plurality of storage servers has been illustrated as connected to the network 104 for clarity of discussion, one of skill in the art will recognize that a plurality of storage management servers, each connected to a plurality of storage servers may, and typically will, be connected to the network 104 . Each of the user device 102 and the storage management server 106 includes a respective network interface for communicating with the network 104 (e.g., outputting information to, and receiving information from, the network 104 ).
[0029] Each of the user device 102 , storage management server 106 , and the plurality of storage servers 108 may include a respective information processing system, a subsystem, or a part of a subsystem for executing processes and performing operations (e.g., processing or communicating information). An information processing system is an electronic device capable of processing, executing or otherwise handling information. Examples of information processing systems include a server computer, a personal computer (e.g., a desktop computer or a portable computer such as, for example, a laptop computer), a handheld computer, and/or a variety of other information handling systems know in the art.
[0030] Referring now to FIG. 1 b , an information processing system 110 which is representative of one of, or a portion of, the information processing systems described above, is illustrated. The information processing system 110 may include any or all of the following: (a) a processor 112 for executing and otherwise processing instructions, (b) a plurality of input devices 116 , which are operably coupled to the processor 112 , for inputting information, (c) a n optional display device 116 , which is operably coupled to the processor 112 , for displaying information, (d) an optional print device 118 , which is operably coupled to the processor 112 , for printing visual images, scanning visual images, and/or faxing visual images, (e) a computer-readable medium 120 , which is operably coupled to the processor 114 , for storing information, as discussed further below, and (f) various other electronic circuitry for performing other operations of the information processing system 110 known in the art. For example, the information processing system 110 may include (a) a network interface (e.g., circuitry) for communicating between the processor 110 and the network 104 and/or other devices, and (b) a memory device (e.g., FLASH memory, a random access memory (RAM) device or a read-only memory (ROM) device for storing information (e.g., instructions executed by processor 112 and data operated upon by processor 112 in response to such instructions)).
[0031] The computer-readable medium 120 and the processor 110 are structurally and functionally interrelated with one another as described below in further detail, and information processing system of the illustrative embodiment is structurally and functionally interrelated with a respective computer-readable medium similar to the manner in which the processor 110 is structurally and functionally interrelated with the computer-readable medium 120 . As discussed above, the computer-readable medium 120 may include a hard disk drive, a memory device, and/or a variety of other computer-readable media known in the art, and when including functional descriptive material, data structures are created that define structural and functional interrelationships between such data structures and the computer-readable medium 120 (and other aspects of the system 100 ). Such interrelationships permit the data structures' functionality to be realized. For example, the processor 112 reads (e.g., accesses or copies) such functional descriptive material from the computer-readable medium 120 onto the memory device of the information processing system 110 , and the information processing system 110 (more particularly, the processor 112 ) performs its operations, as described elsewhere herein, in response to such material stored in the memory device of the information processing system 110 . In addition to reading such functional descriptive material from the computer-readable medium 120 , the processor 112 is capable of reading such functional descriptive material from (or through) the network 104 . In one embodiment, the computer-readable medium is non-transitory.
[0032] Referring now to FIGS. 1 a and 2 , the file storage system of FIGS. 1 a and 1 b creates a logical structure 200 . The logical structure 200 includes a user 202 connected to a proxy 204 . In one embodiment, the user 202 may be provided by the user device 102 , the proxy 204 may be provided by the storage management server 106 , and the user 202 /proxy 204 connection may be created by the coupling of the user device 102 to the storage management server 106 through the network 104 . The proxy 204 is connected to one or more rings 206 such as an object ring 206 a , a container ring 206 b , and an account ring 206 c , described in further detail below, that are connected to an object service 208 , container service 210 , and an account service 212 , respectively, described in further detail below. In other embodiments, there are other types of objects managed by rings, such as a structured data ring, a graph storage ring, or another type of ring (not pictured). In such embodiments, each ring would be connected to an appropriate service, such as a structured data service, a graph service, or another service (not pictured).
[0033] Each of object service 208 , the container service 210 , and the account service 212 are connected to a plurality of storage pools 214 . In one embodiment, the rings 206 may include software that is stored on a computer-readable medium location in the storage management server 106 and/or the storage servers 108 . In one embodiment, the object service 208 , the container service 210 , and the account service 212 may include software that is stored on a computer-readable medium located in the storage management server 106 and/or the storage servers 108 . In one embodiment, the storage pools 208 may be provided by the storage servers 108 . In one embodiment, the proxy 204 /rings 206 /object service 208 /container service 210 /account service 212 /storage pool 214 connections may be created by the connection of the storage management server 106 with the storage servers 108 . In a further embodiment, the rings are implemented at least in part using electrical circuits on a semiconductor chip to achieve better speed and latency.
[0034] In one embodiment, each storage pool 214 is provided by a separate storage server 108 or includes a virtual server that is included in a portion of one of the storage servers 108 or across a plurality of the storage servers 108 . For example, the storage servers 108 may be physically located in one or more data centers, and the resources of the storage servers 108 may be virtualized according to the requirements of a plurality of users (e.g., the user 202 ) such that the plurality of storage pools 214 are provided to the plurality of users in order to store files and/or data objects. Thus, resources for a particular virtual server or storage pool may span across multiple storage servers 108 .
[0035] Referring now to FIG. 3 , the user 202 , which is exemplary of a plurality of users that use the file storage system 100 , has a user account 300 with the file storage system 100 to store and receive data objects, and that user 202 may create a plurality of containers 302 in the user account 300 and store a plurality of data objects 304 in each of the containers 302 for retrieval. In the discussion below, a user account is referred to as an “account”, a container is referred to as a “container”, and a data object us referred to as an “object” for clarity of discussion. One of skill in the art will recognize that the terms “account”, “container” and “object” are generic forms of data naming that are used to direct the file storage system 100 to a specific data object. When other types of rings and services are used, an appropriate name may be substituted. For clarity, discussion of alternative rings and services will be limited to the “account”, “container” and “object” rings and services.
[0036] The components of the file storage system 100 and some of their functions will now be described in detail.
[0037] The Rings 206
[0038] As discussed above, the rings 206 are implemented in a tailored electrical circuit or as software instructions to be used in conjunction with a processor to create a hardware-software combination that implements the specific functionality described herein. To the extent that software is used to implement the rings, it may include software that is stored on a computer-readable medium location in the storage management server 106 and/or the storage servers 108 . Referring back to FIG. 2 , the rings 206 include semiconductor circuits and/or computer-executable instructions that, when executed by a processor, provide subsystems of the file storage system 100 that provide a mapping between the entities stored in the file storage system 100 and the locations of those entities in the storage pools 214 . In the illustrated embodiment, the file storage system 100 includes a separate object ring 206 a , container ring 206 b , and account ring 206 c , and when components of the file storage system 100 need to perform any operation on an object, container, or account, those components interact with the object ring 206 a , container ring 206 b , and account ring 206 c , respectively, to determine the location of that stored entity in the storage pools 214 . However, one of skill in the art will recognize that different ring structures may be provided (e.g., a single ring for the objects, containers, and accounts, more than one ring for each of the objects, containers, and account, etc.) without departing from the scope of the present disclosure. The rings 206 maintains the availability and safety of data in the file storage system 100 through the use of zones, partitions, replicas, and the storage pools 214 , as described below.
[0039] A zone is defined as one or more of the storage pools 214 that are subject to a correlated loss of access or data as a result of a particular event. For example, each storage server 108 in the file storage system 100 may be defined as a storage pool in a separate zone, as each storage server 108 is subject to loss of access to its stored objects as a result of a storage device failure, a catastrophic event at the location where the storage server resides, and/or a variety of other object access-loss scenarios known in the art. For the same reasons, a drive in a storage server 108 may be defined as a storage pool in a separate zone, a plurality of storage servers 108 in a given storage rack or cabinet as a storage pool in a separate zone, a plurality of storage servers 108 coupled to the same switch as a storage pool in a separate zone, a plurality of storage servers 108 in a given datacenter as a storage pool in a separate zone, a plurality of storage servers 108 connected to a common power system as a storage pool in a separate zone, etc. One of skill in the art will recognize that the examples of zones provided above are not limiting, and a variety of zones known in the art will fall into the scope of the present disclosure.
[0040] Logically, a partition is an abstract storage bucket. As discussed in further detail below, the file storage system 100 maps each partition to a plurality of storage pools 214 that are in different zones, and stores data using those partitions. The mapping of a given partition to a plurality of storage pools 214 creates a plurality of partition replicas of that partition (e.g., equal to the number of storage pools 214 the partition is mapped to.) For example, when a given partition is mapped to 3 storage pools 214 that are in different zones, 3 partition replicas of that partition are created.
[0041] The object ring 206 a for the management of objects will be described in detail below. However, one of skill in the art will recognize how the discussion may be applied to the container ring 206 b , the account ring 206 c , and/or a ring for any other stored entity, without departing from the scope of the present disclosure.
[0042] In various replicated, network-based file storage systems, an object from a user is received by a proxy. To determine where the object should be stored, some attribute of the object or the object data itself is hashed. If necessary, some attribute of the object is modified so that three different results are returned from the hashing function. The object is then replicated and stored in the storage pool corresponding to the number returned by the hash function.
[0043] Under typical circumstances, a consistent hashing function is used as the hash function. The use of the consistent hashing function ensures that there will be minimal changes to the assigned storage pools given a change in membership due to adding or removing new storage pools.
[0044] Although the consistent hashing function results in minimal changes to the storage location, sometimes the assignments made by the consistent hashing function or the rearrangements needed due to a change in membership may have undesirable storage characteristics. For example, such methods have been found to result in multiple object replicas for the same object being stored in one or more storage pools that are in the same zone. As discussed above, this is undesirable because then multiple (and possibly all) object replicas for the same object are subject to being lost as a result of a particular event. Alternatively, rebalancing the replicas due to a change in membership has been found to require the movement to two of the replicas 4% of the time, and the movement of all three replicas 1% of the time. It is desirable to never have to move more than one replica at a time.
[0045] In one embodiment, the file storage system 100 solves the problem of multiple object replicas for the same object being stored in storage pools that are in the same zone through the use of the rings 206 . Referring now to FIG. 4 , a method 400 for storing stored entities is illustrated. At block 402 , an object us received by a user. In one embodiment, an object is received from the user 202 by the proxy 204 . The method 400 then proceeds to block 404 where a partition identification is generated. In one embodiment, a consistent hash function is applied to the object received in block 402 , and the hash function returns a partition identification that corresponds to a partition. The method 400 then proceeds to block 406 where the partition associated with the partition identification is mapped to storage pools that are in different zones. This mapping function is constrained so that the physical location of the storage pools is required to have one or more desirable properties, such as having each partition replica in a separate zone.
[0046] There are various embodiments of the constrained mapping function. In one embodiment, the constrained mapping function is the output of a constraint satisfaction solver, in which the desired storage characteristics (such as the requirement that each replica of a partition be in a different availability zone) are inputs to the solving function. The solver then uses one or more search methodologies within the solution space to find a storage layout that maps partitions to storage pools in a desirable manner.
[0047] In a second embodiment, a constrained mapping function is applied to portions of the partition identification (e.g., the portions of the partition identification that the constrained mapping function is applied to) may be bits of the output of the original hashing function is applied to the object. For example, the number of bits to which the constrained mapping function is applied may be known as the partition power, and 2 to the partition power may indicate the partition count. The constrained mapping function is designed to return a storage pool location for each portion of the partition identification to which it is applied, and the storage pool locations returned for a given partition identification will each correspond to storage pools 214 in different zones. These storage pool locations are then associated with the partition identification. Thus, the partition corresponding to the partition identification is replicated multiple times in the file storage system 100 (i.e., a partition replica is included in each storage pool corresponding to the storage pool locations determined from the constrained mapping function.) The method 400 then proceeds to block 408 where the object is stored according to the partition. The object received by the user 202 in block 402 of the method 400 may then be stored according to the partition corresponding to the partition identification, which results in multiple object replicas for the object being stored in storage pools that are in different zones in the file storage system 100 . In another embodiment, the constrained mapping function is used to determined storage pool locations that are in different zones for each partition prior to the object being received by the user 202 , discussed in further detail below.
[0048] The output of the constrained mapping function signifies a particular storage pool where a replica of the partition should be stored. An example of this output is as follows: When an object is received from the user 202 at block 402 of the method 400 , and at block 404 of the method 400 , a hash function is applied to the object. In one exemplary embodiment, the user 202 provides data including an account/container/object name to the proxy 2004 , and a hash function is applied to the account/container/object name as follows:
[0000] Hash function (account/container/object name)==123456789
[0049] Where 123456789 is the partition identification that is returned by the hash function. At block 406 of the method 400 , the partition mapping number may then be divided into 3 parts (e.g., the first three digits, the second three digits, and the third three digits of the partition identification,) and the constrained mapping function is applied to each of those parts:
[0000] Constrained mapping function (123)==storage pool location (zone 1)
Constrained mapping function (456)==storage pool location (zone 7)
Constrained mapping function (789)==storage pool location (zone 3)
[0050] As discussed above, the constrained mapping function is designed to return the storage pool location (zone 1), storage pool location (zone 7), and storage pool location (zone 3) that correspond to storage pools that are in different zones (e.g., zones 1, 3, and 7). The storage pools locations are then associated with the partition identification:
[0051] Partition identification: (storage pool location (zone 1)), storage pool location (zone 7), storage pool location (zone 3))
[0052] Thus, the partition corresponding to the partition identification is replicated across storage pools that are in different zones (here, zones 1, 3, and 7.) At block 408 of the method 400 , the object received from the user 202 is then stored, using the partition corresponding to the partition identification, in each of the storage pools corresponding to the storage pool locations returned by the application of the constrained mapping function to portions of the partition identification. Thus, 3 replicas of the object received from the user 202 are stored in the file storage system 100 in storage pools that are located in different zones (zones 1, 3, and 7.) In one embodiment, each of the storage pool locations are IP addresses, i.e., when each of the storage pools are separate storage servers. In one embodiment, the constrained mapping function is a hash function. However, one of skill in the art will recognize that a variety of functions may be used to ensure that each partition is mapped to storage pools that are in different zones without departing from the scope of the present disclosure.
[0053] In another embodiment, the constrained mapping function is applied to the file storage system 100 before the object is received by the user 202 at block 402 in order to accomplish the mapping of the partitions to storage pools described above with reference to block 406 of the method 400 . For example, the total number of partitions and the total number of storage servers/storage pools in the file storage system 100 may (and typically will) be known. With that knowledge, the constrained mapping function is used to map each partition in the file storage system 100 to a plurality of storage pools that are in different zones, and that information is stored in a constrained mapping database. For example, a constrained mapping database may include partitions mapped to storage pools such as:
[0000] Partition 1: (storage pool location (zone 1)), storage pool location (zone 2), storage pool location (zone 3))
Partition 2: (storage pool location (zone 4)), storage pool location (zone 5), storage pool location (zone 6))
Partition 3: (storage pool location (zone 7)), storage pool location (zone 8), storage pool location (zone 9))
[0054] In one embodiment, the output of the constrained mapping function can be saved for optimized lookup. For example, the saved output may be embodied in a file provided to each of the storage pools 214 , or stored in a database that is available for the appropriate systems to query. If the saved output is contained within a file, the storage pools 214 may then periodically check the modification time of this file and reload their in-memory copies of the ring structure as needed.
[0055] Thus, when an object is received from a user 202 at block 402 , the hash function is applied to that object to get the partition identification (e.g., partition 1, 2, or 3 in the example above) at block 404 , and then at block 406 , the partition identification may then be used with the constrained mapping database to determine the corresponding partition and its associated storage pool locations. This embodiment allows the processing necessary to map partitions to multiple storage pools in different zones to be conducted before objects are received from users so that such processing does not have to be conducted each time an object is received from a user.
[0056] For example, referring now to FIG. 5 , a method for building a ring 206 is illustrated. At block 502 , an ideal number of partitions for each storage pool in the file storage system is determined. In one embodiment, the number of partitions that should ideally be assigned to each storage pool 214 is calculated based the weight (e.g., storage capacity) of each storage pool 214 . For example, if the partition power is 20, the ring 206 will have 1,048,576 (2 20 ) partitions. If there are 1,000 storage pools 214 of equal weight, each storage pool 214 will ideally be assigned 1,048.576 partitions. This may be referred to as an ideal partition count, and in the example, each storage pool 214 starts off empty with a 1,048.576 ideal partition count. The method 500 then proceeds to block 504 where the storage pools are placed in a sorting order. In one embodiment, the storage pools 214 are placed in a sorting order based on their ideal partition count (e.g., highest to lowest), and this sorting order is maintained throughout the method 500 as partitions are assigned storage pools 214 . The method 500 then proceeds to block 506 where partitions are assigned to storage pools based on their sorting order but with a zone restriction. In one embodiment, the partitions are assigned to the storage pool 214 with the highest ideal partition count, but subject to the restriction that the storage pool 214 to which a partition is being assigned is not in the same zone as any other storage pool 214 that includes a partition replica for that same partition. The method 500 then proceeds to block 508 where the sorting order of the storage pools is adjusted. In one embodiment, once a partition is assigned to a storage pool 214 , that storage pool 214 will have its ideal partition count decremented and thus that storage pool 214 is moved to a lower position in the sorting order, and the method 500 then returns to block 506 to continue to assign partitions to storage pools based on their sorting order but with the zone restriction. In such a manner, each partition is assigned multiple storage pools 214 in different zones, and thus objects received from users may have multiple object replicas stored in storage pools in different zones simply by associating those objects with the partitions.
[0057] As mentioned above, another problem relates to the rebalancing of object replicas stored in the file storage system due to changing membership (i.e., adding or subtracting storage servers or storage pools from the file storage system.) Such methods have been found to require the moving of multiple object replicas of the same object in response to a membership change, which is undesirable.
[0058] In one embodiment, the mapping of partitions to multiple storage pools in different zones in the file storage system 100 described above solves these problems. The use of the constrained mapping function to ensure that each partition is mapped to storage pools in different zones ensures that object replicas for the same object are never located in storage pools 214 that are in the same zone (i.e., because any given object received from a user is stored in a partition that is replicated in storage pools that are in different zones.) For example, with each storage server 108 defined as a separate zone, the addition or subtraction of a given storage server 108 from the file storage system 100 thus can only effect one partition replica, and hence one object replica of a given object (i.e., because only one of the partition replica will ever be located on a storage server that is defined as a separate zone.) In similar fashion, the rebalancing associated with changing the zone membership can be accomplished without affecting more than one replica because each zone is guaranteed to only contain one replica of a given partition.
[0059] Periodically, partitions may need to be reassigned to different storage pools 214 , and the reassignment of partitions will result in the building of a new ring from an old ring. Such an event may occur due to the removal and/or addition of a storage pool 214 from the file storage system 100 (e.g., a membership change.) Referring now to FIG. 6 , a method 600 for reassigning partitions in response to the removal of a storage pool is illustrated. The method 600 begins at block 602 where the ideal number of partitions for each storage pool is recalculated. In one embodiment, the ideal partition count for the storage pools 214 remaining in the file storage system 100 (subsequent to the removal of a storage pool) are recalculated. The method 600 then proceeds to block 604 where the storage pools are placed in a sorting order as described above with reference to block 504 of the method 500 . The method then proceeds to block 606 where partitions to be reassigned are grouped. In one embodiment, a partition list for the partitions to be reassigned is created. For example, any storage pools 214 that have been removed from the file system 100 may have all their assigned partitions unassigned and added to the partition list, and any storage pools 214 that have more partitions than their ideal partition count may have random partitions unassigned from them and added to the partition list (i.e., such that those storage pools have a number of partitions that is within a predetermined amount of their ideal partition count.) The partitions on the partition list may then be reassigned to the storage pool 214 in blocks 608 and 610 of the method 600 substantially as discussed above with reference to blocks 506 and 508 of the method 500 . In one embodiment, at block 608 of the method 600 , whenever a partition is reassigned to a storage pool 214 , the time of the reassignment is recorded. Reassignment times may be used when gathering partitions to reassign to storage pools 214 , such that no partition replica for a given partition is moved twice in a predetermined amount of time. However, such reassignment restrictions based on reassignment times may be ignored for partition replicas on storage pools 214 that have been removed from the file storage system 100 , as removing a storage pool 214 only happens upon storage pool 214 /storage server 108 failure and thus requires the reassignment of the partitions.
[0060] In one embodiment, the method 600 is conducted periodically to help balance the amount of data stored by storage pools 214 in the file storage system 100 . For example, the partition reassignment method 600 discussed above may repeated until each storage pool 214 is within a predetermined threshold of a predetermined storage capacity (e.g., within 1% of 60% storage capacity for that storage pool) or when it is determined that partition reassignment will not improve the balance of data stored by the file storage system 100 by more than a predetermined amount. For example, if a first storage server 108 includes 2 TB of storage, a second storage server 108 includes 4 TB of storage, and a third storage server 108 includes 6 TB of storage, data balancing may be conducted to ensure that each of the storage servers 108 holds the same percentage of its storage capacity (i.e., the first storage server 108 holds 0.66 TB of data, the second storage server 108 holds 1.33 TB of data, and the third storage server 108 holds 2 TB of data such that each of the storage servers 108 is at 33% of its storage capacity.) Weights may be applied to storage servers 108 to balance the distribution of data on the storage servers 108 in the file storage system 100 to account for different storage capacities.
[0061] Object Service 208
[0062] As discussed above, the object service 208 is implemented in a tailored electrical circuit or as software instructions to be used in conjunction with a processor to create a hardware-software combination that implements the specific functionality described herein. To the extent that one embodiment includes computer-executable instructions, those instructions may include software that is stored on a computer-readable medium located in the storage management server 106 and/or the storage servers 108 . The object service 208 may include instructions that, when executed by a processor, provide object storage and objection manipulation functionality such that the object service 208 is operable to, for example, store, retrieve and delete stored objects in the storage pools 214 . In one embodiment, a object service 208 is provided for each storage pool that holds object data. For example, an object service 208 may be included on a server that further includes one or more storage drives that provide a storage pool for objects. In one embodiment, the objects are stored as binary files with metadata stored as extended attributes of the file in the file system used by the object storage service. In such an embodiment, the object service 208 will uses the extended attributes of the filesystem to manage the metadata. In a second embodiment, the metadata is stored in a machine-readable format next to the data itself. For example, the metadata for a file is stored in a text file or single file database.
[0063] In one embodiment, objects are stored by the object service 208 using a path derived by applying a hash function to the name of the object along with a timestamp. For example, an incoming object for a user account to be written to a container will have a hash applied to its account/container/object name and the path generated for the object is:
[0000] /objects/<partition>/<storage pool location>/objectname_hash.15673.data
where “objects” indicate that the object data is stored in an object storage pool 214 , <partition> is the partition identification that maps the object to a partition, <storage pool location> is the storage pool location that maps the partition replica to a storage pool 214 in a different zone than its related partition replicas, objectname_hash is the hash of the account/container/object name, and 15672 is the timestamp.
[0064] When there is a request for an object, the file storage system 100 will find all the object replicas in the file storage system 100 that include the objectname_hash and return the object data that has the most recent timestamp value. Special care is needed to record updates that should be persisted as the new canonical value. For example, when an object replica is deleted, a modification sentinel (e.g., a 0 byte “tombstone” file or “.ts” file) is written to the storage pool 214 where the deleted object replica was located and that includes the same objectname_hash as the deleted object replica (i.e., /objectname_hash.15784.ts,) and that tombstone file stays in the file storage system 100 for a predetermined amount of time (e.g., 7 days.) During object replication, discussed in further detail below, when the file storage system 100 encounters a tombstone file, the file storage system 100 checks whether the tombstone file has been in the system for 7 days. If not, the file storage system 100 searches for and deletes any object replicas that it finds related to that tombstone file (e.g., replicas that same objectname_hash as the tombstone file) to ensure that objects that were meant to be deleted from the file storage system 100 are removed and older versions of object replicas of a given object do not appear in the file storage system 100 due to, for example, the temporary failure of a storage server 108 or storage pool 214 that might have prevented the deletion of that object replica previously. If the file storage system 100 determines that a tombstone file has been in the file storage system 100 for longer than the predetermined time, that tombstone file is deleted.
[0065] The mechanism used for recording file deletion is also used to record other types of updates. For example, a “purge” marker indicates that the system should overwrite all copies of the object and set the space to free; a “version” marker indicates that the system should create a copy and mark the copy with a version number; and a “ttl” (time-to-live) marker indicates that the system should check an authoritative source for updates after the expiry of a set time period. Other types of out-of-band changes to the file are also contemplated.
[0066] Container Service 210
[0067] As discussed above, the container service 210 is implemented in a tailored electrical circuit or as software instructions to be used in conjunction with a processor to create a hardware-software combination that implements the specific functionality described herein. To the extent that one embodiment includes computer-executable instructions, those instructions may include software that is stored on a computer-readable medium located in the storage management server 106 and/or the storage servers 108 . The container service 210 may include instructions that, when executed by a processor, provide container storage and container manipulation functionality such that the container service 210 is operable to store, retrieve and delete stored containers in the storage pools 214 . In one embodiment, an container service 210 is provided for each storage pool that holds container data. For example, a container service 210 may be included on a server that further includes one or more storage drives that provide a storage pool for containers, and the container service 210 may include the names of containers and objects in those containers. Thus, In one embodiment, the container service 210 handles the listing of containers, and does not hold the location where the objects are stored (e.g., the storage pool where a given object replica resides), but rather the locations of containers that hold the objects. The listings for the container locations may be stored as database files, and those listings may be replicated across the storage pools 214 in a manner that is similar to the replication of objects (i.e., through their association with partitions,) discussed above. Container storage statistics for the container service(s) 210 may be tracked by the file storage system 100 and may include total number of objects stored by one or more containers, the total storage provided by any given container, and/or a variety of other statistics known in the art.
[0068] Account Service 212
[0069] As discussed above, the account service 212 is implemented in a tailored electrical circuit or as software instructions to be used in conjunction with a processor to create a hardware-software combination that implements the specific functionality described herein. To the extent that one embodiment includes computer-executable instructions, those instructions may include software that is stored on a computer-readable medium located in the storage management server 106 and/or the storage servers 108 . The account service 212 may include instructions that, when executed by a processor, provide account storage and account manipulation functionality such that the account service 212 is operable to store, retrieve and delete stored accounts in the storage pools 214 . In one embodiment, an account service 212 is provided for each storage pool that holds account data. For example, a account service 212 may be implemented by a server that includes storage drives that provide a storage pool for accounts, and the account service 212 may include the names of accounts and containers in those accounts. Thus, the account service 212 is very similar to the container service 210 , discussed above, with the exception that account storage 212 handles the listings of accounts.
[0070] Other Services
[0071] As discussed above, other types of services may be implemented in similar fashion to the object, container, and account services described above. For example, one implementation includes an authorization service. The authorization service may include instructions that, when executed by a processor, handle the storage and manipulation of authorization metadata so that the authorization service is operable to store, retrieve, delete, and query stored credentials from in the storage pools 214 . In one embodiment, an authorization service provides an ACL-based authorization. In a second embodiment, the authorization service provides posix-compatible authorization. In a third embodiment, the authorization service provides tree or graph-based authorization, such as would be provided with an LDAP-based authorization service.
[0072] A second implementation includes a structured data service. The structured data service may include instructions that, when executed by a processor, provide handle the storage and manipulation of structured data such that the structured data service is operable to store, retrieve, delete, and query tabular, graph, or tree-based data from in the storage pools 214 . In one embodiment, an structured data service provides a JSON-based output. In a second embodiment, the structured data service provides XML-based output. In a third embodiment, the structured data service provides HTML output.
[0073] Proxy 204
[0074] The proxy 204 is implemented in a tailored electrical circuit or as software instructions to be used in conjunction with a processor to create a hardware-software combination that implements the specific functionality described herein. The proxy 204 is responsible for tying together the file storage system 100 . For each request received from a user, the proxy 204 determines the location of the account, container, or object in the appropriate ring 206 (e.g., the object ring 206 a , the container ring 206 b , or the account ring 206 c ,) and routes the request accordingly. A public Application Programming Interface (API) may be exposed to users through the proxy 204 . A large number of failures may be handled by the proxy 204 . For example, if a storage server 108 and/or storage pool 214 is unavailable for a object PUT, the proxy 204 may use the rings 206 to determine an appropriate storage server 108 and/or storage pool 214 for that object and route the object there instead. In one embodiment, when objects are streamed to or from a storage server 108 , they are streamed directly through the proxy 204 and proxy server 106 to or from the user 202 and/or user device 102 , and are not spooled by the proxy 204 and the proxy server 106 .
[0075] In another embodiment, there are multiple proxies associated with a file storage service. The existence of multiple proxies may be ascertainable from outside the file storage service, or it may be transparent. Different proxies may be used for different purposes. For example, in one embodiment different proxies are used for different types of files. In another embodiment, different proxies are used for different types of requests. In a third embodiment, an appropriate proxy is chosen to minimize latency, geographic, or network distance between the proxy and the system making the request.
[0076] In one embodiment, one of the functions performed by the proxy is time-stamping or logging all requests into the storage system. The timestamps on the incoming requests are stored as metadata and are used in part to determine the most recent version of a file.
[0077] In an embodiment with more than one proxy, it is possible for more than one request to come in within a short period of time. In that case, it is important to resolve any conflicts associated with multiple simultaneous accesses to the file storage system. In one embodiment, an algorithmic approach for ordering the actions of different independent actors is used, such as the use of a vector clock. In a second embodiment, an independent arbiter is used to resolve conflicts, using an implementation of the Paxos algorithm or the Byzantine Generals algorithm.
[0078] A third embodiment may also be used to simplify and increase the speed of the system by reducing the applicable error window and then algorithmically picking a “winner” in the case of multiple conflicting accesses within the error window. For example, an embodiment may use a time synchronization server and time synchronization code to reduce the clock skew between different computers in a pool, in a zone, or across zones to within a specified ε, for example one millisecond or one microsecond. The applicable c can be determined by analyzing the pattern of accesses over time, and it may be different for different accounts, different types of services, or at different times. In this case, the algorithmic complexity of absolutely ordering the actions across the cluster is traded for the operational complexity of handling time synchronization across the system.
[0079] Given the clock synchronization across the pools or zones within ε, the previously-discussed timestamp will be sufficient to absolutely order the actions of other systems interacting with the file storage system if there are not multiple conflicting accesses to the same stored value within ε. In that case, the timestamping is used to order the actions and pick the most recent version of any information or data.
[0080] If there are multiple conflicting accesses within ε, then the system includes a synchronization rectifier that algorithmically breaks the tie and chooses a winner. In one embodiment, this is handled by asserting that the first copy to replicate (as further discussed below) wins. In a second embodiment, the inconsistency is handled by throwing an error for manual intervention. In a third embodiment, the inconsistency is handled by examining one or more additional types of metadata, such as latency to the originating user (given identical arrival times, the originating server with lower latency issued second), internal file modification or creation times, or an arbitrary ordering on an unrelated value. A fourth embodiment uses geolocation on the requesting IP address and allowing the request that is geographically closer to the timestamping gateway. A fifth embodiment detects the attempted simultaneous access and does not allow any write, instead returning an error in response to both requests. A sixth embodiment evaluates the requests to see if they can be merged and both accesses granted.
[0081] Replicators
[0082] Replicators are implemented in a tailored electrical circuit or as software instructions to be used in conjunction with a processor to create a hardware-software combination that implements the specific functionality described herein. To the extent that one embodiment includes computer-executable instructions, those instructions may be implemented as an software that is stored on a computer-readable medium located in the storage management server 106 and/or the storage servers 108 , and may include instructions that, when executed by a processor, keep the file storage system 100 in a consistent state in the face of temporary error conditions like network outages, storage pool 214 failure, and/or storage server 108 failure. For example, an object replicator may be provided for each storage pool 214 (e.g., a storage server 108 that provides a storage pool) that holds object data. The replicators compare stored entities in their storage pool 214 with each replica of that stored entity in other storage pools 214 in the file storage system 100 to ensure that all related replicas contain the latest version of the stored entity. In one embodiment, object replicators may use a hash list to quickly compare subsections of partitions, while container replicators and account replicators may use a combination of hashes and shared storage account metadata. In one embodiment, replicator updates of stored entities are push based. For example, replicators may compare the replica stored entities in their storage pools 214 with related replica stored entities in other storage pools in the file storage system 100 , and if the replicator determines there is a difference between the replicas (e.g., by applying an order independent check sum to the related replicas), the replicator may then push the data that related replica stored entities in other storage pools need in order to be up to date. In one embodiment, the pushed updates include rsyncing replicas to efficiently provide only the data needed by the out-of-date replica. Account and container replicators may either push missing data over HTTP or rsync whole database files in the event it is determined that a push update will be inefficient. The push-based updates discussed above results in replicas being updated generally only from “local” storage pools 214 to “remote” storage pools 214 . In one embodiment, this provides a benefit as data in a storage pool 214 may not belong there (as in the case of handoffs and ring changes), and a replicator can't know what data exists elsewhere in the file storage system 100 that it should pull in. Thus, it's the duty of any replicator associated with a given a storage pool 214 that contains data to ensure that data gets to other storage pools where it belongs. As discussed above, replicators may also ensure that data is removed from the system by creating the tombstone files as the latest version of a replica when that replica is deleted, and then search out and removing all replicas related to that tombstone file from the file storage system 100 .
[0083] Database Replicators
[0084] Database replicators are a type of replicator, discussed above, that operate on storage pools 214 that contain accounts or containers (i.e., there may be account replicators and container replicators.) To perform the replication discussed above, the first step that a database replicator may perform may be a low-cost hash comparison to find out whether or not two replicas (e.g., a replica on the database replicators local storage pool 214 and a related replica on a “remote” storage pool 214 ) already match. Under normal operation, the hash comparison allows relatively quick verification that databases in the file storage system 100 are already synchronized. If the hashes differ, the database replicator may bring the databases in sync by sharing records added since the most recent previous sync point. This most recent previous sync point notes the last record at which two databases were known to be in sync. After all new records have been pushed to the remote database, the sync table (which lists which remote databases a local database is in sync with) of the local database is pushed to the remote database, so the remote database knows it's now in sync with database that the local database has previously synchronized with. If a database replica (e.g., an account replica or container replica) is found to be missing entirely from a storage pool 214 that it should exist in, the entire local database file may be recreated on that storage pool 214 using rsync techniques known in the art. In one embodiment, when an entire local database file is be recreated on a storage pool 214 using rsync, that database may be vested with a new unique id.
[0085] Object Replicator
[0086] Object replicators are a type of replicator, discussed above, that operate on storage pools 214 that contain objects. In one embodiment, object replicators associated with a storage pool 214 may performed rsync techniques known in the art on remote storage pools to determine appropriate data to push data to remote storage pools. However, as object replication times may increase using this method when the file storage system 100 gets sufficiently large, a hash of the contents for each suffix directory may instead be saved to a per-partition hashes file, and the hash for a given suffix directory is then invalidated when the contents of that suffix directory are modified. The object replicator may then read these hash files, calculate any invalidated hashes, and transmit the hashes to each remote storage pool 214 that should hold the partition, and only suffix directories with differing hashes on the remote server are then rsynced. After pushing data to the remote storage pools 214 , each rsynced suffix directory has its hashes recalculated. Object replicator performance is generally bound by the number of uncached directories it has to traverse, usually as a result of invalidated suffix directory hashes. In one embodiment, the file storage system 100 is designed so that around 2% of the hash space on a normal storage pool 214 will be invalidated per day.
[0087] Updaters
[0088] Updaters are implemented in a tailored electrical circuit or as software instructions to be used in conjunction with a processor to create a hardware-software combination that implements the specific functionality described herein. To the extent that one embodiment includes computer-executable instructions, those instructions may include software that is stored on a computer-readable medium located in the storage management server 106 and/or the storage servers 108 , and may include instructions that, when executed by a processor, process updates that may have failed. An updater may be provided with each storage pool (e.g., on a server that includes the storage pool) to process failed updates. For example, there may be times when container or account data will not be immediately updated. Such incidents may occur during failure scenarios or periods of high load. If an update of a stored entity fails, the update is queued in a storage pool 214 on the file storage system 100 , and the updater that is associated with that storage pool 214 will process the failed updates. In such situations, a consistency window is used. For example, suppose the container service 210 is under load and a new object is put in to the file storage system 100 . The object will be immediately available for reads as soon as the proxy 204 responds to the user 202 that the object has been successfully added to the file storage system 100 . However, due to the heavy load, a container service 210 may not have been able to update its object listing, and so that update would be queued for a later update. Container listings, therefore, may not immediately contain the object, although the object has been saved and replicated within the applicable object storage pool area. In one embodiment, the consistency window needs only to be as large as the frequency at which the updater runs.
[0089] Auditors
[0090] Auditors are implemented in a tailored electrical circuit or as software instructions to be used in conjunction with a processor to create a hardware-software combination that implements the specific functionality described herein. To the extent that one embodiment includes computer-executable instructions, those instructions may include software that is stored on a computer-readable medium located in the storage management server 106 and/or the storage servers 108 , and may include instructions that, when executed by a processor, check the integrity of the objects, containers, and accounts stored in the storage pools 214 . If corruption is found (in the case of bit rot, for example), auditors may quarantine the file, and then replication (discussed above) is used to replace the bad file from another replica. If other errors are found they may be logged (for example, an object's listing can't be found on any container storage that it should be on).
[0091] Large Object Support
[0092] The file storage system 100 may include a limit on the size of a single uploaded object (e.g., 5 GB.) However, the download size of a single object may be made virtually unlimited with the concept of segmentation. Segments of a larger object are uploaded and a special manifest file is created that, when downloaded, sends all the segments, concatenated in order, to emulate a single object. This also offers much greater upload speed by enabling the parallel upload of different segments. For example, a user may specify the segment size to use when splitting a large file (e.g., 1 GB.) The file storage system 100 would then split the large file into 1G segments and begin uploading those segments in parallel. Once all the segments have been uploaded, a manifest file may created so the segments can be downloaded as one. In one embodiment, all the segments may be uploaded into a second container with names like large_file/1290206778.25/21474836480/00000000, large_file/1290206778.25/21474836480/00000001, etc. In one embodiment, the use of a separate container provides a benefit that the main container listings will not be polluted with all the segment names. The use of a segment name format of <name>/<timestamp>/<size>/<segment> provides that an upload of a new file with the same name won't overwrite the contents of the first until the last moment when the manifest file is updated.
[0093] The primary factor driving the limitation of object size in the file storage system 100 is maintaining balance among the partitions of the ring. To maintain an even dispersion of disk usage throughout the file storage system 100 , larger objects are split into smaller segments which are then glued together during a read. This design allows the user to support backup and archiving of large data sets, and improves performance and/or reduces errors due to network interruption. The major disadvantage of this method is that knowledge of the original partitioning scheme is required to properly reassemble the object, which is not practical for some use cases, such as CDN origination. In order to eliminate any barrier to entry for clients wanting to store objects larger than 5 GB, a fully transparent support for large object uploads may be provided. A fully transparent implementation supports a larger max size by automatically splitting objects into segments during upload within the proxy without any changes to the client API. All segments are completely hidden from the client API. The “user manifest” design discussed above provides a transparent download of large objects to the client and still provide the uploading client a clean API to support segmented uploads. Alternative “explicit” user manifest options may be provided that include a pre-defined format for listing the segments to “finalize” the segmented upload.
[0094] Account Reapers
[0095] An account reaper is implemented in a tailored electrical circuit or as software instructions to be used in conjunction with a processor to create a hardware-software combination that implements the specific functionality described herein. To the extent that one embodiment includes computer-executable instructions, those instructions may include software that is stored on a computer-readable medium located in the storage management server 106 and/or the storage servers 108 , and may include instructions that, when executed by a processor, remove data from deleted accounts in the background of the file storage system 100 . An account may be marked for deletion by a user which may put a value of DELETED into the status column in the account service 212 on a storage pool 214 that includes accounts, indicating the data for the account should be deleted later. In one embodiment, there may be no set retention time and no undelete, as it may be assumed the user will implement such features once it is truly desired that the account's data be removed. The account reaper runs on each account service and storage pool 214 and scans the storage pool 214 occasionally for accounts that are marked for deletion. In one embodiment, the account reaper may only trigger on accounts that storage pool 214 is designated as a “primary” storage pool for so that multiple account services aren't trying to do the same work at the same time. The deletion process works as follows: for each container in the account, each object is deleted and then the container is deleted. Any deletion requests that fail won't stop the overall process, but may cause the overall process to fail eventually (for example, if an object delete times out, the container won't be able to be deleted later and therefore the account won't be deleted either). The overall process continues even on a failure so that it doesn't get hung up reclaiming file storage system space because of one troublesome spot. The account reaper will keep trying to delete an account until it eventually becomes empty, at which point the database replicator will eventually remove the database files.
[0096] In one embodiment, deleting an account is accomplished through completely external calls and requires no changes to the file storage system 100 . All data is simply deleted in the same way a user would, through the public ReST API. However, this uses proxy resources and logs everything when such actions aren't necessary, and may require a dedicated system for issuing the delete requests. In one embodiment, a completely bottom-up approach may be used where the object and container servers occasionally scan the data they hold, check if the account has been deleted, and removing the data if the account has been deleted. This provides for the quick reclamation of storage space with no impact on the proxies or logging, but a vast majority of the scanning results in no action while creating a relatively high I/O load with no benefit. In one embodiment, the account server marks all the containers for deletion and the container storage deletes the objects in each container and then themselves. This also provides for quick reclamation of storage space for accounts with a lot of containers, but results in a relatively large load spike. In one embodiment, the load spike may be reduced by slowing down the process, but then the benefit of quick reclamation of storage space is lost while providing a more complex process. In one embodiment, a database replicator scans all the containers for those marked for deletion while performing a replication scan.
[0097] Ring Data Structure
[0098] The list of available areas in the storage pool 214 is known internally to the Ring. In one embodiment, each item in the list of storage pool 214 is a dictionary with the following keys:
[0000]
id
integer
The index into the list storage pools 214.
zone
integer
The zone the storage pool 214 resides in.
weight
float
The relative weight of the storage pool 214 in comparison to other storage pools
214. This usually corresponds directly to the amount of disk space the storage
pool 214 has compared to other storage pools 214. For instance a storage pool
214 with 1 terabyte of space might have a weight of 100.0 and another storage
pool 214 with 2 terabytes of space might have a weight of 200.0. This weight can
also be used to bring back into balance a storage pool 214 that has ended up
with more or less data than desired over time. A good average weight of 100.0
allows flexibility in lowering the weight later if necessary.
ip
string
The IP address(es) of the storage server(s) 108 providing the storage pool 214.
port
int
The TCP port the listening storage server process uses that serves requests for
the storage pool 214.
device
string
The on disk name of the storage pool 214 on the storage server(s). For example:
sdb1
meta
string
A general-use field for storing additional information for the storage pool 214.
This information isn't used directly by the storage server processes, but can be
useful in debugging. For example, the date and time of installation and hardware
manufacturer could be stored here.
[0099] In one embodiment, the list of storage pools 214 contains holes, or indexes set to None, for storage pools 214 that have been removed from the cluster. Generally, storage pool ids are not reused. Also, some storage pools 214 may be temporarily disabled by setting their weight to 0.0.
[0100] Partition Assignment List
[0101] This is a list of array(‘l’) of storage pool ids. The outermost list contains an array(‘l’) for each replica. Each array(‘l’) has a length equal to the partition count for the ring. Each integer in the array(‘l’) is an index into the above list of storage pool 214 .
[0102] Partition Shift Value
[0103] The partition shift value is known internally to the Ring. This value used to shift an MD5 hash to calculate the partition on which the data for that hash should reside. Only the top four bytes of the hash is used in this process.
[0104] In one embodiment, a “live ring” option may be used where each storage server 108 maintains its own copy of the ring and the storage servers 108 use a gossip protocol to communicate when changes made. In one embodiment, all ring lookups are done by calling a service on a separate server or set of servers. In one embodiment, servers submit change requests to a ring server to have a new ring built and shipped back out to the servers. The ring 206 described above has each replica of a partition independently assigned to a storage pool 214 . In one embodiment, a ring may be created that uses a third of the memory of the ring 206 by assigning the first replica of a partition directly while determining the other two replicas by “walking” the ring until additional storage pools 214 are found in other zones. In another embodiment, partition to storage pool 214 assignments are not stored in a big list in memory but rather each storage pool 214 is assigned a set of hashes or anchors. The partition is then determined from the data item's hash and the nearest storage pool 214 anchors determine where the replicas should be stored.
[0105] Various hashing algorithms may be used in different embodiments. The Secure Hash Algorithm (SHA) offers relatively good security but may be slower. MurmurHash may be used as a relatively faster option as compared to SHA. MD5 Hash is desirable for its general availability, good distribution, and adequate speed.
[0106] Although illustrative embodiments have been shown and described, a wide range of modification, change and substitution is contemplated in the foregoing disclosure and in some instances, some features of the embodiments may be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the embodiments disclosed herein.
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Several different embodiments of a massively scalable object storage system are described. The object storage system is particularly useful for storage in a cloud computing installation whereby shared servers provide resources, software, and data to computers and other devices on demand. In several embodiments, the object storage system includes a ring implementation used to associate object storage commands with particular physical servers such that certain guarantees of consistency, availability, and performance can be met. In other embodiments, the object storage system includes a synchronization protocol used to order operations across a distributed system. In a third set of embodiments, the object storage system includes a metadata management system. In a fourth set of embodiments, the object storage system uses a structured information synchronization system. Features from each set of embodiments can be used to improve the performance and scalability of a cloud computing object storage system.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation-in-part of U.S. patent application Ser. No. 13/420,143, filed Mar. 14, 2012, which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/453,498, filed Mar. 16, 2011.
FIELD OF THE INVENTION
The present invention is in the technical field of masonry veneer products, and includes a system using such products. More particularly, the present invention is in the technical field of masonry veneer products installed without a scratch coat and lath system.
BACKGROUND OF THE INVENTION
As described in copending U.S. patent application Ser. No. 13/420,143, which is incorporated herein by reference in its entirety, Masonry veneer systems are commonly used for exterior cladding, as architectural or aesthetic features on residential and commercial buildings.
As described in detail by the Masonry Veneer Manufacturers Association (MVMA), proper installation of stone on a framed building requires the installation of a weather resistant barrier (WRB), then application of a lath secured to the framing with corrosion resistant fasteners and a nominal ½ inch scratch coat. The lath must be properly applied to the wall in order to avoid intrusion of water, and to provide an acceptable structure to which the cladding will be adhered. The lath must be corrosion resistant, applied in an overlapping fashion, and with a corrosion resistant nail that penetrates the studding according to the MVMA recommendations. Additionally, the scratch coat must be applied using a correct mortar at the proper moisture content and thickness, embedded properly in the lath, allowed to cure to “thumb dry”, the scratched to provide grooves, and allowed to cure. These additional products and steps add cost, additional labor and provide opportunities for human error, which can result in a poor installation and future problems. The installation of the WRB, lath and scratch coat must be performed up to 48 hours or more before the installation of the veneer product, allowing the scratch coat to properly cure. Further details are set forth by the MVMA.
Once the scratch coat is properly applied and cured, adhered concrete masonry veneer (ACMV) products are then adhered to the scratch coat using a mortar applied to the ACMV. The MVMA guidelines recommend that the scratch coat should be moist cured to prevent cracking, and that both the scratch coat and the ACMV should be “dampened” when applying the ACMV, adding additional requirements on the installer. The installer typically will take individual ACMV products, “butter” the back of each individual product with mortar, and apply the “buttered” product to the scratch coat, forcing the mortar into the scratch coat to adhere the ACMV to the wall. The consistency of the scratch coat, mortar and skill of the installer each play a role in the reliability of the installation. Additionally, the installation should not be performed during rain or cold weather, thus limiting the time available (and time delay) for completion of the building. These all add to cost and customer dissatisfaction during the construction process.
ACMV products are typically installed as discrete individual stones or brick adhered to a scratch coat on the exterior of a building as described above. Stones are typically installed from the top of the building, and the wall is covered in a downward direction. If the wall is struck (e.g. if drywall is installed on the interior of the building) before the mortar is cured, the stone may be dislodged from the wall. This creates re-work for the installer, or partially dislodged stones may become loose at a later date.
An optional installation technique described in the MVMA guidelines includes a rainscreen drainage plane system, which provides a space to permit incidental water to escape. The recommended ways to provide this space include a drainage mat, formed polymer sheeting (such as Delta®-Dry Stucco and Stone, available from Cosella-Dorken, ref. http://www.cosella-dorken.com), strapping or furring to provide the recommended MVMA air gap of 3/16 to ¾ inch. These systems allow moisture to escape from behind the veneer, but add additional material and labor cost, time and complexity during installation of the ACMV product, and are not used in many installations.
A panelized veneer product, Versetta Stone, is sold by Boral Stone, LLC. (http://masonry.owenscorning.com/versettastone). These panelized veneer products are secured to the exterior of a building using mechanical fasteners driven through a flange embedded in the top of the veneer product. These systems reduce some of the issues with the adhered ACMV products, because the lath, scratch coat and adhesive mortar can be eliminated in many installations of these panelized veneer products. However, these panelized veneer products are relatively large (typically about 8-10 inches high and approximately 32-36 inches wide) and have a limited drainage plane gap. While this enables fast installation on structures where penetrations are not present (such as windows or outlets) or corners, the presence of these penetrations on most buildings results in a large number of panels being trimmed and a fairly large amount of waste (Boral's installation instructions instructs an installer to initially estimate 10% scrap). The large number of cuts takes time and produces excess waste. Additionally, these products are more expensive to manufacture, and the designs present challenges in manufacturing.
Accordingly, it would be desirable to provide an improved product and system for installing veneer products and to eliminate the lath and scratch coat.
SUMMARY OF THE INVENTION
In accordance with the purposes of the present invention as described herein, an improved masonry veneer product (“MVP”) and system (“MVS”) are provided. Such a product and system includes a bracket embedded in the product, the bracket having a first end for securing the upper end of the product to a building. In one embodiment, the bracket also creates an integral air gap behind the product for the escape of moisture. The bracket may include a second end for retaining the bottom end of the product to the building through an interference fit to an adjacent MVP. The system further includes a projection between adjacent MVP to impede moisture from passing between MVP's, and a WRB installed adjacent the structure and air gap to keep moisture from entering the structure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 provides a front view of a pair of masonry veneer products according to the present invention;
FIG. 2 provides a front view of a corner masonry veneer product according to the present invention;
FIGS. 2A and 2B provide isometric views of a drip ledge corner product according to the present invention;
FIG. 3 provides an isometric view of a masonry veneer product according to the present invention;
FIG. 4 provides an isometric view of a first wire retainer according to the present invention;
FIG. 5 provides an isometric view of a second wire retainer according to the present invention;
FIG. 6 provides an isometric view of a masonry veneer product according to the present invention having a long width dimension;
FIG. 7 provides an isometric view of a masonry veneer product according to the present invention useful as an accessory;
FIG. 8 provides an isometric view of a masonry veneer product installed into a starter strip over a WRB according to the present invention;
FIG. 9 provides an end view of a starter strip profile according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1 there are shown a pair of masonry veneer products 10 , 10 ′ illustrated schematically and described herein typically as a dry stack stone product body 12 , similar to a typical box material in appearance. However, the new MVP and MVS have additional inventive features as described herein. The present invention could be applied to nearly any texture of manufactured stone or brick, but is primarily illustrated with a dry stack installation for the sake of simplicity (and as a representative installation). Although not illustrated, one skilled in the art appreciates that an embodiment of the present invention may be used with a grouted texture, and would preferably include a flange on one of the top and bottom of the stone and a second flange on either the left or right end, the flanges each serving as a ledge for a grouted joint. One skilled in the art could modify the current design to utilize the present invention with other textures and configurations.
The embodiment shown in FIG. 1 includes a pair of brackets 14 , 14 ′ embedded in the product body 12 . Each bracket includes a top end 16 and bottom end 18 . The top end 16 is illustrated as having a looped construction forming an eye for receiving a fastener 40 as illustrated in FIG. 8 . The ends 16 , 18 are designed to extend and nest under an adjacent stone as illustrated in FIG. 1 at 21 . Each end preferably includes a curved shape 17 , 19 as illustrated in FIGS. 4 and 5 for holding the body 12 away from the wall to create an air gap for drainage and to allow for deflection of the ends 16 , 18 when attached to the wall. In a preferred embodiment as illustrated in FIG. 4 , the wire 14 includes two attachment eyes 25 , 26 at the bottom end 18 and two attachment eyes 27 , 28 at the top end 16 , formed in a unitary bracket 14 . A lateral connector 13 is provided to enable the formation of the bracket into a single piece, preferably as a unitary construction, to enable efficient manufacture of the product 10 . Although shown connecting the top ends 16 , another embodiment includes a connector for connecting the bottom ends or intermediate portions 20 .
As further illustrated in FIG. 3 , the bracket 14 is embedded into the stone body 12 , with an intermediate portion 20 as shown in FIGS. 4 and 5 . The intermediate portion 20 is embedded in the product body 12 a depth sufficient to ensure adequate engagement to support the stone body 12 when attached to a building (not shown), preferably for the life of the building. The depth and shape may affect the pullout strength, and should be coordinated with the size, shape and weight of the product. In a preferred embodiment, the embedded depth is approximately ¾-1 inch, but may be more or less depending on the surface area of the bracket, the characteristics of the body composition, and the size and shape of the body. In one embodiment the depth is ½ inch. In a heavier product, the depth may be 1.5 inch or more, depending on requirements. The brackets 14 penetrate the stone body 12 to a depth that provides sufficient engagement between the bracket and cured concrete stone, but also which retains a thickness of concrete that will ensure the face of the stone body 12 does not expose the wire or fracture during the life of the building. The brackets 14 are preferably formed from a wire that is corrosion resistant, such as a stainless steel or galvanized steel, and having sufficient strength and sufficient stiffness to not deform and to provide the installation with an interference fit at the bottom as described below. The bracket 14 should be rigid enough to withstand handling, packaging, transport and installation without excessive deformation. In another embodiment, the brackets 14 are formed from a fiberglass material, or any material known to one skilled in the art that is not corroded and will support the masonry product 10 . In yet another embodiment (not shown), the brackets 14 are stamped from sheet metal or formed or molded from another non-corrosive material in a more flattened cross section. One skilled in the art appreciates the bracket preferably has adequate strength and shape retention or memory.
As shown in the embodiment illustrated in FIGS. 1 and 3 , the product may include water shedding feature, which is described herein to include a flashing lip 22 along the top surface 29 of the stone body 12 . This lip 22 is intended to inhibit the passage of moisture, such as wind driven rain, between the stone body 12 and an adjacent stone 10 ′ as illustrated in Fig. In such an embodiment, each stone body 12 may also include a corresponding recess 24 on the bottom surface 30 of the stone body 12 to correspond with the opposing lip 22 of the adjacent stone. This lip 22 and recess 24 also serve to obscure a view of the WRB installed beneath the stone to create a visually appealing dry stack installation. It also enables easier leveling during installation.
Although not illustrated here, the lip 22 may contact the body within the recess, thereby setting the gap between the products. In a similar manner, each stone preferably includes a lip along one end of the stone body, and a corresponding recess along the opposite end of the stone body, which will inhibit moisture intrusion, obscure visibility behind the product, and set the side to side gap.
While the lip and recess 22 , 24 are illustrated in FIGS. 1 and 3 as an angled or chamfered protrusion and recess, one skilled in the art appreciates that while not illustrated as such, the lips 22 , 24 could be simple ridge, a rabbet, shiplap, or other type of configuration that provides a moisture block and an improved line of sight.
As illustrated in the embodiment of FIG. 3 , the bracket 14 includes a first protrusion 34 formed in the bracket 14 . The protrusion extends below the back surface 32 of the stone body 12 to bear against the structure 39 illustrated in FIG. 9 and create an air gap G 1 under the product 10 when installed on a structure, preferably installed over a WRB 38 . In the illustrated embodiment, the bracket 14 includes a bend 36 which holds the top end 16 away from the structure 39 and WRB 38 to create a second gap G 2 . When the bracket 14 is secured through the WRB 38 to the structure 39 as illustrated in FIG. 8 , the top end is urged by the fastener 40 toward the structure 39 . This force on the top end 16 acts as a lever, which urges the opposite second end 18 of the bracket 14 away from the structure 39 and toward the back surface 32 ′ of a second body, such as an adjacent product 10 ′, or into a channel on e.g. a starter strip 42 . Because the second end 18 is wedged below the lower product 10 ′, this causes a second protrusion 35 at the bottom end 18 to be held securely against the structure 39 and therefore the product is secured both at the top by the nail and at the bottom by a wedging action against the second product 10 ′. In a preferred embodiment, the top end is positioned approximately ⅛ inch further away from the structure to ensure the wedging action occurs. This dimension can be modified depending on the stiffness of the wire and the surface against which it bears to provide a gap greater than the height off the wall to enable a cam locking action.
As illustrated in FIG. 3 , in a preferred embodiment, the gap under the top GT is approximately ½ inch and the gap under the bottom GB is approximately ⅜ inch. One skilled in the art appreciates this dimension may be modified based on the air gap desired, concrete penetration and the deformation of the bracket 14 . As illustrated in FIG. 1 the top end 16 preferably extends a distance B 2 above the body 12 and bottom end 18 extends a distance B 1 below the body 12 . In a preferred embodiment B 1 extends approximately ½ inch further than B 2 . In one embodiment B 1 is approximately 1⅝ inch and B 2 is approximately 1⅛ inch. In another embodiment, B 1 is approximately 1¼ inch and B 2 is approximately ¾ inch. One skilled in the art appreciates this dimension may be changed to increase or decrease overlap depending on the nature of the wire, the size of the stone, and other manufacturing and installation factors, and in some embodiments, the dimensions may be the same or opposite to reflect the overall design requirements. One skilled in the art appreciates that the overlap can be lengthened to the height of the stone or more if designed with no interference, and greater overlap may provide a more stable wall.
In another embodiment (not illustrated), the top end of the bracket 14 does not have a bend 36 , and the bottom end 18 of the bracket is bent to lie in a plane above the back surface 32 of the stone body 12 , so the bottom end 18 is installed under an adjacent product (not shown) simply using an interference fit. This interference may be at least 1 mm and could be 2, 3, 4, or 5 mm or more, depending on the stiffness of the bracket. Accordingly, the configuration of the bottom bracket illustrated in FIG. 2 may be used with or without the bent configuration of the top end 16 as illustrated in FIG. 2 . Additionally, the second end 18 may be wedged against another body, such as a starter strip or an accessory, such as a ledge. In certain applications, it may be sufficient to fasten the second end using adhesives, nails, stapes, screws or the like as a substitute for the second body. While the protrusions are illustrated herein as bent wires, one skilled in the art appreciates that a different configuration could include a molded protrusion, a weldment, or other configurations to provide the desired gap.
A system including the product 10 described above preferably includes a building structure 39 such as a frame and sheathing or concrete structure, a weather resistant barrier 38 installed over the structure (similar in nature and installation to that specified by the MVMA), a plurality of products 10 attached to the structure over the WRB 38 and attached to the structure 39 using fasteners 40 projecting through the brackets 14 . The fasteners 40 are preferably non-corrosive, such as galvanized roofing nails, screws or staples; provided however that the fasteners must provide sufficient strength to secure the product 10 to the structure 39 for the life of the structure.
In one embodiment, installation begins from the bottom of the building. In such an instance, a starter strip 42 is installed to the building in a level manner. A preferred starter strip is illustrated in FIG. 9 . The starter strip 42 preferably includes a recess 44 to receive the bottom 18 of the brackets 14 . The starter strip preferably includes weep holes 46 at the bottom of the recess 44 to enable water to drain. The recess 44 preferably includes a lead angle 48 to enable easy installation of the bracket 14 and preferably narrows to a line to line or interference fit to wedge the bracket 14 and hold it in place. In one embodiment, the lead angle is approximately twenty degrees, and the recess has a bottom radius R 1 of 0.06 inch for a 0.12 diameter wire, and a depth L 1 of approximately ½ inch. Products having characteristics similar to the starter strip are also preferably used as flashing around windows and other openings. The starter strip 42 is preferably made from galvanized steel, aluminum, PVC or any common noncorrosive building material used in similar applications. Furthermore, the bottom of the bracket may experience bending and wedging as the bottom legs are fit into the recess of the starter strip and the brackets are secured to the wall.
The starter strip 42 also includes a back portion 50 which extends under the WRB 38 to ensure water does not enter under the WRB, to comply with ASTM requirements. In a preferred embodiment the back portion 50 has a height L 2 of 3.5 inches to satisfy ASTM. In another embodiment, 2 inches may be sufficient. The overlap may be less in some situations or may be more, but practicality limits one is normally acceptable. In another embodiment, a simple j-channel or other starter is used with the products 10 of the present invention. Similarly, one skilled in the art appreciates that either a starter strip or weep screed should provide ventilation at the bottom, and therefore accommodations should be made to provide for air passage. Once the first row is secured to the wall using the starter strip 42 and the top end 16 of the brackets is secured as described above, the second row is installed by inserting the bottom ends 18 of the second row of products behind the rear surface 32 of the first row of products previously installed. Then the top end of successive rows of the product being installed is pushed against the structure 39 and secured at the top end 16 as described above.
The top row of the product may be capped or may extend to the soffit. It is desirable to include an air gap where possible to provide for air flow. Where water drainage does not permit this, MVMA details may be followed. Where the product extends to the soffit, an installation similar to typical brick installation may be performed, i.e. the soffit may be installed after the product is installed. Alternatively the soffit j-channel may include a spacer against the wall to provide for air flow at the top of the wall.
Although not illustrated, in one embodiment, after the product is secured to the structure, a bead of caulk or other material is optionally installed on the product along one of the top and bottom, plus one of the ends, so that the joint between adjacent products is filled with the material to provide a substantially effective water seal. In yet another embodiment, a bead of caulk or foam dam is provided on the top or bottom and one end of each stone at the factory to provide a substantially watertight joint between adjacent products without a field-applied caulk.
One skilled in the art appreciates that while not illustrated here, a grout product may optionally be installed between adjacent products for certain textures. Such a grout is preferably flexible, so that it can perform for an extended period without cracking. Such a grout is also preferably water resistant to minimize the amount of water that enters between adjacent products. Additionally, a grout may be used with the flanged design described above.
As illustrated in FIG. 3 , the product 10 preferably includes a single bracket 14 , but one skilled in the art appreciates that more than one bracket may be utilized to provide additional support and attachment, or to facilitate manufacture. The nature of the product (size, weight) and the nature of the brackets, fasteners and structure and environment can affect these requirements.
As illustrated in FIGS. 2, 2A 6 and 7 , the invention is also applied to corners and accessories, such as drip ledge corners, trim stones, keystones, ledges, light fixtures, outlets, column wraps and other products. In the case of corners, in one embodiment shown in FIG. 2 , only one side of the stone corners are attached to the structure, and a spacer is provided on the backside of the return to provide a consistent air gap and exterior thickness. As shown in FIG. 2 , the corner 60 includes a long leg 62 and a return leg 64 . The bracket 14 is used to attach the long leg 62 to the building and the short leg 64 is supported as part of the body. While the corner 60 is illustrated with the top 66 installed so the return is on the left side, the corner 60 could be inverted so the bottom 68 is installed upwardly so the return 66 is on the right side of the corner 60 . Thus, the corners 60 are reversible. Preferably the reversible corners have a reversible clip that is embedded in the concrete to allow for ease of ordering materials, using as left and right corners and staggered joints during installation to give a more authentic stone look.
As illustrated in FIG. 2B , a corner may include two wires 214 , 214 ′ to ensure both legs are sufficiently supported. In this example, the corner may be a ledge corner. In a similar manner, FIG. 6 illustrates an elongate product 10 ″ having two brackets 614 , 614 ′ to support the elongate product. While not limiting, in this illustration, the elongate product 10 ″ may comprise a ledge piece. FIG. 7 illustrates another accessory piece 70 including brackets 714 according to the principles of this invention. Referring to FIGS. 7 and 2B , one skilled in the art appreciates that one can use single or double clips or a combination of single and double clips and can be installed in vertical or horizontal configurations. This principal can be applied to other accessories including trim stones, surrounds, drip ledge corners, light boxes and other accessories.
In another embodiment, the installation instructions teach the installer to set a gap manually, or to use separate spacers, such as foam or molded parts. In another embodiment, the instant invention is applied to a panelized product. In such a case, it may be necessary to utilize a greater number of brackets to adequately support and secure the panelized product due to its size and weight.
One embodiment of the present invention is applied to individual stones or bricks. This makes installation simple, as fewer products will be cut and less scrap created. Furthermore, it avoids the potential that an installer will align the panels to create unsightly lines or an unattractive panelized wall. Additionally, the individual products also make it simpler to create accessory products that are compatible with this system. As noted above, however, applicant envisions that a panelized system could utilize the present invention, either alone or in combination with the individual products as described above.
While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention.
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A veneer product and system includes a body having an aesthetic front surface and a back surface for installation adjacent the building. The body has a top side and a bottom side and a bracket attached to body and projecting away from the back surface of the body, the bracket further comprising a first end adjacent the top side for attachment to the building and a first protrusion for positioning the back surface a predetermined distance from the building and a second end having a second protrusion for positioning the bottom of the back surface a predetermined distance from the building and a bottom projection adjacent the bottom side for engagement with a second body to retain the bottom end of the veneer product.
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FIELD OF THE INVENTION
The present invention relates to a semiconductor component configured as a micromechanical pressure sensor.
BACKGROUND INFORMATION
In the case of many pressure sensor elements patterned out of silicon by the application of surface micromechanics, the reference pressure cavern is produced so as to make possible an examination of the formation of the cavern in an “open” state. However, such a procedure is not possible in the case of semiconductor components and pressure sensor elements which are described in German Patent Application Number 100 32 579.3. Rather, in that case, producing the cavern or void by thermal treatment of the semiconductor material, that is, above all of silicon, requires new concepts for checking expansion and dimensioning of the void or diaphragm above it with respect to thickness and mobility. The usual standard methods for testing such voids, such as x-ray techniques, ultrasound analysis or thermographic analysis are too costly and not usable in mass production.
SUMMARY
An object of the present invention is to make available a semiconductor component which, after being produced in the “closed” state, is able to be tested in a simple way with respect to the formation of the cavern and the mobility of the diaphragm. During the production of pressure sensors based on porous silicon, whether the cavern generated or the void generated is being formed completely and correctly, and whether there might not be remainders of porous silicon or crystalline column structures in the area of the void which would hinder the desired free mobility of the diaphragm situated above the void are monitored.
Because of its design, the semiconductor component according to the example embodiment of the present invention may increase the ease of examining the generated diaphragm with respect to thickness, mobility and mechanical properties, such as its modulus of elasticity. Furthermore, the dimensions of the generated cavern or the generated void may be monitored, and the still present remains of, for instance, porous silicon or crystalline column structures (support locations) may be detected inside the void.
The semiconductor component, in an airtight, closed state may still be checked after the end of production, so that, after this examination, no further production steps follow that are relevant to the performance reliability of the diaphragm or to the assessment of the structure of the cavern.
Due to the construction of the semiconductor component, the diaphragm opposite the diaphragm floor, i.e. the side of the cavern opposite the diaphragm, may be set to a different electrical potential, so that information may be obtained on the mobility of the diaphragm and the structure and development of the void by way of static and/or dynamic capacitance measurements.
Thus, as a response to the formation of column structures in the region of the void, an electrical short-circuit appears in connection with such capacitance measurements in the borderline case, from which one may conclude that, in the region of the void, the diaphragm is supported by a column and is thereby impeded in its mobility.
It is further possible to set the diaphragm into oscillation, particularly resonant oscillation, via a capacitive excitation. From the resonant frequency and the quality of resonant oscillation, one may be able to draw conclusions on the freedom of motion of the diaphragm and possibly on columns being present even in the edge regions of the void. In addition, such a determination of the resonant frequency or analysis of the quality of the resonant oscillation offers the possibility of retroactively drawing conclusions on the material properties of the diaphragm, such as its modulus of elasticity and/or its thickness.
Finally, by a dying-out of the diaphragm, within the framework of these resonant oscillations, up to the limit stop, the height of the generated void is also able to be checked (maximum diaphragm deflection).
If the diaphragm is made of porous silicon and, on its side facing away from the base layer, is completely covered with the overlayer, the enclosed void or cavern may be closed off in a gastight fashion.
For the electrical insulation of the diaphragm from the area of the base layer which is located on the other side of the cavern, a circumferential edge layer may be furnished laterally around the void or the cavern, which, may be made of silicon, just as the diaphragm and the base layer, but which, in contrast to these, has a different doping, so that, between the diaphragm, the circumferential edge layer and the base layer a pnp junction is implemented which acts electrically insulating.
If the conductor region provided above the diaphragm has at least two subsections, the first subsection covering the entire surface of the side of the diaphragm facing away from the base layer, it is possible to contact the diaphragm electrically; and, starting from the surface of the overlayer, a second subsection of the conductive layer may be provided in the overlayer, which, at least from place to place, is in contact with the first subsection in an electrically conductive manner, and which is able to be electrically contacted on or in the overlayer, via printed circuit traces running there.
The first subsection of the conductor area may be produced in a simple manner by a temperature treatment of the semiconductor component during the course of which an out-diffusion of the doping of the diaphragm occurs into the area of the overlayer lying above it, which makes this diffusion region a comparatively well electrically conducting one, vis-à-vis the remainder of the detection layer.
In a corresponding manner, the second subsection of the conducting region provided in the region of the surface of the overlayer may be produced by a doping of the surface of the overlayer which, likewise, diffuses out during the course of this or a further temperature treatment, and leads to a diffusion region which thus defines the second subsection of the conducting layer. This second subsection of the conducting region, may be electrically well conducting compared to the remaining areas of the overlayer.
During the course of the temperature treatment, as soon as there is contact or an electrically conductive connection between the two subsections of the conducting layer, an electrical contacting of the diaphragm, closed off from the overlayer, is possible without a problem on its upper side, even in the closed state of the semiconductor component.
The conducting region and a plurality of second subsections of the conducting region, circular in a top view, which are, for example, in the area of the corners of the diaphragm, may be electrically connected to several printed circuit traces positioned on the diaphragm symmetrically with respect to a top view of it, to each of the second subsections of the conducting region a printed circuit trace being assigned. An even number of printed circuit traces, for example, four, may be provided, which may run along the plane diagonals, above the diaphragm designed, for example, to be rectangular, square, round or oval.
Because of such a symmetrical arrangement of the printed circuit traces, the means running along in the region of the overlayer, or on the overlayer, for induction and/or detection of a warping of the diaphragm, such as piezoresistive components or also heating elements, may not be differently influenced by lead wires.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 illustrates a top view of an example embodiment of a semiconductor component according to the present invention in the form of a micromechanical pressure sensor.
FIG. 2 illustrates a cross sectional view along the vertical section line drawn in FIG. 1 .
FIG. 3 illustrates a cross sectional view along the diagonal section line drawn in FIG. 1 .
FIG. 4 illustrates a second example embodiment of a semiconductor component in the form of a micromechanical pressure sensor according to the present invention.
FIG. 5 illustrates a cross sectional view along the vertical section line drawn in FIG. 4 .
FIG. 6 illustrates a cross sectional view along the diagonal section line drawn in FIG. 4 .
DETAILED DESCRIPTION
FIG. 1 illustrates a semiconductor component in the form of a pressure sensor element 5 produced by surface micromechanical technique for the atmospheric pressure or near-atmospheric pressure range. This pressure sensor element 5 may be produced on the basis of porous silicon technology, such as is described in German Application Number 100 32 579.3 with respect to construction design and production method, and including modifications according to the present invention as described below.
In FIG. 1 there is first shown in top view of pressure sensor element 5 , how, on the surface or in the area of an overlayer of n-doped silicon, for example, episilicon, first actor elements 11 and second actor elements 12 , each, for instance, in the form of piezoresistors or structured piezoresistive layers, are provided. These may be, for example, made of silicon suitably doped in a conventional manner. FIG. 1 also shows that on the surface, or in the area of the surface of the overlayer, run printed circuit traces 10 , which, for example, are likewise made of correspondingly doped silicon.
In addition, it is shown in FIG. 1 that actor elements 11 , 12 end in an edge area region 14 which is, for example, made of n-doped silicon, particularly episilicon, while printed circuit traces 10 are guided beyond these edge area regions 14 into a diaphragm region 16 , which is formed rectangularly in top view or, for example, square.
Below diaphragm area region 16 and below the overlayer there is a diaphragm 22 , not visible in FIG. 1 , which covers a cavern or a void 23 . First actor elements 11 are, in addition, for example, bent over at right angles in the vicinity of edge area region 14 , which simplifies the warping of diaphragm 22 or also the detection of the warping of diaphragm 22 . This may achieve a more uniform, desired feeding of force into diaphragm 22 , for example, in the edge region of diaphragm 22 . In FIG. 2 it may be seen that edge area region 14 extends into the region above diaphragm 22 , for example, as far as possible.
Actor elements 11 , 12 may be used for the warping as well as the detection of the warping of diaphragm 22 , for instance, by a changing external pressure. Thus, actor elements 11 , 12 may also be designed and operated as sensing elements or as passive components, such as piezoresistive resistors.
FIG. 2 shows a cross sectional view of FIG. 1 along the vertical section line drawn in, second actor elements 12 being recognizable in the region of the surface of overlayer 19 . These are each formed from a first, suitably structured conducting layer 26 which may be used for the electrical contacting and the supply or removal of electrical current, as well as from an actor layer 17 which separates conducting layer 26 from overlayer 19 and may be electrically contacted via it, which runs below first conducting layer 26 . Actor layer 17 may be, for instance, a piezoelectric or piezoresistive layer.
FIG. 2 also shows that overlayer 19 runs above a base layer 18 or a substrate made, for example, of p-doped silicon, a block-shaped void 23 being enclosed between base layer 18 and overlayer 19 , which is delimited from overlayer 19 by diaphragm 22 . In the edge region of cavern 23 , between base layer 18 and overlayer 19 , an edge layer 15 may also be provided, made, for example, of n-doped silicon, which runs around void 23 and is in contact with diaphragm 22 in an encircling manner. This edge layer 15 is also indicated in FIG. 1 as being encircling, however, there it is not visible in the top view.
Diaphragm 22 is made, for instance, of p-doped silicon, which may be porous silicon. Its thickness may range, for example, from to 0.5 μm to 1.0 μm, at a lateral extension in each direction between 100 μm and 800 μm, depending on the pressure range. Overlayer 19 may be gastight and thereby closes off void 23 in a gastight manner from the outer atmosphere. Its thickness may range, for example, from 5 μm to 10 μm, and the height of cavern 23 may lie, for example, between 3 μm and 7 μm. This ensures that, when there is a change in the external pressure, a bending deformation of diaphragm 22 and also overlayer 19 takes place, which is of an order of magnitude of 0.5 μm/bar to 5 μm/bar, especially 1 μm/bar to 2 μm/bar.
FIG. 3 shows a cross sectional view through FIG. 1 , along the diagonals, printed circuit traces 10 now being recognizable in the area of the surface of overlayer 19 , each of which is made of a second, for example, p + -doped and comparatively low-resistance conducting layer 25 , which may be used for electrical supply or electrical contacting, as well as a separating layer 27 present below it, which may be, for instance, p − -doped and of comparatively high resistance. An electrical insulation of separating layer 27 and conducting layer 25 from overlayer 19 may be ensured, in this case, by the pn junction obtained.
Both second conducting layer 25 and separating layer 27 may be, for example, made of silicon which may be, in each case, suitably and differently doped. In FIG. 3 , printed circuit traces 10 extend into diaphragm area region 16 .
In FIGS. 2 and 3 , above diaphragm 22 , a first conducting region 21 made of doped silicon is provided, which conducts well compared to remaining overlayer 19 . This first conducting region 21 covers the entire surface of the surface of diaphragm 22 facing away from base layer 18 . Furthermore, a second conducting region 20 made of p-doped silicon is provided, proceeding from the surface of overlayer 19 facing away from diaphragm 22 , which also conducts well, compared to remaining overlayer 19 . Second conducting region 20 and first conducting region 21 are in contact with each other, or rather pass over into each other, at least from place to place, so that thereby electrical contacting of the entire surface of diaphragm 22 may be possible, starting from the surface of overlayer 19 . According to FIG. 2 or 3 , second conducting region 20 extends to the outer surface of semiconductor component 5 and is thus directly accessible from there, as shown in FIG. 1 in a top view.
According to FIG. 3 , printed circuit traces 10 are connected in electrically conducting fashion to second conducting region 20 , while second actor elements 12 are electrically insulated from second conducting region 20 . In addition, according to FIGS. 2 and 3 , first conducting region 21 is electrically insulated from base layer 18 , since, in the construction, a pnp junction has formed between base layer 18 , edge layer 15 and diaphragm 22 or first conducting region 12 .
In the example embodiment according to FIGS. 1 to 3 , diaphragm 22 is electrically insulated from the bottom of cavern 23 formed by base layer 18 , and at the same time, an electrical lead or an electrical contacting possibility from the surface of overlayer 19 to diaphragm 22 exists.
For the analysis of the mobility of the diaphragm and the extension and cavern 23 , conventional means may be provided, by the use of which a predefinable and or variably adjustable electrical voltage may be applied and/or particularly measured as a function of time between the surface of diaphragm 22 facing void 23 and the part of the surface of base layer 18 lying opposite diaphragm 22 , or by the use of which at least this surface of diaphragm 22 opposite the surface of base layer 18 may be set to a specific electrical potential, for example, one that is changeable as a function of time.
The means may be electrical components by the use of which, for example, a static measurement of the capacitance between the surface of diaphragm 22 facing void 23 and the part of the surface of base layer 18 lying opposite diaphragm 22 may be carried out. Furthermore, using these components, a possibly present electrical short-circuit may also be detected between the surface of diaphragm 22 facing void 23 and the part of the surface of base layer 18 delimiting void 23 and lying opposite diaphragm 22 .
With the aid of the named electrical components, diaphragm 22 may be set into oscillation, for example, a resonant oscillation, by capacitive excitation. At the same time, these may be used for the analysis of the oscillation produced, particularly of the measurement of the resonant frequency and/or the quality of the resonant oscillation, in order thereby to determine mechanical properties of diaphragm 22 as well as its mobility with respect to void 23 , and/or its modulus of elasticity and/or its lateral extension or thickness. Suitable components for this and their interconnection are sufficiently well known from the related art, and do not require detailed explanation here.
As a matter of priority, the preceding explained analysis may determine the electrical capacitance between the lower side of the diaphragm and the cavern floor, which, in the static case, may permit a statement to be made about the cavern height and possibly about shunts or short-circuits, for instance, due to remains of porous silicon or columns in cavern 23 .
In the case of excitation of an oscillation, such as a resonant oscillation, one also obtains from the analysis, such as with respect to frequency and quality of the oscillation, for example, under consideration of the electrical capacitance, information about the mobility of diaphragm 23 , about its maximum deflection, about reinforcement or support locations of diaphragm 22 in the region of cavern 23 , or even about mechanical properties of the diaphragm, such as its thickness or its modulus of elasticity.
FIGS. 4 to 6 explain an alternative example embodiment to that in FIGS. 1 to 3 , for a semiconductor component in the form of a micromechanical pressure sensor element 5 , which differs from the first exemplary embodiment in that second conducting region 20 , as in FIG. 2 or 3 , is developed dot-shaped or circular in top view, in the region of third conducting regions 24 positioned in the corners of diaphragm 22 . This is shown in FIG. 6 , which shows a section along the diagonal shown in FIG. 4 .
According to this example embodiment, it may not be necessary to introduce printed circuit traces 10 into the region above diaphragm 22 , and third conducting regions 24 are limited to relatively tightly defined regions within overlayer 19 , which have been produced by a suitable local doping of overlayer 19 , such as with the aid of an appropriate mask. Thus, according to FIG. 4 , diaphragm area region 16 provided in FIG. 1 may also remain electrically insulating, i.e., it is developed farther away from overlayer 19 of electrically insulating material or of a material such as n-doped silicon that is comparatively poorly electrically conductive, compared to conducting regions 20 , 21 , 24 .
First actor elements 11 and/or second actor elements 12 are not essential for the functioning of the explained pressure sensor, since a warping of diaphragm 22 may, for example, also be detected by a change in capacitance between diaphragm 22 and base layer 18 , due to a changing exterior pressure.
Furthermore, actor elements 11 , 12 may also be developed as heating elements or heat conductors, which may effect warping of diaphragm 22 , via a heat supply and mechanical stresses induced thereby.
Finally, the function of a printed circuit trace 10 and an actor element 11 , 12 may also be unified in one structural element, with the use of which, then, in each case, both electrical contacting of second conducting region 20 and of third conducting region 24 , as well as warping of diaphragm 22 , may be induced or detected.
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A semiconductor component, in particular a micromechanical pressure sensor based on silicon, having a base layer, an at least largely self-supporting diaphragm and an overlayer situated on the diaphragm, the diaphragm and the base layer, at least from place to place, delimiting a void. Furthermore, at least from place to place, above the diaphragm a conducting region is provided in the overlayer which is electrically poorly conductive as compared to the conducting region, to which the surface of the diaphragm that faces the overlayer is able to be electrically contacted.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent application Ser. No. 10/362,615, now pending, filed Nov. 29, 2004. U.S. patent application Ser. No. 10/362,615 is incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a method of manufacturing water-soluble containers and a mould for use therein.
[0004] 2. The Related Art
[0005] It is known to package chemical compositions which may be of a hazardous or irritant nature in water soluble or water dispersible materials such as films. The package can simply be added to water in order to dissolve or disperse the contents of the package into the water.
[0006] For example, WO 89/12587 discloses a package which comprises an envelope of a water soluble or water dispersible material which comprises a flexible wall and a water-soluble or water-dispersible heat seal. The package may contain an organic liquid comprising, for example, a pesticide, fungicide, insecticide or herbicide.
[0007] It is also known to package detergents in water-soluble or water-dispersible containers. For example, WO 94/14941 discloses a water-soluble or water-dispersible capsule containing an aqueous dishwasher detergent. The capsule is made of gelatin.
[0008] CA-A-1,112,534 discloses a packet made of a water-soluble material in film form enclosing within it a paste-form, automatic dishwasher-compatible detergent composition. The water-soluble material may be, for example, polyvinyl alcohol, polyethylene oxide or methyl cellulose. Example 1 illustrates an embodiment wherein a poly(vinyl alcohol)(PVOH) film is made into a 5 cm square packet by heat sealing its edges, and the packet is filled with a composition which contains 8.5 wt. % water.
[0009] In fields such as detergents for domestic use, an attractive appearance for an article is extremely desirable. However in the prior art, such as that described above, a bag is simply formed from a single sheet of water-soluble film. The film is folded and the edges heat-sealed to form the bag. The bag is then filled and heat-sealed. This produces a rather flat, limp envelope containing the product. Furthermore there may be a lack of uniformity between different bags because of their flexible nature.
[0010] We have discovered that this type of product is not deemed to be attractive by an average consumer.
[0011] It is known to form water-soluble containers by thermoforming a water-soluble material. For example, WO 92/17382 discloses a package containing an agrochemical such as a pesticide comprising a first sheet of non-planar water-soluble or water-dispersible material and a second sheet of water-soluble or water-dispersible material superposed on the first sheet and sealed to it by a continuous closed water-soluble or water-dispersible seal along a continuous region of the superposed sheets. It is stated to be advantageous to ensure that the package produced is evacuated of air or the contents are under reduced pressure to provide increased resistance to shock. Furthermore, when the package contains a liquid, the liquid must be an organic liquid which must be reasonably dry and typically contains less than 2 to 3% of water to ensure that it does not attack the water-soluble package and cause leakage.
[0012] EP-A-654,418 describes self-standing flexible pouches which may contain, for example, liquid detergent compositions for refilling other containers. In order to avoid folding of the pouch, which can lead to cracking and leakage, the bag is inflated before it is sealed.
[0013] In order to improve the strength of packages containing liquids, it is also known to provide the package with residual inflatability. Thus, for example, EP-A-524,721 describes a water-soluble package which contains a liquid, wherein the package is inflatable to a volume which is greater than the initial volume of the package. Thus the package is filled to less than its complete capacity, and the unused capacity may be partially, but not totally, filled with a gas such as air. The unused capacity which does not contain gas provides the residual inflatability.
BACKGROUND OF THE INVENTION
[0014] We have now surprisingly discovered a water-soluble container which contains a liquid composition can be given an attractive three-dimensional appearance by using a thermoforming technique, such as that disclosed in WO 92/17382, on a PVOH film and ensuring that the liquid composition has a reasonably large water content of at least 3 wt % free water, based on the weight of the aqueous composition. Immediately after the containers are prepared, they have a limp, unattractive appearance. However, after storage for a short while, for example, from a few minutes to a few hours, they develop a more attractive three-dimensional appearance, and also appear to look fuller. They can also be said to have a “puffed-up” appearance. Although not bound by this theory, it is believed that the water in the aqueous composition shrinks the PVOH film around the liquid composition to provide the attractive appearance. In other words the PVOH film attempts to recover its original shape when contacted with the aqueous composition.
[0015] In our co-pending application entitled “Improvements in or Relating to Aqueous Compositions” we describe a process for producing a container as defined above which comprises the steps of:
[0016] a) thermoforming a first PVOH film to produce a pocket;
[0017] b) filling the pocket with the aqueous composition;
[0018] c) placing a second PVOH film on top of the filled pocket; and
[0019] d) sealing the first film and second film together.
[0020] The method of forming the container is similar to the process described in WO 92/17382. A first PVOH film is initially thermoformed into a mould to produce a non-planar sheet containing a pocket, such as a recess, which is able to retain the aqueous composition. The pocket is generally bounded by a flange, which is preferably substantially planar. The pocket may have internal barrier layers as described in, for example, WO 93/08095. The pocket is then filled with the aqueous composition, and a second PVOH film is placed on the flange and across the pocket. The second PVOH film may or may not be thermoformed. The pocket may be completely filled, or only partly filled, for example to leave an air space of from 2 to 20%, especially from 5 to 10%, of the volume of the container immediately after it is formed. Partial filling may reduce the risk of rupture of the container if it is subjected to shock and reduce the risk of leakage if the container is subjected to high temperatures.
[0021] The films are then sealed together, for example by heat sealing across the flange. A suitable heat sealing temperature is, for example, 120° C. to 195° C., for example 140° C. to 150° C. A suitable sealing pressure is, for example, from 250 kPa to 800 kPa. Examples of sealing pressures are 276 kPa to 552 kPa (40 p.s.i. to 80 p.s.i.), especially 345 kPa to 483 kPa (50 p.s.i. to 70 p.s.i.) or 400 kPa to 800 kPa (4 to 8 bar), especially 500 kPa to 700 kPa (5 to 7 bar) depending on the heat sealing machine used. Suitable sealing dwell times are at least 0.4 seconds, for example 0.4 to 2.5 seconds. Other methods of sealing the films together may be used, for example infra-red, radio frequency, ultrasonic or laser solvent, vibration, electromagnetic, hot gas, hot plate, insert bonding, fraction sealing or spin welding. An adhesive such as water or an aqueous solution of PVOH may also be used. The adhesive can be applied to the films by spraying, transfer coating, roller coating or otherwise coating, or the films can be passed through a mist of the adhesive. The seal desirably is also water-soluble.
[0022] It is, however, extremely difficult to manufacture products using PVOH and other materials having similar physical characteristics, partly because of their hygroscopic nature, but mainly due to the fact that the material is very soft and floppy, making it extremely difficult to handle and cut. In most thermoforming, vacuum forming or other similar forming processes, the films used have a degree of strength and rigidity. Thus friction drives are generally, although not exclusively, used to support the films and to transport them through the machine during the process. PVOH and similar films do not have this strength or rigidity and would stretch, thin and tear if subjected to such handling.
[0023] Furthermore, thermo- and other such forming processes impose a significant amount of drawing and stretching of the material. As such the known method of thermoforming using PVOH materials utilises a single mould for each moulded product, with each PVOH film placed manually over each mould. This means that the amount of material available for deforming is greater, but it is a very labour intensive, slow and therefore costly process to achieve the manufacture of this type of product.
[0024] We have discovered that standard horizontal intermittent motion thermoforming machines, such as those supplied by Multivac, Doyen and Tiromat, can be used to produce thermoformed containers from PVOH and films of a similar nature at normal production speeds. However, some modifications must be made to these machines, in particular to the drive system, in order to run such films at normal production speeds.
[0025] It is therefore an object of the present invention to provide an improvement in the process for manufacturing such containers, to enable a plurality of water-soluble containers to be formed simultaneously. A further objective is to provide a tool for use in a process for producing a plurality of water-soluble containers made from PVOH or other films of a similar physical nature or the like, at each stroke of a horizontal intermittent motion thermoforming machine. Yet another objective is to provide an improved process for producing multiple containers on a production scale.
[0026] The invention therefore provides a process for producing a water-soluble container using a horizontal intermittent motion thermoforming machine which comprises the steps of:
[0027] a) locating a first water-soluble film over a mould, said mould containing a plurality of pocket forming cavities, defined by side walls and a base, in a 2-dimensional array, each cavity being surrounded by a planar surface of the mould on all sides in which the shortest dimension of the planar surface between two adjacent cavities is at least 3 mm and between an edge of the mould and the closest cavity is at least 1.5 mm;
[0028] b) thermoforming the first film to produce a plurality of pockets;
[0029] c) at least partially filling the pockets with a composition; and
[0030] d) sealing the plurality of the at least partially filled pockets, wherein in which the cavities are positioned in the array such that there is a plurality of continuous strips of uninterrupted planar surface of the mould from a leading to a trailing edge of the mould, for receiving support means fitted to the machine for supporting the film.
[0031] The invention further provides a mould for use in a thermoforming process for manufacturing water-soluble containers from water-soluble films, in which said mould contains a plurality of pocket forming cavities, defined by side walls and a base, in a 2-dimensional array, each cavity being surrounded by a planar surface of the mould on all sides in which the shortest dimension of the planar surface between two adjacent cavities is at least 3 mm and between an edge of the mould and the closest cavity is at least 1.5 mm, and in which the cavities are positioned in the array such that there are a plurality of continuous strips of uninterrupted planar surface of the mould from a leading to a trailing edge of the mould.
DESCRIPTION OF THE DRAWINGS
[0032] The invention will now be described, in further detail, by way of example only, with reference to and as shown in the accompanying drawings in which:—
[0033] FIG. 1 is an end elevation of a mould used in the present invention;
[0034] FIG. 2 is a side sectional elevation of the mould of FIG. 1 on the line I-I;
[0035] FIGS. 3 to 5 are respectively plan views and cross sectional side elevations of a section of the mould of FIG. 1 showing the dimensions of the cavities;
[0036] FIG. 6 is a plan view of the mould of FIG. 1 ; and
[0037] FIG. 7 is a schematic representation illustrating a support rail;
[0038] FIG. 8 shows support rails supporting a web of material on a horizontal intermittent thermoforming machine.
[0039] FIG. 9 is a schematic representation showing the stages and series of stations for sealing of the plurality of the at least partially filled pockets.
DETAILED DESCRIPTION OF THE INVENTION
[0040] FIGS. 1 and 2 show a mould 10 used for thermoforming a plurality of containers from PVOH or films having similar physical characteristics on a horizontal intermittent thermoforming machine comprising a series of stations as shown in FIG. 7 . These are the forming area 30 , at which the film 31 is supplied from a reel to the moulds 10 and where the first thermoforming step takes place to form pockets; the filling station 32 , at which the pockets are filled; the sealing station 33 , to which a further film 34 is supplied to seal the pockets; the cooling station 35 ; and the cutting station 36 where the sealed containers are separated from each other by shear knives 38 .
[0041] FIG. 9 shows the stages and series of stations for sealing of the plurality of the at least partially filled pockets. These are the forming area 30 , at which the film 31 is supplied from a reel 40 to the moulds 10 and where the first thermoforming step takes place to form pockets 41 ; the filling station 32 , at which the pockets 41 are filled; the sealing station 33 , to which a further film 34 is supplied to seal the filled pockets 102 .
[0042] Each mould 10 comprises a 2-dimensional array of pocket forming cavities 11 . Although the Figures illustrate a regular array of 6×7 cavities 11 to form 42 containers simultaneously, the number and relative positioning of the cavities 11 may be varied. Essentially the surface dimensions of the mould are determined by the width and draw of the machine on which it is to be used. The best arrangement of the individual cavities 11 is determined according to the following considerations.
[0043] Each cavity 11 must be surrounded by a planar surface 18 on all sides, to allow for subsequent sealing of the second film to the first films. This dimension should be at least 1.5 mm, but is preferably in the range of 2 mm to 5 mm. Thus the distance between any cavity and the edge of the mould 10 is at least 1.5 mm and the distance between any two cavities 11 is at least 3 mm. The maximum distance is obviously determined by the size of the mould 10 , but in practice, for commercial reasons, the spacing would not normally exceed 15 mm.
[0044] As the materials used are very flexible, the web of film tends to sag. In order to enable all of the cavities 11 to be filled, support means must be fitted to the machine, from the end of the thermoforming station to the start of the filling station, and also preferably to the cutting station 36 , to support the web of film. The support means may be provided by rails, bars, filaments, wires, rope, cable or the like. Most preferred are wires or rails. Where rails 1 are used, as shown in FIG. 7 , the leading ends of the rails may have a smooth cam surface 2 for lifting the web. The support means can be intermittent or, more preferably, continuous.
[0045] FIG. 8 shows how the web is drawn down from the thermoforming station by being held by grippers 3 which are pulled apart to provide some tension in the web. Too much tension will displace the thermoformed pockets. However, not enough tension is provided so that the web remains flat for filling. The support rails 1 maintain the web as a substantially flat surface. This places an extra constraint on the arrangement of the cavities within the space available i.e. there must be clear channels 21 (see arrows Z on FIG. 6 ) through the pattern of cavities 11 from the leading edge of the mould 10 to the trailing edge. It is preferred that these channels 21 are available between each cavity 11 (across the web i.e. on the leading edge), but this is not essential, depending on the number of cavities 11 across the leading edge. At least every other cavity should be supported.
[0046] Located in the mould 10 beneath the cavities 11 are air channels 15 , which communicate with the cavities 11 via air bores 16 . The number and positioning of the air bores 16 has an effect on how the film is drawn into the cavities 11 during the thermoforming process, and therefore consideration must be given to an appropriate arrangement of air bores 16 depending on the specific configuration of the cavities 11 used. In particular they must be designed and arranged to effect the most even deformation of the film into the cavities 11 . In a preferred embodiment the air bores 16 are located in the regions where the end and side walls 12 , 13 of the cavities 11 join the cavity base 14 . The holes are preferably of 0.1 mm to 1 mm diameter and more preferably 0.4 mm to 0.5 mm. Vacuum release bores 17 are drilled in the cavity bases 14 .
[0047] The shape of the cavities 11 is dictated partly by the intended use of the containers, but also by the processing constraints. A particularly convenient shape for an automatic dishwasher composition is illustrated in FIG. 3 to 5 . The dimensions of the cavities are determined by the required fill volume of the containers and any constraints resulting from the intended use of the containers. For example, if the containers are to be used as refill sachets for a trigger spray, the width of the containers, and therefore the cavities is determined by the diameter of the spray bottle neck. If the containers are to be used for a dishwasher product, all three dimensions are determined by the dispenser into which the containers will eventually be placed.
[0048] One particularly suitable embodiment which we have found for a dishwasher product has a rectangular cavity mouth, the dimensions of which are 29 mm×39 mm, with rounded corners, having a radius R 1 of, preferably, 10 mm.
[0049] The depth of the cavities depends partly on the area of the cavity mouth, to ensure that the film, can be drawn down without over thinning and tearing. This can also be affected by the area of film available between adjacent cavities 11 . Referring to FIG. 6 , the upper surface 18 of the mould 10 can clearly be seen. The gaps between the cavities 11 are marked as dimensions X and Y in this particular layout. The ratio X:Y is desirably 1:2 to 2:1, preferably 1.5:1 to 1:1.57 most preferably about 1:1. X and Y are desirably from 5 to 13 mm, preferably 7 to 12 mm, preferably about 10 mm. The preferred depth is in the range of 10 to 80% of the shortest dimension of the cavity mouth, and more preferably in the range of 40 to 60%. A preferred depth of the cavities 11 where the mouth of the cavities 11 is 29 mm by 39 mm is 16 mm.
[0050] The corners 19 formed where the end and side walls 12 , 13 of the cavities 11 join the cavity base 14 , are preferably radiussed to avoid over thinning or tearing of the film, as it is drawn down the side walls 13 and the corners 19 . The corners 19 preferably have a radius R 2 and R 3 of between 8 mm and 10 mm.
[0051] The cavity base 14 may be planar or rounded. Especially where a greater cavity depth is used, such as 18 mm or 19 mm, it may be preferable to have a rounded base 14 to prevent regions of thicker material from being drawn directly downward to the centre of the base 14 . A suitable radius for the base 14 , in particular where the cavity depth is 18 mm, is 20 mm. The use of a rounded base 14 means that the positioning and direction of the air bores 16 may be different from those used with flat-bottomed cavities 11 . This changes the way in which the film is drawn into the cavities 11 .
[0052] The edges 20 , where the cavity end and side walls 12 , 13 join the upper surface 18 of the mould 10 , are preferably rounded to allow for a smooth movement of the film over the edges 20 during the thermoforming process, to minimise the risk of the film snagging or tearing. The radius R 4 is preferably small, e.g. 1 mm, as it is difficult to fill this area of the cavities 11 without risk of fouling the sealing area.
[0053] Another dimension which must be carefully controlled to enable the film to be drawn into the cavities 11 without tearing, is the spacing between the cavities 11 . For cavities of the dimensions given above, it is preferred that the spacing between the cavities lies in the range of 9 mm to 16 mm.
[0054] The draft angle of the side walls 12 , 13 is preferably 3° to 5° to assist in the release of the containers. However, for certain very soft materials, such as PVOH, draft angles may not be necessary.
[0055] The sizing of the mould 10 , incorporating an array of cavities 11 in this manner, enables the film to be supported. The width of the web of film is determined by the width of the machine in which the mould is fitted. The mould is designed to fit the width of the machine with a suitable “overhang” of film, which can be used for transporting the film. It is suggested that small clips or grippers attached to a plurality of driven chains would enable the films to be transported appropriately. The grippers preferably toe-out to provide tension as the web of film moves through the machine.
[0056] A first PVOH film is thus positioned over the mould 10 and thermoformed in a known manner to form a plurality of pockets. The pockets are then filled with an aqueous or other composition and a second film brought into position over the plurality of pockets. The second film may be the same as the first film or another material and is heat, or otherwise sealed, to the parts of the first film remaining on the upper surface 18 of the mould, as described previously.
[0057] The filled containers may then be separated from each other. Alternatively, they may be left conjoined and, for example, perforations provided between the individual containers so that they can be separated easily at a later stage, for example by a consumer. If the containers are separated, the flanges may be left in place. However, desirably the flanges are reduced in order to provide an even more attractive, three-dimensional appearance. Generally the flanges remaining should be as small as possible for aesthetic purposes while bearing in mind that some flange is required to ensure the two films remain adhered to each other. A flange having a width of 1 mm to 10 mm is desirable, preferably 1.5 mm to 6 mm, most preferably about 5 mm.
[0058] For containers of compositions having a high water content, the containers may then be left for a while to attain their attractive appearance, or may be immediately packaged into boxes for retail sale, and left to attain their attractive appearance in the boxes. The containers may themselves be packaged in outer containers if desired, for example non-water soluble containers which are removed before the water-soluble containers are used.
[0059] If more than one film is used for the containers, the films may be identical or different. The film may be partially or fully alcoholised or hydrolysed, for example, it may be from 40 to 100%, preferably 70 to 92%, more preferably about 88% or about 92%, alcoholised or hydrolysed, polyvinyl acetate film. The degree of hydrolysis is known to influence the temperature at which the PVOH starts to dissolve in water. 88% hydrolysis corresponds to a film soluble in cold (i.e. room temperature) water, whereas 92% hydrolysis corresponds to a film soluble in warm water. An example of a preferred PVOH is ethoxylated PVOH. The film may be cast, blown or extruded. It may also be unorientated, mono-axially oriented or bi-axially oriented.
[0060] It is possible for suitable additives such as plasticisers, lubricants and colouring agents to be added to the film. Components which modify the properties of the polymer may also be added. Plasticisers are generally used in an amount of up to 20 wt %, for example, from 15 to 20 wt %. Lubricants are generally used in an amount of 0.5 to 5 wt %. The polymer is therefore generally used in an amount of from 75 to 84.5 wt %, based on the total number of the composition used to form the film. Suitable plasticisers are, for example, pentaerythritols such as depentaerythritol, sorbitol, mannitol, glycerine and glycols such as glycerol, ethylene glycol and polyethylene glycol. Solids such as talc, stearic acid, magnesium stearate, silicon dioxide, zinc stearate or colloidal silica may also be used.
[0061] It is also possible to include one or more particulate solids in the films in order to accelerate the rate of dissolution of the container. This solid may also be present in the contents of the container. Dissolution of the solid in water is sufficient to cause an acceleration in the break-up of the container, particularly if a gas is generated, when the physical agitation caused may, for example, result in the virtually immediate release of the contents from the container. Examples of such solids are alkali or alkaline earth metal, such as sodium, potassium, magnesium or calcium, bicarbonate or carbonate, in conjunction with an acid. Suitable acids are, for example, acidic substances having carboxylic or sulfonic acid groups or salts thereof. Examples are cinnamic, tartaric, mandelic, fumaric, maleic, malic, palmoic, citric and naphthalene disulfonic acids.
[0062] The film is generally cold water (20° C.) soluble, but, depending on its degree of hydrolysis, may be insoluble in cold water at 20° C. and only become soluble in warm water or hot water having a temperature of, for example, 30° C., 40° C., 50° C. or even 60° C. If the film is soluble in cold water, or water at a temperature of up to say 35° C., steps must be taken to ensure that an aqueous composition contained inside the container does not dissolve the film from the inside. Steps may be taken to treat the inside surface of the film, for example by coating it with a semi-permeable or partial water barrier such as polyethylene or polypropylene or a hydrogel such as a polyacrylate. This coating will simply fall apart or dissolve or disperse into microscopic particles when the container is dissolved in water. Steps may also be taken to adapt the composition to ensure that it does not dissolve the film. For example, it has been found that ensuring the composition has a high ionic strength or contains an agent which minimises water loss through the walls of the container will prevent the composition from dissolving the PVOH film from the inside. This is described in more detail in EP-A-518,689 and WO 97/27743.
[0063] It is particularly important to avoid pinholes in the film through which leakage of the contained composition may occur. It may therefore be appropriate to use a laminate of two or more layers of a different or the same film, as pinholes are unlikely to coincide in two layers of material.
[0064] When first and second films are used to form the containers of the present invention, the first film will generally have a thickness before thermoforming of 20 to 500 μm, especially 70 to 400 μm, for example 70 to 300 μm or 90 or 110 to 150 μm. The thickness of the second PVOH film may be less than that of the first film as the second film will not generally be thermoformed so localised thinning of the sheet will not occur. The thickness of the second film will generally be from 20 to 150 μm or 160 μm, preferably from 40 or 50 to 90 or 100 μm, more preferably from 50 to 80 μm. The films may be chosen, if desired, such that they have the same thickness before the first film is thermoformed, or have the same thickness after the first sheet has been thermoformed in order to provide a composition which is encapsulated by a substantially constant thickness of film.
[0065] The containers of the present invention generally contain from 5 to 100 g of aqueous composition, especially from 15 to 40 g, depending on their intended use. For example, a dishwashing composition may weigh from 15 g to 20 g, a water-softening composition may weigh from 25 to 35 g, and a laundry composition may weigh from 10 to 40 g, especially 20 to 30 g or 30 to 40 g.
[0066] The containers may have any shape achievable by thermoforming. For example they can take the form of a cylinder, cube or cuboid, i.e. a rectangular parallelepiped whose faces are not all equal. In general, because the containers are not rigid, the sides are not planar, but rather are convex. If the container is formed from a thermoformed film and a planar film, the seam between the two films will appear nearer one face of the container rather than the other. Apart from the deformation of the container due to the shrinkage of the film discussed above, deformation may also occur at the stage of manufacture if desired. For example, if the pocket is filled with a gelled composition having a height greater than that of the pocket, the second film will be deformed when placed on top of the pocket. A shaped sealing platen is required to achieve this effect.
[0067] In general the maximum dimension of the filled part of the container (excluding any flanges) is 5 cm. For example, a rounded cuboid container may have a length of 1 to 5 cm, especially 3.5 to 4.5 cm, a width of 1.5 to 3.5 cm, especially 2 to 3 cm, and a height of 1 to 2.5 cm, especially 1 to 2 cm, and more especially 1.25 to 1.75 cm.
[0068] The container desirably contains an aqueous composition which is a fabric care, surface care or dishwashing composition. Thus, for example, it may be a dishwashing, water-softening, laundry or detergent composition or a rinse aid. In this case the container is preferably suitable for use in a domestic washing machine such as a laundry washing machine or a dishwashing machine. The composition may also be a disinfectant, antibacterial or antiseptic composition intended to be diluted with water before use, or a concentrated refill composition, for example a trigger-type spray as used in domestic situations. Such a composition can simply be added to water already held in the spray container. Examples of surface care compositions are those used to clean, treat or polish a surface. Suitable surfaces are, for example, household surfaces such as worktops, as well as surfaces of sanitary ware, such as sinks, basins and lavatories.
[0069] The composition preferably contains greater than 3 wt % free water based on the weight of the aqueous composition, in order to ensure that the container has an attractive appearance. The actual amount of water present in the composition may be in excess of the amount of free water, since the total water content includes water of salvation and water held within a gelled matrix. Free water can be determined by a standard loss-on-drying determination test carried out at 60° C. for 3 hours at 200 mbar (20 kPa). Desirably the composition contains more than 10 wt %, 15 wt %, 20 wt %, 25 wt % or 30 wt % total water, but desirably less than 80 wt % total water, more desirably less than 70 wt %, 60 wt %, 50 wt % or 40 wt % total water. It may, for example, contain from 30 to 65 wt % total water.
[0070] The remaining ingredients of the composition depend on the use of the composition. Thus, for example, the compositions may contain surface active agents such as an anionic, nonionic, cationic, amphoteric or zwitterionic surface active agents or mixtures thereof.
[0071] Examples of anionic surfactants are straight-chained or branched alkyl sulfates and alkyl polyalkoxylated sulfates, also known as alkyl ether sulfates. Such surfactants may be produced by the sulfation of higher C 8 -C 20 fatty alcohols
[0072] Examples of primary alkyl sulfate surfactants are those of formula:
[0000] ROSO 3 − M +
[0073] wherein R is a linear C 8 -C 20 hydrocarbyl group and M is a water-solubilising cation. Preferably R is C 10 -C 16 alkyl, for example C 12 -C 14 , and M is alkali metal such as lithium, sodium or potassium.
[0074] Examples of secondary alkyl sulfate surfactants are those which have the sulfate moiety on a “backbone” of the molecule, for example those of formula:
[0000] CH 2 (CH 2 )N(CHOSO 3 − M + )(CH 2 ) M CH 3
[0075] wherein m and n are independently 2 or more, the sum of m+n typically being 6 to 20, for example 9 to 15, and M is a water-solubilising cation such as lithium, sodium or potassium.
[0076] Especially preferred secondary alkyl sulfates are the (2,3) alkyl sulfate surfactants of formulae:
[0000] CH 2 (CH 2 ) X (CHOSO 3 −1 M + )CH 3 AND
[0000] CH 3 (CH 2 ) X (CHOSO 3 − M + )CH 2 CH 3
[0077] for the 2-sulfate and 3-sulfate, respectively. In these formulae x is at least 4, for example 6 to 20, preferably 10 to 16. M is a cation, such as an alkali metal, for example lithium, sodium or potassium.
[0078] Examples of alkoxylated alkyl sulfates are ethoxylated alkyl sulfates of the formula:
[0000] RO(C 2 H 4 O)NSO 3 − M +
[0000] wherein R is a C 8 -C 20 alkyl group, preferably C 10 -C 18 such as a C 12 -C 16 , n is at least 1, for example from 1 to 20, preferably 1 to 15, especially 1 to 6, and M is a salt-forming cation such as lithium, sodium, potassium, ammonium, alkylammonium or alkanolammonium. These compounds can provide especially desirable fabric cleaning performance benefits when used in combination with alkyl sulfates.
[0079] The alkyl sulfates and alkyl ether sulfates will generally be used in the form of mixtures comprising varying alkyl chain lengths and, if present, varying degrees of alkoxylation.
[0080] Other anionic surfactants which may be employed are salts of fatty acids, for example C 8 -C 18 fatty acids, especially the sodium, potassium or alkanolamine salts, and alkyl, for example C 8 -C 18 , benzene sulfonates.
[0081] Examples of nonionic surfactants are fatty acid alkoxylates, such as fatty acid ethoxylates, especially those of formula:
[0000] R(C 2 H 4 O)NOH
[0082] wherein R is a straight or branched C 8 -C 16 alkyl group, preferably a C 9 -C 15 , for example C 10 -C 14 or C 12 -C 14 , alkyl group and n is at least 1, for example from 1 to 16, preferably 2 to 12, more preferably 3 to 10.
[0083] The alkoxylated fatty alcohol nonionic surfactant will frequently have a hydrophilic-lipophilic balance (H LB) which ranges from 3 to 17, more preferably from 6 to 15, most preferably from 10 to 15.
[0084] Examples of fatty alcohol ethoxylates are those made from alcohols of 12 to 15 carbon atoms and which contain about 7 moles of ethylene oxide. Such materials are commercially marketed under the trademarks Neodol 25-7 and Neodol 23-6.5 by Shell Chemical Company. Other useful Neodols include Neodol 1-5, an ethoxylated fatty alcohol averaging 11 carbon atoms in its alkyl chain with about 5 moles of ethylene oxide; Neodol 23-9, an ethoxylated primary C 12 -C 13 alcohol having about 9 moles of ethylene oxide; and Neodol 91-10, an ethoxylated C 9 -C 11 primary alcohol having about 10 moles of ethylene oxide.
[0085] Alcohol ethoxylates of this type have also been marketed by Shell Chemical Company under the Dobanol trademark. Dobanol 91-5 is an ethoxylated C 9 -C 11 fatty alcohol with an average of 5 moles ethylene oxide and Dobanol 25-7 is an ethoxylated C 12 -C 15 fatty alcohol with an average of 7 moles of ethylene oxide per mole of fatty alcohol.
[0086] Other examples of suitable ethoxylated alcohol nonionic surfactants include Tergitol 15-S-7 and Tergitol 15-S-9, both of which are linear secondary alcohol ethoxylates available from Union Carbide Corporation. Tergitol 15-S-7 is a mixed ethoxylated product of a C 11 -C 15 linear secondary alkanol with 7 moles of ethylene oxide and Tergitol 15-S-9 is the same but with 9 moles of ethylene oxide.
[0087] Other suitable alcohol ethoxylated nonionic surfactants are Neodol 45-11, which is a similar ethylene oxide condensation products of a fatty alcohol having 14-15 carbon atoms and the number of ethylene oxide groups per mole being about 11. Such products are also available from Shell Chemical Company.
[0088] Further nonionic surfactants are, for example, C 10 -C 18 alkyl polyglycosides, such as C 12 -C 16 alkyl polyglycosides, especially the polyglucosides. These are especially useful when high foaming compositions are desired. Further surfactants are polyhydroxy fatty acid amides, such as C 10 -C 18 N-(3-methoxypropyl) glycamides and ethylene oxide-propylene oxide block polymers of the Pluronic type.
[0089] Examples of cationic surfactants are those of the quaternary ammonium type. Examples of amphoteric surfactants are C 10 -C 18 amine oxides and the C 12 -C 18 betaines and sulfobetaines.
[0090] The total content of surfactants in the composition is desirably 0.1 to 95 wt %, especially 60 or 75 to 90 wt %.
[0091] The total content of surfactants in the laundry or detergent composition is desirably 60 to 95 wt %, especially 75 to 90 wt %. Desirably, especially in a laundry composition, an anionic surfactant is present in an amount of 50 to 75 wt %, a nonionic surfactant is present in an amount of 5 to 20 wt %, and/or a cationic surfactant is present in an amount of from 0 to 10 wt % and/or a amphoteric surfactant may be present in an amount of from 0 to 10 wt %. Desirably, in a dishwashing composition, the anionic surfactant is present in an amount of from 0-1 to 50 wt %, a non-ionic surfactant is present in an amount of 0.5 to 20 wt % and/or a cationic surfactant is present in an amount of from 1 to 15 wt %. These amounts are based
[0092] On the solids content of the composition, i.e. excluding any water or solvent which may be present.
[0093] The compositions, particularly when used as laundry washing or dishwashing compositions, may also comprise enzymes, such as protease, lipase, amylase, cellulase and peroxidase enzymes. Such enzymes are commercially available and sold, for example, under the registered trade marks Esperese, Alcalase, Savinase, Termamyl,
[0094] Lipolase and Celluzyme by Nova Industries A/S and Maxatasc by International Biosynthetics, Inc. Desirably the enzymes are present in the composition in an amount of from 0.5 to 3 wt %, especially 1 to 2 wt %.
[0095] Dishwasher compositions usually comprise a detergency builder. Suitable builders are alkali metal or ammonium phosphates, polyphosphates, phosphonates, polyphosphonates, carbonates, bicarbonates borates, polyhydroxysulfonates, polyacetates, carboxylates and polycarboxylates such as citrates. The builder is desirably present in an amount of up to 90 wt %, preferably 15 to 90 wt %, more preferably 15 to 75 wt %, relative to the total content of the composition.
[0096] Further details of suitable components are given in, for example, EP-A-694,059, EP-A-518720 and WO 99/06522.
[0097] The compositions may, if desired, comprise a thickening agent or gelling agent. Suitable thickeners are polyacrylate polymers such as those sold under the trade mark CARBOPOL, or the trade mark ACUSOL by Rohm and Haas Company. Other suitable thickeners are xanthan gums. The thickener, if present, is generally present in an amount of from 0.2 to 4 wt %, especially 0.5 to 2 wt %.
[0098] The compositions can also optionally comprise one or more additional ingredients. These include conventional detergent composition components such as further surfactants, bleaches, bleach enhancing agents, builders, suds boosters or suds suppressors, anti-tarnish and anti-corrosion agents, organic solvents, co-solvents, phase stabilisers, emulsifying agents, preservatives, soil suspending agents, soil release agents, germicides, phosphates such as sodium tripolyphosphate or potassium tripolyphosphate, pH adjusting agents or buffers, non-builder alkalinity sources, chelating agents, clays such as smectite clays, enzyme stabilizers, anti-limescale agents, colourants, dyes, hydrotropes, dye transfer inhibiting agents, brighteners and perfumes. If used, such optional ingredients will generally constitute no more than 10 wt %, for example from 1 to 6 wt %, of the total weight of the compositions.
[0099] The builders counteract the effects of calcium, or other ion, water hardness encountered during laundering or bleaching use of the compositions herein. Examples of such materials are citrate, succinate, malonate, carboxymethyl succinate, carboxylate, polycarboxylate and polyacetyl carboxylate salts, for example with alkali metal or alkaline earth metal cations, or the corresponding free acids. Specific examples are sodium, potassium and lithium salts of oxydisuccinic acid, mellitic acid, benzene polycarboxylic acids, C 10 -C 22 fatty acids and citric acid. Other examples are organic phosphonate type sequestering agents such as those sold by Monsanto under the trade mark Dequest and alkyl hydroxy phosphonates. Citrate salts and C 12 -C 18 fatty acid soaps are preferred.
[0100] Other suitable builders are polymers and copolymers known to have builder properties. For example, such materials include appropriate polyacrylic acid, polymaleic acid, and polyacrylic/polymaleic and copolymers and their salts, such as those sold by BASF under the trade mark Sokalan.
[0101] The builders generally constitute from 0 to 3 wt %, more preferably from 0.1 to 1 wt %, by weight of the compositions.
[0102] Compositions which comprise an enzyme may optionally contain materials which maintain the stability of the enzyme. Such enzyme stabilizers include, for example, polyols such as propylene glycol, boric acid and borax. Combinations of these enzyme stabilizers may also be employed. If utilized, the enzyme stabilizers generally constitute from 0.1 to 1 wt % of the compositions.
[0103] The compositions may optionally comprise materials which serve as phase stabilizers and/or co-solvents. Example are C 1 -C 3 alcohols or diols such as methanol, ethanol, propanol and 1,2-propanediol. C 1 -C 3 alkanolamines such as mono-, di- and triethanolamines and monoisopropanolamine can also be used, by themselves or in combination with the alcohols. The phase stabilizers and/or co-solvents can, for example, constitute 0 to 1 wt %, preferably 0.1 to 0.5 wt %, of the composition.
[0104] The compositions may optionally comprise components which adjust or maintain the pH of the compositions at optimum levels. Examples of pH adjusting agents are NaOH and citric acid. The pH may be from, for example, 1 to 13, such as 8 to 11 depending on the nature of the composition. For example, a dishwashing composition desirably has a pH of 8 to 11, a laundry composition has a pH of 7 to 9, and a water-softening composition has a pH of 7 to 9.
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Methods of manufacturing water-soluble containers using a horizontal intermittent motion thermoforming machine which comprises the steps of: a) locating a first water-soluble film over a mould, said mould containing a plurality of pocket forming cavities, defined by side walls and a base, in a 2-dimensional array, each cavity being surrounded by a planar surface of the mould on all sides in which the shortest dimension of the planar surface between two adjacent cavities is at least 3 mm and between an edge of the mould and the closest cavity is at least 1.5 mm; b) thermoforming the first film to produce a plurality of pockets; c) at least partially filling the pockets with a composition; and d) sealing the plurality of the at least partially filled pockets. The cavities are positioned in the array such that there are a plurality of continuous strips of uninterrupted planar surface of the mould from a leading to a trailing edge of the mould, for receiving support means fitted to the machine for supporting the film.
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This application claims foreign priority benefits from Canadian Patent Application 2,479,043, filed Aug. 24, 2004.
FIELD OF THE INVENTION
The present invention relates to a tub filler and overflow combination device for being supported within an opening formed in a tub wall of a bath tub for both filling the bath tub and providing an overflow drain to the bath tub through a common opening in the tub wall.
BACKGROUND
Bath tubs and other similar types of basins typically have hot water and cold water supply lines with either separate valves or a common valve provided for controlling flow of hot and cold water to a mixed outlet feeding a tub filler line. Bathtub spouts are then commonly mounted on the tub filler line. A separate drain waste and over flow system is typically provided having a drain at a bottom of the basin with a branch line extending upwardly to an over flow connection communicating through an opening in the tub wall spaced upwardly from the bottom of the tub. The overflow remains open to also act as a vent for the drain line. In general it is aesthetically unappealing to have both a spout and a separate overflow spaced apart along the tub wall. Furthermore installation requires unnecessary effort in forming two separate holes in the wall for plumbing the two components separately.
One known device is manufactured by Geberit Manufacturing Inc. of Michigan City, Ind., as described at http://www.us.geberit.com. The device provides a tub filler and an overflow within a common housing. To prevent back flow, a check valve is connected in series with the flow into the device in combination with a required vacuum breaker upstream and in series with the flow into the device, at higher elevation than the flood level of the tub, that is a top edge of the tub. The flow inlet of the tub filler is provided at a side of the device, perpendicular to the flow outlet into the tub, requiring extra elbow connectors and installation time as compared to a conventional spout. As the backflow prevention components of the check valve and vacuum breaker are required to be upstream from the device servicing would require messy and time consuming removal of components from the plumbing line buried within the wall.
SUMMARY
According to one aspect of the present invention there is provided a filler and overflow combination device for being supported within an opening formed in a tub wall, the device comprising:
a body having first and second portions;
mounting means for supporting the body to extend through an opening in a tub wall from the first portion of the body to the second portion of the body on opposing sides of the tub wall;
a flow passage extending through the body from a flow inlet at the first portion to a flow outlet at the second portion;
a drain passage extending through the body from a drain inlet at the second portion to a drain outlet at the first portion; and
a backflow prevention device supported in series with the flow passage,
the backflow prevention device being slidably removable from the body through the flow outlet.
The flow outlet and the drain inlet may be concentric with one another at the second portion of the body. Preferably, the flow inlet is parallel to the flow outlet such that the flow inlet and flow outlet are formed in opposing sides of the body.
By providing a backflow prevention device which is slidably removable through the flow outlet, the backflow prevention device can be readily serviced with minimal disassembly of the device and no destruction of the wall or plumbing line being required. By providing an inline connection of the flow inlet at the rear parallel and opposite from the flow outlet at the front, the device is readily manufactured and can be installed easily in a manner similar to conventional spouts.
The backflow prevention device may comprise a pair of check valves supported in series with one another. There may be provided a releasable retainer member retaining the backflow prevention device within the flow outlet.
According to a second aspect of the present invention there is provided a filler and overflow combination device for being supported within an opening formed in a tub wall, the device comprising:
a body having first and second portions;
mounting means for supporting the body to extend through an opening in a tub wall from the first portion of the body to the second portion of the body on opposing sides of the tub wall;
a flow passage extending through the body from a flow inlet at the first portion to a flow outlet at the second portion; and
a drain passage extending through the body from a drain inlet at the second portion to a drain outlet at the first portion;
the flow outlet and the drain intlet being concentric with one another at the second portion of the body; and
the flow inlet being parallel to the flow outlet such that the flow inlet and flow outlet are formed in opposing sides of the body.
There may be provided a cap member selectively mounted on the second portion of the body concealing the flow outlet and the drain inlet.
The cap member may include first and second chambers formed within an exterior body for communication with the flow outlet and the drain inlet respectively wherein each of the first and second chambers communication through the exterior body of the cap member by respective apertures formed therein.
The apertures in the exterior body are preferably all formed in a bottom side of the cap member.
The flow outlet may be connected with the first chamber by a suitable sealing member preventing direct flow from the flow outlet to the drain inlet within the cap member.
The cap member may be selectively mounted on the second portion of the body by a set screw for ready removal when replacing the components of the backflow prevention device.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, which illustrate an exemplary embodiment of the present invention:
FIG. 1 is schematic view of the device as installed in a bathtub.
FIG. 2 is a partly sectional side elevational view of the device.
FIG. 3 is a front elevational view of the device.
FIG. 4 is a perspective view of the cap member showing the bottom side thereof.
DETAILED DESCRIPTION
Referring to the accompanying drawings, there is illustrated a tub filler and overflow combination device generally indicated by reference numeral 10 . The device 10 is suitable for being supported within an opening 12 formed in a tub wall 14 of a bathtub 16 for both filling the bathtub and providing an overflow drain 18 to the bathtub through the common opening 12 in the tub wall.
The device 10 includes a body having a first portion 20 to be mounted externally of the tub wall, and a second portion 22 projecting through the opening in the tub to be located internally within the tub in the mounted position. The first portion 20 includes an annular mounting face 24 extending about the body at the junction of the first and second portion so as to be oriented to face towards the second portion of the body. When the second portion extends through the opening in the tub, the annular mounting face 24 is arranged to overlap about a full periphery of the opening in the tub wall at the exterior side thereof.
The second portion 22 comprises a cylindrical threaded collar concentric with the annular mounting face 24 projecting coaxially therewith through the opening and beyond the tub wall into the interior of the bathtub. A mount includes a threaded mounting ring 26 which mounts about the threaded collar defining a second potion 22 and similarly includes an annular mounting face 28 which confronts the face 24 of the first portion far clamping the tub wall there between about the periphery of the opening. A suitable sealing ring 30 or sealing member of resilient material is supported between the mounting face 28 of the ring and the tub wall so that he mounting face 28 engages the sealing ring about the full periphery of the opening in the tub wall.
The collar defining the second portion 22 includes a hollow interior forming a drain inlet 32 at the second potion which communicates with a sleeve 33 forming a part of the first portion of the body. The sleeve is also hollow and defines a drain outlet 34 at an open bottom end thereof. The sleeve and the collar are substantially perpendicular with one another with the axis of the sleeve lying approximately at 93 degrees to the axis of the collar defining the second portion so that the drain outlet and the flow outlet are offset from perpendicular with one another within a range of 1 to 5 degrees. The collar and sleeve are enclosed at the point of communication with one another to define an enclosed drain passage extending from the opening at the drain inlet 32 of the collar to the opening in the sleeve defining the drain outlet 34 .
The body also includes a flow passage formed therein in the form of a tube 36 extending concentrically through the threaded collar defining the second portion. A flow outlet 38 of the flow passage extends coaxially through and beyond the collar defining the second portion although being smaller in diameter so as to define an annular space between the tube 36 and the surrounding collar which comprises the drain inlet. The flow inlet lies coaxially, so as to be parallel and concentric, with the flow outlet to extend through the opposing side of the body so that the flow inlet 40 projects through a rear face of the body at the first portion thereof.
The flow inlet is internally threaded for receiving a standard plumbing fitting therein. The threaded portion of the flow inlet 40 terminates at an internal shoulder where the flow passage increases in diameter for the remainder thereof towards the flow outlet. The diameter is suitable for slidably receiving a pair of check valves in series through the open end of the flow outlet 38 for abutment against the internal shoulder 42 of the flow passage.
An internal; annular groove 44 is formed adjacent the open end of the flow outlet for receiving a C-shaped retainer clip 46 therein which selectively retains the pair of check valves 48 within the flow passage.
Each of the check valves 48 is a self contained unit including a cylindrical housing, a valve head, a valve seat and biasing means for biasing the valve towards the closed position. The check valve only permits flow in one direction therethrough.
The check valves are supported within the flow passage so that both are oriented to only allow flow from the flow inlet to the flow outlet through the flow passage. In this configuration the two check valves 48 together form a back flow preventer or backflow prevention device in series with the flow passage.
A cap member 50 is provided to cover and conceal the flow outlet and drain inlet at the second portion of the body. The cap member includes a cylindrical body 52 having a hollow interior which is capped at an outer end 54 while remaining open at an opposing inner end 56 . A divider wall 58 spans the hollow interior to divide the cap member into a first chamber 60 adjacent the outer end 54 and a second chamber 62 adjacent the open inner end 56 .
A central aperture 64 in the divider wall 58 includes an integral mounting collar 66 supported thereon for receiving the end of the tube defining the flow outlet which projects beyond the collar forming the drain inlet 32 . An integral groove 68 formed within the collar 66 receives an O-ring therein for sealing between the flow outlet and the first chamber. The O-ring prevents any direct flow of fluid from the flow outlet and first chamber to the second chamber or the drain inlet within the interior of the cap member 50 . A set screw 70 holds the mounting collar 66 firmly in place in relation to the tube defining the flow outlet.
A plurality of spaced apart apertures 72 are provided in only the bottom portion of the cylindrical body 52 in communication with both the first and second chambers respectively. Flow from the flow outlet into the first chamber is thus even disbursed through the apertures 72 in the bottom of the chamber for dispensing into the bath tub. Similarly, rising water in the bathtub rises up through the bottom apertures in the second chamber for communication with the annular shaped drain inlet in communication through the open end of the cap member 50 . The backflow preventer formed by the check valves in series prevents the rising water from entering into the potable water supply fed to the flow passage.
The device 10 is installed within the opening 12 formed in a tub wall 14 typically for use with a conventional overflow device. The sleeve projecting downwardly from the device forming the drain outlet connects to a conventional plumbing tee 80 coupled to a drain line 82 of a drain 84 in the bottom of the bathtub. The tub filler line 86 coming from the mixer 88 of the hot and cold water supply lines is then connected to the rear face of the device at the flow inlet similar to connection to a conventional spout.
Periodically when the check valve forming the back flow prevention device requires servicing, the cap member is simply removed by loosening the set screw in the mounting collar thereof and the retainer clip at the flow outlet is then removed so that the check valves can be slidably removed through the flow outlet and replaced as desired.
While one embodiment of the present invention has been described in the foregoing, it is to be understood that other embodiments are possible within the scope of the invention. The invention is to be considered limited solely by the scope of the appended claims.
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A tub filler and overflow combination device is supported within a common opening formed in a tub wall. Both a flow passage and a drain passage extend through the body of the device to communicate through the common opening in the tub wall. A backflow preventer of the flow passage is slidably removable through the flow outlet for readily servicing the components of the backflow preventer as desired. The flow inlet is parallel and opposite to the flow outlet for ease of manufacturing and for ease of installation into a bathtub.
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BACKGROUND OF THE INVENTION
This invention relates to an integrated filter arrangement comprising a resistor section coupled between the input and the output of the arrangement and a capacitor section connected across the output of the arrangement.
Such filter arrangements are generally known per se. If such filters are to be integrated, problems are bound to arise as the resistance and capacitance values increase, in particular because components having comparatively large values also occupy a comparatively large substrate area.
A solution to this problem is the use of transconductor filters as is described, for example, by J.O. Voorman et al in the article "Bipolar Integration of Analog Gyrator and Laguerre Type Filters (Transconductor-Capacitor Filters)", Proceedings of the sixth European Conference of Circuit Theory and Design, Sept. 6-8, 1983, VDE-Verlag GmbH, Berlin Offenbach. In a transconductor filter the resistance is simulated by means of a kind of differential amplifier. The value of the resistor thus simulated is equal to the inverse of the transconductance of the differential amplifier. The resistance value is adjusted by varying the tail current of the differential amplifier and in principle it can be defined accurately.
For several uses and in particular for d.c. control loops, low-pass filters are needed to provide a maximal rejection of a.c. components superimposed on the direct voltage. Such a filter should provide a maximal rejection of spurious signals rather than an accurately defined cut-off frequency. In practice this means that the cut-off frequency should be below a specific value. For many uses it is required, for example, that the cut-off frequency be lower than 10 Hz. If such a filter is to be integrated completely the customary integration techniques will impose a limit of approximately 1 nF on theum maximum capacitance value. This means that in order to obtain a cut-off frequency lower than 10 Hz a resistance value of at least 16 mΩ is needed. In the case of a transconductor filter the tail current of the differential amplifier used therein is required to have value of 6 nA or less. This is such a low current level that leakage currents in the integrated circuit are likely to impair the correct operation of the filter. Moreover, the 1 nF capacitor occupies a comparatively large surface area on the IC (typically approximately 1 mm 2 ). Realising such filters by means of a filter circuit of the transconductor type therefore poses several problems.
SUMMARY OF THE INVENTION
It is an object of the invention to indicate how low-pass filters with a very low cut-off frequency can be integrated without the above problems.
In a filter arrangement of the type defined in the opening paragraph, this object is achieved in that the resistor section comprises two diodes arranged in anti-parallel. According to the invention, use is made of the very high differential resistance of diodes which are operated around the zero point in order to attain the high resistance value required in the arrangement.
If the direct voltage appearing across the diodes poses a problem in view of the resulting offset between the input voltage and the output voltage, it is preferred to utilise a filter arrangement comprising two resistor sections arranged between the respective symmetrical input terminals and the respective symmetrical output terminals, and at least one capacitor section connected to the output, which filter arrangement is characterized in that each of the resistor sections comprises two diodes arranged in anti-parallel.
Another preferred embodiment of the filter arrangement in accordance with the invention is characterized in that each anti-parallel diode array is formed by means of an NPN transistor and a PNP transistor, each having a short-circuited base-collector junction, each having its collector connected to the respective input terminal and whose emitters are connected to the respective output terminal. Such an embodiment has the advantage that the instantaneously cut-off diodes do not contribute to the leakage current to the substrate of the integrated circuit and hence cannot cause a reduction of the differential resistance and a consequent reduction of the filter attenuation.
If the direction and the order of magnitude of the leakage current are known it may be possible to simplify the filter arrangement by dispensing with the non-conductive diode in each anti-parallel diode array. This reduces the parasitic capacitance across each resistor section, resulting in an improved highfrequency rejection.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail, by way of example, with reference to the accompanying drawing, in which:
FIG. 1 shows a basic diagram of the integrated low-pass filter in accordance with the invention.
FIG. 1a shows an integrated low pass filter which uses a single diode-connected transister poled in the forward direction for the leakage current.
FIG. 2 shows a voltage-current characteristic of an anti-parallel diode array.
FIG. 3 shows a symmetrical filter arrangement in accordance with the invention.
FIG. 4 shows a filter arrangement similar to that of FIG. 3, utilising diode-connected transistors.
FIG. 4a shows a low pass filter similar to that in FIG. 1 where the diodes consist of diode-connected transistors.
FIG. 5 shows the components of a computer model used to study the performance of the filter arrangement in accordance with the invention.
FIGS. 6, 7, 8, 9, 10 and 11 show output signal waveforms obtained by means of a computer simulation based on the arrangement shown in FIG. 5.
FIG. 12 shows a simplified embodiment of the symmetrical filter arrangement in which the non-conducting diodes have been dispensed with.
FIGS. 13 to 16 show output signal waveforms obtained by a computer simulation based on the simplified embodiment shown in FIG. 12, the corresponding output signals for the arrangement of FIG. 5 being shown for comparison.
FIG. 17 illustrates the effect of unequal leakage currents in the simplified arrangement shown in FIG. 12.
FIG. 18 shows a modified embodiment in which the single capacitor in FIG. 12 is divided into two seperate capacitors.
FIGS. 19 and 20 illustrate the performance of the arrangement of FIG. 18, when an input voltage of 1 V applied, FIG. 20 being a kind of "magnification" of FIG. 19.
FIGS. 21 and 22 also illustrate the performance of the arrangement shown in FIG. 18 when an input voltage of 1 V is applied, FIG. 22 showing the magnified first part of the signal waveform of FIG. 21.
FIG. 23 shows a further embodiment of the arrangement in accordance with the invention in which the junction capacitances of anti-parallel diodes are employed to replace the capacitor.
FIG. 24 illustrates the performance of the arrangement shown in FIG. 23 for an input voltage of 1 V.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates the principle of the filter arrangement in accordance with the invention. The arrangement comprises two diodes D1 and D2 arranged in anti-parallel between an input terminal k1 and an output terminal k2. A capacitor C is arranged between the output terminal k2 and a common terminal k3. This common terminal k3 is at a reference potential, generally ground potential. The output signal of the arrangement is supplied to a subsequent circuit, represented diagrammatically by A, via the output terminal k2.
FIG. 2 shows the voltage-current characteristic of the parallel array of the two diodes D1 and D2. If the current through this parallel array is kept small the circuit operates in the range around the zero point where the parallel array has comparatively high differential resistance. In the filter in accordance with the invention, this high differential resistance is utilized in order to attain a very low cut-off frequency.
If the filter is integrated this will inevitably lead to a from the terminal k2 to the terminal k3 carrying the common reference potential. In FIG. 1 this leakage current is represented diagrammatically as a current source Ils connected between the output terminal k2 and the common terminal k3. Moreover, there is an output current Io through the terminal k2 to be subsequent stage A. The sum of the two currents Ils and Io should be minimized in order to ensure operation within the range of high differential resistance. The leakage current to the substrate depends on the method of integration but can be very low, of the order of a few pico-amperes, in practice. The output current to the circuit A can be minimized by utilizing, for example, a MOSFET input stage or a n-fold Darlington transistor arrangement. The requirements to be imposed on the current through the diodes will be described in detail hereinafter.
Although the arrangement shown in FIG. 1 can be employed in order to realize a filter having a very low cut-off frequency, whose properties will be described in more detail hereinafter, it is sometimes a disadvantage that a voltage developes across the diodes D1/D2 when a current flows through these diodes. Even for very small currents a forward voltage of a few hundreds of millivolts may arise and this forward voltage constitutes an offset between the input voltage and the output voltage of the filter. The use of a symmetrical filter arrangement enables said offset voltage to be reduced substantially, or even to be eliminated completely.
FIG. 3 shows an example of such a symmetrical arrangement. This arrangement comprises two anti-parallel arrays of diodes, namely the diodes D3 and D4 and the diodes D5 and D6. The array D3/D4 is connected between the input terminal k4 and the output terminal k6 and the array D5/D6 is connected between the input terminal k5 and the output terminal k7. The capacitor C is connected between the output terminals k6 and k7. An input voltage which is symmetrical with respect to ground (or another common symmetry potential) is applied to the input terminals k4 and k5, the output voltage appearing on the output terminals k6 and k7 being also symmetrical.
In this symmetrical embodiment two different leakage currents to ground occur, namely a leakage current Ils1 from the output terminal k6 to ground and a leakage current Ils2 from the output terminal k7 to ground. In FIG. 3 both leakage currents are symbolized by current sources. These leakage currents are exactly equal and if the characteristics of all the diodes are also identical, the offset voltages across the diodes in the two branches will be equal and will consequently cancel one another in the output signal.
In practical integrated circuits the diodes will generally comprise short-circuited transistors. In a preferred embodiment of the invention each parallel array utilizes a combination of an NPN and PNP transistor, each having its base-collector junction short-circuited. Such an arrangement is shown diagrammatically in FIG. 4.
FIG. 4 employs a combination of a PNP transistor T1 and an NPN transistor T2 connected in anti-parallel between the input terminal k4 and the output terminal k6. The base-collector junction of each of said transistors is short-circuited. Similarly, the PNP transistor T3 and the NPN transistor T4 are arranged in anti-parallel between the input terminal k5 and the output terminal k7, both transistors having their base-collector junctions short-circuited. In FIG. 4 the leakage currents are again symbolized by by sources Ils1 and Ils2. Such transistor combinations have the advantage that the cut-off diode junctions of these transistors do not contribute to the leakage current to the substrate. The total leakage current to be allowed for can thus be reduced substantially.
In order to examine the performance of the arrangements shown in FIGS. 1, 3 and 4 use is made of a computer model, of which the various components are shown in FIG. 5. In the same way as the arrangement shown in FIG. 4, the circuit arrangement comprises the transistors T1 to T4, the capacitor C, the input terminals k4 and k5, and the output terminals k6 and k7. Again two leakage-current sources Ils1 and Ils2 are shown, the leakage currents Ilek of both sources being assumed to be equal. In order to enable this filter arrangement to be compared with a known RC filter, the computer model also includes such a filter, comprising the resistors R1 and R2 and the capacitor C1, which are connected as shown between the input terminals k4 and k5. The value of C1 is equal to the value of C. Each of the resistors R1 and R2 has a value V T /Ilek≈0.025/Ilek.
FIG. 6 shows the input signal V in and the output signal V out as a function of time for a specific case. The input signal is a voltage having an amplitude of20 mV pp and a frequency of 250 Hz. The input voltage in FIG. 6 is shown to a scale of 1:200. The output signal V out is shown to full scale. A comparison of the two signals reveals that the alternating voltage appearing in the output signal has been attenuated by a factor of 80. Assuming that the filter has a first order characteristic, identical to that of a normal RC filter, this means that the cut-off frequency is approximately 3 Hz. There is no, or hardly any, difference between the diode filter and the RC filter, as will become apparent from a comparison between V RC and V out .
For a better understanding of the operation of the arrangement, in particular in the case of varying alternating voltage amplitudes, it is useful to examine the variation of the current I c through the capacitor C. It is found that the situation of FIG. 6 applies to comparatively small input signals for which Vin<25 mV. For larger input signals the input voltage is situated in a range for which Vin>V T ; V T =kT/q≈0.025 V. Assuming that the leakage currents from the two leakage current sources Ils1 and Ils2 are equal, hereinafter referred to as Ilek, the current through T2 will be equal to Ic+Ilek. Two situations may then be distinguished:
(a) T4 carries a current Ilek-Ic and T3 is off,
(b) T3 carries a current Ic-Ilek and T4 is off.
If it is also assumed that Vout is substantially lower than Vin, case (a) complies with: ##EQU1## Moreover, if the junctions of the transistors have identical properties, it is correct to assume that Is2=Is4, which yields: ##EQU2## In addition, Vin>>V T so that it follows from the foregoing that Ic Ilek. Case (b) complies with: ##EQU3## Again it is assumed that Is2=Is3 which yields ##EQU4## If it is again assumed that V in >>V T it follows from the above that Ic≈Ilek. Thus, in both cases the current Ic through the capacitor is found to be at least approximately equal to the leakage current Ilek through the leakage current sources Ils1 and Ils2.
FIG. 7 shows the current Ic as a function of the input voltage. This figure shows that there is a range for which Ic≈Ilek independently of the input voltage. This range is specifically situated between approximately 50 mV and 1 V. If the input voltage is equal to Vin=Vin.sin(2π.f.t) a sinewave voltage distorted to a triangular voltage will appear across the capacitor C, which voltage has a peak-to-peak value of ##EQU5## In this range the output voltage is found to depend only on the leakage current and is found to be independent of, or hardly dependent on, the input voltage amplitude, which indicates that the relative attenuation of the a.c. signal in the output voltage should increase as the input voltage amplitude increases. This is corroborated by computer simulations carried out by means of the model shown in FIG. 5, the results of which are given in FIGS. 8 and 9. FIG. 8 illustrates the situation in which the input voltage Vin=100 mVpp. A comparison between FIGS. 6 and 8 shows that the relative attenuation of the a.c. voltage signal in FIG. 8 is higher than in FIG. 6. The attenuation factor has increased to approximately 120.
FIG. 9 illustrates the situation in the case that Vin=500 mVpp. The relative attenuation of the a.c. signal has now increased even further, the attenuation factor having increased to approximately 450.
FIGS. 8 and 9 also show the output signal of the RC filter. It is evident that for increasing input signal the attenuation is smaller than the attenuation provided by the diode filter in accordance with the invention.
However, if the amplitude of the input voltage V in increases even further the current through the diodes at approximately twice the threshold voltage of these diodes will constantly increase and charge the capacitor C. This is also evident from FIG. 7, which shows a substantial increase in the current through the capacitor above approximately 1 V. In other words, if Vin becomes higher than twice the threshold voltage of the diodes the voltage across each of the diodes will not increase any further and the residual voltage will appear across the capacitor C. It is to be noted that this applies only to the symmetrical embodiment (FIGS. 3, 4 and 5). For the asymmetrical basic embodiment (FIG. 1) this transition will occur at approximately once the threshold voltage.
The performance of the symmetrical embodiment for higher input voltages is illustrated in FIGS. 10 and 11. FIG. 10 illustrates the situation for Vin=1 Vpp. As will become apparent from a comparison between FIGS. 9 and 10, the relative attenuation of the a.c. signal decreases. In FIG. 10 the attenuation factor is only approx. 50. FIG. 11 illustrates the situation for Vin=1.2 Vpp and this figure shows that a further increase of the input voltage leads to a rapid degradation of the filter. This means that the diode filter can be used only for input voltages of such an amplitude that the threshold voltage of the diode or diodes in the filter arrangement is not exceeded.
FIGS. 10 and 11 also show that in this range of input voltages the performance of the RC filter is better than that of the diode filter.
If at least the approximate magnitude of the input signal is known and the level and the direction of the leakage current are known, the filter may be simplified in some cases. In the amplitude range in which only the diodes T2 and T4 conduct (see FIG. 5) and T1 and T3 are off (case a) intended above), T1 and T3 may be dispensed with. If the leakage current flows in the opposite direction and the transistors T1 and T3 conduct, the two other transistors T2 and T4 may be dispensed with. In this situation the input voltage should still meet the following requirement: ##EQU6##
If two of the four diode-connected transistors are dispensed with, this has the advantage that the parasitic capacitance of each anti-parallel diode pair is reduced, as a result of which the attenuation of the filter at higher frequencies increases. Obviously, the filter can thus be simplified only if the leakage current direction is known and, consequently, if it is known which of the diodes in each anti-parallel array does not conduct and may be dispensed with.
FIG. 12 shows an embodiment of a simplified filter. The various components bear the same reference numerals as in FIG. 5. In FIG. 12 it is assumed that the two leakage-current sources carry the same leakage current Ilek. In comparison with FIG. 5 the transistors T1 and T3 have been dispensed with in this simplified embodiment.
FIGS. 13 to 16 illustrate the performance of the simplified embodiment shown in FIG. 12 for different input voltage amplitudes. For the purpose of comparison these figures show the corresponding output signals obtained with the embodiment shown in FIG. 5 and already described with reference to FIGS. 6, 8, 9 and 10. As is apparent from FIGS. 13 to 16, the performance of the two filters is the same for the signals for which the threshold voltage of the diodes is not exceeded. However, if larger signals are applied there appears to be a distinct difference in performance between the two filters, as can be seen in FIG. 16. In the filter comprising the anti-parallel diodes the amplitude of the output voltage increases substantially, in other words the attenuation factor of the filter decreases. However, in the simplified embodiment the amplitude of the output signal remains low. This means that this simplified embodiment is suitable for use with a larger range of input amplitudes.
A disadvantage of this simplified embodiment is that differences in the leakage currents Ilek in the case of overranging of the filter may have an adverse effect. This is illustrated in FIG. 17. This Figure is based on a situation in which the leakage current Ilek at the side of the transistor T2 (see FIG. 12) is 100 pA and the leakage current Ilek at the side of T4 is 150 pA. If in this situation the input signal exceeds the threshold voltage, T4 will be turned off. As a result of this, the leakage current of 150 pA through the lower leakage-current source will charge the capacitor C during the time interval in which T4 is off (every half-cycle). Consequently, the capacitor is charged with a direct current Ilek/2=75 pA. As is shown in FIG. 17, this leads to an increasing d.c. output voltage on which the attenuated alternating voltage is superimposed. Such an effect does not occur in the embodiment of FIG. 5. In said embodiment only said d.c. offset effect arises, leading to a capacitor offset voltage of V T ×ln (Ilek1/Ilek2)= 10 mV.
A solution to this capacitor charging problem may be to split the capacitor into two separate capacitors, each arranged between an output terminal and the symmetry potential of the input and the output voltage. Such an embodiment comprising split capacitors is shown in FIG. 18. The two capacitors bear the references C1 and C2 and the other components bear the same reference numerals as in the preceding Figures. Although the actual charging problem of the capacitors is now avoided, this arrangement has some other disadvantages. First of all, the effective value of the capacitance between the output terminals is reduced to a quarter of the original value. This means that in the case of full integration of this circuit arrangement the chip area required for the capacitors is four times as large in order to obtain the same filter performance. Another disadvantage is that when a considerable peak voltage is applied to the filter the d.c. content of the capacitors is drained only slowly because this is possible only via the leakage current path.
FIGS. 19 to 22 illustrate the performance of the arrangement of FIG. 18 when driven with 1 V. FIG. 20 shows a part of FIG. 19 and FIG. 22 shows a part of FIG. 21 to an enlarged scale. These Figures show that the capacitors are discharged only slowly by the leakage currents. If it is assumed that each of the capacitors has a value of 200 pF and that the leakage currents are again 100 pA and 150 pA respectively, discharging will take approximately 0.4 seconds. The effect of the offset in the leakage current does not disappear until after this time interval.
A solution to the offset problem is illustrated in FIG. 23. In this Figure a combination of additional anti-parallel diodes T5//T6 is arranged across the capacitor C. If the d.c. content of the capacitor becomes too high one of these two additional diodes will drain the leakage current difference, which has a stabilising effect. Moreover, the junction capacitances of the two additional diodes may be added to the overall capacitance value required, so that the actual capacitor can be reduced or under specific conditions may be dispensed with. This last mentioned possibility is in fact illustrated in FIG. 23. In the embodiment shown in FIG. 23 the additional diodes T5 and T6 are also constructed by means of transistors.
FIG. 24 illustrates the response of the arrangement of FIG. 23 to an input signal of 1 V. Comparison of FIG. 24 with FIG. 20 shows that the offset problem has been eliminated effectively and that only a brief response of the circuit occurs at the beginning of the signal burst.
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An integrated low-pass filter arrangement comprising one or more resistor sections coupled between the input terminals and the output terminals and a capacitor section coupled between the output terminals. Each resistor section comprises two diodes arranged in anti-parallel. The impedance connected to the output and the amplitude of the input alternating voltage are selected in such a way that the threshold voltage of the anti-parallel diodes is not exceeded. If the direction and magnitude of the leakage currents through the diodes are known the instantaneously non-conducting diode of the anti-parallel diode array may be omitted.
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BACKGROUND OF THE INVENTION
The present invention relates generally to fuel injection systems for internal combustion engines.
More particularly, the present invention relates to a pressure-regulated fuel injector having two, serially connected control valves.
In fuel injection systems with high pressure collecting chambers (common rail), which maintain a high pressure in the system, the initiation of injection and the end of the injection are adjusted with electrically adjustable injectors. The injectors are secured with grip-spring tensioning elements onto the cylinder head of the internal combustion engine, without significant changes to the cylinder head. However, under high pressure, such injectors with a smaller valve wear covering can lead to considerable leakage, which commonly impairs the operation of the injectors.
DE 197 01 879 A1 discloses a fuel injection device for combustion engines which includes a high pressure pump arranged with a high pressure-collecting chamber (common rail) filled with fuel. The high pressure-collecting chamber is connected via an injection line with an injection valve projecting into the combustion chamber of the internal combustion engine. The opening or closing movements are controlled, respectively, by an electrically controlled control valve. The control portion is formed as 3/2-way valve, which is connected with the injection line or a release line to a high-pressure channel flowing to an injection opening of the injection valve. A hydraulic working chamber, or pressure release chamber, fillable with high-pressure fuel, is provided on a control member. The working chamber is controllable through adjustment of the set position of the control member in a release channel.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a pressure-controlled injector which avoids the disadvantages of the prior art.
More particularly it is an object of the present invention to provide a pressure-controlled injector which avoids the leakage problem noted above.
In keeping with these objects and with others which will become apparent hereinafter, one feature of present invention resides, briefly stated, in a pressure controlled injector which has an injector for injecting fuel in a combustion chamber of an internal combustion engine, comprising a housing provided with a housing opening; a control valve body vertically movable in said opening of said housing; a ring chamber which encloses said control valve body; an inlet connectable with a high pressure collecting chamber and opening into said ring chamber; a nozzle inlet arranged so that during the vertical movement of said control valve body said nozzle inlet is connected with said inlet or separated from the latter; and 2/2-way control valves arranged inside said housing in series so that one of said 2/2-way control valves is force-equalized in an open condition.
The two-way valves (2/2 valves) of the present invention, which are serially connected, allows the upper control valve portion, on which the constant high pressure from the high pressure collecting chamber is based, to be formed in an opened position for regulating or equalizing force, since the valve diameter of the control member of the upper two-way valve corresponds to the guide diameter. Consequently, the two-way control valve which interrupts the high pressure from the high pressure-receiving chamber regulates in a direct way, via a controllable operating unit, such as a piezoregulating unit, which is connected to a hydraulic converter.
A 2/2-way valve, formed as a simple and inexpensive ball valve, is connected on the waste oil side near the force regulating unit of the valve body of the upper 2/2-way valve which interrupts the high pressure from the high pressure collecting chamber, as described above. The ball valve is pressed into its sealing seat when the piezo-regulating unit is controlled and its opening movement opposed. Upon maximum opening of the upper 2/2-way valve, a defined closing of the ball of the lower 2/2-way valve is ensured, so that the disadvantageous results, such as an increase in leakage with small valve wear coverings, are corrected.
Upon closing of the upper 2/2-way valve, the nozzle inlet to the nozzle chamber of the injection nozzle can be released via a ball element of the lower 2/2-way valve, which is disposed in a hollow chamber on the housing side. Based on the fact that the ball body of the lower 2/2-way valve is acted upon with a pressure spring force, the waste oil valve, which operates to counter the piezo element, can close the control valve body of the upper 2/2-way valve (or assist in its closing movement in a vertical direction).
The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the pressure-controlled injector of the present invention, in a longitudinal cross-sectional view.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described with reference to accompanying FIG. 1 . The inventive pressure-controlled injector 1 , as shown in FIG. 1 has 2/2-way valves which are arranged in series in a housing bore 2 . They preferably include an upper 2/2-way control valve 7 and a lower, ball-shaped 2/2-way control valve 21 .
The upper 2/2-way control valve 7 is essentially formed as a rotationally symmetrical member, relative to a line of symmetry 29 . On the upper side of the 2/2-way control valve body 8 is a first face 18 . The 2/2-way control valve body 8 also includes an oppositely disposed second face 17 .
Above the upper face 18 , a control volume of a hydraulic multiplier 6 is provided, a side of which can be acted upon by pressure of a piston 5 . The piston 5 , in turn, is acted upon on its side via a controllable piezoregulating unit 4 , which is not specifically represented here. Instead of a piezoregulating unit 4 , a magnetic valve with a short control time or a mechanical converter for operating the piston 5 could be used to the same effect.
The rotationally symmetrical 2/2-way control valve body 8 includes a constriction 13 , or a tapered portion, on which a valve diameter 14 is incorporated. When the 2/2-way control valve body 8 is closed, it lies with its valve diameter 14 on a seating surface 11 provided on the housing side and connects the inlet 15 coming from the high pressure collecting chamber in this manner. In the closed position, a transverse bore 19 , as well as the nozzle inlet 20 to the nozzle chamber of an injection nozzle (not specifically represented), are closed off from high pressure.
The inlet 15 , which comes from the high pressure collecting chamber, empties in an annular chamber 12 within the housing 3 of the injector 1 . The fuel volume coming from the high pressure collecting chamber via the inlet 15 is located in this annular chamber 12 and thereby regulates the high pressure.
The 2/2-way control valve body 8 is supported in the housing 3 , specifically in a housing bore. The 2/2-way control valve body 8 includes a first guide portion 9 and a second guide portion 16 . By means of both guide portions 9 , 16 , the control valve body 8 is guided cant- or swing-free in the housing 3 of the injector 1 . The force regulating unit of the control valve body 8 in the opened position (that is, upon connection of the nozzle inlet 14 with the transverse bore 19 of the intermediate inlet 20 ) causes the first and second guide portions 9 , 16 of the control valve body 8 to be guided in the same diameter as the valve diameter 14 of the two-way control valve body 8 with the leading or guiding edge 11 . Based on these dimensions, the two-way control valve body 8 , in the opened state, is operated by the piezoregulating unit 4 . The upper two-way control valve 7 is connected on the waste oil side to a ball-shaped two-way valve 21 . A ball-shaped closure element 23 lies on the lower face 17 of the two-way control valve body 8 . The ball-shaped closure element 23 is surrounded by a hollow chamber 25 in the housing 3 of the injector 1 and is constantly positioned against the lower face 17 of the two-way control valve body 8 by means of a spring element 26 . A waste oil line 22 empties into the hollow chamber 25 , in which is found the closure element 23 of the ball-shaped two-way valve 21 . A throttle element 27 is provided beneath the hollow chamber 25 , which is provided with the fuel volume via a shunt 28 from the nozzle inlet 19 , 20 .
By way of example, if the operating unit 4 is a piezoregulating unit, the piston 5 is then acted upon, and the hydraulic converter (multiplier) 6 causes a pressure increase so that the upper face 18 of the control valve body 8 is impacted with pressure. The control valve body 8 moves downwardly in the housing 3 of the injector 1 so that the valve diameter 14 of the control valve body 8 , which is joined to the seating surface 11 in the housing, is returned to its seat and the inlet 15 from the high pressure collecting chamber is opened through the annular chamber 12 to the transverse bore 19 to the nozzle inlet 20 . Thereby, pressurized fuel is disposed in the nozzle chamber of the injection nozzle (not represented). The downward, vertical movement of the control valve body 8 in the housing 3 of the injector 1 causes a descent of the lower surface 17 of the control valve body 8 in the lower hollow chamber 25 . The ball-shaped closure element 23 of the two-way valve 21 is driven into the lower chamber 25 into its seating against the operation of a pressure spring 26 . The valve diameter 24 of the ball-shaped closure element 23 closes the inlet, in which a throttle element 27 is disposed. Up to this point, the nozzle inlet 19 , 20 contains high pressure, while the waste oil line 22 is closed off from high pressure through the closure element 23 which is moved to its sealing seat 24 .
If the piezoregulating unit is no longer charged, the piston 5 moves upwardly, releasing the hydraulic converter 6 , so that the face 18 of the control valve body 8 is driven upwardly. The two-way control valve body 8 moves with its valve diameter 14 in the seating surface 11 , guided in its guide portions 9 , 16 in the housing 3 , and closes the nozzle inlet 19 , 20 from the inlet 15 of the high pressure collecting chamber. The residual pressure in the nozzle inlet 19 , 20 extends over the shunt 28 (or the throttle element 27 ) on the sealing seat 24 of the closure element 23 of the lower, ball-shaped two-way control valve. The residual pressure in the shunt 28 and in the transverse bore 19 , or the nozzle inlet 20 , supports the ascent of the ball-shaped closure element 23 from its sealing seat and, therewith, the closing movement of the upper control valve body 8 in his sealing seat. In this position, the ball-shaped closure element is opened so that the nozzle inlet 20 can be released via the shunt 28 . The throttle element 21 can also be released, as well as the housing-side hollow chamber 25 via the waste oil line 22 .
Since the ball-shaped closure element 23 is acted upon via the spring element against the operation of the piezoregulating unit 4 , the opening movement of the ball-shaped closure element 23 can be facilitated by its support on the lower face 17 of the control valve body 8 which supports the closing movement of the control valve body 8 in its sealing seat 11 in the housing 3 .
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the invention has been illustrated and described herein as a fuel injector with serially connected control valves, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims.
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An injector for injecting fuel in a combustion chamber of an internal combustion engine has a housing provided with a housing opening, a control valve body movable in the opening of the housing, a ring chamber which encloses the control valve body, an inlet connectable with a high pressure collecting chamber and opening into the ring chamber, a nozzle inlet arranged so that during the movement of the control valve body the nozzle inlet is connected with the inlet or separated from the latter, and 2/2-way control valves arranged inside the housing in series so that one of the 2/2-way control valves is force-equalized in an open condition.
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This is a division, of application Ser. No. 320,595, filed Nov. 12, 1981, now U.S. Pat. No. 4,393,524.
BACKGROUND OF THE INVENTION
Marine sanitary devices in particular and waste disposal system in general have been proceeding through an evolutionary process for a number of years. The Environmental Protection Agency (EPA) has issued various specifications regarding requirements for processing liquid and solid human waste as set forth in 33 CFR 159. Sewage or waste disposal basically requires that under certain circumstances, substantially all of the solid waste be removed from any liquid discharged from a vessel. In many instances recirculation of the fluid, for example water, is desirable.
Separation of solid waste and collection can be accomplished in a variety of different well known manners. The difficulty resides in storage and disposal. Clearly improvements in this area are necessary particularly when stringent EPA sanitary regulations are taken into consideration and criteria such as size, cost and efficiency of operation are kept in mind.
SUMMARY OF THE INVENTION
With the above background in mind, it is among the primary objectives of the present invention to provide a system for processing liquid and solid human waste in a manner consistent with the stringent requirements of the United States EPA. The system includes a self-contained unit including a removable disposable filter media cassette designed to achieve "white glove" servicing of the system. The system is compact and the cassette can be interconnected with a toilet bowl and packaged beneath the toilet bowl in a compact arrangement which is particularly useful in confined areas such as found in marine use.
It is also an objective to utilize low cost filtration materials to achieve minimum cost per flush of the system. Also, the system is energy efficient and only a small amount of electrical power is required for use. Furthermore, the system requires no chemical additions for sanitizing purposes.
A unique two stage filtration process is incorporated in the cassette with initial phase separation that satisfies United States EPA requirements for suspended solids.
More particularly, the basic objective of the system is achieved with the use of a filter cassette which is removable and disposable and acts in cooperation with a toilet bowl. The cassette is designed to roll a filter material about a spindle or take up roll assembly. Solid waste material is rolled up into the take up roll. Two stage filtration can be accomplished by first screening out or projecting out with the aid of a flapper design the majority of the solid waste ingredient. A second stage or solids removal is achieved with a filter media such as an unwoven plastic fabric. The two stage filter material method employs one roll of screen and one roll of filter media positioned adjacent to one another and adapted to be rolled together onto the take up roll. The first stage of separation through the screen material removes approximately 97% of the solids from the fluid. The majority of the remaining 3% of the solids is collected by the second stage filter in the form of the filter media. When the filter is fully rolled up it can be replaced by removing the filter cassette and replaced by a new one. The filter cassette can then be disposed in a simple and clean manner.
A still further objective of the invention is to provide a unique take up roll including a triangular configuration which facilitates directing the larger portion of the solid waste on the filter material with the material wrapping around the roll for collection and storage.
Also among the objectives of the present invention is to provide increased storage capacity for solid material in the unique filter cassette design. Conventional disposal filter devices usually are fully loaded when they have collected solids in a quantity of approximately 1 to 5% of the total volume of the device. In the present invention, the two stage filter concept permits separation of very large quantities of solid material from the fluid which is then conveyorized into storage. The screen material and finer filter media are both wrapped around the take up roll because screen material provides additional traction for moving the solid material onto the roll. As the solid material is entering the area of the take up roll there is a tendency for it to compress or extrude through the coarse screen material. The fine filter media is immediately behind the coarse filtering screen material and stops or prevents the possibility of extrusion. By the time the filter cassette is totally used up, approximately 40 to 50% of its volume has filled with waste plus the filter material. Conventional disposable filter devices would have to be 10 to 20 times larger to do the same job.
It is an objective of the invention to provide a toilet bowl as part of this system for receiving human waste and to contain fluid for dilution of the waste, transporting of the waste material from the bowl into the filter cassette, and also to assist in rinsing or cleaning the bowl. It is contemplated that appropriate electro magnetic flush valve controls can be used to maintain the fluid in the bowl until such time as the operator commands the dumping of the bowl contents and a subsequent refilling of the bowl with clean recycled fluid.
The unique filter cassette has two prime functions, first to separate both the coarse and fine solid particles from the fluid and second to store the solids in a compact manner for subsequent disposal.
A further objective is to provide a system incorporating a fluid pump to transport fluid from the interior of the system to fill the toilet bowl after a flush, to transport fluid from the filter cassette beneath the filter material and place it on top of the filter material to provide recirculation, and to transport fluid from the interior of the system when it is in excess. The excess fluid is transported out through the exterior of the unit to a location determined by an effluent pipe.
Appropriate valving structure is provided to facilitate control, storage and direction of the fluid in the sequence set forth above.
Also incorporated in the system is a decoloring cell, for example a carbon canister, for the purpose of removing color from the recirculated system fluid as well as providing fine filtration. The decoloring is achieved by activated carbon adsorption. The fine filtration is achieved through the "deep bed effect" of the carbon particles.
A further objective is to provide a system incorporating an electrolytic cell for conversion of the chlorides normally found in human urine into chlorine compounds which in turn are capable of sanitizing and deodorizing the recirculated fluid.
Also contemplated as part of the system is a coloring cell located in the toilet bowl flush circuit and provided to function in the conversion of the slightly yellow tinted cloudy fluid into a masked blue solution to improve its aesthetic appearance in the bowl.
Also, an appropriate arrangement of electronic controls are provided to separately flush, filter and recirculate fluid containing only liquid waste; flush, filter and recirculate fluid containing solid waste while collecting and storing the solid waste in a unique filter cassette, store the filtered fluid for recirculation and reuse, dispose of excess fluid in the system when desired, and collect and store solid waste while filtering the fluid therefrom and collecting the fluid for recirculation and reuse, and indicate when a filter cassette is advanced and when it is in condition for replacement.
Suitable controls are also provided to facilitate replacement of the filter cassette and carbon canister without dismantling or substantially effecting the remainder of the system. The replacement can be accomplished in a quick efficient and clean manner.
The present system is capable of being utilized in marine environments, camping sites, construction locations, mobile vehicles, and other similar places where self-contained waste disposal systems are applicable.
In summary, a self-contained sewage waste disposal system is provided. The system includes a housing structure and a toilet bowl adapted to receive human waste and fluid for diluting the waste, transporting the waste and rinsing the bowl in the housing. A removable filter cassette is in the housing in communication with the toilet bowl. Means is provided for flushing the bowl and dumping the contents into the filter cassette and for subsequent refilling of the bowl. Filter means in the cassette is provided for separating the coarse and fine particles of solid material from the fluid received from the bowl. Storage means is in the cassette to store the solid material in a compact manner for subsequent disposal upon removal of the cassette. Pump means including interconnected conduits in the housing is provided to transport fluid from the interior of the system to fill the bowl after a flush, to transport filtered fluid from the filter cassette to a position for recirculation, and to transport excess fluid from the interior of the housing to the exterior thereof. Means is in the housing and positioned to sanitize and deodorize the recirculated fluid. Control means is provided to pass the fluid through the system to facilitate the collection and disposal of sewage waste within the system in a predetermined sequence.
With the above objectives among others in mind, reference is made to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In The Drawings:
FIG. 1 is a perspective view of the self-contained sewerage waste disposal system of the present invention;
FIG. 2 is a sectional front view thereof;
FIG. 3 is a sectional side view thereof taken along the plane of line 3--3 of FIG. 2;
FIG. 4 is a schematic drawing of the electrical circuitry employed in the invention;
FIG. 5 is a block diagram of the sequence of operations of the system of the invention;
FIG. 6 is an end plan view of a valve assembly for controlling fluid flow in the system of the invention;
FIG. 7 is a sectional view thereof taken along the plane of line 7--7 of FIG. 6;
FIG. 8 is a sectional view thereof taken along the plane of line 8--8 of FIG. 7;
FIG. 9 is a plan view of the other end of the valve assembly employed for fluid flow in the system of the invention;
FIG. 10 is an enlarged sectional view of the filter cassette used in the system of the invention; and
FIG. 11 is a sectional view thereof taken along the plane of line 11--11 of FIG. 10.
DETAILED DESCRIPTION
System 20 as shown includes a compact housing structure 22 which provides a decorative and attractive enclosure for the system components as well as providing a weight support contoured for the user. All of the components of system 20 are incorporated within the housing and thus it is an entirely self-contained system designed for disposal of sewage waste. In this manner, it is particularly useful in the marine environment and more so since it will satisfy certain stringent EPA requirements for handling of human waste.
The basic parts of system 20 within housing 22 are shown in FIGS. 1-3 and include a control panel assembly 24 positioned within the upper portion of the housing and encaptured by a cover panel assembly 26. A conventional seat and cover arrangement 28 is positioned on the housing for the user and is aligned with a bowl assembly 30 on the housing and extending within. An electrolytic cell assembly 32 is positioned within housing 34.
The bowl extends within lower portion 34 of the housing 22 which has a hollow interior 36. Mounted within the interior of housing portion 34 is a motor assembly drive 38. A flush valve assembly 40 is in the interior 36 and is supported at the bottom opening in the bowl assembly 30.
A pump 42 is in the lower rear portion of the housing interior 36. Removably positioned within the bottom end of housing portion 34 is a filter cassette assembly 44. In the upper portion of housing 22 a decoloring cell assembly 46 is mounted and a coloring cell assembly 48 is mounted below the decoloring cell 46 and is in the lower portion of the housing 22. A four way valve 50 is positioned adjacent the coloring cell and mounted within the interior of the lower portion of the housing.
All of the components are mounted in a conventional manner and are interconnected in the desired manner for operation of the system as described in detail below by appropriate tubing.
Toilet bowl assembly 30 is a conventional type of bowl shaped device, of ceramic or other conventional material, for receiving human waste. The bowl 30 is bolted to the housing by a conventional bolt assembly, has a hollow interior 54, a large upper access opening 56 at the top and a smaller discharge opening 58 at the bottom for discharge or dumping of the waste material collected therein. A conventional flush ring 60 surrounds the upper rim portion of the bowl assembly 30. The flush ring is conventionally connected for introduction of fluid. Fluid introduced through the flush ring into the bowl is normally retained in the bowl for dilution of the waste. This fluid adds in the transport of the waste material from the bowl into the next stage of the system 20. The bowl fluid also assists in rinsing or cleaning the bowl.
Seat and cover assembly 28 is shown in the closed position in FIG. 3 and in phantom is shown in the open position hinged in a conventional manner about pivot pin 62. Naturally one or both of the seat and cover components can be shifted between the open and closed positions.
Flush valve 40 is an electromagnetic flush valve normally closing discharge opening 58 at the bottom of the bowl. In this manner, flush valve 40 is used to maintain the fluid in the bowl until such time as the operator commands the dumping of the bowl contents and a subsequent refilling of the bowl with clean recycled fluid.
Electrolytic cell assembly 32 is mounted on the interior of the housing by a conventional mounting plate 64 and extends downward allowing gas bubbles to leae its enclosure. Appropriate connectors 66 extend from the electrolytic cell for circulating fluid through the cell. The purpose of the circulation is to convert the chlorides found normally in human urine into chlorine compounds which in turn are capable of sanitizing and deodorizing the recirculated fluid within the system.
The motor and drive assembly 38 is also mounted in a conventional manner to the interior of the housing and includes a drive shaft 68 interconnectable by a suitable chain 70 to an extending shaft on the filter cassette for advancing a take up roll within the cassette. The motor and drive assembly is a conventional well known commercial product.
Pump 42 is also a conventional commercially available product and is the type of fluid pump which can accomplish three functions within the system 20. It is used to transport fluid from the interior of system 20 to fill the toilet bowl 30 after a flush. It also transports fluid from the filter cassette 44 beneath the filter material in the cassette and places it on top of the filter material to provide for recirculation. It also transports fluid from the interior of the system when it is in excess. This fluid is transported out through the exterior of the unit to a location determined by an effluent pipe.
The pump 42 is beneath a coloring cell 48 which is vertically aligned with a decoloring cell 46. Appropriate fluid connections are made for recirculation of fluid through the decoloring cell by means of connectors 71, 72, 73 and 74 and similarly, circulation of fluid through the coloring cell during bowl refill is accomplished by means of connectors 76 and 78. Decoloring cell 46 is a common type of element in waste disposal systems generally referred to as a carbon canister and is for the purpose of removing color from the recirculated system fluid as well as providing fine filtration. The decoloring is achieved by activated carbon adsorption. The fine filtration is achieved through the "deep bed effect" of the carbon particles. Common commercial alternatives are acceptable as well for color removal and for fine filtration.
The coloring cell 48 is located in the toilet bowl flush circuit and functions to convert the slightly yellow tinted cloudy fluid into a masked blue solution to improve its aesthetic appearance in the bowl.
Filter cassette assembly 44 is removable from housing structure 22 for disposal and replacement. The details of filter cassette 44 can be best seen in FIGS. 10 and 11. The cassette 44 includes a casing 80 to house the filter components. The shape of the casing is designed to conform with the available space in the bottom of the housing 22 of system 20 to facilitate formation of a compact low cost self-contained structure.
An entrance opening 82 is in the upper side of the cassette for introduction of the waste material to be filtered. A suitable female disconnect 84 is at the bottom rear of the casing of a cassette for removal of filtered fluid for further treatment and recirculation and reuse. A horizontal shaft 86 is mounted for rotation within casing 80 and extends outwardly through a side opening in the cassette to be keyed in an external drive shaft 88 attached to chain 70 from the motor assembly 38 to thereby drive and rotate the shaft 86 when the filter cassette is placed in the system, interconnected therein and flushed.
A pressure plate 90 is in the casing and affixed at one end thereto and aligned with entrance opening 82 in the upper side of the casing. The pressure plate 90 provides support for the filter material passing thereover and extending above the plate and the solid waste material collected thereon.
A splash guard 92 extends interiorally of the casing in cantilever fashion into overlying and resilient engagement with take up roll 94 to prevent undesirable bypassing of waste as it is being stored on the roll. Take up roll 94 is mounted in fixed position on rotatable shaft 86 to rotate therewith when it is driven by the motor and drive assembly and thereby advance filter material within the cassette and collect solid waste thereabout. In addition to the take up roll within casing 80 a pair of supply rolls 96 and 98 are mounted in the casing and are spaced from take up roll 94. The rolls are positioned so that filter material from both of the supply rolls 96 and 98 will pass across the casing beneath entrance opening 82 and then will travel onto the take up roll 94 for collection.
Supply roll 98 contains a coarse filter material or screening material 100 which will first contact the waste discharged into the cassette and separate the majority of the solid particles contained therein. The other supply roll 96 includes a fine particle filter media 102 for secondary filtering of the waste material which is predominantly fluid that has passed through the screening filter material 100. Thus, fine filter media 102 provides a secondary filtering action. Both supply rolls 96 and 98 are rotatably mounted within the casing about suitable horizontal axes and are positioned adjacent to one another and substantially spaced from the take up roll 94.
The coarse filter material 100 extends from the upper side of supply roll 98 and is supported intermediate its travel path by pressure plate 90. It then extends unsupported into direct engagement with the exposed surface of take up roll 94.
The coarse filter material 100 extends from the upper side of supply roll 98 and is supported intermediate its travel path by pressure plate 90. It then extends unsupported into direct engagement with the exposed surface of take up roll 94.
Material 102 from supply filter roll 96 takes a somewhat different path. It extends about roller guide 104 mounted beneath the supply roll 96 in the casing and then extends beneath screen material 100 over the portion of the cassette where waste material will travel through onto the filter. The filter guide 106 then directs the filter media 102 onto the take up roll 94 with the coarser or screen filter material 100 being captured between the outer surface of roll 94 and the inner surface of filter media 102.
A filter table 108 is fixed in position in the casing beneath the filter material and provides a further support for the filter material.
After the take up roll enlarges through the storage of waste it then comes in contact with filter table 108 which supports filter media 102 and keeps it from sagging due to the weight of recirculated fluid.
Filter table 108 includes a resilient cantilever end portion 109 to apply compression to the filter material being collected on the take up roll and support the exterior of the roll as it enlarges.
A suitable conventional collar 110 is provided where the take up roll extends through opposing side apertures in the casing for keying and interconnection with the motor and drive assembly. Collar 110 is a conventional sealing means to prevent leakage at those apertures in the casing and to facilitate journaling and rotation of the shaft of the take up roll. To facilitate the seal a conventional O ring 112 can be mounted within the collar 110 and in engagement with the outwardly extending shaft of the take up roll.
A further splash guard 114 is positioned adjacent the entrance opening 82 to the cassette to facilitate the prevention of waste material being dumped or splashed behind the filter supply rolls and instead being directed to the filtering portion of the screen material 100 and thereafter the secondary fine filtering media 102.
The filter table 108 is spaced from the bottom of the casing and mounted on suitable ribs 116. Table 108 includes a plurality of spaced parallel bars with the openings therebetween permitting the passage of fluid. The space beneath the filter table 108 forms a storage chamber for filtering fluid for further treatment and recirculation and reuse when it is pumped from the cassette. It also serves as a weir and allows sediment to settle out of the fluid during periods of non-use. The ribs serve to entrap the fluid to alleviate the danger of fluid contacting the roll and leaching solids and color.
Cassette 44 can be mounted in housing 22 in a quick and efficient manner and can be similarly removed for replacement after collection of waste material therein without contamination and basically with a white glove procedure. Cassette 44 is introduced through an access opening 116 in the front of the bottom portion 34 of housing structure 22. It is introduced completely within the housing until male disconnect 118 from pump 42 passes through female disconnect 84 in the bottom of the casing of the cassette into communication with the storage chamber for filtered fluid in the bottom of the casing. At the same time, chain 70 and interconnected conventional connecting structure is attached to a portion of the take up roll 94 extending outwardly of the casing of the cassette to provide for drive and rotation of the take up roll. In this position, entrance opening 82 in the upper side of the casing is in alignment with a corresponding opening 120 in a surrounding plenum on the interior of housing structure 22 which generally conforms with the outer upper configuration of the cassette. The two aligned apertures 120 and 82 are also in alignment with the discharge opening 58 from the bowl 30. In this condition, the cassette 44 is in position and ready for use as part of system 20.
It should also be noted that cassette 44 is affixed or locked in position by means of a reciprocally shiftable locking pin 160 passing through aligned apertures in the housing structure 22 and the casing of cassette 44. Withdrawal of the pin 160 as shown in phantom in FIG. 2 will remove the end of the pin from the cassette casing and permit removal of the cassette for disposal and replacement. Spring 162 surrounding the pin normally biases the pin into locking position in the casing of the cassette.
Four way valve 50 is shown in detail in FIGS. 6-9. The valve housing 124 includes connector ports 126, 127, 128 and 129 extending through a front cover 130. A spacer 132 spaces the cover 130 from the back cover 134. A vane 136 is within the spacer 132 and adjacent to the inner wall of back cover 134. A second spacer 138 is positioned between the outer surface of the back cover 134 and a mounting plate 140. A cam shaft 142 extends through a central opening in back plate 134 and is rotatably mounted in position. The vane is mounted on the cam shaft 142 to rotate therewith and sequentially close and open the ports. A suitable O ring seal 144 is located in the central aperture through the back cover plate to seal against the outer surface of the cam passing therethrough. A group of three micro switches 146 are annularly spaced about the inner surface of mounting plate 140 in position to be sequentially actuated by a cam 148 on cam shaft 142 as it is rotated. These are conventional commercially available micro switches.
Since the valve assembly is a four way valve assembly, there are four ports in front cover 130 with three of the ports being annularly arranged around the central part 128 as shown in FIG. 6.
Screw and nut arrangements 150 serves to interconnect the bottom of the front and rear cover plates and spacer 132 positioned therebetween by passing through aligned apertures in those three elements. Similarly, screw, nut and washer assemblies 152 passing through aligned apertures interconnects the upper ends of front cover plate 130, rear cover plate 134 and spacer 132 and also connects therewith spacer 138 and mounting plate 140. In fact, as shown in end view in FIGS. 6 and 9, there are three annularly spaced screw assemblies 150 and similarly three annularly interspaced screw assemblies 152 about the periphery of the valve assembly 50. In this manner, all of the components are retained in fixed position.
Mounted on the exposed face of mounting plate 140 is a conventional gear motor 154 of a commercially available type. The rotatable drive shaft 156 of the motor extends through a central aperture in the mounting plate and into a recess in cam shaft 142. In this manner, the cam shaft and motor are mounted together with the assistance of a set screw 158 projecting through a side orifice in the cam shaft and into engagement with the drive pin of the motor. Thus, rotation of the motor shaft 156 will rotate the cam shaft and accordingly the cam 148 will actuate the three micro switches 146 in sequence. Four way valve assembly in this form is then mounted in fixed position in a conventional manner within system housing structure 22 and is interconnected for facilitating operation of fluid flow within the system in the manner described below. The operation of valve 50 is such that a voltage is supplied to motor 154 through a selected normally closed micro switch 146 upon the command of the electronic control circuit in the system through a relay. Each micro switch 146 corresponds to a desired position for the valve 50, which when moved to this position will cause cam shaft 142 attached to the output shaft 156 of the motor to break the electrical supply to the motor in accordance with the circuitry arrangement for the plurality of micro switches 146. In this manner, the flow through the valve 50 is channeled through the required passages to perform the necessary functions in the system 20. The vane 136 serves to block the chosen outlet port 126, 127 or 129 depending on rotation of the cam 142 to which it is attached. The central inlet port 128 is thus sequentially brought into communication with one or more of the outlet ports to provide the desired flow path in the system at any given point in time. Each outlet port is designed for a particular function in the system, a flushing operation, a recirculation of fluid operation, removal of excess fluid or effluent. It is contemplated that a valve assembly of this type can be made entirely of inexpensive material such as plastic with the exception of the shaft and motor combination which is normally formed of non-corrosive steel.
Filter cassette 44 receives fluid from the toilet bowl passing through flush valve 40 into the filter cassette 44. The primary function of the cassette 44 is to separate both the coarse and fine solid particles from the fluid. A second function of the cassette is to store the solids in a compact manner for subsequent disposal.
The conduits for fluid flow through the system 20 can be best seen in FIGS. 2 and 3 with arrows showing the direction of flow. Pump 42 pumps fluid through conduit 43 into the four way valve 50. One outlet of the valve 50 is for directing fluid through conduit 45 through connector 78 into the bottom of the coloring cell 48. Fluid exiting from the coloring cell 48 travels through conduit 49 extending from connector 76 at the upper end of the coloring cell. Conduit 49 extends into communication with the flush ring assembly through which the fluid is introduced to the interior 54 of the toilet bowl. A second outlet from four way valve 50 is interconnected with conduit 51 for directing effluent fluid from the system when that appropriate valve outlet or connector port is opened.
The remaining outlet port of four way valve 50 is interconnected with conduit 53 which communicates and is attached to the two entrance connectors 71 and 73 of decoloring cell 46. In this manner the fluid can be passed into the decoloring cell and exits, after being suitably treated therein, through exit connectors 72 and 74 into conduit 75. Conduit 75 extends onto inlet connector 66 of electrolytic cell assembly 32. In this manner the fluid can be introduced into the electrolytic cell for further treatment. The fluid passes from exit connector 66 of the electrolytic cell through conduit 77 through the flush valve assembly and into the base of the bowl for of fluid therethrough into the bowl. In this manner, the fluid flow functions of the system can be accomplished through the various interconnected conduits. For example, excess or effluent fluid can be discarded, fluid can be introduced for flushing of the bowl, and fluid can be directed for recirculation through the system.
For operation of the system 20, reference is made to the schematic electrical circuitry of FIG. 4 and the flow diagram as shown in FIG. 5. The flush switch 164 is depressed to the L position. This starts the main cycle time portion of the dual solid state timer 166. This timer in turn energizes the electrolytic cell relay 168. In this manner the electrolytic cell 32 is energized. While the flush switch 164 is depressed, the flush valve coil 198 is de-energized and the bowl content is allowed to drop into the interior of the system to provide a rinshing action. As soon as the switch is allowed to spring return to its neutral position, the flush valve coil is then reenergized. At the same time as the electrolytic cell is energized the fluid pump 42 is also energized. When the flush switch is released, the pump provides the refilling of the toilet bowl with clean recycled fluid. The fluid rises in the bowl until the liquid level sensor which is called "bowl level control" 170 is electrically "made". When the switch is "made", the bowl level control relay 172 then becomes energized. This relay then causes the four way valve 50 to switch from the bowl "fill" position to the "fluid recirculation" position. This recirculation will continue until the main cycle timer 166 completes its timing cycle.
When the main cycle time period for processing the fluid is not occurring, that is the system 20 is at rest, the system can execute the detection and disposal of excess fluid from the system. This fluid is referred to as effluent. The existance of excess fluid is determined by the effluent level control switch 186. When it is "made" by the conductivity of the effluent and when the toilet system is in an approximate horizontal position as determined by the effluent level control horizontal switch 190, the effluent level control relay 188 becomes energized. This causes the fluid pump 42 to operate and also causes the four way valve 50 to direct the effluent to the effluent discharge. When the fluid level falls below the intermediate electrode of the effluent level control switch 186 the circuit is broken, and the effluent system ceases functioning.
If the flush switch 164 is depressed into the "S" position to achieve "solid flush", both the main cycle timer and the filter advanced timer portions of the dual solid state timer 166 are energized. The main cycle timer portion of the timer 166 functions in the same manner as previously described. The filter advance portion of the timer 166 causes the filter advance control relay 200 to be energized. This in turn energizes the filter advance drive motor 38. This drive motor advances the filter material in the filter cassette 44 by approximately 6 inches. Any solid waste collected on the filter material is rolled up around the take up roll 94. Relay 200 also de-energizes the flush valve coil 198 so that the unit operates in a bowl "rinse" mode while the filter material is being advanced.
While this is occurring the filter change signal light 184 is incapable of being energized. In order to verify and detect proper advancement of the filter material, a system is devised whereby a tiny amount of magnetic material 202 is implanted in the end of the filter supply roll 98 or, alternatively supply roll 96, located within filter cassette 44. Filter advance sensor switch 174 and filter advance travel sensor switch 180 are located outside of cassette 44 within system 20. As the filter supply roll 98 rotates to supply filter media at the drive take up roll 94, the magnet 202 will "make" switch 180. This in turn will energize filter advance travel relay 182. This relay establishes a hold circuit around switch 180 as well as opens one of the possible voltage paths to the filter change signal light 184. The magnet continues to rotate until it reaches a position where it actuates the switch 174. This energizes the filter advance relay 178. When this relay is energized, it opens one of the possible paths to filter change signal light 184. It also de-energizes the filter advance control relay 200 which in turn stops the filter advance drive 38. The circuit is designed so that subsequent liquid flushes will not cause filter advance roll operation and also maintains relay 178 and relay 182 in their energized positions. If the filter media detaches from the filter supply roll, the magnet 202 will cease rotation and switch 174 and switch 180 will not close during a solid flush. This will cause relay 200 to become de-nergized without energizing relay 178 or relay 182. When this sequence of events occurs, the filter change signal light 184 becomes illuminated and the filter advance drive ceases to be actuated. This light tells the operator to install a new filter cassette. If the filter roll, instead of being depleted of filter material, becomes full; the full filtered switch 192 will illuminate the filter change signal light 184 and stop the filter advance drive.
In order to have a filter cassette change the operator switches the filtered change switch 196. This action causes the flush valve coil 198 to be maintained regardless of other controls. The operator then calls for a liquid flush by depressing the flush switch 164 to the "L" position. This causes the pump 42 to provide the bowl with clean recycled fluid. The bowl level control relay 172 is disabled by the actuation of switch 196. Therefore, pump 42 continues to remove fluid from the interior of the system and place it in the bowl until no pumpable fluid remains in the system. This will be ascertained by observing that no more liquid is entering the bowl from the flush ring of the bowl. At this point cassette 44 can be removed and a new cassette installed by simply removing pin 160 from engagement with the cassette casing and biasing spring 162 to permit withdrawal of the cassette through opening 116 in the housing structure 22. The new cassette is introduced through the same access opening and the pin released so that spring 162 biases the pin into engagement with the casing of the new cassette. The other appropriate connections to the system as described above are accomplished and, thereafter, switch 196 can be switched back to the normal operating mode and the operator can give the unit a solid flush command to put it into a "ready" condition.
Replacement of the decoloring canister 46 can be accomplished at the same time as the filter cassette replacement. The decoloring contents can be either activated carbon, and other similar decoloring materials. The sequence of events related to the electrical control system are as described above. Once all the pumpable fluid is in the bowl, the pump will continue to pump until the processing period has transpired. This is controlled by the main cycle timer 166. When the pump is off, the carbon canister and filter cassette may be removed and replaced. After the new cassette and canister are in place approximately one quart of water should be added to the bowl to make up for the fluid lost in the transfer. The unit is now ready for a solid flush command to put the unit into a "ready" condition.
There are certain advantages in utilizing a triangular configuration or any other polyagonal configuration for the take up roll 94. Round spools can cause difficulty in consuming semi-solid material, such as human waste, into a storage take up roll without slippage. The triangular configuration provides straight sides leading at a point which accomplishes biting of the material and thus facilitating the breakdown, collecting and storing of the material on the roll. This is particularly advantageous when the spool size is relatively small as with a compact system of the present type. A further modification that will also work adequately would be to provide the sides of the triangularly shaped take up roll with concave surfaces. This acts in a similar manner and breakdown collection and storage of the solid waste material.
After several revolutions, the take up roll beings to round out. It eventually becomes eliptical in shape and, as the sides get larger, the included angle is such that the triangular configuration is not necessarily required and the eliptical roll will consume the semi-solid material. The variation with concave sides permits even more semi-solid material to be stored in the take up roll and minimizes the final take up roll size.
As discussed above, there are numerous advantageous features obtained with the use of a filter cassette of the present design. Improved filtering ability, white-glove service, compactness, minimum cost and minimum energy are clear advantages. Another feature of the unit is the realization that most filter devices of a disposable nature usually are fully loaded when they have collected solids in a quantity which never exceeds one to five percent of the total volume of the device. But when the filter has this much solid material in it, it becomes plugged up or blocked. The two stage filter concept utilized here is such that very large quantities of material are separated from the fluid and then conveyorized into storage. This is achieved by wrapping the coarse or screen filter material and the fine filter media around a take up mandrel or roll. The coarse triangularly shaped take up roll with concave surfaces. This acts in a similar manner and breakdown collection and storage of the solid waste material.
After several revolutions, the take up roll beings to round out. It eventually becomes eliptical in shape and, as the sides get larger, the included angle is such that the triangular configuration is not necessarily required and the eliptical roll will consume the semi-solid material. The variation with concave sides permits even more semi-solid material to be stored in the take up roll and minimizes the final take up roll size.
As discussed above, there are numerous advantageous features obtained with the use of a filter cassette of the present design. Improved filtering ability, white-glove service, compactness, minimum cost and minimum energy are clear advantages. Another feature of the unit is the realization that most filter devices of a disposable nature usually are fully loaded when they have collected solids in a quantity which never exceeds one to five percent of the total volume of the device. But when the filter has this much solid material in it, it becomes plugged up or blocked. The two stage filter concept utilized here is such that very large quantities of material are separated from the fluid and then conveyorized into storage. This is achieved by wrapping the coarse or screen filter material and the fine filter media around a take up mandrel or roll. The coarse media or screen material provides the traction necessary to move this solid material into the mandrel. As the solid material is entering the mandrel area, there is a tendency for it to compress or extrude through the coarse screen media. The fine filtered media is immediately behind the coarse filter media and stops or prevents the possibility of extrusion. By the time the filter cassette is totally used up, approximately forty to fifty percent of its volume has solidly filled with waste plus the filter media. A conventional type of filter devices would have to be ten to twenty times larger to do the same job.
It should also be noted that the filter cassette of the present design is constructed to facilitate removal and disposal of solid waste collection stored in the device. It is provided with quick-couplings both to the fluid inlet and its fluid outlet. When it is removed for disposal, the fluid outlet automatically seals itself. The fluid inlet is "capped off". The exterior of the cassette is totally clean and bacteria free.
Thus the several aforenoted objects and advantages are most effectively attained. Although several somewhat preferred embodiments have been disclosed and described in detail herein, it should be understood that this invention is in no sense limited thereby and its scope is to be determined by that of the appended claims.
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A self-contained sewage waste disposal system is provided including a housing structure and a toilet bowl adapted to receive human waste and fluid for diluting the waste, transporting the waste and rinsing the bowl is provided in the housing structure. A removable filter cassette is placed in the housing structure in communication with the toilet bowl. The bowl is adapted to be flushed to dump the contents into the filter cassette and to be subsequently refilled. The coarse and fine particles of solid waste material are separated from the fluid received from the bowl by filter material in the cassette. The solid material is stored in the cassette in a compact manner for subsequent disposal upon removal of the cassette from the housing. A pump and interconnected conduits in the housing transport fluid from the interior of the system to fill the bowl after a flush, to transport filtered fluid from the filter cassette to a position for recirculation, and to transport excess fluid from the interior of the housing to the exterior thereof. The recirculated fluid is sanitized and deodorized in the housing. Controls are provided to pass the fluid through the system to facilitate the collection and disposal of sewage waste within the system in a predetermined sequence.
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BACKGROUND OF THE INVENTION
This invention relates generally to automated inspection systems, and more particularly, to systems and methods for monitoring a presence and/or condition of components using RFID systems and other sensor motes.
At least some known airlines are governed by government and/or safety regulations that require each airplane seat is properly equipped with a floatation device for use by the passenger in the unlikely event of a water landing. A current known airplane inspection process to verify that each seat has the requisite floatation device is time consuming and labor intensive. The inspection process requires a person, to check underneath each seat or a compartment beside the seat, to verify that there is a floatation device and also ensure that its expiration date is within acceptable limits in accordance with the governing regulations. Some airplanes may be configured with hundreds of seats such that the inspection process for each seat would have to be repeated for every seat leading to the time consuming and labor intensive characteristics of the process. Furthermore, due to the labor intensive characteristic, the process is prone to possible errors and thereby requiring additional cross-checks as deemed appropriate. The time consuming characteristic of the floatation device check may also adversely impact airplane turn-around time thereby mitigating its utilization efficiency. Therefore, both the time consuming and labor intensive nature of the manual airplane inspection process for floatation device check result in increased operational costs.
Currently, life vests can be detected on the airplane by attaching an RFID tag onto the vest. By this method, an RFID reader can detect the plurality of life vests on the airplane, and by counting, can determine that all required vests are on the plane. This does not determine that all vests are properly stowed, as stolen items placed in passengers' baggage or misplaced vests are still detected. Further, numerous signals are received from all the RFID tags attached to all the seats in the “view” of the reader.
Currently, life vest tampering can be detected by placing a frangible RFID tag on the life vest pocket, such that removing the life vest destroys the RFID tag. Again, an RFID reader can detect the life vests on the airplane, and can, by counting, verify that all the required vests are present and not tampered with. However, the stolen vest cannot be detected at all, and the problem of multiple signals remains.
BRIEF DESCRIPTION OF THE INVENTION
In one embodiment, an automated safety device inspection system for a vehicle includes an RFID reader including a transmit portion and a receive portion wherein the reader is physically translatable along a predetermined path, a directional antenna communicatively coupled to the reader wherein the antenna is configured to transmit and receive radio frequency (RF) signals in a direction substantially normal to the path, a relative position indicator configured to determine a relative position of the reader from a starting point, and a controller communicatively coupled to the reader. The controller includes a user interface, a processor communicatively coupled to the user interface, and a database communicatively coupled to the processor wherein the database includes location data of a plurality of safety devices in a plurality of different types of vehicles, the processor is configured to control the transmitted RF signals based on the location data.
In another embodiment, a method for automated location of an object includes traversing a reader in a first direction along a path adjacent the object, transmitting an interrogation signal from the reader in a direction substantially normal to the first direction, transmitting a response signal from the object when the object receives the interrogation signal, and determining a presence of the object, an identification of the object and a location of the object based on the response signal.
In yet another embodiment, an automated inspection system includes a radio frequency identification (RFID) reader including a transmit portion and a receive portion wherein the reader is physically translatable along a predetermined path and wherein the RFID reader is configured to generate radio frequency signals that interrogate an RFID enabled tag such that the tag responds to the interrogation with a tag identification signal. The system also includes a directional antenna communicatively coupled to the reader wherein the antenna is configured to transmit and receive radio frequency (RF) signals in a direction substantially normal to the path and wherein the directional antenna is further configured to generate a narrow beamwidth selected to ensure that the tags are within the field of view of the antenna beam. The system further includes a relative position indicator configured to determine a relative position of the reader from a starting point and a controller communicatively coupled to the reader. The controller includes a user interface, a processor communicatively coupled to the user interface wherein the processor is configured to determine an RFID-enabled tag location based on the relative position of the reader and a received signal strength indicator (RSSI) signal received from the reader, the processor is further configured to determine an RFID-enabled tag location based on the relative position of the reader, and a time difference of arrival (TDOA) signal from the reader, the processor is still further configured to determine an RFID-enabled tag location based on the position-stamps of the plurality of received RF signals, and a database communicatively coupled to the processor, the database including location data of a plurality of safety devices in a plurality of different types of vehicles, the processor configured to control the transmitted RF signals based on the location data.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic plan view of an exemplary fuselage of an aircraft in accordance with an embodiment of the present invention;
FIG. 2 is a schematic view of an exemplary automated floatation device checking system in accordance with an embodiment of the present invention;
FIG. 3 is a schematic view of an exemplary portion of an aircraft interior during a scan using the automated floatation device checking system 200 shown in FIG. 2 ; and
FIG. 4 is a schematic view of another exemplary portion of the aircraft interior during a scan using the automated floatation device checking system shown in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
Many specific details of certain embodiments of the invention are set forth in the following description in order to provide a thorough understanding of such embodiments. One skilled in the art, however, will understand that the present invention may have additional embodiments, or that the present invention may be practiced without several of the details described in the following description.
FIG. 1 is a schematic plan view of an exemplary fuselage of an aircraft 10 in accordance with an embodiment of the present invention. Aircraft 10 includes a plurality of internal equipment arranged in one of a plurality of configurations. For example, passenger seats 12 , galleys 14 , lavatories 16 , and bulkheads 18 may be arranged in configurations designed to accommodate different passenger class areas and service requirements. Passenger seats 12 are generally arranged in a configuration that permits access to an aisle 20 from no more than two or three seats away. In the exemplary embodiment, passenger seats 12 comprise a pair of seats fabricated together to form a seat assembly 22 . Seat assemblies 22 are grouped together in such a manner that aisles 20 and a space accommodating passengers' legs are formed. A pitch of seat assemblies 22 between each row 24 of seat assemblies is dependent on the space selected for accommodating passengers' legs. In various passenger class areas, seats 12 and spacing between seat assemblies 22 may be different. An aircraft configuration details the placement of the interior equipment and in particular the position of seat assemblies 22 . The configuration of the aircraft internal equipment may be changed to accommodate a change in service for the aircraft. Aisles 20 define a path 26 that include a starting point 28 and an ending point 30 .
In the exemplary embodiment, each seat 12 includes a flotation device or life vest (not shown) for use by the passenger seated in seat 12 in a case of an emergency landing in water. Safety and government regulations generally require a check of the presence of a life vest for each seat and an efficiency of each life vest as demonstrated typically by an expiration date associated with each life vest. The life vest is typically stowed under seat 12 or in an armrest associated with seat 12 . As described above, a manual check of each life vest is labor intensive and time consuming. Simply applying a sensor mote such as an RFID-enabled tag to each life vest can identify that one or more life vests are missing or tampered with, but cannot localize the missing or tampered with life vest, still requiring a manual check of at least some of the life vest locations to determine which of the life vests that are missing or tampered with.
FIG. 2 is a schematic view of an exemplary automated floatation device checking system 200 in accordance with an embodiment of the present invention. Automated floatation device checking system, includes a mobile RFID tag reader 202 and a computing system 204 , that are mounted on a cart 206 that can be traversed along path 26 from starting point 28 to ending point 30 , usually by rolling cart 206 on a pair of wheels 208 (only one wheel 208 shown in FIG. 2 ). automated floatation device checking system 200 includes a directional antenna 210 communicatively coupled to RFID tag reader 202 and mounted substantially perpendicularly to path 26 , i.e., perpendicular to aisle 20 , at a first height 212 of a seat underside, where the floatation devices are located. Height 212 is adjustable to position antenna 210 at a second height 214 , of a seat armrest for use with seats in for example, business class where fewer seats in a row and wider seats permit stowing the flotation devices in the seat armrests.
In the exemplary embodiment, cart 206 includes a rotary position transducer 216 coupled proximate wheel 208 or a shaft 218 coupled to wheel 208 . Rotary position transducer 216 is communicatively coupled to computing system 204 to enable a relative position of cart 206 along path 26 to be determined.
In the exemplary embodiment, antenna 210 is a directional antenna such as a horn antenna or a Yagi antenna capable of radiating an RF beam 219 having a predetermined angular beamwidth 220 , of for example, between approximately ten degrees and approximately twenty-five degrees such as approximately seventeen degrees. In an alternative embodiment, antenna 210 is an active directional antenna such as a such as phased-array antenna having a beamwidth that is selectable by changing phase angles of excitation signals fed into individual elements of the active electronically phased array antenna. The beamwidth is selectable based on the configuration of the interior equipment of the aircraft. For example, in one embodiment, a beamwidth is selected based on a configuration that includes three seats in a row of seats, a seat pitch and width of approximately thirty inches, and a standoff distance between antenna 210 and a seat edge of approximately ten inches.
Mobile RFID tag reader 202 and antenna 210 are configured to transmit with a selectable Effective Isotropic Radiated Power (EIRP) to ensure desired signal attenuation/roll-off at a predetermined distance, for example, a distance that approaches link budget limits. In the exemplary embodiment, a distance of approximately one-hundred inches is assumed. During traversing of cart 206 along path 26 , RFID tags associated with floatation devices under seats that are not in the field-of-view (FOV) of reader 202 and antenna 210 are not powered-up and do not enter a tag ready state. Reader 202 interrogates the tags when triggered by computing system 204 . In one embodiment, reader 202 interrogates the tags when antenna 210 is adjacent a row of seats based on an input from rotary position transducer 216 .
During operation, a user selects the seat layout configuration for the aircraft being scanned using a user interface (UT) 222 associated with reader 202 or computing system 204 . In the exemplary embodiment, UT 222 includes a keyboard 224 , a mouse 226 , and a display screen 228 . UT 22 displays the selected seat layout configuration on display 228 . The user is prompted to position cart 206 at a selected starting position 28 for a selected path 26 and the user then indicates that cart 206 is positioned in the position indicated on display 228 . Alternatively, the user positions cart 206 at a selected location in the aircraft and indicates such position on the seat layout configuration on display 228 . The location of cart 206 is displayed on the seat layout configuration display 228 .
Computing system 204 maintains a relative position of cart 206 based on an input from rotary position transducer 216 . The position of cart is be initialized to a defined point within aisle 26 by selecting a corresponding point on the seat layout configuration display 228 . Computing system 204 automatically configures reader 202 to transmit EIRP based on the selected seat layout configuration. Computing system 204 is pre-calibrated for seat layout configurations for a plurality of different aircraft and their respective seating classes.
Upon user initiation computing system 206 triggers RFID reader 220 to interrogate and read the RFID tags coupled to flotation devices at each seat when the cart is at a predetermined seat row or cluster such that the RFID tag reads are synchronized to seat cluster locations. Unique RFID tags read per seat cluster are displayed on the seat layout configuration UI. Upon completion of scanning path 26 computing system 204 displays at least a pass/fail indication for the aircraft. If the flotation device check fails, computing system 204 displays the seat(s) identification having missing, tampered with, or expired floatation device(s).
Although described herein in the context of an RFID-enabled system, system 200 may comprise any number of other sensor motes and readers capable of performing the functions described herein.
FIG. 3 is a schematic view of an exemplary portion of an aircraft interior during a scan using automated floatation device checking system 200 (shown in FIG. 2 ). A plurality of seats 22 being scanned may be treated as a seat cluster 302 . In the exemplary embodiment, three seats 22 across row 24 by three rows comprise a cluster 302 . Seats 22 are identified similarly as seats 22 are identified in an aircraft, for example, seat A being closest to a window of the aircraft, seat B being a middle seat, and seat C being an aisle seat. Each seat 22 includes a distance between a seat axial centerline and path 26 . In the exemplary embodiment, the A seats are positioned a distance D 1 from path 26 , the B seats are positioned a distance D 2 from path 26 , and the C seats are positioned a distance D 3 from path 26 . The distances D 1 , D 2 , and D 3 are predetermined based on the seating configuration of the aircraft interior.
FIG. 4 is a schematic view of another exemplary portion of an aircraft interior during a scan using automated floatation device checking system 200 (shown in FIG. 2 ). In the exemplary embodiment, reader 202 is configured to selectably radiate beam 219 using antenna 210 toward seats 22 adjacent to reader 202 . Because beam 219 is diverging from antenna 210 , a width 402 of beam 219 at distance D 3 is less than a width 404 of beam 219 at distance D 2 , and a width 406 of beam 219 at distance D 1 is less than width 404 . Accordingly, a strength of beam 219 is less at D 1 than at D 2 or D 3 . Conversely the width of beam 219 is greatest at D 1 and least at D 3 . Width 406 is large enough that more than just the RFID tags in the row adjacent to antenna 210 may be interrogated by a signal from reader 202 . Beam 219 is controlled to manage RF beamwidth, link budget, and propagation characteristics to be closer to a Rician fading model than Rayleigh fading model such that a strong dominant component is present and minimize the degree of multi-path signals. This dominant component can for example be the line-of-sight wave extending from antenna 210 . As used herein, a link budget is an accounting of all of the gains and losses from reader 202 , through the medium to the RFID tag. link budget takes into account the attenuation of the transmitted signal due to propagation, as well as the loss, or gain, due to the antenna.
To determine a location of an RFID tag and its associated flotation device several methods are described in detail below. In one embodiment, a position-stamping accounting method is used. By an accurate accounting of position-stamps of each detected RFID tag during a scan a location of each RFID tag can be determined. In another embodiment, a Received Signal Strength Indicator (RSSI) method is used to associate a response from a floatation device RFID tag to an associated seat within a seat cluster and in yet another embodiment, a Time Difference Of Arrival (TDOA) method is used to associate a response from a floatation device RFID tag to an associated seat within a seat cluster.
As illustrated in FIG. 4 , as reader 202 is traversed along path 26 in a direction 408 and is adjacent a row n, it can be seen that due to the geometry of beam 219 , additional RFID tags other than just the tags in row n may be illuminated by beam 219 . For example, an RFID tag associated with the flotation device at seat A in the n+1 row and the n−1 rows may also be illuminated by beam 219 . Similarly, an RFID tag associated with the flotation device at seat B in the n+1 row and the n−1 rows may also be illuminated by beam 219 . Additionally, the RFID tag associated with the flotation device at seat B in the n+1 row may not yet be illuminated while the B seat in the n−1 row may still be illuminated by beam 219 . As reader 202 is traversed in direction 408 along path 26 , each seat in a cluster of seats is illuminated in an order determined by the seating configuration of the seat cluster. Using a position of reader 202 from rotary position transducer 216 each first response received from the RFID tags is position stamped or otherwise accounted. The position-stamped responses are correlated to the seating configuration for the aircraft being scanned to determine which seat 22 each response is associated with. In one embodiment, reader 202 automatically modulates beam 219 dynamically during a scan to ensure each RFID tag is read and identified. Responses from tags are associated with a given seat cluster and it may not be possible to singulate responses from tags associated with a given seat cluster to their relative position within the seat cluster. Accordingly, a set of tags is associated with a particular seat cluster.
In other embodiments, it is assumed that seat closest to reader 202 is associated with a larger value of higher RSSI and a smaller value of Time of Arrival (TOA) when compared to a seat farther away from reader 202 . A Relative location of a seat within a seat cluster is determined by RSSI and TDOA values derived from measured time of arrival (TOA) values respectively. To facilitate determining a location of the RFID tags associated with each seat, reader 202 controls RF beamwidth, link budget, and propagation characteristics to the fidelity level desired to yield discriminating RSSI and TOA signatures from each RFID tag read within the seat cluster being scanned.
In one other embodiment, the RSSI associated with the RFID tags provides a measure of the energy observed at antenna 210 . In the exemplary embodiment, the RSSI is used as a relative measure if signal strength having a value from for example, 0 to 255 when using an 8-bit value. Propagation loss is given by the equation:
L=r n (4π) 2 /λ 2 , where (1)
r represents the distance between RFID reader 202 and an RFID Tag such as, D 1 , D 2 , and D 3 ; λ represents the wavelength at an operating frequency of reader 202 , for example, UHF 915 MHz, which is approximately 12.1 inches; and n, ranges between 2 to 4.
In the exemplary embodiment, the variation of n in equation 1 is based on the radio frequency (RF) environment characteristics, for example, RF characteristics of the airplane interior resonant cavity. Another example is that different wall materials have different reflectivity and absorption characteristics for RF and therefore n is a function of the environment within which RF waves propagate. When one does not have direct line of sight and one has to rely on multipath for the transmitter signal to be detected by the receiver then one would expect the n value to be higher and extent is determined by the type of material the RF waves bounce against.
Due to propagation loss the RSSI at distance D 3 is greater than the RSSI at distance D 2 and the RSSI at distance D 2 is greater than the RSSI at distance D 1 . The RSSI value differential facilitates determining the relative location of Seats A, B, and C for a given row.
In another embodiment, the TOA provides a measure of the distance between RFID reader 202 and the RFID tag. The TOA comprises a round-trip propagation delay between RFID reader 202 and the RFID tag, computation time for the RFID tag to receive and respond to the interrogation command, a transmission duration from RFID reader 202 to the RFID tag plus a transmission duration from the RFID tag to RFID reader 202 . In the exemplary embodiment, the TOA measurements are performed during an access command transmission to a singulated RFID tag. The duration is measured from the time the access command is issued by RFID reader 202 to when reader 202 receives the response from the RFID Tag with the assumption that the computation time and transmission duration are substantially equal for all RFID tags. Accordingly, due to the round-trip propagation delay the TOA at distance D 3 is less than the TOA at distance D 2 and the TOA at distance D 2 is less than the TOA at distance D 1 . The TDOA, determined from measured TOA values, facilitates determining the relative location of Seats A, B, and C for a given row.
The foregoing description of the exemplary embodiments of the invention are described for the purposes of illustration and are not intended to be exhaustive or limiting to the precise embodiments disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be limited not with this detailed description, but rather by the claims appended hereto.
The above-described methods and systems for identifying and locating objects such as aircraft flotation devices are cost-effective and highly reliable. The system permits automatically detecting and identifying each of a plurality of objects. Accordingly, the methods and systems described herein facilitate operation of vehicles including aircraft in a cost-effective and reliable manner.
Exemplary embodiments of systems for identifying aircraft flotation devices are described above in detail. The components of these systems are not limited to the specific embodiments described herein, but rather, components of each system may be utilized independently and separately from other components described herein. Each components of each system can also be used in combination with other component identifying systems.
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.
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Methods and systems for an automated safety device inspection system for a vehicle are provided. The system includes an RFID reader including a transmit portion and a receive portion wherein the reader is physically translatable along a predetermined path, a directional antenna communicatively coupled to the reader wherein the antenna is configured to transmit and receive radio frequency (RF) signals in a direction substantially normal to the path, a relative position indicator configured to determine a relative position of the reader from a starting point, and a controller communicatively coupled to the reader. The controller includes a user interface, a processor communicatively coupled to the user interface, and a database communicatively coupled to the processor wherein the database includes location data of a plurality of safety devices in a plurality of different types of vehicles, the processor is configured to control the transmitted RF signals based on the location data.
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RELATED APPLICATION
This application is a continuation-in-part of parent application Ser. No. 09/158,464 filed Sep. 22, 1998 and issued on Apr. 4, 2000 as U.S. Pat. No. 6,047,104, the entire contents of which are hereby incorporated by reference in this patent specification.
FIELD
This patent specification is in the field of electric machines such as power generators and pertains more specifically to an ability to vary one or both of the mechanical rotation speed of the prime mover and the output frequency of the generator substantially independently of each other, and also to eliminating the need for a torque gear box when using an arrangement in which the mechanical rotation speed and the output frequency are difficult to match, such as when a high RPM prime mover drives a lower output frequency generator.
BACKGROUND
Electric generators have been used for over a century, the principle dating back to Faraday and Fouquet and simply stated as follows: If a wire in a magnetic field is moved relative to the field by a mechanical force (greater than the electromagnetic force), a current in the wire or a voltage across the wire is generated and thus mechanical motion is converted to electric power. To satisfy the various requirements of energy generation standards, different forms of electric generator systems have been devised. All can be said to obey the electromotive principle of Faraday, as later more precisely described by Lenz.
The prevalent type of power generators are AC generators, although DC generators are used in certain applications. There are many configurations of AC generators, the most common being a generator in which the coils that supply the electrical power are stationary and the magnetic field that induces the current therein rotates. The main components of a typical synchronous AC generator are the stator and the rotor. The rotor typically has an even number of poles of alternating polarity. Each pole has a field coil, and the field coils are electrically connected to form a field winding. An exciter feeds DC current into the field winding, and the resulting mmf (magnetomotive force) creates the desired rotating magnetic field. The exciter can be a DC generator driven by the same prime mover (e.g., a hydroturbine, or a steam or gas turbine) as the rotor. The DC current is fed into the rotor field winding via brushes and slip-rings. In a “brushless” exciter, the DC current can be obtained from a separate AC winding placed on a separate rotor connected directly to the main rotor, through a rectifier circuit placed on the rotor and rectifying this AC current.
The stator or armature winding, in which the desired emf (electromotive force) is generated, is typically placed in regularly arranged slots on the stator's inside or outside surface. The stator winding comprises coils arranged such that the coil sides are one pole division apart. For example, for use with a four-pole rotor, they are 90° apart. As the prime mover rotates the rotor, the magnetic flux the field winding on the rotor generates sweeps the armature winding, inducing therein the desired emf. With a four-pole rotor, a full cycle of emf is obtained when the rotor turns through 180 mechanical degrees, which corresponds to 360 electrical degrees. In the more general case of a p-pole generator (where p is a positive integer), rotated mechanically at n RPM, the electrical frequency in Hz is related to the number of poles p and the mechanical rotation speed in RPM as f=pn/120. Conversely, n=120 f/p.
A single phase AC generator has a single armature winding on the stator, but this typically is used only for low power applications because of factors such as mechanical vibration and power pulsations. The most common arrangement for higher power is the three-phase system that produces three voltages, at three terminals that have equal rms values (relative to a fourth, neutral terminal) but phases that are 120° apart.
A synchronous generator typically feeds a power grid (often through a step-up transformer) but can be connected to the grid only when several conditions are satisfied: (a) the frequency of the grid and the generator emf are the same (e.g., for a 60 Hz grid, the generator's rotor turns at 3600 RPM for a 2-pole rotor, 1800 RPM for a 4-pole rotor, etc.); (b) the phase sequences of the generator and grid are the same; (c) the generator's emf is the same as the grid voltage; and (d) there is no phase difference between the generator's emf and the grid voltage. Only when all four conditions are satisfied can the generator be safely connected, or can stay connected, to the grid to feed power thereto.
Because an AC synchronized generator typically links its mechanical rotating speed to line frequency, so that a 2-pole 60 Hz generator would rotate at 3600 RPM and a 2-pole 50 Hz generator at 3000 RPM, it can be difficult to achieve efficient operation of the prime mover, or to change from one output frequency to another, or to operate the prime mover in a way that effectively and efficiently respond to load changes. For example, with the advent of prime mover improvements certain engines can produce very high horsepower if allowed to operate at very high RPM. This can be incompatible with the desired output electrical frequency, and can mean reducing the engine weight and improving its efficiency but having to add on a heavy, torque gear box, which would decrease the overall efficiency and increase maintenance and cost.
Typical known generators are discussed in O. I. Elgerd, et al., Electric Power Engineering , 2 nd Ed., Chapman & Hall, Int'l Thomson Publishing 1998, which is hereby incorporated by reference, and is referred to below by its title.
SUMMARY
A preferred embodiment described below overcomes these and other disadvantages of the known prior art by providing the ability to drive the generator at a convenient mechanical speed while producing another output frequency as desired. Stated differently, the magnetic field the rotor produces can rotate at a speed substantially independent of the rotor's mechanical rotational speed. As a result, the prime mover can rotate the rotor at a speed substantially different from the speed that otherwise would be dictated by the desired output electrical frequency—for example, a high speed turbine can drive the rotor shaft at its own speed and still feed a 60 Hz or a 50 Hz power grid. As another example, the same generator can be efficiently used to feed either a 60 Hz or a 50 Hz power grid, the difference being only in settings of the electronic controls that establish and maintain the rotational speed of the magnetic field the rotor produces, without a need to change the rotor's mechanical rotation speed. As yet another example, a generator that does not feed a power line of a fixed frequency can be efficiently operated at any one of a number of output frequencies without needing to change the prime mover RPM. Moreover, the load conditions can be accounted for by changing the prime mover's speed to match the current load while keeping the electrical frequency constant or changing in a different way. In this manner, the prime mover can be operated at speeds that are efficient for the current load, but the generator's output frequency can stay the same, or can change in a desired way.
As described in the parent patent, such advantages can be achieved by primarily mechanical or primarily electronic controls. In a mainly mechanical implementation, the differential speed required to drive the brushes supplying power to the field winding is determined after the drive speed and desired output frequency are selected. A mainly electronic implementation allows more design freedom, and computer-age electronics and principles enable auto-synchronization for preferable results. Eliminating the transient stabilization cage, used with current synchronized generators, is an important developmental step. Since the stabilization cage is designed for an induction motor rotor system, a slip frequency between the field winding and armature produces a strong back emf if the rotor is running at off-synchronization speed; this, in turn, produces a bucking torque against the non-synchronized motion.
One objective of the systems and methods disclosed herein is to provide an electronic commutating circuit that can synchronize with the power line starting at zero mechanical speed. Another objective is to stabilize a generator without an induction motor cage. A further objective is to easily convert a brushless synchronized generator into a brushless universal generator. Yet another objective is to improve the operation of generators while being able to continue to use most of the basic construction and arrangement of known generators, e.g., rotor and field winding, stator and armature winding, and commutator bars as they exist in known AC generators, such as single phase and three-phase generators. Additional objectives will become apparent from the detailed disclosure set forth below.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1 a , 1 b and 1 c illustrate a typical mechanical carbon brush commutating system and the currents in armature coils produced as the brush moves from one commutator bar to the next.
FIG. 2 illustrates a current switching profile of a commutating bar.
FIGS. 3, 3 a and 3 b are circuit schematics illustrating electronic circuits used in supplying power to commutator bars and thus to the field winding, without needing brushes or slip rings.
FIG. 4 is a block diagram illustrating a typical control circuit for supplying power to commutator bars for rotating the rotor magnetic field at a speed substantially independent of the rotors mechanical rotation speed.
FIG. 4 a is a timing diagram used in explaining ramp voltages controlling field winding currents.
FIG. 5 illustrates a phase-lock circuit for synchronizing a generator with a power grid or some other reference in terms of frequency, phase, emf, and phase sequence.
FIG. 6 illustrates a typical arrangement for electronically controlling the rotation of the rotor's magnetic field substantially independently of the mechanical rotational speed of the rotor.
FIG. 7 illustrates a typical brushless variable speed synchronized generator.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 a illustrates a portion of a typical mechanical brush system that functions as a switch to convert the current flowing direction of one set of armature coils in a AC generator's stator from a positive to a negative direction in the course of relative rotation between a brush and the commutator bars. It also converts adjacent armature coils from negative to positive. As seen in FIG. 1 a , a brush 10 at a positive voltage level makes electrical contact with a commutator bar segment a that is a part of a conventional commutator bar 12 . As a result of this electrical contact, a current (I a ) moves around a coil 14 in the direction indicated in FIG. 1, and in the indicated directions in the other coils that are illustrated and are a part of the same armature winding. For simplicity, a single phase generator is illustrated, but the principles apply to 3-phase generators as well. As seen in FIG. 1 b , when relative motion between the same brush 10 and commutator bars 12 has brought brush 10 in electrical contact with commutator bar segment b, and out of electrical contact with segment a, the direction of current (I b ) in the same armature coil 14 is opposite the direction that current (I a ) had, and the direction of the current in the other coils due to the contact of brush 10 with segment b is as illustrated in FIG. 1 c . FIG. 1 c illustrates the same brush 10 in two different positions relative to commutator bar 12 (assumed at different times during relative motion between the brush and the commutator bars) and the directions of the currents due to electrical contact with segment a and electrical contact with segment b.
FIG. 2 illustrates the time history of a current (I) during the switching of one segment of commutating bar 12 . The contact surface between brush 10 and commutator bar regulates the flow of the current through the brush's relatively high resistivity. A linear time current profile in the commutation time indicated in FIG. 2 is desirable for maintaining a constant current flow for the rest of the armature coils 14 .
FIG. 3 is a detailed circuit schematic of an electronic switching circuit for a 32-segment commutator that can replace a bush arrangement of the type discussed in connection with FIGS. 1 a - 1 c , and FIG. 3 a is an enlargement of the driver for one commutator bar segment. Any suitable low-loss transistor system can be used; the circuit illustrated in FIG. 3 uses for each commutator bar segment a pair of N-type and P-type field effect transistors (F.E.T.). Using a typical commutating bar switching circuit, it is seen in FIG. 3 that the input signal from a functional master-switching computer determines the segment of the commutating bar to be used in the sequence. If a particular segment is selected, and depending on the current directions that need to be switched, either the N-channel or the P-channel F.E.T. receives a ramp signal at the biased gate input.
FIG. 3 a illustrates one of the commutator segment drivers of the circuit shown in FIG. 3 . In response to a control signal 1 _P, a P-channel transistor Q 41 turns on to connect a power supply 30 to an output terminal labeled “ 1 _Commutating Bar,” which is electrically connected to a respective commutator bar segment. Conversely, in response to a control signal 1 _N, N-channel transistor Q 53 turns on to connect the same output terminal “ 1 _commutating Bar” to ground. Capacitors C 61 and C 85 are connected across the F.E.T. Q 41 and Q 53 to pick up the magnetic stored energy (C 61 across the P-channel Q 51 and C 85 across the N-channel Q 53 ). The F.E.T. capacitor C 73 is a stabilizing capacitor that further absorbs transient voltages. Resistors R 41 and R 53 are part of bias and gate control circuits. Source 30 can be an exciter circuit of a known type for supplying DC currents to a field winding.
FIG. 3 b is the equivalent circuit for a squirrel cage armature configuration, discussed in greater detail in connection with a brushless construction generator.
FIG. 4 illustrates in block diagram form a complete digital commutation switching circuit. In FIG. 4, the terms “even commutating bars” and “odd commutating bars” represent alternate commutating bar segments. The even and odd-numbered segments are driven by different signals because, as one commutator bar segment (say an odd one) is being turned on by a ramped gate signal, the previous even commutator bar segment is being turned off by an oppositely phased ramp signal during the same commutator bar time slot. Additionally, pairs of P-channel and N-channel drivers that are 180° apart are turned on and off at the same time; however, because of the complementary nature of these transistors, the gates require oppositely-phased ramps that are referenced to the power supply voltage and ground, respectively.
In the example of FIG. 3, where there are 32 commutator bars, the N-channel F.E.T. Q 53 on the firth commutator bar segment would be turned on at the same time as the P-channel F.E.T. 41 on the 21st segment. During this same time period, the N-channel on fourth segment and the P-channel on the 20 th segment would be turned off. If the number of commutator bar segments is not divisible by 4, then odd and even N and P-channel devices are not paired. For example, with a 22-segment commutator bar, the N-channel on the 5 th segment would be turned on at the same time as the P-channel on the 16th segment.
It should be clear that the term commutator bar segment is used because this is a typical element of a DC generator. While the same structure can be used in the embodiments disclosed here, the pertinent aspect is that a segment is connected electrically to a particular point at the armature winding. As no brushes or slip rings need be used in the disclosed embodiment, the commutating bar segments can be simply terminals to which driver outputs, such as output terminal “1-Commutating Bar,” can be connected electrically through connections that can (but need not) be permanent.
The control circuit illustrated in FIG. 4 generates a frequency by means of a voltage-controlled oscillator (VCO) 16 . If the power generator need not be synchronized to a grid, the output frequency of VCO 16 can be controlled manually, for example by a variable resistor arrangement 16 a . The output of VCO 16 controls up/down counter 18 , which counts up for one pulse from VCO 16 through 256 steps, and then its direction is reversed by a signal from up/down control 20 , to count down 256 steps, this sequence being repeated. If it is desired to operate the power generator synchronized to a power grid (or to some other standard), the up/down counter 18 can be controlled by a signal from a component illustrated in FIG. 5 and discussed below, in which case VCO 16 need not be used and can be omitted from FIG. 4 . The digital output of counter 18 (256 steps up or 256 steps down) is converted to an analog up-ramp or down-ramp signal at a D/A converter 21 , with amplitude control over the analog ramps being provided by a variable resistor arrangement 21 a that can be manually operated or can be controlled through a feedback loop that maintains a desired amplitude level for the ramps from converter 21 . The analog ramps from converter 21 pass through complementary amplifiers 21 b and 21 c and emerge as a positive ramp (ramp+) and a negative ramp (ramp−) respectively. The two ramps are mirror images of each other, and 180° out of phase. The output of amplifier 21 b is a sawtooth waveform and the output of amplifier 21 c is another sawtooth waveform, with one having a positive peak where the other has a negative peak. These ramps are supplied to differential amplifiers 29 a through 29 d , which also receive an input from a power source such as a DC/DC converter 28 through a variable offset control 28 a . A voltage source labeled V in FIG. 4 and serving as a V cc power supply powers the electronics. The function of the offset due to control 28 is described below in connection with FIG. 4 a . The outputs of amplifiers 29 a and 29 b are supplied to a multiplexer 22 as signals labeled “even P” and “even N,” respectively, and the outputs of amplifiers 29 c and 29 d are supplied to a similar multiplexer 24 as signals labeled “odd P” and “Even P.” The multiplexers operate under the control of segment counter 26 to switch their outputs to successive commutator bar segments for each ramp.
Referring to FIG. 4 a , the ramps from amplifiers 29 a through 29 d are illustrated, using the same notation as in FIG. 4 for “even P,” “odd P,” “even N,” and “odd N.” As seen in FIG. 4 a , the respective ramp signals are 180° out-of-phase, and are offset, e.g. through an offset circuit such as 28 a in FIG. 4, to account for the threshold voltages of transistors such as Q 41 and Q 53 in FIG. 3 a . A label in FIG. 4 a identifies the duration of one commutator bar (segment) period, which correspond to the duration of one up ramp or one down ramp. FIG. 4 a also identifies time periods in which two drivers (such as the driver of FIG. 3 a ) for two adjacent commutator bar segments are turned on simultaneously and, therefore, a local coil is shorted.
Referring again to FIG. 4, each of multiplexers 22 and 24 has 32 outputs (in the case of using a 32-segment commutator bar), going into segment drivers 22 a and 22 b , and 24 a and 24 b , respectively. Multiplexer 22 feeds the drivers for the even-numbered commutator bar segments and multiplexer 24 feeds the drivers for the odd-numbered commutator bar segments. Drivers 22 a and 22 b are in fact 16 circuits that are the same as the driver of FIG. 3 a . The outputs from multiplexer 22 going into the box labeled “even P drivers” in fact go to input terminals such as the terminal labeled “ 1 _P” in FIG. 3 a , and the outputs going into a box labeled “even N drivers” in FIG. 4 in fact go to input terminals such as the terminal labeled “ 1 _N” in FIG. 3 a . The output labeled “even commutator bars” in FIG. 4 in fact is the same as the output labeled “ 1 _commutating bar” in FIG. 3 a . Of course, in the case of a 32-segment generator, there are respective driver circuits, and respective input and output signals, for each of 16 even-numbered commutator bar segments. The structure and operation of multiplexer 24 and elements 24 a and 24 b are similar, taking into account the labels in FIGS. 3 a and 4 and the fact that the odd-numbered 16 commutator bar segments are relevant.
FIG. 5 illustrates a phase-lock circuit for self-synchronization, a facility not available or entirely practical in purely mechanical systems. Thiscircuit allows a generator 31 to synchronize with the phase of the line voltage at power line 32 at any shaft speed of generator 31 . For example, in FIG. 5 the phase of the line voltage can be sampled via an optical coupler 34 . When the rotor in generator 31 is rotating and the generator outputs an open circuit voltage, an optical coupler 36 is used to detect the self-generated voltage for phase comparison with the line voltage signal at a phase detector 38 . The output of a voltage-controlled oscillator 40 , controlled by the phase detector 38 through an electronic switch 39 , is fed into up/down counter 18 in FIG. 4, through an opto coupler 42 , replacing the use of the output of VCO 16 in FIG. 4 .
In operation, when switch 39 is in the shown position and phase detector 38 receives inputs from the output of generator 31 and power line 32 (but not from source 32 a ), phase detector 38 produces a signal related to any phase difference between its two inputs, as changed by a signal from a lock error source 38 a that in effect allows a window of permissible phase error. The output of phase detector 38 controls the frequency of VCO 40 , which has built-in limits of upper and lower allowable frequencies. By changing the frequency of VCO 40 in the appropriate direction depending on the signals from phase detector 38 , the control circuit of FIG. 5 speeds up or slows down the rotation of the magnetic field of the rotor in generator 31 toward convergence, within the allowable error window, between the phases of the output of generator 31 and the power line grid 32 . A circuit 43 detects when a phase lock is achieved, and LED indicators 44 light up to indicate this, so that a power switch (not shown) can be closed to connect the output of generator 31 to the power grid, provided the other conditions for that purpose are satisfied (emf, phase sequence, and frequency).
If desired, generator 31 can be phase-synchronized in a similar manner to another source 32 a of a phase signal, in which case no phase input would be used from power line 32 .
If no phase synchronization is needed or desired, switch 39 can be used to the position opposite that shown, to thereby disconnect phase detector 38 from VCO 40 , and manually or otherwise control the output frequency of VCO 40 by a signal from an arrangement 45 that can include a variable resistor.
Start up can be otherwise similar to the procedures currently used for such generators, using an exciter and a feedback circuit to bring up the generator to the appropriate output frequency and emf and appropriate phase sequence (if a multi-phase generator is used). The additional torque in start-up may change the shaft speed, but the phase-lock circuit adjusts the speed to keep it synchronized. Drivers, which can be any mechanical or electrical prime movers, can detect the change in torque and R.P.M. requirements to provide proper mechanical energy.
FIG. 6 illustrates a typical mechanical arrangement that mounts on the generator 31 shaft so that the commutator control circuit described above will rotate with the shaft. Power for the circuit comes from either slip rings or a self-exciter system through a rectifier. The mechanical arrangement comprises a series of discs 60 , which comprise typical electronic fiberglass circuit boards. These discs 60 carry the segment drivers, i.e., circuits such as illustrated in FIG. 3 for the respective segments. An additional disc 62 can carry logic circuitry for the drivers, such as a voltage regulator and driver logic and a photo detector 66 . The discs rotate with the rotor shaft. VCO 40 discussed earlier need not be mounted with the rotating parts, and supplies the frequency information to the rotating parts through a modulated laser 68 whose output is detected by a photodetector, thus providing optical isolation. A VCO 16 can replace VCO 40 in FIG. 6 or power grid voltage serves as a reference frequency for the phase-locked circuit to feed into the system via optical signals. If a self-exciter (see FIG. 7) provides the power necessary to drive the field winding and power for the electronics, this can make the arrangement brushless.
FIG. 7 illustrates a typical brushless variable speed synchronized generator. The mechanical shaft 70 is attached to the main generator field winding (labeled “armature” in FIG. 7) and the exciter armature 74 . The voltage supplied to the field winding 72 is controlled by the exciter coil 76 , which receives its signal from an external control circuit. The generated AC power first feeds through a rectifier circuit 78 , then into the electronic commutating system 80 . The electronic commutating system 80 now controls the switching of individual coils on the field winding. This generates a rotor field, which interacts with a typical armature coil in the stator; the stator coil generates power. A typical brushless configuration according to this patent disclosure comprises the self-excitation power source of an ordinary synchronized generator and a DC brush-type commutating armature working in tandem. The system works as a mechanical electricity converter; using the field, the mechanical energy amplifies the electrical energy, raising it to a much higher generator output level. The mechanical energy also feeds into the exciter; this can be interpreted as a signal for amplification by the main armature system. Although normal feedback control can be used in this arrangement, the field of the exciter system usually uses a DC source. In the disclosure herein, either a DC or a rotating AC source is functional. The AC excitation can work with either a rotating or non-rotating field, but typically, if a rotating AC field is used, it is desirable for the field to rotate in the opposite direction of the mechanical shaft. This would amplify the required energy for the generator at a higher speed. As described before, and due to the back E.M.F., the feedback control of the generator can be different than that of ordinary synchronized generators. Since the feedback control involves the torque/ R.P.M. relationship, it will be individually programmed depending on the particular prime mover type being used.
Brushless Construction
Modern synchronized generators tend to be brushless. The field coil of the AC exciter is supplied by either an outside source or is linked to the output of the generator. An alternate power source for the excitor is a Variac. The exciter armature generates a variable frequency AC power, which is converted into DC power to feed the generator's rotor winding. Since the AC exciter is on the same shaft as the generator's rotor, it eliminates the need for the slip rings that brush type generators require, making the generator brushless. Although the same general type of a brushless arrangement can be used in this patent disclosure, the electronic signal from the outside control system can feed from optical couplers. Further, an AC exciter field can help generate power while the shaft is not rotating. Therefore, the rotating direction of the exciter field should be opposite that of the shaft so that higher voltage can be generated when the shaft eventually starts to move. This results in a higher power generation to feed the main armature windings and assures that the frequency will not decrease to zero at any shaft speed.
The configuration of a preferred variable frequency generator is a brushless configuration. The armature of the brushless synchronized generator is rewound so that the main armature field winding is configured as a DC armature without commutating bars, but with commutator connections. An electronic commutating system communicates the commutating speed difference between the line frequency and the actual shaft R.P.M. of the generator to provide a differential commutating speed. An AC exciter on the same shaft supplies the power for the generator's armature. It is converted into a DC power source, rendering the configuration brushless. The generator's field strength is controlled by the exciter field's strength, and the exciter field can be controlled by either a DC source or an AC source. If an AC source controls the exciter field, preferably this source would provide a rotating field for the excitor. The rotation should be in the opposite direction from that of the mechanical shaft. The input to the electronic commutator for the line frequency and the mechanical shaft R.P.M. should create a phase-locked R.P.M. linked by optical couplers. The actual mechanical configurations can be done so that the electronic commutation is located at the very end of the whole armature shaft, which comprises the exciter armature; the rectifier; the ball bearing; and the main field armature in the mechanical drive. The mechanical R.P.M. speed can be linked to the torque curve by a mechanical prime mover such as a gas turbine; a steam turbine; a hydraulic turbine; a wind turbine; or an internal combustion engine. This link can provide a particularly economical operation for a prime mover. For example, consider the efficiency of a single-shafted gas turbine rotating at 3600 R.P.M., regardless of load conditions. If the gas turbine is driving a traditional synchronized generator, its efficiency will drop off very rapidly under partial load conditions. Since the gas turbine must still run at 3600 R.P.M., it processes the same amount of air. The control method used decreases the working temperature which, in turn, lowers the thermal dynamic efficiency. However, if the gas turbine uses a variable speed generator of the type disclosed in this patent specification, it can operate more productively under partial load conditions at a speed below 3600 RPM. It will process less working fluid (air) and keep the operating temperature as high as possible with consideration for the engine specifications. Thus, the partial load efficiency of the gas turbine is increased through the use of the generator system disclosed here.
As another example, if a diesel engine is the prime mover for a generator, it is known that such an engine works best when its RPM can vary with torque load. However, since a typical prior art system is configured as a diesel generator set, the diesel engine must run at the synchronized speed regardless of its load conditions. This action does not match natural diesel engine operating characteristics. As a result, the diesel engine can only operate in a limited load range; otherwise, it must sacrifice a great deal of its thermal efficiency and require high fuel consumption. However, in an embodiment as disclosed here, the diesel engine RPM can vary with load changes.
An important design criterion here is the use of shunt capacitors across all the transistors as a means of suppressing transients as seen in FIGS. 3, 3 a and 3 b . The armature design has built-in stabilization characteristics for use under pulsating torque conditions, such as when the generator is driven by a piston engine, by means of capacitors linking the bars. The capacitors also serve the dual function of storing the inductive energy from the onset of the armature coil and switching the directions of its current. Unlike the carbon brush system, this system allows the inductive energy to resistively dissipate into heat. Provided that it operates as an isolated power supply without linking to a utility transmission line, the generator can also use an oscillator circuit as a reference instead of a line voltage frequency to operate at desired frequencies. As shown in FIG. 3 b , the capacitors linking the commutating bars stabilize the pulsating torque; at high impulse conditions, this circuit behaves like a squirrel cage induction motor armature.
If the mechanical shaft stands still, the rotating R.P.M. of the electronic brush can approximate the generating frequency of the generator; when this happens, the variable frequency self-synchronization generator becomes an energy converter. It can then be used for purposes such as converting the DC energy source of a battery bank or fuel cell, or using the frequency feeding into the energy converter to generate a different desired frequency for power systems. This method of operation is possible because of the variable frequency synchronization generator design disclosed herein. For special applications, the exciter side of the generator winding can be designed appropriately to match the requirements of the generator energy needs. Regarding a DC to AC converter, an exciter is no longer required; only the DC source can be fed into the electronic commutator with the local oscillator as a reference for line voltage synchronization.
Ramifications
An electronic commutating system with an auto-synchronized phase-locked circuit provides a much easier way to operate a synchronized generator, since the mechanical gear box can be totally eliminated. The phase-locked circuit accelerates the synchronization action of the generator. This provides operational convenience and physically reduces the components required, thereby reducing manufacturing and maintenance costs. Since most generator systems can operate in the reverse manner of a motor system, the principles disclosed here apply to an electric motor design as well.
To drive a motor, today's variable speed drive circuits typically convert an AC source into a DC source, then convert an AC back into a variable frequency. This can make such a system expensive and inefficient. Controls as disclosed above can replace the old system of a variable speed drive, and the combination of a generator frequency converter and a variable speed drive can provide a major improvements in the use of electrical energy for industrial applications. Applications such as pumps, fans, variable speed drive paper machines, and textile operations can all benefit from using the control principles disclosed above, and the most important application of those principles can be electrical cars. Using the disclosure of this patent specification can make electrical cars less expensive, and lead to wider scale use of electric cars more rapidly. The variable speed drive disclosed herein when applied to electrical motor can change the power transmission systems for high speed railroads and electrical boat propulsion systems. Since the differential speed can be fed through fiber optic couplers, the system can be controlled using a single fiber optic wire linked to a computer control systems as a fly-by-wire control system for the future augmentation of control applications.
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A power generator in which the rotor's mechanical rotation speed and the output frequency can be varied substantially independently of each other through electronic controls, to achieve results such as better match between speed and load regime of the primary mover and the generator's output.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of reinforcing fibres and of composites and, in particular, to the deposition of size compositions on glass filaments (or yarns).
2. Description of the Background
The manufacture of reinforcing glass yarns is carried out, in a known way, starting from streams of molten glass flowing out of the orifices of spinnerets. These streams are drawn in the form of continuous filaments, and these filaments are then converged into base yarns, which are then collected.
Before they are converged into the form of yarns, the filaments are coated with a size by passing over a sizer. This deposition is necessary for obtaining the yarns and allows them to be combined with other organic and/or inorganic materials in order to produce composites.
The size firstly acts as a lubricant and protects the yarns from the abrasion that results from high-speed friction between the yarns and various devices during the aforementioned process.
The size may also, especially after it has cured, provide with the aforementioned yarns integrity, i.e. the mutual bonding of the filaments within the yarns. This integrity is especially desired in textile applications in which the yarns are subjected to high mechanical stresses. This is because, if the filaments are poorly held together, they break more easily and disrupt the operation of the textile machinery. What is more, non-integrated yarns are considered to be difficult to handle.
However, the size is also employed in cases in which this integrity is not desired, such as in the case of reinforcing fibres, when a high rate of impregnation with the material to be reinforced is desired. Thus, in the manufacture, for example, of pipes using direct impregnation and filament winding techniques, open yarns in which the filaments are separated from one another are used. Small quantities of size, especially less than 0.5% by weight, are then used.
The size also facilitates the wetting and/or impregnation of the yarns by the materials to be reinforced and helps to create bonds between the said yarns and the said materials. The mechanical properties of the composites obtained from the material and from the yarns depend in particular on the quality of the adhesion of the material to the said yarns and on the ability of the said yarns to be wetted and/or impregnated by the said material.
Most sizes currently used are aqueous sizes which are simple to handle but which must be deposited in large quantities on the filaments in order for them to be effective. Water generally represents more than 90% by weight of these sizes (especially for viscosity reasons), and this means that the yarns have to be dried before they are used, it being possible for water to impair the good adhesion between the yarns and the materials to be reinforced. These drying operations are lengthy and expensive and their effectiveness is not always optimal; they require the use of large-capacity ovens. In addition, when they are carried out during the fibre-forming operation (that is to say before the yarns obtained by converging the filaments have been collected), either on filaments (WO 92/05122) or on yarns (U.S Pat. No. 3,853,605), they require the installation of dryers under each spinneret and, when they are carried out on yarn packages, they run the risk of causing irregular and/or selective migration of the components of the size within the packages (aqueous sizes already have a tendency to be distributed over the yarns in an irregular manner because of their nature) and possibly of causing yarn-coloration or package-distortion phenomena. Moreover, without drying, package distortion is often observed on straight-sided packages (rovings) of fine yarns (i.e. yarns having a “count” or “linear density” of 300-600 tex (g/km) or less) which are coated with aqueous sizes.
It is to remedy these drawbacks that a novel type of size, which is virtually free of solvents and called an anhydrous size, has been developed. Anhydrous sizes are curable and/or crosslinkable solutions which optionally contain organic solvents and/or water in small amounts, generally of less than 5% by weight. They are distinguished advantageously from aqueous sizes by their ability to be distributed in a homogeneous and uniform manner on the surface of the filaments, i.e. forming films of constant thickness, and by the fact that they make any subsequent drying or solvent-removal treatment unnecessary since the small quantities of solvent evaporate during deposition of the size on the filaments and during curing of the size.
Furthermore, the quantities of anhydrous size deposited on the filaments are much less than those of aqueous size; thus, when depositing by means of a sizing roller, a film is formed on the surface of the latter with a thickness not exceeding 15 μm in the case of an anhydrous size instead of a film with a thickness of approximately 90 μm in the case of an aqueous size. Moreover, these small quantities of anhydrous size are deposited on the filaments with a much higher efficiency, possibly reaching 100% when the operating conditions are chosen judiciously, whereas this efficiency is generally about 40 to 75% with aqueous sizes.
Anhydrous sizes fall mainly into three categories.
The first category encompasses UV-curable sizes as described in Patent EP 0,570,283 and comprising, for example:
at least one mono-unsaturated or polyunsaturated monomer and/or oligomer of the polyester acrylate, epoxy acrylate, silicone compound or urethane acrylate type;
at least one photoinitiator, such as benzoin, acetophenone, benzophenone, sulphonylacetophenone and their derivatives, as well as thioxanthones;
if necessary, at least one organic solvent; and, optionally,
additives such as at least a wetting agent, an adhesion promoter, an anti-shrinkage agent, a compatibilizer consisting especially of a silane.
The second family of anhydrous sizes is that of thermally curable and/or crosslinkable sizes, as described in Patent Applications FR 93/14792 and 96/00067.
By way of example, the basic system of these compositions comprises:
an acrylic component and a heat-activated radical-initiating peroxide; or
an epoxy component and an anhydrous constituent which cure by reacting with each other.
The third category of anhydrous sizes forms part of the teaching of Applicant FR 97/05926: these are room-temperature curable sizes, the basic systems of which may contain one or more homopolymerizable monomers and/or at least two copolymerizable monomers which require no external supply of energy. In the case of copolymerization of two monomers, these may be deposited on the filaments in the form of their mixture in solution, immediately after this mixture has been formed, or in the form of a first stable solution containing a first monomer mixture and of a second stable solution containing a second monomer mixture. In the latter variant, the first solution is applied to the filaments and the second is applied subsequently thereto, at the latest while the filaments are being combined into yarns. Be that as it may, the copolymerization generally starts on the filaments as soon as the first and second monomers come into contact with each other and, if necessary, with the required catalyst or catalysts.
The UV-radiation treatments and heat treatments required to cure the sizes of the two first types mentioned above are carried out in one step or in several steps, after the filaments have been converged into yarns. Thus, depending on the envisaged use and on the nature of the yarns, an irradiation or heat pretreatment is sometimes carried out at the time of collecting the yarns in various forms of packages, in order to precure the size, the actual curing of which is carried out in a subsequent radiation or heat treatment when the yarn is unwound for the specific application for which it is intended, namely a textile application or an application of reinforcing organic or inorganic materials. This is because the yarn coated with the as yet uncured composition does not exhibit integrity in the ordinary sense of the term since the sheathed filaments of which the yarn is composed may slip over each other. This yarn can therefore be handled easily and, when it is wound in the form of packages, can be easily extracted from the packages without first having to undergo a treatment to cure the size. The yarn coated with the as yet uncured size composition has, moreover, a very high capability of being wetted and impregnated by materials to be reinforced, it thus being possible for impregnation to take place more rapidly (increase in productivity) and the composites obtained thus having a more homogeneous appearance and having certain of their mechanical properties improved.
However, as described in Patent EP-0,570,283, curing the size by the UV irradiation of a yarn in the form of a package may also have advantages.
With regard to depositing anhydrous sizes on glass filaments, several techniques are known. Thus, according to Application FR 97/05926 already mentioned, this deposition is carried out with the aid of a roller or of a sprayer, with the aid of a device which also acts as a converging means, or by the use of other yarns or filaments coated with the composition and brought into contact with the glass filaments. The latter technique makes reference to the special case of producing composite yarns, consisting of comingled glass filaments and thermoplastic polymer filaments or yarns.
By definition, deposition by spraying is inevitably accompanied by quite a significant amount of loss of size; the recovery of this lost proportion, assuming that it is possible, constitutes a handicap.
The method of deposition by means of a roller or of a device for converging the filaments into yarns consists of taking up size from a somewhat viscous and thick liquid film formed on a smooth surface, having ranges of physical properties, especially surface hardness and surface microporosity, of the type of those of metal surfaces. Starting from the observation that the chemical nature of the anhydrous sizes allows them to be used in ever lower quantities, there is currently a requirement for a process for forming an ever thinner liquid film, of perfectly uniform, controllable and reproducible thickness, on a macroscopicaly smooth surface of the metallic, ceramic or organic type. This is because it may be expected that the take-up of size onto the filaments from such a film results in the filaments being coated with a minimum quantity of size, with an increased deposition efficiency, i.e. a reduction in the amount of size lost, and for this to be achieved under completely controlled conditions. Finally, the aim is, of course, to obtain filaments and yarns, and reinforced materials containing them, which have sufficient, or at least preserved, mechanical properties or even in certain respects novel mechanical properties.
Currently, there is no process making it possible to form, in a controllable manner, a thin film of anhydrous size at the surface, for example, of a metal roller. This is because the immersion of the lower part of the roller in the size solution coupled with the rotation of the roller results in the formation, at the surface of the roller, of a layer whose characteristics can be controlled only to a small extent by varying the viscosity of the solution and the rate of rotation of the roller. The thickness of this layer is too great and irregular, and it is impossible to avoid loss of size, in the device for converging the filaments into yarns or for collecting the yarns, by the size being thrown off the yarns under the effect of the inherent centrifugal force at the high winding rates employed.
Moreover, no system for depositing size on a sizing roller with the aid of a metering pump and of an injection nozzle has yet allowed the formation of the desired film.
Furthermore, the previously-mentioned Patent EP 0,570,283 briefly mentions, in its part describing FIG. 1, a coating device 13 consisting of an applicator provided with a felt moistened with a reactive mixture using a metering pump. This is because the structure of a felt allows it to soak up a solution in a particularly homogeneous manner. However, the take-up of size suggested by the European patent, from the felt onto the glass filaments, is not satisfactory in the context of the technical problem mentioned above since the deposition of the required small quantities of size on the filaments could not be achieved except at the cost of the felt drying out somewhat, a situation which, given the naturally irregular structure of the felt, the surface of which has fibres of varied dimensions, directions or even textures, would run the risk of the glass filaments catching thereon and therefore the risk of the said filaments breaking. Only relatively large amounts of size can thus be deposited in the manner described in the document.
SUMMARY OF THE INVENTION
Consequently, the object of the invention is to provide a process for depositing, on the surface of glass filaments, minimal quantities of size solutions in the form of films of uniform thicknesses and capable of completely coating each filament, in such a way that these thicknesses can be precisely determined by choosing the operating conditions appropriately and can be reproduced with satisfactory reliability.
To this end, the main subject of the invention is a process for manufacturing a continuous yarn, which consists in forming a multiplicity of continuous filaments by the mechanical drawing of a multiplicity of streams of molten thermoplastics flowing out of the orifices of at least one device and which consists in depositing a mixture, in the liquid state, on the surface of at least some of the filaments before they are combined into at least one yarn. The invention lies more particularly in the successive steps consisting:
in continuously impregnating a mat of mechanically held-together fibres, such as a felt or a woven fabric, with the mixture in the liquid state;
in continuously taking up at least some of the said mixture by means of a rotating roller in contact with the said mat; and
using the sizing roller, in depositing the said mixture on the filaments while they are being drawn.
This process opens the door to the uniform deposition, on the filaments, of quantities of size as low as 0.5 to 1% by weight with respect to the weight of the filaments—quantities which are sufficient in the case, especially, of currently known high-performance anhydrous sizes—with a deposition efficiency close to or equal to 100%.
This efficiency together with the homogeneity and reproducibility of the deposit formed on the filaments are achieved by virtue of the possibility, provided by the invention, of forming, on the surface of the sizing roller, a liquid film whose thickness is almost constant and less than 8 μm, preferably between 3 and 5 μm, with remarkable precision and reproducibility.
There is no loss of size to worry about; the gain in productivity is appreciable. For example, in the case of a spinneret producing 800 kg/day of filaments, a sizing rate as low as 160 to 350 g/h will be sufficient.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to the most common method of implementation, all the filaments constituting the yarn are made of glass. However, the invention does not exclude the variant in which the yarn consists of glass filaments and of organic filaments, only the glass filaments being provided with a coating of the said mixture in the liquid state or, on the contrary, the organic filaments also being provided with this coating, or with a coating of a different size, the various size compositions being especially capable of reacting with one another. Organic filaments should be understood to mean thermoplastic polymer filaments, such as polypropylene, polyamide or polyester filaments. These polymer filaments may be sprayed between the already-sized glass filaments, before all these filaments are converged into a yarn, as described in Patent EP 0,599,695.
Given the abovementioned properties of the anhydrous sizes, as well as their excellent capability of wetting the filaments, it is understandable that the liquid mixture to be deposited on the filaments preferably consists of such an anhydrous size, for the definition of which reference is made to the contents of the already-mentioned Patent EP 0,570,283 and of the already-mentioned Applications FR 93/14792, 96/00067 and FR 97/05926.
Furthermore, a double or multiple application of the process of the invention to the filaments while they are being drawn, before they are converged into yarn(s), for the purpose of transferring thereto liquid compositions capable of reacting with one another especially at ambient temperature by the copolymerization of constituents belonging to such separate compositions, also forms part of the invention. In other words, the overall dimensions of the device necessary for implementing the process of the invention in no way prevents two or more of them being combined in order to deposit a double coating or a multiple coating on a single set of filaments, as described in Application FR 97/05926.
The yarns obtained by the process of the invention are generally collected in the form of packages on rotating supports. The yarns obtained according to the invention can be easily unwound from the packages and can be easily handled.
The yarns may also be collected on receiving supports undergoing translational motion. They may in fact be sprayed by a device, which also serves to draw them, onto the collecting surface which is moving transversely to the direction of the sprayed filaments, for the purpose of obtaining a web of intermingled continuous yarns, called a “mat”. The yarns may also be chopped before collecting by a device serving also to draw them.
The yarns obtained according to the invention may thus be in various forms after collection, especially in the form of reels of continuous filaments (rovings, cakes, cops, etc.), or in the form of chopped yarns, and may be converged in the form of braids, tapes, mats or networks, these being in woven or non-woven form, etc. The glass filaments forming these yarns may have a diameter of between 5 and 30 microns and the glass used for producing these filaments may be any glass: E glass, AR (alkali-resistant) glass, etc.
The yarns obtained by a process according to the invention may be advantageously combined with various materials to be reinforced for the purpose of producing composite components which have good mechanical properties. The composites are advantageously obtained by combining at least one of the glass yarns according to the invention with at least one organic and/or inorganic material, the glass content of these composites generally being between 30 and 75% by weight.
Consequently, the subject of the invention is also a product consisting, at least in part, of a yarn obtained by a process as described above. This yarn may or may not have been subjected to a subsequent chopping or weaving treatment, to mechanical spraying or to any other shaping process; optionally, it is mixed with an organic or inorganic material in order to reinforce the latter.
This yarn has a low loss on ignition of at most 3% by weight and even, in many embodiments, at most equal to 1% by weight.
Other features and advantages of the invention will appear in light of the following description of the appended drawings in which:
FIGS. 1 to 3 are diagrammatic representations of three devices for implementing the process of the invention.
These devices comprise a tank 1 of size optionally maintained at a constant temperature, ensuring that the product is well preserved, so as to guarantee that the metering conditions remain stable.
According to FIG. 1, the size is drawn up by a pump 2 of the peristaltic or diaphragm type, which subjects the fluids to particularly low shear stresses.
The quantity drawn up is transferred onto the distributing felt 10 after having passed through a flow meter 3 .
In addition, a microcomputer 4 is connected both to the flow meter 3 and to the pump 2 so as permanently to adapt the volume or the mass of size delivered by the pump 2 depending on the information supplied by the flow meter.
The devices shown in FIGS. 2 and 3 employ, for feeding the felt 10 , a compressed-air supply 5 at the start of the fluid circuit upstream of the tank 1 .
According to FIG. 2, the size coming from the tank 1 passes through a flow meter 3 and a regulating valve 6 , both of these being connected to a microcomputer 4 . This time, the microcomputer 4 uses the information delivered by the flow meter 3 to control, in real time, any correction to the flow rate by means of the regulating valve 6 .
This regulating function is provided, in the simplified device shown in FIG. 3, by a temperature-compensating volumetric regulating valve 7 inserted in the fluid circuit between the pressurized-air supply 5 and the tank 1 . The valve 7 , having an integrated and autonomous regulating function, makes it unnecessary to use an auxiliary management and control device of the computer type.
The felt 10 is fixed to a rigid plate, the inclination of which plate may be modified and the pressure exerted on the roller by which plate may be controlled, for example, by means of a controlled-thrust pneumatic cylinder (not shown).
The felt 10 uniformly fed with size, has the function of distributing the latter over a portion of the surface of the sizing roller 11 which is slightly larger than that with which the web of filaments 12 , delivered by the spinneret 13 and being drawn, comes into contact. The size flows into and is distributed in the inclined felt 10 by the action of gravity. The width of the impregnated area of the felt 10 (i.e. its transverse dimension with respect to a longitudinal direction defined by the flow over the inclined plane), the flow time and the distribution time depend on the viscosity of the size, on the characteristics of the felt (nature of the constituents, density, texture, dimensions) and on the positioning geometry (inclination).
The texture of the felt and the viscosity of the size are intimately connected. For example, a dense felt will be wetted on the surface by a viscous size whereas a liquid size will easily penetrate a not very dense felt and will flow out of it without being distributed over its entire width.
The inclination of the felt also plays an important role in distributing the size by allowing the gravitational forces to have a greater or lesser effect. This makes it possible to adjust the operation and to compensate for any shortcomings in the distribution which are due to a not entirely suitable felt.
The optimum correspondence between the viscosity of the size and the density of the felt is indicated in the table below in the case of a 30° inclination of the felt with respect to the horizontal, a flow length of 6 cm, a distribution width of 6 cm and a cylinder pressure on the coating device of 1 bar:
Viscosity of the size
Density of the felt
at 20° C. (cP)
(g/dm 3 )
<20
200-400
20-50
150-250
50-100
125-175
100-250
100-150
250-400
<100
The nature of the felt has an effect on the quality with which the size is distributed in respect of three criteria associated with the type of fibre employed: the chemical nature of the fibres, their diameter and their homogeneity.
The great majority of the fibres making up the felts are composed of cellulose fibres or wool fibres. Synthetic fibres are also starting to be used, such as polypropylene fibres or polyester fibres.
In the case of size compositions whose constituents are not very polar, polypropylene-type synthetic felts are very suitable and the chemical compatibility is satisfactory. In the case of compositions having a marked polar character (which is the case with many constituent components in sizes), natural felts, of the wool type (which is more hydrophilic), are preferred.
The chemical compatibility of the various materials of the felts may be modified in one direction or another by a suitable chemical treatment of the fibres. However, the interactions with the components of the size (which, because of their monomeric character, are very good solvents) become difficult to control. In most cases, untreated fibres are preferred.
In general, the diameter of the fibres must be as homogeneous as possible in order to make it easier to transfer the size onto the roller. Any heterogeneity in the fibres, in particular the presence of coarse fibres, causes localized differences in thickness of the film of size on the surface of the sizing roller, but these are nevertheless liable to cause drying-induced breakages at the roller. Fibres of small diameter (generally 20 microns) are preferred. In addition, the fibres must be long enough, flexible enough and sufficiently entangled as to avoid any entrainment of entire fibres or breaks at the surface of the roller. The presence of foreign elements at the surface of the roller generally causes breakages whose origin is difficult to determine.
In normal operation, 100% of the size is transferred onto the sizing roller. To achieve such a performance, it is possible to vary different parameters.
In the first place, the pressure exerted by the felt on the roller leads to the formation of compressed area within the felt through which the flow is very greatly reduced. However, the pressure must not be too high so as not to damage the roller or the drive mechanisms.
The rotating roller takes up the size available, the latter being sufficiently compatible with the material of the roller not to cause the phenomenon of dewetting. In addition, the quantity of size is always much less than the roller is capable of taking up.
By way of example, in the case of a 40 mm diameter graphite roller having a felt/roller contact length of 80 mm, the pressure that needs to be exerted is, in most cases, between 0.5 and 3 bar.
Secondly, the speed of rotation of the roller has a certain effect on felt/roller transfer in a few special cases. Thus, when the size has a low viscosity and the surface of the roller is very effectively wetted thereby (generally, in the case of weakly polar sizes) and/or when the final product requires a high loss on ignition, i.e. a large quantity of size, it is useful to increase the speed of rotation of the sizing roller in order to increase the take-up area to be wetted and finally to increase the quantity of size transferred. When a 40 mm diameter graphite roller is used, the rate of rotation of the roller may be varied between 50 and 150 rpm in order to be satisfactory in most cases.
The third and final parameter to be taken into consideration in the quality of felt/roller transfer is that of the chemical nature and of the surface finish of the roller. Moreover, this parameter is incidentally even more significant in respect of the quality of roller/fibre transfer.
Given that the felt/roller and roller/glass-fibre transfer characteristics are intimately related, the best material is currently graphite.
In normal operation, the technique of depositing anhydrous sizes, as described above, allows a deposition efficiency of very close to or equal to 100% to be achieved. With aqueous sizes, this efficiency is generally about 40 to 75%. Given that the cost of the raw materials (in terms of dry matter) are substantially equivalent, the economic advantage of anhydrous sizes deposited using this method is readily apparent.
In addition, from the environmental standpoint, it is advantageous to eliminate one source of waste which is potentially polluting and gives rise to additional costs in order to destroy the effluents generated.
Should effluent be produced (generally in very small quantity) during cleaning, testing or operating under special conditions, and given that all of the waste is of an organic nature, this waste may be easily destroyed by incineration in suitable plants.
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A process for manufacturing a continuous yarn, which entails the steps of:
a) continously impregnating a mat of mechanically held-together fibers with a mixture of anhydrous size in a liquid state;
b) continuosly taking up at least some of the mixture of the anhydrous size by a sizing roller in contact with the mat such that a liquid film having an almost constant thickness of less than 8 μm is formed thereon; and
c) depositing the mixture of the anhydrous size, using the sizing roller, on a surface of at least some of a multiplicity of continuous filaments which are formed by mechanical drawing of at least a multiplicity of streams containing molten glass flowing out of orifices of at least one device.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. patent application Ser. No. 14/533,841 filed on Nov. 5, 2014, which is a continuation-in-part of PCT Patent Application No. PCT/IL2013/050823, filed on Oct. 13, 2013, which claims the priority benefit under 35 U.S.C. §119 of U.S. Provisional Application No. 61/818,611 filed May 2, 2013, the contents of which are hereby incorporated in their entireties by reference.
TECHNOLOGICAL FIELD AND BACKGROUND
[0002] The present disclosure relates to units substantially or entirely made of cardboard that may be used as structural elements in structures and devices such as wheeled devices (e.g. bicycle or tricycle).
[0003] WO11067742 discloses a human-powered land vehicle sufficiently rigid so as to transport a human rider. The vehicle is constructed from pulpably recyclable and shreddably recyclable materials.
GENERAL DESCRIPTION
[0004] The present disclosure provides, by a first of its aspects, a structural unit made from or comprising cardboard as its major component. This means that cardboard constitutes typically at least about 60%, 65%, 70%, 75%, 80%, 85%, 90%, and at times even at least 95% of the total weight of the structure. The unit comprises, as will be illustrated below, low density cardboard layers.
[0005] By a first aspect, the unit of this disclosure comprises reinforcing, elongated members that may be made of cardboard, e.g. may be cardboard cylinders or rods; or may be made of other light materials, such as wood or plastic. The elongated members are then wholly or partially enveloped by portions of the low density cardboard panel formed to be in tight association with said elongated members. Some other portions of the cardboard panel are associated with one another to define a multi-layer cardboard element.
[0006] By a second aspect, the multi-layer cardboard unit comprises a high density cardboard layer. For example, two low density cardboard layers may sandwich a high density cardboard layer. A particular example is a 3-layer structure with two external layers of low density cardboard sandwiching a high density cardboard layer.
[0007] A unit of this disclosure may also combine features of both aspects, namely comprising one or more such elongated members as well as a high density cardboard layer sandwiched between two low density cardboard layers.
[0008] Said elongated members with the associated portions of the cardboard panel jointly form a core-envelope element. The core-envelope element may be situated at and define edges of a multi-layer planar unit. The core-envelope element has usually also a functional significance in reinforcing the structural rigidity in bend, compression and tension resistance disclosure, as will also be explained further below. The structure of the disclosure may constitute a part of a device, such as a wheeled device, e.g. parts of a bicycle or tricycle.
[0009] The disclosure, thus provides, by the first aspect, a substantially planar, cardboard-based unit comprising (i) two or more layers of cardboard that are closely associated, typically adhered, with one another and that may be constituted by a formed low-density cardboard panel, and comprising (ii) two or more integral core-envelope elements, each comprising enveloping portions of the low density cardboard that are tightly associated with corresponding two or more elongated members. For example, the unit may be constituted from a formed cardboard panel that is wrapped about the elongated members, with portions of the panel facing one another are tightly associated with one another, e.g. by an adhesive.
[0010] Provided, by the second aspect of this disclosure, is a unit comprising a high density cardboard panel sandwiched between two layers of low-density cardboard.
[0011] The combination of one or more layers of a high density cardboard, particularly when tightly sandwiched between two layers of low-density cardboard as provided by the second aspect, provides for additional reinforcement, especially against compression or deformation in a direction normal to the plane of the cardboard layers, as compared to such a unit that has a similar layers' structure but devoid of the high density cardboard layer.
[0012] It should be noted that the structural unit may also comprise an external varnish or other coating layer. The reference made herein to a multi-layer structure excludes such layers and focuses on the structural elements of the unit. Thus, for example, a unit with a 3-layer cardboard structure may also comprise additional coating layers.
[0013] Generally, the term “elongated” means that the element has a length dimension that is significantly more prominent than other measurements of the element. Such an element may generally have the structure similar to that of the elongated element disclosed in co-owned PCT application having the publication number WO2014/061012 (hereinafter: “the '012 PCT application”). One or both of the panel portions embracing the elongated member (referred to therein as the “rectangular sub-structure”) is integral with panel portion that forms other parts of the structure.
[0014] The term “cardboard panel” means a planar or substantially planar cardboard piece with a broad surface that is substantially thin as compared to its length and width. The cardboard panel may be a uniform cardboard piece but may also, for example, be made of two or more planar cardboard pieces glued or otherwise adhered together to form a larger cardboard panel that is formed into the unit's different elements.
[0015] The term “formed” (or any of its linguistic variations) means to denote the act of giving form or shape to the cardboard panel, namely forming the panel into a final intended shape in the unit. Such forming comprises, for example, wrapping a portion of the panel over the elongated member to thereby obtain the core-envelope structure of the so-formed elongated element. Such forming may also comprise, in some embodiments, defining voids in said planar element.
[0016] The term “integral” means that the panel portions that are used in the formation of the different elements are all portions of a single, formed panel. Thus, for example, in the case of a panel portion that is enveloping the elongated member, defining two skirts of the panel extending from an apex defined along the elongated member, at least one or both of the skirt portions of the panel extends into other portions of the panel that define one or more other elements of the unit.
[0017] As noted, portions of the panel according to said first aspect are wrapped about two or more elongated members such that the panel comes into tight association with said members to thereby define said elongated, core-envelope elements. The elongated core-envelope element, formed through the association between the elongated member and the enveloping cardboard panel, may impart an increased rigidity, e.g. bend, tension and compression resistance to the cardboard structure, as compared to rigidity and said resistance of a similar cardboard structure that does not include such elongated core-envelope elements. Said elongated core-envelope element may define an edge of a planar multi-layer (e.g. bi-layer) cardboard unit. Typically, two such elongated core-envelope elements define edges of a substantially planar element that extends therebetween.
[0018] The elongated members (which, as noted above, may be made of cardboard, wood or plastic) typically have a rounded shape, e.g. circular cross-section (although at times it may be oval, elliptical, etc.); and accordingly said elongated core-envelope elements are typically rounded, although they may be shaped by the use of appropriate dies into other shapes, e.g. to have a substantially rectangular external cross-sectional shape.
[0019] The disclosure embodies some features, common with those of the '012 PCT application as well as of another PCT application Serial No. PCT/IL2013/050823, the relevant contents of both incorporated herein by reference.
[0020] The cardboard-based unit of the first aspect of this disclosure has a 3- or 4-point bending strength normal to said elongated core-envelope elements that is significantly larger than that of a cardboard structure devoid of such elongated core-envelope elements. The term “significantly larger” means that it is at least two, five and, at times, at least 10-fold larger than that of either the reinforcing members or the regular bi-layer cardboard structure, one without the elongated members. Some explanations and parameters concerning this bend resistance can be found in the '012 PCT application, the contents of which, as noted above, is incorporated herein by reference for the relevant portions thereof.
[0021] The “low density cardboard panel” denotes a cardboard panel comprising (i) at least one low-density layer made of paper, high density paper or cardboard (for ease of reference the term “paper”, will be used hereinafter to refer collectively to paper, high density paper or cardboard) arranged to define a plurality of cells or voids, e.g., formed by corrugated, fluted or otherwise loosely packed paper sheets or strips that define a plurality of voids therebetween, and comprising (ii) one or more liner cardboard sheets lined at one side or both sides of the low-density layers (namely sandwiching the low-density layer between them). Examples of such cardboard panels are such known as “corrugated cardboard”, which consists of a fluted or corrugated paper panel(s) or strip and one or two flat linerboards at one or both (i.e. sandwiching) sides of the fluted or corrugated paper; and may also be such referred to as “honeycomb cardboard”. Such materials are widely used in the manufacture of boxes and shipping containers. The corrugated or honeycomb cardboard panels may be single-walled or multi-walled cardboard panel.
[0022] The term “high density cardboard” denotes a cardboard panel that is substantially uniform throughout its cross-section. A high density cardboard does not have a low-density layer of the kind described above.
[0023] By one embodiment of the first aspect, the cardboard-based unit comprises two first elongated core-envelope elements that are parallel to one to the other, being formed with corresponding parallel elongated members. Such first elongated core-envelope elements define edges of a planar element that extends therebetween. The first elongated core-envelope elements are associated to corresponding first parallel elongated members. Said first elongated members may separate each between a central segment of the original cardboard panel and one of first or second flanking segments that flank the central segment; the flanking segments and the central segment, once a portion of the panel is wrapped over the elongated members, jointly form a two-layer element.
[0024] According to one embodiment, one or more portions of a first face of the first flanking segment are attached to one or more portions (opposite in the formed structure) of the first face of the central segment. By another embodiment, one or more portions of the first face of the first flanking segment and one or more portions of the first face of the second flanking segment are both attached to corresponding portions of the first face of the central segment. According to this embodiment at least two parallel elongated members are associated with the first face of the panel. The structure is typically formed such that opposite edges of the original panel, being the edges at the end of the flanking segments, are brought into proximity with one another. In this manner a closed loop structure (as can best be seen in a cross-section) is formed by the panel, with the first elongated core-envelope elements defining the extreme ends of such a loop.
[0025] By another embodiment, rather than forming a closed loop structure, a cardboard panel is folded into a form generally resembling an “S” shape with oppositely oriented folds. In such a configuration, one or more portions of a first face of the first flanking segment is attached to corresponding one or more portions of the first face of the central segment; while one or more portions of the second face of the central segment is attached to corresponding one or more portions of the second face of the second flanking segment. In this configuration, the elongated members within the first parallel elongated core-envelope elements are associated one with the first face and the other with the second face of the panel.
[0026] By one embodiment such a planar cardboard unit is substantially uniform with a complete cardboard multi-layer structure over the entire surface. In another embodiment, one or more voids are formed in this planar cardboard element, which may have decorative or functional significance, e.g. through cut-outs from the multi-layer cardboard element or through appropriately forming of the original cardboard panel.
[0027] In accordance with one embodiment, the cardboard-based unit comprises one or more integral second elongated, core-envelope elements (formed by a portion of the cardboard panel that is wrapped about an elongated member oriented normal to said first elongated core-envelope elements.
[0028] In accordance with some embodiments, the cardboard-based unit of this disclosure (of both the first and the second aspects) constitutes part of a wheeled device or a land vehicle, such as a bicycle or tricycle.
[0029] Provided by a third aspect this disclosure is a vehicle, such as a tricycle or bicycle comprising a structural unit of the kind described herein. A particular example is a bicycle of the kind known as a “balance bike” or “run bike”, which is a training bicycle, intended primarily for children, having no pedals or drive chain, and where the rider (typically the child) propels itself by pushing the ground with his/her feet. In such a bicycle or tricycle the body may be a structural unit with the characteristics of that of this disclosure. Also, or alternatively, the front wheel steering frame may also be a structural unit with the characteristics of that of this disclosure.
[0030] By one embodiment the fork assembly has a fork with the characteristics of a structural unit according to the first aspect, with or without an additional high density cardboard panel sandwiched between the two low density cardboard panels; and the body has the characteristics of a structural unit according to the second aspect.
[0031] Provided by an embodiment of the invention is a bicycle that comprises (i) a body that extends between a front end and a rear end of the bicycle with a rear wheel that is fitted at the rear end of the body, namely at the end itself or close to it, and (ii) a fork assembly that is pivotally coupled to the body and having a front wheel that is rotationally fitted to said fork. The body and the fork assembly comprise each an element that has the characteristics of the units disclosed herein. The body and the fork assembly are typically constituted entirely out of cardboard and have the characteristics of said units.
[0032] By one embodiment the body comprises a planar body element embodying the characteristics of the unit of the second aspect of this disclosure and the fork assembly comprising an element embodying the characteristics of the unit of the first aspect of this disclosure.
[0033] An exemplary bicycle, e.g. a training bike, has the following characteristics:
[0034] (i) a body that comprises two planar body elements, each defining a vertical plane and are, typically, mirror images of one another and having both a front end and a rear end, the two body elements being attached to one another at their front end portion to define a front body block and diverge from one another towards the rear end to thereby define a body space between them; each of said elements embodying the characteristics of the unit of said second aspect;
[0035] (ii) a rear wheel fitted within the body space and being rotationally coupled to the two panels at a rear end thereof by a horizontal axle that is received within co-axial bushings (typically, but not exclusively, made of plastic) fitted in said panels;
[0036] (iii) a steering assembly comprising a planar fork member embodying the characteristics of the unit of the first aspects and formed by cut-outs to define (1) a fork portion with two stems defining between them a stem space, and (2) a panel opening in a mid-portion of the panel;
[0037] (iv) a vertical pivot-accommodating receptacle formed within said front body block and accommodating a pivot that extends vertically through the panel opening between bushings (typically, but not exclusively, made of plastic) formed at opposite edges of said opening to hinge said fork to said body; and
[0038] (v) a front wheel fitted within the stem space and being rotationally coupled to the two stems by a horizontal axle that is received within co-axial bushings fitted in said stems.
EMBODIMENTS
[0039] Some exemplary embodiments are defined in the numbered paragraphs below. The description of these embodiments is not intended to derogate but rather to add onto the general description above and the detailed description that follows.
1. A unit, comprising
[0041] one or more substantially planar elements comprising two or more layers of low density cardboard that are closely associated with one another, particularly such that are constituted from a formed low density cardboard panel; and two or more integral core-envelope elements that comprises enveloping portions of the low density cardboard that are tightly associated with corresponding two or more elongated members.
2. The unit of embodiment 1, wherein the cardboard layers in said planar elements are attached to one another at portions thereof. 3. The unit of embodiment 1 or 2, wherein said elongated members have a rounded cross-section. 4. The unit of embodiment 3, wherein said elongated members have a circular cross-section. 5. The unit of any one of embodiments 1-4, wherein said elongated members are made of wood, cardboard or plastic. 6. The unit of any one of embodiments 1-5, wherein said cardboard panel comprises (i) at least one low-density layer and (ii) one or more liner cardboard sheets lining at least one side of the at least one low-density layer. 7. The unit of embodiment 6, wherein the low-density cardboard is corrugated cardboard or honeycomb cardboard. 8. The unit of any one of the embodiments 1-7, wherein said elongated core-envelope elements impart an increased rigidity and bend resistance to the cardboard unit. 9. The unit of any one of the embodiments 1-8, wherein said elongated core-envelope elements define edges thereof. 10. The unit of embodiment 9, wherein said edges have a rounded external cross-sectional shape. 11. The unit of any one of embodiments 1-10, wherein two of said elongated core-envelope elements are parallel one to the other. 12. The unit of embodiment 11, wherein the two parallel elongated core-envelope elements define edges of a substantially planar structural element that extends therebetween. 13. The unit of any one of embodiments 1-12, wherein two flanking segments of a panel are folded over the elongated members and are associated with a central segment of the panel that is defined between said elongated members. 14. The unit of embodiment 13, wherein one or more portions of one face of said first flanking segment are attached to one or more portions of the same face of said central segment. 15. The unit of embodiment 13 or 14, wherein the panel has first and second faces and wherein the first face of the two flanking segment are attached to the first face of said central segment. 16. The unit of embodiment 14 or 15, wherein the elongated members are associated with the same face of the panel. 17. The unit of any one of embodiments 13-16, wherein
[0057] the panel has first and second faces,
[0058] the first face of each of the flanking segments is associated with the first face of the central segment, and wherein
[0059] opposite edges of the panel, at the end of said flanking segments, are proximal to one another.
18. The unit of embodiment 13 or 14, wherein
[0061] one or more portions of a face of one flanking segment are attached to corresponding one or more portions on the same face of said central segment, and
[0062] one or more portions of said second flanking segment are attached to corresponding one or more portions of the opposite face of said central segment. 19. The unit of embodiment 18, wherein
[0063] one of the parallel elongated members is associated with one face of the panel, and
[0064] the other of the parallel elongated members is associated with the opposite face of the panel.
20. The unit of any one of the embodiments 1-19, wherein said planar element comprises one or more voids. 21. The unit of any one of embodiments 11-20, comprising one or more integral second core-envelope elements oriented normal to said parallel elongated core-envelope elements. 22. The unit of any one of embodiment 1-21, comprising a high density cardboard panel sandwiched between two layers of low-density cardboard. 23. A structural unit having a planar element that comprises a high density cardboard layer sandwiched between two layers of low-density cardboard. 24. The unit of embodiment 23, wherein the two layers of low density cardboard that sandwich a high layer are formed from a single folded cardboard panel. 25. The unit of embodiment 23 or 24, wherein each layer is adhered to a neighboring layer. 26. The unit of any one of embodiments 23-25, being shaped according to structural requirements by cut-outs in the planar element. 27. The unit of any one of embodiments 1-26, being part of a wheeled device. 28. The unit of embodiment 27, wherein the wheeled device is a bicycle or tricycle. 29. The unit of embodiment 27 or 28, having the following characteristics:
[0075] being a fork of a bicycle or tricycle and configured for coupling with (i) a front wheel and (ii) one or more other parts of the bicycle or tricycle.
30. The unit of embodiment 29, comprising a core-envelope element integral with said planar element and configured as a handlebar of the bicycle or tricycle. 31. The unit of any one of embodiments 1-30, comprising at least one hollow elongated member. 32. The unit of embodiment 31, wherein at least one of the hollow elongated members is cylindrical and accommodates an axle. 33. A land vehicle comprising a structural unit as defined in any one of embodiments 1-32. 34. The land vehicle of embodiment 33, being a bicycle or tricycle. 35. The land vehicle of embodiment 34, being a balance bike. 36. The land vehicle of embodiment 34 or 35, comprising a front-wheel steering unit having the characteristics of a unit of any one of embodiments 1-32. 37. A bicycle comprising a body extending between a front end and a rear end, a fork pivotally coupled to the body, a front wheel fitted to said fork, and a rear wheel fitted at the rear of said body, the body and the fork assembly comprising each an element having the characteristics of the unit of any one of embodiments 1-32. 38. The bicycle of embodiment 37, wherein
[0085] the body comprises a planar body element embodying the characteristics of the unit of any one of embodiments 23-25; and
[0086] the fork assembly comprises an element embodying the characteristics of the unit of any one of embodiments 1-22.
39. A bicycle comprising:
[0088] a body extending between a front end and a rear end, a fork pivotally coupled to the body, a front wheel fitted to said fork and a rear wheel fitted at the rear of said body.
[0089] the body and the fork assembly comprising each an element having the characteristics of the unit of any one of embodiments 1-32.
40. The bicycle of embodiment 39, wherein
[0091] the body comprises a planar body element embodying the characteristics of the unit of any one of embodiments 23-25; and
[0092] the fork assembly comprising an element embodying the characteristics of the unit of any one of embodiments 1-22.
41. A bicycle, comprising:
[0094] a body that comprises two planar body elements, each defining a vertical plane and are, typically, mirror images of one another and having both a front end and a rear end, the two body elements being attached to one another at their front end portion to define a front body block and diverge from one another towards the rear end to thereby define a body space between them; each of said elements embodying the characteristics of the unit of any one of embodiments 23-25;
[0095] a rear wheel fitted within the body space and being rotationally coupled to the two panels at a rear end thereof by a horizontal axle that is received within co-axial bushings fitted in said panels;
[0096] a steering assembly comprising a planar fork member embodying the characteristics of the unit of any one of embodiments 1-22 and formed by cut-outs to define
a fork portion with two stems defining a between them a stem space, and a panel opening in a mid-portion of the panel;
[0099] a vertical fork pivot-accommodating receptacle formed within said front body block and accommodating a pivot that extends vertically through the panel opening between bushings formed at opposite edges of said opening to hinge said fork to said body; and
[0100] a front wheel fitted within the stem space and being rotationally coupled to the two stems by a horizontal axle that is received within co-axial bushings fitted in said stems.
42. The bicycle of embodiment 41, wherein one or more of the bushings, typically all of them, are made of plastic. 43. The bicycle of embodiment 42, being a training bike.
BRIEF DESCRIPTION OF THE DRAWINGS
[0103] In order to better understand the subject matter that is disclosed herein and to exemplify how it may be carried out in practice, embodiments will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:
[0104] FIG. 1A is a schematic representation of the manner of production of a cardboard-based unit according to an embodiment of the disclosure.
[0105] FIGS. 1B and 1C show, respectively, a schematic perspective view and a view from above, of the so formed unit.
[0106] FIGS. 2A is a schematic representation of the manner of production of a cardboard-based unit according to another embodiment of the disclosure.
[0107] FIGS. 2B and 2C show, respectively, a schematic perspective view and a view from above, of the so formed unit.
[0108] FIG. 3A is a schematic illustration of the manner of production of a cardboard-based unit according to a further embodiment of the disclosure.
[0109] FIG. 3B shows a cardboard-based unit according to that embodiment.
[0110] FIG. 3C shows a side vies of the unit of FIG. 3B .
[0111] FIG. 4 shows a front view of a cardboard-based unit according to another embodiment of the disclosure, which similar on overall shape to that of FIG. 3B , with some functional cut-outs.
[0112] FIG. 5A is a front view of a cardboard panel with marked segments to be cut-out prior to forming of the cardboard-based unit according to another embodiment of the disclosure.
[0113] FIG. 5B shows the panel of FIG. 5A with segments cut-out and after positioning of the elongated members.
[0114] FIG. 5C shows a front view of the cardboard-based unit formed from the panel of FIG. 5B .
[0115] FIGS. 6A-6B are schematic representations showing a perspective view and front view, respectively, of a balance bike according to an embodiment of the invention.
[0116] FIGS. 7A-7H are schematic illustrations of steps in the manufacture of the body of a balance bike.
[0117] FIGS. 8A-8H are schematic illustrations of steps in the manufacture of the handlebar and fork assembly.
DETAILED DESCRIPTION OF EMBODIMENTS
[0118] The disclosure will now be illustrated below with reference to a number of embodiments, schematically represented in the attached drawings. In the description below, FIG. 1 (namely 1 A, 1 B and 1 C) relate to one embodiment, and each of FIGS. 2, 3, 4 and 5 relate to different embodiments. The different components of these embodiments are each indicated by a three digit numeral, the first digit given according to the figure in which they appear (for example, in FIGS. 1 the numerals all begin with “1”; whereas in FIGS. 2 with the numeral “2”); while the last two digits are specific for the component. In different figures like components are indicated by a three digit numeral having the same last two digits. By way of example, component 102 in FIGS. 1A and 1B is like (having similar function to) component 202 in FIGS. 2A and 2B . Such like components may not be described each time and the reader is directed to look into the description of the corresponding component in other embodiments.
[0119] It should be noted that for the purpose of illustration, some dimensions were drawn out of proportion. By way of example, in some figures a cardboard panel is shown, from which a cardboard-based unit is produced. The panel is shown to have a thickness that is out of proportion of the thickness of at least some of the actual panel to be used in accordance with the disclosure. The out of proportion thickness is for illustration purposes only as had it been drawn to proportion, it may have been more difficult to view it in the drawings.
[0120] Reference is first being made to FIG. 1A showing a cardboard panel 100 associated with two elongated members 102 , 104 positioned on corresponding parallel lines 106 , 108 , on a first face 140 of panel 100 , equidistant from respective opposite edges 110 , 112 (lines 106 , 108 are imaginary lines that do not exist in the actual panel). Elongated members 102 , 104 , that are parallel to one another, separate between respective flanking portions 114 , 116 and a central portion 118 of the panel.
[0121] In order to form a cardboard-based unit according to an embodiment of the disclosure, panel 100 is folded along lines 106 , 108 , as represented by arrows 106 A, 108 A such that portions thereof 120 , 122 along and flanking lines 106 , 108 wrap around and envelope tightly the elongated members 102 , 104 , such that in the eventually formed unit, as seen in FIGS. 1B and 1C , portions 114 , 116 are tightly associated at their first face, e.g. through use of adhesive, with the first face of portion 118 .
[0122] In the formed unit shown in FIGS. 1B and 1C , two elements can be identified: two parallel, elongated, core-envelope elements 130 , 132 that define edges of the unit with a planar bi-layer element 134 extending therebetween. Also, in this embodiment, panel edges 110 , 112 are brought into close proximity with one another. In this way, the formed cardboard panel defines a closed loop configuration about the two elongated members.
[0123] The elongated members 102 , 104 in this embodiment and those described below have a circular cross-section. In some embodiments they may have other round cross-sections, e.g. elliptical, oval.
[0124] The elongated, core-envelope elements 130 , 132 , as also the other elongated, core-envelope elements in the embodiments described below, have rounded edges which are a result of the forming process. However, through the use of appropriate dies or molds, the edges may be press-formed to have other forms, e.g. rectangular. The cardboard panel may, by one embodiment, be a corrugated or honeycomb cardboard panel. However, the disclosure is not limited to cardboard panels of this type.
[0125] Reference is now being made to FIGS. 2A-2C which illustrates a unit according to another embodiment ( FIGS. 2B and 2C ) and the manner of forming such a unit ( FIG. 2A ). As distinct from the embodiments of FIGS. 1A-1C , according to those of FIGS. 2A-2C the cardboard panel is formed into a shape resembling an “S”, rather than a closed loop.
[0126] In describing the embodiments of FIGS. 2A-2C , in order to facilitate description, reference will be made to two opposite faces of the panel designated as a first face 240 and a second opposite face 242 .
[0127] As can be seen in FIG. 2A , elongated member 202 is associated with first face 240 (positioned along line 206 parallel to edge 210 ) and elongated member 204 (parallel to elongated member 202 ) is associated with the second face 242 (positioned along line 208 parallel to edge 212 ).
[0128] As illustrated in FIG. 2A , lines 206 , 208 define three portions of substantially the same widths, including two flanking portions 214 , 216 , and a central portion 218 . The panel 200 is formed by folding it along line 206 in the direction represented by arrow 206 A and in the opposite direction along line 208 in the direction represented by arrow 208 A. Eventually the so-formed cardboard-based unit, seen in FIGS. 2B-2C has two parallel, elongated, core-envelope elements 230 , 232 at opposite ends of an overall substantially planar 3-layer element 234 .
[0129] In the two embodiments of FIGS. 1A-2C , as previously described, parallel elongated members 102 , 104 and 202 , 204 (corresponding to elongated core-envelope elements 130 , 132 and 230 , 232 ) extend the entire length of the original cardboard panel and hence along the entire length of the formed cardboard-based unit. However, in some embodiments, such members may extend only the partial length, typically the majority of the length of the panel. According to another embodiment, rather than a single elongated member in said elongated, core-envelope element, two or more elongated members, arranged along the same axis, may be comprised within the elongated elements. In other words, the elongated member, in this case, is defined by a number of individual segments that may all be of the same or a different length. Such segments may be positioned such that an end of one is position adjacent an end of another; or such segments may, at times, be spaced apart from one another. The different segments may be made of the same or a different material. While such segments will typically have the same cross-sectional shapes, they may, at times, have different cross-sectional shapes.
[0130] Another cardboard-based unit and the manner in which it is formed are shown in FIGS. 3A-3C , which has a somewhat more complex design than that of the preceding illustrated embodiments.
[0131] Turning now to FIG. 3A , a cardboard panel 300 and three elongated members 302 , 304 , 350 can be seen. Elongated members 302 , 304 are situated parallel to one another and to edges 310 , 312 , along lines 306 , 308 ; and elongated member 350 is positioned parallel to edge 358 , namely, oriented normal to elongated members 302 , 304 . Cardboard panel 300 is cut along lines 306 B, 308 B which extend parallel to edge 358 from respective edges 310 , 312 to respective lines 306 , 308 .
[0132] The flanking portions 314 , 316 defined between lines 306 , 308 and respective cuts 306 B, 308 B are folded in the direction of arrows 306 A, 308 A, in a similar manner to that described with respect to FIG. 1A , to eventually form, in the unit shown in FIG. 3B , a vertical structure 370 with a bi-layer element defined between two parallel, elongated core-envelope elements 330 , 332 at the edges thereof. The top portion 354 of the cardboard panel, defined between lines 352 and edge 358 , is then folded along line 352 and over elongated member 350 in the direction of arrow 352 A to form a transverse elongated, core-envelope element 372 . As can best be seen in FIG. 3C , the cardboard panel portion extending down from element 372 is integral with the central portion of the panel in structure 370 .
[0133] Turning now to FIG. 4 , showing a cardboard-based unit according to another embodiment of the disclosure, having the overall shape as that shown in FIGS. 3B and 3C . As can be seen, the unit in FIG. 4 differs from that of FIG. 3B by having two cut-outs voids 476 , 478 that may be cut-out after forming the unit of FIG. 3B . The unit may serve as a front element of a tricycle in which cut-out 478 accommodates a front wheel of a tricycle, the wheel received through axle holders embedded in the bottom part of element 470 (not shown in this Fig. but will be illustrated further below); while cut-out 478 is articulated to the rear part of a tricycle via a vertical axle receptacle embedded in element 470 (not shown but will be illustrated in FIGS. 5B and 5C ).
[0134] In some distinction from unit of FIG. 4 , the cutouts may also be pre-formed in the panel. This is illustrated in FIG. 5 . The cardboard panel 500 seen in FIG. 5A has an overall rectangular shape, but several pieces thereof, drawn as shadows, are cut out to yield the pre-formed panel shown in FIG. 5B .
[0135] Similar as in the case of FIG. 3A , elongated members 502 , 504 are positioned along parallel, vertical lines 506 , 508 and another elongated member 550 is positioned along line 552 normal to lines 506 , 508 . Short axle receptacles 580 , 582 are placed close to the bottom end of portions 518 A, 518 B, defined at the two sides of the cut-out 578 , which are typically hollow plastic tube segments for receiving respective ends of the axles of the front wheel of a tricycle. Also placed at the cardboard's first face are two vertical segments 584 , 586 , which may be also hollow plastic tubes, and serve for articulation to the main body of a tricycle. The pre-formed panel is then folded about the elongated member in the direction represented by arrows 506 A, 508 A and 552 A and then, after adhering opposite cardboard faces to one another, the cardboard-based unit shown in FIG. 5C is formed.
[0136] Shown in FIGS. 6A-6B is a balance bike 600 having body 602 , fork and handlebar and fork assembly 604 , seat 606 , and front and rear wheels 608 , 610 . The primary material out of which the balance bike 600 is cardboard; main exception include the wheels and some elements to be described below that include the axles, the elongated members, the bushings and the pins.
[0137] As can further be seen in FIGS. 6A-6B , body 602 is composed of two planar body elements 612 , 614 that define each a vertical plane, and are essentially mirror images of one another. Elements 612 , 614 are attached to one another at the front end portion 616 to define a front body block 617 and diverge towards the rear end 618 defining between them a body space 620 , which widens towards the rear end.
[0138] As will further be explained, embedded in front body block 617 is a set of co-axial bushings (not seen in FIGS. 6A-6B but will be described below and illustrated in other Figs.) which accommodate a fork pivot (also to be described below) that provides for rotational engagement between the fork assembly 604 and body 602 , permitting a child rider holding handlebar 622 to steer the front wheel 608 . Fitted within the body space 620 is a stem 624 of seat 606 , which is held in position by pins 626 that cross between the two body elements 612 , 614 and through stem 624 . Wheels 608 , 610 are rotationally coupled to respective fork 605 and rear end 618 of body 602 , through respective axles 628 , 630 .
[0139] The manner in which the body, as well as the fork assembly, is constructed and hence also their constituents will now be described with reference to FIGS. 7A-7H and 8A-8H .
[0140] FIGS. 7A-7H illustrate the manner of construction of body 602 , of which FIGS. 7A-7G illustrate steps for constructing one of body elements 612 , 614 . At a first step, a cardboard panel 700 having a general rectangular shape is provided and a groove 702 is formed at about the midline 704 (represented by a dotted line) to thereby define two portions (A) of substantially the same dimensions. The cardboard panel may, for example, be corrugated or honeycombed cardboard, e.g. of 10-14 mm, 11-13 mm or at times 12 mm thickness.
[0141] A high density cardboard panel 706 , typically a 600 g/m 2 cardboard sheet, having the same dimensions as portions A, shown in FIG. 7B , is provided and a thin layer of glue is spread on both of its faces. Panel 706 is then integrated with panel 700 , which is folded about the midline 704 , to embrace and tightly associate through adherence to panel 706 , as seen in FIG. 7C . This thus brings to the formation of the three-layered structure 710 with two external layers 708 A, 708 B of low density cardboard, e.g. corrugated or honeycombed, and an internal layer of high density cardboard. This three-layered structure is rigid and has load-bearing characteristics of a unit of the second aspect.
[0142] At a next step structure 710 is shaped to the intended body shape to achieve the desired form, as shown in FIG. 7D . Then, as represented in FIG. 7E , the edges of the structure, other than edge 712 which is defined by fold 704 , are then layered with a cardboard or paper strip 714 .
[0143] A horizontal bore 716 is then formed at one end that will become the rear end of the body, and a vertical groove 718 having two peripheral wide portions 720 A, 720 B linked by a narrow portion 722 is formed at the other end, as seen in FIG. 7F . Then, as seen in FIG. 7G , two plastic bushings 724 A, 724 B are fitted into portions 720 A and 720 B, respectively.
[0144] Another of elements 612 , 614 , which is a mirror image to the first element is then prepared by identical steps and the two are attached tom one another at their front end portion to form body 602 with a front body block 617 , with a bore 725 that is defined by bushings 724 A and 724 B, as seen in FIG. 7H . Two plastic bushings 726 , 728 are then fitted into openings 716 ; these plastic bushings being intended to receive axle 630 of rear wheel 610 . At the next step (not shown) two lateral openings are formed in each of elements 612 , 614 to accommodate seat holding pins 626 , 628 .
[0145] Reference is now being made to FIGS. 8A-8H illustrating the manner of production and the structure of the fork assembly 604 .
[0146] These depressions define a central segment 830 and two flanking segments 832 , 834 . Also formed are two short longitudinal grooves 806 , 808 at about midline 810 of the panel; and two lateral grooves at the bottom end of the panel crossing depressions 802 , 804 , having central segments 812 A, 814 A and lateral segments 812 B, 814 B.
[0147] As can be seen in FIG. 8B , longitudinal members that are constituted by rods 816 , 818 are fitted into depressions 802 and 804 , respectively, the rods spanning the entire length of the grooves and having, respective, top portions 816 A and 816 B that project out of the top edge of the panel. Rods 816 , 818 are typically, but not exclusively, made of wood, cardboard or plastic but may also be made of metal and many other materials. As can also be seen, bushing 820 is fitted at the bottom end of groove 806 and bushing 822 is fitted into groove 808 . Furthermore, bushings 824 and 826 are fitted into the two central groove segments 812 A and 814 A, respectively. Rods 816 , 818 and bushings 820 , 822 , 824 and 826 are typically secured in position through the use of an adhesive.
[0148] At the next step, seen in FIG. 8C , a high density cardboard panel, which may have similar characteristics to the high density cardboard described above with regard to the body, is then formed to have the shape matching that of the panel's central segment 830 . The high density cardboard panel is then attached to the central segment 830 , typically through application of an adhesive.
[0149] The two lateral segments 832 , 834 are then folded in the direction of arrows X 1 and X 2 to form the structure 840 , seen in FIG. 8D , in which the lateral edges of segments 832 , 834 are associated with one another at the midline 810 to thereby define a three-layered structure with external low density cardboard layers. As can also be seen, after such folding, groove segments 812 A, 813 B jointly define a bore 842 ; a mirror-image opening, of course, also exists at the other end (not seen in this Figure).
[0150] At the next step, rectangular section 848 is cut out from a mid-portion of structure 840 to define an opening 848 A and an elongated section 850 with a curved upper end is cut from a bottom portion of structure 840 to define a wheel space 850 A, to thereby form the fork unit 605 , seen in FIG. 8E .
[0151] Visible in FIG. 8E is also bore 846 , defined by bushing 826 which is revealed by the cut out of portion 848 and is coaxial with bore 842 . Cut out of portion 850 reveals bore 854 defined by bushing 822 which is coaxial with bore 852 defined by groove 806 (which accommodates at its bottom portion bushing 820 ). Bushings 824 and 826 within bores 842 and 846 , respectively, are intended to accommodate pivot 630 . Bushings 820 and 822 within respective bores 852 and 854 are intended to accommodate axle 856 , as seen in FIG. 8 , to thereby couple the body and the fork in a pivotal manner to enable for steering, as described above.
[0152] Handlebar 622 is seen in FIG. 8G and includes a cardboard cylinder 858 formed with three bores 860 , 862 , 864 , the latter accommodating pin 866 . The bore and the pin are positioned and dimensioned such that bores 860 and 862 can accommodate projections 816 A and 818 A of rods 816 and 818 , respectively, while the pin fits into bore 852 . The length of pin 866 is such that once inserted into bore 852 , it will fit into the space above bushing 820 . By combining the handlebar with the fork, assembly 604 is formed, seen in FIG. 8H .
[0153] By inserting body block 617 into opening 848 A and then inserting pivot 630 through bore 852 to pass through the bore 725 in body block 617 , the body 602 becomes pivotally coupled to assembly 604 . The front wheel 608 may then be fitted into the wheel space 850 A and rotationally coupled to the fork through axle 630 .
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The present disclosure provides a cardboard-based unit, structural elements comprising said unit and land-vehicles comprising said units and structural elements.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a spindle apparatus for winding fibers and, more particularly, to a spindle apparatus of the type that is directly coupled to and driven by an electric motor. Still more particularly, the invention is concerned with a fiber winding spindle apparatus directly driven by an electric motor, which is improved to prevent lifting of rotary parts and suppress vertical oscillation of the rotary parts.
2. Description of the Prior Art
Japanese Patent Examined Publication No. 54-32864 and U.S. Pat. No. 1,840,642 disclose, respectively, a spindle apparatus in which a plurality of spindles are directly driven by independent electric motors, in contrast to conventional apparatus in which the spindles are driven by a motor through tapes. The direct-drive type apparatus is advantageous in that no substantial radial load is applied to each spindle bearing as compared with the tape-driven type apparatus in which the spindle bearings are radially loaded due to tension in the driving tapes. In addition, the direct-drive type apparatus suffers from reduced fluctuation in the rotational speed, so that a high fiber-winding speed can be attained.
Current spindle apparatus for winding fibers are required to operate a high speed of from 15,000 to 30,000 rpm or higher. With the conventional tape-driven type apparatus, it is extremely difficult to attain such a high operation speed because, at such a high operation speed, the driving tapes tend to slip on the surface of the spindle wharve. In addition, a difference in the operation speed tends to be caused between different spindles, so that the spindle apparatus as a whole cannot operate satisfactorily. The tape-driven type apparatus also tends to exhibit precessions of spindles due to large radial load applied to the spindle, with the result that the bearings are worn down rapidly and heat is generated in the bearings. In consequence, the life of the spindle apparatus is shortened and the levels of noise and vibration are increased during operation of the spindle apparatus.
In the prior art direct-drive type spinde apparatus, the rotary portions of the apparatus are allowed to freely move upwards to certain heights. Therefore, the rotary portions may oscillate vertically when the rotational speed of the spindle apparatus is increased or when any unbalance of rotating mass is caused due to unbalanced winding of fibers. The sole factor which can suppress the vertical oscillation of the rotary parts is the weight of the rotary parts. Therefore, once the vertical oscillation of the rotary parts has taken place, the insert bearing, particularly the pivot bearing of the foot step in the lower portion of the apparatus, tends to be damaged, resulting in a shortened life of the spindle apparatus.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a direct-drive type spindle apparatus which is improved to suppress the tendency for the rotary parts to oscillate vertically to thereby ensure a smooth and stable operation of the spindle apparatus.
According to the present invention, there is provided a spindle apparatus of the type that is directly driven by an electric motor, comprising: a blade rotatably supported by an insert bearing; a cylindrical wharve having an upper end fixed to the blade and a lower end which opens downward; an electric motor having a rotor fixed to a lower portion of the outer peripheral surface of the wharve and rotatable about a vertical axis and a stator carrying a stator winding and facing the rotor across an air gap. The stator is adapted to be excited by an electric current supplied to the stator winding to cause the rotor to rotate about the vertical axis. The apparatus further includes a thrust generating means including a pair of thrusting members which are magnetically coupled to each other, one of the thrusting members being fixed to a rotary part of the spindle apparatus while the other is fixed to a stationary part of the spindle apparatus so that the thrusting members magnetically interact with each other to apply a downward thrust force to the blade.
In general, a spindle apparatus employing an insert-type bearing is provided with a suitable mechanical stop which prevents the spindle from upwardly coming off the bearing. Unfortunately, however, this stop is ineffective to prevent such a small lift on the order of from 1 to 2 mm or less is encountered with the spindle apparatus of the type to which the present invention pertains.
According to the present invention, the thrust generating means generates a downward thrust force to urge the rotary parts downwards so as to fix the rotary parts with respect to the vertically immovable part, to thereby prevent undesirable lift of the rotary parts without aid of any contacting member.
Thus, then spindle apparatus of the present invention can operate in quite a stable manner over a wide range of operational speed because the lift of the rotary parts and, hence, the vertical oscillation of the rotary parts are suppressed.
The above and other objects, features and advantages of the present invention will become more clear from the following description of the preferred embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of an embodiment of the spindle apparatus in accordance with the present invention;
FIG. 2 is a fragmentary sectional view of the embodiment shown in FIG. 1; and
FIGS. 3, 4, 5, 6 and 7 are fragmentary sectional views of other embodiments.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of the direct-drive type spindle apparatus of the present invention will be described with reference to FIGS. 1 and 2. The first embodiment of the spindle apparatus has an insert bearing 1, a bolster 2 which is fixed to a stationary portion (not shown) of the apparatus and receiving the insert bearing 1, and a blade 3 rotatably supported by the insert bearing 1.
Although not shown in detail, a bobbin is adapted to be secured to an upper portion of the blade 3. The arrangement including the insert bearing 1, the bolster 2 and the blade 3 is well known, so that detailed description thereof is omitted. The insert bearing 1 is constituted by a combination of a suitable damping device and a spring device and receives the lower half portion of the blade 3 which extends vertically. More specifically, the blade 3 is supported at its lower end by a pivot bearing structure provided by a foot step 20 and at its intermediate portion by a radial bearing which is provided in an upper portion of the insert bearing 1. The foot step 20 is constituted by, for example, a spiral leaf spring provided in the bolster 2 and resiliently supports the blade 3 with suitable levels of spring constant and damping characteristic. According to this arrangement, the weight applied to the blade 3 is borne by the foot step in the insert bearing 1 while lateral oscillation of the blades 3 is suppressed by the radial bearing which is provided in the insert bearing 1.
The spindle apparatus further has a spindle wharve 4 which is fixed to the blade 3 and opens downward. An electric motor for directly driving the spindle apparatus has a rotor 5 secured to the outer peripheral surface of a thin-walled cylindrical lower end portion of the wharve 4. The rotor 5 has a laminated core and a secondary winding which is, for example, a cage-type winding provided on the core and having a lower end ring 5a. The electric motor also has a stator 6 which surrounds the rotor 5 with an air gap G of a predetermined size left therebetween. The stator 6 has a laminated core and a stator winding thereon. A reference numeral 7 designates a motor housing to which the stator 6 is fixed. The motor housing 7 is fixed at its lower end to the upper end of the bolster 2. A cover 8 is fixed to the upper end of the housing 7. The arrangement may be such that the cover 8 is divided into a plurality of sections which are inserted in a labyrinth-like manner into grooves formed in the wharve 4. An axial clearance is left also in such an arrangement in order to allow the rotary parts to move up and down.
This embodiment is characterized in that the electric motor is so designed and constructed that the axial center of the rotor 5 is positioned above the level of the axial center of the stator 6 so that an electromagnetic attracting force is produced so as to thrust the rotor 5 downward during operation of the motor. Thus, in this embodiment, the tendency for the rotary parts including the blade 3 to be lifted is suppressed by the downward thrust.
A detailed description will be made of the principle of this operation with specific reference to FIG. 2.
Referring to FIG. 2, the axial length of the rotor 5 of the electric motor is represented by L. In this embodiment, the stator 6 of the electric motor also has the same axial length L as the rotor 5, although different axial lengths may be employed. The axial center P of the rotor 5 of the electric motor is upwardly offset from the axial center Q of the stator 6 by a distance e. The diameter of the air gap of the electric motor and the magnetic flux density in the air gap are represented by D and B, respectively. The downward electromagnetic attracting force, i.e.,the downward thrust F, produced by the interaction between the stator 6 and the rotor 5 and acting on the rotor 5, is expressed by the following formula (1): ##EQU1##
From this equation, it will be seen that the magnetic flux density B increases as the amount e of offset increases. Therefore, when the amount e of offset is within a small range as compared with the axial length L of the rotor 5, the downard thrust force F varies in proportion to biquadrate of the offset amount e. Conversely, when the offset amount e is determined to be too lage with respect to the axial length L, the magnetic flux density B in the air gap is increased so that exciting current in the electric motor is increased with the result that the performance of the electric motor is impaired. In this embodiment, therefore, the offset amount e is determined such that the ratio e/L ranges between 5 and 20%.
From the view point of various characteristics of the apparatus, it is considered to be advantageous to design the apparatus such that the radial bearing 21 in the upper portion of the insert bearing 1 is received in the thin-walled cylindrical lower end portion of the wharve 4 to which the rotor 5 of the electric motor is fixed.
The direct-drive type spindle apparatus of the described embodiment starts to operate when electric power is supplied to the electric motor. In the case where the electric motor is an induction motor, the power supply is commenced when a predetermined A.C. power supply is connected to the stator winding of the electric motor. The rotor 5 and, hence, the wharve 4 and the blade 3 connected to the rotor 5 start to rotate. At the same time, an electromagnetic downward thrust is produced in accordance with the amount e of offset, so that the rotor 5 is pulled downward.
As explained before, the rotary parts tend to be lifted due to various reasons such as unbalance of the masses of the rotary parts and mass unbalance which may be caused by unbalanced winding of the fiber. Such a moment, however, is effectively cancelled by the electromagnetic downward thrust force which acts on the rotor 5, so that the tendency for the rotary parts to be lifted is effectively suppressed. Thus, the described embodiment of the spindle apparatus can stably operate over a wide range of operating condition.
The axial offset of the rotor 5 with respect to the stator 6 contributes to a reduction in the axial length of the wharve 4. This in turn contributes to a reduction in the axial length of the rotary parts and serves to increase the resonance frequency of the rotary parts.
Thus, the described embodiment ensures that the direct-drive type spindle apparatus can operate highly accurately and stably over a wide range of operating condition.
Another embodiment of the invention will be described with reference to FIG. 3. In contrast to the embodiment of FIG. 1 in which the lifting tendency of the rotary parts is prevented by the axial offset of the rotor 5, the embodiment shown in FIG. 3 employs a different arrangement for generating the downward axial thrust. Namely, in this embodiment, the outer peripheral surface of the rotor 5 and the inner peripheral surface of the stator 6 are so shaped that the diameter of the air gap G formed therebetween is greater at the upper end than at the lower end. In other words, the air gap G has a frusto-conical form which diverges upwardly. In operation, the lifting of the rotary parts including the rotor 5 is suppressed by an axial component F v of the magnetic attracting force F which acts between the rotor 5 and the stator 6, thereby suppressing vertical oscillation of the rotary part. A symbol F h represents the horizontal component of the electromagnetic attracting force F.
FIG. 4 shows a further embodiment in which a pair of attracting members 9a and 9b are provided on the top wall of the interior of the opening of the wharve 4 and the upper end of the insert bearing 1 so as to oppose each other across an air gap g. Thus, one 9a of the attracting members is fixed to a rotary part of the apparatus, while the other attracting member 9b is fixed to a stationary part of the apparatus. The attracting members 9a and 9b may be annular permanent magnets of opposite polarities made froma rare earth metal, or may be a combination of a permanent magnet and a member made from a ferromagnetic material. With this arrangement, it is possible to downwardly attract the rotary part towards the stationary part directly and in a non-contacting manner, so that vertical oscillation of the rotary part is effectively suppressed also in this embodiment.
FIG. 5 shows a still further embodiment which employs a magnetic disk 10 which has a tapered outer peripheral surface 10a confronting the inner peripheral surface of the upper coil end 6a of the stator 6 and having a greater diameter at its upper end than at its lower end. The magnetic disk 10 is secured to the outer peripheral surface of the wharve 4. The coil end 6a of the stator 6 has a frusto-conical inner peripheral surface which diverges upwardly, and the magnetic disk 10 is secured to the portion of the wharve 4 above the rotor 5 of the electric motor such that an air gap of a suitable size is formed between the tapered outer peripheral surface 10a of the magnetic disk 10 and the tapered inner peripheral surface of the upper coil end 6a of the stator 6. In operation, the electric current flowing through the coil end 6a produces a magnetic flux which interacts with the magnetic disk 10. In consequence, force is generated to act on the tapered outer peripheral surface of the magnetic disk 10 in such a direction as to attract the magnetic disk 10 towards the coil end 6a. Since the surface 10a is tapered, the force acting thereon has a downward component which acts to attract the rotary parts downward. In consequence, the vertical oscillation of the rotary part is prevented also in this embodiment.
The magnetic disc 10 used in the embodiment of FIG. 5 as the thrust generating means can serve also as a balance ring which compensates for any mass unbalance of the rotary parts.
Further embodiments of the invention will be described with reference to FIGS. 6 and 7. These embodiments employ ferromagnetic hollow members 11 and 12 which are each mounted on a stationary part of the apparatus, i.e., on the upper portion of the bolster 2, in such a manner as to oppose the inner peripheral surface of an end ring 5a of the rotor 5.
More specifically, in the embodiment shown in FIG. 6, the hollow member 11 has a cylindrical form and is sandwiched between the insert bearing 1 and an upper part of the bolster 2. The hollow member 11 has an upper end portion which is thick-walled so as to extend radially outwardly in a flange-like form. The upper portion of the outer peripheral surface of the thick-walled portion of the member 11 faces a lower portion of the inner peripheral surface of the end ring 5a with an air gap g 1 of a predetermined size left therebetween. Thus, the hollow member 11 is partially received in the end ring 5a with the lower portion of the member 11 exposed below the end ring 5a. In operation, the electric current flowing through the coil end 5a produces a magnetic flux which interacts with the hollow member 11 so as to attract the hollow member 11, thereby suppressing vertical oscillation of the rotary part.
Referring now to FIG. 7, a downwardly diverging frusto-conical air gap g 2 is formed between the upper portion of the outer peripheral surface of the hollow member 12 and the lower portion of the inner peripheral surface of the end ring 5a. With this arrangement, a downward component of the magnetic attracting force acting between the coil end 5a and the hollow member 12 serves to effectively suppress the vertical oscillation of the rotary part. Although the hollow members 11 and 12 in the embodiments of FIGS. 6 and 7 are independent from the insert bearing 1, this is only illustrative and these hollow members may be provided integrally with the insert bearings 1 in the respective embodiments. Namely, an equivalent effect is produced when the hollow members 11 and 12 are substituted by flange-like portions formed on the insert bearings in the respective embodiments.
As will be understood from the foregoing description, according to the present invention, the undesirable vertical oscillation of rotary parts of a direct-drive spindle apparatus can be effectively prevented by the thrust generating means which can downwardly bias the rotary part without making any mechanical contact therewith. This arrangement also prevents the applications of abnormal vibratory load which may otherwise be applied to the pivot bearing structure of the foot step in the insert bearing and other parts, thereby eliminating damage and rapid wear of these parts, thus ensuring a long life of the bearing in the direct-drive type spindle apparatus of the kind described. In addition, the spindle apparatus of the invention can operate stably and smoothly by virtue of the elimination of vertical oscillation.
Although different embodiments having different constructions of thrust generating means have been described, it is to be understood that the spindle apparatus of the present invention can employ a combination of two or more of these thrust generating means. Obviously, the magnitude of the downward thrust force to be generated by the thrust generating means and characteristics of insert bearing and other parts of the apparatus can be freely selected in accordance with conditions of operation of the spindle apparatus.
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A spindle apparatus for winding fibers has a spindle which is directly fixed to a rotor of an electric motor. One of a pair of magnetically-coupled thrusting members is fixed to a rotary part of the apparatus, while the other of the thrusting members is fixed to a stationary part of the apparatus, so that a downward thrusting force is applied to the spindle to prevent lift of the spindle during rotation thereof.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part application of U.S. application Ser. No. 13/515,623 filed Jul. 11, 2012, which is a national entry of International Application No. PCT/KR2010/008090, filed on Nov. 16, 2010, which claims a priority to and benefits of Korean Patent Application No. 10-2009-0123684 filed on Dec. 14, 2009, the contents of which are incorporated herein by reference in their entireties.
TECHNICAL FIELD
The present invention relates to a casting belt used for manufacturing an optical film by means of a solvent casting process, in more detail, a casting belt for producing a transcendental wide width film which is used to produce a film in a gel state by casting a dope when manufacturing a film that is used for a polarizer of liquid crystal displays or optical compensation films.
BACKGROUND ART
Cellulose acylate films have high transparency and mechanical properties, and also have dimensional stability that is little dependent on humidity and temperature. Therefore, they are widely used as supports of optical materials requiring those features. In general, the cellulose acylate films are manufactured by casting a dope made by melting a solvent with polymer onto a continuous support.
The casting method can be largely divided into belt casting and drum casting in accordance with the types of continuous supports. The belt casting is a method that casts a dope on a belt, dries and separates a solvent, and conveys a film to the next process, while the drum casting is a method that casts a dope on a drum, separates it without drying, and conveys a film to the next process.
In general, the belt casting can manufacture a variety of films because it can control dry conditions of films, while the drum casting can be used for mass production, because it can perform high-speed casting. Both of the methods should accurately machine the surfaces of the drum and the belts, which are continuous supports, to implement a clean surface required for liquid crystal displays.
It is required to accurately polish the surfaces of both the belt and drum in order to accurately machine the surface of the continuous supports. The belt is manufactured by grinding and polishing a belt made of stainless steel while the drum is manufactured by plating nickel and hard chrome on a drum made of carbon steel and polishing it.
Although it is not a problem in the drum, referring to FIG. 1 , it is required for the belt to forming a joint 11 connecting both ends of the belt to achieve a continuous support. Welding is widely used to form the joint, and TIG welding and laser welding are commonly used. The welding may be performed before polishing, and may be performed after polishing. The welded portion should be polished to prevent a problem in manufacturing a film, because the welded portion may remain on the belt after the welding. However, it is impossible to completely remove the welded portion and it is possible to see the welded portion with naked eyes. Therefore, some products are used with the welded portion cut off, when a polarizer or an optical compensation film is manufactured by using produced cellulose acylate.
Recently, the size of liquid crystal displays gradually increases, and accordingly, the width of polarizers and optical compensation films increases. Therefore, it needs to increase the width of cellulose acylate to come up with the increase in width and to increase yield in manufacturing the polarizers and optical compensation films.
Since a drum having a width of 2030 mm or more can be manufactured by technologies that have been developed at the present time, a wide film can be manufactured, whereas it is known that a belt having a width of maximum 2030 mm can be manufactured. Therefore, two belts can be longitudinally welded to achieve a wide belt having a width over 2030 mm; however, a joint is formed at the center longitudinally between two belts by welding, such that the central joint is imprinted on a manufactured film and the film cannot be used itself.
The dope casted on the belt is separated and manufactured in a film by a tender and a drier. The film contacts in the width direction from casting to separating, such that necessary extension is performed by the tender. The dimensions of the film are not largely changed in the drying process using the drier. In general, a trimming process that cuts off both ends of the film is performed to smoothly convey the film and keep the properties of the entire film, and the trimming process is performed at one to two times after the casting process, the tender process, and the drying process.
Therefore, when a belt having a width of 2030 mm is used, the width of an available film is 2030 mm or less. Considering stability, extension in the tender, and cutting-off of both ends of the film in the substantial casting, the available maximum width is 1800 mm, such that it is difficult to manufacture a film according to the increase in width.
SUMMARY OF THE INVENTION
The present invention provides a casting belt for producing a transcendental wide width film which makes it possible to manufacture a transcendental wide width film without imprinting a welded portion on a film in manufacturing the film.
The present invention provides a casting belt for producing a transcendental wide width film which makes it possible to increase quality of a welded portion by using a jig for transverse welding with laser.
The present invention provides a casting belt where a polymer solvent is casted to form a gel-state film in manufacturing an optical film by means of a solvent casting process, wherein the casting belt 100 includes transverse welded portions 111 formed in the transverse direction of the casting belt 100 to connect adjacent casting belt sections 110 such that the adjacent casting belt sections are longitudinally connected without welded portions longitudinally formed, the thickness t w of the transverse welded portions is 0.95 t b ≦t w ≦1.05 t b when the thickness of the casting belt sections is t b , and the size of pin holes formed in the transverse welded portions 111 is 20˜50 μm and the depth is within 50 μm.
In the present invention, the width W w of the transverse welded portions 111 maybe within 2 mm, the transverse welded portions 111 may make an angle of 20° with the transverse cross-section of the casting belt 100 , and the width of the casting belt 100 maybe 2000 mm or more.
According to the present invention, it is possible to manufacture a wide film having a width of 2000 mm or more without imprinting welded portions, because casting belt sections that are longitudinally adjacent to each other are connected by transverse welded portions, not longitudinal welded portions that connects casting belt sections that are transversely adjacent to each other.
When a transcendental wide width casting belt is manufactured by longitudinal welding using laser, it is difficult to fix belts in welding and it is required to weld a long belt, such that it is difficult to satisfy quality required in manufacturing an optical film. However, a transcendental wide width casting belt is manufactured only by transverse welding, a jig can be used, such that, in the present invention, it is possible to perform transverse welding, with the casting belt sections fixed; therefore, it is possible to improve quality of the transverse welded portions
Further, according to the present invention, it is possible to easily manufacture a film having a necessary width while satisfying limited conditions in an in-surface phase difference, an on-surface phase difference, and a thickness of a film, because it is possible to manufacture a wide film without increasing elongation of the film in the extending process of the manufacturing process of an optical film.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become apparent from the following description of preferred embodiments given in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view of a casting belt of the related art.
FIG. 2 is a perspective view of an embodiment of the present invention.
FIG. 3 is a plan view of an embodiment of the present invention.
FIG. 4 is a side view of a casting belt of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings.
An embodiment of the present invention relates to a casting belt for producing a transcendent wide width film according to the present invention.
FIG. 2 is a perspective view of an embodiment of the present invention. FIG. 3 is a plan view of an embodiment of the present invention. FIG. 4 is a side view of a casting belt of the present invention.
Manufacturing an optical casing by means of solvent casting performs a casting process that casts a dope containing a polymer solution on a belt to manufacture a film, using the polymer solution, a separating process that separates a gel-state film formed in the casting process, an extending process that extends the separated film with a tender, a drying process that dries the extended film, and a winding process that winds the dried film.
An embodiment of the present invention relates to a belt that is used in a casting process for manufacturing an optical film by means of solvent casting, that is, a casting belt for manufacturing a transcendental wide width where a dope containing a polymer solvent is casted to form a gel-state film.
Referring to FIG. 2 , a casting belt 100 for manufacturing a transcendental wide width film is composed of five casting belt sections 110 . The sizes and shapes of the casting belt sections 110 may be the same.
Referring to FIG. 2 , the casting belt sections 110 adjacent to each other in the longitudinal direction of the casting belt 100 is connected by transverse welded portions 111 . That is, the transverse welded portions 111 are joints that connect the adjacent casting belt sections 110 longitudinally arranged, to make a continuous belt from the casting belt sections 110 . The transverse welded portions 111 are formed by welding, for example, YAG laser welding or common laser welding.
Referring to FIGS. 3 and 4 , when the transverse welded portion is formed by the YAG welding, the width W w of the transverse welded portion 111 can be within 1 mm, and when it is formed by the common laser welding, the width W w of the transverse welded portion 111 can be within 2 mm. When the width of the transverse welded portion 111 is large, the welded portion is likely to be imprinted on a film, such that it is preferable that the width W w of the transverse welded portion 111 is within 2 mm.
Referring to FIGS. 3 and 4 , the transverse welded portion 111 is formed at an angle of θ, 20°, from the transverse cross-section of the casting belt 100 . This is for preventing the transverse welded portion 111 from breaking by maximally distributing the force applied to the casting belt sections 110 in an operation with tension exerted in the casting belt 110 for manufacturing a transcendental wide width film.
Thought not shown in the drawings, pin holes are formed in the transverse welded portion 111 , and the size of the pin hole is 20˜50 μm and the depth is within 50 μm. Blowholes are formed in welding, and they are made in the pin holes. It is known that the maximum size of the pine hole which can be seen by naked eyes of common people is 20 μm. Therefore, the size may not case a problem up to 50 μm, but larger sizes have a limit in being used for films for LCDs.
On the other hand, though not shown in the drawings, when the thickness of the casting belt sections 110 is t b , the thickness t w of the transverse welded portion is 0.95 t b ≦t w ≦1.05 t b . That is, the difference in thickness of the transverse welded portion 111 and the other portions is within 5%. This is for prevent the welded portion from being imprinted on the film in solvent casting.
Meanwhile, the width of the casting belt 100 is 2000 or more, for example, 2000 mm or 2030 mm, which is the maximum belt width in the related art.
The present invention has the advantage that it is possible to manufacture a transcendental wide width film having a width of 1800 mm or more, without imprinting the transverse welded portions 111 on the film, by reducing the size and depth of the pin holes formed in the transverse welded portions 111 and reducing the difference in thickness of the transverse welded portions 111 and the other portions. That is, when an optical film is manufactured by solvent casting, the surface state of the film is largely influenced by the surface state of the belt, as compared with common extrusion casting; however, according to the present invention, it is possible to achieve a wide film without a welded portion imprinted.
When the transcendental wide width casting belt 100 is manufactured by longitudinal welding using laser, it is impossible to fix the left belt at the transversely left side and the right belt connected to the left belt, at the transversely right side, because a jig cannot be used, such that defects are easily generated in the welded portion due to bad longitudinal welding. The present invention manufactures the casting belt for producing a transcendental wide width film by performing transverse welding that transversely welds the casting belt 100 , not longitudinal welding that longitudinally welds the casting belt 100 . On the other hand, when the transcendental wide width casting belt 100 is manufactured by transverse welding using laser, a jig can be used, such that, in the present invention, it is possible to perform transverse welding, with the casting belt sections 110 fixed; therefore, it is possible to improve quality of the transverse welded portions 111 .
The present invention has the advantage of easily manufacturing a film having a necessary width while satisfying limited conditions in an in-surface phase difference, an on-surface phase difference, and a thickness of a film, because it is possible to manufacture a wide film without increasing elongation of the film in the extending process of the manufacturing process of an optical film.
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Disclosed is a casting belt used for manufacturing an optical film by means of a solvent casting process, in more detail, a casting belt for producing a transcendental wide width film which is used to produce a film in a gel state by casting a dope when manufacturing a film that is used for a polarizer of liquid crystal displays or optical compensation films.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a clock extraction circuit for data transmission, especially to a clock extraction circuit which is able to extract a clock from input data, even when random jitter or frequency shit or the like have been occurred.
[0003] 2. Description of the Related Art
[0004] Generally, in data transmission a main cause for jitters that bring about an erroneous selection of data is attributable to deterministic jitter and random jitter. The deterministic jitter is peculiar to a transmission line and resulted from frequency bandwidth of the transmission line and impedance unmatching. On the other hand, the random jitter is randomly generated irrespective of the transmission line and resulted from power noises or thermal fluctuations. As data transfers at high speed it has a tendency to increase a ratio dominated for the most part by random noises over jitters.
[0005] [0005]FIG. 8 is a schematic diagram explaining an existence probability of edges when data is affected by the random jitter.
[0006] The random jitter generally has a Gaussian distribution as shown in FIG. 8. In FIG. 8, the vertical axis designates the existence probability of edges and the horizontal axis designates time, respectively. As shown in FIG. 7, with the position where no jitters can be found as the center, the smaller jitters become the larger the existence probability of an edge that the jitter may have becomes. Conversely, the larger the jitters become the smaller the existence probability of the edge that the jitter may have becomes. Further, with jitter=0 as the center, the random jitter has a property that it is symmetric at both plus (+) and minus (−) sides.
[0007] Here, the region from +n to −n is defined as a dead region. The random jitter generally has a Gaussian distribution as mentioned above but, when the random jitter has occurred, the provision of this dead region in the center of the Gaussian distribution endures an influence of the random jitter. That is, time constant increases relative to the random jitter. Meanwhile, when the frequency shift has occurred, the dead region is not affected by it for the reason that data is input to a clock data recovery (CDR) circuit, with the center of the Gaussian distribution being shifted.
[0008] [0008]FIG. 9 a block diagram schematically showing a cause that brings about the frequency shift.
[0009] What has to be considered in data transmission is the frequency shift occurred between the transmission and the reception sides. In the case of data transmission, in general, clocks for transmission and reception are generated on the basis of a common clock source 90 shared between a transmission side LSI 100 and a reception side LSI 110 . In this event, however, a delay time taken from the clock source 90 to the transmission side LSI 100 and that from the clock source 90 to the reception side LSI 110 are not necessarily equal. When frequency fluctuations have occurred in the clock source 90 , a frequency difference is, from microscopic point of view, made between the transmission side LSI 100 and the reception side LIS 110 .
[0010] [0010]FIG. 10 is a block diagram showing a configuration of the conventional clock extraction circuit disclosed, e.g., in Publication of Unexamined Patent Application No. 7-162402.
[0011] Referring to FIG. 10, reference numeral 120 denotes a data input terminal, 130 denotes a clock input terminal, 140 denotes a delay unit including therein a plurality of delay lines (not shown), 150 denotes a phase judgement unit for judging a phase by comparing an edge of input data and a leading edge of a clock, 160 denotes a counter for determining a unit of selection, as well as for leading or delaying a phase of data, 170 denotes a data selector for outputting data and data of a proper phase margin based on results from the phase judgement unit 150 , 180 denotes a data output terminal. In the conventional clock extraction circuit that is essential for data transmission, when the currently selected clock and an edge position of the input data are closed each other, the configuration is generally taken where the phase margin is secured by keeping away from each other.
[0012] The operation of the conventional clock extraction circuit will now be described.
[0013] When data is input from the data input terminal 120 to the delay unit 140 , the input data goes through different delay elements, so that a plurality of data delayed in various ways are outputted from outputs DO to Dn. The phase judgement unit 150 inputs all of the data to check if a change point of data and the leading edge of a clock are closed each other, or the duty of a sampling timing of a clock is dulled. If so, a clock (UP) for leading a phase of data or a clock (DOWN) for delaying a phase of data is inputted depending on how things stand now. Then, the phase judgement unit 150 supplies a count signal for determining the unit of selection to the counter 160 . The data selector 170 selects and outputs data of a proper phase margin between the data and clock based on results from the phase judgement unit 150 . In this manner, the conventional phase judgement unit 150 has been taken a way of judging a phase difference for all of the data and outputting a signal for leading or delaying a phase of data at respective positions.
[0014] Therefore, the conventional clock extraction circuit thus configured as mentioned above inevitably involves problems as follows.
[0015] [0015]FIG. 11 is a conventional schematic diagram explaining a response and weighting when data is affected by the random jitter.
[0016] In the case where the counter 160 is configured such that the data selector 170 is immediately affected by an output from the phase judgement unit 150 , it has a possibility that wrong data might be selected due to a trifling difference in a random number when data is affected by the random jitter. FIG. 11 shows a data input with eye patterns. In FIG. 11, when an edge exists at the position f versus the edge existence probability distribution, since the phase judgement unit 150 judges that a clock position and an edge position are closed each other, the unit 150 tries to shift the clock position backward. However, because the ideal data latch position e is not shifted, it follows that the data latch position of the clock extraction circuit shifts by a gap g relative to the ideal data latch position e. As a result, a bit error would probably be taken place. It is to be noted that this corresponds to situations where the counter 160 has a small count threshold and time constant.
[0017] [0017]FIG. 12 is a conventional schematic diagram explaining a response and weighting when data is affected by the frequency shift.
[0018] Then, in the case where the counter 160 is configured such that the data selection unit 170 is gradually influenced by an output from the phase judgement unit 150 , when data is affected by the frequency shift, the time that requires for the response to reflect on a data selection becomes longer. As a result, it would probably be misselection of data. Here, when the frequency shift has occurred, the ideal data latch position h will be shifted backward. The phase judgement unit 150 can detect this shift, but a more time is required in order that the results exert an influence upon the data selector 160 , as the counter 160 has a large count threshold. The data latch position of the clock extraction circuit shifts by a gap i relative to the ideal data latch position h. As a result, a bit error would probably be taken place. It is to be noted that this corresponds to situations where the counter 160 has a large count threshold and time constant.
[0019] In the conventional clock extraction circuit, even if the count and time constant are small or large, when data is affected by the random jitter and the frequency shift, a bit error is likely to be taken place.
SUMMARY OF THE INVENTION
[0020] The present invention has been made to solve the above problems, and an object thereof is to provide a clock extraction circuit which is able to manage random jitter and frequency shift.
[0021] A clock extraction circuit according to the present invention includes an edge detection unit for detecting a phase at which a trailing edge or a leading edge of the input data is coincided with each other; a phase judgement unit for comparing an edge position of the detected input data and a position of input clock, and for putting a weight; wherein the weight is put so that a shifting amount of the clock is changed in accordance with a difference between the edge position of the input data and the position of the input clock.
[0022] As described above, according to the present invention, since the contents of the weighting table are set such that a small weight is put on the random jitter having a Gaussian distribution, while a large weight is put on the frequency shift, it can manage both random jitter and the frequency shift.
[0023] A clock extraction circuit according to the present invention includes an edge detection unit for detecting a phase at which a trailing edge or a leading edge of the input data is coincided with each other; a phase judgement unit for comparing an edge position of the detected input data and a position of an input clock, and for putting a weight; wherein the weight is varied depending on whether or not a difference between an edge position of the input data and the position of the input clock falls within a predetermined region.
[0024] As described above, according to the present invention, since the contents of the weighting table is set such that a weight of “0” is put on the random jitter having a Gaussian distribution, while a weight of “1” is put on the frequency shift, it can not only manage both the random jitter and the frequency shift but reduce circuit scale and power consumption. In addition, the invention realizes high speed and high quality data transmission.
[0025] The above and other objects and the attendant advantages of the invention will become readily apparent by referring to the following detailed description of the preferred embodiments when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] [0026]FIG. 1 is a block diagram showing an exemplary configuration of a clock extraction circuit of a first embodiment.
[0027] [0027]FIG. 2 is a block diagram showing an exemplary internal configuration of the phase judgement unit shown in FIG. 1 of the first embodiment.
[0028] [0028]FIG. 3 is a table showing exemplary contents of the weighting table.
[0029] [0029]FIG. 4 is a schematic diagram explaining a response and weighting when data is affected by the random jitter.
[0030] [0030]FIG. 5 is a schematic diagram explaining a response and weighting when data is affected by the frequency shift.
[0031] [0031]FIG. 6 is schematic diagram explaining a response and weighting when data is affected by the random jitter of the second embodiment.
[0032] [0032]FIG. 7 is a schematic diagram explaining a response and weighting when data is affected by the frequency shift.
[0033] [0033]FIG. 8 is a schematic diagram explaining an existence probability of an edge when data is affected by the random jitter.
[0034] [0034]FIG. 9 is a block diagram schematically showing a cause that brings about the frequency shift.
[0035] [0035]FIG. 10 is a block diagram showing a configuration of the conventional clock extraction circuit.
[0036] [0036]FIG. 11 is a schematic diagram explaining a response when data is affected by the random jitter.
[0037] [0037]FIG. 12 is a schematic diagram explaining a response when data is affected by the frequency shift.
[0038] Throughout the figures, the same reference numerals, and characters, unless otherwise noted, are used to denote like features, elements, components, or portions of the illustrated embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] The preferred embodiments of the present invention will be described in detail, referring to the accompanying drawings.
First Embodiment
[0040] [0040]FIG. 1 is a block diagram showing an exemplary configuration of a clock extraction circuit according to the first embodiment.
[0041] Referring to FIG. 1, reference numeral 10 denotes a data input terminal for inputting data, 20 denotes a clock input terminal for inputting a 6-phase clock, 30 denotes a sampling unit for latching input data using the 6-phase clock and for retiming at a specific phase out of the 6-phase clock, 40 denotes an edge detection unit for detecting a phase at which a leading edge or a trailing edge is coincided out of an output data and for outputting the detected results, 50 denotes a phase judgement unit for relatively comparing a phase at which a leading edge or a trailing edge is coincided and a position of the currently selected data, and for outputting a signal for increasing or decreasing a count value of the counter 60 at the subsequent stage depending on the results, 60 denotes a counter that has a threshold therein and when the count value exceeds the threshold, it moves forward and backward a data selecting position SEL, 70 denotes a data selector for outputting a data that comes under an output data SEL of the counter 60 to the subsequent stage out of output data D 0 to D 5 of the sampling unit 60 .
[0042] [0042]FIG. 2 is a block diagram showing an exemplary internal configuration of the phase judgement unit 50 .
[0043] Referring to FIG. 2, reference numeral 51 denotes a weighting table in which weights are set in order to put a weight on detected results of the edge detection unit 40 , 52 , 53 denote AND circuits, 54 , 55 denote logical gates for generating UP and DOWN signals from a SEL (data selection) signal, an EDGE (edge position) signal, and AND of the weighting table 51 .
[0044] [0044]FIG. 3 is a table showing an exemplary contents of the weighting table 51 .
[0045] Referring to FIG. 3, reference numeral 51 a denotes each SEL signal, 51 b denotes weights on each EDGE signal. As shown in FIG. 3, the weighting is varied depending on which of SEL signal selects. When a leading edge is directly opposed to a trailing edge, a weight is set to “0”. Thus, the weighting increases as the SEL signal and the leading edge or the trailing edge are closed each other.
[0046] The operation of the clock extraction circuit of the first embodiment will now be described.
[0047] [0047]FIG. 4 is a schematic diagram explaining a response and weighting when data is affected by the random jitter. FIG. 5 is schematic diagram explaining a response and weighting when data is affected by the frequency shift.
[0048] In the case where data is affected by the random jitter, as shown in FIG. 4, an edge existence probability will become large in the vicinity of the jitters due to the nature of the Gaussian distribution. In this event, a SEL signal, e.g., “SEL=6′b000010” is selected from the weighting table to put a small weight on the region as indicated by reference character a. Thus, since an absolute value of the count increase and decrease in the counter 60 and consequently a shifting amount of a clock becomes small, the clock extraction circuit is hardly affected by the random jitter, thereby allowing an appropriate response.
[0049] On the contrary, in the case where data is affected by the frequency shift, as shown in FIG. 5, the center of the jitter drifts forward and backward. In this event, a SEL signal, e.g., “SEL=6′b0000001” is selected from the weighting table to put a large weight on the region as indicated by reference character b. Hence, since an absolute value of the count increase and decrease in the counter 60 becomes large and consequently a shifting amount of a clock becomes small, the clock extraction circuit can appropriately response to the input data that is subjected to the frequency shift.
[0050] As is clear from the above description, according to the first embodiment, since the contents of the weighting table is set such that a small weight is put on the random jitter having the Gaussian distribution, while a large weight is put on the frequency shift, it can manage both random jitter and frequency shift.
Second Embodiment
[0051] In this second embodiment, only the contents of the weighting table 51 in the phase judgement unit 50 is different from that of the first embodiment, and therefore descriptions of the same components as the first embodiment are omitted for brevity's sake. Besides, an illustration of a table showing an exemplary contents of the weighting table 51 of the second embodiment is also omitted for the same reason.
[0052] In the second embodiment, the contents of the weighting table 51 is set to “0” for the random jitter, while to “1” for the frequency shift.
[0053] The operation of the clock extraction circuit of the second embodiment will now be described.
[0054] [0054]FIG. 6 is a schematic diagram showing a response and measures thereof when data is affected by the random jitter. FIG. 7 is a schematic diagram showing a response and measures thereof when data is affected by the frequency shift.
[0055] In the case where data is affected by the random jitter, as shown in FIG. 6, it has a large edge existence probability in the vicinity of the center of jitters due to the nature of a Gaussian distribution, a weight of “0” is put on the region (within a predetermined region) as indicated by reference character c. Thus, a count increase and decrease of the counter 60 come to 0 and consequently a clock does not shift. Accordingly, the clock extraction circuit is hardly affected by the random jitter, thereby allowing an appropriate response.
[0056] On the contrary, in the case where data is affected by the frequency shift, as shown in FIG. 7, since the center of jitter drifts forward and backward, a weight of “1” is put on the region (without a predetermined region) as indicated by reference character d. Hence, a count increase and decrease of the counter 60 do not undergo a change and a shifting amount of a clock remains unchanged. Accordingly, the clock extraction circuit can appropriately response to the input data that is subjected to the frequency shift.
[0057] As is clear from the above description, according to the second embodiment, since a weight of “0” is put on the random jitter having the Gaussian distribution, while a weight of “1” is put on the frequency shift, it is not only hardly affected by the random jitter but quickly responses to the frequency shift. This can reduce circuit scale and power consumption as well as manage both the random jitter and the frequency shift.
[0058] While in the first and second embodiments an output of the sampling unit 30 using a 6-phase clock for explanation is selected by the data selector 70 , it is appreciated that an output of the delay unit 140 may be selected by the data selector 70 like the Related Art.
[0059] Further, while weights of the weighting table 51 are set as shown in FIG. 3, as a result of the 6-phase clock, as a mater of course, more or less phase clock may be adopted.
[0060] Moreover, while a description has been made on assumption that weights are previously set into the weighting table 51 , without being limited thereto, e.g., a circuit may be separately provided for detecting the random jitter and the frequency shift in order to dynamically set corresponding weights depending the random jitter or the frequency shift.
[0061] While, in the above prior arts and preferred embodiments of the invention, it should be understood by those skilled in the art that various modifications and changes may be made without departing from the sprit and scope of the invention.
[0062] Also, it should be noted that the invention meets all the objects mentioned above and also has the advantages of wide commercial utility, and that the invention has been set forth for purposes of illustration only and not of limitation. That is, the invention is limited only by the following claims which follow. Consequently, reference should be made to the following claims in determining the full scope of the invention.
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A clock extraction circuit includes an edge detection unit for detecting a phase at which a trailing edge or a leading edge of input data is coincided with each other, and a phase judgement unit for comparing an edge position of the detected input data and a position of an input clock and for putting a weight, wherein the weight is put so that a shifting amount of the input clock is varied depending on a difference between the edge position of the input data and the position of the input clock.
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BACKGROUND OF THE INVENTION
The present invention relates to an automatic sewing machine for sewing workpieces of different sizes, in which relative movement between a workpiece and a sewing head is controlled by a computer which receives a program according to a contour to be stitched.
In general, it is known from the manufacturing of workpieces such as shirt collars, to achieve different sizes by inserting an extending section into the middle of the collar, while the shape in the area of the collar tips remains the same.
In a technical information sheet named "IDEALNECCHI AUTOMATION FOR THE APPAREL INDUSTRY Mechanization Series Class 2001 Numerical Control Automatic Unit for producing any sewing shape" edited by the IDEAL EQUIPMENT CO. LTD., Quebeck/Canada, there is described such an automaton, in which the program for producing a stitch contour is inserted into the computer by means of punched tape. The data of the contour is determined by coordinates of some significant points which represent the variables of an algorithm applied for figuring all required values of the contour by using linear or square interpolation. Additionally, the algorithm considers besides the aforementioned variables, further information for determining the size of the contour to be sewn. In this automaton the size adjustment depending on the size adjustment of the workpiece receiving device, is manually inserted into the computer by means of appropriate push buttons at a panel. The manual input of the sizing information basically allows the operator to match the sewing contour to different workpiece sizes, with, however, accompanying disadvantages. On the one hand, sizes of garments are not standardized in such a way as to form fixed sizes to each other but, in practice, vary depending on the manufacturer. At the same time, the material of a workpiece is exposed to various influences such as for example coloring, moisture, fusing of lining etc. which cause undesired variations of the workpiece dimensions. In production, these conditions steadily require manual size adjustments according to the actual workpiece dimensions. As described above, the contour's size is manually inserted into the computer by push buttons, whereas the adjustment of the workpiece receiving elements can be set in a stepless manner. From this it may happen that a contour is not placed at the technologically required position. Such conditions may cause sewing into the fused lining of a workpiece such as a shirt collar, and this is not acceptable. Besides this disadvantage, the nonautomatic input of information into the computer is time consuming and reduces the productivity of the automaton.
It is, therefore, an object of the present invention to provide an automatic sewing machine of the above-described type with a device for detecting the size adjustment of the workpiece receiving device, in order to automatically match the size adjustment with the sewing contour controlled by the computer which controls relative motion between the workpiece and the needle of the sewing head.
Another object of the present invention is to provide a device, as described, which allows to detect the size adjustment of the workpiece-receiving device in a continuous manner.
Further objects of the present invention are to provide a device, as described, for reducing downtimes of the automaton and eliminating false data input of the machine's operator, and finally eliminating the possibility of collision between the sewing head and the workpiece receiving elements.
Still another object of the present invention is to provide a device of the foregoing character, which is simple in construction and reliable in operation.
SUMMARY OF THE INVENTION
The objects of the present invention are achieved by providing the workpiece receiving device with a measuring device for detecting the size adjustment and automatically informing the computer controlling the machine. The measuring device facilitates a fine adaption of the stitched contour to the workpiece, and eliminates additional actions of the operator related to size adjustments.
By using a measuring device having a linear characteristic, the size adjustment of the workpiece receiving device equals or corresponds to the necessary information for the computer, without any additional data conversion. This simplifies the total arrangement and positively affects the processing time.
The application of a potentiometer as the essential element within the measuring device optimally meets the requirements for linear measurement and is, furthermore, a standardized interchangeable item. The mechanical linkage of the potentiometer by means of a rack and pinion guarantees a slipless and rigid drive.
The arrangement of a separate power supply for the measuring device allows for adaption to the characteristic of the potentiometer and the data processing circuit. The application of an AD-converter within the adapting electronic unit prevents the feeding of analog information over long distances.
Other objects, advantages and features of the present invention will appear from the detailed description of the preferred embodiment, which will now be explained in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective total view of an automatic sewing machine;
FIG. 2 is a partial front plane view of the automatic sewing machine in the direction of arrow II in FIG. 1;
FIG. 3 is a partial side view of the sewing machine in the direction of arrow III in FIG. 2;
FIG. 4 is a partial top plan view of the sewing machine in the direction of arrow IV in FIG. 3, without sewing head however;
FIG. 5 is a perspective view showing the essential parts of a workpiece receiving device;
FIG. 6 is a perspective view showing the workpiece receiving device including a measuring device with a potentiometer; and
FIG. 7 is a basic circuit diagram of the measuring device having a connection to a computer.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawings, in FIG. 1 there is illustrated an automatic sewing machine 7 for producing shirt collars of different sizes, which is controlled by a computer 1 having a tape reader 2. The functions of the computer 1 are manually released by means of a panel 3. Prior to a sewing cycle, the tape reader 2 is loaded with a control tape 4, having coded information which is read into the computer 1 as soon as the command is inserted into the panel 3.
Besides coded information for a workpiece receiving device 5 (FIG. 6) receiving a workpiece 6, the tape 4 carries information about significant points defining a sewing contour to be controlled. For the seam to be produced, these significant points are fed into the computer 1 as X-Y-coordinates which represent parameters for the algorithm of computation, in order to calculate the remaining points of the contour by applying linear or square interpolation. Moreover, information of special points of the contour are read into the computer 1, as for example, the corners of collar tips, so that, after reaching such significant points, the computer logic is capable to branch the program for considering the complicated control operation adjacent to these points. Furthermore, the tape 4 delivers information to the computer 1, for which, at sections of the contour, additionally offered parameters have to be considered. Among other things, such parameters define the continuous sizing for adaption to the different manufacturing sizes. These parameters are considered by the computer 1 in the contour sections as provided by the tape 4.
According to FIGS. 2 and 3, the automatic sewing machine 7 is equipped with a sewing head 8 carrying a needle 9. The workpiece receiving device 5 is secured to a stationary bracket 10. As shown in FIGS. 2, 3 and 4, the sewing head 8 is moveably arranged on two guide bars 11 (X-direction) and 12 (Y-direction) which are horizontal and perpendicular to each other, and installed so as to allow the sewing head 8 to move in a horizontal plane. The sewing head 8 is drivingly connected by timing belts 15, 16 to servo motors 13, 14.
The servo motors 13, 14 are equipped with encoders 17, 18 (FIGS. 2 and 4), which indicate the position of the needle 9 relative to the stationary workpiece receiving device 5 in X- and Y-direction. Prior to operation, the encoders 17, 18 are calibrated in conjunction with the switches 19, 20. The sewing head 8 (FIG. 3) is driven by a sewing head drive 21 including an encoder 22 which puts out regular pulses and a zero pulse per one revolution, in order to inform the computer 1 at any time about the position of the needle 9, i.e. the angular position of the needle drive mechanism (not shown).
As illustrated in FIGS. 5 and 6, the workpiece receiving device 5 consists of two parts, a stationary workpiece receiving element 23 secured to the stationary bracket 10, and a movable workpiece receiving element 25 received in a guide 24 formed as an oblong hole. The movable workpiece receiving element 25 is releasably locked in the guide 24 by a handle 26. The stationary and the movable workpiece receiving elements 23, 25 are provided each with a supporting plate 27 or 28, a contoured supporting plate 29 or 30 and a congruent clamping plate 31 or 32. The contoured supporting plate 30 is shaped as to overlap the contoured supporting plate 29 for forming an uninterrupted support for the workpiece 6 at any adjusted position of the movable workpiece receiving element 25. In order to prevent a step at the overlapping, the contoured supporting plates 29, 30 are cut, for example, from sheet material having a thickness of 0.5 mm. According to FIG. 6, the clamping plates 31 and 32 are movably arranged by means of levers 35 and 36 operated by air cylinders 33 and 34. The air cylinder 33 is stationarily fixed to the bracket 10, while the air cylinder 34 is adjustably connected to the movable workpiece receiving element 25 received in the guide 24.
For adjustment purposes the movable workpiece receiving element 25 is installed with a handle 37. The position of the movable workpiece receiving element 25 is picked up or sensed by a measuring device 38 (FIG. 6). In the preferred embodiment, the measuring device 38 is arranged at the stationary workpiece receiving element 23 which is located oppositely to the movable workpiece receiving element 25. As illustrated, the stationary bracket 10 is provided with a bracket 43 having two bearings 50, 51 for slidably receiving a rack 49 which is connected to the movable workpiece receiving element 25 by means of a connecting block 52 and a bolt 53. Furthermore, the bracket 43 is formed with a recess 42, in which a flange 41 of a potentiometer is secured by means of set screws 44. The potentiometer 40 has a shaft 45 pivoted in a bushing 46 and is installed with a pinion 47 cooperating with toothing 48 of the rack 49. In order to achieve a precise position of the movable workpiece receiving element 25, the potentiometer 40 is of the type which has 10 revolutions over its measuring range.
The potentiometer 40 is connected to the computer 1 by means of an adapting electronic unit 39 which now will be described in connection with FIG. 7. The potentiometer 40 is a standard type and has two supply connections 54, 55 and a tape 56. By rotating the shaft 45, the tap 56 provides output voltages which are proportional to the supply voltage and proportional to the position of the tap 56 in relation to its final position within the potentiometer 40. The potentiometer 40 is connected to a standard power supply 57 which is commercially available with an accuracy of better than 0.01%. As illustrated, the power supply 57 is also connected to a voltage splitting device consisting of two resistors 58, 59 which have low resistance in relation to the resistance of the potentiometer 40 and are connected in series. This may be achieved without any difficulties by providing the potentiometer 40 with 100-kohm resistance in conjunction with a voltage splitting device having a total resistance of 1 kohm.
By dimensioning the resistor 58 with a value of 50 kohms, a 0-volt potential is achieved at the tap 56 without damaging the potentiometer 40 by running against its internal stops. Accordingly, the maximum voltage of 10 volts, for example, is provided at a position of the tap 56 of about 5% off the other stop even by adjusting the stationary and movable workpiece receiving elements 23 and 25 in their farthest positions to each other. An AD-converter 60 is connected to the tap 56 and a branching connection 62 for converting the analog voltage into coded digital information fed into the computer 1 by means of a circuit connection 61. Due to the drive connection of the potentiometer 40 with the stationary and movable workpiece receiving elements 23 and 25, the coded information represents an absolute dimension for the adjusted size.
The operation of the automatic sewing machine with the novel measuring device may be described as follows:
For size adjustment, the operator unlocks the handle 26 and adjusts the movable workpiece receiving element 25 by means of the handle 37 according to the dimensions of the workpiece 6, in order to achieve a suited stitch contour in relation to the fused lining of the collar. It might be necessary to make fine readjustments after the first collar has been stitched. By adjusting the movable workpiece receiving element 25, the potentiometer 40 is turned due to the cooperation of the rack 49 and the pinion 47. The adjusted position of the movable workpiece receiving element 25 is detected by the measuring device 38 at which the information is transferred via the adapting electronic unit 39 into the computer 1 as a variable to be considered during the control process. Prior to sewing, the operator firmly arrests the movable workpiece receiving element 25 by tightening the handle 26. During the sewing operation, the computer 1 obtains information about the position of the sewing head 8 in X- and Y-direction from the encoders 17 and 18, and about the position of the needle 9 from the encoder 22, while the sewing head 8 is driven by the sewing head drive 21 as the X- and Y-movements of the workpiece 6 are fed into the machine by the servo motors 13 and 14 in conjunction with the timing belts 15 and 16.
As described in the foregoing procedure of adjustment, there is enough time for the AD-converter 60 to carry out the data conversion, so that even time-consuming integrated circuits of the described kind may be applied. The computer 1 considers the coded size information, as the particular section of a stitch contour containing the size variation, is to be calculated. This arrangement allows the application of an inexpensive AD-converter.
For adjusting the measuring device 38 (FIG. 6) the power supply 57 is connected to the supply connections 54, 55 of the potentiometer 40 and to the resistors 58 and 59, as a voltmeter indicating positive and negative potential is connected to the tap 56 and the branching connection 62. For defining the zero position of the stationary and movable workpiece receiving elements 23 and 25, the handle 26 (FIG. 5) must be unlocked in order to displace the movable workpiece receiving element 25 into its closest position relative to the stationary workpiece receiving element 23. In this set position--representing an adjustment for producing the smallest size of a collar--the set screws 44 (FIG. 6) are to be loosened for allowing rotation of the potentiometer 40 until the voltmeter indicates zero volt-potential. Subsequently, the handle 26 will be untightened for displacing the movable workpiece receiving element 25 into its farthest position in relation to the stationary workpiece receiving element 23, in order to adjust the required maximum voltage with respect to the AD-converter 60 by means of a not shown adjusting means within the power supply 57.
In accordance with the selected resistor values of the potentiometer 40 and the resistors 58 and 59 for protecting the potentiometer 40 against mechanical damage, the ratio of the rack 49 and pinion 47 is dimensioned so as to achieve nine revolutions at the potentiometer 40 over the displacement of the movable workpiece receiving element 25 through its total range of size adjustment.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention, and therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the following claims.
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An automatic sewing machine for sewing workpieces of different sizes is described, in which relative movement between a workpiece and the needle of a sewing head is controlled by a computer receiving the program according to the contour to be stitched. A measuring device is provided for automatically matching the relative movement of the sewing process with the size adjustable workpiece receiving elements. The measuring device continuously detects the size adjustment of the workpiece receiving elements and feeds the size adjustment into an adapting electronic unit converting analog information into digital information used by the computer controlling the stitching operation.
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[0001] This invention claims the benefit of U.S. Provisional Patent Application No. 61/646,583 filed on May 14, 2012, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments of the invention relate to the structure of an LED (light-emitting diode) bulb. More particularly, they relate to the structure of a heat sink within an LED bulb. Although the embodiments of the invention are suitable for a wide scope of applications, it is particularly suitable for more effective heat dissipation and heat isolation in multi-LED element light bulbs.
[0004] 2. Discussion of the Related Art
[0005] In general, an LED light bulb includes one or more LED elements. An LED element produces illumination by turning a given amount of electric power into a certain amount of light. Electric power is typically measured in watts and the amount of light illumination is measured in lumens. An LED element converts electric power into light more efficiently than standard incandescent filament. LED bulbs are bright enough to replace incandescents. More specifically, an LED bulb producing the same number of lumens as a standard 60-watt incandescent bulb is only using twelve watts of power. In other words, a 60-watt incandescent bulb produces about 800 lumens of light just like a 12-watt LED bulb.
[0006] Unlike an incandescent bulb that typically uses only a single light source, which is a filament, an LED bulb typically has a collection of a plurality of light sources in that each light source is an LED element. Thus, the collection of LED elements cumulatively produces the light emanating from a LED bulb. For example, a 12-watt LED bulb can be a collection of four 3-watt LED elements, three 4-watt LED elements or six 2-watt elements to produce 800 lumens of light. Each of the LED elements can include one or more LED chips.
[0007] Although LED bulbs are much more efficient in converting electric power into light than incandescent bulbs, the LED elements still create heat. Further, an LED element can overheat so as to quit working, have severely shortened lifespan or incur damage that reduces power-to-light conversion efficiency. Higher wattage LED elements tend to be more efficient in converting electric power to light but also tend to be more susceptible to overheating. Thus, heat sink requirements for an individual LED element increases as the wattage capability for an LED element increases.
[0008] FIG. 1 is a perspective view of a prior art LED bulb with multiple LED elements on a heat sink under a single dispersion lens. As shown in FIG. 1 , an LED bulb 100 includes a socket base 101 . One end of the socket base 101 has a screw cap 102 for insertion into a light fixture. The other end of the socket base 101 opposite to the screw cap 102 has a base plate 103 . AC-to-DC conversion circuitry is housed within the socket base 101 between the screw cap 102 and the base plate 103 .
[0009] The LED bulb 100 shown in FIG. 1 also includes a heat sink 113 attached to the base plate 103 . The heat sink 113 can be attached by screws (not shown) that go through the screw holes 104 in the base plate 103 and screw into the heat sink 113 to fasten the heat sink 113 to the base plate 103 . The heat sink 113 can be metallic, such as Al or Cu. In the alternative, the heat sink 113 can be heat conductive ceramic, such as alumina.
[0010] The LED bulb 100 shown in FIG. 1 further includes LED elements 120 a - 120 d mounted on the heat sink 113 . The wiring (not shown) for the LED elements 120 a - 120 d passes through the heat sink 113 and through wiring holes 104 of the base plate 103 into the socket base 101 . The LED elements 120 a - 120 d can each be an LED module with one or more LED chips within the LED module. In the case of LED modules as the LED elements 120 a - 120 d, the modules can be permanently attached to the heat sink 113 by soldering (not shown) or removably attached to the heat sink 113 with screws (not shown).
[0011] The LED bulb 100 shown in FIG. 1 has a lens 130 overlying the LED elements 120 a - 120 d on the heat sink 113 . The lens 130 can be a dispersion lens that disperses light from the LED elements 120 a - 120 d. In the alternative, the lens 130 can be a conversion lens that focuses light from the LED elements 120 a - 120 d. Both the dispersion lens and the conversion lens can include materials for light diffusion and/or have structural features for light refraction/diffusion purposes. The lens 130 can be made of a glass material, a polymer material or layers of such materials.
[0012] The prior art LED bulb, as shown in FIG. 1 , generally has at least four portions. The first portion is a socket part containing AC-to-DC conversion circuitry that is configured to screw into a light fixture. The second portion is a heat sink part attached to the socket part. The third portion is the LED elements, which can be LED modules, mounted on the heat sink part. The fourth portion is an optical element part above the LED elements to disperse or, alternatively, focus light from the LED elements. The LED elements is the portion that typically has a failure in the prior art LED bulb.
[0013] A single LED element, such as an LED module, of a prior art LED bulb can fail. Further, a failing LED element of a prior art LED bulb tends to overheat and accelerate the failure of other LED elements on the heat sink. Replacing a single LED module in an LED bulb is more cost effective than replacing the entire LED bulb. An LED module can be replaced in a prior art LED bulb by removing the optical element and replacing a module that is removably attached to the heat sink 113 . However, a removably attached LED module has less thermal conductivity to the heat sink 113 than an LED module permanently attached to the heat sink.
SUMMARY OF THE INVENTION
[0014] Accordingly, embodiments of the invention is directed to a solid state power source with frames for attachment to an electronic circuit that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.
[0015] An object of embodiments of the invention is to provide an LED bulb with a modular heat sink structure.
[0016] Another object of embodiments of the invention is to provide improved heat dissipation for LED elements in an LED light bulb.
[0017] Another object of embodiments of the invention is to provide thermal isolation between LED elements in an LED light bulb.
[0018] Additional features and advantages of embodiments 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 practice of embodiments of the invention. The objectives and other advantages of the embodiments of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0019] To achieve these and other advantages and in accordance with the purpose of embodiments of the invention, as embodied and broadly described, a light emitting diode bulb includes: a socket base configured for insertion into a light fixture; a plurality of separate heat sinks attached to the socket base; light emitting diode elements mounted on the plurality of separate heat sinks; and an optical element covering one of the light emitting diode elements.
[0020] In another aspect, the light emitting diode bulb includes: a socket base configured for insertion into a light fixture; a plurality of spaced-apart heat sinks on the socket base; light emitting diode elements mounted on the plurality of spaced-apart heat sinks; and lenses respectively mounted on the plurality of spaced-apart heat sinks.
[0021] In yet another aspect, the light emitting diode bulb includes: a socket base configured for insertion into a light fixture; a plurality of spaced-apart heat sinks on the socket base; light emitting diode elements mounted on the plurality of spaced-apart heat sinks; optical elements respectively mounted on the plurality of spaced-apart heat sinks to cover the light emitting diode elements; and a retention plate positioned across each of the plurality of spaced-apart heat sinks.
[0022] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of embodiments of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The accompanying drawings, which are included to provide a further understanding of embodiments of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of embodiments of the invention.
[0024] FIG. 1 is a perspective view of a prior art LED bulb with multiple LED elements on a heat sink under a single dispersion lens.
[0025] FIG. 2 is a perspective view of an LED bulb with multiple LED elements that are each on an individual heat sink according to an embodiment of the invention.
[0026] FIG. 3 is a front view of multiple LED elements that are each on an individual heat sink according to an embodiment of the invention.
[0027] FIG. 4 is a perspective view of multiple LED elements that are each on an individual heat sink according to an embodiment of the invention.
[0028] FIG. 5 is a perspective view of an LED bulb with multiple LED elements that are each on an individual heat sink and are each covered by a respective dispersion lens according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] Reference will now be made in detail to preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Reference will now be made in detail to the preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. The invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the invention to those skilled in the art. In the drawings, the thicknesses of layers and regions are exaggerated for clarity. Like reference numerals in the drawings denote like elements.
[0030] FIG. 2 is a perspective view of an LED bulb with multiple LED elements that are each on an individual heat sink according to an embodiment of the invention. As shown in FIG. 2 , an LED bulb 200 according an embodiment of the invention includes a socket base 201 . One end of the socket base 201 has a screw cap 202 for insertion into a light fixture. Although the exemplary embodiment shown in FIG. 2 illustrates a screw cap 202 , other plug types for light fixtures can be alternatively implemented for insertion into a light fixture on the base 201 . The other end of the socket base 201 opposite to the screw cap 202 has a base plate 203 .
[0031] The LED bulb 200 shown in FIG. 2 also includes separate heat sinks 213 a - 213 d attached to the base plate 203 . The separate heat sinks 213 a - 213 d can be respectively attached to the base plate 203 by screws (not shown) that go through the screw holes 204 in the base plate 203 and screw into the separate heat sinks 213 a - 213 d to fasten each of the separate heat sinks 213 a - 213 d, respectively, to the base plate 203 . The separate heat sinks 213 a - 213 d can be metallic, such as Al or Cu. In the alternative, the separate heat sinks 213 a - 213 d can be heat conductive ceramic, such as alumina. As shown in FIG. 2 , each of the separate heat sinks 213 a - 213 d can have fins 213 a - 213 d for increasing the transmittance of heat from the respective separate heat sink into the air surrounding the LED bulb 200 . As shown in FIG. 2 , each of the separate heat sinks 213 a - 213 d generally has a triangular shape such that they can all be combined into a circular configuration. In the alternative, each of the separate heat sinks 213 a - 213 d can generally have a rectangular shape such that they can all be combined into a larger rectangular-shaped configuration.
[0032] The LED bulb 200 shown in FIG. 2 further includes LED elements 220 a - 220 d mounted on the separate heat sinks 213 a - 213 d , respectively. The wiring (not shown) for the LED elements 220 a - 220 d passes through the separate heat sinks 213 a - 213 d, respectively, and through wiring holes 204 of the base plate 203 into the socket base 201 . In the case of LED modules as the LED elements 220 a - 220 d, the modules can be permanently attached to the separate heat sinks 213 a - 213 d, respectively, by a thermal conductive adhesive, such as solder (not shown). In the alternative, the modules can be replaceably attached to the separate heat sinks 213 a - 213 d , respectively, by fasteners, such as screws (not shown).
[0033] The LED bulb 200 shown in FIG. 2 has lens mounts 230 a - 230 d with lens 231 a - 231 d overlying the LED elements 220 a - 220 d on the separate heat sinks 213 a - 213 d, respectively. Each of the lens 231 a - 231 d can be a dispersion lens that disperses light from the LED elements 220 a - 220 d. In the alternative, the lens 231 a - 231 d can be a conversion lens that focuses light from the LED elements 220 a - 220 d . Both the dispersion lens and the conversion lens can include materials for light diffusion and/or have structural features for light refraction/diffusion purposes. The lens 231 a - 231 d can be made of a glass material, a polymer material or layers of such materials. The lens mounts 230 a - 230 d can be metallic, such as Al or Cu. A metallic lens mount can act as another heat sink for the LED element. In the alternative, the lens mounts 230 a - 230 d can be a polymer.
[0034] Embodiments of the invention include the LED elements 220 a - 220 d shown in FIG. 2 being energized simultaneously or, alternatively, having stages of lighting brightness. For example, the LED bulb 200 can be three-way bulb in that LED element 220 a comes on in a first stage, LED elements 220 b and 220 c come on in a second stage and LED elements 220 a - 220 d come on in a third stage. In another example, the LED bulb 200 can be three-color bulb in that LED elements 220 a and 220 d comes on in a first stage as red light, LED elements 220 b and 220 c come on in a second stage as green light and LED elements 220 a - 220 d come on in a third stage to make yellow light.
[0035] FIG. 3 is a front view of multiple LED elements that are each on an individual heat sink according to an embodiment of the invention. As shown in FIG. 3 , the separate heat sinks 213 a - 213 d are space-apart from one another. By spacing the separate heat sinks 213 a - 213 d apart from one another, air AF can flow between and through the spaced-apart heat sinks 213 a - 213 d . The air AF flowing or moving between or through the spaced-apart heat sinks 213 a - 213 d increases the transmission of heat from the spaced-apart heat sinks 213 a - 213 d into the air. In addition, the spacing between the spaced-apart heat sinks 213 a - 213 d isolates the spaced-apart heat sinks 213 a - 213 d from one another. That is, heat from one of the spaced-apart heat sinks 213 a - 213 d is not transferred directly to the other spaced-apart heat sinks 213 a - 213 d . The holes 214 in each of the spaced-apart heat sinks 213 a - 213 d are screw holes.
[0036] As shown in FIG. 3 , one or more LED chips 221 a - 221 d can be on the LED elements 220 a - 220 d within the lens mounts 230 a - 230 d. Although FIG. 3 shows four LED chips on each of the LED elements 220 a - 220 d, each of the LED elements 220 a - 220 d can alternatively contain just two LED chips, three LED chips or any number of LED chips in an array. In another alternative, the LED elements 220 a - 220 d can have a different number of LED chips. Usually each of LED elements 220 a - 220 d has the same amount of light output but the LED elements 220 a - 220 d can be configured such that the LED elements 220 a - 220 d each emit different amounts of light buy using different light elements.
[0037] FIG. 4 is a perspective view of multiple LED elements that are each on an individual heat sink according to an embodiment of the invention. As shown in FIG. 4 , the lens mounts 230 a - 230 d are fastened onto the spaced-apart heat sinks 213 a - 213 d with screw sets 232 a - 232 d, respectively. Gaskets 233 a - 233 d can be provided between the lens mounts 230 a - 230 d and the spaced-apart heat sinks 213 a - 213 d , respectively. The gaskets 233 a - 233 d provide weatherproof seals between the lens mounts 230 a - 230 d and the spaced-apart heat sinks 213 a - 213 d , respectively. By removing one of the screw sets 232 a - 232 d for one of the lens mounts 230 a - 230 d , that one of the LED elements 220 a - 220 d can be replaced to affect a repair.
[0038] A retention plate 215 is shown in FIG. 4 positioned across each of the spaced-apart heat sinks 213 a - 213 d. The screws 216 a - 216 d attach the retention plate 215 onto the spaced-apart heat sinks 213 a - 213 d through the screw holes 214 shown in FIG. 3 . The retention plate 215 maintains the spacing relationship of the spaced-apart heat sinks 213 a - 213 d.
[0039] FIG. 5 is a perspective view of an LED bulb with multiple LED elements that are each on an individual heat sink and are each covered by a respective dispersion lens according to an embodiment of the invention. As shown in FIG. 5 , AC-to-DC conversion circuitry 206 is housed within the socket base 201 between the screw cap 202 and the base plate 203 . The spaced-apart heat sink 213 a is mounted on the base plate 203 by screw set 217 a through holes 204 in the base plate 203 . An LED element 220 a is mounted on the spaced-apart heat sink 213 a. A lens mounts 230 a with a lens 231 a is fastened onto the spaced-apart heat sink 213 a with screw set 232 a. The spaced-apart heat sink 213 a is attached to the retention plate 215 with the screw 216 a.
[0040] In embodiments of the invention, the LED bulb 200 can have an LED element repaired by replacement of the LED element together with the heat sink on which the LED element is positioned along with the lens mounts having a lens overlying the LED element. For example, the LED element 220 a mounted on the spaced-apart heat sink 213 a along with the lens mounts 230 a having a lens 231 a can be repaired by replacement. Such a repair includes removing the screw set 217 a and screw 216 a, and then removing the spaced-apart heat sink 213 a with the LED element 220 a. Subsequently, another spaced-apart heat sink with an LED element can be positioned on the base plate 203 but below the retention plate 215 , and then the screw set 217 a and screw 216 a are reinstalled.
[0041] Replacing LED elements in a LED bulb by replacing both the LED element and the heat sink upon which the LED element is positioned not only enables repair by replacement of failing portions of the bulb but also isolates overheating LED elements from other LED elements of the LED bulb. The spaced-apart heat sinks enable air flow that increase the cooling capability of the spaced-apart heat sinks. The LED elements can be attached to a spaced-apart heat sink so as to maximize heat transference from the LED elements to the spaced-apart heat sink.
[0042] It will be apparent to those skilled in the art that various modifications and variations can be made in the embodiments of the invention without departing from the spirit or scope of the invention. Thus, it is intended that embodiments of the invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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A light emitting diode bulb includes: a socket base configured for insertion into a light fixture; a plurality of separate heat sinks attached to the socket base; light emitting diode elements mounted on the plurality of separate heat sinks; and an optical element covering one of the light emitting diode elements.
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RELATED APPLICATIONS
[0001] This application claims the benefit of German patent application number DE 10 2011 015 334.9 filed Mar. 28, 2011, the content of which is incorporated by reference herein in its entirely.
TECHNICAL FIELD
[0002] The invention relates to an ultrasonic transmitting and receiving device for measuring the transmission and/or reflection of an ultrasonic signal on a material sheet (material foil). Based on the transmission and/or reflection measurement, the layer thickness and/or the grammage (mass per unit area) of the material sheet can be absolutely determined.
BACKGROUND
[0003] From DE 42 36 436 A1, a measurement method for contact-less determination of the grammage of thin material sheets by means of ultrasonic sound is known. In the method, by means of an ultrasonic transmitter and an ultrasonic receiver, the transmission absorption of an ultrasonic beam upon passage through a material foil is determined in contact-less manner. Based on the absorption and a calibration factor, the grammage is calculated.
[0004] From DE 201 09 119 U1, a further device for measuring the thickness of material sheets is known. There, the material sheet is pulled over a roller, wherein a sensor is arranged on a rolling cart moving back and forth over the roller in traversing manner for thickness measurement.
[0005] Further ultrasonic sensor arrangements for grammage determination or for grammage comparison are known from DE 103 27 389 B3, DE 199 08 932 A1, DE 10 2005 037 086 A1, DE 203 12 388 U1 and DE 30 48 710 A1.
[0006] There is a need for providing an ultrasonic transmitting and receiving device, an arrangement including the device as well as a method, in which the thickness measurement and/or grammage measurement on a material sheet are improved.
SUMMARY
[0007] To address the foregoing problems, in whole or in part, and/or other problems that may have been observed by persons skilled in the art, the present disclosure provides methods, processes, systems, apparatus, instruments, and/or devices, as described by way of example in implementations set forth below.
[0008] According to one implementation, an ultrasonic transmitting and receiving device is provided, by which the transmission and/or the reflection of the ultrasonic waves through or from a thin material sheet are measured by means of the ultrasonic waves. The thickness and/or the grammage (mass per unit area) of the material sheet may be determined based on the measured transmission and/or reflection. The device comprises a plurality of ultrasonic transmitters, wherein each of the ultrasonic transmitters is oriented such that an ultrasonic signal can be emitted towards a thin material sheet. The ultrasonic signal may be a signal pulse or a sequence of signal pulses (“signal burst”). The device unit may include a control unit, by means of which the absolute layer thickness and/or the grammage can be calculated using a calibration value or a calibration curve and the measured transmission and/or reflection and can be displayed and/or output as an absolute value.
[0009] An ultrasonic receiver may be associated with each of the ultrasonic transmitters and oriented towards this such that the ultrasonic signal emitted by the associated ultrasonic transmitter can be received. For example, for determining the transmission, the receiver may be arranged on the side of the material sheet opposing the ultrasonic transmitter and oriented towards the ultrasonic transmitter. For example, for measuring the reflection, either a separate receiver may be arranged on the same side of the material sheet as the ultrasonic transmitter, or the ultrasonic transmitter may operate as a transceiver, by which the signal can be both radiated and received.
[0010] Dedicated receiver electronics may be associated with each of the ultrasonic receivers, or group receiver electronics may each be associated with a group of ultrasonic receivers, such that parallel processing of the ultrasonic signals received and converted by the ultrasonic receivers can be executed with the receiver electronics or group receiver electronics. Within the group receiver electronics a dedicated electronics unit may be associated with each ultrasonic receiver in the group of the ultrasonic receivers which are associated with the group receiver electronics, such that parallel processing of the received voltage signal converted by the receiver can also be executed for each member of the group.
[0011] By the plurality of ultrasonic transmitters, ultrasonic receivers and receiver electronics or group receiver electronics, it is provided to emit, to receive ultrasonic signals and to at least partially condition or process them by the electronics in time-parallel manner. Therefore, it is possible to substantially increase the spatial density and/or the repetition rate of the transmission and/or reflection measurements on the material sheet as compared to for example a reversing system with only one transmitting/receiving unit. Thereby, for example, the quality control by means of thickness and/or grammage determination on a material sheet can be substantially improved. For example, thereby, the fault detection in a material sheet such as a fuel cell membrane, battery membrane or the like increases such that the reject rate is considerably decreased related to the entire production process due to the fault detection of material defects.
[0012] The ultrasonic transmitters may be arranged so as to be distributed on a supporting device such that they extend in transverse direction to the material sheet. Thereby, it is no longer required to provide a traversing device moving the ultrasonic transmitters back and forth across the width (transverse direction) of the material sheet. The ultrasonic transmitters may be fixedly arranged, i.e. they are moved neither in transverse direction nor in longitudinal direction to the material sheet, i.e. during the measurements, exclusively the material sheet moves in longitudinal direction. Thereby, the expenses for providing mechanically moving parts are reduced or are completely avoided. In an embodiment, it can be provided that the supporting device for the ultrasonic transmitters is moved over a small transverse stroke, for example a transverse stroke of less than 1/10, 1/15, 1/20 or 1/30 of the material sheet width.
[0013] In an embodiment, the ultrasonic transmitters are arranged so as to be spatially distributed both over the transverse direction of the material sheet and over a predetermined depth in longitudinal direction of the material sheet. By the distribution of the ultrasonic transmitters in longitudinal direction, it becomes possible to achieve the coverage of the measurement points in longitudinal direction of the material sheet with temporal repetition in nearly continuous or even overlapping manner in a clocked, non-continuous measurement even at high sheet longitudinal velocities. Alternatively or additionally, it is possible to increase the resolution of the measurement locations in transverse direction with both transverse and longitudinal offset of the adjacent ultrasonic transmitters such that complete or nearly complete coverage with measurement points in transverse direction is achieved.
[0014] Notably, multiple lines of ultrasonic transmitters extending in transverse direction of the material sheet may be provided, wherein all of the ultrasonic transmitters of a line are offset to each other in transverse direction and the lines are offset to each other in longitudinal direction. Therein, the dual offset is advantageous such that with projection of the ultrasonic transmitters in longitudinal direction, thus upon viewing the ultrasonic transmitters in the direction of the running direction of the material sheet, the projection of the ultrasonic transmitters is arranged equidistantly to each other. Therein, viewed in projection and in transverse direction, a uniform sampling density in transverse direction of the material sheet is achieved. In an alternative or additional embodiment, a sequence of the ultrasonic transmitters results in a projection in longitudinal direction such that a repeating permutation of the line number of the associated ultrasonic transmitter arises in projected sequence in transverse direction. (Example for illustration: if the lines and columns result in a skewed array or a skewed matrix A ij of the size 3×3 with the column number i=1, 2, 3 and the line number j=1, 2, 3, then the permutation sequence a 11 , a 12 , a 13 , a 21 , a 22 , a 23 , a 31 , a 32 , a 33 results in longitudinal projection). With such an arrangement, the ultrasonic transmitters can be arranged next to each other on a small area in compact manner, while the coverage with ultrasonic transmitters (and the ultrasonic signals radiated by them to the material sheet, respectively) projected in longitudinal direction is provided in transverse direction to the material sheet in continuous or nearly continuous manner.
[0015] The ultrasonic transmitters may be arranged such that only each one ultrasonic transmitter is located in longitudinal direction of the moving material sheet, i.e. all of the ultrasonic transmitters are offset to each other in transverse direction. However, this does not mean that the active transmitting surfaces of the ultrasonic transmitters do not overlap in longitudinal projection (see below). If for example two lines of ultrasonic transmitters with ultrasonic transmitters arranged as distributed over the transverse direction are provided and if the two lines are offset in longitudinal direction, thus, advantageously, the ultrasonic transmitters of the second line are arranged offset by half the distance of the ultrasonic transmitters of the first line in transverse direction with respect to the ultrasonic transmitters of the first line. Thereby, in longitudinal projection, each of the ultrasonic transmitters of the second line is located between two ultrasonic transmitters of the first line (except for the last ultrasonic transmitter of the second line).
[0016] According to an embodiment, the device includes multiple lines of ultrasonic transmitters arranged to be offset to each other in longitudinal direction, wherein the ultrasonic transmitters of the same column are located on one line in the lines located one behind the other, which is under an angle with respect to the longitudinal direction of the material sheet. In some implementations, the angle of this line is in a range of 10° to 80° to the longitudinal direction, or in other implementations in a range of 20° to 70°, 30° to 60° or 40° to 50°.
[0017] Each of the ultrasonic transmitters may have an active transmitting surface extending both in longitudinal direction and in transverse direction. In some implementations, the transmitting surface of the ultrasonic transmitters is round or elliptical. In an embodiment, the ultrasonic transmitters are arranged such that in projection of the ultrasonic transmitters in longitudinal direction of the material sheet, the transmitting surfaces of the ultrasonic transmitters lying next to each other in transverse direction overlap. Thereby, seamless coverage of the sampling of the material sheet in transverse direction in projection is achieved. In some implementations, the overlapping degree between each two ultrasonic transmitters adjacent in projected transverse direction is at least 10% in transverse direction of the projected transmitting surface, or in other implementations at least 15%, 20%, 30%, 35% or 40%.
[0018] In some implementations, 100% of the sheet width is covered by means of the ultrasonic transmitters or the ultrasonic beam emitted by the ultrasonic transmitters, and in some implementations at least partially overlapping coverage in transverse direction of the material sheet is achieved.
[0019] A sensor unit of the device is composed of an ultrasonic transmitter and one or two ultrasonic receivers associated with the ultrasonic transmitter (two receivers in case of the simultaneous measurement of transmission and reflection). The radiating direction of the ultrasonic signal from the ultrasonic transmitter towards the surface may be perpendicularly or approximately perpendicularly oriented to the material sheet. The receiver of the sensor unit therein may be oriented such that it is arranged opposing the ultrasonic transmitter with respect to the material sheet in transmission and receives the transmitted signal. Alternatively or additionally, the ultrasonic receiver measuring the reflection is arranged on the same side of the material sheet as the ultrasonic transmitter. The ultrasonic receiver may at the same time be the ultrasonic transmitter.
[0020] If both transmission and reflection are measured, then in some implementations, one dedicated receiver electronics is provided for each of the reflection receivers and transmission receivers or one group electronics is provided each for a group of reflection receivers and transmission receivers. The described parallel processing of the received signals therein relates to both the transmission and the reflection signals. In the processing or calculation the quotients of the transmission and reflection signals may each be processed for each sensor unit (transmitter and associated transmission and reflection receivers) (quotient either T/R or R/T).
[0021] In an embodiment, the ultrasonic receivers are arranged on a second supporting device paired to the arrangement of the ultrasonic transmitters on the first supporting device. In transmission measurement, the second supporting device may be arranged on the side of the material sheet opposing the first supporting device for the ultrasonic transmitters. By the arrangement of the receivers on a common, second supporting device, all of the receivers can be collectively oriented to the ultrasonic transmitters such that individual orientation of each receiver to its associated transmitter is not required.
[0022] Each of the receiver electronics or group receiver electronics may include an amplifier, in which the amplification is adjustable. In particular, each of the amplifiers may be adjustable in multiple amplification stages and/or the amplification of each of the amplifiers is individually, but centrally adjustable under control of a main control unit via the control or programming of the main control unit. By means of the adjustable amplification, the basic amplification for the amplification of the received ultrasonic signal converted to a voltage signal can be calibrated for each of the ultrasonic receivers. Thereby, for example, an amplification of the received signal is adjusted such that the same signal (for example same signal amplitude and/or signal voltage) is present with all of the amplified signals on identical measurement conditions. Such a uniform or identical measurement condition for example exists if no material sheet is provided between transmitter and receiver or in reflection arrangement towards the radiated signal such that a basic signal in air (transmission signal/reflection signal against air) results in a uniform signal strength after amplification. In some implementations, even when using the group receiver electronics the amplification is also individually adjustable for each individual ultrasonic receiver of the group. Thereby, differences in the transmitting strength of the ultrasonic transmitters, the receiver sensitivities of the signal receivers or different attenuations on the signal paths can be normalized.
[0023] The receiver electronics or the group receiver electronics may have a microcontroller, in particular a microcontroller, by which or in which the amplification of the amplifier of the receiver electronics is adjustable. This correspondingly applies to the group receiver electronics. Here too, the amplification again may be individually and independently adjustable for each of the ultrasonic receivers of the group.
[0024] Alternatively or additionally, each of the receiver electronics or the group receiver electronics includes a signal processor for evaluating the signal or signals received by the associated ultrasonic receiver or the group of ultrasonic receivers. With the signal processor, it is possible to provide signal processing on the level of the receiver electronics or group receiver electronics such that parallel processing is implemented. The signal processor in the group receiver electronics may have a processing speed for processing the signals of the ultrasonic receivers of the group in parallel or sequentially. For example with clocked measurement the evaluation or calculation for each receiver of the group is terminated before a new measurement clock begins. Alternatively, a dedicated signal processor is provided or implemented for each of the receivers of the group in the group receiver electronics.
[0025] A main control unit may be provided, by means of which a transmit signal can be generated, which is supplied to each of the ultrasonic transmitters via a bus line or parallel lines. In particular the signal generation and signal transmitting connection between the main control unit and the ultrasonic transmitters is such that the ultrasonic transmitters radiate the ultrasonic signal at the same time or with a slight temporal offset. If a temporal offset is present, then in clocked measurement operation the period of time between the earliest ultrasonic signal emitted by one of the ultrasonic transmitters to a time, at which the last ultrasonic transmitter emits the signal in the same measurement clock, is smaller than the propagation time of undesired sound reflections and/or propagation times between an ultrasonic transmitter and a signal receiver not associated with this ultrasonic transmitter (i.e. from an ultrasonic signal passing between different sensor units).
[0026] Besides the ultrasonic transmitter and receiver pairs, a measuring group (in the following also referred to as a “sensor unit”) with at least one signal transmitter and a signal receiver may be associated with the device, by which the layer thickness and/or the grammage (mass per unit area) of the material sheet can be determined during a reversing movement or reciprocation of the measuring group transversely to the material sheet. In the sensor unit, a sensor for detecting transmission and/or reflection values of the material sheet is movable in transverse direction of the material sheet transported in longitudinal direction. The sensor unit can be moved back and forth in traversing manner along the device (for example between the outer longitudinal edges of the material sheet) by means of a drive unit. Thereby, for example, during a production process of the material sheet, the transverse distribution of the layer thickness and/or the grammage is monitored (e.g. along a zigzag-shaped measuring path along the material sheet).
[0027] The device may include a sensor calibration position, in which the sensor unit is moved out of the material sheet measuring section. In the sensor calibration position, a supporting device with a calibration sample (as a calibration standard) is arranged. In the sensor calibration position, the sensor is moved relatively to the calibration sample and/or the calibration sample is moved relatively to the sensor by means of a drive.
[0028] In an embodiment, a rotation and/or linear movement is effected by means of a rotation and/or linear drive, which moves the calibration measurement sample retained in the supporting device relatively to the sensor. Additionally or alternatively in the sensor calibration position the sensor can be moved over the calibration sample retained in the supporting device planar or at least in a linear direction, which in some implementations is preferably in the transverse direction of the material sheet.
[0029] The sensor unit may include an ultrasonic sensor unit, in which the measurement signal for layer thickness and/or grammage determination is an ultrasonic pulse. Alternatively, an optical sensor is used, which for example uses a laser beam or a light emitting diode beam. Further alternatively, the sensor unit may have a ray sensor emitting and receiving gamma or beta rays.
[0030] In an embodiment, the sensor unit is exclusively constructed as a transmission unit, in which only the absorption in transmission of the sensor signal through the material sheet is determined. Or the sensor unit is exclusively a reflection unit, in which the reflection of the measurement signal from the material sheet or from the backside of the material sheet is detected. Or alternatively, the sensor unit is a combined transmission and reflection measurement unit, in which both the attenuation of the sensor signal in reflection and in transmission are determined. In such a transmission and reflection measurement, one of the values can be used for plausibility check of the other value and/or for averaging in the layer thickness and/or grammage determination.
[0031] The sensor unit may be used for calibration of the plurality of the ultrasonic transmitter and receiver pairs of the device and/or the sensor unit may be calibrated in the sensor calibration position with the calibration sample.
[0032] According to another implementation, an arrangement includes a device according to one of the preceding embodiments and an extruder, in which an actuator of an extrusion die of the extruder is adjustable depending on the layer thickness and/or grammage measurement of the device. Thereby, control of the layer thickness or of the grammage in the manufacture of a material sheet, for example a foil sheet, is provided.
[0033] According to another implementation, an ultrasonic transmitting and receiving device with a plurality of sensor units is used, wherein each sensor unit is formed of an ultrasonic transmitter and an ultrasonic receiver associated with it. The device may be formed as above described, i.e. the above described elements can also be used individually or in any combination with each other in the device for the method.
[0034] In the method, a control signal is supplied to all of the ultrasonic transmitters at the same time or with a little temporal offset within a time window such that the ultrasonic transmitters emit their ultrasonic signal at the same time or within the time window. The time window is dimensioned such that a spurious reflection signal and/or a signal of another ultrasonic transmitter is not received by an ultrasonic receiver associated with the ultrasonic transmitter in a corresponding time window of the measurement of the ultrasonic signal. By the simultaneous or nearly simultaneous transmission of the ultrasonic signal, parallel measurement of all sensor units is provided, wherein at the same time cross-talk between the sensor units or an error signal by reflection within the measuring section of a sensor unit is excluded.
[0035] Furthermore, in the method, a parallel or substantially parallel processing is provided, wherein one receiver electronics is associated with each of the ultrasonic receivers or one group receiver electronics is associated with a group of ultrasonic receivers, by which evaluation or pre-processing of the signals of the ultrasonic receivers can be executed in parallel or substantially in parallel. Using the group receiver electronics the processing may also be effected for all of the signals of the receivers associated with the group or by fast electronics such that in a clocked measurement the processing result for all of the receivers of the group is finished before the next measurement clock occurs.
[0036] The evaluated or pre-processed signals may be supplied to the receiver electronics or the group receiver electronics of a main control device. Evaluation of the signal for determining the thickness and/or grammage determination may be effected either already on the level of the receiver electronics or group receiver electronics or in the main control device after forwarding the pre-processed signals to the main control device.
[0037] Thereby, by means of the method, both parallel emission (multiple measurement positions on the material sheet at the same time) and parallel processing of the signals is provided such that an intensive detection of the thickness and/or the grammage of a material sheet is provided with high density and repetition rate.
[0038] In an embodiment, the sensor units are calibrated by measuring a basic sensitivity based on a signal transmitted through the air (thus without material sheet). This value may be used in determining the sensitivity in order to adjust an amplification factor individual to the transmitting unit in the receiver electronics or group receiver electronics such that a receive signal is obtained after amplification with identical conditions on the measuring section, which has the same size or strength normalized for all transmitting units.
[0039] Alternatively or additionally, a calibration and detection of a conversion factor between transmission value and/or reflection value and association with a thickness and/or a grammage of a material sheet is effected by using the calibration at a calibration sample or calibration standard, which is applied between the sensor units such that measurement on a material sheet is simulated. After removal of the calibration sample a corresponding material sheet to be measured can then be interposed between the sensor units, the measurements on the material sheet can be carried out and the thickness and/or the grammage can be assigned by means of the previously determined calibration value.
[0040] Other devices, apparatus, systems, methods, features and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] The invention can be better understood by referring to the following figures. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. In the figures, like reference numerals designate corresponding parts throughout the different views.
[0042] FIG. 1 is a schematic plan view of a measuring unit for measuring the grammage of a material sheet.
[0043] FIG. 2 is a schematic side view of the ultrasonic transmitters and receivers of the measuring unit above and below the material sheet.
[0044] FIG. 3 is a schematic side view of the measuring unit with the transmitting block arranged above the material sheet and the receiving block arranged below the material sheet.
[0045] FIG. 4 is a block diagram of the transmitting, receiving and control unit of the measuring unit.
[0046] FIG. 5 schematically shows a group of ultrasonic receivers and the group controller associated therewith.
[0047] FIG. 6 is a time diagram with received signals and measurement time windows.
[0048] FIG. 7 is a set of intensity profiles of the ultrasonic signals emitted by the ultrasonic transmitters in projection.
[0049] FIG. 8 is a plot of the intensity of the ultrasonic signal in transmission and reflection depending on the thickness of the material sheet.
[0050] FIG. 9 is a block diagram of the transmitting, receiving and control unit in further embodiment of the measuring unit.
[0051] FIG. 10 is a schematic plan view a measuring unit according to further embodiment with a calibration station and a traversing sensor unit in an arrangement with a foil extruder.
[0052] FIG. 11 is a schematic representation of the measuring and control arrangement when positioning the traversing sensor unit in the calibration station of FIG. 10 .
DETAILED DESCRIPTION
[0053] FIG. 1 shows in schematic plan view a measuring unit 2 for thickness measurement and/or grammage determination at a material sheet 100 . In the measuring unit, a plurality of ultrasonic transmitters 10 and an equal number of ultrasonic receivers 12 in the form of an array are arranged planar above the material sheet (in the illustrated example, the ultrasonic transmitters 10 ) and below the material sheet (in the illustrated example, the ultrasonic receivers 12 ). For simplicity, the transporting device for moving the material sheet 100 forward in the longitudinal direction x thereof is not represented. In the figures, the size ratios and distance ratios are not represented to scale, but are presented such that they serve for explaining the invention.
[0054] FIG. 2 shows in schematic and partially perspective representation the distribution of the ultrasonic transmitters 10 and the ultrasonic receivers 12 arranged correspondingly opposite and coaxial to each of the ultrasonic transmitters.
[0055] FIG. 3 shows in schematic lateral view a portal 4 of the measuring unit 2 with an upper transverse beam and a lower transverse beam as well as the lateral pillars, which together leave open a slot 7 extending in x direction through the portal 4 . The material sheet 100 is transported in x direction through the slot 7 . The portal and thus the array arrangement extends transversely, thus in y direction, to the material sheet 100 .
[0056] FIG. 1 indicates by means of the circles, which represent the ultrasonic transmitters 10 , how the ultrasonic transmitters form three lines I, II and III, wherein each line is offset in x direction to the preceding one. The columns of the array are formed by the columns a, b, c and d. The ultrasonic transmitters 10 are not on a straight line in x direction, but are arranged offset to each other in an angle α to the x direction. An ultrasonic receiver 12 is oriented coaxially in z direction to each of the ultrasonic transmitters 10 . Thus each one of the ultrasonic sensors is formed by one of the ultrasonic transmitters and one paired ultrasonic receiver, which is arranged in the direction of the normal perpendicularly to the center of the sound emitting surface of the ultrasonic transmitter. I.e. in a sensor, the center of the receiving surface of an ultrasonic receiver 12 is oriented coaxially to the axis of a transmitter 10 . Thereby, a pairing of ultrasonic transmitter and ultrasonic receiver respectively results, wherein 4×3=12 ultrasonic transmitting/receiving pairs are provided in the example illustrated in the figures.
[0057] Both the number of the lines I, II and III and the number of the columns a, b, c, d can be selected differently depending on the material sheet width and the desired overlap or the distance of the measurement regions (see below). The ultrasonic transmitters 10 are mechanically supported distributed in planar manner on a transmitting block 6 , wherein the transmitting block 6 in turn is mounted on the upper transverse beam of the portal 4 . Furthermore, FIG. 3 shows a receiving block 8 below the material sheet 100 on which the ultrasonic receivers 12 are supported distributed in planar manner, wherein here the receiving block 8 is mounted on the lower transverse beam of the portal 4 . In an embodiment, it can be provided that both the transmitting block 6 and the receiving block 8 are displaced synchronously with each other in reversing manner in transverse direction (y direction), while the material thickness or the grammage is measured. By this optional transverse displacement it is effected that the non-uniform signal distribution of the ultrasonic signal is drawn over various “tracks” in x direction of the material sheet in a temporally varied manner. In a synchronous, harmonic transverse displacement of the blocks 6 , 8 , thus, there results a sinusoidal extension of the measurement points in x direction of the material sheet. The reversing, synchronous displacement of the blocks 6 , 8 is effected such that the coaxial orientation of the ultrasonic transmitters 10 to the ultrasonic receivers 12 is maintained. However, the blocks 6 and 8 are preferably rigidly supported on the portal 4 or on a frame of the measuring unit 2 .
[0058] In the schematic side view of FIG. 2 and the plan view of FIG. 1 , the extension of the main intensity cone 14 of an ultrasonic signal distribution is illustrated. Therein, the signal lobe 14 illustrates the lateral divergence of an ultrasonic wave of the ultrasonic signal, which is radiated from an ultrasonic transmitter 10 . The diameter of the lobe 14 is greater than the diameter of the radiation surface of the ultrasonic transmitter 10 on the level of the receiving surface of the ultrasonic receivers 12 . As indicated by means of the dotted circles 14 in FIG. 1 , the distance between the adjacent ultrasonic transmitters 10 is selected such that each ultrasonic receiver 12 substantially only receives the main intensity of the ultrasonic signal of the ultrasonic transmitter 10 associated with and opposing it. Thereby, interferences or cross-talk of a transmitter/receiver pair with the other transmitter/receiver pair (between the sensors) is minimized.
[0059] The angular offset a of the transmitter/receiver pairs of the columns relative to the x direction allows performing the grammage determination in y direction in at least a partially overlapping manner such that in ideal case the thickness and/or grammage distribution of the material sheet 100 over the entire width of the material sheet is possible at each time. This arrangement thus substantially differs from that known from the above cited DE 201 09 119 U1, in which—due to the traversing operation of the ultrasonic transmitter—the detection of a material sheet defect (thickness and/or grammage deviation) rather is left to the statistical coincidence than a systematic measurement as it is allowed with the present invention.
[0060] FIG. 4 shows in block diagram manner the construction of the measuring unit 2 . Here, only two of the ultrasonic transmitters 10 and ultrasonic receivers 12 are exemplarily illustrated. The ultrasonic signal 14 propagates from the transmitter 10 towards the material sheet 100 , passes it with attenuation of the intensity of the signal, which impinges on the receiving surface of the receiver 12 after exiting on the bottom of the material sheet. In each measurement interval (time window G in FIG. 6 ), the signal illustrated as a signal sequence 24 in FIG. 4 is supplied to each transmitter. The signal sequence 24 is generated in a main control unit 22 and supplied to the ultrasonic transmitters 10 in parallel or simultaneously via a transducer 18 .
[0061] The ultrasonic signal 14 converted into an electrical signal by the ultrasonic transducer of the ultrasonic receivers 12 is supplied to a receiver controller 28 . A dedicated controller 28 is associated with each ultrasonic receiver 12 . The electrical signal is processed by means of a digital signal processor in the receiver controller 28 such that just on the level of the controllers 28 signal pre-processing is executed. The signal processing may be effected by means of corresponding calibration values such that the controllers 28 may output a signal value corresponding to the material thickness or the grammage to the control unit 22 via a receive signal line 32 . Thereby, the main control unit 22 is relieved from the individual signal conditioning or processing and only statistical and control tasks have to be executed by the control unit 22 . By the parallel processing in the controllers 28 respectively associated with a receiver 12 , a parallel processing is provided, which together with the planar distribution of the sensor units 10 , 12 in the array allows a nearly complete “in situ” monitoring of the material quality of the material sheet 100 . Even in fast production processes for the material sheet, thereby, high-speed quality monitoring of high density is made available such that high-quality material sheets (such as electrolyte membranes, fuel cell membranes or high-performance battery isolator foils or membranes) can also be produced and the quality thereof can be monitored online.
[0062] FIG. 5 shows a further embodiment, in which a group controller 29 is provided for each four receivers 12 instead of each one controller 28 per receiver 12 . In the 3×4 array of FIG. 1 , then, three group controllers 29 are used instead of twelve individual controllers 28 . The group controllers have a dedicated amplifier component with individual amplification for each receiver 12 belonging to the group. By means of the signal processor DSP of the group controller 29 , the signals of the associated receivers 12 are evaluated sequentially one after the other, but with such a velocity that the computing result is available and output before the next measurement interval begins. With respect to FIG. 6 this means that the result of the signal evaluation of all of the associated receivers 12 is transmitted to the main control unit before the next time window G starts (the evaluation period of time is thus shorter than the sum of the periods of time G and U). Programming of the amplification, the supply of the supply voltage(s) of the controller 29 and programming of the signal processor DSP of the controller 29 are effected via the control line 30 coming from the main control unit 22 . The evaluation signals of the controller 29 are supplied to the main control unit 22 via the line 32 .
[0063] The time diagram of FIG. 6 illustrates the voltage signal at the output of the receivers 12 . The measurement is performed with the repetition rate 1/(G+U), thus also with this rate, the signal sequence 24 is output to the transmitters 10 . Therein, G is the time window or the time gate, in which the received signal 24 a is evaluated in order to determine from it the thickness and/or the grammage of the material sheet by means of the DSP. U is a time interval or a period of time, during which the ultrasonic signal is not received and processed. The duration of G is dimensioned such that the evaluation can be performed with an error as low as possible (multiple wave trains after excitation with the pulse burst 24 ). The duration of U is dimensioned such that undesired spurious signals are masked in this time. Here, exemplarily illustrated spurious signals are a reflection signal 24 b , which arises in that the signal radiated from the transmitter surface is partially reflected on the material sheet surface, returns to the transmitter surface, is again reflected there and again passes the material sheet and is recorded by the receiver 12 with corresponding propagation time delay. A further spurious signal 24 c arises in that the transmit signal is radiated by a transmitter 10 laterally towards an adjacent receiver 12 and there in the adjacent receiver induces a signal 24 c which is propagation time-delayed but weaker.
[0064] FIG. 7 shows in x projection the ultrasonic signal intensity extending in y direction until it results by the array of the transmitting/receiving pairs across the width of the material sheet. In FIG. 7 , for simplicity, only 3 of the overall 12 intensity curves P are illustrated. Therein, the intensity P is that of one transmitter 10 , respectively. Therein, the intensity curve is approximately Gaussian, and with respect to the z axis there is rotational symmetry of the intensity distribution because the ultrasonic transmitting surfaces are round and radiate in rotationally symmetric manner.
[0065] As is apparent from FIG. 7 , the maximum diameter ranges of the diameter D of the radiation surfaces of the ultrasonic transmitters 10 overlap in x projection such that an overlapping region O results in the transmitter 10 closest in y direction. Thereby, the measurement intensity P of all transmitters 10 never drops to 0 in the extension of the y direction, and in transverse direction (y direction) of the material sheet 100 , a width region does not arise, which is not covered by the measurement or the ultrasonic signal. Therefore, due to the array and the columns of the array arranged in an angular offset, a dead zone in transverse direction of the material sheet does not arise.
[0066] FIG. 8 schematically shows the intensity curve of an ultrasonic signal in transmission T and in reflection R depending on the thickness d of the material sheet. Based on such calibration curves for an ideal material sample the thickness or the grammage can be determined based on the actually measured signal variation. In the illustrated arrangement, measurement is made in transmission such that the curve T is used in the thickness or grammage determination.
[0067] For example, if a thicker or thinner material sheet would result in an intermediate region between the intensity maxima of the intensity curve P of two transmitters 10 adjacent in y direction in the material sheet to be measured due to a systematic production fault, thus, this systematic fault can be identified either by detecting systematically a deviating value in the two concerned transmitter/receiver pairs 10 / 12 . Or, alternatively, as described in connection with FIG. 3 , the transmitting block and the receiving block 6 , 8 are displaced synchronously with a short y stroke in y-direction such that the measurement sensitivity is shifted towards maximum of the intensity curve P with such a systematic fault.
[0068] FIG. 9 shows a further configuration of the measuring unit 2 as a measuring unit 2 a . Identical, same or equivalently acting elements of the measuring unit 2 a are labeled with the same reference characters or with reference characters supplemented with the addition “a” as the corresponding element of the measuring unit 2 . In the measuring unit 2 a , the reflection signal 15 reflected back from the material sheet 100 towards the ultrasonic transmitter 10 can also be evaluated or is evaluated with respect to the reflection R (cf. FIG. 8 ).
[0069] The unit 2 a allows the following measurement modes: transmission measurement, reflection measurement, transmission and reflection measurement and additionally to these or alternatively to these a propagation time measurement for direct thickness calculation.
[0070] With respect to the transmission measurement, the setup is as described above with respect to FIGS. 1 to 8 . For reflection measurement, the ultrasonic transmitter 10 a operates as a transceiver receiving the ultrasonic signal 15 reflected on the material sheet 100 and converting it into a voltage signal. First, the signal sequence 24 generated by the main control unit 22 is supplied to the receiving controllers 28 a modified with respect to the receiving controllers 28 . During the transmit interval of the signal sequence 24 , a switch 31 provided at each receiving controller 28 a connects the input of the line 20 to the input on the respective ultrasonic transmitter 10 a such that it operates like the ultrasonic transmitter 10 in this phase and radiates an ultrasonic signal 14 towards the material sheet 100 . After the end of the signal sequence 24 , the switch 31 connects the ultrasonic transmitter 10 a to the microcontroller μC+DSP at the receiving controller 28 a . Therein, the converted reflection signal 15 is supplied to the microcontroller and the signal processor thereof for evaluation. Concerning the evaluation and the temporal gating of the reflection receive signal, the above described in communication with the measuring unit 2 for evaluation of the transmission signal applies.
[0071] Here, the adjustment of the amplification individually programmable for each receiving controller 28 a and the calibration are correspondingly applicable, wherein it applies to the reflection signal instead of the transmission signal. If transmission and reflection are measured at the same time, the receiving controllers 28 and 28 a operate in parallel as it was described above for the operation of the receiving controllers 28 . The results of the evaluated signals or the pre-processed signals are supplied to the main control unit 22 via the line 32 a . Programming, control and current supply of the receiving controllers 28 a as well as switching of the switches 31 is effected from the main control unit 22 via the control line 30 a.
[0072] In an embodiment, instead of individual receiving controllers 38 a , a group controller can be used, which is configured analogously to the group controller 29 of FIG. 5 . The switch 31 can be a controllable switch, which connects the transmitter 10 a to the microcontroller/DSP or to the signal line 20 according to control. Or the switch 31 can be a unidirectional direction gate passing signals 24 incoming from the line 20 towards transmitter 10 a and supplying returning signals from the transmitter 10 a to the microcontroller.
[0073] In evaluation or processing of the signals for thickness and/or grammage determination, the quotient of the values of transmission and reflection (T/R) can be used in the calculation in the measuring unit 2 a . Via the quotient formation, measurement errors affecting proportionally or approximately proportionally both the transmission and the reflection are cancelled out. Examples of the cause of such measurement errors are the air temperature, air pressure or air humidity.
[0074] If thick or highly absorbing materials are measured as the material sheet, the reflection measurement can provide the more accurate results. For example, in transmission, a thickness measurement is unfavorable if the material thickness approaches to λ/4 of the wavelength of the ultrasonic sound or exceeds this value. In the reflection signal, it is also possible to determine the thickness of the material sheet 100 directly from the propagation time difference of the reflection signal. The propagation time difference is the difference between the first reflected signal arising upon impinging of the signal 14 on the surface of the material sheet, and the last (without regard to multiple reflections) reflected signal occurring after passage of the signal 14 through the material sheet on the second surface or exit surface. With known sound velocity in the material, then, the material thickness can be directly determined via the propagation time difference determined by means of signal evaluation.
[0075] FIG. 10 schematically shows in plan view a further configuration of a grammage measuring unit 2 b arranged on a material sheet 100 advanced in longitudinal direction x. In the following, the same reference characters are used for the same or equally acting elements as for the above described embodiments of the measuring units 2 , 2 a . Unless otherwise mentioned, the above explanations also apply to the measuring unit 2 b . As above, for simplicity, the transporting device for advancement of the material sheet 100 is not illustrated. The material sheet is directly measured during the manufacturing process with the measuring unit 2 b (also 2 or 2 a ). As illustrated, the material sheet 100 is extruded as a foil through a flat extrusion die 102 of a foil extruder. In FIG. 10 the further elements of the foil extruder are not illustrated—except for the control unit 101 of the extruder in FIG. 11 . Instead of the flat extrusion die, a round extrusion die can also be employed for the foil extruder, wherein after extrusion the material sheet is stretched to a flat material sheet in the transport, before it enters the portal 4 b of the measuring unit 2 b.
[0076] As noted above, the grammage measuring unit 2 b has a transverse portal 4 b as the basic component, which extends above and below the material sheet 100 across the full width of the material sheet. In this case, the transverse portal 4 b extends on one side considerably beyond the sheet width, since a standby and calibration station 116 for a traversing or reciprocating measuring group or sensor unit 108 is additionally arranged laterally to the material sheet. On the upper transverse beam of the transverse portal 4 b (cf. arrangement of FIG. 3 , the beam extending at the top in y direction), a carriage console 110 is supported on a carriage not visible in the figure, wherein the carriage is movable transversely (thus in y direction) to the material sheet 100 in reversing manner by means of a linear drive.
[0077] The carriage console 110 supports a transmitting head 112 , which can be moved across the full width of the material sheet 100 by means of the carriage console 110 . The carriage console 110 supports the transmitting head 112 radiating ultrasonic pulses to the top of the material sheet for measuring. The ultrasonic signal propagates under attenuation through the material sheet 100 to the lower side thereof, where the attenuated ultrasonic signal exits and impinges on a receiving head 114 opposing the transmitting head 112 . The receiving head 114 is arranged on a carriage console not illustrated, which in turn is movable on the lower beam of the transverse portal 4 b (cf. FIG. 3 ). The lower carriage with the carriage console for the receiving head 114 is moved synchronously with the upper carriage with the console 110 such that the transmitting head 112 and receiving head 114 of the measuring group 108 oppose each other at any time in moving along the material sheet and in the standby and calibration station 116 (with the material sheet 100 or the calibration sample 122 in between).
[0078] At the extrusion die 102 , the thickness of the material sheet is adjusted by means of the pivotable die lip 104 , wherein the adjustment is effected by means of actuators 106 arranged equidistantly to each other transversely to the sheet width. The actuators 106 are for example thermal expansion bolts, the longitudinal expansion of which is adjustable by temperature variation such that they adjust the work angle of the die lip 104 by the length variation. Therein, each actuator 106 acts locally in its width region such that the thickness of the material sheet in the corresponding y width range is substantially determined by the actuator 106 in this width range or in intermediate ranges between two adjacent actuators 106 by the cooperation of these two actuators.
[0079] At the measuring unit 2 b , ultrasonic transmitters 10 and ultrasonic receivers 12 paired thereto are arranged over the width of the material sheet on the portal 4 b , the common measurement regions of which cover the full width of the material sheet. The arrangement is as described above, wherein here the transmitting block 6 with the transmitters 10 and the receiving block 8 with the receivers 12 are preferably stationary supported on the portal 4 b . In this implementation, two array lines I, II offset to each other in transverse direction (y) and six array columns a-f are provided. The above mentioned relating to the transmitters 10 and receivers 12 , the electronic control and evaluation thereof (cf. FIGS. 4 and 9 ) as well as to the procedure of transmitting/receiving/evaluating correspondingly applies.
[0080] As is apparent based on the dot-dashed lines in sheet longitudinal direction (x direction), within the measuring array of the measuring unit 2 b one transmitting/receiving pair 10 , 12 per actuator 106 is arranged in the longitudinal direction of the sheet 100 . The distance of the actuators is in the range of 20 to 40 mm or 25 to 35 mm, typically it is 25.4 or 30 mm. Correspondingly, the center distance of the pairs 10 / 12 in y direction is equal to the distance of the actuators 106 . Here, the association is exemplary from left to right, wherein the transmitting/receiving pair 10 / 12 in line I and column a is associated with the leftmost actuator 106 and the transmitting/receiving pair 10 / 12 in line II and column f is associated with the rightmost actuator 106 . By this association, it is provided that the measurement results of the layer thickness and/or grammage determination are transmitted from the main control unit 22 to the control unit 101 of the extrusion device as illustrated in FIG. 11 . The adjustment of each individual one of the actuators 106 by means of the extruder control unit 101 can then be effected depending on which value of the thickness and/or of the grammage the associated transmitter/receiver pair 10 / 12 provides. The adjustment of the actuators 106 may be effected continuously and in the form of a feedback control arrangement.
[0081] In the schematic cross-sectional view of FIG. 11 , the arrangement of transmitting head 112 and receiving head 114 of the measuring group 108 is illustrated in lateral view, wherein the y direction is perpendicular to the drawing plane in FIG. 10 in the lateral view. By 136 an ultrasonic transmission beam is graphically illustrated, which emanates from the transmitting head 112 . In the illustrated parking position 118 of the measuring group 108 , the transmission beam 136 passes through a calibration sample 122 and impinges on the receiving head 114 .
[0082] The standby and calibration station 116 is laterally offset to the material sheet, thus offset in y direction or transverse direction to the material sheet 100 . The standby and calibration station 116 comprises the parking position 118 , in which both the transmitting head 112 and the opposing receiving head 114 are parked during measurement interruptions or for calibration of the measuring group 108 with the transmitting/receiving unit 112 , 114 .
[0083] In the standby and calibration station 116 , a clamping ring 120 is rotatably supported, which is set into rotation on its outside by means of a pinion 126 . As apparent from FIG. 11 , the pinion or gear 126 is driven by a drive motor 124 . The pinion 126 engages with a ring gear formed at the outer side of the clamping ring 120 such that the rotating speed or angular position of the clamping ring 120 can be controlled by means of the motor 124 . The calibration sample 122 is clamped in the clamping ring 120 . The calibration sample 122 is a round blank of a standard material to be employed for calibration. The blank has an area of a square centimeter such that the grammage of the standard can be determined in simple manner by weighing the blank on precision weighing machine. The calibration standard in form of the calibration sample 122 represents a set value for the thickness and/or the grammage of the material sheet 100 and is employed for repeated calibration of the measuring group 108 including the transmitting and receiving heads 112 , 114 .
[0084] FIG. 11 shows the relative position of the calibration sample 122 besides the schematic lateral view of the transmitting and receiving head 112 , 114 . Similarly, the control and monitoring electronics for the grammage measuring unit 2 b relating to the measuring group 108 and calibration station 116 is illustrated in the form of a block diagram. The control of the measuring group 108 and the calibration station 116 is effected by the same main control unit 22 , which also provides the control, supply and read-out of the transmitting/receiving units 10 / 12 of the arrays of the measuring units 2 or 2 a . In the unit 2 b , the control unit 22 additionally provides the current supply, control, pulse triggering and signal read-out for the measuring group 108 and calibration station 116 .
[0085] In the standby and calibration station 116 , by means of a position sensor 128 , it is detected whether the transmitting head 112 and the receiving head 114 have arrived at the correct parking position 118 in order to perform the calibration for example. The position sensor 128 reports its signal to the control unit 22 of the grammage measuring unit 2 b.
[0086] The control unit 22 controls a transmitter controller 132 of the measuring group 108 . For example, the transmitting controller 132 obtains the supply voltage and an amplification adjusting signal for adjusting the signal amplification from the control unit 22 . With the preset signal amplification, a pulse signal also received from the control unit 22 for the transmitting head 112 is amplified. The transmitter controller 132 outputs the amplified pulse signal to the transmitting head 112 , which converts the voltage signal into the ultrasonic signal 136 .
[0087] The ultrasonic signal received at the receiving head 114 is converted into an electric signal and supplied to a receiver controller 134 . The receiver controller executes signal conditioning and passes the conditioned receive signal to the control unit 22 . For example, the receiver controller 134 comprises a digital signal processor, which provides a signal processing algorithm by a corresponding programming via the control unit 22 , in order to perform the computationally intensive signal evaluation already on the level of the receiver controller 134 .
[0088] In order to for example compensate for thermal drifts, ageing processes, contaminants on the transmitting/receiving path of the ultrasonic signal 136 and the like effects, the measurement of the grammage or of the layer thickness of the material sheet 100 is interrupted in presettable or predefined time intervals for calibration. To this, the transmitting and receiving head 112 , 114 (group 108 ) moves laterally out of the measuring section or path (width of the material sheet 100 ) into the parking position 118 . If the correct position of the transmitting and receiving head 112 , 114 is detected by means of the position sensor 128 , the control unit 22 controls the motor 124 such that the calibration sample 122 clamped in the clamping ring 120 is rotated between transmitting head and receiving head. The center of the transmitting/receiving surface of the transmitting/receiving head 112 , 114 is offset radially to the center of the calibration sample 122 such that the center of the transmitting/receiving head is moved relatively to the calibration sample on a circular orbit.
[0089] During rotation of the calibration sample 122 , ultrasonic transmit pulses are continuously transmitted by the transmitting head 112 and detected by the receiving head 114 .
[0090] Thereby, the transmission values from the calibration sample 122 are measured at different positions distributed over the surface of the calibrations sample. The measured values are recorded by means of the control unit 22 . After one-time or multiple-time rotation of the calibration sample 122 , the control unit 22 forms an average from the measured transmission values and uses it to calibrate the calibration curve for the grammage determination or layer thickness determination by the traversing measuring group 108 .
[0091] FIG. 8 shows exemplarily and schematically with the curve t a calibration curve for the intensity I of the transmission of the ultrasonic signal 136 (cf. signal 14 in FIG. 2 ) depending on the thickness d (the same also applies to the grammage) of the material sheet 100 . If the averaging of the previously described determined transmission measurement results in a deviating calibration value for the layer thickness d or the grammage, thus, the calibration curve is correspondingly upwardly or downwardly corrected.
[0092] Thereby, a newly calibrated calibration curve is available after the calibration and the layer thickness measurement by means of the measuring group 108 transversely to the material sheet 100 can be continued with the new calibration curve such that the grammage or layer thickness determinations can be performed with higher reliability.
[0093] As illustrated in the configuration of the measuring unit 2 b in FIG. 10 , the measuring unit includes both the traversing measuring group 108 (i.e. reciprocating across the material sheet 100 ) as well as the stationary array with the (here twelve) transmitting/receiving pairs 10 / 12 . The measuring group 108 is absolutely calibrated in the calibration station 116 by means of the sample 122 . The calibrated measuring group 108 is then used to calibrate the transmitting/receiving pairs 10 / 12 as follows. The cooperation of material sheet 100 moved in longitudinal direction x and measuring group 108 reciprocating in transverse direction y results in the zigzag-shaped sampling path t illustrated dotted in FIG. 10 .
[0094] Along the sampling path t, the measuring group 108 detects measurement values of the layer thickness and/or the grammage with the repetition rate of the pulsed measurement (cf. FIG. 6 ). Therein, the path t also sweeps the center of the measurement region of the transmitting/receiving pairs 10 / 12 extending in the longitudinal direction x, which is exemplarily illustrated dot-dashed with line s for the pair 10 / 12 in line I, column d (in the following referred to as “(I, d) pair 10 / 12 ”). For this example, the five measurement points m 1 to m 5 are the crossing points of the crossing measuring lines or paths s and t. For calibration of this (I, d) pair 10 / 12 , for example, the average of the five measurement points m 1 -m 5 for the thickness and/or the grammage each for the measurement by means of the measuring group 108 and the measurement by means of the (I, d) pair 10 / 12 is formed, and if they deviate from each other, the calibration value for the (I, d) pair 10 / 12 is newly set such that the averaged values for the measurement points m 1 to m 5 between measuring group 108 and (I, d) pair 10 / 12 coincide. At least, the new calibration value is used in the following measurements for the (I, d) pair 10 / 12 until it again has been calibrated against the measuring group 108 . In this manner, the other transmitting/receiving pairs 10 / 12 are calibrated with the corresponding measurement values on the crossing points of the sampling path t and the associated measuring line s of the transmitting/receiving pair 10 / 12 extending in x direction. This represents a relative calibration of the transmitting/receiving pairs 10 / 12 against the measuring group 108 .
[0095] The feedback of the measurement value of the layer thickness or the grammage of the material sheet from the transmitting/receiving pairs 10 / 12 via the control unit 22 and the control unit 101 for adjusting the actuators 106 on the extrusion die 102 allows a substantially faster control as if for example only the reversing measuring group 108 would be used for measuring and controlling. Moreover, in the measurement at the material sheet 100 and when using only the reversing measuring group 108 it is not possible to identify whether a thickness variation in the longitudinal profile (direction x) or transverse profile (direction y) of the sheet 100 has occurred. A thickness variation in the longitudinal profile for example occurs if the sheet transport proceeds unstably or the foil material exits the die 102 non-uniformly (e.g. on the whole width) due to pressure variations in the extruder. A thickness variation in the transverse profile for example occurs if an individual actuator 106 operates non-uniformly or differently or the die 102 is locally occluded at one or more of the actuators.
[0096] In an embodiment, in the measuring unit 2 b too, the transmitting heads 112 and opposing the receiving heads 114 can be arranged on a transmitting block 6 and receiving block 8 y-displaceable synchronously with each other as in the measuring unit 2 a.
[0097] It will be understood that various aspects or details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation—the invention being defined by the claims.
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An ultrasonic transmitting and receiving device is provided for measuring the transmission and/or reflection of ultrasonic waves on a thin material sheet, in particular on a foil sheet. The device may include a plurality of ultrasonic transmitters, a plurality of ultrasonic receivers, wherein the number of the ultrasonic transmitters corresponds to the number of the ultrasonic receivers, and one receiver electronics respectively for each of the ultrasonic receivers or each a group receiver electronics respectively for a predetermined number of ultrasonic receivers. A method is provided for ultrasonic absorption and/or transmission measurement, in which signals are emitted by multiple ultrasonic transmitters at the same time or nearly at the same time which are received by ultrasonic receivers and in which the received signals are evaluated in parallel.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a dispenser capable of sifting various quantities of material in a controlled manner
2. Brief Description of the Prior Art
Some cooking procedures call for sifting baking powder, cream of tartar, baking soda, flour, corn meal and the like into the recipe or onto a cooking surface. The process usually involves measuring the material with a measuring cup or measuring spoon and imprecise shaking of the product into the recipe or onto the designated surface. For the addition of a “pinch” of salt or a “dash” of spice, a cook may put his or her fingers in the spice container, which is unsanitary, and finger application also results in uneven sprinkling. What is needed is a measuring cup or measuring spoon that can be used for measuring particulate materials and for sifting them in a controlled manner.
BRIEF SUMMARY OF THE INVENTION
In view of the above, it is an object of the present invention to provide a cup or spoon that may double as a true measurer and that can be used to sift materials in a controlled manner. Other objects and features of the invention will be in part apparent and in part pointed out hereinafter.
In accordance with the invention, a material dispenser such as a measuring spoon or a measuring cup is provided for sifting quantities of material in a controlled manner. The material dispenser has a sifter body attached to a handle. The sifter body has a bottom with openings designed to distribute particulate materials placed in the sifter body and a tab at a top edge. The material dispenser distributes particulate materials placed in the sifter body through the openings in the bottom of the sifter body more or less evenly over a designated surface when tapped on the tab by a user. When the handle includes a collar into which the sifter body can be snapped in and popped out, a plurality of sifter bodies with different sized openings may be provided. This permits a dispenser with appropriate sized openings to be selected depending on the material being sifted. While the focus is on measuring and sifting consumables, the material dispenser can be used for other purposes, such as sprinkling glitter on an art project and so forth.
The invention summarized above comprises the constructions hereinafter described, the scope of the invention being indicated by the subjoined claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
In the accompanying drawings, in which several of various possible embodiments of the invention are illustrated, corresponding reference characters refer to corresponding parts throughout the several views of the drawings in which:
FIG. 1 is a perspective view of a spoon in accordance with the present invention with a sifter body seated in a collar of a handle;
FIG. 2 is perspective view of the spoon with a sifter body popped out of the collar in the handle;
FIG. 3 is top plan view of the spoon;
FIG. 4 is a side elevation of the spoon;
FIG. 5 is front end view of the spoon;
FIG. 6 is a back end view of the spoon;
FIG. 7 is a bottom plan view of the spoon;
FIG. 8 is a perspective view showing a tab on the spoon being tapped from the side;
FIG. 9 is a perspective view showing the tab being tapped on top; and,
FIG. 10 is perspective view of a cup with a sifter body and tab in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings more particularly by reference character, reference character 10 refers to a material dispenser in accordance with the present invention in the form of a measuring spoon, as shown in FIGS. 1-9 , and a measuring cup 12 as shown in FIG. 10 .
Beginning with FIGS. 1-9 , spoon 10 has a handle 14 with a first end configured to be grasped by a user's hand 16 . Handle 14 is preferably long enough to reach into larger spice jars, for which purpose handle may be 5 inches or more long. First end may include an aperture 18 for hanging the tool on a hook. As best seen in FIG. 2 , a second end of handle 14 terminate in a collar 20 into which may be seated a sifter body 22 . As shown in FIGS. 1-9 , sifter body 22 is an open ended, perforated container with a ring portion 24 (rolled edge, frustoconical section or the like) about its open end by which it is supported in collar 20 . In some embodiments, sifter body 22 and collar 20 may be integrally formed and sifter body 22 not removable.
With continuing reference to FIGS. 1-9 , sifter body 22 is circular in plan but it may have other shapes including, square, rectangular, oval, polygonal and so forth so long as sifter body 22 matches the shape and form of collar 20 . A rectangular or oval shape may be preferred in some instances for the purpose of slipping into small spice jars. Perforated container may be formed of mesh or with a plurality of narrow slits or an array of holes, the shape and size being suitable to the application for which dispenser is to be used.
A set of spoons 10 may be provided when sifter body 22 is not detachable, ranging from ⅛ teaspoon to 1 tablespoon with the perforation size increasing with increasing spoon size, or not. When sifter body 22 is detachable from handle 14 , sifter bodies that snap into place and pop out of collar 20 easily may be provided with different mesh bowls 26 that vary in mesh size.
A tab 28 is formed on collar 20 for use in sifting material out of sifter body 22 in a controlled manner. As shown in FIG. 8 , when tab 28 is tapped on the side, the material is distributed over a broad area and when tab 28 is tapped on top which may be flattened for that purpose, the material is dropped in a more concentrated manner. Tab 28 may be used as a ledge for resting spoon 10 on the open end of a spice jar and when tab is formed as a hook it may be used to hang spoon 10 on the edge of a cup, glass or bowl.
In use, when spoon 10 is a standard measuring spoon size, spoon 10 can function as a true measuring spoon and, in some case, save the user an extra step. Spoon 10 can be used to sprinkle fine particles of consumables such as paprika on deviled eggs, powdered sugar on brownies and other baked goods, sugar on top of strawberries, decorative sugars and decorations on cutout cookies. Nutmeg, cocoa or cinnamon can be sprinkled on top of hot drinks (like coffee or cocoa) or cold drinks (like eggnog or iced coffee) and dill or dried thyme can be sprinkled on entrees for a splash of color and brightness, not to mention added flavor. With precise measuring and/or application, there is no mess and no waste; spoon 10 is sanitary and unused (and uncontaminated) spices can be returned to the jar.
When sifter body 22 snaps out of collar 20 , a user can select a sifter body 22 with the right size mesh 26 . For instance, with a strong spice like paprika or nutmeg, a user may want to use a sifter body with the finest mesh bowl. For decorating sugars and powdered sugar, a medium mesh bowl 26 may be selected while for herbs, the mesh bowl with the largest mesh 26 may be best.
Turning to FIG. 10 , measuring cup 12 like spoon 10 includes a sifter body 22 in the form of an open ended container 30 with apertures 18 in the bottom designed to distribute particulate materials placed in the sifter body. Cup 12 has a tab 28 opposite to handle 14 . Handle 14 is attached to the outside of container 30 and tab 28 is attached to container 30 at or near its open end. In use, as with spoon 10 , tab 28 may be used for more precise and controlled dispersing of material placed in cup 12 .
In view of the above, it will be seen that the objects of the invention are achieved and other advantageous results attained. 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 shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
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A measuring cup or measuring spoon, the bottom of which has a plurality of openings through which particles can be sifted and a top edge of which has a tab that when tapped allows a user to control the pattern that the particles are sifted.
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This application is a continuation of co-pending application Ser. No. 07/181,922, filed on Apr. 15, 1988, now abandoned, which is a continuation-in-part of co-pending application Ser. No. 057,695, filed on June 1, 1987, now abandoned, which is a continuation-in-part of co-pending application Ser. No. 905,553, filed on Sept. 9, 1986, now abandoned, which is a continuation-in-part of copending-pending application Ser. No. 784,875, filed on Oct. 4, 1985, now abandoned, which is a continuation-in-part application of co-pending application Ser. No. 683,153, filed on Dec. 17, 1984, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for alternating the pressure points of a low air loss bed. The advantages of such an apparatus as well as the particular problems solved by this invention are discussed below.
Low air loss beds use inflatable cushions or air bags as the supporting surface for a patient. By using a fluid supporting medium such as air within the bags, an irregularly shaped body placed on top of the air bags will deform the supporting surface in such a manner so as to provide a more uniform distribution of load bearing pressure points than can be attained with a conventional mattress. When a patient lies supinely on a flat surface, or even on a conventional mattress, most of the load is borne by protuberances of the posterior surface of the body such as the heels, the buttocks, the scapula, and the occipital region of the head. The relatively small areas of soft tissue at these points are then subjected to high pressures by being compressed between the skeleton and the supporting surface. When this pressure becomes great enough to cause collapse of small capillaries and veins, pressure sores may result. By uniformly distributing the supporting pressure points along the body surface, the pressure at these critical areas can be reduced. Patients are also predisposed to pressure sores by the accumulation of moisture at the skin surface. For this reason, air bags which are permeable to water vapor are preferred. A continuous flow of air through the bags from a source of pressurized air is then necessary to remove the water vapor, the air being exhausted through separate outlets or pores in the fabric of the bags. It is this feature which distinguishes a low air loss bed from a simple inflatable mattress.
U.S. Pat. No. 3,822,425 discloses a low air loss bed consisting of a number of cells or bags, each having a surface which supports the patient, formed from a material which is said to be gas permeable but non-permeable to liquids and solids. That patent also discloses an air supply for inflating the cells to the required pressure and outlets or exhaust ports in the cells to allow the escape of air. The bed disclosed is divided into sections, each of which comprises a group of air bags. Each section is provided with a pressure sensor and a control valve allowing each section of the bed to be inflated to different pressures. Alternatively, the air pressure in each section is controlled by valves in the outlets from the section.
Low air loss beds of the type disclosed in the '425 patent are typically also provided with means for adjusting the patient's attitude on the bed. For instance, the head of the bed can be raised to sit the patient up or the angle of the entire frame of the bed can be changed with respect to the horizontal when, for therapeutic reasons, the patient is placed in the Trendelenburg or reverse Trendelenburg positions. Those changes require re-adjustment of the air supply in each section of air bags. Movement of the patient may also necessitate adjustment of the pressure in each section as the patient's weight distribution on the bed changes.
Various other approaches have been taken to solving the problem of preventing bedsores in bedridden patients. One common approach is the use of what is referred to as an alternating pressure mattress. Such mattresses are comprised of two sets of alternately inflatable, interdigitated cells or tubes either connected to form a mattress or formed from closely approximated sheets of air impermeable material which have been heat sealed or otherwise bonded at the edges and with tubes or channels formed therein to form alternating cells. Such mattresses are disclosed in, for example, U.S. Pat. Nos. 3,595,223, 4,193,149, and 4,391,009. In all such mattresses, a separately controllable air supply is provided to each set of cells. By alternately inflating and deflating each set of cells in opposite phase to the other set, the supporting surface of the mattress is alternated between each set of cells. The object of these devices is to periodically relieve and transfer points of contact between the patient's body and the supporting surface. These devices, however, are not low air loss beds. This means that the pressure in each set of cells is merely varied from a full inflate to a full deflate condition. Alternating pressure mattresses have not been designed in the past to provide the uniform patient support provided by low air loss beds. Some have even been designed to do the opposite in order to provide a vigorous massaging action.
The degree of uniformity of support provided by a low air loss bed varies with the pressure existing within the air bags for any given patient. The pressure exerted against a body resting on an air bag is approximately equal to the air pressure within the bag when the air bag is deformed only to an extent which flattens the body contacting surface of the bag. Further deformation increases the pressure exerted by the bag surface against the body because the body contacting surface of the bag, in addition to being pushed by the air pressure within the bag, is pulled by the tension existing in the bag fabric surrounding the body. This tension is maintained by the air pressure exerted against the inner surfaces of the bag which surround the body. In any case, of course, the pressure exerted against the body by the bag surface integrated over the total body contacting surface equals the weight of the body.
In order to maximize the uniformity of support provided by a low air loss bed, the air pressure within the bags should be maintained at a value low enough to allow the supporting surface to be deformed in order to increase the weight bearing surface area but not low enough that too much tension is produced in the bag fabric surrounding the body contacting surface. Such tension in the fabric interferes with the deformation of the supporting surface by protruding body parts. Therefore, for a body of any particular size and weight, there exists a pressure value which maximizes the degree of uniformity of support provided to the body by the air bag. Since weight is not distributed evenly on the human frame, this ideal pressure value varies with different body regions. Heavier regions such as the buttocks require greater pressure to achieve uniform support while lighter regions such as the feet require less pressure.
Of course, no matter how uniform the support provided to a patient by a low air loss bed, areas of the patient's body necessarily are subjected to some pressure. Furthermore, for the reasons discussed above, protruding areas of the body are subjected to relatively greater pressure. It would be advantageous, therefore, for the pressure points in a low air loss bed to be periodically shifted from one body area to another without compromising the uniform supporting characteristics of a low air loss bed.
A low air loss bed which also incorporates some of the characteristics of an alternating pressure mattress would present a number of advantages. Periodically relieving alternate body areas of pressure would ensure that no body area becomes completely ischemic due to excessive support pressure. Also, if the bags are positioned transversely, periodically increasing the pressure to alternate body areas has the effect of compressing subcutaneous veins which, owing to the one-way valves existing in human veins, provides an impetus to the flow of blood back to the heart. Not only does this improve arterial circulation, but it also makes less likely venous pooling which can cause edema and predispose the patient to pressure sores.
In order not to compromise the uniform supporting characteristics of the low air loss bed, however, the air bags cannot simply be separated into two sets, interdigitated, connected to two separate pressure sources, and then alternately inflated and deflated. As aforesaid, an ideal air bag pressure exists for each patient of a particular size and weight which maximizes the degree of uniformity of support. After being determined empirically, the ideal pressure should be maintained in each bag within limits. Furthermore, this ideal pressure varies with the particular body region being supported by a group of air bags. What is needed, therefore, is a low air loss bed which allows operator selection of the air bag pressure for each set of air bags supporting a particular body region and maintains that ideal Pressure as a setpoint or baseline value about which the pressures are raised and lowered as the pressure points are alternately shifted from one set of interdigitated bags to another.
It would be further advantageous for such a low air loss bed to allow the operator to select the degree of relative increase and decrease from the ideal pressure for each set of air bags when in the alternating pressure mode.
Yet another advantage would accrue if the setpoint pressure could be automatically changed for the different sets of air bags as different sections of the bed frame are adjusted from the horizontal.
SUMMARY OF THE INVENTION
These advantages are accomplished in the present invention by providing low air loss beds with a frame having a plurality of sections pivotable with respect to each other, each section corresponding to a portion of the body of a patient supported on the bed. First and second sets of water vapor permeable air bags are mounted transversely to each of the sections. The air bags of the first set of air bags are mounted alternately in between the air bags of the second set of air bags on each section so as to form an interdigitated supporting surface. A means for maintaining a preselected baseline or setpoint pressure in the group of air bags mounted to each section of the frame is provided, as is a means for separately sensing the pressure in the air bags of the first and second sets of air bags mounted to each section. A means is also Provided for changing the pressure in the air bags of each of the first and second sets of air bags mounted to each section in response to the changes in the signal from a pivot sensing means when the sections are pivoted with respect to each other.
Also provided is a source of pressurized air for supplying air to separate gas manifolds communicating with the interior of the air bags belonging to each set and each section. An air control box is mounted to the bed frame and interposed in the flow of air from the air source to the air manifolds, and is provided with individually adjustable valves for changing the amount of air supplied to each of the air manifolds. The air control box is also provided with means for selectively opening all of the valves to the atmosphere, allowing the gas to escape from each of the sets of air bags to collapse the air bags with the result that the patient is supported by the frame of the air bed rather than the air bags. This facilitates performance of cardiopulmonary resuscitation procedures. The air control box is also provided with means for simultaneously fully opening the valves to cause the air bags to fully inflate. There also exists means for heating the air flowing through the air control box with a means for switching the heating means on and off in response to the temperature in the air control box.
Maximum and minimum pressures defined as target pressures above and below the baseline pressure can be preselected for each of the first and second sets of air bags. Means are provided for alternately changing the pressure in the first set of air bags to the maximum target pressure while changing the pressure in the second set to the minimum target pressure and vice-versa in cyclical and repetitive fashion. In this way, the pressure points on the supporting surface of the bed to which a patient is subjected are alternated without compromising the uniform support characteristics of the low air loss bed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a presently preferred embodiment of the patient support system of the present invention.
FIG. 2 is a cross-sectional view of the patient support system of FIG. 1 taken along the lines 2--2 in FIG. 1.
FIG. 3 is a schematic diagram of the air plumbing of the patient support system of FIG. 1.
FIG. 4 is a perspective view of one of the baseboards of the patient support system of FIG. 1.
FIG. 5 is an enlarged, exploded perspective view of the underside of the baseboard of FIG. 4, showing the baseboard partially cut away to show the details of attachment of a low air loss air bag thereto.
FIG. 6 is an end view of the patient support system of FIG. 1 with the head portion raised to show the construction of the frame the components mounted thereto.
FIG. 7 is an end view of the patient support system of FIG. 1 with the foot portion raised to show the construction of the frame and the components mounted thereto.
FIG. 8 is a sectional view of the air box of the patient support system of FIG. 1 taken along the lines 8--8 in FIG. 9A.
FIGS. 9A and 9B are cross-sectional views taken along the lines 9A--9A and 9B--9B, respectively, through the manifold assembly of the air box as shown in FIG. 8.
FIG. 10 is a schematic electrical diagram of the patient support system of FIG. 1.
FIG. 11 is a perspective view of a portion of the bed frame of the patient support system of FIG. 1 showing a potentiometer mounted to one frame section which is pivotally connected to an adjacent frame section.
FIG. 12 is schematic diagram of the electrical cables and controls which open and close the valves to route air to the air bags of, the patient support system of FIG. 1.
FIG. 13 is a flow chart of a presently preferred embodiment of the program for controlling the operations of the patient support system in FIG. 1 from the control panel shown in FIG. 12.
FIG. 14 is a flow chart of the general timer subroutine for controlling the operation of the patient support system of FIG. 1.
FIG. 15 is a flow chart of the switch processing subroutine for controlling the operation of the patient support system of FIG. 1.
FIG. 16 is a flow chart of the air control subroutine for controlling the operation of the patient support system of FIG. 1.
FIG. 17 is a flow chart of the valve motor driver subroutine for controlling the operation of the patient support system of FIG. 1.
FIG. 18 is a flow chart of the power fail interrupt subroutine for controlling the operation of the patient support system FIG. 1.
FIG. 19 is a general diagrammatic description of the control software for controlling the operation of the patient support system of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1, 6 and 7, there is shown a patient support system 10 including a frame 12. The frame 12 is comprised of a plurality of sections 14', 14'', 14''' and 14'''', hinged at the points 44', 44'' and 44''', and end members 16. Cross-members 18 (FIGS. 6 and 7) and braces 19 (FIG. 7) are provided for additional rigidity. The frame 12 is provided with headboard 20 at one end and a foot board 21 at the other end.
A separate sub-frame, indicated generally at reference numeral 27 in FIGS. 6 and 7, is mounted on a base 22 comprised of longitudinal beams 24, cross-beams 26 and cross-member 28 by means of a vertical height adjustment mechanism as will be described. The base 22 is mounted on casters 30 at the corners of the base 22. A foot pedal 42 is provided for braking and steering the casters 30.
Sub-frame 27 is comprised of cross beams 29, hoop brace 35, and longitudinal beams 31 (see FIGS. 6 and 7). Sub-frame 27 is provided at the corners with uprights 33, having tabs 33' thereon, for mounting of IV bottles and other equipment. Means is provided for raising and lowering the sub-frame 27 relative to the base 22 in the form of a conventional vertical height adjustment mechanism, not all of the details of which are shown. Height is adjusted by rotation of an axle under influence of a power screw, hidden from view in FIG. 7 by drive tunnel beam 37, which is powered by a motor which is also hidden from view. Power is transferred from the power screw to an axle by means of eccentric levers journaled in and hidden by drive tunnel beam 37. Sub-frame 27 rises on levers 32 which are pivotally mounted to the cross-beams 26 of base 22 by members 34 and to frame 12 by the ears 38 which are mounted to the longitudinal beams 31 of subframe 27.
The section 14'' of frame 12 is mounted to the longitudinal beams 31 of sub-frame 27 by support members 41 (see FIG. 6). The section 14' of frame 12, with the head baseboard 52 thereon, and the section 14'''' of frame 12, with foot baseboard 46 thereon, pivot upwardly from the horizontal at the hinges 44' and 44'40 40 , respectively. The purpose of that pivoting is to provide for the adjustment of the angle of inclination of the various parts of the body of the patient, and the details of that pivoting are known in the art and are not shown for purposes of clarity, although the motors are located within the boxes shown at 45 and are controlled by the switches 233, 235, 236, 237, 238, and 239 on control Panel 346, or from the redundant controls on bed hand control 361 (see FIG. 12), and the circuitry for those functions is contained within box 43 (FIG. 7).
Supports 17 (see FIG. 6) are provided on the cross member 18 under head baseboard 52 which rest on the longitudinal beams 31 of sub-frame 27 when head baseboard 52 is horizontal. When foot baseboard 46 is raised (FIG. 7), cross-bar 47 rises therewith by means of the pivoting connection created by cross-bar 47 and the notches 49 in brace 19 (cross-bar 47 is shown detached from braces 19 in FIG. 7 for purposes of clarity). The sets of notches 49 provide means for adjusting the height to which cross-bar 47 can be raised, cross-bar 47 pivoting on brackets 51 which are pivotally mounted to the longitudinal beams 31 of sub-frame 27. The tips 53 of cross-bar 47 rest on longitudinal beam 31 when foot baseboard 46 is lowered to the horizontal.
Side rails 81 are mounted to brackets 83 (see FIG. 6) which are pivotally mounted to the mounting brackets 85 mounted on the underside of head baseboard 52. Side rails 87 are mounted to brackets 89 (see FIG. 7), and brackets 89 are pivotally mounted to the mounting brackets 91. Mounting brackets 91 are affixed to the braces 19 on the underside of foot baseboard 46.
The frame 12 is provided with a feet baseboard 46, a leg baseboard 48, a seat baseboard 50 and a head baseboard 52 (shown in shadow lines in FIG. 3), each being mounted to the corresponding section 14', 14'', 14''' and 14'''' of the frame 12. Means is provided for releasably securing air bags 58 to each of the baseboards 46, 48, 50 and 52. Referring to FIGS. 2, 4, and 5, there is shown a presently preferred embodiment of that releasable securing means. In FIGS. 4 and 5, there is shown a portion of the feet baseboard 46, which is provided with holes 64 therethrough which are alternating and opposite each other along the length of the feet baseboard 46, as well as leg baseboard 48, seat baseboard 50 and head baseboard 52. Every other hole 64 on each side of the baseboards is provided with a key slot 11 for receiving the post 54, having retainer 55 mounted thereon, which projects through the bottom surface 79 of air bag 58, the flange 71 of which is retained between patch 69, which is stitched to the bottom surface 79 of air bag 58, and the bottom surface 79. Air bag 58 is shown cutaway and in shadow lines in FIG. 5 for purposes of clarity. Air bag 58 is also provided with a nipple 23 of resilient polymeric plastic material having an extension tab 15 integral therewith and secured in the bottom surface 79 of air bag 58 in the same manner as post 54 is secured thereto. To releasably secure the air bag 58 to feet baseboard 46, or any of the other baseboards 48, 50, or 52, post 54 is inserted through hole 64 until retainer 55 has emerged from the bottom thereof. Post 54 is then slid into engagement with key slot 11 and retainer 55 engages the bottom side of feet baseboard 46 around the margin of hole 64 to retain air bag 58 in place on feet baseboard 46. Nipple 23 is then inserted into the hole 64 opposite the hole 64 having key slot 11 therein and rotated until extension tab 15 engages the bottom of the head of flat head screw 13 to help secure nipple 23 in place.
Referring to FIG. 2, the air bags 58 are substantially rectangular in shape, and are constructed of a coated fabric or similar material through which water vapor can move, but which water and other liquids will not penetrate. The fabric sold under the trademark "GORE-TEX" is one such suitable material. The air bags 58 can include one or more outlets for the escape of the air with which they are inflated or they can be constructed in a "low air loss" conformation. The air bags 58 may be constructed in a "low air loss" conformation. The low air loss air bag shown at reference numeral 58 in FIG. 2 can be a composite of a gas impermeable fabric, which makes up the bottom 79 and the walls 61 of the air bag 58, and the gas permeable fabric described above, which makes up the top 63 of the air bag. The top 63 and walls 61 are stitched or otherwise joined at shadow lines 63'. The gas impermeable fabric of the walls 61 and bottom 79 is, for instance, a polymer-coated nylon. The use of a low air loss air bag 58 allows the pressurization of the air bag 58 with a smaller flow of gas, which results in the possibility of maintaining sufficient pressure with just one blower 108 operating while using low air loss air bags 58.
As noted above, all of the air bags 58 are substantially rectangular in shape with dimensions of approximately 14×39 inches. A baffle 460 is attached to the side walls 61 of each air bag 58 by stitching 63' to hold the side walls 61 against bowing when the air bag 58 is inflated. Each of the corners 448 of air bag 58 has a radius of curvature of approximately three inches, and the use of individual air bags 58 rather than a single air cushion allows the replacement of individual bags should one develop a leak, need cleaning or otherwise need attention. When it is desired to remove an individual air bag 58 from its respective baseboard 46, 48, 50, or 52, post 54 is slid out of key slot 11 and retainer 55 and post 54 are removed from hole 64. Nipple 23 is then rotated until extension tab 15 rotates out of engagement with screw 13 and is pulled firmly to remove it from hole 64. Removal can even be accomplished while the patient (not shown) is lying on the inflated air bags 58.
Referring to FIG. 6, there is shown an end view of a bed constructed according to the present invention. Brace 102 is secured to the cross beam 29 of sub-frame 27 by means of bolts 104. Blowers 108 are mounted to the brace 102 by means of bolts 110 through the mounting plates 112 which are integral with the blower housing 116. A gasket, piece of plywood or particle board (not shown), or other sound and vibration dampening material is interposed between mounting plates 112 and brace 102. A strip of such material (not shown) can also be inserted between brace 102 and cross beam 29. The blowers 108 include integral permanent split capacitor electric motors 114. When motors 114 are activated, blowers 108 move air out of the blower housings 116, through the blower funnels 118 and up the blower hoses 120 to the air box funnels 122 and on into the air box 124 (see FIGS. 3, 8, 9A and 9B).
Blowers 108 receive air from filter box 96 through hoses 98 (see FIG. 3). Filter box 96 is retained within a frame 100 (see FIG. 6) for ease in removal. Frame 100 is mounted to frame 27 and is, for the most part, blocked from view by cross-beam 26 of base 22 and cross beam 29 of frame 27 in FIG. 6. The second blower 108 is provided to increase the volume which is delivered to the air bags 58, thereby increasing the air pressure within air bags 58. A cover (not shown) lined with sound absorbing material can also be provided to enclose blowers 108 and thereby reduce noise.
The air control box 124 is an airtight box mounted on the underside of head baseboard 52 by brackets 125, the details of which are shown in FIG. 8. The front of air box 124 is provided with a manifold assembly 126. Manifold assembly 126 is provided with a manifold plate 145 having holes (not numbered) therein for connection to a means for changing the amount of air supplied to the air bags 58 mounted to baseboards 46, 48, 50 and 52 in the region of the feet, legs, seat, back, and head, respectively. Gasket 115 prevents the escape of air from between air box 124 and manifold plate 145. In a presently preferred embodiment, the means for changing the amount of air supplied to the air bags 58 takes the form of a plurality of valves, indicated generally at reference numerals 128, 130a and 130b, 132a and 132b, and 134a and 134b (see also FIG. 3). Each of the valves 128, 130a and 130b, 132a and 132b, and 134a and 134b is provided with a motor 138 having a nylon threaded shaft 139 (see FIGS. 8, 9A and 9B) mounted on the drive shaft (not numbered) of each motor 138 and held in place by set screw 149 in collar 148. Plug 140 moves rotatably in and out along the threaded shaft 139 when limit pin 141 of plug 140 engages one or the other of the supports 142 which are immediately adjacent that particular plug 140 and which hold the motor mounting bracket 143 to the back of the full inflate plate 144.
Full inflate plate 144, having openings 202 therein forming part of valves 128, 130a and 130b, 132a and 132b, and 134a and 134b, is mounted to the back of the manifold plate 145 by hinges 146 (see also FIGS. 9A and 9B). A gasket 147 is provided to prevent the escape of air from between the full inflate plate 144 and manifold plate 145. The motors 138 are not provided with limit switches, the movement of plug 140 back and forth along the threaded shaft 139 of each motor 138 being limited by engagement of plug 140 with the opening 202 as plug 140 moves forward and by the engagement of the back side of plug 140 with collar 148 as plug 140 moves back on threaded shaft 139. An 0-ring 204 is provided on plug 140 which is compressed between plug 140 and opening 202 as plug 140 moves forward into opening 202. Compression continues until the load on motor 138 is sufficient to cause it to stop. The 0-ring 206 which is provided on collar 148 operates in similar fashion when engaged by the back side of plug 140.
The stopping of motors 138 by the loading of O-rings 204 and 206 facilitates the reversal of the motors 138 and direction of travel of plug 140 along threaded shaft 139 because threaded shaft 139 is not bound. Threaded shaft 139 is free to reverse direction and turn such that the load created by the compression of 0-rings 204 or 206 is released by the turning of threaded shaft 139, and plug 140 will rotate with threaded shaft 139 until limit pin 141 contacts support 42, stopping the rotation of plug 140 and causing it to move along shaft 139 as it continues to turn.
A dump plate 150 is mounted on the outside of manifold plate 145 by means of hinges 151 (see FIGS. 9A and 9B). A gasket 106 is provided to prevent the escape of air from between the manifold plate 145 and the dump plate 150. The dump plate 150 is provided with couplers 153, the interiors of which are continuous with the holes in manifold plate 145 when dump plate 150 is in the position shown in FIGS. 8, 9A, and B, for connection of the appropriate bed frame air supply hoses 174, 176a and 176b, 178a and 178b, and 182a and 182b, as will be explained.
Block 154 is attached to dump plate 150 by means of screws 155, and serves as a point at which the cable 156 can be anchored, by means of nut 157, so that a line 158 can slide back and forth within cable 156 to allow the dump plate 150 to be selectively pivoted away from manifold plate 145 on hinge 151. The line 158 is secured to the manifold plate 145 by the threaded cable end and locknut 159. Line 158 is secured at its other end to the bracket 183 mounted on tube 190 (see FIG. 7). Bed frame 12 is provided with quick dump levers 165 on both sides thereof, the quick dump levers 165 being connected by lube 190 so that both levers 165 provide a remote control for operation of dump plate 150 by causing the movement of line 158 through cable 156. When either of quick dump levers 165 is moved from the position shown in FIG. 7, eccentric lever arm 181 pulls on line 158, cable 156 being anchored on bracket 183, so that line 158 moves through cable 156. The details of the anchoring of cable 156 and movement of line 158 therethrough under the influence of lever arm 181 are the same as those for the anchoring of cable 160 and movement of line 162 therethrough under the influence of lever arm 185 (see below). Movement of line 158 causes dump plate 150 to pivot away from manifold plate 145, allowing the air in air bags 58 to escape through manifolds 76, 78, 80, 82 and 84 and bed frame air supply hoses 174, 176a, 178a, 180a, 176b, 178b, and 180b to the atmosphere from the opening thus created between manifold plate 145 and dump plate 150 so that air bags 58 will rapidly deflate. A coil spring 201' encloses line 158 within bores (not numbered) in dump plate 150 and manifold plate 145 to bias dump plate 150 and manifold plate 145 apart.
As is best shown on FIGS. 8 and 9B, a separate cable 160 passes through manifold plate 145 in threaded fitting 161 so that line 162 can slide back and forth therein. The line 162 is anchored in the full inflate plate 144 by means of nut 163, which allows the full inflate plate 144 to pivot away from the manifold plate 145 on hinge 146. Pivoting of full inflate plate 144 away from manifold plate 145 in this manner removes full inflate plate 144, motor mounting bracket 143, and all other parts mounted to those parts, from the flow of air to allow the unrestricted entry of the air in air box 124 into the couplers 153 of valves 128, 130a and 130b, 132a and 132b, and 134a and 134b and on into bed frame air supply hoses 174, 176a and 176b, 178a and 178b, and 182a and 182b, resulting in the rapid and full inflation of air bags 58 to raise the patient on air bags 58 to facilitate patient transfer or other needs. A coil spring 201 encloses line 162 in a bore (not numbered) in manifold plate 145 and full inflate plate 144 to bias manifold plate 145 apart from full inflate plate 144.
Line 162 is anchored at the end opposite full inflate plate 144 on lever arm 185 (FIG. 7) which is attached to the bar 195 upon which full inflate knob 193 is mounted. Bed frame 12 is provided with full inflate knobs 193 on both sides thereof, the full inflate knobs 193 being connected by bar 195 so that both control the movement of line 162 through cable 160. Cable 160 is affixed to bracket 187 by threaded cable end 199, which is mounted on the DELRIN synthetic plastic bearing 209 which is integral with support member 210 and which receives bar 195 so that rotation of full inflate knobs 193 causes line 162 to slide therein, pivoting full inflate plate 144 on hinge 146. The weight of motors 138, supports 142 and motor mounting bracket 143 bias full inflate plate 144 toward the position in which full inflate plate 144, motor mounting bracket 143, and the parts mounted thereto, are removed from the flow of air into the couplers 153 of valves 128, 130a and 130b, 132a and 132b, and 134a and 134b. This bias allows knobs 193 to act as a release such that either of knobs 193 need only be turned enough to move the connection between line 162 and lever arm 185 out of its over center position, at which point gravity causes the Plate 144 to open. When knobs 193 are returned to their initial position, lever arm 185 turns to the point at which the connection between line 162 and lever arm 185 is rotated past 180° from the point at which line 162 approaches bar 195, i.e., over center. As noted below, the microprocessor 240 included within controller 198 includes an alarm buzzer (not shown). Switches can be provided for activating that alarm when either of knobs 193 or levers 165 are used to inflate or deflate air bags 58.
Air enters the air box 124 through air box funnels 122 in back plate 121 (FIG. 3). Air box funnel 122 is provided with a one-way flapper valve, shown schematically at reference numeral 117, so that air will not escape from the air box 124 when only one blower 108 is being operated. The air box 124 is provided with a heating strip indicated schematically at reference numeral 172. Heating strip 172 is mounted in bulkhead 133 in air box 124, effectively partitioning air box 124 into two compartments. Because air enters the air box 124 in one compartment (i.e., behind heating element 172) and leaves the air box 124 from the other compartment, a flow of air must pass through the space 135 between bulkhead 133 in which heating element 172 is mounted, being mixed and heated in the process.
Referring to FIG. 3, blowers 108 are switched on, forcing or pumping air (or other gases) received from filter box 96 through hoses 98 up the blower hoses 120, through one-way valves 117, and into air box 124. The air escapes from the air box 124 through valves 128, 130a and 130b, 132a and 132b, and 134a and 134b into the respective bed frame air supply hoses, 174, 176a and 176b, 178a and 178b, and 182a and 182b. Bed frame air supply hoses 174, 176a and 176b, 178a and 178b, and 182a and 182b route the air to the manifolds 76 and 76', 78 and 78 , 80 and 80', 82 and 82', and 84. Bed frame air supply hoses 178a and 178b are connected to seat air manifolds 80 and 80 , which are connected by bed frame air supply hoses 180a and 180b to leg air manifold 78'. Bed frame air supply hoses 182a and 182b route air to back air manifolds 82 and 82', respectively. Bed frame air supply hose 174 routes air to head air manifold 84. Each of the air manifolds 76 and 76', 78 and 78', 80 and 80', 82 and 82', and 84 is mounted to the underside of the baseboards 46, 48, 50 and 52, feet baseboard 46 having air manifolds 76 and 76' mounted thereto, leg baseboard 48 having air manifolds 78 and 78 mounted thereto, and seat baseboard 50 having air manifolds 80 and 80' mounted thereto. The head baseboard 52, and its corresponding section 14'''' of frame 12, is provided with two back air manifolds 82 and 82' and head air manifold 84.
Because the feet baseboard 46 extends beyond the end member 16 of the frame 12 at the foot of the bed, T-intersects 86 and 86' are provided from the feet air manifolds 76 and 76', respectively, to route feet extension hoses 88 and 88' to the holes 64 and 64 at the extreme ends of the feet baseboard 46 (see FIGS. 3, 7 and 11). Clamps 65 are provided to hold the feet extension hoses 88 and 88' in place on the nipples 23 in holes 64 and 64' and on T-intersects 86 and 86'. The head baseboard 52 likewise extends beyond the end member 16 of frame 12 at the head end of the bed (FIGS. 3 and 6), and T-intersect 92 is provided from the head air manifold 84 to provide air to the hole 64 at the extreme end of the head baseboard 52 by means of the head extension hose 94. A clamp 65 is provided to retain head extension hose 94 on T-intersect 92 and on the receptacle 66 in hole 64.
Air enters the air manifolds 76 and 76', 78 and 78', 80 and 80', 82 and 82', and 84 from each respective bed frame air supply hose 174, 176a and 176b, 178a and 178b, 180a and 180b, or 182a, and then passes down the length of each air manifold 76 and 76', 78 and 78', 80 and 80', 82 and 82', or 84. Air escapes from the air manifolds 76 and 76', 78 and 78', 80 and 80', 82 and 82', or 84 into the air bags 58 through the holes 64 and 64' in the baseboards 46, 48, 50 and 52, thereby inflating the air bags 58.
As described above, the holes 64 and 64' through base boards 46, 48, 50 and 52 into the air bags 58 are staggered down the length of the frame 12 of patient support system 10. In other words, every other hole 64, or 64', is provided with a key slot 11 (see FIG. 4). Air bags 58 are provided with a single nipple 23, and a post 54 with retainer 55 thereon for engagement of key slot 11 in hole 64 or 64' at the other end thereof. The air bags 58 alternate in their orientation on baseboards 46, 48, 50 and 52, resulting in about half the air bags 58 being oriented with nipple 23 closer to one side of bed frame 12 than the nipple 23 of the other half of the air bags 58 mounted thereon. In this manner, and as will be explained, the air bags 58 of patient support system 10 are divided into first and second sets, i.e., one set having the nipple 23 closer to one side of the bed frame 12 and a second set having the nipple 23 closer to the other side of bed frame 12.
Because each of the bed frame air supply hoses 174, 176a and 176b, 178a and 178b, 180a and 180b, and 182a and 182b is continuous with a corresponding air manifold 76 and 76', 78 and 78', 80 and 80', 82 and 82', or 84, the amount of air supplied to each air manifold 76 and 76', 78 and 78', 80 and 80', 82 and 82', or 84 can be varied using the valves 128, 130a and 130b, 132a and 132b, and 134a and 134b on the air box 124. Since each of the valves 128, 130a and 130b, 132a and 132b, and 134a and 134b controls the amount of air supplied to one of the manifolds 76 and 76', 78 and 78', 80 and 80', 82 and 82', or 84, each valve 128, 130a and 130b, 132a and 132b, 134a and 134b controls the amount of air supplied to the set of air bags 58 inflated by each individual air manifold 76 and 76', 78 and 78', 80 and 80', 82 and 82', or 84.
As will be explained, means is provided for alternately inflating first the air bags 58 connected to back, seat, leg and feet air manifolds 76, 78, 80 and 82, respectively, and then deflating those air bags while inflating the air bags 58 connected to back, seat, leg and feet air manifolds 76', 78', 80' and 82'. The alternating inflation and deflation of the first set of air bags 58 and the second set of air bags 58 causes the pressure exerted against a patient (not shown) supported thereon to be alternately exerted by a first set of air bags 58 and then by a second set of air bags 58 because of the alternating arrangement of the air bags 58 on baseboards 76, 78, 80, 82 and 84.
To accomplish the changing of the location at which pressure is exerted against the patient, the two sets of air bags 58 are alternately inflated and deflated in a repetitive and cyclical fashion under microprocessor control. Referring to FIG. 3, valves 130a, 132a, and 134a feed air to manifolds 82, 80, 78 and 76. These manifolds feed air to the first set of air bags 58 having their nipples 23 closer to a first side of bed frame 12. Similarly, valves 130b, 132b, and 134b feed air manifolds 82', 80', 78' and 76' which feed air to the second set of air bags 58 having their nipples 23 closer to the second side of bed frame 12, i.e., in fluid connection with manifolds 82', 80', 78' and 76'. Valve 128 feeds air to manifold 84 which supplies air to the air bags 58 supporting the head of the patient. Pressures in each manifold can be controlled by microprocessor 240 (see FIG. 12) by adjustment of the individual valves which supply air to each manifold.
Also shown in FIGS. 3 and 7 is a portable power unit, or transporter, indicated generally at 426. Portable power unit 426 is comprised of case 428, which encloses batteries 430, blower 432 and battery charger 434, and hose 436. Hose 436 is provided with a releasable coupler 438 which mates with the coupler 440 of the hose 442 which is mounted on sub-frame 27 and which connects to air box 124 through funnel 444. Brackets 446 are mounted to subframe 27 for releasably engaging the case 428 of portable power unit 426. Portable power unit 426 provides air pressure to support a patient when an electrical outlet is unavailable, for instance, during patient transport.
The microprocessor 240 contained within controller 198 (see FIG. 12) is programmed to operate on an internal interrupt basis. That is, the software idles until a specified number of clock pulses is received, at which point an interrupt signal is generated internally by microprocessor 240. When the software detects this internal interrupt, the various functional software modules shown in FIG. 19 are executed sequentially. Since microprocessor 240 is configured to generate the internal interrupt every fifty milliseconds, the functional software modules of FIG. 19 are executed every fifty milliseconds.
Referring now to FIG. 19, there is shown a block diagram of the functional software modules used to accomplish the control functions of the present invention. Initialization and interrupt driven power-down routines, as described below, are also present in the software but have been omitted from this diagram for simplicity. FIG. 19 merely depicts the application software which is executed every fifty milliseconds by microprocessor 240. Some of the functional modules or routines of FIG. 19 will be described in greater detail below. What follows is an overview of how these routines are integrated to accomplish the objectives of the present invention.
RAM data table 903 is a block of memory which is used to store variables needed by the control software. Those variables include software timers, status flags, switch status inputs, analog data inputs, baseline pressure values, and a target temperature value. Software timers are simply memory contents which are initialized with a specified value and then decremented every fifty milliseconds by general timer routine 252 (shown in more detail in FIG. 14). Switch status inputs are digital inputs received from control panel 346 or from various switches described elsewhere. The status of each of these switches is stored in RAM data table 903 so that spurious switch bounce conditions can be detected, as is described in greater detail below. Status flags are memory words used by the software to communicate to the software modules a certain status which affects how a software module is to operate. For example, a status flag is used to signify whether the air bags 58 in fluid connection with manifolds 76, 78, 80 and 82 or the air bags in fluid connection with manifolds 76', 78', 80' and 82', i.e., the air bags of the first or second sets of air bags 58, are to be inflated. Status flags can be changed by external inputs or by the timing out of certain software timers. Also, the target pressures and temperature, which the software attempts to maintain and is adjustable by operator input, are stored in RAM data table 903. Analog data, corresponding to values received from pressure and temperature transducers, are processed by microprocessor 240 and converted into status flags.
Upon receiving the aforementioned internal interrupt, the first module to be executed by microprocessor 240 is general timer routine 252. This routine decrements the various software timers and sets certain status flags which affect the operation of other modules when a timed out condition occurs. Next, switch processing routine 254 (see FIG. 15), which scans all the digital inputs, is executed. When a change is detected in a digital input, the appropriate switch function routine 284 is executed. As will be described below, those switch function routines activate the selected operation according to the specific switch input change detected.
After all the digital inputs have been scanned, inflation control routine 292 (FIG. 16) is executed. Inflation control routine 292 determines whether valves 128, 130a and 130b, 132a and 132b, or 134a and 134b need to be opened, closed, or maintained in their present position to maintain or increase or decrease the pressure in the first or second set of air bags 58. To make that decision, inflation control routine 292 relies on analog data from the pressure transducers, baseline pressure values, timer values and status flags which tell the routine which baseline pressure values to use. Inflation control routine 292 sets status flags which are then read by motor valve routine 316 (FIG. 17). Motor valve routine 316 actually controls the valve motors 138 according to the decisions made by inflation control routine 292. Those decisions are communicated to motor valve routine 316 by status flags.
Heater/blower control routine 905 retrieves present and target temperature values from analog data RAM data table 903, compares them, and either turns heater strip 172 on or off with a digital output. The last module to be executed as part of the internal interrupt driven loop is the display writer-driver routine 901. This routine retrieves data from RAM data table 903 which is to be output to control panel 346 (see FIG. 12). Display writer-driver routine 901 then drives the bar graph displays 356 of control panel 346 according to the data retrieved. Analog input routine 904 operates continuously according to external interrupts generated from the temperature and pressure transducers (shown collectively at reference numeral 900 in FIG. 19) by an analog-to-digital converter shown schematically at reference numeral 800, but which is internal to control box 198 and, therefore, not shown elsewhere. Analog input routine 904 retrieves data from analog-to-digital converter 800 for use by various software modules.
Referring now to FIGS. 13-18, the programming of microprocessor 240 will be discussed. As shown in FIG. 13, the initialization of the program is at 242. Variable memory or RAM is cleared at step 244. Before internal or external interrupts are enabled, all RAM variable contents are zeroed and those requiring specific data, such as those stored at power down in the electrically alterable ROM described below, are initialized at step 246. Data and direction registers for the four eight bit ports of microprocessor 240 are then initialized at step 248.
The control software then idles in loop 250 until it receives a 50 millisecond interrupt from the hardware interrupt timer internal to microprocessor 240. Microprocessor 240 then sequentially executes the subroutines 252, 254, 292 and 316, diagrammed in FIGS. 14-7. General timer subroutine 252 (see FIG. 14) decrements most of the software driven timers contained in the RAM, including the electrically alterable ROM power "ON" delay before erase timer, the cardiopulmonary switched "OFF" to the audible alarm "ON" delay timer, the audible alarm silence timer, and the rotation timer. General timer subroutine 252 is entered from FIG. 13 at connector 253, and the first step 255 is to test to determine whether the power on/off pushbutton 851 (see FIG. 12) has been switched to the "OFF" position or the run/pause adjust button 728 has been activated, a step which is required because the loop 250 runs at 50 msec intervals whenever main power cord 218 (see FIG. 10) is plugged into a power source (not shown). If either of those buttons 851 or 728 have been activated, the subroutine 252 continues to step 259A, if not, the status of the air pulsation timer is checked at step 256. The air pulsation timer is used to time the inflation/deflation of the air bags of the first and second sets of air bags 58 from the selected baseline pressures as will be described. If the target (zero) has not been attained, the air pulsation timer is decremented at step 257. If target has been attained, the pulsation mode is advanced to the next sequential pulsation phase and the timer is re-initialized at step 258.
As will be described, temperature set switch 152 is used in conjunction with display 168 on control panel 346 (see FIG. 12) to set the target temperature in air manifold feeding the bags by pressing and holding one or the other of switches 152A or 152B to increment or decrement the counter which advances the target temperature by an increment each time a selected number of 50 msec pulses have elapsed (or decreases by that same increment). If switch 152A or 152B has been activated by the operator, a test is made at step 259B to determine which switch was activated. If decrease/decrement switch 152B was activated, the counter is checked to determine whether the count is at minimum count at step 259C. If so, the subroutine advances to step 259, and if not, the counter is decremented at step 259D and the subroutine 252 continues to step 259. If the status check at step 259B indicates that the temperature increase/increment switch 152A has been activated, the counter is checked to determine whether the count is at a maximum at step 259E. If so, subroutine 252 advances to step 259, and if not, the counter is incremented at step 259F and subroutine 252 then advances to step 259.
If the power "ON" delay timer is not zero at step 259, that timer is decremented at 260, and the subroutine advances to step 261. The cardiopulmonary timer is decremented at step 262 if the timer is not zero, and checked again at step 263. If the timer has just expired and there is an alarm condition, the alarm (not shown) in microprocessor 240 is activated at 264; if the timer has not expired, the routine advances to the audible beep silence timer at 265. If that timer has not expired, the timer is decremented at 266, checked again at 267, and if just expired, the alarm is activated at 268. The general timer subroutine 252 is then exited when the last timer has been processed, and connects back into the control software at 270 (see FIG. 13).
The switch processing subroutine 254 is diagrammed in FIG. 15, and monitors the status of the switches on control panel 346, the switches 226 and 228 in air box 124, the status of the switches (not shown) of hand control 361 (see FIG. 12), and pressure sensor pad switches 231a and 231b. Switch processing subroutine 254, entered from FIG. 13 at connector 272, assigns a number to each input at step 274, and processes each numbered input in loop fashion. Each input is tested for status at 50 millisecond intervals at step 276, although it will be understood by those skilled in the art who have the benefit of this disclosure that other time intervals may likewise be appropriate for testing the status of the inputs. Switch status is tested by comparing the current switch status with the status of the switch from the last interrupt at step 278. If a change is detected, a switch bounce condition is assumed and the switch number is incremented at step 280 for processing the next switch input. If a change from the prior switch status is detected, a switch position change test is made at step 282 and switch function is executed at step 284 if a switch change is detected. If the switch status is consistent through three successive tests, no switch position change is indicated and the switch number is incremented at step 280 as described above. Switch number is compared to a limit number at step 286, and if less then that limit number, the switch number is incremented at 285 and the above processing is repeated in loop 288 for the incremented switch number. Provision is made to initialize the switch states on power up by testing at step 287 to determine whether the first pass is being made through the switches. If so, the power down memory is read at 289 and those toggle mode switches for which data is stored in the electrically alterable ROM are initialized at 283 to reflect the switch status at the time of the previous power off. Switch processing subroutine 254 is exited when the last switch number has been processed and connects back into the control software at 290.
There are separate switch function routines 284 for each functional set of operator inputs to control panel 346. Referring to FIG. 12, control panel 346 is provided with air adjust switches 349, 351, 353, and 355. Each air adjust switch 349, 351, 353, and 355 is actually a pair of buttons which raises or lowers the baseline or target pressure to be achieved in each set of air bags 58 by indirect adjustment of each of valves 128, 130a and 130b, 132a and 132b, 134a and 134b upon operator command. These target pressures are stored in memory locations by microprocessor 240. In the air pulsation subroutine described below, the baseline pressures are used as setpoints which the software attempts to achieve and/or maintain by opening and closing valves 128, 130a and 130b, 132a and 132b, 134a and 134b. There are four baseline pressures, one for each of the patient's head, shoulder, body and leg, and it is those four baseline pressures which are stored into memory, i.e., the RAM data table 903 (see FIG. 19) and which are attained if the power on switch 851 is activated without subsequent adjustment with the controls of control panel 346. Those baseline pressures are reflected in the bar graphs 356 immediately above each respective air adjust switch 349, 351, 353, and 355 for each portion of the patient's body. As will be explained, bar graphs 356 can be used to display actual pressure in air bags 58 during normal operation of patient support system 10 or to display baseline pressures during operator programming. On activation of the power on switch 851, each of the bar graphs 356 display the left and right averages of actual air pressures in the four sections of the patient's body above each corresponding pair of air adjust switches 349, 351, 353, and 355. To change a baseline pressure, the operator activates air adjust switch 630 and then uses the desired air adjust switch 349, 351, 353 or 355 to increase or decrease the baseline pressure that is to be changed. Switch function routine 284 (see FIG. 15) then increments or decrements the memory location in RAM which corresponds to that baseline pressure. At the same time, the changing baseline pressure is output to the bar graph 356 corresponding to the particular air adjust switch that has been activated. In this way, each of the four baseline pressures for the four portions of the patient's body is defined by the operator. The air adjust switch 630 is then depressed again to exit the air adjust mode.
Default settings are provided for three weight ranges of patients, each default setting having a tall and a short patient option. These default settings are preset baseline pressures likewise permanently programmed into memory locations in RAM table 903. Buttons are provided on control panel 346 for selection of these baseline pressures for tall patients in the light weight range 350A, for short patients in the light weight range 350B, for tall patients in the medium weight range 352A, for short patients in the medium weight range 352B, for tall patients in the heavy weight range 354A and short patients in the heavy weight range 354B. These "tall" and "short" designations are subjective and merely constitute a range of baseline pressures which can be selected based upon the subjective height and weight combination of the patient. In a presently preferred embodiment, the light, medium, and heavy patient weight guidelines correspond to patients weighing between 100 and 160, 150 and 210, and 200 and 250 pounds, but those skilled in the art who have the benefit of this disclosure will recognize that other guidelines may be equally appropriate. These guidelines were selected by determining the average baseline pressures needed to satisfactorily support the largest number of patients on air bags 58. The average baseline pressures were determined by experimentation involving a large number of persons on a patient support system such as that shown at reference numeral 10 of random height and weight, and recording the air pressure settings required to support each person satisfactorily. When grouped according to the above-described subjective height-weight combinations, the pressure settings fell into recurring patterns such that the use of the default settings provides for proper support of most patients, even when used by hospital personnel unfamiliar with the operation of a patient support system constructed in accordance with the present invention or the unique advantages of low air loss therapy.
Indicator lights 357A, 357B, and 357C are provided above each of the switches 350A and 350B, 352A and 352B, and 354A and 354B to provide an immediate indication of which range of patient weight and height has been selected by the operator. The bar graph 356 located immediately thereabove provides a display of the baseline target pressures resulting from selection of one of the switches 350A and 350B, 352A and 352B, or 354A and 354B. Further, air adjust switch 630 can be activated and baseline pressures adjusted in the same manner as described above. Switch 630 must be active for 350A, 350B, 352A, 352B, 354A, and 354B to work as well. Once the switch 350A or 350B, 352A or 352B, or 354A or 354B has been activated, and the adjusted baseline pressure is stored in RAM data table 903 the air adjust switch 630 is then depressed again to exit the air adjust mode.
Another switch function routine 284 similar to that described above allows the operator to adjust the pause time, i.e., the period of time during which the patient is supported by the air bags of either the first or second set of air bags 58. The pause time is stored in a timer location which the timer routine decrements after each interval interrupt. The pause time is adjusted by depressing the pause adjust button 728 and monitoring the bar graph 356 immediately above switch 728 on control panel 346.
Another switch function routine 284 is executed when the switch processing routine 254 detects an operator input from height adjust switches 233, 235, 236, 237, 238, and 239. Switches 233 and 237 raise and lower the frame section 14' of patient support system 10, respectively, while switches 236 and 239 raise or lower frame section 14'''', respectively. Switches 235 and 238 raise or lower the entire frame 12 of patient support system 10, respectively. The switch function routine which is executed when one of those switches is depressed causes actuation of the power screws described above to effect the appropriate height adjustment.
Similarly, another switch function routine 284 allows the operator to adjust the temperature at which the air supply to air manifolds is to be maintained. The target temperature is used as a setpoint by microprocessor 240 to control heater strip 172. The target temperature is adjusted using switches 152A and 152B, and a digital display 168 of the target temperature is driven by the software.
The pulsation subroutine 292 is shown in FIG. 16. This routine is entered at connector 294 after general timer subroutine 252 has adjusted the appropriate software timers to determine the baseline pressure to which the patient support system is to be either altered or maintained. Subroutine 292 is then executed for each of valves 128, 130a and 130b, 132a and 132b, 134a and 134b to alternately inflate and deflate the two sets of air bags 58 supplied with air by manifolds 76, 78, 80, and 82 and 76', 78', 80' and 82' to alternately support the patient on either the first or second set of air bags 58. The particular valve number is read at step 296 and the operator mode checked to determine whether the normal or diagnostic mode (see below) has been selected at step 297. Next, the baseline pressure for that particular valve set as described above is read from RAM table 903 at step 300 and the resultant target pressure is then calculated dependent upon PULSE status and time into the cycle. Baseline values are used if PULSE is off.
Once pulse pushbutton 358 has been selected, controller 198 including microprocessor 240 therein operates to alternately signal valves 128, 130a and 130b, 132a and 132b, and 134a and 134b to increase the pressure in the first set of air bags 58 to a predetermined maximum pressure, decrease the pressure in the second set of air bags 58 to a predetermined minimum pressure, and then raise the pressure in the second set of air bags 58 to a predetermined maximum pressure and lower the pressure in the first set of air bags 58 to a predetermined minimum pressure.
______________________________________ Low Pulse High Pulse______________________________________Maximum +12.5% +25%Minimum -25% -50%______________________________________
Each number in the above table is a percentage of the baseline Pressure, i.e., if the low pulse switch 632 is selected, the maximum pressure is 12.5% above baseline pressure and the minimum pressure is 25% below baseline pressure. It will be understood by those skilled in the art who have the benefit of this disclosure that these percentages are a range of pressures which may vary depending upon the weight of the patient, the baseline pressure selected, whether one or both of blowers 108 is being operated, and a variety of other factors.
At step 302, theoretical pressure is calculated. Reference is made to theoretical pressures because of the active nature of the operation of the patient support system 10. Beginning with the baseline pressure, the deviation of target pressure from the baseline is calculated at this step, and that deviation will, of course, depend upon whether the air bags 58 under the control of a particular motor 138 are being inflated or deflated, i.e., whether the patient support system is being operated in the pulse mode, and time into the PULSE mode cycle. Consequently, theoretical pressure is baseline pressure if the patient support system 10 is not in the pulsation mode.
At step 307, an individual valve 128, 130a and 130b, 132a and 132b, or 134a and 134b may or may not be adjusted according to the output signal of potentiometer 468 which is also read at step 300. Potentiometer 468 inputs a voltage value to analog-to-digital converter 474 which converts that voltage to a digital value representing the angular displacement of a section 14' with respect to the adjacent section 14''. As the section 14' of frame 12 is pivoted with respect to the section 14'', the distribution of the weight of the body of the patient supported on the air bags 58 is changed. Accordingly, microprocessor 240 adjusts the target pressures to compensate for that change in weight distribution.
Referring to FIG. 11, two adjacent frame sections 14' and 14''are shown joined by hinge 44'. Bracket 462 is attached to frame section 14'' by bolt 464 and nut 466. Potentiometer 468 is mounted upon bracket 462 such that the shaft 467 thereof is free to rotate throughout an appropriate operating range. The shaft 467 of potentiometer 468 and hinge 44' are arranged so that their axes of rotation are aligned, and the shaft 467 of potentiometer 468 is journaled in frame section 14'. When frame section 14'' is pivoted with respect to section 14', connector 470 is likewise rotated, causing the rotation of the shaft 467 of potentiometer 468, resulting in a change in the output voltage of potentiometer 468 which is proportional to the angular displacement between frame sections 14' and 14''. That change in output results in a signal which is transmitted by wire 472 to microprocessor 240 (see FIG. 12). The output signal of potentiometer 468 is adjusted so that for each increment in the elevation of frame section 14' from the horizontal of about 15°, the pressure in the sets of air sacs mounted on baseboards 48 and 50 is increased by.
An actual pressure is obtained by sensing the air pressure in the air chuck 212 (see FIGS. 8, 9A, and 9B) corresponding to the particular valve 128, 130a and 130b, 132a and 132b, or 134a and 134b, which is at, or close enough to the air pressure in the air bags 58 which are inflated or deflated by opening or closing that valve to provide an air pressure measurement that can be compared to the theoretical pressure to allow any necessary adjustment as described below. The pressure from air chucks 212 is transmitted by air pressure lines 213 to pressure transducers (not shown) mounted in control box 198. The pressure transducers are of a type suitable for reading pressures in the range of about 0-1 psig available Microswitch Corp. (Freeport, Illinois) and Sensym Corp. (Sunnyvale, Calif.). The pressure transducers output a voltage proportional to the particular pressure to an analog-to-digital converter within control box 198 which then inputs data to microprocessor 240.
Once the theoretical pressures have been calculated and the actual pressures read, the two pressures are compared at step 306. If the actual pressure is too high, the degree of difference is determined at step 306a, and if the degree of difference is small, the opening 202 of that valve is closed by activating the motor to run slowly at step 307a. If the degree of difference is large, the opening 202 of that valve is closed by activating the motor 138 to run quickly at step 307b. If the actual pressure is too low at step 306, the degree of difference is determined at step 306b. If the degree of difference is small, the motor 138 is activated to open the opening 202 of that valve slowly at step 307d, and if the degree of difference is large, the motor 138 is activated to open the opening 202 of that valve quickly in step 307c. If the theoretical and actual pressures for that set of air bags 58 are equal, the valve motor 138 of the valve corresponding to that set of air bags 58 is turned off at step 308b.
After execution of step 308b, provision is made for display of the actual air pressure in the air chucks 212 in fluid connection with the couplers 153 of each of the valves 138, 130a and 130b, 132a and 132b, and 134a and 134b on bar graphs 356. The operator selects whether actual or target pressures are displayed at step 310 by whether air adjust switch 630 (see FIG. 12) has been actuated. Actual display data is calculated at step 312 and output to bar graphs 356 at step 314. If switch 630 has been actuated, target display data is calculated at step 315 and output at 314 as before. Pulsation subroutine 292 is then exited at connector 298. Left and right pressures are averaged for the display.
Pulsation subroutine 292 is also provided with a diagnostic mode entered by key stroke sequence available to qualified personnel. In the diagnostic mode, the valve motors 138 do not run on their own; instead, they are immediately turned off and pressures are allowed to drift. The individual air adjust switches 349, 351, 353, and 355 can then be used to manually open or close a particular valve 138, 130a and 130b, 132a and 132b, and 134a and 134b. Those switches are read at step 305 and the appropriate motor function executed at step 308. If the deflate switch has been activated, motor 138 is activated to close the valve quickly at step 307b. If the inflate switch has been activated, the motor 138 is activated to open the valve quickly at step 307c. If no switches have been activated, the motor 138 remains off at step 308b. The air pressure is then displayed as discussed above.
Referring to FIGS. 1 and 12, pushbutton switches 851, 357, 358, 852, and 853 are mounted in auxiliary control Panel 850. Pushbutton 851 is the main power on/off switch. Depressing pushbutton 358 puts the patient support system 10 in the pulsation mode whereby microprocessor 240 directs the inflation/deflation of air bags 58 cyclically above and below the previously programmed baseline pressures to the programmed maximum or minimum pressures stored in RAM data table 903. Activating pushbutton 358 a second time places the patient support system 10 in the air suspension therapy mode and returns the air bags 58 to baseline pressure values. Pushbuttons 52 and 53 duplicate the function of switches 628 and 632 on control panel 346 as described above. Activating pushbutton 357 causes the air in the air bags 58 of both the first and second sets of air bags mounted to leg and seat baseboards 48 and 50, in other words, the air bags 58 which are supplied with air manifolds 78, 78', 80 and 80', to deflate rapidly. Deflation of those air bags 58 facilitates the transfer of a patient, or the movement of the patient under the patient's own power, onto or off of patient support system 10. The function of pushbutton 357 is duplicated by pushbutton switches 854 and 856, shown schematically in FIG. 12, and located on the sides of the frame 12 of patient support system 10.
The valve motor subroutine 316, diagrammed in FIG. 17, converts valve motor movement commands generated by the switch processing and pulsation subroutines 254 and 292, respectively, into valve motor operations, i.e., starting and reversing each of the motors 138 used to open and/or close valves 128, 130a and 130b, 132a and 132b, and 134a and 134b. Each motor 138 is provided with a timer (not shown), and is pulsed on and off under control of that timer, which is in turn controlled by valve motor subroutine 316. Valve motor subroutine 316 is entered at connector 318. Each motor 138 is assigned a number at step 320 and is tested for its current status, i.e., on or off, at step 370. If the current motor status is off, the timer is checked to determine whether the counter has counted down to zero at step 372. If the timer has timed out, then the software can turn the motor back on, and in the next step 374, the software is checked to determine whether there is a pending run command. If there is no pending run command, as would be the case if the air pressures in the respective air bags 58 are at the determined target pressures, the routine is exited by checking the motor number to determine whether all the motors 138 have been checked at step 382. If the last motor number has not been reached, the motor number is decremented at step 386 and the motor status of the next motor is checked at step 370 by operation of loop 376. If there is a pending run command at step 374 as a result of a difference in actual and theoretical pressure, valve motor subroutine 316 turns the motor 138 that supplies air to that particular set of air bags 58 on at step 378 and re-initializes the timer for that motor at step 380. The motor number is then checked to determine whether that motor was the last motor at step 382; if so, valve motor subroutine 316 is exited through connected 384, and if not, the motor number counter is decremented at step 386 and processing continues by way of loop 376.
If a motor is on at step 370, the valve motor subroutine 316 continues by decrementing the RUN mode timer at step 388. The timer is then tested to determine whether the counter has reached zero at step 390. If not, a test is made at step 392 to determine whether there are any pending stop or reverse commands. If not, the motor number is tested at step 382 to determine whether the last motor has been reached and processing continues as described above. If the counter has decremented to zero at step 390, that motor is turned off at step 402, the timer is initialized at step 404, and the number assigned to that motor is tested at step 382 to determine whether that motor number is the number of the last motor 138. If that number is not the last motor number, the motor number counter is decremented at step 386 and the above processing repeated.
A power fail interrupt subroutine 416, diagrammed in FIG. 18, writes certain controller configuration parameters such as blower and pulsation mode status in electrically alterable ROM in the event of a power failure or when patient support system 10 is unplugged. Power fail interrupt subroutine 416 is entered upon receipt of an interrupt from hardware circuit not shown. If the electrically alterable ROM, power on delay before erase, timer (EEROM timer) tested at step 418 is zeroed, i.e., if patient support system 10 has been powered on for more than a few seconds such that the electrically alterable ROM is available for writing, the aforementioned parameters are stored to memory at step 420 and the EEROM timer is initiated at step 422 before returning to the codes before the interrupt at step 424. If the EEROM timer is not zeroed at step 418, patient support system 10 has probably just been powered on and the memory is not available for writing. Should the control software (see FIG. 13) receive a power interruption that generates the power fail interrupt and performs the memory write but does not actually interrupt power to the control software, power fail interrupt subroutine 416 initializes the EEROM timer and will be available to rewrite the memory after the EEROM timer has once again timed out.
As noted above, the frame 12 is hinged at 44', 44'' and 44'40 ', allowing the baseboards 46 and 52 to be raised from the horizontal, changing the angle of inclination for the comfort of the patient or for therapeutic purposes. However, especially when head baseboard 52 is raised, the deviation from the horizontal places a disproportionate amount of the weight of the patient on the air bags 58 over the legs 48 and seat 50 baseboards. In a presently preferred embodiment of the present invention, there are only three air bags 58 mounted on each of the baseboards 48 and 50, such that a great proportion of the patient's weight, which is spread out over more than 20 of the air bags 58 when the sections 14', 14'', 14''' and 14'''' are all in the same horizontal plane, is concentrated onto as few as six of the air bags 58, and then that weight is concentrated onto even fewer air bags 58 when the air bags of the first and second sets of air bags are alternately inflated and deflated. Pressure sensor pad switches 231a and 231b (see FIG. 12) are placed flat on legs baseboard 48 and seat baseboard 50 so that, in the event a portion of the patient's body contacts either one of those switches 231a or 231b, the above-described audible alarm is activated by microprocessor 240, and can be silenced by activation of switch 347 by the operator, and the air pressure in air bags 58 mounted to seat baseboard 50 can be raised by the operator. This alarm is disabled during the CPR and seat deflate modes.
Referring to FIG. 10, there is shown a schematic electrical diagram of a patient support system constructed according to the teachings of the present invention. Alternating current enters the circuitry in electric cord 218 which is connected to power distribution board 219 (see also FIG. 12). Power distribution board 219 includes a power supply module, shown schematically at reference numeral 220, to supply power to microprocessor 240 through cable 211 and solid state relays (not numbered) to control each of the blowers 108 and heater strip 172. Power distribution board 219 also provides power to the motors (not shown) within boxes 45 (see FIG. 7) for raising, lowering and positioning the frame 12 of patient support system 10 by means of lead 223 which connects to the junction box 224 of bed circuitry 43. Power distribution board 219 also powers the electric motors 114 of blowers 108. Each of the blowers 108 is provided with a capacitor 216. Blowers are indirectly controlled by switch 192 and other status inputs which are read by microprocessor 240. The cable connecting microprocessor 240 and switch 241 is buried in the cable 211 shown in FIG. 12.
Referring to FIG. 12, a temperature sensor, shown schematically at 194, is located in seat manifold 80 (also shown schematically). When the target temperature set by the operator using switches 152A or 152B and display 168 is more than the temperature of the air in seat manifold 80, heating strip 172 (shown schematically in FIG. 12) is switched on by microprocessor 240, again through the connection provided by a cable buried in cable 211. Heating strip 172 is provided with current by wires 167i and 167o from main power supply module 220 (see also FIG. 10). Switch 191 on control Panel 346 is used to activate or deactivate heating strip 172, and a separate switch 189 is provided for switching display 168 from ° C to ° F The microprocessor turns the heat off when both blowers are off.
As described above, limit switches 226 and 228 are provided in manifold plate 145 and on full inflate plate 144, respectively (see FIGS. 8, 9A and 12). Limit switch 226 is closed when push button 230 is engaged by dump Plate 150 (not shown in FIG. 12). When push button 230 is disengaged by the movement of dump plate 150 away from manifold plate 145 under the influence of levers 165, the circuit is opened and blowers 108 are shut off. As described above, limit switch 228 is affixed to full inflate plate 144 by screws 232, and the circuit including limit switch 228 and formed by wires 228i and 228o is open when lever arm 234 engages manifold plate 145. When full inflate plate 144 is opened under the influence of full inflate knobs 193, limit switch 228 is closed, activating both blowers 108, if not already on and the audible alarm which is incorporated into microprocessor 240. A switch 347 is provided on control panel 346 to silence that alarm.
Control panel 346 is connected to controller 198 by ribbon connectors 200. Controller 198 is provided with plug-type receptors 205 for receiving the plugs 207 of cables 170a and b, 208, 211, 225, 227, and 472.
Cable 208 connects controller 198 to temperature sensor 94. Cable 225 connects pressure sensor pad switches 231a and b to controller 198. Cables 170a and 170bare provided with separate wires 184i and 184o for each motor 138, thereby conducting low voltage D.C. current to each of the motors 138 under the control of microprocessor 240. Cable 170a is also provided with separate wires 226i and 226o and 228i and 228o connecting separately to limit switches 226 and 228i respectively.
Cable 227 is provided with plugs 359 on the other end from plug 207 for engaging a complementary plug 360 on a separate hand control 361 which duplicates the function of the switches 233, 235, 236, 237, 238, and 239 on control panel 346. Hand controls 361 are shown schematically in FIG. 12 because they merely duplicate keyboard 346 functions. Plugs 359 are provided on both sides of bed frame 12 (not shown in FIG. 12) to facilitate easy access by hospital personnel with hand control 361.
Although the present invention has been described in terms of the foregoing preferred embodiments, this description has been provided by way of explanation only and is not to be construed as a limitation of the invention, the scope of which is limited only by the following claims.
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A method and apparatus for therapeutically treating immobile patients is disclosed. A low air loss bed is provided having groups of transversely oriented air bags, each group corresponding to a different portion of the body of a patent supported thereon. Each group comprises first and second sets of air bags alternately positioned in an interdigitated fashion. Valves and circuitry are provided for maintaining a selectable baseline pressure in the air bags belonging to each group. The valves and circuitry is also capable of changing the pressures in each of the sets of air bags mounted to each section of the frame to selectable maximum and minimum values above and below the baseline pressure in a repetitive and cyclical fashion.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a tool for boring a hole in an element and, more particularly, to a staged tool for boring a hole in a heated element, which boring proceeds by axial penetration and which boring involves deformation of the material of the element being bored.
2. Discussion of Background and Relevant Information
A number of difficulties may be encountered when attempting to form a hole in a solid material. It is frequently desired to form such holes, especially in metallic elements. Such holes have been formed by tools that punch into and/or through the material; such holes have also been formed by forming a small pre-hole in the element and then by guiding a relatively large tool through the pre-hole. Difficulties arise because of constraints based on the resistance and rheology of the material being deformed, as well as because of friction and lubrication problems.
Staged tools have heretofore been developed to form holes in solid material. Examples of such tools are shown and described in Russian patent document No. A-880,545; Japanese patent document No. A-54109056; French patent document No. A-552,043; and French patent document No. E-25550. Each of the tools described in these various patents successively includes, beginning at the forward ends of the tools, a front end portion, which is cylindrical or conical; a neck; and a working portion having a right straight section of revolution which increases in the direction opposite to that of the advancement of the tool. These tools can be utilized with their working surfaces in direct contact with the wall of the hole pierced in the element or with a lubrication layer interposed between their working surfaces and the wall of the hole. If such a lubricant is utilized, it is generally positioned in the inlet of a pre-hole bored in the element, as is described, for example, in French patent document No. A 2 067 226, French patent document No. A 1 130 759, and British patent document No. A 1 365 510 . Such lubrication systems have a shortcoming, that shortcoming being that the lubricant mass, e.g., a flexible sheet of glass, a sheet of glass fabric, or a cone of powder of an agglomerated glass, may be pushed, to a large degree, in front of the tool where it cannot properly perform its lubricating function.
SUMMARY OF THE INVENTION
The present invention attempts to overcome the shortcomings of the prior art by providing a combined staged tool, of particularly simple design, making it possible to perform all of the work in a single operation and with a better qualitative result.
The staged tool according to the present invention, which tool may be used to bore a hole in an element made of a material such as a metal, by axial penetration of the tool while hot, and plastic deformation of the material of the element, comprises successively, beginning at its front end, an end front end portion which is cylindrical or conical, of a first relatively small diameter, then at least one neck followed by a working portion of right cross section of revolution increasing in the direction opposed to that of the advancement of the tool, the working portion having a major base having a second diameter greater than that of the first diameter. The staged tool of the present invention is characterized in that the neck which is situated at the rear of the front end portion is provided, before penetration of the tool into the element, with a mass of lubricant in a solid state. This mass of lubricant has a melting point that is less than the temperature at which the element is at during the boring operation, so that the solid lubricant melts when the tool penetrates into the hot element. Accordingly, the contact surface between the element and the working portion is constantly lubricated by a melted lubrication film formed from the melted lubrication mass contained in the neck.
The generative line of the working portion of the tool can be linear, which would cause the working portion to have truncated conical shape. It can also be partially or totally nonlinear, e.g., totally or partially curved, in which case the working portion would have a pseudo-truncated conical shape. The tool according to the present invention may comprise a plurality of successive working portions. In such a case, total work may be distributed between or among these working portions as a function of the properties of the material (e.g., rheology, resistance, triaxial aptitude by cold-hammering or welding). In embodiments of the present invention that comprise a plurality of successive working portions, spaces are generally arranged between the working portions, which spaces are formed based on the kinetic crystalline restoration of the material and on the heating or cooling period of the surface subjected to the work. These spaces are utilized to establish reserves or deposits of lubricant, which may be under pressure, and the volume of these reserves is provided in relation with the surfaces of the working portions to be lubricated.
The combined tool according to the present invention has several advantages. From an economic point of view it allows for reduction in time of manufacture, cost of assembly and disassembly, ultimate cost of heating, and cost of effective transformation and of complexity of the sequencing (of production). The tool also makes it possible to increase the amount of force that may be generated by the basic machine because it lowers the amount of force necessary for deformation based on relubrication. It also makes it possible to have access to those which can undergo a single cycle, e.g., a single heating. From a qualitative point of view and, consequently, also from an economic point of view, it makes it possible to reduce the number of rejects by avoiding friction which generates grooves and tears, folds, and decentering, when working while hot. Further, movement of each working portion is facilitated because each successive working portion is guided over the path of the preceding working portion.
According to the present invention, a staged tool for boring a hole having a wall in an element that has been heated to a predetermined temperature by axial penetration of the tool in a desired direction, includes a front end portion having a first diameter; a first working portion having a lateral surface with a right cross-sectional area that increases in the direction opposite that in which the tool advances, the first working portion further having a major base with a second diameter, the second diameter being greater than the first diameter; and a first neck portion connecting the front end portion and the first working portion, the first neck portion adaptable to receive and hold a first solid lubricant having a melting point temperature lower than the predetermined temperature to which the element to be bored is heated. When this tool penetrates the heated element, the first lubricant melts and effectively lubricates contact areas between the first working portion of the tool and the heated element.
The first end portion may be cylindrically shaped or it may be conically shaped.
A staged tool according to the present invention may also include a second working portion having a lateral surface with a right cross-sectional area that increases in the direction opposite that in which the tool advances, the second working portion further having a major base with a third diameter, the third diameter being greater than the second diameter; and a second neck portion connecting the first working portion and the second working portion, the second neck portion adaptable to receive and hold a second solid lubricant having a melting point temperature lower than the predetermined temperature to which the element to be bored is heated.
Still further, a tool according to the present invention may include a thermally insulated layer interposed between the second solid lubricant and any portion of the tool the second solid lubricant may come into contact with during tool use.
The first neck portion of a tool according to the present invention may include a piston shaft having an end distant from the front end portion, and the tool may further include a piston connected to the end of the piston shaft distance from the front end portion; an internal chamber in which the piston is slidingly disposed, the chamber having a side closest to the front end portion; and a compression spring, the compression spring surrounding the piston shaft and being disposed in the internal chamber between the piston and the side closest to the front end portion. Even still further, a tool according to the present invention may include an annular piston slidably mounted around the second neck portion, the annular piston operable to retain the second solid lubricant held by the second neck portion between itself and the second working member, the annular piston having an outer surface that rubbedly engages the wall of the bored hole so as to slightly compress the second lubricant.
The first working portion may be axially movably mounted with respect to the second working member.
The second working portion may have portions defining an internal, cylindrical, axial chamber having a diameter substantially equal to the diameter of the second neck portion, which neck portion extends into the internal, cylindrical, axial chamber, and, further, wherein the second working member has portions defining a conduit between the chamber and the tool exterior, which conduit is adapted to be capped and which, in operation, would normally be capped and would not be uncapped until after engagement of the second working portion and the element to be bored.
The element to be bored may have a pre-hole that has been formed in it, the pre-hole having a certain diameter, and further, wherein the cylindrically shaped front end portion has a diameter substantially equal to the diameter of the pre-hole.
The element to be bored may have a conical pre-hole formed into it, wherein the front end portion comprises a conical center head which is adapted to measure centering of the tool and the conical pre-hole, and wherein the second working portion has a major rear base having a diameter corresponding to the desired final diameter of the hole bored in the element to be bored.
A tool according to the present invention may have a cylindrical front end portion and a cylindrical neck portion and, further, the first working portion may have a minor base to which the first neck portion is connected and a major base with a diameter corresponding to the desired final diameter of the hole bored in the element to be bored.
A tool according to the present invention may also include a first cylindrical guidance bearing surface, this first cylindrical guidance bearing surface having the same diameter as the major base of the first working portion and this first cylindrical guidance bearing surface extending the first working portion.
A tool according to the present invention may also include a second cylindrical guidance bearing surface, this second cylindrical guidance bearing surface having the same diameter as the major base of the second working portion and this second cylindrical guidance bearing surface extending the second working portion.
The element to be bored may have a pre-hole formed into it, the front end portion which engages the pre-hole may be rounded, the first neck portion may have a truncated conical shape having a curved generator and a concavity turned towards the exterior, and the first working portion may have a truncated conical shape having a rectilinear generator. In such a case the tool could include a second neck portion having a truncated conical shape and a concavity turned towards the exterior and a second working portion having a truncated conical shape having a rectilinear generator. During operation of such a tool, the first and second working working portions would be in simultaneous contact with the boundaries of the hole being bored in the element to be bored.
The first lubricant may include a crown of glass lubricant which is adapted to melt in the heated element. Likewise, the second lubricant may include a crown of glass lubricant which is adapted to melt in the heated element.
A lubricant may be predisposed in the mouth of the hole being bored, which hole may be conical, whereby, after melting, the lubricant could be enclosed in annular spaces defined by the first and second truncated conical portions having a curved generator so as to lubricate the first and second working portions.
According to the teachings of the present invention, a tool for boring includes a front end portion having a first diameter; a first working portion in the shape of a truncated cone with a minor base and major base, the major base having a second diameter which is greater than the first diameter, the minor base being positioned so as to be disposed closer to the front end portion than any other part of the first working portion; and a first neck portion interconnecting the front end portion and the first working portion.
A tool according to the present invention may also include a second working portion in the shape of a truncated cone with a minor base and a major base, the major base having a second diameter which is greater than the first diameter, the minor base being positioned so as to be disposed closer to the front end portion than any other part of the second working portion; and a second neck portion interconnecting the first working portion and the second working portion.
As stated before, the first lubricant may include a glass crown. Such a glass crown may include at least two crown portions, which at least two crown portions could be adapted to be maintained in place by attachments that disappear with heat. Alternatively, the two crown portions could be adapted to maintained in place by a sash of fusible fabric material. To facilitate their manufacture, the two crown portions may be half portions.
Both the first and second lubricants could include glass crowns. Both the first and second glass crowns each could include at least two crown portions, which at least two crowned portions could be adapted to be maintained in place by attachments that disappear with heat or by a sash of fusible fabric material.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, advantages, and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings wherein:
FIG. 1 is an axial cross-sectional view of a staged tool according to the present invention;
FIG. 2 is an axial cross-sectional view of a staged tool according to the present invention;
FIG. 3 is an axial cross-sectional view of an alternative embodiment of the staged tool according to the present invention;
FIG. 4 is an axial cross-sectional view of an alternative embodiment of the staged tool according to the present invention;
FIG. 5 is an axial cross-sectional view of an alternative embodiment of the staged tool according to the present invention;
FIG. 6 is an axial cross-sectional view of an alternative embodiment of the staged tool according to the present invention;
FIG. 7 is an axial cross-sectional view of an alternative embodiment of the staged tool according to the present invention;
FIG. 8 is an axial cross-sectional view of an alternative embodiment of the staged tool according to the present invention;
FIG. 9 is an axial cross-sectional view of an alternative embodiment of the staged tool according to the present invention;
FIG. 10 is an axial cross-sectional view of an alternative embodiment of the staged tool according to the present invention; and
FIG. 11 is an axial cross-sectional view of an alternative embodiment of the staged tool according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A staged tool 1 shown in FIGS. 1 and 2 is adapted to pierce a metallic element 2, which has first been brought to its forgoing temperature. The tool 1 pierces by an axial movement from top to bottom to produce a hole of large diameter a. A pre-hole 3, a smaller hole of diameter b, may or may not be formed before use of tool 1. Tool 1 is progressively driven axially into element 2 by being guided through pre-hole 3, if present, by means of a pusher P. Element 2 is maintained on the exterior, in a conventional manner, in a matrix or template (not shown).
The staged tool 1 shown in FIG. 1 comprises a plurality of portions of different diameters. At its lower or front end the tool 1 comprises a conical portion 1a, having a frontward facing point and whose rear base diameter is equal to the diameter b of the pre-hole 3. Front truncated conical portion 1a serves, in this case, only for guidance of the front end of the tool in the pre-hole 3. Above this extreme front end 1a is located a first cylindrical portion 1b of diameter c, which diameter c is less than the diameter b. To first cylindrical portion 1b is connected a first working portion 1c. This first working portion 1c has a lateral surface having a right cross-section which increases progressively upwardly, i.e., in the direction opposite to that direction in which the tool moves. First working portion 1c has, for example, a truncated conical shape, with a front small base of diameter c, through which it is connected to the cylindrical portion 1b, and a large rear base of a diameter d, which is less than the final diameter a. The large base of the first working portion 1c is extended towards the rear by a second cylindrical portion 1d of a diameter e less than the diameter d. To this second cylindrical portion 1d there follows a second working portion 1e which has a lateral surface having a right cross-section which increases upwardly, for example, in a truncated conical shape, connected through its small base of diameter e to the second cylindrical portion 1d and having a rear major base of diameter a. The angle at the apex of the first working truncated conical portion 1c is less than that of the second working truncated conical portion 1e which is thus more widened out than the preceding portion, as can be seen in FIGS. 1 and 2. However, this arrangement is not be taken as limiting and the angles at the apex of the two working portions could be the same or the angle at the summit of the first working portion 1c could be even greater than that of the second working portion 1e.
According to the present invention, the staged tool 1 is provided, before being engaged in the metallic element, with a lubricant which is positioned in the necks formed around the cylindrical portions 1b and 1d which respectively assure the attachment between the end conical portion 1a and the first truncated conical working portion 1c and between the first and second truncated conical portions 1c and 1e.
The lubricant constitutes two crowns 4 and 5 which are formed, on tool 1, respectively around two cylindrical portions 1b and 1d, before it is introduced into element 2. The two crowns 4 and 5 each preferably comprise two half-crowns made of glass obtained by molding of powder with an agglomerate or by casting, these two crowns 4 and 5 being maintained in place by attachments which disappear when heated. One can likewise utilize for this purpose a fabric sash of fusible material, for example, glass, joined at the same location.
The lower lubrication crown 4 which is positioned in the pre-hole 3 is found only in the melted state, i.e., in the position of the tool shown in FIG. 1. This is because crown 4 has, at that point, been brought to a temperature greater than the fusion point temperature of glass. As the tool 1 descends, this crown of melted glass 4 assures the lubrication of the contact surface between the element 2 and the first truncated conical working portion 1c. In FIG. 1, the upper crown of glass 5 is shown in the solid state since it is not yet engaged in element 2 and it is not yet heated sufficiently to be able to melt. On the contrary, this upper crown of glass 5 is likewise in the melted state, when it is engaged in element 2, as is shown in FIG. 2. This upper crown of melted glass 5 assures the lubrication in the contact zone between the metallic element 2 and the second working portion 1e.
In the embodiment of the invention shown in FIG. 3, a thermal insulation layer 6 which is adapted to facilitate the heating of the lubricant when the properties of the latter require it, is interposed between the lubrication crown 5 surrounding the second cylindrical portion 1d and the portion of the tool 1 with which this crown is in contact. This thermal insulation layer 6 extends on the annular shoulder formed at the connection between the upper major base of the first truncated conical working portion 1c and of the cylindrical portion 1d, all around the lateral surface of this cylindrical portion 1d, and the length of the lower portion of the lateral surface of the second truncated conical portion 1c.
In the embodiment of the invention shown in FIG. 4, the front truncated conical portion 1a of tool 1 is not an integral portion of the rest of the tool but it is affixed to a piston shaft 7 extending axially within the body of tool 1 to open into an internal chamber 8. In this chamber, shaft 7 ends in a piston 9 and a compression spring 11, surrounding shaft 7, is positioned between the piston 9 and the end of chamber 8. Under the effect of the spring, the piston 11 tends to push towards the top of shaft 7 and, consequently, the front end portion 1a which serves to compress the lubrication crown 4 surrounding the first cylindrical portion 1b, i.e., a mass of melted lubricant. In this embodiment, tool 1 further comprises an annular piston 12 mounted to slide freely around the second cylindrical portion 1d and which retains the lubrication crown 5 surrounding the second cylindrical portion 1d. Piston 12 which rubs on the lateral wall of the bored hole, is decelerated and thus contributes to the slight compression of the lubricant 5, which action helps assure lubrication of the contact surface of the second truncated conical working portion 1c.
In the embodiment of the invention shown in FIG. 5, the first truncated conical portion 1c is movably axially mounted with respect to the second truncated conical working portion 1e. To this end, the second cylindrical portion 1d which extends from the first truncated conical working portion 1c, forms a piston axially sliding within an axial chamber 13 of the same diameter provided in the second truncated conical working portion 1e and opening into the minor base of that portion. This chamber 13 communicates with the exterior through a conduit 14 which can normally be blocked and which is not unblocked until after engagement of the second working portion 1e in the element 2.
In the embodiment of the invention shown in FIG. 6, the front conical end portion 1a and the first front working portion 1c are replaced by a front end cylindrical portion 1f of a diameter corresponding substantially to the diameter d of a pre-hole already resulting from a first operation. The cylindrical portion 1f assures the axial guidance of the tool which, by its upper truncated conical working portion le, enlarges the hole to the final diameter a.
In the embodiment of the invention shown in FIG. 7, tool 15 comprises a first front centering conical head 15a which is adapted to assure the centering of the tool in a conical pre-hole formed in element 2. Above this front centering head 15a tool 15 comprises an annular neck 15b containing a lubricating mass 16, for example a glass crown, and above the neck 15b a working portion 15c, of a truncated shape and whose major rear base has a diameter a corresponding to the final diameter which one desires to obtain for the hole. At the working portion 15c a cylindrical portion 15d of a diameter a follows whose role is to avoid deviation of the hole in the course of its being made.
In the embodiment of the invention shown in FIG. 8, tool 16 comprises a cylindrical head 16a followed by a cylindrical portion 16b of a smaller diameter, defining a neck containing a lubricating mass 17 such as melted glass. The head 16a preferably has, in its frontal surface, an annular cavity 16d centered on the axis and containing a small quantity of lubricant. At the rear of the cylindrical portion 16b extends the truncated conical working portion 16c whose front minor base is connected to the cylindrical portion 16b and whose rear major base defines the final diameter a of the bored hole.
In the embodiment of the invention shown in FIG. 9, tool 1 of FIGS. 1 and 2 has been modified such that the front end conical portion 1a is extended towards the rear by a bearing surface of cylindrical guidance 1g of diameter b connected to the first cylindrical portion 1b of smaller diameter. The major rear base of the first truncated conical working portion 1c is extended upwardly by a second bearing surface of cylindrical guidance 1h of diameter d, connected to the second cylindrical portion 1d, and the major rear base of the second truncated conical working portion 1e is extended by a third guidance bearing surface 1i of diameter a.
In the embodiment of the invention shown in FIG. 10, tool 1 of FIG. 9 has been modified to present, above the second cylindrical portion 1d, a cylindrical guidance bearing surface 1i of the same diameter d as the bearing surface of cylindrical guidance 1h, which is followed by a working portion 1k having a non-linear generator, convex or concave, which can itself be followed, if desired, by a working portion 1l having a linear generator. The first working portion 1c could also have a totally or partially linear generator.
The tool shown in FIG. 10 has several advantages with respect to the distribution of lubricant. One avoids presenting a mass in the shape of a substantial hydraulic wedge, which can distort the shape of the working portions. The successive bores nest in one another without risk of deviation; thus, final centering is improved. Because one avoids movement of the edge of the initial hole, or of the one preceding it and losses of material, it is possible to diminish the size of the initial pre-hole, limited only by first lubricant needs.
In the embodiment of the invention shown in FIG. 11 tool 18 has a generally truncated conical shape having a point engaged in a pre-hole 3 of small diameter b. The front end portion 18a of the tool 18 which is engaged in the pre-hole 3 is rounded. It is extended towards the rear by a first portion of a truncated conical shape having a curved generator 18b, having a concavity turned toward the exterior, then a second truncated conical portion 18c having a rectilinear generator, then a third portion 18d of a truncated conical shape having a curved generator, having a concavity turned towards the exterior, then a fourth conical portion 18e, having a rectilinear generative line. In this embodiment the two working portions are constituted by two truncated conical portions 18c and 18e that are in simultaneous contact with the mouth of the cone in element 2. The lubricator is, in this case, simply predisposed in the mouth of the cone and, after melting, it is enclosed in the annular spaces defined by the two truncated conical portions 18b and 18 d having a curved generative line to lubricate the two working portions 18c and 18c.
Obviously, many modifications and variations of this invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
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A staged tool for boring a hole in a heated element of a material such as metal. The tool is adaptable to being axially forced and operation of the tool causes plastic deformation of the bored material. The tool successively includes, beginning at its front end, a front cylindrical or conical end portion having a first relatively small diameter, a neck followed by a working portion of evolving revolution having a right cross-section which increases in the direction of advancement of the tool, whose major base has a second diameter greater than the first diameter. To improve lubrication during boring, positioned on the neck at the rear of the front end portion is a mass of solid lubricant having a fusion point less than the temperature of the element during the piercing operation. The solid lubricant melts when the tool penetrates into the heated element and the contact surface between the element and the working element is constantly lubricated by a melted lubricating film.
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DESCRIPTION
1. Technical Field
The invention relates to a tool for cleaning the interior of pipes and more particularly to an improved handle construction for such a tool.
2. Background Art
In U.S. Pat. No 3,137,974 W. S. Kirkland disclosed a spin-blast tool of a type having a hollow tubular handle connected at one end to a blast slurry supply pipe and at the opposite end to a spinning jet head. The blast slurry supply pipe carries an abrasive material such as sand in a sand-air mixture at approximately 110 pounds of pressure. The air pressure forces rotation of the jet head at approximately 1000 revolutions per minute. Under this pressure, the jet head would rotate even faster, causing severe vibration and ultimately destruction of the tool. To slow the rotation of the jet head a centrifugal brake is provided, slowing the speed of rotation. Excessive rotational speed indicates a worn or defective brake lining or a brake control component. Typically, brake linings must be replaced after approximately four hours use.
Another of the problems encountered and solved in the prior art spin-blast tool mentioned above, was protecting the seals at opposite ends of the handle. Protection was provided by annular leather dust seals, with annular sleeves pushing the leather seals against bearing seals. Like the brake linings, the leather dust seals must be replaced from time to time.
An object of the invention is to devise an improved spin-blast tool wherein handle components, especially the brake mechanism and bearing seals, last longer, but do not diminish performance of the tool.
DISCLOSURE OF INVENTION
The above object has been achieved in an improved spin-blast tool having a handle which features a hydraulic drag brake. The improved handle has coaxial inner and outer pipes, with the inner pipe supported by opposed bearings within the outer pipe. The bearings form a plenum between the two pipes which is filled approximately two-thirds full with viscous fluid. Vanes extending radially outwardly from the pipe resist rotation of the inner pipe as viscous fluid within the plenum seeks to flow around the vanes.
A protective seal at one end of the handle consists of a shaft seal surrounding the inner pipe, with a lateral side contacting the inner rotating race of a sealed bearing as well as a shaft seal retainer on the opposite lateral side. The improved seal construction features the inner pipe notched at its outer surface in a direction parallel to the pipe axis so that a small leak is provided from the viscous fluid plenum, underneath the bearing to the interface between the bearing and the shaft seal. By lubricating the surface of the shaft seal facing the rotating bearing race, there is little wear on the shaft seal due to rotation of the inner bearing race, yet a tight dust seal is provided.
The advantage of the present invention is that prior art brake linings are eliminated. Similarly, leather dust seals are eliminated. Both the brake linings and the leather seals are replaced by members which have far longer lifetimes, eliminating maintenance time and costs.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a side view of the present invention, connected to a blast slurry supply pipe.
FIG. 2 is an exploded side view of the improved spin-blast tool shown in FIG. 1.
FIG. 3 is a side sectional view of the improved spin-blast tool shown in FIG. 1.
FIG. 4 is a view taken along the lines 4--4 in FIG. 3.
FIG. 5 is a view taken along lines 5--5 in FIG. 3.
FIG. 6 is a perspective cutaway view of the improved handle of the present invention.
BEST MODE FOR CARRYING OUT THE INVENTION
In FIG. 1 it will be seen that the major assemblies of the spin-blast tool include the jet head 11 and the tubular handle 20. A blast slurry supply pipe 61 is connected to the rear flange 57. Handle 20 and slurry supply pipe 61 do not rotate. Of the major external components, only jet head 11 rotates. The handle 20 is intended to be mounted axially within a pipe to be cleaned. Mounting is by means of outwardly extending arms as shown in FIG. 9 of the previously mentioned U.S. Pat. No. 3,137,974. Other axial mounting means may be used, such as outwardly extending skids, evenly spaced about the handle periphery. A pipe to be cleaned is pushed past the skids so that the spinning jet nozzles blast the inside diameter of a pipe to be cleaned with slurry material.
With reference to FIGS. 2 and 3 the improved spin-blast tool of the present invention is shown in side view. A spinning jet head 11 is of the same type as described in the previously mentioned U.S. Pat. No. 3,137,974, incorporated by reference herein. The jet head has plural nozzles, including nozzle 13 in a hollow body 15. Blast slurry ejected through nozzle 13 causes rotation of the jet head in a direction opposite to the blast slurry stream. Usually two nozzles are provided, on opposite sides of the jet head, spraying blast slurry material in opposite directions, complementing each other in causing rotation of the jet head 11. The hollow chamber 15 is screwed to thread 17 of rotating inner pipe 19. The jet head is fixed relative to pipe 19 so that spinning of the jet head causes spinning of inner pipe 19. Inner pipe 19 is coaxial with and slightly longer than outer pipe 21. Typically, the inner pipe may have an inside radius of approximately 1/2 inch and an outer radius of 3/4 inch. The outer pipe may have an inside radius of approximately 11/4 inches and an outside radius of approximately 11/2 inches. Inner pipe 19 is held in place by front bearing 23 and rear bearing 25. Each of these bearings is a sealed bearing which is press fit in place. Each of the bearings has an inner race and an outer race, with ball bearings between races. The inner race is fixed to inner pipe 19 while the outer race is fixed to outer pipe 21. Front bearing 23 is capped by a cover plate 27 having screws 29 which connect the cover plate to forward end 31 of pipe 21. It will be noted that forward end 31 has a slightly larger diameter than central portion 33 of pipe 21.
Extending radially outwardly from inner pipe 19 is a plurality of vanes 35a, 35b, 37, 39a and 39b. These vanes are perpendicular to the surface of pipe 19 and typically are thin steel plates which are welded to the pipe surface. The radial extent of the vanes is such that there is no contact with outer pipe 21, yet the vanes approach the inside diameter of pipe 21. Vanes 35a and 35b lie in the same plane and are the same size. Each of the vanes has a lateral edge adjacent, but not contacting bearing races. A gap is provided between the vanes 35a and 35b, as well as 39a and 39b, for hydraulic fluid motion between the vanes. Midway between vanes 35a, 35b and vanes 39a, 39b, about the inner pipe outer circumference, the vane 37 is located. Unlike vanes 35a and 35b or 39a and 39b, vane 37 is unitary, having no central fluid path. Instead, a fluid path is provided at opposite ends 43 and 45 of the vane.
The plenum between inner and outer pipes and between forward and rear bearings is filled with a viscous hydraulic fluid, such as S.A.E. 90 motor oil. The vanes 35a, 35b, 37, 39a and 39b, as well as a vane diametrically opposite vane 37, i.e., 180° away, work against the viscous fluid, which tends to remain in place, flowing laterally around the vanes, as the vanes rotate. The viscous fluid resists vane motion. The viscous fluid has a tortuous lateral flow path which may be viewed as starting with gap 41, thence proceeding around vane 37 to the regions 43 and 45, thence through gap 44 and then to other gaps similar to the gaps near the regions 43 and 45, except on the opposite side of the pipe and then back to gap 41. Another smaller gap is provided in the space between the most radial outward distance from the vane and the inside diameter of the outer pipe. Outer pipe 21 will be seen to have an oil fill hole 47 and an air outlet hole 49. Once the plenum is supplied with the viscous fluid to the extent of approximately two-third full, the holes 47 and 49 are capped with screws.
At the rearward end of outer pipe 21, adjacent to the rear bearing 25 a shaft seal 53 is disposed about the inner pipe 19 at a location 51, approximately flush with the rear end of the outer pipe 21. This shaft seal has a lateral side contacting the rotating inner race of rear bearing 25, yet the shaft seal does not rotate. Rotation is prevented by feeding a slight amount of oil along a notch beneath the inner race of bearing 25 so that the shaft seal is lubricated. The shaft seal 53 is held in place by retainer 55 which is press fit into end 51 of outer pipe 21. A rear flange 57 is connected to pipe 21 by means of screws 59 which are seated in the enlarged rearward periphery of pipe 21.
In FIG. 3, it is seen that the flange 57 has internal threads which connect to mating threads on the outside of blast slurry supply pipe 61. The inside of the stationary blast slurry supply pipe communicates with rotating inner pipe 19. It will be seen that shaft seal 53 is of the well-known type having an annular spring 54 which clamps the seal to inner pipe 19.
With reference to FIG. 4, the axial relationship of inner pipe relative to outer pipe 21 may be seen. The vanes 35a, 37, 39a and 40 may be seen to have the same radial extent. The vanes approach, but do not touch the inside periphery 42 of outer pipe 21. A lengthwise axial slot 63 may be seen. This slot allows hydraulic fluid in the plenum between inner and outer pipes to escape beneath the forward sealed bearing to lubricate shaft seal 53.
The slot may be seen more clearly in the end view of FIG. 5. The slot is only approximately 1 mil deep in the outside periphery of inner pipe 19, extending beneath the sealed bearing so that a trickle of hydraulic fluid reaches the interface between shaft seal 53 and the inner race of sealed bearing 25 in FIG. 3. Returning to FIG. 5, the shaft seal 53 is sufficiently lubricated so that it remains stationary, contacting the stationary retainer 55, as well as the rotating inner bearing race, not visible as a flgure. The retainer 55 is press fit into an end of outer pipe 21 and held in place by a set screw, not shown, extending from the outer periphery of outer pipe 21 into the circumferential periphery of retainer 55.
Again in FIG. 6, the slot 63 may be seen extending beneath bearing 53. The figure also shows radial vanes 35a, 35b and 37, projecting from inner pipe 19. The inner pipe is maintained in coaxial relation with respect to the outer pipe by the sealed bearings indicated by dashed lines 23 and 25. The radially extending vanes within the hydraulic fluid provide a brake for an improved spin-blast tool such that wear due to abrasion is minimized. The same hydraulic fluid which is used to provide the braking effect is used to lubricate the shaft seal so that protective dust covers, which needed replacement in a prior art, can be eliminated.
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An improved spin-blast tool having a stationary handle with coaxial inner and outer pipes. The inner pipe, connected to a jet head, rotates at high speed relative to the stationary outer pipe. A plenum defined by the outer surface of the inner pipe and the inner surface of the outer pipe, as well as by opposed lateral sealed bearings, supporting the inner pipe within the outer pipe, define a plenum which is filled with a viscous fluid. The inner pipe supports radially outwardly extending vanes which work against the viscous fluid, thereby slowing rotation and preventing damage to the inner shaft and the jet head. An axial groove along the outer peripheral surface of the inner pipe leaks small amounts of the viscous fluid beneath at least one of the sealed bearings for the purpose of lubricating a stationary shaft seal which comes in contact with rotating members.
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RELATED APPLICATION
The present application claims priority of European Patent Application No. 05011526.00 filed May 27, 2005, which is incorporated herein in its entirety, by this reference.
FIELD OF THE INVENTION
The present invention relates to protocol selection techniques. More particularly, the present invention relates to possible application in producing interfaces such as mass storage cards.
DESCRIPTION OF THE RELATED ART
Present-day host devices such as MP3 players, digital cameras, palmtops, etc. may use different communication protocols, such as MultiMediaCard (MMC) and SecureDigit (SD) to communicate e.g. with flash mass storage cards.
Some host devices can support multiple protocols so that they can use different memories. An intrinsic problem plaguing these solutions lies in the great number of existing communication standards. In practical terms a number of existing solutions (especially at the card level) use only one protocol.
Certain host devices are in a position to operate with a restricted set of protocols, such as SDIO (Secure Digital Input/Output), SD or MMC.
Although a few hosts can support many protocols, old hosts do not support new cards, and no commercial memory cards are known which support multiple protocols.
SUMMARY OF THE INVENTION
In view of the foregoing, the need is felt for arrangements that may dispense with the drawbacks and impracticalities of the prior art arrangements discussed in the foregoing. An object of the invention is thus to provide an improved solution fulfilling such a need.
According to the present invention, a protocol-based communication between a host device (e.g., MP3 player, digital camera, palmtop, etc.) and an interface (e.g., flash mass storage card) is established automatically by providing a plurality of protocol-supporting facilities in the interface, each facility supporting communication with the host device based on a respective protocol, by sending a query message from the host device to the interface specifying at least one protocol for use in protocol-based communication, by searching, within the plurality of protocol-supporting facilities provided in the interface one protocol-supporting facility supporting the protocol proposed in the query message, and if such protocol-supporting facility is found within the plurality of protocol-supporting facilities provided in the interface, by setting up the protocol-based communication between the host device and the interface based on the protocol proposed in the query message issued from the host device.
The invention also relates to a corresponding interface as well as a related computer program product, loadable in the memory of at least one computer and including software code portions for performing the steps of the method of the invention when the product is run on a computer. As used herein, reference to such a computer program product is intended to be equivalent to reference to a computer-readable medium containing instructions for controlling a computer system to coordinate the performance of the method of the invention Reference to “at least one computer” is intended to highlight the possibility for the present invention to be implemented in a distributed/modular fashion.
In a preferred embodiment of the invention protocol-based communication between a host device and an interface, such as a memory card, is automatically set-up by providing, in said interface, a plurality of protocol-supporting facilities, such as memory controllers, each said facility adapted for supporting communication with said host device based on a respective protocol, sending from said host device towards said interface a message specifying at least one protocol for use in said protocol-based communication, searching, within said plurality of protocol-supporting facilities one protocol-supporting facility supporting said at least one protocol proposed in said message, and if such protocol-supporting facility is found in said plurality of protocol-supproting facilities, setting up said interface for protocol-based communication with said host based on said at least one protocol proposed in said query message.
The arrangement described herein may be exploited to give rise, for example, to a multi-protocol automatic card setup, namely an operating arrangement wherein—depending on the host device—card set up can take place according to a selected required protocol (e.g. SDIO, SD or MMC).
A single card type is thus adapted to operate with several different protocols, which represents a major advantage on the consumer side. On the manufacturer side, such an arrangement may be exploited to develop a single project for several protocols, This while ensuring compatibility with old hosts, which represents an additional advantage on the consumer side.
A preferred embodiment of the arrangement described herein is an interface with two distinctive traits:
it supports multiple protocols, and it senses the protocol preferred by the host. This latter point applies even in the case where more than one protocol is supported, so that—according to standard specifications—the host first tries the protocol it prefers best, in order to configure the interface accordingly.
Although different implementations are feasible, a particularly preferred embodiment of the invention is based on a specific subsystem that detects the first communication sent by the host that, according to the specifications, queries the card using its preferred protocol, recognizes the protocol, configures the card so as to let the card reply to the host using the right protocol and de-activates itself.
The process described above is completely transparent to the host. The specific embodiment described in the foregoing is adapted to be mapped e.g. to reconfigurable hardware platforms such as Celaro (a HW emulator by Mentor Graphics) and MP4CF (a FPGA-based fast-prototyping platform by Aptix Corp.).
Similarly, the arrangement described is completely transparent to the types of protocols considered. Consequently, while protocols such as SDIO, SD or MMC have been mentioned in the foregoing as exemplary of protocols adapted to best benefit from the arrangement described herein, the scope of the invention is in no way limited to the adoption/choice of these specific protocols.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of example only, by referring to the enclosed figures of drawing, wherein:
FIG. 1 is a schematic representation of the typical scenario of use of the present invention;
FIG. 2 is a functional diagram representative of operation of a prior-art arrangement;
FIG. 3 is a functional diagram representing, by way of direct comparison to FIG. 2 , operation of the arrangement of the present invention; and
FIGS. 4 and 5 are a functional block diagram and a flow chart, respectively, providing further detail of the structure and operation of the arrangement of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The arrangement described herein is intended to operate within the scenario schematically represented in FIG. 1 , namely a host device 10 (of any known type, e.g. an MP3 player, a digital camera, a palmtop, and so on), and another device 12 intended to co-operate with the host device 10 . Exemplary of the device 12 , also referred to herein as an “interface”, is a storage card such as a flash mass storage card. As is well known these cards are essentially in the form of “smart” cards that support a certain amount of data processing circuitry adapted to perform the processing tasks that are described in greater detail in the rest of this description.
In the following, it is generally assumed that the host device 10 is a position to support many different protocols for communication with different interfaces 12 . For the sake of simplicity, it is generally assumed that interaction between the host device 10 and the interface (i.e. the card 12 ) takes place by using a single protocol selected as better detailed in the following. Extension of the arrangement described herein to arrangements wherein the host device 10 and the interface 12 can interact by using one of a plurality of different protocols is however within the scope of the present invention.
The functional diagram of FIG. 2 is exemplary of the pattern of operation of a prior art arrangement wherein a host device 10 attempts to co-operate with an interface 12 (hereinafter, reference is made throughout to a storage card for the sake of simplicity).
The leftmost portion of FIG. 2 shows the host 10 sending towards the card 12 a query message 100 in the form of command of a given protocol (for instance SDIO) In the case the card 12 does not support such a protocol, no response is provided, as schematically indicated at 102 , towards the host 10 .
The attempt to establish communication thus fails, and at that point, the host 10 may attempt, as schematically shown in 106 , to establish communication using a new protocol (for instance MMC).
In the case the card 12 does not support MMC, the same steps considered in the foregoing are repeated, namely.
a (MMC) query command 100 ′ is sent from the host 10 towards the card 12 ; no response is provided from the card 12 towards the host 10 , as schematically indicated at 102 ′; and the attempt of establishing communication fails again as indicated at 104 ′.
At this point host 10 can make a further attempt (as schematically shown at 106 ′) to establish communication with the card 12 by using still another protocol. The sequence just described may continue through all the set of protocols supported by the host device 10 and ends when the query message sent from the host 10 is in compliance with the protocol supported by the card 12 . Alternatively, if no matching protocol is found to be supported by the card 12 , the attempt to establish communication and interaction is finally aborted.
FIG. 3 is representative of how the same process is successfully handled within the arrangement described herein. In the exemplary instance considered, a query message 200 is sent from the host device 10 towards the card 12 . The query message 200 prompts a command evaluation process 13 at the card level: this process leads, in step designated 15 , to selection of given protocol within several protocols supported by the card 12 . The query message 200 sent from the host 10 towards the card 12 may specify a given protocol proposed for interaction (say, a generic protocol Pi) and the command evaluation/protocol selection process in the card 12 aims at achieving set up of the card 12 according to the required protocol proposed by the host 10 . A corresponding acknowledgement message 202 is then sent from the card 12 towards the host 10 which results in connection being established in step 204 between the host 10 and the card 12 .
The arrangement just described herein (namely the host 10 indicating—i.e. “proposing”—one specific preferred protocol and the card 12 sensing the protocol preferred by the host 10 ) represents a currently preferred choice. This arrangement in fact permits—according to standard specifications—the selection by the host 10 of the protocol it prefers best and the ensuing configuration of the card 12 in conformity therewith.
In alternative embodiments of the arrangement described herein, the query message 200 issued by the host 10 may include the indication of a set of different protocols proposed for communication by the host 10 . In that case, the command evaluation/protocol selection process prompted at the card level 12 aims at identifying at least one protocol supported by the card 12 and matching the set of protocols proposed by the host 10 .
In the block diagram of FIG. 4 , the reference 14 indicates a host bus acting as a communication link adapted to carry command, clock and data signals exchanged between the host 10 and the interface (card) 12 .
The card 12 includes a set of memory controllers 16 a , 16 b , . . . , 16 n each storing the necessary information for supporting interaction with the host 10 by using a given protocol (such as e.g. SDIO, SD, MMC, and so on) over the bus 13 . Such interaction takes place according to criteria that are well known to those of skill in the art, thus making it unnecessary to provide a more detailed description herein. Specifically, in the representation of FIG. 4 , C i :P j denotes the i-th controller supporting the j-th protocol in a given list.
The interface 12 additionally includes a protocol selector 18 driven by a command line 14 a included in the host bus 14 . Output from the protocol selector 12 is via a plurality of protocol configuration lines 20 each of which comes down to a respective one of the memory controllers 16 a , 16 b , . . . 16 n . Consequently, when a given protocol enable signal is generated by the protocol selector 18 over one of the protocol configuration lines 20 a corresponding one of the memory controllers 16 a , 16 b , . . . 16 n is enabled and interaction between the host 10 and the interface 12 is activated using the corresponding protocol.
In the flow chart of FIG. 5 , the block indicated 1002 designates a step wherein the host 10 sends towards the interface 12 the command generally designated 200 in the schematic representation of FIG. 3 . As a result of this query signal, sent over the command line 14 a , the protocol selector 18 performs the command evaluation/protocol selection steps represented by the blocks 13 and 15 of FIG. 3 . Specifically (by making reference to the flow chart of FIG. 5 ) the related processing involves a command recognition step 1004 , followed by a step 1006 wherein a check is made as to whether the type of command sent is known to the interface 12 : essentially this amounts to establishing whether the protocol or the protocols specified in the command 200 received during the step 1002 corresponds to one of the protocols supported one of the controllers 16 a , 16 b , . . . , 16 n in the interface 12 .
In the case command is not known, a corresponding signal is issued in the step 1008 towards host 10 and the process evolves towards a final stop condition.
If, conversely, the command is known (i.e., positive outcome of step 1006 ) in a subsequent step 1010 the protocol selector 18 proceeds by asserting a corresponding protocol. This step involves issuing on a respective one of the protocol configuration lines 20 a signal enabling the one memory controller in the set 16 a , 16 b , . . . , 16 n which contains the information required for setting up the interface 12 for communication with the host 10 using the protocol selected.
Without prejudice to the underlying principles of the invention, the details and the embodiments may vary, also appreciably, with respect to what has been described, by way of example only, without departing from the scope of the invention as defined in the claims that follow.
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A protocol-based communication between a host device (e.g., MP3 player, digital camera, palmtop, etc.) and an interface (e.g., flash mass storage card) is established automatically by providing protocol-supporting facilities in the interface, each facility supporting communication with the host device based on a respective protocol, by sending a query message from the host device to the interface specifying at least one protocol for use in protocol-based communication, by searching, within the plurality of protocol-supporting facilities provided in the interface one protocol-supporting facility supporting the protocol proposed in the query message, and if such protocol-supporting facility is found within the plurality of protocol-supporting facilities provided in the interface, by setting up the protocol-based communication between the host device and the interface based on the protocol proposed in the query message issued from the host device.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This patent application is a continuation-in-part of U.S. application Ser. No. 14/144,401, filed Dec. 30, 2013, which is a continuation-in-part, application of U.S. patent application Ser. No. 13/540,502, filed Jul. 2, 2012, which is a continuation of U.S. patent application Ser. No. 12/854,823, filed Aug. 11, 2010, now U.S. Pat. No. 8,211,043, which is a continuation-in-part application of U.S. patent application Ser. No. 12/769,518, filed Apr. 28, 2010, which applications are incorporated in their entirety here by this reference.
TECHNICAL FIELD
[0002] This invention relates to a support belt or stabilizing belt.
BACKGROUND
[0003] There are various modes of transportation in which two or more people may ride in tandem. For example, riding motorcycles, watercraft vehicles, all-terrain vehicles (ATV), snowmobiles, horseback riding, bicycles, or skiing are circumstances in which two or more people may be riding in tandem. In such situations, the back rider may hold onto the front rider in various uncomfortable and restricting ways to stabilize or balance himself or herself. In addition, current stabilizing belts are too cumbersome and, therefore, lack the versatility to be used across different activity, lack proper lumbar support, and are uncomfortable as the belt digs into the wearer's body.
[0004] Other circumstances may require the ability to stabilize the wearer of the belt, such as medical assistance and therapy. These belts also tend to be cumbersome and lack lumbar support. In addition, it is inconvenient, uncomfortable, and problematic to have an individual already in a weakened state to be forced to where a belt or vest so as to be assisted in movement.
[0005] For the foregoing reasons there is a need for an unproved stabilizing belt that is versatile enough to be used across various activities, provide adequate lumbar support, is comfortable to wear, and easy to use for those requiring assistance for movement.
SUMMARY
[0006] The present invention is directed to a stabilizing belt that can be used for a variety of activities, provides adequate lumbar support, is comfortable to wear, and easy to use for those requiring assistance, such as medical assistance. One aspect of the present ration is to provide a stabilizing belt designed to provide adequate lumbar support yet provide flexibility for movement.
[0007] Another aspect of the present invention is to provide a stabilizing belt in which the fastening mechanism does not dig into the wearer and cause discomfort.
[0008] Another aspect of the present invention is to provide a stabilizumg belt that can be used across various activities as opposed to a single activity.
[0009] Another aspect of the present invention is to improve the functionality of a stabilizing belt.
[0010] Another aspect is to provide assistance to those having difficulty with movements, such as a patient, without requiring the patient to don any additional equipment or device.
BRIEF DESCRIPTION OF DRAWINGS
[0011] FIG. 1 shows an exploded view of an embodiment of the present invention;
[0012] FIG. 2 shows a perspective view of an embodiment of the present invention;
[0013] FIG. 3 shows an embodiment of the interior side of the cover;
[0014] FIG. 4 shows an exploded view of another embodiment of the present invention;
[0015] FIG. 5 shows a perspective view of the embodiment shown in FIG. 4 assembled;
[0016] FIG. 6 shows a plan view of the exterior side of an embodiment of the present invention;
[0017] FIG. 7 shows a plan view of the interior side of an embodiment of the present invention;
[0018] FIG. 8 shows the present invention in use for assisted mobility;
[0019] FIG. 9 shows a plan view of another embodiment of the present invention;
[0020] FIG. 10 shows the embodiment in FIG. 9 worn in a first configuration; and
[0021] FIG. 11 shows the embodiment in FIG. 9 worn in a second configuration.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The detailed description set forth below in connection with the appended drawings is intended as a description of presently-preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed or utilized. The description sets forth the functions and the sequence of steps for constructing and operating the invention in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.
[0023] With reference to the figures, the present invention is directed towards a stabilizing belt 100 for use, for example, by a pair of riders riding a vehicle, such as a motorcycle or watercraft, in tandem; or for assisted movement. The stabilizing belt 100 worn by the front rider provides a means for the back rider to stabilize himself or herself during the ride. In other uses, such as for medical assistance, the stabilizing belt 100 may be worn by the patient or the caregiver. In situations in which it is difficult for the patient to don the stabilizing belt 100 the caregiver can don the belt 100 providing the patient with multiple grasping points to find the best leverage.
[0024] The stabilizing belt 100 comprises a pad 102 , a belt 104 to wrap around the pad 102 and secure the pad 102 to a wearer, and at least one handle 106 attached to the pad 102 . The pad 102 provides support and comfort for the wearer. The belt 104 allows the pad 102 to be attached to the wearer. The handle 106 provides the means for the back rider, patient, or caregiver to stabilize himself or herself against the wearer or assist the wearer.
[0025] The pad 102 comprises an interior side 108 that abuts the wearer, and an exterior side 110 opposite the interior side 108 , the interior and exterior sides 108 , 110 defining a first edge 112 , a second edge 114 opposite the first edge 112 , a top edge 116 adjacent to the first and second edges 112 , 114 , and a bottom edge 118 opposite the top edge 116 and adjacent to the first and second edges 112 , 114 . The designation of the top and bottom edges 116 , 118 has been made only for the sake of clarity and ease of discussion. Either edge can serve as the top or bottom depending on how the wearer wears the stabilizing belt.
[0026] Also, for the sake of clarity and ease of discussion the distance from the first edge 112 to the second edge 114 will be referred to as the length and the distance from the top edge 116 to the bottom edge 118 will be referred to as the width. These designations apply to the other features of the present invention, such as the cover, strap, the mesh, and the like.
[0027] In some embodiments, the pad 102 may have a simple geometric shape. For example, the pad 102 may be rectangular, trapezoidal, oval, circular and the like. In some embodiments, the top and bottom edges 116 , 118 of the pad 102 are uniquely contoured to provide better support, comfort, and versatility. Therefore, the width of portions of the pad 102 may vary along the length of the pad 102 as shown in FIGS. 1 and 4 .
[0028] As shown in FIG. 1 , in the some embodiments, the pad 102 comprises a lumbar support area 120 and bilateral side support areas 122 , 124 that extend away from the lumbar support area 120 and terminate at the first and second edges 112 , 114 , respectively. The side supports 122 , 124 may extend away from the lumbar support 120 in a uniform fashion, thereby forming a rectangular configuration. In some embodiments, the side supports 122 , 124 may taper as they extend away from the lumbar support 120 , thereby forming a triangular, trapezoidal, or oval configuration. In some embodiments, the width of the side support 122 , 124 may expand rather than taper away from the lumbar support 120 .
[0029] The lumbar support 120 occupies the middle portion of the pad 102 . To enhance support given to the lumbar region of the wearer while minimizing weight of the stabilizing belt or discomfort to the wearer, the lumbar support 120 may be wider than the side supports 122 , 124 . In some embodiments, the lumbar support area 120 may be a single enlarged area extending from one side to the other side of the lumbar region of the wearer.
[0030] In some embodiments, to further add flexibility without compromising the support, the top and bottom edges 116 , 118 within the lumbar support area 120 may converge toward each other at a central area 126 . The central area 126 is the area that would be positioned along the spine of the wearer. Thus, the width of the central area 126 is less than the width of the lumbar support area 120 . In such an embodiment, the lumbar support area 120 can be described as having two distinguishable or separate lumbar support areas 120 , one for the left side and one for the right side of the wearer.
[0031] Due to the difference in width between the lumbar support areas 120 and the central area 126 , the wearer is able to move and twist his or her body more freely as the central region 126 facilitates the twisting movement of the lumbar support areas 120 out of their natural plane.
[0032] As shown in FIG. 4 , in some embodiments, the pad 102 may be generally rectangular in shape with the top and bottom edges 116 , 118 tapering towards each other at the central area 126 of the pad 102 . Therefore, the width at the central area 126 may be generally smaller than the widths at the first and second edges 112 , 114 . In addition or alternatively, the width at the central area 126 of the pad 102 may be generally smaller than the width of the pad at regions of the lumbar support area 120 laterally adjacent to the central region as shown in FIGS. 1 and 4 .
[0033] The pad 102 is generally flat and made of a cushion type material. Suitable materials for the pad 102 include foam, rubber, and variations thereof. In some embodiments, the interior side of the lumbar support area 120 may comprise a bulge. In other words, the surface of the interior side 108 on the lumbar support area 120 may be convex to match the curvature of the lumbar region of the spine of the wearer. This provides added support to the wearer.
[0034] To secure the pad 102 to the wearer, a belt 104 is provided to wrap around the pad 102 and the wearer. Preferably, since the belt 104 must withstand the pulling of the handles 106 by a second rider, a caregiver, a patient, and the like, the belt 104 should be made from a strong, generally inelastic material. For example, the belt 104 may be made of nylon, leather, canvas, or other sturdy fabrics, or materials that can be made sturdy. In some embodiments, additional belts 104 a may be used to reinforce security and sturdiness.
[0035] The belt 104 further comprises a means for securing 128 the pad 102 to the wearer. The securing means 128 may be hook-and-loop fasteners, zippers, buttons, buckles, and the like. The belt 104 further comprises an adjustment strap 130 so that the belt 104 can be tightened or loosened before or after fastening.
[0036] In some embodiments, the belt 104 is fastened to the pad 102 , preferably on the exterior side 110 . In other embodiments, the belt 104 remains detached from the pad 102 relying on the frictional forces generated from tightening the belt 104 around the pad 102 for securement.
[0037] To improve the sturdiness and securement of the handles 106 to the pad 102 , the handles 106 may be attached to handle supports 132 . Handle supports 132 may be hard, thin sturdy pieces of plastic, metal, wood, composite material, or the like that is fastened to the pad 102 and the belt 104 . In some embodiments, the handle supports 132 may have rounded and beveled edges. The force from pulling, twisting, and tugging of the handles 106 during use gets dispersed throughout the entire handle support 132 thereby minimizing damage to the pad 102 . Otherwise, without the handle support 132 , the force would be localized at the point of connection to the pad 102 , which could easily damage the pad 102 .
[0038] In the preferred embodiment, the handle supports 132 are irreversibly fastened to the pad with fasteners, such as by rivets 134 . As such, through-holes 136 may be provided on the handle supports 132 through which a rivet 134 may be inserted to fasten the handle support 132 to the pad 102 . Additional through-holes 136 may also be provided to fasten the handles 106 to the handle support 132 .
[0039] Other fastening means may also be used, such as stitching, adhesives, nuts and bolts, and the like. Irreversible fastening refers to fasteners that cannot be removed without noticeably damaging the fastener or the material to which the fastener is fastened. Reversible fasteners may also be used if it provides secure attachment without adding discomfort to the wearer.
[0040] Although the handle supports 132 may be attached anywhere on the pad 102 , the preferred position is to attach the handle supports 132 to the lumbar support area 120 as shown in FIG. 2 . In some embodiments, as shown in FIG. 4 , multiple handles 106 a - 106 d, and multiple handle supports 132 a - 132 d may be used. The handles 102 a - 102 d and handle supports 132 a - 432 d can be positioned in a number of different strategic locations so as to maximize the function of the belt.
[0041] To facilitate the securement of the belt 104 to the pad 102 , each handle support 132 may comprise a pair of elongated slits 138 through which the belt 104 can be interlaced as shown in FIG. 1 (the lower belt 104 a ). The slits 138 may be positioned at the opposite lateral edges of the handle support 132 . In such an embodiment, the belt 104 may be attached to the pad 102 via the handle support 132 rather than being directly attached to the pad 102 . Since the belt 104 is not directly fastened to the pad 102 , this also allows the belt 104 to be adjusted to the left or to the right by adjusting the belt 104 through the slit 138 . In embodiments utilizing multiple belts 104 , multiple pair of slits 138 can be provided on the handle support. 132 accordingly. Alternatively, each belt. 104 can have a separate handle support 132 . In some embodiments, to allow the handle support 132 to be used in a vertical manner or at an oblique angle, opposing slits 132 a, 132 b on the same handle support 132 may be offset as shown in FIG. 4 .
[0042] In some embodiments, the stabilizing belt 100 may further comprise a cover 140 to conceal and protect the underlying components of the stabilizing belt 100 . The cover 140 is similar in shape as the pad 102 ; therefore, the cover 140 comprises an exterior side 142 and an interior side 144 opposite the exterior side 142 , the exterior and interior sides defining a first edge 212 , a second edge 214 opposite the first edge 212 , a top edge 216 adjacent to the first and second edges 212 , 214 , a bottom edge 218 adjacent to the first and second edges 212 , 214 and opposite the top edge 216 , and a central region 127 centrally located in between the first and second edges 212 , 214 , wherein the top and bottom edges 216 , 218 define a width of the cover 140 , wherein the width of the cover at the central region 127 is smaller than the width of the cover at a region laterally adjacent to the central region 127 . Therefore, the cover has the same or similar contours as the pad 102 .
[0043] The interior side 144 of the cover 140 may be overlaid on top of the handle support 132 , at least a portion of the belt 104 , and the pad 102 . In the preferred embodiment, the cover 140 has substantially the same shape as the pad 102 so as to fully cover the pad 102 while minimizing any excess material. In some embodiments, the cover 140 may completely cover or envelop the pad 102 . In other embodiments, the cover 140 only covers the exterior side 110 of the pad 102 .
[0044] In embodiments with a cover 140 , the belt 104 and/or strap 154 may be attached to the cover 140 rather than the pad 102 . In some embodiments, the belt 104 and/or strap 154 may be attached to both the pad 102 and the cover 140 . Therefore, the belt 104 may be attached to the pad 102 , the cover 140 , or both, and the strap 154 may be attached to the pad 102 , the cover 140 , or both, or any combination thereof can be used.
[0045] In some embodiments, the cover 140 comprises a slit 146 . On the interior side 144 of the cover 140 adjacent to the slit 146 may be a pouch 148 . For example, if the slit 146 is a horizontal slit, a pouch 148 may be positioned just below the slit 146 so that the slit 146 and pouch 148 can function as a pocket. A user can insert various items through the slit 146 into the pouch 148 .
[0046] The cover 140 may be made from any durable material, such as rubber, nylon, leather, canvas and other fabric material. In some embodiments, the cover 140 may be water proof or water resistant to keep the pad 102 dry for water sport activities.
[0047] The handles 106 may be attached through the exterior surface 142 of the cover 140 to the handle supports 132 . Handle supports 132 may be made from hard, sturdy material such as metal, plastic, wood, and the like. The end portions 150 a, 150 b of the handles 106 can be riveted through the cover 140 onto the handle support 132 for secure attachment. In addition, the end portions 150 a, 150 b may be double stitched to the cover 140 . The grip portion 152 of the handle 106 may be covered with foam or rubber to provide a comfortable grip.
[0048] In some embodiments, the handles 106 may be reversibly fastened to the handle supports 132 . Utilizing reversible fasteners provides a means for adjusting the orientation or placement of the handles. By way of example only, the two handle supports 132 may be arranged parallel to each other a specified distance apart. Each handle 106 may be secured parallel to one handle support 132 , thereby having a vertical orientation when the stabilizing belt 100 is worn. This allows the rear user to grasp the handles with his palms facing toward each other. To rearrange the orientation of the handles 106 , the user can remove the fastener and re-fasten the handles 106 in a horizontal orientation, perpendicular to the handle supports 132 by fastening one of the end portions 150 a of the first handle 106 to one end 132 a of the first handle support 132 and the second end 150 b of the first handle 106 to the same end 132 a of the second handle support 132 . The second handle 106 a can be similarly fastened to the opposite end 132 b of both handle supports 132 . This allows the user to utilize a palm up or palm down grip.
[0049] In some embodiments, the handles 106 , 106 a and handle supports 132 may be configured to provide a means for adjusting the placement or orientation of the handle without having to disassemble the stabilizing belt. For example, the handle support 132 may be frame-shaped or be a single rectangular or square plate having slits and/or a plurality of holes. The ends 150 a, 150 b of the handles 106 may have retractable pins that can be retracted by the push of a button on the handles 106 , 106 a. In the retracted configuration, the handles may be free to slide along the slits and positioned at different holes. Release of the button allows the pins to engage the holes so as to be locked in place. This allows the user to change the distance between the handles 106 , 106 a or change the orientation and placement of the handles 106 , 106 a. In such an embodiment, the cover would also comprise slits or openings to allow the handles 106 , 106 a to move to a different position. Reversible fasteners that can be used in this embodiment include, but are not limited to nuts and bolts, magnets suction cups, clips, spring loaded pins, bayonet-style connectors, mounts, and the like. In these embodiments, care should be taken so that the handles 106 do not slip out from the handle support 132 during use.
[0050] In some embodiments, the stabilizing belt 100 may comprise a plurality of handles 106 a - 106 e arranged in various configurations so as to provide the option of a variety of different grip positions without having to make any adjustments as shown in FIGS. 4 , 5 , and 9 . In addition, having a plurality of handles 106 a - 106 e allows the user to change his or her grip instantly at any time. Handles 106 a - 106 e may be arranged in a variety of positions, such as vertically, horizontally, at any oblique angle therebetween, and any combination thereof. Reference to the orientation of the handles is with respect to the wearer standing upright and the stabilizing belt being worn as intended. Each handle 106 a - 106 e may have associated with it a handle support 132 .
[0051] In another example, the stabilizing belt 100 may comprise four handles 106 arranged in a square or rectangular orientation. For example, a pair of horizontally oriented handles may be positioned at opposite ends of the vertically oriented handles 106 .
[0052] In some embodiments, to facilitate securement of the pad 102 to the wearer, a strap 154 may extend out from each of the first and second edges 112 , 114 of the pad 102 . Preferably, the strap 154 may be an elastic material or partially elastic material comprising a fastening means 155 so that the pad 102 and strap 154 can be wrapped around the wearer's body and fastened in the front, rear, or sides. For example, the strap 154 may comprise a fastening means 155 , such as hook-and-loop fasteners, zippers, buttons, buckles and the like. In some embodiments, the strap 154 may be a two piece strap, with the first piece 154 a extending from the first edge 112 and the second piece 154 b extending from the second edge 114 . In some embodiments, the first and second pieces 154 a, 154 b may be attached to their respective edges 112 , 114 . In some embodiments, the strap 154 may be one continuous piece that overlaps the entire pad 102 . The one piece strap may be fastened to the pad 102 . The strap 154 allows the pad 102 to remain in place while the belt 104 securely fastens the pad 102 to the wearer.
[0053] The strap 154 also serves as an interface between the belt 104 and the wearer. This prevents the belt. 104 from uncomfortably digging into the wearer's skin when the belt 104 is tightened around the wearer. To accommodate this function, the width of the strap 154 may be greater than the width of the belt 104 . In embodiments comprising multiple belts 104 the width of the elastic strap 154 may be greater than the combined width of all of the belts and the spaces therebetween.
[0054] In embodiments having a two piece strap, as shown in FIG. 4 , the first strap piece 154 a may be elastic and the second strap piece 154 b may be made of an inelastic fabric. The inelastic fabric material provides additional comfort and protection from the belt 104 . The first strap piece 154 a and the second strap piece 154 b may have fastening means 155 to fasten the first strap piece 154 a to the second strap piece 154 b. For example, the first and second strap pieces may comprise hook-and-loop fasteners to fasten to each other. In some embodiments, the fastening means 155 of the second strap piece 154 b may be overlaid on top of the second strap piece 154 b.
[0055] In some embodiments, the second strap piece 154 b may comprise a series of lumbar supports 160 secured to the second strap piece 154 b. These lumbar supports 160 may be elongated strips of a relatively rigid material, such as plastic, wood, metal, and the like. In this embodiment, the pad 102 is worn on the front and the second strap piece 154 b wraps around the back at the lumbar region and fastens to the first strap piece 154 a. When the stabilizing belt 100 is pulled by the handles 106 , the second strap piece 154 b does not fold or collapse, but rather, remains firm, thereby providing more comfort and support to the wearer.
[0056] In some embodiments, the stabilizing belt 100 further comprises a breathable fabric 156 attached to the interior side 108 of the pad 102 . For example, the breathable fabric 156 may be mesh or some other type of lining to provide comfort when the stabilizing belt 100 is worn by the wearer, particularly when worn without clothes.
[0057] In some embodiments, as shown in FIG. 4 , in addition to or in lieu of the breathable fabric 156 , the stabilizing belt 100 may further comprise a rubberized material 158 as the final layer below the pad 102 .
[0058] Having disclosed the various features of the present invention, many different variations can be designed by the various combinations of features without departing from the scope of the present invention.
[0059] For example, in some embodiments, the pad 102 may be omitted. Although this may decrease comfort, it may also allow for a lower manufacturing cost. In such an embodiment, the cover 140 would essentially function like the pad 102 . Therefore, any belt 104 , strap 154 , handle 106 , and handle support. 132 that would have been attached to the pad 102 could be attached to the cover 140 . Even in embodiments with the pad 102 , any belt 104 , strap 154 , handle 106 , and handle support 132 could be attached to the cover 140 , or any combination of attachments to the cover 140 and pad 102 .
[0060] In some embodiments, to further improve the supporting capability of the stabilizing belt 100 , any of the embodiments discussed previously may further comprise a harness system. By way of example only, FIG. 9 shows one of the embodiments with the harness system. The harness system comprises a plurality of fastening mechanisms and a pair of harness straps. The plurality of fastening mechanisms are strategically positioned on the stabilizing belt 100 so that the harness system can be used to wrap over a wearer's shoulder in a first configuration as shown in FIG. 10 , or wrap under a wearers legs in a second configuration as shown in FIG. 11 . Preferably, the harness system is attached to the pad 102 and/or the cover 140 of the stabilizing belt 100 . For ease of description, the pad 102 and/or cover 140 will be referred to generically as the base 300 . Thus, the base 300 may be the pad 102 , the cover 140 , or the combination of the pad 102 and cover 140 . As such, when the harness system is described as being attached to the base 300 , this means the harness system can be attached to the pad 102 , the cover, 140 , or both. Similarly, when referring to the side edges 312 , 314 , the top edge 316 , or the bottom edge 318 of the base 300 , this is meant to refer to the side edges 112 , 114 , top edge 116 , or bottom edge 118 , respectively, of the pad 102 , or the side edges 212 , 214 , top edge 216 , or bottom edge 218 , respectively, of the cover 140 , or both.
[0061] As shown in the example of FIG. 9 , in the preferred embodiment the fastening mechanisms are rings with associated hooks, or buckles. However, other fastening mechanisms can be used, such as snap buttons, hook-and-loop fasteners, zippers, and the like. These fastening mechanisms can be fixed to the base 300 , for example by stitching, or removably or adjustably attached to the base 300 so that the fastening mechanisms can be moved to different locations on the base 300 or adjusted for comfort and effectiveness,
[0062] In the preferred embodiment, a first upper fastener (shown as ring 200 a ) may be positioned along the top edge 316 of the base 300 . Preferably, the first fastener (e.g. ring 200 a ) is positioned along the centerline C of the base 300 . In some embodiments, two upper fasteners may be bilaterally arranged about the centerline C on the top edge 316 .
[0063] Two side fasteners (e.g. rings 200 b, 200 c ), one each, may be positioned along the first edge 312 and the second edge 314 . Two lower fasteners (e.g. rings 200 d, 200 e ) may be positioned along the bottom edge 318 medial to the two side fasteners. In some embodiments, a single lower fastener nay be used and positioned on the centerline C along the bottom edge 318 .
[0064] A pair of harness straps 170 a, 170 b are provided that can attach to the upper fastener 200 a, side fasteners 200 b, 200 c and lower fasteners 200 d, 200 e. Each strap 170 a, 170 b has a first free end 172 a, 172 b and a second free end 174 a, 174 b on the opposite side. These straps 170 a, 170 b can be made adjustable as is known in the art. A padding 176 a, 176 b may be attached to the straps 170 a, 170 b in between the first free end 172 a, 172 b and the second free end 174 a, 174 b for added comfort. At each end of the harness straps are reciprocal fasteners 178 a, 178 b, 180 a, 180 b that can attach to the fasteners. In the example shown, the reciprocal fasteners are latched hooks (like a carabiner) or buckles.
[0065] In use, the first end 172 a of one of the harness straps 170 a can be attached to a side fastener 200 b. The second end 174 a of the harness strap 170 a can be fastened to the lower fastener 200 d or the upper fastener 200 a. This can be done while the wearer is wearing the stabilizing belt 100 . Therefore, while wearing the stabilizing belt 100 , the wearer can attach the first end 172 a to a side fastener 200 b, then place the harness strap 170 a over the shoulder and attach the second end 174 a to the upper fastener 200 a. This process can be repeated on the other side, as shown in FIG. 10 .
[0066] Alternatively, the second end 174 a of the harness strap 170 a can be wrapped under the leg and fastened to the lower harness 200 d. This can be repeated on the opposite side for better lower body support, as shown in FIG. 11 .
[0067] In some embodiments, to improve the versatility of the harness system, multiple fasteners can be positioned on the stabilizing belt 100 . In the embodiment shown in FIG. 9 , the stabilizing belt 100 has seven harness fasteners: an upper fastener (e.g. ring 200 a ) located along the centerline C on the top edge 316 ; two bilaterally arranged side fasteners (e.g. rings 200 b, 200 c ), one side fastener (e.g. ring 200 b ) along the first edge 318 , and one side fastener (e.g. ring 200 c ) along the second edge 314 ; two auxiliary fasteners (e.g. buckles 190 a, 190 b ) bilaterally arranged at the bottom corners where the side edge 314 and the bottom edge 318 meet, and where side edge 312 , 314 and the bottom edge 318 meet; and two bilaterally arranged lower fasteners (e.g. rings 200 d, 200 e ) along the bottom edge 318 . The harness strap 170 a has a first end 172 a with a first reciprocal fastener (e.g. buckle 180 a ), and a second end 174 a with a second reciprocal fastener (e.g. latched hook 178 a ). In this example, the buckle 180 a is removably attached to a second latched hook 182 a, wherein the second latched hook 182 a attaches to the side fastener (ring 200 b ). Detachment of the buckle fastener 180 a at the first end 172 a allows the buckle fastener 180 a to be fastened to the auxiliary fastener 190 a. Thus, the wearer has multiple options that he or she can choose from to provide the best comfort and support for a given use.
[0068] For example, the first end 172 a can be attached to either the side fastener 200 b or the auxiliary fastener 190 a, and the second end 174 a can be fastened to either the upper fastener 200 a, or the lower fastener 200 d. The same options are available for the opposite side. So, the first end 172 b can be attached to either the side fastener 200 c or the auxiliary fastener 190 b, and the second end 174 b can be fastened to either the upper fastener 200 a, or the lower fastener 200 e.
[0069] In this example, since the first ends 172 a, 172 b are buckles, but the side fasteners 200 b, 200 c are rings, intermediate buckles 184 a, 184 b may be used as adapters to allow the first ends 172 a, 172 b to connect to their respective side fasteners 200 b, 200 c with latched rings 182 a, 182 b. Alternatively, the auxiliary fasteners 190 a, 190 b may also be rings so that the first end can connect to any of the side fasteners 200 b, 200 c, auxiliary fasteners 190 a, 190 b, and lower fasteners 200 d, 200 e using latched rings. Alternatively, the side fasteners 200 b, 200 c, auxiliary fasteners 190 a, 190 b, and lower fasteners 200 d, 200 e may be buckles so that the first ends 172 a, 172 b can connect to these fasteners using the buckle system. Any other type of fastening mechanism and any combinations thereof (with or without adapters) can be used so long as the first ends 172 a, 172 b and the second ends 174 a, 174 b are capable of attaching and detaching from the fasteners so that the harness straps 170 a, 170 b can be used as shoulder supports or leg supports.
[0070] In sonic embodiments, a back support may be provided that can be built into the base 300 or made attachable to the base 300 . Therefore, the stabilizing belt 100 can be used with our without the back support. Preferably, the back support is attached to the central region of the base to provide added stiffness as necessary. Therefore, the back support may be any rigid structure, such as a piece of plastic, metal, wood, and the like. The back support may be flat and rectangular in shape. In some embodiments, the back support may be contoured to fit better against the lumbar region of the back.
[0071] Due to the unique design of the stabilizing belt 100 , a single belt can be used for various activities. Some stabilizing belts utilize an entire chest harness. Although suitable for watercraft activities, these may be too cumbersome for other activities. The stabilizing belt 100 of the present invention can be used for motorcycle or bicycle riding, watercraft sports, ATV's, snowmobiles, horseback riding, skiing, hiking, walking, sexual activity, medical assistance, therapy, and more. In addition, the stabilizing belt 100 can be configured to carry animals such as dogs, cats, and other animals.
[0072] When used for medical assistance, the stabilizing belt 100 may be worn either by the patient (or person requiring assisted mobility) 12 or the caregiver 10 . When worn by the caregiver 10 , the patient 12 is able to grasp any of the various handles 106 a - 106 e that is most comfortable to the patient 12 and provides the best leverage as shown in FIG. 8 . In the meanwhile, the caregiver 10 still has his hands free to utilize them however he wishes.
[0073] In some uses, the patient can wear the stabilizing belt 100 and allow the caregiver 10 to lift the patient 12 by any of the handles 106 a - 106 e. In embodiments with a harness system, the fasteners can also be used to help move the patient. For example, the upper fastener 200 a can be connected to a crane-type lifting machine, so that a machine can lift the patient wearing the stabilizing belt 100 .
[0074] In some uses, both the patient 12 and the caregiver 10 can wear the stabilizing belt 100 maximizing the option of having the caregiver hold on to the patient, the patient hold on to the caregiver, or both.
[0075] The foregoing description of the preferred embodiment of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention not be limited by this detailed description, but by the claims and the equivalents to the claims appended hereto.
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A stabilizing belt for use by a person in need of assisted mobility or in recreation, the stabilizing belt comprising a base, a belt to secure the base to a wearer, and a pair of handles attached to the base. The base may be uniquely contoured to provide support and comfort for the wearer. A harnessing system may be provided for added security and stability. The harnessing system is versatile so as to go over the shoulders or under the legs, as necessary. The belt may further comprise handle supports for reinforcement, a pad for comfort, a cover for durability, and a pocket for versatility.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for the preparation of heterosubstituted acetals by reaction of heterosubstituted vinyl compounds with alkyl nitrites in the presence of palladium in metallic or bonded form.
Heterosubstituted acetals of the formula (I) specified later on below are suitable as starting materials for the synthesis of other organic compounds, such as medicaments, plant protection agents or dyes. Thus, for example, diethyl 2,2-dimethoxyethylphosphonate can be employed for the chain lengthening of ketones and aldehydes (Org. Synth. 53 (1973), 44-48). The transacetalization of this compound leads, furthermore, to phosphorus-containing polymers (J. Polym. Sci. 22 (1984), 3335-3342; J. Polym. Sci. A 26 (1988), 2997-3014); polymers of this type are employed in the sectors of flameproofing agents, hydrometallurgy and membrane technology.
Phenylsulphonyl-acetaldehyde diethyl acetal is reacted in accordance with DE-A 34 19 750 to give precursors for the preparation of pyrethroids.
Phenoxysulphonyl-acetaldehyde dialkyl acetal can be converted to 1,2-benzoxathiine 2,2-dioxide, which can be reacted in accordance with EP 128 116 and EP 337 947 to give herbicides.
2. Description of the Related Art
The literature describes with sporadic cases the preparation of acetals by reaction of the parent olefins with alkyl nitrites in the presence of palladium salts. Thus, for example, EP 55 108 describes the oxidation of compounds such as ethene, propene, butylene, cyclohexene, acrylic esters and acrylonitrile. The yields obtained in these oxidations, however, are low, so that any industrial utilisation would have to take account of considerable expenditure on production isolation and on the recycling of catalyst and solvent. In particular, the gas phase reaction proposed in EP 55 108 cannot be used for preparing acetals of the formula (I) specified later on below, since at the high temperature necessary for this reaction the occurrence of decomposition reactions and other secondary reactions would have to be expected.
J. Heterocyclic Chem. 29(1992), 1625 describes the reaction of 2-nitro-styrenes with alkyl nitrites in liquid phase, with the simultaneous addition of oxygen, to give the corresponding acetals. However, this reaction may give rise to ignitable mixtures, a fact which--especially in the case of industrial implementation--leads to a relatively high expenditure for the provision of the necessary safety measures.
The literature consequently contains only processes which can be used to react unsubstituted olefins, or olefins which are mono- or disubstituted on at least one carbon atom with a further carbon atom; in particular, the literature contains no processes which can be used to convert heterosubstituted vinyl compounds to acetals. Owing, however, to the many possible applications of heterosubstituted acetals, there was a need to provide processes for their preparation.
SUMMARY OF THE INVENTION
It has now been found that vinyl compounds of the formula (II) specified later on below can, surprisingly, be reacted in high yields, by reaction with alkyl nitrites under the conditions of the process according to the invention, to give acetals of the formula (I).
The invention relates to a process for the preparation of heterosubstituted acetals of the formula ##STR2## in which R 1 represents straight-chain or branched C 1 -C 8 -alkyl, preferably C 1 -C 2 -alkyl, particularly preferably methyl, and
A 1 represents a heteroatom from the group consisting of silicon, oxygen, sulphur, selenium, tellurium, nitrogen and phosphorus, which, within the scope of its bonding ability, carries one or more identical or different substituents from the group consisting of double-bonded oxygen, C 1 -C 8 -alkoxy, C 1 -C 8 -alkyl, aryloxy, substituted aryloxy, aryl and substituted aryl, and may in addition carry a positive charge,
which is characterized in that vinyl compounds of the formula
CH.sub.2 ═CH--A.sup.1 (II),
in which
A has the above meaning,
are reacted, in the presence of palladium in metallic or bonded form and in alcohols or ethers or mixtures of two or more of them as reaction medium at from 0 to 120° C., preferably from 40° to 80° C., with alkyl nitrites of the formula
R.sup.1 --ONO (III),
in which
R 1 has the above meaning.
DETAILED DESCRIPTION OF THE INVENTION
Straight-chain or branched C 1 -C 8 -alkyl is, for example, methyl, ethyl, propyl, isopropyl, butyl, isobutyl, tert-butyl, the isomeric pentyls, hexyls, heptyls and octyls. Alkyl is preferably methyl or ethyl, particularly preferably methyl.
Straight-chain or branched C 1 -C 8 -alkoxy is, for example, methoxy, ethoxy, propoxy, isopropoxy, butoxy, isobutoxy, tert-butoxy, the isomeric pentyloxy, hexyloxy, heptyloxy and octyloxy. C 1 -C 4 -alkoxy is preferred, and methoxy and ethoxy are particularly preferred.
Aryl has 6 to 12 carbon atoms and is, for example, phenyl, biphenylyl or naphthyl. Aryl can be substituted by from 1 to 3 identical or different substituents consisting of methyl, ethyl, methoxy, ethoxy, chlorine and bromine. Aryloxy likewise has 6 to 12 carbon atoms and is derived from the aryl described, in unsubstituted or substituted form.
A 1 is a heteroatom from the group consisting of silicon, oxygen, sulphur, selenium, tellurium, nitrogen and phosphorus, preferably from the group consisting of silicon, oxygen, sulphur, nitrogen and phosphorus and with particular preference from the group consisting of sulphur and phosphorus.
Accordingly, preferred vinyl compounds are those of the formula
CH.sub.2 ═CH--A.sup.2 (IV)
where
A 2 denotes a substituted heteroatom from the group consisting of silicon, oxygen, sulphur, nitrogen and phosphorus.
Particularly significant vinyl compounds are those from the group consisting of ##STR3##
In these particularly significant vinyl compounds, R 2 , R 3 and R 4 denote independently of one another straight-chain or branched C 1 -C 8 -alkoxy, C 1 -C 8 -alkyl, C 6 -C 12 -aryloxy or C 6 -C 12 -aryl, in which case aryl and/or aryloxy may be substituted in the above manner. Where the heteroatom carries a positive charge, as is evident from the above formulations, such a compound contains an anion X - which denotes chloride, bromide, 1/2 sulphate, nitrate, acetate, trifluoroacetate, formate, propionate or benzoate. From the series of the above, particularly significant vinyl compounds listed by way of their formulae, the following are preferred: ##STR4##
In these formulae
R 5 and R 6 independently of one another denote methyl, ethyl or phenyl.
Palladium may be employed in metallic or bonded form. When palladium is used in metallic form it may be transformed, at least in part, into the bonded form during the reaction according to the invention. Preferably, however, palladium in bonded form is employed. The bonded form comprises both simple salts and complex salts and also complex compounds in which the palladium has the valency zero. Such palladium salts should be wholly or partially soluble in the reaction mixture. Examples of palladium salts which may be mentioned are palladium chloride, palladium bromide, palladium acetate, palladium trifluoroacetate, palladium salts of organic carboxylic acids such as propionic acid, benzoic acid or other aliphatic or other aromatic carboxylic acids, palladium salts of heteropoly acids, especially palladium salts of the heteropoly acids derived from vanadium, molybdenum, niobium and tungsten. Preferably suitable palladium compounds are the palladium halides mentioned, and in particular palladium chloride. Palladium in bonded form, especially palladium in the form of the salts mentioned, can be supplemented by salts of other metals, such as the alkali metals or alkaline earth metals or salts of ammonium or of amines with different degrees of substitution. Suitable anions for such salts include those specified above for the palladium. Many of these salts form complexes with palladium in bonded form, so that they are also examples of the abovementioned complex salts of palladium. Supplementary salts of this kind are preferably lithium chloride or sodium chloride, preferably lithium chloride.
Alcohols and ethers which are suitable for the implementation of the process according to the invention are C 1 -C 4 -alkanols, such as methanol, ethanol, propanol, iso-propanol, butanol, isobutanol or tert-butanol, and also ethylene glycol, 1,2- or 1,3-propylene glycol or 1,2-, 1,3-, 1,4- or 2,3-butylene glycol, their ethers or semiethers with one another, such as ethylene glycol dimethyl ether or diethylene glycol, and also dioxane or tetrahydrofuran. Ethers of these substances with one another furthermore comprise compounds such as diisopropyl ether, dibutyl ether, and diethylene glycol mono- and diethyl ether. In order to simplify the reaction regime and the working-up procedure, it is preferred to work in one of the C 1 -C 4 -alkanols mentioned. It is particularly preferred to work in the alkanol on which the alkyl nitrite used for the reaction according to the invention is based.
Examples of the alkyl nitrite which may be mentioned are methyl nitrite, ethyl nitrite, propyl nitrite, isopropyl nitrite, butyl nitrite or isobutyl nitrite.
The process according to the invention is carried out at a temperature in the range of 0° to 120° C., preferably from 40° to 80° C. The pressure at which the reaction according to the invention is carried out is not critical and may be in the range of 0.5-10 bar, preferably 1.0-6 bar and particularly preferably 1-5 bar. However, it is also possible to work at higher or lower pressures.
For the implementation of the reaction it is possible, for example, first of all to suspend or wholly or partially dissolve the palladium, in metallic or bonded form, in one of the solvents mentioned. The vinyl compound, mixed if desired with a portion of the relevant solvent, is added to this suspension or total or partial solution at the stated temperature. The alkyl nitrite is then added, continuously or in portions, in liquid or in gaseous form. It is also possible, however, to add the vinyl compound and the alkyl nitrite simultaneously. When, as preferred, methyl nitrite is employed, it is expediently passed into the reaction solution as a mixture with an inert gas. Suitable examples of the inert gas are nitrogen, argon or carbon dioxide, preferably nitrogen. In the case where other alkyl nitrites are used it may also be sensible, for example on considerations of safety, to work in the presence of an inert gas. The quantity of solvent is from 1 to 100 mol, preferably from 5 to 40 mol, per mol of vinyl compound employed.
The molar ratio of the vinyl compound (II) to the alkyl nitrite (III) is from 1:1 to 1:10, preferably from 1:1.5 to 1:5.
The quantity of the palladium in metallic or bonded form, calculated as metal, is from 0.001 to 0.2 g-atom, preferably from 0.001 to 0.1 g-atom, per mol of vinyl compound.
The reaction products are isolated and worked up in a manner familiar to the person skilled in the art, for example by distillation of the solvent followed by precision distillation of the reaction product under reduced pressure, by crystallization or by a combination of these measures, as well as by chromatography if desired.
EXAMPLES
Example 1
A mixture of 200 ml of methanol, 0.4 g (2.3 mmol) of palladium chloride and 0.2 g (4.7 mmol) of lithium chloride was heated to 60° C.
Subsequently the continuous introduction of a stream of gas comprising 10 l/h of nitrogen and 0.2 mol/h of methyl nitrite was commenced.
After 15 min, 32.8 g (0.2 mol) of diethyl vinylphosphonate were added dropwise over the course of 10 minutes.
For a further 2 hours methyl nitrite was passed in in a stream of nitrogen, so that a total of about 0.5 mol of methyl nitrite was consumed.
When the introduction of methyl nitrite had ended, the mixture was stirred for 1 hour in a stream of nitrogen.
Methanol was distilled off from the solution and the residue was distilled in vacuo.
38.2 g of diethyl 2,2-dimethoxy-ethylphosphonate were obtained (85% of theory). Boiling point: 90°-92° C./1 mbar.
Example 2
A mixture of 200 ml of methanol, 0.25 g (1.4 mmol) of palladium chloride and 0.125 g (2.9 mmol) of lithium chloride was heated to 60° C.
Subsequently the continuous introduction of a stream of gas comprising 10 l/h of nitrogen and 0.1 mol/h of methyl nitrite was commenced.
After 15 min, 8.4 g (0.046 mol) of phenyl vinylsulphonate, dissolved in 20 ml of methanol, were added dropwise.
For a further 2 hours methyl nitrite was passed in, so that a total of about 0.2 mol of methyl nitrite was consumed.
When the introduction of methyl nitrite had ended, the mixture was stirred for 1 hour in a stream of nitrogen.
Methanol was distilled off from the solution and the residue was distilled in vacuo.
9.1 g of phenyl 2,2-dimethoxyethyl sulphonate were obtained (81% of theory). Boiling point: 135° C./0.5 mbar.
Example 3
400 mg (2.3 mmol) of palladium chloride and 200 mg (4.7 mmol) of lithium chloride were dissolved with heating at 60° C. in 240 ml of methanol.
Subsequently a continuous gas stream comprising 10 l/h of nitrogen and 0.2 mol/h of methyl nitrite was introduced.
After 15 min, a solution of 30 g (0.18 mol) of phenyl vinyl sulphone in 60 ml of methanol was added dropwise.
For a period of 2 hours more methyl nitrite was passed in, so that a total of about 0.4 mol of methyl nitrite was consumed.
Methanol was distilled off from the solution and the residue was distilled in vacuo.
31.6 g (0.14 mol) of 2,2-dimethoxy-ethyl phenyl sulphone were obtained (77% of theory). Boiling point: 139-140° C./0.7 mbar.
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Heterosubstituted acetals of the formula ##STR1## can be obtained by reacting vinyl compounds of the formula
CH.sub.2 ═CH-A.sup.1 (II)
with alkyl nitrites of the formula
R.sup.1 --ONO (III.)
The reaction is performed in the presence of palladium in metallic or bonded form and in alcohols or ethers as reaction medium at from 0° to 120° C.
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This application is a continuation-in-part of application Ser. No. 09/054,042, filed Apr. 2, 1998, now U.S. Pat. No. 6,151,727, which claims the benefit of U.S. provisional application Ser. No. 60/043,366, filed Apr. 2, 1997.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to bathtubs and bathtub/shower combinations that satisfy the needs of persons with temporary or permanent disabilities that render use of a conventional bathtub difficult or impossible. In particular, the present invention relates to a bathtub apparatus having a movable front panel and an elevated bed or seat, so that the bathtub can be accessed directly from a wheelchair with only lateral movement.
2. Discussion of Background
Existing bathtubs and bathtub/shower combinations come in a variety of sizes, types and configurations, ranging from older cast iron tubs that are raised on feet, to newer tubs that have oval or rounded rectangular tub recessions set into the tub structure at an angle. Some tubs have built-in Jacuzzi™ or other whirlpool units, heaters, and other devices that add to the user's comfort and enjoyment.
Despite the growing awareness that large numbers of people simply cannot use conventional bathroom fixtures safely (or even use them at all), essentially all present-day bathrooms contain bathtubs designed for the hypothetical “average” adult. Whatever their age or type, conventional bathtubs have raised walls that the user must step over, or steps that the user must climb in order to use the tub. Many people have temporary or permanent disabilities that render the use of a conventional bathtub difficult or impossible, even with the assistance of a nurse or other caregiver. (As used herein, the term “disability” refers to any condition, temporary or permanent, that hinders a person's access to and use of conventional bathtubs and/or showers. Such disabilities include paraplegia, missing limbs, fractures, osteoporosis, impaired balance, arthritis, multiple sclerosis, and so forth.) In the United States alone, over six million people routinely use a mobility-assisting device such as crutches, canes, wheelchairs, scooters, and the like; over four million people have difficulty taking a bath or shower; and almost three million need personal assistance in taking a bath or shower. Thus, there is a growing market for universally-accessible bathroom designs, a market that is anticipated to parallel the increase in the average age of the U.S. population and growing awareness of the needs of disabled persons and the elderly. A variety of devices are available to assist disabled persons in bathing, showering, etc., ranging from non-skid surfaces and sturdy grab bars to bath lifts, fixed or swiveling bathtub seats, and tubs with access doors. Presently-available devices include tubs with access doors such as those made by the Silcraft Corporation of Traverse City, Minn. and the Kohler Company of Kohler, Wis.
Bathtub devices are shown in a number of U.S. Patents, including Bourgraf, et al. (Des. 351,018) and Sween (Des. 285,346), which disclose ornamental designs for bathtubs. U.S. Pat. No. 5,701,614 issued to Appleford, et al. shows a bathtub having a side opening which extends over the full width and height of the bath and is surrounded by an outwardly and downwardly extending skirt. A door with a channel on its inner surface is upwardly translatable in its own plane to bring the door over the opening and force the skirt into sealing engagement with a seal in the channel. The seal may be a foamed rubber seal or a part fluid-filled flexible tube.
McAllister, et al. (U.S. Pat. No. 5,463,780 disclose a ramp which is pivotable from a generally horizontal position for elevating wheel chairs into a shower or other location to a generally vertical position which uses the ramp to hold shower curtains within the shower. The ramp has a dam which prevents water from running onto the floor.
Sills, et al. (U.S. Pat. No. 5,446,929) show a bath tub with a main tub body, a door support, a tambour door assembly, a door seal, and a control system. The tambour door is in a horizontal position under the floor when open and in a vertical position closing the open side of the main tub body when closed. The seal includes an inflatable tube.
Sween (U.S. Pat. No. 5,255,400) discloses a bathing tub apparatus that includes a tub with a sealable door, a prefillable reservoir positioned above the tub, and a support unit which includes a storage cabinet, a liquid circulation system, and a hand-held shower. The reservoir is held by the support unit. The Sween device also includes a hand held shower that may be used by the person in the tub.
Williams (U.S. Pat. No. 4,953,241) shows a bathtub with an entrance wall with an opening which conforms to the shape of the door, a front wall adjacent to the entrance wall, a seat located in the tub, and a locking mechanism which can secure the door in an open or closed position. The front edge of the door is attached adjacent to the front wall of the bathtub by a double axis hinge. When the door is opened, its front edge is guided directly inwardly in the tub by a tracking mechanism; the door is configured so that, during movement, it does not swing over the seat.
Corlew (U.S. Pat. No. 4,796,312) provides a bath tub having side walls, a rear wall, an entrance, and a door for closing the entrance. The entrance has a seal engageable with a chamfered inner surface of the door when the door is closed and water pressure is exerted on the seal.
Schenstrõm (U.S. Pat. No. 4,672,693) discloses a tub having an opening extending almost down to the bottom of the tub and a hatch to close the opening. The hatch is placed on the inside of the bathtub and the hydrostatic forces of the water force the hatch against the edges of the opening where a seal is provided on the hatch.
S Houle, et al. (U.S. Pat. No. 4,546,506) disclose a bathtub with an access opening in one side, and a vertically sliding door to close the access opening, a combination door guide and grab bar arrangement, an adjustable control console, and a power door lock which securely closes the door without significant manual effort.
Budlong (U.S. Pat. No. 4,034,424) provides an auxiliary bathtub mounted above a conventional bathtub, including a rectangular frame approximating the shape of a conventional bathtub and a flexible waterproof liner extending between the side and end walls of the frame and along the inside faces thereof to form a watertight container. At least one of the side walls pivots downwardly to allow entry and exit from the tub, and is held in its upright position by a releasable latching mechanism.
Finch, et al. (U.S. Pat. No. 3,864,762) show an elevated bathtub with a floor supported at approximately normal chair height and a side opening serving as en entryway through one of the walls of the tub. The entryway is provided with a water-tight barrier which may be moved out of the way to permit a person to enter the tub, and replaced once the person is inside the tub.
In addition to the above-described bathtubs, “walk-in” and “wheel-in” showers are becomingly increasingly common in hospitals, nursing homes, and even private homes designed for accessibility. However, showers cannot duplicate the therapeutic effects of soaking in a bathtub, and many people simply prefer tub baths to showers. Some estimates suggest that the United States market for accessible bathtubs could easily approach 30,000 or more per year. However, it is believed that presently available bathtub designs do not satisfactorily address the needs of the large and growing population of individuals who cannot use a conventional bathtub.
Many of the above-described bathtubs require more space for doors, tracks, lifts, water reservoirs, and other components than is available in typical bathrooms. Many are also complex, high-maintenance, and prohibitively expensive for all but institutional use.
This invention relates generally to the design and construction of bathtubs and bathtub/shower combinations, and more specifically to the design and construction of bathtubs and bathtub/shower combinations that address the unique needs of persons with disabilities. Appropriate bathtub designs for this group would not only help such persons in an important activity, but also reduce a major occupational hazard of nurses and other caregivers: sprained/strained backs and shoulders that result from assisting patients into and out of conventional bathtubs. The emphasis of the present invention is to provide a bathtub or combination bathtub/shower apparatus that people with disabilities can use to care for themselves and maintain an independent lifestyle (the terms “bathtub,” “bathtub/shower,” “bathtub apparatus” and “bathtub/shower apparatus” are used interchangeably in the following specification).
A bathtub apparatus that addresses these needs should have the following features:
1. As a baseline criterion, the bathtub must be accessible, without assistance, by a person in a wheelchair.
2. The bathtub should preferably be dimensioned to be comparable to a full-sized, soak-bath type bathtub, and accommodate virtually everyone (except perhaps, a small percentage of the population due to size or weight considerations). The user should be able to access and control the water temperature, flow rate, and drain.
3. The bathtub should be capable of being installed in a typical bathroom, either as a new installation or retrofitted to an existing unit.
4. The bathtub should be usable by substantially all persons. Non-disabled users (that is, those without conditions that restrict their access to conventional tubs and showers) should be able to use the bathtub to bathe and/or shower in a normal manner; disabled users should be able to bathe and/or shower with minimal risk of falling.
5. The bathtub must be cost-effective and easily installed.
Designing such a bathtub apparatus requires an understanding that, for a person with disabilities, bathing—or being bathed—involves not just the act of bathing itself (i.e., the act of immersing a person in a liquid for cleaning). It also encompasses people-handling in the psychological and physiopsychological sense: understanding and accommodating the desire for independence, dignity, safety, and security, combined in many instances with a reluctance to ask others for help.
In U.S. Pat. No. 6,151,727, entitled “Bathtub for Persons With Digabilities,” I disclose a bathtub apparatus with a pivotable front panel and an elevated bed that allows direct lateral access by the user (that is, a user can access the bathtub directly by stepping into the open tub, sitting on the seat and moving his or her feet into the tub, or sliding from a wheelchair to the seat). The bathtub can be installed in a new or remodeled bathroom. It can also be installed above an existing conventional bathtub, thereby avoiding the necessity of removing the old tub before installing the new one.
Despite the variety of presently-available bathtubs of various shapes and sizes, and of varying accessibility, there is a continuing need for a cost-effective, maximally-accessible tub which can be installed in new or existing bathrooms in residential, commercial (hotel, motel, etc.) and institutional (hospital, nursing home, assisted living facility, etc.) settings.
SUMMARY OF THE INVENTION
According to its major aspects and broadly stated, the present invention is an accessible bathtub apparatus having a floor panel, a wall panel, a movable front panel or door panel that can be opened to permit access into (and out of) the bathtub, a door seal, and pivotable connectors operable to move the door panel from a first, open position to a second, closed position. One end of the floor panel forms a stationary, raised tub bed or seat on which the user's back or buttocks rest; the other end forms a foot well. The wall panel, which is preferably integrally formed with the floor panel, may include head, rear, and foot panels (also termed “end walls”) analogous to those found in conventional bathtubs. The floor panel, the wall panel, and the movable front panel cooperate to form a liquid-containing enclosure. The apparatus, hereinafter referred to as “Alden's Tub” or the “ATI Tub,” permits direct lateral movement by the user to and from the tub bed: a nondisabled user can access the apparatus directly by stepping into the open tub; a disabled or nondisabled user can sit down on the seat and move his feet into the tub; a disabled user can slide from a wheel-chair to the seat. These modes of access are referred to herein as “direct access,” “direct lateral access,” or “direct lateral movement.”
The apparatus can be provided as a stand-alone model which is generally similar to a conventional bathtub/shower or bathtub/shower combination. A drop-in model which is installed in a platform base (similarly to installation of a kitchen sink in a cut-out or recess in a kitchen counter), but is otherwise similar to the stand-alone type. A portable model which can be installed on an existing conventional bathtub such as those typically found in private homes, hotel or motel rooms, and other facilities, thereby avoiding the necessity (and expense) of removing the old tub before installing the new one. The invention can be used in private homes, hotels and motels, dormitories, hospitals, nursing homes, assisted living facilities, and other locations; it can be used by persons with disabilities that would otherwise preclude them from bathing unattended or unassisted.
Its versatility and cost-effectiveness constitute major features of the present invention. Most bathrooms, either new or existing, have been designed to utilize either right-handed or left-handed bathtubs (i.e., bathtubs having plumbing fixtures and drainage either at the right or left side as the user faces the tub); some have centrally located plumbing. Existing bathtubs and bathtub/shower combinations come in a wide variety of sizes, types and configurations, some having built-in Jacuzzi™ or other whirlpool units, water heaters, and other devices intended to add to the user's comfort and convenience. The ATI Tub can be installed instead of another type of bathtub; alternatively, it can be retro-fitted—permanently or temporarily—to the vast majority of presently-existing bathtubs. Because the ATI Tub has no “handedness,” it can be used with either left-handed or right-handed plumbing fixtures.
As will be seen in the Detailed Description, the ATI Tub is simpler to manufacture and requires less materials and labor than other known designs, therefore resulting in a more cost-effective product. The ability to quickly and easily install the ATI Tub over an existing conventional bathtub reduces installation costs, since there is no need to demolish and remove the old tub before installing the new one.
An important feature of the present invention is the movable front, door panel which permits direct lateral access by the user. The front panel may extend the full length of the ATI Tub or only a portion of the length, and may take a number of different forms to permit it to be moveable and sealable relative to the stationary parts of the tub as will be described in detail below.
Depending on the needs and preferences of the user, the front panel may be bottom-hinged for a fold-up/fold down motion, side-hinged for lateral swing-out/swing-in motion, a banker's roll-top desk type of panel, a pivotable panel that pivots up or down about a pivot point away from the panel itself, or a parallelogram type panel utilizing two lever arms and pivot points at the ends of the tub. A variety of different type of seals may conveniently be used with the invention, including but not limited to compression-type seals such as are used with refrigerator doors, pneumatically-inflatable or hydraulically-inflatable seals, and diaphragm-type seals. In a preferred embodiment of the invention, the front panel is pivotable between its open and closed positions. Retainers, spring-loaded pivots, or other suitable devices hold the front panel in its open position during ingress and egress by the user.
Another feature of the present invention is the elevated tub bed, which is at a comfortable seating height when the bathtub is installed. Typical heights are approximately 15″-16″ (about 38-41 cm) above floor level, although heights outside this range may also be useful. This feature permits a person to move laterally to and from the ATI Tub from a wheelchair, for example, by sliding (with assistance if needed) from the wheelchair onto the tub bed.
Still another feature of the present invention is the foot well, which is preferably located at the same end of the ATI Tub where the water valves, nozzle, and drain would be located in a conventional bathtub. The foot well may be approximately 24″×24″ (about 61×61 cm) in horizontal dimensions and approximately 12″ (about 30 cm) deep, and serves several functions: (a) it increases the effective length of the ATI Tub for tall users so that all portions of the body, including the knees, can be submerged; and (b) it permits non-disabled users to both bathe and shower in a conventional manner.
Yet another feature of the present invention is the ability to fit it to an existing bathtub. Many conventional bathtubs have one or more ledges at the sides or back, together with a front wall which a user must step over to access the tub. In tubs having adequate ledges, recesses, or other structural features for support, the invention can be installed so that the enclosure rests on the ledges. Supplemental longitudinal and lateral supports, expanded plastic foam, or other devices may be used to fix it permanently in position. Alternatively, the invention may be supported by brackets attached to the existing tub and/or the surrounding walls. Pallets that interface the invention to the existing tub, filler materials, or shims may also be used where appropriate.
Other features and advantages of the present invention will be apparent to those skilled in the art from a careful reading of the Detailed Description of Preferred Embodiments presented below and accompanied by the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings,
FIG. 1 is a schematic, isometric view of a portable bathtub apparatus according to a preferred embodiment of the present invention;
FIG. 2 is an orthographic view of the bathtub apparatus of FIG. 1, shown positioned above an existing bathtub/shower combination in preparation for installation;
FIG. 3 is an end elevation view of the bathtub apparatus of FIG. 1, showing the apparatus installed in an existing bathtub having front and rear ledges, wherein the apparatus is supported by such front and rear ledges;
FIG. 4 shows the bathtub apparatus of FIG. 1 installed in an existing bathtub, wherein a supplemental filler material is provided between the apparatus and the existing bathtub;
FIG. 5A is an isometric view of the off-center cam used as a pivot point for the front panel of the bathtub of FIG. 1;
FIGS. 5B and 5C show the cam of FIG. 5A in “closed” and “open” positions, respectively;
FIG. 5D shows two off-center cam pivots connected by a lever arm;
FIG. 6 is an isometric view of a bottom-hinged, fold-down front panel utilizing folded diaphragms for leak-proof sealing, showing the panel in the “closed” position; and
FIGS. 7A-E are schematic, end elevation views of moveable front panels usable with the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the following description, reference numerals are used to identify structural elements, portions of elements, or surfaces in the drawings, as such elements, portions or surfaces may be further described or explained by the entire written specification. For consistency, whenever the same numeral is used in different drawings, it indicates the same element, portion, surface and area as when first used. As used herein, the terms “horizontal,” “vertical,” “left,” right,” “up,” “down,” as well as adjectival and adverbial derivatives thereof, refer to the relative orientation of the illustrated structure as the particular drawing figure faces the reader. It should be understood that only those components having particular functional importance or that would not otherwise be identified have been assigned reference numerals.
Referring now to FIG. 1, there is shown a bathtub apparatus 10 (“Alden's Tub” or “ATI Tub”) according to a preferred embodiment of the present invention. Bathtub 10 includes a wall panel 18 , and a floor panel 20 with a tub bed or seat portion 22 and a recessed foot well portion 24 . Wall 18 includes a head end wall, rear side wall, and foot end wall analogous to those found in conventional bathtub installations, being readily identifiable and therefore not numbered.
Foot well 24 has a drain 26 , sealable with a conventional elastomeric drain plug or some other suitable means. Tub bed 22 and foot well 24 , together with wall 18 , are stationery when bathtub 10 is installed for use, whether the installation is temporary or permanent. Tub bed 22 (and foot well 24 , if desired) may have textured surfaces for increased traction. Alternatively, textured strips or mats of non-slip material may be attached to tub bed 22 and foot well 24 . Bathtub 10 is illustrated schematically: the tub may have generally flat, rectangular walls as shown herein, or gently curved edges and surfaces to further user comfort and esthetic appeal. If desired, tub bed 22 may be contoured to form a comfortable seat for the user.
A pivotable door or front panel 30 is connected to the stationary portions of bathtub 10 by any suitable means, preferably by two off-center cam pivots 34 located at each end of front panel 30 as will be described further below. A seal (for example, the seal shown schematically as 28 ) seals front panel 30 to wall 18 when the panel is in a closed position. Front panel 30 may have handles, hand rails, or grab bars permanently attached thereto, such as a grab bar 32 , to assist the user in maneuvering into and out of bathtub 10 . Additional hand rails, of any convenient size and design, may be attached to the side walls and rear wall of bathtub 10 . For stability, grab bars 32 are preferably fixed in position.
FIG. 2 shows the bathtub of FIG. 1 suspended over a conventional bathtub or combination bathtub/shower 40 having a permanently-installed drain 42 (the water supply nozzle and valving for bathtub 40 are indicated but not numbered). It should be understood that bathtub 40 and associated plumbing are usable with the invention, but do not form part of the invention. Bathtub 10 includes pivotable front panel 30 , as well as foot well 24 , drain 26 , and the other above-described portions of the ATI Tub.
An optional auxiliary rear support 44 is shown schematically in FIG. 2 . Support 44 may be included when bathtub 10 cannot readily be supported in position by pre-existing bathtub ledges and the like (as shown in FIG. 3 and discussed under FIG. 4 ).
In use, front panel 30 of bathtub 10 is raised to the upright, “open” position shown in FIG. 1 and the user moves into the bathtub in one of several ways: with or without assistance from a nurse or other caregiver, the user moves to a sitting position with his or her buttocks resting on tub bed 22 and feet in foot well 24 . An ambulatory user may simply step into bathtub 10 and sit down on tub bed 22 . Alternatively, to minimize the risk of falling while stepping into bathtub 10 , he may sit down on tub bed 22 , swing his feet into foot well 24 , and turn so that he is facing afoot end wall 100 with his back towards a head end wall 102 . A user seated in a wheelchair pulls himself parallel to bathtub 10 at tub bed 22 facing foot end wall 100 , moves the arm rest of the wheelchair out of the way, and, holding onto the wheelchair for support if needed, slides onto tub bed 22 . Once seated on tub bed 22 , he lifts his legs (with assistance if needed), together or one at a time, into foot well 24 . Thus, tub bed 22 combines the functions of a seat and a transfer surface that a mobility-impaired person can use for entering and leaving bathtub 10 . Tub bed 22 preferably meets the ANSI (American National Standards Institute) standard for a transfer surface (i.e., at least approximately 15″ (about 38 cm) deep).
After the user is seated in bathtub 10 , he or she lowers front panel 30 to its closed position. Panel 30 may also include an interior handle or other device (not shown) whereby the user may open and close the panel while seated on tub bed 22 or while standing in foot well 24 .
Front panel 30 is then lowered and locked into its “closed” position (as indicated in FIG. 2 ), and a drain seal put into drain 26 . With front panel 30 in the closed position, front panel 30 , wall 18 , and floor 20 form a substantially water-tight (i.e., fluid-tight, liquid-tight) enclosure. Hot and cold water is introduced into bathtub 10 by means of a hose and handheld shower head or other suitable plumbing (such plumbing is not a part of this patent application).
Upon completion of bathing, drain 26 is opened and water from bathtub 10 drains into existing tub 40 and drain 42 . Front panel 30 is again raised. The user exits bathtub 10 by standing and moving out of the bathtub, or by sliding from seat 22 to a waiting wheelchair. If the user requires assistance, that assistance is substantially enhanced because a caregiver can quickly and easily operate front panel 30 and has ready access to the interior of bathtub 10 . For those users needing assistance to enter or leave bathtub 10 , the caregiver may be able to help the user slide onto tub bed 22 rather than having to lift him or her into the bathtub. This feature facilitates assistance by a family member, thereby delaying the necessity for hiring professional caregivers or moving to a nursing home.
Most existing, conventional bathtubs have a front wall which a user must step over to access the tub. Many of these bathtubs have a ledge at the opposite wall; some also have ledges at the front and/or foot end walls. Bathtub 10 can be installed in substantially all existing bathtubs, some of which may require the use of appropriate supplemental supports, expanded plastic foam, and other such devices as are known in the art.
For example, FIG. 3 is an end elevation view of an ATI Tub according to the present invention installed in an existing bathtub as described above, wherein bathtub 10 is shown fully inserted into the existing tub 40 and supported along its sides by a front wall 106 and a rear ledge 108 of the existing tub (for clarity, tub 40 is shown in cross-section). Pivotable front panel 30 is shown in its closed position.
FIG. 4 is an end elevation view of an ATI Tub with an auxiliary rear support 44 installed in an existing bathtub 40 (as in FIG. 3, tub 40 is shown in cross-section). Support 44 may be configured to provide lateral and/or longitudinal support for bathtub 10 as may be needed. Alternatively, bathtub 10 may be supported by suitable brackets attached to bathtub 40 and/or the surrounding walls. Bathtub 10 may also be partly supported by a recess or other structural feature in bathtub 40 . For some existing bathtub installations, pallets that interface the existing bathtub 40 to bathtub 10 may be provided. Such pallets would be cut to whatever size and shape may be needed.
In an exiting installation where there are insufficient ledges, recesses or other structural features for supporting bathtub 10 and where brackets are not feasible, a filler material or shims may need to be installed between the bed and sidewalls of tub 40 and support 44 (if present) and foot well 24 of bathtub 10 . The filler material may take any of several different forms. By way of example, thin-walled, flexible plastic sleeves may be positioned under support 44 and foot well 24 , and chemicals injected therein to form a foamed-in-place, expandable plastic filler material (indicated generally as 50 ). However, it will be understood by those of ordinary skill that other types of filler or shim may also be suitable for use with the invention.
When raised to an open, generally upright position, front panel 30 may be held in that position by any suitable fasteners, including but not limited to latches, clips, snaps, clamps, hooks, magnetic retainers, or other suitable devices indicated schematically as 110 (FIG. 3 ). Alternatively, at least one hydraulic or pneumatic cylinder, spiral spring, spring-loaded counterbalance, or other suitable device (indicated schematically as 112 ) may retain front panel 30 in an upright position when the panel is raised, but allow the user (or caregiver) to easily lower the panel to its closed position when desired. Where device 112 includes a counter-balance, the device may include provision for adjusting the spring tension, and optionally an adjustable stop for positively locating front panel 30 in the open position.
Turning now to FIGS. 5A-C, there are shown detail views of off-center cam pivot 34 of FIG. 1 . Pivot 34 includes a generally circular outer body pivot 60 , a rear plug 62 , and an off-center pivot 64 which is inserted into a suitable bushing in the wall of bathtub 10 . In a preferred embodiment of the present invention, bathtub 10 includes two such pivots 34 , one at each end of front panel 30 (as shown schematically in FIG. 5 D). A rigid operating lever arm 66 in the form of an inverted “U” connects the two pivots 34 , causing the pivots to operate essentially in unison when lever arm 66 latches or unlatches front panel 30 against bathtub 10 . However, other pivot means may also be useful for the practice of the invention.
FIG. 6 shows another preferred embodiment of the invention, wherein a front panel 70 is hingedly connected to the stationary portions of bathtub 10 at a lower edge 72 . Panel 70 is movable between the “open” and “closed” positions indicated in FIG. 6 . Sealing of panel 70 to bathtub 10 may be accomplished by any convenient means. By way of example, an elastomeric strip may cover the hinge, and be attached to both tub bed 22 and front panel 70 . Alternatively, folded elastomeric sheet diaphragms 74 may be connected between the front and the end walls of bathtub 10 . Latching of front panel 70 can be accomplished in a number of different ways within the spirit of the present invention.
FIGS. 7A-7E illustrate schematically a variety of additional front panel or door designs usable with the present invention. By way of example, FIG. 7A shows the operation of a front panel 80 that includes a rolling diaphragm-type seal. FIG. 7B shows a bottom-hinged fold-down front panel 82 such as that shown in FIG. 6 . Alternatively, front panel 82 may be side-hinged for lateral swing-out/swing-in motion if preferred. Other designs include a folding panel 84 (FIG. 7 C), a pantograph-type panel 86 (FIG. 7 D), and a two-way slide panel 88 (FIG. 7 E).
From the above narrative, a number of variations and alternatives may be considered as lying within the scope of the present invention. It will be clear to those skilled in the art that factors such as the particular application affect the design approach. The following discussion outlines a few of the major application factors that may impact the design approach.
One factor is the intended market segment for the ATI Tub. Potential markets include hotel and motel chains, retirement and assisted care homes, nursing homes and rehabilitation facilities, hospitals, and private homes. For all of these markets, the purchase of a bathtub for either permanent or temporary installation is an option, whether the bathtub is installed in a newly-designed (or remodeled) bathroom or retrofitted to an existing tub. Other options include renting or leasing a bathtub that can be temporarily installed in an existing bathroom in order to meet a short-term need. A bathtub according to the present invention can help businesses satisfy the requirements of the Americans With Disabilities Act (ADA). The ADA addresses discrimination against individuals on the basis of a physical or mental handicap; it is designed to end physical barriers in the use of public accommodations and transportation.
Another factor is the selection of a particular design. The ATI Tub may be provided as a “stand-alone” model with the above-described features, but which is otherwise similar to a conventional bathtub or combination bathtub/shower. This stand-alone embodiment of the invention may be permanently installable in the user's bathroom. Alternatively, the ATI Tub may take the form of a “drop-in” model which can be installed in a suitably-dimensioned recess in a platform, in a manner similar to installation of a kitchen sink in a cut-out or recess in a kitchen counter. These models, which replace a conventional bathtub installation, may be preferred for new or remodeled bathrooms designed for universal accessibility. Alternatively
In another embodiment of the invention, a portable model ATI Tub (such as that shown in FIG. 1) may be installed above an existing conventional bathtub such as those commonly found in private homes, hotels and motels, hospitals, nursing homes, assisted living facilities, etc. While all embodiments of the ATI Tub may be manufactured in any desired size and color, a few standard sizes are preferable from the standpoint of manufacturing and market economics.
A bathtub according to the present invention may be made of any suitable materials, preferably of materials that can be molded by techniques known in the art of bathtub manufacturing. Suitable techniques include spray-molding, roto-molding, blow-molding, compression molding, and injection molding. Lightweight, durable materials such as acrylic resins and other plastics, Fiberglas™, and reinforced plastics (i.e., composites composed of a thermosetting or thermoplastic resin and fibers, filaments, or whiskers of glass, metal, boron, aluminum silicate, etc.) are broadly suitable for use with the invention.
As noted above, a variety of movable front panels may be used with the invention, including but not limited to a bottom-hinged panel for a fold-up/fold down motion, a side-hinged panel for lateral swing-out/swing-in motion, a banker's roll-top desk type of panel, a pivoted panel permitting the movable panel to pivot up or down about a pivot point away from the panel itself, and a parallelogram-type panel utilizing two lever arms and pivot points at the ends of the bathtub. These may be used with all of the above-described models of the ATI Tub, subject to physical restrictions that may exist within any particular bathroom.
A variety of seals are usable with the invention, including but not limited to compression-type seals such as those used for refrigerator doors, pneumatically-inflatable or hydraulically-inflatable seals, and diaphragm-type seals. For example, diaphragm seals such as folded sheets, fan-fold sheets, or rolling diaphragm seals may be used on bottom-hinged or side-hinged panels to make the seal leak-proof.
Typical bathrooms are designed to utilize either right-handed or left-handed bathtubs, that is, plumbing fixtures and drainage are either at the right or left as a person faces the tub, as well as centrally located plumbing. Existing bathtubs and bathtub/shower combinations come in a variety of sizes, types and configurations, ranging from older cast iron tubs that are raised on feet, to newer tubs that have oval or rounded rectangular tub recessions set into the tub structure at an angle. The ATI Tub can be used in essentially all of the above-noted configurations, contributing to both interchangeability and economy in production. The invention has no handedness per se, thus, it can readily be installed for use with existing left-handed or right-handed plumbing fixtures.
A bathtub apparatus according to the present invention is believed to be simpler to manufacture, and require less materials and labor than other designs for accessible bathtubs, therefore resulting in a cost-effective product. In one embodiment of the invention, bathtub 10 can be used in place of conventional bathtubs (or bathtub/shower combinations) for new construction or renovations. In another embodiment, the portable model of the invention can be installed quickly and easily over an existing conventional bathtub. The principal advantages of portability are two-fold: the reduced costs associated with not having to remove an existing bathtub and permanently install a new tub, and the capability to quickly (and, if need be, temporarily) retrofit the ATI Tub to an existing installation. For instance, rather than remodeling an existing bathroom, a motel operator can install a portable ATI Tub in a bathroom for a customer that may only need the tub for a night or two. A homeowner can likewise install a portable ATI Tub, temporarily or permanently, for use by a resident or guest.
Based on assessments of existing companies that produce bathtubs for persons with disabilities, there are no known products that compete with the ATI Tub concepts, and therefore the hotel/motel, institutional (hospital, nursing home, etc.) and the private residential markets. The testing markets (hotels and motels, hospitals, nursing homes, private homes, etc.) are estimated at more than 150,000 units over a period of five years. However, the market for accessible design is anticipated to increase substantially over the coming years, paralleling the increase in the average age of the U.S. population and growing awareness of the needs of disabled persons and the elderly.
With respect to the above description of the invention, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing description is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. Thus, it will be apparent to those skilled in the art that many changes and substitutions can be made to the preferred embodiment herein described without departing from the spirit aid scope of the present invention as defined by the appended claims.
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An accessible bathtub apparatus for persons with disabilities, including an enclosure with an elevated bed with a seat and a foot well, a door panel, a door seal, connectors operable to pivot the door panel from an open position to a closed position, and retainers that hold the door panel in the open position until released by the user. The elevated bed allows direct lateral access by the user. The bathtub can be installed in a newly-constructed or renovated bathroom. Alternatively, it can be installed on an existing conventional bathtub, thereby avoiding the necessity of removing the old tub before installing the new one. It can be used in private homes, hotels/motels, and other locations; it can be used by persons with disabilities that would otherwise preclude them from bathing unattended or unassisted.
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BACKGROUND OF THE INVENTION
The present invention relates to fruit drinks which contain residual sulfur dioxide and/or sodium bisulfite.
Fruit drinks and fruit juice containing products are known to develop an undesirable brown or dark color in a relatively short period of time when exposed to air, due in part at least to oxidative changes. In the absence of air, fruit juices also turn brown but more slowly, apparently from interreaction of juice constituents, to form dark-colored products.
The latter form of browning is a non-enzymic, anaerobic browning. Although sulfur dioxide is used to effectively retard such browning in "air-tight" systems by reacting with reducing sugars, such use is disadvantageous due to sulfur dioxide's characteristic odor and the fact that it eventually gives rise to a unique and unpleasant off-taste described as "skunky", e.g., U.S. Pat. No. 3,219,458.
The former type of browning is from oxidation, such as would be expected to occur in gas permeable containers. It is generally counteracted by several means for reducing atmospheric oxygen to a very low level at the time of packaging. This is accomplished by purging the container with an oxygen-removing gas and thereafter sealing the container. Accordingly, sulfur dioxide and sulfur dioxide producing compounds, e.g., sodium bisulfite, were heretofore believed to find little utility in such fruit drink systems. In fact, U.S. Pat. No. 2,825,651 teaches that sodium bisulfite, in anhydrous form, does not work by itself as an oxygen remover, and in the hydrated form is too active to handle conveniently. This patent teaches that unless copper sulfate pentahydrate is brought into intimate contact with the sulfites either by grinding or by compression into pellets, oxygen removal is ineffective. Also, U.S. Pat. No. 2,628,905 teaches that sodium bisulfite is so acid that solutions of its salts are too unstable, in giving off sulfur dioxide, which is too offensive for treating air exposed slices of fruits and vegetables unless buffered to a pH of from 5.2 to 6.5. One skilled in the art might believe that these limitations apply equally as well to fruit drinks.
Accordingly, a method of packaging fruit drinks which contain sodium bisulfite and residual sulfur dioxide, unbuffered, and uncombined with oxygen-removal compounds, and without extraneous means for reducing atmospheric oxygen at the time of packaging, yet which effectively inhibits oxidative browning while avoiding an offensive odor or taste would be an unexpected and advantageous advancement of the art.
SUMMARY OF THE INVENTION
It is an object of the present invention to package fruit drinks in an inexpensive, gas permeable container, and yet avoid oxidative browning while simultaneously avoiding use of a conventional oxygen-removal system.
It is a further object of the present invention to provide a packaged, unbuffered fruit drink which contains sodium bisulfite and residual sulfur dioxide yet which does not give rise to an offensive odor or taste.
Briefly, the objects of the invention are fulfilled by packaging a fruit juice containing mixture with sodium bisulfite and residual sulfur dioxide at a pH of about 2.6 to about 3.0 in a gas permeable container.
The theoretical explanation for success of the invention, is not precisely understood. For example, since sodium bisulfite, according to the prior art, was not believed to work as an oxygen-remover by itself, the permeability of the container should give rise to rapid oxidative browning, but it does not. Likewise, unexplainable is the fact that sodium bisulfite even at the low pH of the invention (about 2.6 to about 3.0) does not give rise to the offensive skunky taste or odor, frequently referred to in the prior art. One explanation could be that the permeability of the container allows the sulfur dioxide to escape. However, even this reasoning causes a dilemma because such permeability should by the same token allow atmospheric oxygen to enter and produce a browning effect. Additionally, there is a chance that the sulfites react with reducing sugars thereby preventing amino acid browning but tests have shown that the browning is not caused by amino nitrogen activity in the system.
In an article entitled "Carbonyl Compound in the Non-Enzymic Browning of Lemon Juice", by K. M. Clegg and A. D. Morton, Journal of Science and Food Agriculture, XVI, 1965, pgs. 191-198, Clegg and Morton investigated browning. They found that when the characteristic browning was attributed to solely ascorbic acid, there was an increase in the carbonyl content of lemon juice. The browning increased for approximately 10 days, then polymerization of carbonyl products caused a plateau and even decline of the carbonyl content. The presence of citric and amino acids delayed the peak carbonyl absorption for a week but the visible browning increased. It is significant that sodium bisulfite reaction was one of the confirmatory analyses for carbonyls, but sodium bisulfite was not emphasized as a satisfactory inhibitor of these complex browning steps.
Nevertheless, the objects of this invention are fulfilled as the following description of preferred embodiments will more readily indicate.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention broadly comprehends within its scope the discovery that packaging fruit drinks, which contain sodium bisulfite and residual sulfur dioxide at very low pH's, in gas permeable containers will effectively retard oxidative browning without giving rise to offensive odor or taste in the product.
The fruit drink products of the present invention will contain from 50 to 60% of sugar solids, from 0.005 to 0.050%, preferably 0.020% to 0.025% alkali metal sulfite or bisulfite or 0.003 to 0.03% sulfur dioxide, 0.050 to 0.075% preservatives such as potassium sorbate and sodium benzoate, 0.25% to 2.5% flavoring, 9 to 11% fruit juice concentrate, 0.08 to 0.12% ascorbic acid, 1.4 to 1.5% citric acid, and 33 to 38% water. Generally, in preparing the fruit drinks of the present invention, liquid sugar and alkali metal sulfites, bisulfites, or equivalent proportions of sulfur dioxide and other sulfurous antibrowning agents are mixed with the concentrated fruit juice and various preservatives. Subsequently, an aqueous solution of ascorbic, citric and any other acids are mixed into the product mix, with water, to form the resultant fruit drink.
More specifically, the liquid sugar is any conventional slurry, gel or meal of liquid, solid or amorphous sugar or mixture of sugars utilized in fruit drinks or fruit juice containing products. Preferably, the liquid sugar slurry will contain an effective amount of open-chain aldehydic forms of carbohydrates commonly referred to as reducing sugars. Such an effective amount is capable of reacting with sulfites to form hydrosulfonic acids and thereby augment the antibrowning function. However, it is not essential for purposes of this invention that the reducing sugars be present. The most preferred embodiment of this invention is characterized by a liquid sugar slurry analyzing at from 55 - 58% sucrose, 12 - 15% sugar invert, 30% water, all percentages based on total weight of the slurry, and having 70° Brix solids content.
The preservatives utilized in the process of this invention are any conventional preservatives for fruit juice products such as potassium sorbate and sodium benzoate.
The concentrated fruit juice may be any of several fruit juice mixtures, for example, grapefruit, lemon-lime, grape, orange, cherry, pineapple, etc. The fruit juice is in liquid form and at about 60° to 70° Brix.
Although sodium bisulfite is the preferred sulfur containing compound of the present invention, any edible alkali metal or alkaline earth metal bisulfite would be adequate, as well as sulfur dioxide.
The pH is adjusted to between about 2.6 and about 3.0.
The product is packaged in a gas permeable container. Any reasonably porous plastic container can be utilized such as polystyrene, polyvinylchloride, polyethylene, and Barex*, XT Polymer**, modified ethylene vinyl acetate. Materials having an oxygen barrier measuring as poor as 450 cc mils/100 in 2 , 24 hours atm. 75°F. were found by this process to inhibit browning to the point of consumer acceptability over a six month storage period. However, it is preferred for purposes of economy and effectiveness to utilize polystyrene containers.
The following specific example is illustrative of the process and product of the present invention, but it is to be understood that the invention is not to be limited to the specific details thereof.
EXAMPLE 1
To a mixing tank is added 4,000 pounds (355 gallons) of liquid sugar and agitation is begun. Then 17 pounds of potassium sorbate and 17 pounds of sodium benzoate are dissolved in 10 gallons of water. This solution is added to the mixing tank. Next, 11 pounds 7 ounces sodium bisulfite is dissolved in 5 gallons of water and added to the mixing tank. An additional 32,398 pounds (2,884 gallons) of liquid sugar is metered into the tank, while simultaneously 99 gallons 64 ounces of flavor is also pumped into the tank. Then 500 gallons of 60° Brix concentrated fruit juice is added. Next dissolve 56 pounds 2 ounces of ascorbic acid and 673 pounds 3 ounces citric acid in 250 gallons of water. The solution is pumped to the mixing tank. Allow mixing to continue for an additional 10 minutes. The product is poured directly into polystyrene containers.
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Fruit drinks which contain residual sulfur dioxide will have improved taste and odor and improved vitamin C retension if packaged in a substantially gas permeable container.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 11/006,278, filed Dec. 6, 2004, entitled “Benefits Administration System and Methods of Use and Doing Business,” the disclosure of which is hereby incorporated by reference. U.S. patent application Ser. No. 11/006,278 claims the benefit of U.S. Provisional Patent Application Ser. No. 60/526,961, filed Dec. 5, 2003, entitled “Benefit Administration System and Methods of Use and Doing Business,” the disclosure of which is hereby incorporated by reference.
[0002] The following document is a copyrighted text. All copyrights are reserved as allowed by law.
BACKGROUND
[0003] The present invention relates to benefits administration systems and methods of use and doing business. The present invention also relates to automated systems for administering benefits.
[0004] In business and industry, benefits plans are common. They often include health care, savings or retirement plan, insurance, and other funding or services for employees. Administration of benefits has long presented a substantial challenge for business and industry.
[0005] One prior art automated system designed for administration of benefits has been known as the “Phoenix” system. The Phoenix system automated certain benefits administration tasks and included features such as:
a. enrollment of beneficiaries through a limited-access, private computer network such as an business's internal computer network; b. automated but limited application of certain basic business rules to inform the user, at the time of entry on-screen only, of certain limited missing information such as a beneficiary's address, birthdate dependents, or benefits plan choice; c. automated reconciliation of payments provided they exactly match the amount invoiced to the customer; d. limited automation of physical letter generation such as generation of a welcome letter to a new customer setting forth little more than the effective date of initiation of plan coverage for the customer; e. automated maintenance of certain limited carrier data, including certain carrier rates and rating areas; f. limited automation of Cobra enrollment by re-keying data for the Cobra enrollment into the system; g. limited automation of open enrollment and re-qualification by automated sending out of notices and issuance of failure to re-qualify reports, allowing manual entry of termination if desired by the administrator; h. automated termination and issuance of termination notice to the carrier upon-first termination of a customer and thus well prior to conclusion of the re-instatement option period; and i. limited periodic reconciling of payments actually received in-house by receipt at the system administrator's mailroom, routing to the finance department for entry into the system; if the payments matched exactly the amount of their respective invoices, the finance department would initiate a program through that would reconcile the cash received against the invoice; non-matching payments would require substantial manual involvement in the reconciliation process j. The Phoenix system included numerous limitations and issues, however, including: k. limited carrier data such as not including data (only zip codes and rates); l. lack of automated creation of a Cobra record from information already in the system for a given beneficiary; m. with regard to issuance of notices for enrollment or re-qualification, lacked ability select sub-groups (e.g., groups under 5 employees) for issuance of notices only to them, and also lacked automatic termination of groups that do not re-qualify; n. providing notice of termination of a group to a carrier prior to expiration of a re-qualification period for the group including Cobra members of the group; o. lack of automatic changing of employee status upon change of employee coverage (e.g., by changing from employee-only coverage to employee and spouse coverage), along with lack of automated corrected billing as a result of the change; p. lack of automated reconciliation of cash upon closing of a batch of inputted premium checks, and automatic reconciling of premium notices with payments provided by multiple payments (e.g., multiple checks providing payment for a particular premium amount); q. limited application of business rules to ensure correct data entry and limiting of enrollment as allowed by the rules, and relatedly, no ability to issue notices other than on-screen notices of certain limited types of information that may be missing; r. limited ability to generate required notices, and limited or no ability to send notices through differing media (e-mail, mail, fax); s. no ability to allow system access through remote or separate networks, such as via the Internet; t. no ability to reconcile payments that do not exactly match invoice amounts, and no ability to issue notices based on matching discrepancies; and u. limited data handling capacity, requiring periodic purge data to run the system.
BRIEF SUMMARY OF CERTAIN ASPECTS OF THE INVENTION
[0027] In summary, the present invention relates to an automated benefit administration system and methods of use and doing business. In certain embodiments, a full system includes a wide range of features including application of business rules to enrollment, eligibility, and maintenance data input, making of business decisions based on the specific data entered, and issuing of notices based on business rule discrepancies including notices to third parties when deemed appropriate. The full system also is secure while providing remote access, including through the Internet, limits access based on user hierarchy, allows user customization of various features including communications vehicles (e-mail, letter correspondence, or facsimile) and of the format of certain communications, provides automatic enrollment in COBRA without re-entry of beneficiary data, accomplishes various types of financial reconciliation, accommodates differing organizational structures and groupings of entities, provides business rule over-ride capability for certain users, and provides robust information about carriers and their services.
[0028] There are many other novel aspects and aspects of embodiments of the present invention. They will become apparent as the specification proceeds. In this regard, it is to be understood that the scope of the invention is not be determined by whether given subject matter addresses all or particular issues in the prior art noted above or provides all or particular features identified in this brief summary.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIGS. A- 1 to A- 3 are diagrams illustrating aspects of architectures in which embodiments of the present invention may be implemented.
[0030] FIGS. H- 1 A and H- 1 B show a flowchart illustrating an example process of creating a master record for a carrier, FIGS. H- 2 to H- 9 illustrate example screens used in carrier record functions in embodiments of the present invention, and FIG. H- 10 shows an associated screen flow.
[0031] FIGS. H- 11 A, H- 11 B and H- 11 C show a flowchart illustrating an example process of creating a plan, FIGS. H- 12 to H- 14 illustrate example screens used in plan creation functions in embodiments of the present invention, and FIG. H- 15 shows an associated screen flow.
[0032] FIGS. H- 16 to H- 19 are flowcharts illustrating example processes for admin fee, agent fee, additional fee and rate differential, FIGS. H- 20 to H- 31 illustrate example screens used in fee and rate functions in embodiments of the present invention, and FIG. H- 32 shows an associated screen flow.
[0033] FIG. H- 33 is a flowchart illustrating example zip processes, FIGS. H- 34 to H- 35 illustrate example screens used in zip functions in embodiments of the present invention, and FIG. H- 36 shows an associated screen flow.
[0034] FIGS. I- 1 and I- 2 are flowcharts illustrating example COBRA processes, FIGS. I- 3 to I- 11 illustrate example screens used in COBRA functions in embodiments of the present invention, and FIG. I- 12 shows an associated screen flow.
[0035] FIGS. I- 13 to I- 23 show screen flows for screens used in change management in embodiments of the present invention.
[0036] FIG. I- 24 is a flowchart illustrating example requalification and open enrollment processes,
[0037] FIGS. I- 25 to I- 30 illustrate example screens used in requalification and open enrollment functions in embodiments of the present invention, and FIGS. I- 31 to I- 33 show associated screen flows.
[0038] FIG. I- 34 is a flowchart illustrating example termination processes, FIGS. I- 35 to I- 59 illustrate example screens used in termination and reinstatement functions in embodiments of the present invention, and FIG. I- 60 show an associated screen flow.
[0039] FIGS. I- 61 to I- 64 illustrate example screens used in appeals and grievances functions in embodiments of the present invention, and FIG. I- 65 show an associated screen flow.
[0040] FIGS. I- 66 to I- 71 illustrate example screens used in association masters functions in embodiments of the present invention, and FIG. I- 72 show an associated screen flow.
[0041] FIGS. I- 73 to I- 76 illustrate example screens used in carrier issues functions in embodiments of the present invention, and FIG. I- 77 show an associated screen flow.
[0042] FIGS. J- 1 to J- 8 illustrate example screens used in billing, cash receipt, cash reconciliation and risk adjustment functions in embodiments of the present invention.
[0043] FIGS. P- 1 to P- 12 are flowcharts illustrating example security mechanism processes, and
[0044] FIGS. P- 13 to P- 38 illustrate example screens used in security mechanism functions in embodiments of the present invention.
DETAILED DESCRIPTION
[0045] Certain embodiments of the benefits administration system may (i) apply rules to enrollment, eligibility, and/or group maintenance data input, preferably all such input, and (ii) make business rule decisions based on the specific data entered, preferably including automatic actions related to correct business rules as well as issuance of notices for business rule discrepancies. These capabilities can, in certain embodiments, include business rule over-rides based on user authority level.
[0046] For example, in the insurance industry, an enrollment application is required for enrollment into any insurance plan. Enrollment rules may pertain to the input of data from this application into the benefits administration system. An example of an enrollment rule may include inputting a Social Security number (SSN) that has been assigned to another member previously. In certain embodiments, the benefits administration system can produce a notification of a duplicate SSN and may not allow the completion of the member's enrollment utilizing the duplicate SSN.
[0047] Another example of an enrollment business rule is the entry of information for a new member who requests family health coverage but does not list any dependents on the new member's enrollment application in the system. In certain embodiments, the business rules within and automatically applied by benefits administration system can require the data entry of one spouse and at least one child in order to comply with family coverage. Without this dependent information, the system may refrain from allowing finalization of the enrollment. In certain embodiments, the system can then automatically designate the member's application as pending and generate one or more notices (such as letters) advising of the need for, or requesting, the missing information.
[0048] Eligibility rules may pertain to the specific business rules set up by the insurance companies. For example, to be eligible for a certain type of insurance, an employer group may require at least two employees; or in order for an employee to be eligible, the employee may have to work at least thirty hours per week. In certain embodiments, the benefits administration system may implement these types of specific rules.
[0049] For example, if a user seeks to enter an employer group with only one employee, in certain embodiments the system can thus refuse to finalize the enrollment unless another employee's information is entered. As another example, if user enters hours—work—per week for an employee less than the business rule of 30 hours, in certain embodiments, the system will not allow finalization of the enrollment. In certain embodiments, the system may accommodate exceptions such as when a user with a predetermined authority level, such as a manager, desires to over-ride the eligibility business rule. In certain embodiments, the system can allow the exception based on pre-arranged authority levels within the system.
[0050] Group maintenance may pertain to enrollment/eligibility activities that occur after the finalization of a group's enrollment. One example may be the addition a newly hired employee to the employer group's plan. In certain embodiments, once the new employee application is received and data is entered, the system may apply one or more business rules for the waiting period for the new hire within the group within which the new hire is hired. Based on this comparison, the system may either assign a correct effective date or deny the enrollment because the employee has not properly satisfied the waiting period. In additional embodiments, if the employee is enrolled, the system may automatically issue an enrollment letter; or if denied, the system may automatically issue a denial letter.
[0051] Yet another group maintenance example may be the receipt of monthly insurance premium payments. In certain embodiments, the system may automatically issue an invoice outlining activity affecting the premium for a given period of time, such as the past month. Such activity may include adding a newly hired employee or disenrolling a terminated employee. In certain embodiments, the system may implement business rules to provide automatic reconciliation of the premium to the amount of an invoice.
[0052] In certain embodiments, the system may also be flexible enough to take into consideration activity that occurred after the creation of the invoice in reconciling the premium. For example, the monthly invoice to a given customer may total a particular amount. By the due date of the invoice, the employer may have sent notification of an employee disenrollment. The employer may have only sent a payment that deducts the premium for the disenrolled employee. In certain embodiments, the system can automatically reconcile the received payment against the invoice amount and the termination credit for the disenrolled employee.
[0053] In certain embodiments, the benefits administration system may implement varying authority levels for data entry and system operation. For example, the system may provide that (i) a data entry position may have authority to enter data but not to finalize enrollment even if all business rules are met; (ii) yet another position may have authority to finalize enrollment if all business rules have been satisfied; (iii) a supervisor may have authority to finalize enrollment with, as possible examples, minor premium shortages or non-eligibility-related missing enrollment information; (iv) managers may have authority to finalize enrollments with significant premium shortages or non-eligibility issues; and (v) a system administrator may have authority to over-ride any business rule.
[0054] Certain embodiments may also provide remote access through disparate networks, such as, for example, through the Internet, for enrollment, eligibility, or group maintenance data input. In certain embodiments, the system may then make business rule decisions based on the specific data entered. In certain embodiments, the system also may automatically perform actions related to the business rules. In certain embodiments, the system also may automatically issue notices, including on-line notice in certain embodiments, for business rule discrepancies. In certain embodiments, the system may include business rule over-rides based on the authority level of user.
[0055] In certain embodiments, the system can allow an external business customer to process enrollment, eligibility, or group maintenance via the Internet. For example, in the insurance industry, an enrollment application typically is required for enrollment into an insurance plan. In certain embodiments, the benefits administration system may allow this application to be entered remotely through a, preferably secure, Web site.
[0056] For example, an employer may request enrollment in a health insurance plan. In certain embodiments, the employer then may access the Web site provided by the system and enter the employer's current employees' demographic and health carrier information. The employer also may pay the first month's premium on-line through the Web site.
[0057] Preferably, the system prompts the on-line user for information. While the data is being entertained, in certain embodiments the system may compare the data to the business rules associated with each field. Once the input is completed properly, in certain embodiments the system may present an enrollment summary sheet summarizing enrollment information for the on-line user. For example, in certain embodiments implementing the a wage and tax form requirement for new group enrollments, the system may present the on-line user with the completed form and instructions to return the form to, for example, the insurance company for further processing. In certain embodiments, once the insurer approves enrollment, the system may automatically e-mail or otherwise forward an enrollment acceptance form to the user.
[0058] In certain embodiments, business rules remain identical whether for in-network or remote on-line transactions such as, for example, through the Internet.
[0059] Group maintenance may involve enrollment/eligibility activity occurring after the finalization of a group's enrollment. For example, if an employer or designated contact person is attempting to enroll a newly hired employee on-line, the employee is hired to work twenty hours per week, and the business rule set up for this particular group is that all employee's must work forty hours per week, in certain embodiments the system may dis-allow the finalization of the enrollment. In certain embodiments, the system may automatically issue a notice informing the group of the non-enrollment and, preferably, the reason(s) for the non-enrollment.
[0060] Another group maintenance activity can be employee or dependent disenrollments. In certain embodiments, the employer or designated person may access the appropriate group information on-line and enter the requested termination date. If the requested termination date complies with the business rule, in certain embodiments the system may immediately process the termination, preferably including the sending of a termination notice and COBRA information to the disenrolled employee, adjusting the applicable premium invoice, and notifying the appropriate insurance carrier. If the requested termination date is not within the pertinent business rules, in certain embodiments the system may calculate the termination date and display the date to the on-line user. If the user were to accept this date, in certain embodiments the system may complete the termination and, preferably, issue a notification to the user, such as by e-mail. If the user were to decline the system's proposed termination date, in certain embodiments the system may place the requested employee termination on hold and, preferably automatically, issue a notice of the situation to an appropriate representative.
[0061] In certain embodiments, the system may limit the capability to over-ride business rules to in-house personnel (e.g., the personnel of the entity that administers the system).
[0062] In certain embodiments, the system can provide a security application or process in order to control access to the system. In certain embodiments, the security framework includes a security information database as well as an administrator login capability. In certain embodiments, the system can allow the administrator to create users, modules, groups, applications, and assign user roles and access control lists (ACLs), etc. Preferably, the system significantly restricts access to the core administrative system.
[0063] In certain embodiments, the system generates an ACL for each user at the time the user logs into the system. Access to any resource in the core administrative system may be determined by the ACL, and the determination may be stored in, e.g., a user profile object, which may be stored into the session. A user can include a person working in any of the departments in a company, Internet users, or persons accessing an in-house system from an external location. In certain embodiments, individual user permissions take precedence over group permissions. In certain embodiments, even if the group permission is less restrictive than the user permission, the user permission overrides the group permission.
[0064] For example, the agent/broker of a large association group may want to allow the members of the association to enroll through the Internet but to also provide for agent/broker review of applications prior to actual enrollment. In certain embodiments, the system, through its security system, can allow such members to enroll through the Internet (with the application being processed through the enrollment/eligibility business rules), then route the completed application to the agent/broker (versus directly into the system after passing all the business rules), in order to allow the agent/broker to review the application. In certain embodiments, upon completion of such review and approval by the agent/broker, the system can automatically finalize the enrollment.
[0065] In certain embodiments, the benefits administration system may also provide the automatic generation of documents and other communications, customizable to the desires of the users. In this regard, the system may provide a flexible mail merge system for handling external business correspondence. In certain embodiments, the merge templates are basically RTF files with placeholders for dynamic data to be merged into them. In certain embodiments, the output is either a RTF file or a PostScript or a PDF document.
[0066] In certain embodiments, the system can also maintain a log of mail merge letters generated. The log information may include the template identification, a timestamp, the triggering application, and identification of the user generating the letter and to whom the letter is addressed (i.e., which group or member or agent). In certain embodiments, the templates are readily available, and the system may accommodate a virtually unlimited number of templates.
[0067] For example, when the agent/broker provides final approval for association member enrollment, in certain embodiments the system may issue enrollment approval and related correspondence. In certain embodiments, such correspondence or other documentation may be customized through the system to issue on the agent/broker's letterhead.
[0068] In certain embodiments, the system may provide for customizable work groups. Workgroups may define the broad categorization of a group of agents, internal working personnel, external working personnel, and mailing groups. In certain embodiments, the workgroup customization process includes creating a hierarchy of one or more parent entities and defining other workgroups under the parent(s).
[0069] In this event, a parent may be the highest in the hierarchy of a workgroup. Examples of parent work groups may include agent work groups or internal work groups. Examples of workgroups under the parent group may include groups of agents of differing authority levels within a given agent work group. In certain embodiments, further sub-groups or child groups may be established within the system. An example may include may include agents in a given geographical area or a customer group that has been enrolled in the system. In certain embodiments, the system includes the ability to exchange workgroup members or duplicate workgroup members in whole or in part.
[0070] In certain embodiments, the benefits administration system provides automatic but flexible account reconciliation. Cash reconciliation can provide a process of reconciling the cash receipts to individual invoices and reconciling the amount paid by the group. In certain embodiments, the system may provide a rule for reconciliation such as, for example:
a. determine if negative cash is available and reconcile it with the positive cash (e.g., for NSF checks); and b. identify the oldest unreconciled invoice and reconcile it with the oldest cash. c. The reconciliation process may include automatic review of all invoices that have not been reconciled for a specific group and reconciling the invoice that has the earliest date with the cash received. It also may match the cash receipt with the invoice amount. d. In certain embodiments, the reconciliation process can be started automatically when a cash receipt batch is closed to reconcile cash received with invoices. e. Other functions that may be automatically performed cash reconciliation may include one or more of the following: f. Billed amounts and cash receipt: this reconciliation process may reconcile an invoice that has not yet been reconciled for a specific group, determine if the invoice is the earliest unreconciled invoice for the specific group, and reconcile the invoice with the cash received from the group/member; g. Cash to negative cash: this process may reconcile negative cash with the positive cash received from the group. This may arise from receipt of a NSF (Non-Sufficient Funds) check after the applicable group's invoice has been reconciled. Upon receipt of notification of the NSF check, the NSF cash receipt entry may be created in the system. Upon receipt of a replacement check for the NSF check, the NSF check may be automatically reconciled with the replacement check provided the amount of the replacement check is the same as the amount of the NSF check.
[0078] Adjustments to cash: this process may include reconciling a cash receipt with the adjustment that may be available in the next invoice. For example, if the group has received the invoice for the next month and an employee has been terminated during the month but after the generation of invoice, the generated invoice may not identify this adjustment for the termed employees. The applicable group may deduct the adjustments for the terminated employee and forward the cash that does not match the original invoice. In certain embodiments, the system can automatically identify the discrepancy and adjust the cash receipt for the invoice with the termination adjustment taken in to account. In certain embodiments, the next invoice may identify the cash receipt and the adjustment for employee termination.
[0079] Adjustment to billed amounts: this process can identify previously billed invoices for the group provide adjustment as needed to the next invoice.
[0080] Billed amount to itself if no payment is due: this process can identify if the group has been terminated after the invoice for the group has been created. In certain embodiments, the system automatically creates an invoice for the terminated group and adjusts the amount due based on the previous invoice. In certain embodiments, the system issues a final invoice for the terminated group showing net amount due, if any, or refunded.
[0081] Adjustment to adjustment: this process may reconcile invoice adjustments against each other. For example, if a payment late fee accrues but is later waived, in certain embodiments the system may automatically adjust (eliminate) the late fee. Another may involve reinstatement of an employer group termination and associated charging of a reinstatement fee. If such a fee were to then be waived, in certain embodiments the system may automatically reconcile the waived fee.
[0082] Certain embodiments of the benefits administration system provide a substantially improved ability to handle much larger data sets and to handle data more efficiently. In addition, certain embodiments utilize an independent platform and portable programming language such as Java. Preferably, the system components are built using object oriented programming concepts. Preferably, these object-oriented components can be reused in other applications with similar requirements or extended further with additional features when and wherever required. Preferably, the system is developed using scalable J2EE standards.
[0083] In certain embodiments, the system may allow a given user to work with the system in differing roles or capacities. For example, a manager may seek to perform the role of data entry as well as that of a manager or authorizing entity. In certain embodiments, the system allows modification or addition of user roles as desired. In certain embodiments, the CAS (Core Administration System) system is, however, preconfigured for a basic set of predefined roles.
[0084] In certain embodiments, the benefits administration may further provide one or more of the following aspects:
a. selective issuance of notices to sub-groups meeting certain criteria; b. automated creation of a Cobra record from information in the system for a given beneficiary; c. automatic issuance of notice to a member prior to termination of the re-qualification period; d. automatic revision of employee status upon change of employee coverage; e. automatic issuance of notices when data is not entered correctly or completely, including issuance of other than on-screen notices to one or more system administrators or other entity; f. ability of a user to customize how the user may be provide notices or correspondence, such as by e-mail, mail, or facsimile; and g. enhanced carrier data maintenance within the system.
[0092] The system may be utilized by a benefits provider as part of it business and operation. Alternatively, the system may be utilized by a service provider, such as for or in connection with remuneration provided to the service provider by customers. For example, user fees may be provided by the users of the system, such as benefits providers or employers.
[0093] The system may also be utilized by an employer or group of employers, and their employees, to provide automated benefits administration for the employer or group of employers.
[0094] In certain embodiments, all features identified above may be provided by the system. The system may thereby provide an automated benefits administration and method of use of the system and doing business in conjunction with it.
[0095] There are many other novel aspects and aspects of embodiments of the present invention. They will become apparent as the specification proceeds. In this regard, it is to be understood that the scope of the invention is not be determined by whether given subject matter addresses all or particular issues in the prior art noted above or provides all or particular features identified in this brief summary.
Benefit Partners Inc
BPI—Software Architecture Document
Architectural Design Specification Document
Document Id: BPI CAS ADS
Version: <1.0>
1. Introduction
[0096] The Software Architecture Document will provide an overview of the entire “Software Architecture” that will be used to develop Web Interface Module for BPI.
1.1. Purpose
[0097] This document provides a comprehensive architectural overview of the system, using a number of different architectural views to depict different aspects of the system. It is intended to capture and convey the significant architectural decisions that have been made on the system.
1.2. Definitions, Acronyms and Abbreviations
[0098] Some of the common acronyms used in this document are as follows:
[0000]
Abbreviations
Description
EJB
Enterprise Java Beans
HTML
Hypertext Markup Language
J2EE
Java 2 Enterprise Edition
JMS
Java Messaging Services
JNDI
Java Naming and Directory Interface
JSP
Java Server Pages
MVC
Model View Controller
W3C
World Wide Web Consortium
XML
Extensible Markup Language
BPI
Benefit Partners Inc
1.3. Overview
[0099] This Software Architecture Document, at high level, will contain:
a. Architectural representation of proposed system b. Architectural goals c. Software requirement d. Software selection for the proposed system e. Standards and methodologies that will be adopted for the proposed system
2. Architectural Goals
[0105] These guidelines will lay a foundation for the design and implementation strategy, selection of development tools, application software, and testing tools. The basic goals of the architectural design are discussed below.
[0106] 2.1. Portability
[0107] Java is a platform independent and portable language. Applications developed in Java are proven to be portable across popular platforms.
[0108] 2.2. Distribution
[0109] The J2EE Standards will be adopted to develop the new application. J2EE standards demonstrate consistency of distributed applications that access various data sources:
[0110] 2.3. Reusability
[0111] The components will be built using Object Oriented concepts. These object-oriented components can be reused in other applications with similar requirements or extended further with additional features when and wherever required.
[0112] 2.4. Scalability
[0113] Applications developed using the J2EE Standards are proven to be scalable. Therefore, the system will be built in conformance with the J2EE Standards.
[0114] 2.5. Performance
[0115] Identifying the latencies within the system and outside the system boundaries enables us to increase the performance of the application. Since most of the threading issues that lower the performance of an application are well handled within the Websphere application server, Websphere server's features and resources will be effectively utilized to achieve performance.
3. Architectural Representation of the Proposed System
[0116] The System will be developed based on the J2EE specification and follow the N-tier MVC architecture.
[0117] A tier is a logical partition of the separation of concerns in the system. Each tier is assigned its unique responsibility in the system.
[0118] J2EE specifications are multi tiered consisting of the Client Tier, Middle Tier (Presentation Layer, Business Layer, and Integration Layer), and the Data source. The J2EE architecture diagram is described below. (See FIG. A- 1 )
[0119] 3.1. Client Tier
[0120] This tier represents all devices or system clients accessing the system or the application. In this case, the client would be a web browser or other application.
[0121] 3.2. Middle Tier
[0122] The middle tier can be classified into multiple logical layers depending upon the business requirements and programming model. Three basic classifications are discussed below.
[0123] 3.2.1. Presentation Layer
[0124] This tier encapsulates all presentation logic required to service the clients that access the system. The presentation tier intercepts the client requests, provides single sign-on, session management and accesses business services, constructs the response, and delivers the response to the client. Servlets, JSP, HTML reside in this tier.
[0125] 3.2.2. Business Layer
[0126] This tier provides the business services required by the application clients. The tier contains the business data and business logic. All business processing for the application is centralized into this tier. The enterprise bean components are the choice for implementing the business objects in the business tier.
[0127] 3.2.3. Integration Layer
[0128] This tier is responsible for communicating with external resources and systems, such as data stores and legacy applications. The business tier is coupled with the integration tier whenever the business objects require data or services that reside in the resource tier. The components in this tier can use JDBC, J2EE connector technology, or some proprietary middleware to work with the resource tier.
[0129] 3.3. Data Source
[0130] This is the tier that contains the database and external resources such as legacy systems, business-to-business (B2B) systems, and services, such as, credit card authorization and EFT.
[0131] 3.4. Framework
[0132] The following figure depicts the interaction model of a typical Model View Controller or the JSP Model 2 Architecture that is adopted in the Framework. (See FIG. A- 2 )
[0133] Here, the servlet acts as the controller and is in charge of processing the request and creating any objects of the beans used by the JSP. It also redirects, to the respective JSP, based on the Browser's request. There will be very minimal logic present in the JSP regarding the presentation. All the database access and program business logic will be processed within the bean.
[0134] There will be different beans for data source access (database, enterprise systems, queue, XML, etc.), error handling, access logging, and module wise application business logic processing. This clearly separates the presentation from the content and enables easy maintenance and scalability.
[0135] This model is the widely used and accepted model for application development in Java. This model is also adopted by Apache Stnits framework for Java application development.
4. Software Selection for the Proposed System
[0136] This section provides an insight on the software selection for the various tiers depicted in this document.
[0137] 4.1. Software Selection
[0000]
Component
Software Name and Version
Ooerating System
Server/Client - Win NT/Win2000
Browser
IE 5.5 and above
Client Side Scriotmc
HTML 4.0, Java Script 1.2
Server Side
JSP 1.1, Java Servlets 2.2, JDK 1.3
Programming
Database Server
DB2 UBD Version V 7.3
Web Server
IBM HTTP Server V 1.3.19
Application Server
Websphere Application Server Advanced
Edition Version 4.0
Report Server
Seagate Crystal Reports 8.5
Office Tools
Microsoft Office 2000 (select Word 2000,
Excel 2000 and Outlook 2000 and Access
2000), Post Script Printer, Adobe Acrobat 5.0
Servlet, Bean
Visual Age 4.0
Development
HTML, JSP, XML, etc.
Dream Weaver 4.0
Testing
JTest 4.5
Data Flow and Class
UML Studio
Design
[0138] 4.2. API Versions
[0000]
API Name
Version
Remarks
J2EE
Specification 1.2
Supported by Websphere 4.0
EJB
Specification 1.2
Supported by Websphere 4.0
JDK
JDK 1.2.2
Supported by Websphere 4.0
Servlet
Servlet 2.2
Supported by Websphere 4.0
JSP
JSP 1.1
Supported by Websphere 4.0
HTTP
HTTP/1.1
Stable W3C Specification
5. Standards and Methodologies
[0139] The standards and methodologies that will be followed for the application development are discussed below.
[0140] 5.1. Design Document
[0141] Detailed design document will be prepared based on the scope of the application prior to the development. This document will contain the details on graphic user interface, navigation, class diagrams, data dictionary, field validation criteria, and program logic.
[0142] 5.2. Bean Classification
[0143] The types of Java beans that will be used to perform different business logics will be decided during the design stage. The bean types will be classified based on the complexity of the business logic and the scalability.
[0144] 5.3. Coding
[0145] A separate document will be prepared outlining the coding standards that will be adopted in the application development. The document will contain details on program naming conventions to be used while coding. All programs developed will follow this standard.
[0146] 5.4. Testing
[0147] Test plan and test case documents will be prepared for unit and integration testing of the application. The test cases will be used to test the application modules and integration. JTest will be used for testing code construction (white-box testing), code functionality (black-box testing), and code integrity (regression testing).
[0148] 5.5. Error Handling
[0149] All error messages and error codes for the application will be stored in the database. Run time errors will be logged to text files that will be generated periodically by the system. Input validations will occur in both the client tier and the middle tier. The input validation error messages captured in the client tier will be displayed using JavaScript alerts. The input validation error messages captured in the middle tier will be displayed in HTML format, on the same page on which the error has occurred, in a different color.
[0150] 5.6. Page Design
[0151] A Page Design Guidelines document will be created by Mascon, and approved by BPI, prior to the development. All pages in the application will conform to the standards depicted in this document. This document will contain the specifications for fonts, layouts, images, and other relevant details.
[0152] 5.7. Parameterization
[0153] Custom JSP tag libraries will be created for all initial values and parameters used in the application. JSP tag libraries define declarative, modular functionality that can be reused by any JSP page. Tag libraries reduce the necessity to embed large amounts of Java code in JSP pages by moving the functionality provided by the tags into tag implementation classes. In doing so, tag libraries make authoring JSP pages easier and modular.
6. System Architecture and Hardware Selection
[0154] This section provides the details of the system architecture with nodes, terminals and their placement within the respective zones.
[0155] 6.1. Physical Architecture (See FIG. A- 3 )
[0156] 6.2. Hardware Selection
[0000]
Current
#
Server
Base
Configuration
Software/Hardware
Database Server
Intel Pentium
Intel XEO
1. Windows 2000
Processor, 2
Processor
Advanced Server
CPU,
1 CPU
2. IE 5.5 and above
HD 104 GB, 2 GB
HDD 34 GB
3. IBM DB2 UDB
RAM, Raid 5
2 GB RAM
version 7.2.x
CPU 2.4 Ghz.
2
Application
Intel Pentium
Intel XEO
1. Windows 2000
Server -
Processor, CPU
Processor
Advanced Server
Intranet
1, HD 18 GB, 2 GB
1 CPU
2. IE 5.5 and above
RAM
HDD 200 GB
3. Websphere
2 GB RAM
Application Server
CPU 2.4 Ghz.
Advanced Edition
Version 4.0
4. IBM DB2 UDB
version 7.2.x (For
WAS Repository)
5. IBM HTTP Server
1.3.19
6. Microsoft Office
2000 (select Word
2000, Excel 2000
and Outlook 2000
and Access 2000),
Post Script Printer,
Adobe Acrobat 5.0
3
Application
Intel Pentium
Not Available
1. Windows 2000
Server -
Processor, CPU
Advanced Server
Internet
1, HD 18 GB, 2 GB
2. IE 5.5 and
RAM
Netscape 4.7 and
above
3. Websphere
Application Server
Advanced Edition
Version 4.0
4. IBM DB2 UDB
version 7.2.x (For
WAS Repository)
5. Microsoft Office
2000 (select Word
2000, Excel 2000
and Outlook 2000
and Access 2000),
Post Script Printer,
Adobe Acrobat 5.0
4
Report Server -
Intel Pentium
Intel Processor
1. Windows 2000
Crystal Reports
Processor, CPU
1 CPU
Advanced Server
1, HD 18 GB, 2 GB
HDD 17 GB
2. IE 5.5 and above
RAM
2.3 GB RAM
3. Seagate Crystal
CPU 1266 Mhz.
Reports 8.5
4. Microsoft Office
2000 (select Word
2000, Excel 2000
and Outlook 2000
and Access 2000),
Post Script Printer,
Adobe Acrobat 5.0
5. lIS for Crystal
reports
5
Web Server -
Intel Pentium
Not Available
1. Windows 2000
Internet
Processor, CPU
Advanced Server
1, HD 18 GB, 2 GB
2. IE 5.5 and above
RAM
3. IBM HTTP Server
1.3.19
4. Microsoft Office
2000 (select Word
2000, Excel 2000
and Outlook 2000
and Access 2000),
Post Script Printer,
Adobe Acrobat 5.0
7. Browser Client Application Limitations and Work Around Solutions
[0157] The limitations of the Web Browser (thin client) based application, when compared to thick clients, are as follows:
a. Input field masking, such as automatic date formatting and phone number formatting, are not easily handled in this environment. The thin client user interface is not as easy and robust as the thick client user interface. A work around must be designed to force the user to enter values in the required format. b. Due to the limitations of different browsers, a common methodology will be adopted that will work for all indicated browsers. This narrows down the user interface implementation features in a browser. c. Because of the lower level on interactivity, some actions that are presented entirely on one screen in the thick client may span multiple screens. Since each screen presentation involves a round trip to the server, this will result in slightly slower screen response when compared to the single screen approach. This can be minimized with some re-design of the user interface workflow, but overall, thin clients require more “clicks” than thick clients. d. Hot-keys validation scripts are cumbersome and take longer to download. Thus, hot-key functionality will be limited.
Benefit Partners Inc
Process Specification
BPI_CAS_FSD_CM — 01
1. Introduction
[0162] 1.1. Purpose
[0163] This purpose of this document is to identify the process associated with the business use case Create Carrier Master.
[0164] 1.2. Business Use Case Specification Reference
Business Use Specification
[0000]
Business Use Specification ID
Business Use Case Name
BPI_SCOPE_CM_001
Create Carrier Master
[0166] 1.3. Definitions, Acronyms & Abbreviations
[0000]
Term
Explanation
2. Process Identification
[0167] 2.1. Background
[0168] Create Carrier Master is user for creation of master record for the carrier which includes the general information about the carrier, Department Contact Information, Mode of Communications Line of Coverage, plan type and the benefit level offered by the carrier and the benefit description.
[0169] 2.2. Process Description & Flow
[0170] This process describes the Use Case “Create Carrier Master”. This document is the amendment of BPI_CAS_FSD_CM — 01 (Version 1.1).
[0171] 2.2.1. Create Carrier Master
The flow of the process is as described below. a. Input the general information about the carrier. b. Input the Department Contact Information c. Validate if the department contact information has the right data type. d. If yes add the information to a temporary storage. e. If not re enter the information correctly and add again. f. Continue adding further department contact information. g. If yes follow steps from b) to e) h. Edit or delete the Department Contact Information. i. On edit remove the data from temporary storage and populate the department contact information data to the fields and change the data. Continue from c) to e). j. On delete remove the data from the temporary storage. k. Can continue from step b) onwards or go to step l) l. If not then check if the data entered for the general carrier information is correct or erroneous. m. If erroneous re enter the correct data. n. If Correct then save the data to the repository. o. System auto generates a unique identification number for the carrier. p. Choose the Line of coverage q. For the line of coverage choose the system show the Plan type. r. Choose the Plan Type s. For the plan type choose the system show the benefit level t. Choose the benefit level and enter the benefit level name for the specific carrier and add. u. The Line of coverage, plan type, Benefit Level and the name is populated in and shown. v. Check if the data entered is correct or erroneous. w. If erroneous then edit or delete the benefit level name. x. Else continue adding the next line of coverage y. If the process is completed save the data. z. The data is saved into the repository and unique identification number is generated for the all the benefit level offered by the specific carrier a CarrierName_PlanType_BenefitLevel_UniqueID
[0199] 2.2.2. Process Flow Diagrams
(See FIG. H- 1 )
3. User Interface
[0201] 3.1. User Interface Screens
[0202] 3.1.1. Screen ID's
[0000]
Corresponding HTML File
Screen ID (SID)
Screen Name
Name
carrier.general
Carrier General Info
/bpi/cas/carrier/master/
CarrierInfo.jsp
carrier.search
Carrier Search
/bpi/cas/carrier/master/
CarrierSearch.jsp
carrier.view
Carrier General Info
/bpi/cas/carrier/master/
View
CarrierGeneralInfo.jsp
carrier.product
Carrier Product Info
/bpi/cas/carrier/master/
CarrierProduct.jsp
carrier.prodsearch
Search Product
/bpi/cas/carrier/master/
ProductSearch.jsp
carrier.prodinfo
Carrier Product Info
/bpi/cas/carrier/master/
ProductView.jsp
[0203] 3.1.2. User Interface ID: Create Carrier Master
[0204] 3.1.2.1. Screen Name: Create Carrier Master
(BPI_CAS_SCR_CM — 001 — 001) (See FIG. H- 2 )
[0207] 3.1.2.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element Name
Type
Label
Purpose
Main Header
Text
Main Header
To give the heading for the screen being
Create
Create Carrier
navigated
Carrier
Master
Master
Sub Header
Text
Sub Header
Proved Content Area Text
Carrier
Carrier
General
General
Information
Information
Sub Header
Text
Sub Header
Text for the Company Address
Address
Address
Company
Text
Company
Text for the entry field
Name
Name
Company
Entry Field
Company
Entry Field for Company name
Name (Entry
Name (Entry
Field)
Field)
Address
Text
Address
Text for the Address
Address (Entry
Entry Field
Address (Entry
Entry Field for Address
Field)
Field)
Suite/Apt #
Text
Suite/Apt #
Text for Suite/Apt #
Suite/Apt #
Entry Field
Suite/Apt #
Entry Field for Suite/Apt #
(Entry Field)
(Entry Field)
City
Text
City
Text for City
City (Entry
Entry Field
City (Entry
Entry Field for City
Field)
Field)
State
Text
State
Text for state
State (Entry
Entry Field
State (Entry
Entry Field for State
Field)
Field)
ZIP
Text
ZIP
Text for ZIP
ZIP (Entry
Entry Field
ZIP (Entry
Entry Field for ZIP
Field)
Field)
Sub Header
Text
Sub Header
Text for the sub heading
Contact
Contact
Department
Department
Department
Drop Down
Department
List all the departments for the carrier for
List
contact information
Contact Name
Text
Contact Name
Text for Contact name
Salutation
Text
Salutation
Text for Salutation
First Name
Text
First Name
Text for First name
Middle name
Text
Middle name
Text for middle name
Last name
Text
Last name
Text for last name
Suffix
Text
Suffix
Text for Suffix
Title
Text
Title
Text for title
Salutation
Entry Field
Salutation
Entry Field for Salutation
First Name
Entry Field
First Name
Entry field for first name
Middle name
Entry Field
Middle name
Entry field for middle name
Last name
Entry Field
Last name
Entry field for last name
Suffix
Entry Field
Suffix
Entry Field for Suffix
Title
Entry Field
Title
Entry Field for title
Address
Text
Address
Text for the Address
Address (Entry
Entry Field
Address (Entry
Entry Field for Address
Field)
Field)
Suite/Apt #
Text
Suite/Apt #
Entry Field for Suite/Apt #
Suite/Apt #
Entry Field
Suite/Apt #
Entry Field for Suite/Apt #
(Entry Field)
(Entry Field)
City
Text
City
Text for City
City (Entry
Entry Field
City (Entry
Entry Field for City
Field)
Field)
State
Text
State
Text for state
State (Entry
Entry Field
State (Entry
Entry Field for State
Field)
Field)
ZIP
Text
ZIP
Text for ZIP
ZIP (Entry
Entry Field
ZIP (Entry
Entry Field for ZIP
Field)
Field)
Mode of
Drop Down
Mode of
List various of contact preferred
Communication
List
Communication
Phone
Text
Phone
Text for phone
FAX
Text
FAX
Text for FAX
Email
Text
Email
Text for email
Phone
Entry Field
Phone
Entry Field for Phone number
FAX
Entry Field
FAX
Entry field for FAX
Email
Entry Field
Email
Entry field for email
ADD
Button
ADD
To add the above details on to the html table
(HTML
after validation check
Submit
button)
Table
HTML
Table
Table for adding up the contact information
Table
Delete
Button
Delete
To delete the contact information checked for
(HTML
deletion
Button)
Check All
Text Link
Check All
To check all the check boxes in the table
Clear All
Text Link
Clear All
To un check all the check boxes checked in
the table
Delete
Check box
Delete
To check the items for deletion
Edit
Button
Edit
To edit the contact information against the
(HTML
row selected for edition
Button)
Department
Text
Department
Shows the name of the department added.
Name
Name
For example finance, marketing etc.
Last Name
Text
Last Name
Name of the contact person
Phone
Text
Phone
Phone of the contact person
FAX
Text
FAX
FAX of the contact person
Email
Text
Email
Email address of the contact person
SAVE
Button
SAVE
Save all the above information to the
HTML
repository)
Submit
button)
CANCEL
Button
CANCEL
To reset the entries made in all the fields
(HTML
reset
button)
[0208] 3.1.2.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the associated message—Success/Error Message text
[0000]
#
Element Name
Action/Validation Details
Message
1.
Company Name
Refer Document No.
Refer Document No.
(Entry Field
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
2.
Address (Entry
Refer Document No.
Refer Document No.
Field)
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
3.
Suite/Apt #
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
4.
Suite/Apt # (Entry
Refer Document No.
Refer Document No.
Field)
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
5.
City
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
6.
City (Entry Field)
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
7.
State
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
8.
State (Entry Field)
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
9.
ZIP (Entry Field)
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
10.
Department
Should list various departments like
If none of the option is
Finance, Sales, Administration,
selected. Then should
Technical, Miscellaneous etc from the
show an Error Dialog Box
repository.
With message.
The First option should be
“Department Name - Is
Choose One. Subsequent options
required”
should be listed alphabetically.
11.
Salutation
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
12.
First Name
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
13.
Middle name
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
14.
Last name
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
15.
Suffix
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
16.
Title
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
17.
Address (Entry
Refer Document No.
Refer Document No.
Field)
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
18.
Suite/Apt # (Entry
Refer Document No.
Refer Document No.
Field)
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
19.
City (Entry Field)
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
20.
State (Entry Field)
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
21.
ZIP (Entry Field)
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
22.
Mode of
Should list various types of Mode of
If none of the option is
Communication
Communications like Phone, FAX,
selected. Then should
email, USPS etc. from the repository.
show an Error Dialog Box
The First option should be
With message.
Choose One. Subsequent options
should be listed alphabetically.
23.
Phone
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
24.
Email
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
25.
FAX
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
26.
ADD
Should function with Enter Key
Error Dialog Box Text:
Cursor Positioned on the “ADD”
“Department Name - Is
button or Mouse Click.
required”
Check if the Contact Department is
selected. If choose one default
option is only selected throw a Java
script error message.
Check if the Mode of Communication
is selected. If choose one default
option is only selected throw a Java
script error message.
Check if the value entered for the
fields for the Department contact
information are correct. If not throw
error message.
Success: Populates the HTML Table
with the data on each column as
relevant with the data entered in the
entry field.
27.
Table
Should have column header and each
subsequent row should be identified
by alternate color combinations, i.e.
First row should have color ‘x’ and the
next row should have color ‘y’. The
next row should have color ‘x’ again
and so on. The size of any text inside
any cell should be wrapped if the text
becomes too long.
28.
Delete
Should function with Enter Key
Error Message: “Please
Cursor Positioned on the “Delete”
choose the row or rows to be
button or on Mouse Click.
deleted.”
Delete Button should work on
multiple deletes based on the check
box or boxes selected. If the user
clicks on the delete button without
checking any of the delete check box
should throw error message.
Success: Deletes the row or rows
from the HTML Table (temporary
storage)
29.
Check All
On clicking the “Check All” link
On clicking the “Check All”
should check all the check boxes in
link should check all the
the HTML table.
check boxes in the HTML
table.
30.
Clear All
On clicking the “Clear All” link
On clicking the “Clear All”
should uncheck all the checked check
link should uncheck all the
boxes in the HTML table.
checked check boxes in the
HTML table.
31.
Delete
Check box option with default
Check box option with
“unchecked”
default “unchecked”
32.
Edit
Should function with Enter Key
Should function with Enter
Cursor Positioned on the “edit” button
Key Cursor Positioned on
or on Mouse Click.
the “Edit” button or on
On clicking the edit button the row
Mouse Click.
edited should be removed from the
On clicking the edit button
HTML table and the data should be
the row edited should be
populated back on the editable entry
removed from the HTML
fields.
table and the data should be
populated back on the
editable entry fields.
33.
Department Name
Display the data in a text
34.
Name
Display the data in a text
35.
Phone
Display the data in a text
36.
Email
Display the data in a text
37.
FAX
Display the data in a text
38.
SAVE
Should function with Enter Key
Error Dialog Box Text:
Cursor Positioned on the “SAVE”
“The value entered for ‘FIELD
button or on Mouse Click.
NAME’ is incorrect. Please
On saving the data the data gets saved
enter the correct value.”
to the database.
Note: The field name should
Validation Check: For the entire
be picked up dynamically
field on the carrier general
for the each field that is
information.
erroneous.
Check if the data entered for the
For general script
Carrier General Information is
validations for common
correct.
functionality refer
If not throw error message.
BPI_CAS_FSD_COMMON
Check if there is data populated on the
System Error: Common
Department Contact information
Text shall be followed for
field. If yes show a dialog box with
the System Error.
message “Would you like to Add the
Dialog Box Text:
department contact information
before saving” Yes/No.
If yes allow the user to add the data.
If no save the data without adding the
Department contact information to
the HTML Table.
On Successful saving the flow should
automatically be navigated to the next
screen.
(BPI_CAS_SCR_CM_001_002)
39.
Cancel
Cancel Button should clear all the
content filled on the entry fields.
[0211] 3.1.3. User Interface ID: Create Product
[0212] 3.1.3.1. Screen Name: Create Product
(BPI_CAS_SCR_CM — 001 — 002) (See FIG. H- 3 )
[0215] 3.1.3.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Main Header
Text
Main Header
To give the heading for the screen being
Carrier
Carrier
navigated
Offered Plan
Offered Plan
Trans Id
Text
Trans Id
Text for Trans Id
Trans Id
Entry Field
Trans Id
To Enter the Trans Id
Plan Name
Text
Plan Name
Text for Plan Name
Plan Name
Entry Field
Plan Name
To Enter Plan Name
Carrier Name
Text
Carrier Name
Text for Carrier Name
Carrier Name
Drop Down
Carrier Name
Lists various Carrier Names
List
Line of
Text
Line of
Text for Line of Coverage
Coverage
Coverage
Line of
Drop Down
Line of
Lists various line of coverage offered.
Coverage
List
Coverage
Example Medical, Dental, Vision, CAM etc.
Plan Type
Text
Plan Type
Text for plan type
Plan Type
Drop Down
Plan Type
List the Plan Type available for the line of
List
coverage selected. Example HMO, PPO, PSO
etc.
Add
Button
Add
To add the Benefit Level Name to the HTML
(HTML
table.
Button)
Table
HTML
Table
For adding and displaying all the names of the
table
benefit level offered by the carrier
Delete
Button
Delete
To delete single or multiple rows of the
(HTML
benefit level checked
Button)
Check All
Text Link
Check All
To check all the check boxes in the table
Clear All
Text Link
Clear All
To un check all the check boxes checked in
the table
Enrolment
Button
Enrolment
To Navigate to Enrolment Transmission
Screen
Premium
Button
Premium
To Navigate to Premium Transmission
Screen
Delete
Check box
Delete
To check the items for deletion
Edit
Button
Edit
To edit the benefit level against the row
(HTML
selected for edition
Button)
SAVE
Button
SAVE
Save all the above information to the
(HTML
repository
Submit
button)
Cancel
Button
Cancel
To reset the entries made in all the fields
(HTML
reset
button)
[0216] 3.1.3.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the associated message—Success/Error Message text
[0000]
#
Element Name
Action/Validation Details
Message
1.
Trans Id
This name should be brought from the
Plan Id is required
previous screen
PlanId accepts
BPI_CAS_SCR_CM_001_001.
alphanumeric values only
2.
Line of Coverage
Should list various types of Line of
Note: The Screen
Coverage from the database.
should not be refreshed
Default Line of Coverage should be
when choosing different
Choose One
Line of Coverage.
Subsequent line of coverage should
Line of Coverage is
be listed alphabetically.
required
On choosing the line of coverage
corresponding Plan Type should be
listed.
On choosing different Line of
Coverage the Plan Type List should
be refreshed and new set of plan type
should be listed for the new line of
coverage selected.
3.
Plan Type
Should list various types of Plan Type
Note: The Screen
from the database.
should not be refreshed
Plan Type should be Listed
when choosing different
alphabetically
Plan Type.
On choosing the Plan Type
Plan Type is required
Corresponding Benefit Level Should
be listed.
On choosing different Plan Type the
Benefit Level List should be refreshed
and new set of Benefit Level should
be listed of the new Plan Type
selected.
4.
Carrier Name
Should be entered
Carrier Name is required
5.
Plan Name
Should be entered
Plan Name is required
6.
Add
Should function with Enter Key
Error Dialog Box Text:
Cursor Positioned on the “ADD”
“The name entered for
button or Mouse Click.
alternate Benefit Level
Check if alternate Benefit Level name
Name is incorrect. Please
is valid.
enter the correct name.”
If not throw error message.
“The is no name entered
Check if there is no duplicate entry
for Benefit Level Name.
for the Combination of Line of
Please enter the name.”
Coverage, Plan Type and Benefit
Error Dialog Box Text:
level selected.
“The Benefit Level Name
If Duplicate Show Error Message
for the combination of
Check if there is blank field if so
Line of Coverage, Plan
throw error message
type and Benefit Level is
Success: The items selected with the
already entered. Please
benefit level name are added to the
select other
HTML table below (temporary)
combination.”
7.
Table
Should have column header and each
subsequent row should be identified
by alternate color combinations. i.e.
First row should have color ‘x’ and the
next row should have color ‘y’. The
next row should have color ‘x’ again
and so on. The size of any text inside
any cell should be wrapped if the text
becomes too long.
8.
Delete
Should function with Enter Key
Error Message: “Please
Cursor Positioned on the “Delete”
choose the row or rows to
button or on Mouse Click.
be deleted.”
Delete Button should work on
multiple deletes based on the check
box or boxes selected. If the user
clicks on the delete button without
checking any of the delete check box
should throw error message.
Success: Deletes the row or rows
from the HTML table (temporary
storage)
9.
Check All
On clicking the “Check All” Link all
On clicking the “Check
the rows with the check box option
All” Link all the rows
are checked.
with the check box option
are checked.
10.
Clear All
On clicking the “Clear All” Link all
On clicking the “Clear
the rows with the check box option
All” Link all the rows
checked are unchecked.
with the check box option
checked are unchecked.
11.
Delete
Check box option with default
“unchecked”
12.
Edit
Should function with Enter Key
Note: All edits that are
Cursor Positioned on the “Edit”
done on the data from the
button or on Mouse Click.
repository or database,
On clicking the edit button the row
history of the changes
edited should be removed from the
made must be available.
table and the data should be populated
back on the editable entry field.
13.
SAVE
Should function with Enter Key
Common Text shall be
Cursor Positioned on the “SAVE”
followed for the System
button or on Mouse Click.
Error.
Validation Check:
Dialog box:
Check if there is any data entered in
“Would you like to Add
the alternate Benefit Level Name
the Alternate Benefit
field.
Level name before
If yes show a dialog box with
saving” Yes/No.
message “Would you like to Add the
Alternate Benefit Level name before
saving” Yes/No
If yes allow the user to add the data.
If no save the data without adding the
Alternate Benefit Level Name to the
HTML Table.
On saving the data the data gets saved
to the database.
Success:
On Successful saving the flow should
be automatically be navigated back to
the previous screen.
(BPI_CAS_SCR_CM_001_001)
14.
Cancel
Cancel Button should clear all the
content filled on the entry fields
[0219] 3.1.4. User Interface ID: Search Carrier Master
[0220] 3.1.4.1. Screen Name: Search Carrier Master
(BPI_CAS_SCR_CM — 001 — 003) (See FIG. H- 4 )
[0223] 3.1.4.2. Element Name, Element Type, Label & Purpose
[0224] 3.1.4.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the associated message—Success/Error Message text
[0000]
#
Element Name
Action/Validation Details
Message
1.
Carrier name
Default option on the list is
Choose One
Lists all the active carrier in
alphabetical order
2.
View
Should function with Enter Key
Error Dialog Box Text:
Cursor Positioned on the “View”
“Please choose a carrier
button or on Mouse Click.
to view information”
On clicking the View Button if no
Carrier name is selected then throw an
error message.
Else Success should navigate to the
view page
BPI_CAS_SCR_CM_001_006 with
the data pertaining to the carrier
selected.
3.
Edit
Should function with Enter Key
Error Dialog Box Text:
Cursor Positioned on the “Edit”
“Please choose a carrier
button or on Mouse Click.
to Edit information”
On clicking the Edit Button if no
Carrier name is choose then throw an
error message.
Else Success should navigate to the
Edit pages
BPI_CAS_SCR_CM_001_004 with
the data pertaining to the carrier
selected.
[0227] 3.1.5. User Interface ID: Modify Carrier Master
[0228] 3.1.5.1. Screen Name: Modify Carrier Master
(BPI_CAS_SCR_CM — 001 — 004) (See FIG. H- 5 )
[0231] 3.1.5.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element Name
Type
Label
Purpose
Main Header
Text
Main Header
To give the heading for the screen being
Edit Carrier
Edit Carrier
navigated
Master
Master
Sub Header
Text
Sub Header
Provide Content Area Text
Carrier General
Carrier General
Information
Information
Sub Header
Text
Sub Header
Text for the Company Address
Address
Address
Company
Text
Company
Text for the entry field
Name
Name
Company
Entry Field
Company
Entry Field for Company name with data
Name (Entry
Name (Entry
filled and editable
Field)
Field)
Address
Text
Address
Text for the Address
Address (Entry
Entry Field
Address (Entry
Entry Field for Address with data filled and
Field)
Field)
editable
Suite/Apt #
Text
Suite/Apt #
Text for Suite #
Suite/Apt #
Entry Field
Suite/Apt #
Entry Field for Suite/Apt # with data filled
(Entry Field)
(Entry Field)
and editable
City
Text
City
Text for City
City (Entry
Entry Field
City (Entry
Entry Field for City with data filled and
Field)
Field)
editable
State
Text
State
Text for state
State (Entry
Entry Field
State (Entry
Entry Field for State with data filled and
Field)
Field)
editable
ZIP
Text
ZIP
Text for ZIP
ZIP (Entry
Entry Field
ZIP (Entry
Entry Field for ZIP with data filled and
Field)
Field)
editable
Sub Header
Text
Sub Header
Text for the sub heading
Contact
Contact
Department
Department
Department
Drop Down
Department
List all the departments for the carrier for
List
contact information
Contact Name
Text
Contact Name
Text for Contact name
Salutation
Text
Salutation
Text for salutation
First Name
Text
First Name
Text for First name
Middle name
Text
Middle name
Text for middle name
Last name
Text
Last name
Text for last name
Suffix
Text
Suffix
Text for suffix
Title
Text
Title
Text for title
Salutation
Entry Field
Salutation
Entry Field for salutation
First Name
Entry Field
First Name
Entry field for first name
Middle name
Entry Field
Middle name
Entry field for middle name
Last name
Entry field
Last name
Entry field for last name
Suffix
Entry Field
Suffix
Entry Field for suffix
Title
Entry Field
Title
Entry Field for title
Address
Text
Address
Text for the Address
Address (Entry
Entry Field
Address (Entry
Entry Field for Address
Field)
Field)
Suite/Apt #
Text
Suite/Apt #
Text for Suite #
Suite/Apt #
Entry Field
Suite/Apt #
Entry Field for Suite/Apt #
(Entry Field)
(Entry Field)
City
Text
City
Text for City
City (Entry
Entry Field
City (Entry
Entry Field for City
Field)
Field)
State
Text
State
Text for state
State (Entry
Entry Field
State (Entry
Entry Field for State
Field)
Field)
ZIP
Text
ZIP
Text for ZIP
ZIP (Entry
Entry Field
ZIP
Entry Field for ZIP
Field)
Mode of
Drop Down
Mode of
List various modes of contact preferred
Communication
List
Communication
Phone
Text
Phone
Text for phone
FAX
Text
FAX
Text for FAX
Email
Text
Email
Text for email
Phone
Entry Field
Phone
Entry Field for Phone number
Email
Entry Field
Email
Entry field for email address
FAX
Entry Field
FAX
Entry field for FAX
ADD
Button
ADD
To add the above details on the HTML table
(HTML
below
Submit
button)
Table
HTML
Table
Table for adding up the contact information.
Table
The table also contains all the contact
information already available in a multiple
rows.
Delete
Button
Delete
To delete the contact information
(HTML
Button)
Check All
Text Link
Check All
To check all the check boxes in the table
Clear All
Text Link
Clear All
To un check all the check boxes checked in
the table
Delete
Check box
Delete
To check the items for deletion
Edit
Button
Edit
To edit the contact information against the
(HTML
row selected for edition
Button)
Department
Text
Department
Shows the name of the department added. For
Name
Name
example finance, marketing etc.
Last Name
Text
Last Name
Last Name of the contact person
Phone
Text
Phone
Phone of the contact person
Email
Text
Email
Email address of the contact person
FAX
Text
FAX
Fax of the contact person
SAVE
Button
SAVE
Save all the above information to the
(HTML
repository
Submit
button)
CANCEL
Button
CANCEL
Cancels the current operations and sets to the
(HTML
value as before saving
Reset
button)
EDIT
Button
EDIT
Navigates to the next screen without saving
CARRIER
(HTML
CARRIER
the data. The purpose is if the editing needs to
OFFERED
Submit
OFFERED
be done for the next screen
PLAN
button)
PLAN
(BPI_SCREEN_005)
New
Button
New
To create a new page as first time.
(HTML
button)
[0232] 3.1.6. User Interface ID: Modify Carrier Product
[0233] 3.1.6.1. Screen Name: Modify Carrier Product
(BPI_CAS_SCR_CM — 001 — 005) (See FIG. H- 6 )
[0236] 3.1.6.2. Element Name, Element Type, Label & Purpose
[0237] 3.1.6.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the associated message—Success/Error Message text
[0000]
#
Element Name
Action/Validation Details
Message
1.
Carrier name
This name should be brought from the
previous screen
BPI_CAS_SCR_CM_001_004.
2.
Line of Coverage
Should list various types of Line of
Note: The Screen should
Coverage from the database.
not be refreshed when
Default Line of Coverage should be
choosing different line of
Choose One
coverage.
Subsequent line of coverage should be
listed alphabetically.
On choosing the line of coverage
corresponding Plan Type should be
listed.
On choosing different Line of Coverage
Plan Type List should be refreshed and
new set of plan type should be listed for
the new line of coverage selected.
3.
Plan Type
Should list various types of Plan Type
Note: The Screen should
from the database.
not be refreshed when
Plan Type should be Listed
choosing different Plan
alphabetically
Type.
On choosing the Plan Type
Corresponding Benefit Level Should be
listed.
On choosing different Plan Type the
Benefit Level List should be refreshed
and new set of Benefit Level should be
listed of the new Plan Type selected.
4.
Benefit Level
Should list various types of Benefit Level
from the database.
Benefit Level should be listed
alphabetically.
5.
Benefit Level Name
The field is used for filling Benefit Level
Name
6.
Alternate name
The field is used for entering Alternate
Error Dialog Box Text:
Benefit Level Name
“The value entered for
Alternate Benefit Level
Name is incorrect. Please
enter the correct value.”
7.
Add
Should function with Enter Key Cursor
Error Dialog Box Text:
Positioned on the “ADD” button or
“The value entered for
Mouse Click.
Benefit Level Name is
Check if Alternate Benefit Level name is
incorrect. Please enter the
valid.
correct value.”
If not throw error message.
Embedded Error
Check if there is no duplicate entry for
Message:
the Combination of Line of Coverage,
Show this message on space
Plan Type and Benefit Level selected. If
above the HTML table with
Duplicate Show Error Message
RED color.
Success: The items selected with the
“The Benefit Level Name
benefit level name are added to the
for the combination of Line
HTML table below (temporary)
of Coverage, Plan type and
Benefit Level is already
available. Please select
other benefit level.”
8.
Table
Should have column header and each
subsequent row should be identified by
alternate color combinations. i.e. First
row should have color ‘x’ and the next
row should have color ‘y’. The next row
should have color ‘x’ again and so on. The
size of any text inside any cell should be
wrapped if the text becomes too long.
9.
Delete
Check box option with default
“unchecked”
10.
Delete
Should function with Enter Key Cursor
Error Message: “Please
Positioned on the “Delete” button or on
choose the row or rows to
Mouse Click.
be deleted.”
Delete Button should work on multiple
deletes based on the check box or boxes
selected. If the user clicks on the delete
button without checking any of the delete
check box should throw error message.
Note: the delete action should only delete
the single or multiple rows selected from
the view inside the table.
However the data must not be deleted
from the database on saving. It should
only inactivate the benefit level
name/names selected for deletion.
11.
Edit
Should function with Enter Key Cursor
Repository Data should be
Positioned on the “Edit” button or on
green in color and the
Mouse Click.
Temporary data should be
On clicking the edit button the row edited
red in color.
should be removed from the table and the
data should be populated back on the
editable entry field.
12.
SAVE
Should function with Enter Key Cursor
System Error: Common
Positioned on the “SAVE” button or on
Text shall be followed for
Mouse Click.
the System Error.
Validation Check:
Dialog box:
Check if there is any data entered in the
“Would you like to Add the
Alternate Name field.
Alternate Benefit Level
If yes show a dialog box with message
name before saving”
“Would you like to Add Alternate
Yes/No.
Benefit Level name before saving”
Note: For all the changes
Yes/No.
made history of changes
If yes allow the user to add the data.
should be available for
If no save the data without adding the
viewing via reports for the
Benefit Level Name to the HTML Table.
specific modules.
On saving the data the data gets saved to
the database.
Success:
On Successful saving the flow should be
automatically be navigated back to the
Search Screen.
(BPI_CAS_SCR_CM_001_003)
Note: Data must not be deleted from the
database on saving. It should only
inactivate the benefit level name/names
selected for deletion.
13.
Cancel
To cancel the previous operation.
[0240] 3.1.7. User Interface ID: View Carrier Master
[0241] 3.1.7.1. Screen Name: View Carrier Master
(BPI_CAS_SCR_CM — 001 — 006) (See FIG. H- 7 )
[0244] 3.1.7.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Main Header
Text
Main Header
To give the heading for the screen being
View Carrier
View Carrier
navigated
Master
Master
Sub Header
Text
Sub Header
Name for the sub header
carrier general
carrier general
Information
Information
Carrier name
Dynamic
Carrier name
Name of the carrier being viewed
Text
Sub Header
Text
Sub Header
Name of the sub header
Address
Address
Company
Text
Company
Text for the entry field
Name
Name
Company
Text
Company
Text for Company name with data filled
Name
Name
Address
Text
Address
Text for the Address
Address
Entry Field
Address
Text for Address with data filled
Suite/Apt #
Text
Suite/Apt #
Text for Suite #
Suite/Apt #
Text
Suite/Apt #
Test for Suite/Apt # with data filled
City
Text
City
Text for City
City
Text
City
Text for City with data filled
State
Text
State
Text for state
State
Text
State
Text for State with data filled
ZIP
Text
ZIP
Text for ZIP
ZIP
Text
ZIP
Text for ZIP with data filled
Table
HTML
Table
Table for populating the contact details
Table
Department
Text
Department
Shows the name of the department added. For
Name
Name
example finance, marketing etc.
Name
Text
Name
Name of the contact person
Phone
Text
Phone
Phone of the contact person
Email
Text
Email
Email address of the contact person
FAX
Text
FAX
Fax of the contact person
Back
HTML
Back
Submit Button to navigate to the start screen
Button
Delete
HTML
Delete
Button to delete the particular record currently
Button
viewed.
[0245] 3.1.7.3. Front End Validations
[xxx] None.
[0247] 3.1.8. User Interface ID: Search Product
[0248] 3.1.8.1. Screen Name: Search Product
(BPI_CAS_SCR_CM — 001 — 007) (See FIG. H- 8 )
[0251] 3.1.8.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Search Product
Text
Search
To give the heading for the
Product
screen being navigated
Plan name
Text
Plan name
Title for carrier name
Plan name
Drop Down
Plan name
List all the active carrier
List
names available in the system
View
HTML
View
Button to view the carrier
Button
name selected
Edit
HTML
Edit
Button to edit the carrier
Button
name selected
[0252] 3.1.8.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the associated message—Success/Error Message text
[0000]
#
Element Name
Action/Validation Details
Message
1.
Carrier name
Default option on the list is
Choose One
Lists all the active carrier in
alphabetical order
2.
View
Should function with Enter Key
Error Dialog Box Text:
Cursor Positioned on the “View”
“Please choose a carrier
button or on Mouse Click.
to view information”
On clicking the View Button if no
Carrier name is selected then throw an
error message.
Else Success should navigate to the
view page
BPI_CAS_SCR_CM_001_006 with
the data pertaining to the carrier
selected.
3.
Edit
Should function with Enter Key
Error Dialog Box Text:
Cursor Positioned on the “Edit”
“Please choose a carrier
button or on Mouse Click.
to Edit information”
On clicking the Edit Button if no
Carrier name is choose then throw an
error message.
Else Success should navigate to the
Edit pages
BPI_CAS_SCR_CM_001_004 with
the data pertaining to the carrier
selected.
[0255] 3.1.9. User Interface 10: View Product Info
[0256] 3.1.9.1. Screen Name: View Product Info
(BPI_CAS_SCR_CM — 001 — 008) (See FIG. H- 9 )
[0259] 3.1.9.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Main Header
Text
Main Header
To give the heading for the screen being
Carrier
Carrier
navigated
Product Info
Product Info
Sub Header
Text
Sub Header
Name for the sub header
Plan Info
Plan Info
Plan Id
Text
Plan Id
Provide Text
Plan Id
Dynamic
Plan Id
Name of the Plan Id being viewed
Text
Plan Name
Text
Plan Name
Provide Text
Plan Name
Dynamic
Plan Name
Name of the Plan Name being viewed
Text
Carrier Name
Text
Carrier Name
Provide Text
Carrier Name
Dynamic
Carrier Name
Name of the Carrier Name being viewed
Text
Line of
Text
Line of
Provide Text
Coverage
Coverage
Line of
Text
Line of
Name of the Line Of Coverage Name being
Coverage
Coverage
viewed
Plan Type
Text
Plan Type
Provide Text
Plan Type
Dynamic
Plan Type
Name of the Plan Type being viewed
Text
Carrier name
Dynamic
Carrier name
Name of the carrier being viewed
Text
Sub Header
Text
Sub Header
Name of the sub header
Address
Address
Table
HTML
Table
Table for populating the plan offered
Table
Benefit level
Text
Benefit level
For showing the benefit level name
name
name
Product Name
Text
Product Name
For showing the Product name
Delete
HTML
Delete
Button to delete the particular record currently
Button
viewed.
Back
HTML
Back
To Navigate to Search Screen
Button
[0260] 3.1.9.3. Front End Validations
None.
[0262] 3.1.10. Screen Flow
(See FIG. H- 10 )
Benefit Partners Inc
Process Specification
BPI_CAS_FSD_CM — 02
1. Introduction
[0264] 1.1. Purpose
[0265] This purpose of this document is to identify the process associated with the business use case Create Plan. This document is the amendment of
[0266] BPI_CAS_FSD_CM — 02 (Version 1.0).
[0267] 1.2. Business Use Case Specification Reference
[0000]
Business Use Specification ID
Business Use Case Name
BPI_SCOPE_CM_002
Create M Plan
[0268] 1.3. Definitions, Acronyms & Abbreviations
[0000]
Term
Explanation
2. Process Identification
[0269] 2.1. Background
[0270] This process identifies the functionality for creation of Line of Coverage, Plan Type and Benefit Level.
[0271] This process is used to create various Line of Coverage, Plan type and benefit level offered by PacAdvantage. Line of coverage includes the coverage offered by PacAdvantage e.g. Medical, Dental, Vision, Chiropractic, Voluntary Medical etc. These classify broad range of all the line of coverage offered.
[0272] Plan type includes plan type for specific line of coverage e.g. PPO, HMO, PSO etc. Benefit Level specifies the specific benefit level offered for the line of coverage and plan type e.g. Standard, Preferred, preferred plus etc.
[0273] 2.2. Process Description & Flow
[0274] 2.2.1. Create Line of Coverage
1. Input Line of Coverage name 2. Validate Line of Coverage name 3. If yes add the information to a temporary storage. 4. If not re enter the information correctly and add again. 5. Edit or delete Line of Coverage name 6. If erroneous re enter the correct data. 7. If Correct then save the data to the repository 8. System auto generates a unique identification number for Line of Coverage Refer Process Flow Diagram
[0284] 2.2.2. Create Plan Type
1. Input Plan Type name 2. Validate Plan Type name 3. If yes add the information to a temporary storage. 4. If not re enter the information correctly and add again. 5. Edit or delete Plan Type name 6. If erroneous re enter the correct data. 7. If Correct then save the data to the repository 8. System auto generates a unique identification number for Plan Type Refer Process Flow Diagram
[0294] 2.2.3. Create Benefit Level
1. Input Benefit Level name 2. Validate Benefit Level name 3. If yes add the information to a temporary storage. 4. If not re enter the information correctly and add again. 5. Edit or delete Benefit Level name 6. If erroneous re enter the correct data. 7. If Correct then save the data to the repository 8. System auto generates a unique identification number for Benefit Level Refer Process Flow Diagram
[0304] 2.2.4. Process Flow Diagrams
(See FIG. H- 11 )
3. User Interface
[0305] 3.1. User Interface Screens
[0306] 3.1.1. Screen ID's
[0000]
Screen ID
(SID)
Screen Name
Corresponding HTML File Name
plan.loc
Line of Coverage
/bpi/cas/carrier/mplan/LineOfCoverage.jsp
plan.plan
Plan Type
/bpi/cas/carrier/mplan/PlanType.jsp
plan.ben
Benefit Level
/bpi/cas/carrier/mplan/BenefitLevel.jsp
[0307] 3.1.2. User Interface ID: Create Line of Coverage
[0308] 3.1.2.1. Screen Name: Create Line of Coverage
(BPI_CAS_SCR_CM — 002 — 001)
(See FIG. H- 12 )
[0309] 3.1.2.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Main Header
Text
Main Header
To give the heading for the
Line of
Line of
screen being navigated
coverage
coverage
Line of
Text
Line of
Provide text
Coverage
Coverage
Loc Name
Entry Field
Loc Name
Entering line of coverage
Add
HTML
Add
Button for adding the Line of
Button
coverage to the table below
Table
HTML table
Table
For adding and displaying all
the names of the Line of
Coverage
Delete
Button
Delete
To delete the line of Coverage
(HTML
checked
Button)
Check All
Text Link
Check All
To check all the check boxes
in the table
Clear All
Text Link
Clear All
To un check all the check
boxes checked in the table
Delete
Check box
Delete
To check the items for
deletion
Edit
Button
Edit
To edit the Line of coverage
(HTML
against the row selected
Button)
for edition
Save
Button
Save
Save all the above information
(HTML
to the repository
Submit
button)
Cancel
Button
Cancel
To resent the entries made
(HTML
in all the fields
reset button)
[0310] 3.1.2.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the associated message—
[0000]
#
Element Name
Action/Validation Details
Message
1.
Line of coverage
This field is used for entering the line of
“Line of Coverage - Is
Entry
coverage. The Line of coverage should
required.”
be alphanumeric only. The special
“Line of Coverage -
character permitted is only space bar
Accepts alphanumeric
between the two words. And can have
values only”
max length 20. Blank line of coverage not
allowed
2.
Add
On Clicking add button or pressing enter
On click of Add button
key field with the cursor position on the
checks for the above
Add button, The data gets added to the
mentioned validations +
table. Validation checks are done to not
“Line of Coverage -
allow null value on the entry field and the
Already exists.”
entry field should have only
(Occurs on duplicate record
alphanumeric values. Duplicate name for
entry)
the line of coverage should not be
allowed.
3.
Table
Should have column header and each
subsequent row should be identified by
alternate color combinations. i.e. First
row should have color ‘x’ and the next
row should have color ‘y’. The next row
should have color ‘x’ again and so on. The
size of any text inside any cell should be
wrapped if the text becomes too long.
4.
Delete
Should function with Enter Key Cursor
“! Select record(s) for
Positioned on the “Delete” button or on
deletion”
Mouse Click.
(If the operation is in Edit
Delete Button should work on multiple
Mode & delete operation is
deletes based on the check box or boxes
invoked)
selected. If the user clicks on the delete
button without checking any of the delete
check box should throw error message.
Success: Deletes the row or rows from
the table (temporary storage)
5.
Check All
On clicking the “Check All” link should
check all the check boxes in the HTML
table.
6.
Clear All
On clicking the “Clear All” link should
uncheck all the checked check boxes in
the HTML table.
7.
Delete
Check box option with default
Delete Check box is
“unchecked”
disabled and grayed out if
the data in the corresponding
row/rows has child parent
relationship (I.e. it has
reference somewhere else in
the database.)
8.
Edit
Should function with Enter Key Cursor
“! Complete the update
Positioned on the “Edit” button or on
process”
Mouse Click.
(If the operation is already in
On clicking the edit button the row edited
Edit Mode & another Edit
should be disabled and the data should be
operation is invoked)
populated back on the editable entry
field.
Note: All data that are from the
repository should be in green color. The
data that is added and not saved should be
in red. The data selected for editing
should be displayed in gray. The “Add”
button will be changed to “Update”
button.
9.
Save
Should function with Enter Key Cursor
For general script
Positioned on the “SAVE” button or on
validations for common
Mouse Click.
functionality refer
On saving the data the data gets saved to
BPI_CAS_FSD_COMMON
the database.
System Error: Common
Check if there is data populated for
Text shall be followed for
editing. If yes show a dialog box with
the System Error.
message “Complete update Process.”
“! Do any operation to save.”
(Displayed when invoked
immediately after the screen
is loaded).
“! Complete the update
process”
(Displayed when Save is
invoked in edit Mode).
10.
Cancel
Should reset all the entries to previous
status before saving. i.e. the fields should
be blank. If any of the data has been
selected for editing, the same data should
appear when cancel button is clicked.
[0313] 3.1.3. User Interface ID: Create Plan Type
[0314] 3.1.3.1. Screen Name: Create Plan Type
(BPI_CAS_SCR_CM — 002 — 002) (See FIG. H- 13 )
[0315] 3.1.3.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Main Header
Text
Main Header
To give the heading for the
Plan Type
Plan Type
screen being navigated
Plan Type
Text
Plan Type
Provide text
Plan type
Entry Field
Plan type
Entering Plan type
Entry
Entry
Add
HTML
Add
Button for adding the Plan
Button
Type to the table below
Table
HTML table
Table
For adding and displaying all
the names of the Plan Type
Delete
Button
Delete
To delete the Plan Type
(HTML
checked
Button)
Check All
Text Link
Check All
To check all the check boxes
in the table
Clear All
Text Link
Clear All
To un check all the check
boxes checked in the table
Delete
Check box
Delete
To check the items for
deletion
Edit
Button
Edit
To edit the Plan Type against
(HTML
the row selected for edition
Button)
SAVE
Button
SAVE
Save all the above information
(HTML
to the repository
Submit
button)
CANCEL
Button
CANCEL
To reset the entries made
(HTML
in all the fields
reset button)
[0316] 3.1.3.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the associated message—Success/Error Message text
[0000]
#
Element Name
Action/Validation Details
Message
1.
Plan type Entry
This field is used for entering the Plan
Error Dialog Box:
Type. The Plan Type should be
“Plan Name - Is required.”
alphanumeric only. The special character
“Plan Name - Accepts
permitted is only space bar between the
alphanumeric values only”
two words. And can have max length
255. Blank line of coverage not allowed
2.
Add
On Clicking add button or pressing enter
Error Dialog Box:
key field with the cursor position on the
On click of Add button
button, The data gets added to the table.
checks for the above
Validation checks are done to not allow
mentioned validations +
null value on the entry field and the entry
“Plan Name - already
field should have only alphanumeric
exists.”
values.
(Occurs on duplicate record
entry)
3.
Table
Should have column header and each
subsequent row should be identified by
alternate color combinations. i.e. First
row should have color ‘x’ and the next
row should have color ‘y’. The next row
should have color ‘x’ again and so on. The
size of any text inside any cell should be
wrapped if the text becomes too long.
4.
Delete
Should function with Enter Key Cursor
Error Dialog Box:
Positioned on the “Delete” button or on
“! Select record(s) for
Mouse Click.
deletion”
Delete Button should work on multiple
“! Complete the update
deletes based on the check box or boxes
process”
selected. If the user clicks on the delete
(If the operation is in Edit
button without checking any of the delete
Mode & delete operation is
check box should throw error message.
invoked)
Success: Deletes the row or rows from
the table temporarily
5.
Check All
On clicking the “Check All” link should
check all the check boxes in the HTML
table.
6.
Clear All
On clicking the “Clear All” link should
uncheck all the checked check boxes in
the HTML table.
7.
Delete
Check box option with default
Delete Check box is
“unchecked”
disabled and grayed out if
the data in the corresponding
row/rows has child parent
relationship (I.e. it has
reference somewhere else in
the database.)
8.
Edit
Should function with Enter Key Cursor
“! Complete the update
Positioned on the “Edit” button or on
process”
Mouse Click.
(If the operation is already in
On clicking the edit button the row edited
Edit Mode & another Edit
should be disabled and the data should be
operation is invoked)
populated back on the editable entry
field.
Note: All the data inside the table that are
from the repository should be green in
color. The temporary data should be red
in color text. The data selected for editing
should be displayed in gray. The “Add”
button will be changed to “Update”
button.
9.
Save
Should function with Enter Key Cursor
For general script
Positioned on the “SAVE” button or on
validations for common
Mouse Click.
functionality refer
On saving the data the data gets saved to
BPI_CAS_FSD_COMMON
the database.
BPI_CAS_FSD_COMMON
Check if there is data populated for
System Error: Common
editing. If yes show a dialog box with
Text shall be followed for
message “Complete update Process.”
the System Error.
“! Do any operation to save.”
(Displayed when invoked
immediately after the screen
is loaded).
“! Complete the update
process”
(Displayed when Save is
invoked in Edit Mode).
10.
Cancel
Should reset to the previous status on
clicking the cancel button. i.e. make all
the entry field blank. If any of the data
has been selected for editing, the same
data should appear when cancel button is
clicked.
[0319] 3.1.4. User Interface ID: Create Benefit Level
[0320] 3.1.4.1. Screen Name: Create Benefit Level
(BPI_CAS_SCR_CM — 002 — 003) (See FIG. H- 14 )
[0321] 3.1.4.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Main Header
Text
Main Header
To give the heading for the screen being
Benefit Level
Benefit Level
navigated
Benefit Level
Text
Benefit Level
Provide text
Name
Name
Benefit Level
Entry Field
Benefit Level
Entering the benefit level name
Name Entry
Name Entry
Add
HTML
Add
Button for adding the Benefit Level to the table
Button
below
Table
HTML table
Table
For adding and displaying all the names of the
Benefit Level
Delete
Button
Delete
To delete the Benefit Level checked
(HTML
Button)
Check All
Text Link
Check All
To check all the check boxes in the table
Clear All
Text Link
Clear All
To un check all the check boxes checked in the
table
Delete
Check box
Delete
To check the items for deletion
Edit
Button
Edit
To edit the Benefit Level against the row
(HTML
selected for edition
Button)
Save
Button
Save
Save all the above information to the repository
(HTML
Submit
button)
Cancel
Button
Cancel
To reset the entries made in all the fields
(HTML
reset button)
[0322] 3.1.4.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the associated message—Success/Error Message text
[0000]
#
Element Name
Action/Validation Details
Message
1.
Benefit Level
This field is used for entering the Benefit
Error Dialog Box:
Level. The Benefit Level should be
“Benefit Level - Is
alphanumeric only. The special character
required.”
permitted is only space bar between the
“Benefit Level - Accepts
two words. And can have max length
alphanumeric values only”
255. Blank line of coverage not allowed
2.
Add
On Clicking add button or pressing enter
Error Dialog Box:
key field with the cursor position on the
On click of Add button
button, The data gets added to the table.
checks for the above
Validation checks are done to not allow
mentioned validations +
null value on the entry field and the entry
“Benefit Level - already
field should have only alpha values.
exists.”
Should check for duplicate entries
(Occurs on duplicate record
entry)
3.
Table
Should have column header and each
subsequent row should be identified by
alternate color combinations. i.e. First
row should have color ‘x’ and the next
row should have color ‘y’. The next row
should have color ‘x’ again and so on. The
size of any text inside any cell should be
wrapped if the text becomes too long.
4.
Delete
Should function with Enter Key Cursor
Error Dialog Box:
Positioned on the “Delete” button or on
“! Select the record(s) for
Mouse Click.
deletion”
Delete Button should work on multiple
“! Complete the update
deletes based on the check box or boxes
process”
selected. If the user clicks on the delete
(If the operation is in Edit
button without checking any of the delete
Mode & delete operation is
check box should throw error message.
invoked)
5.
Check All
On clicking the “Check All” link should
check all the check boxes in the HTML
table.
6.
Clear All
On clicking the “Clear All” link should
uncheck all the checked check boxes in
the HTML table.
7.
Delete
Check box option with default
Delete Check box is
“unchecked”
disabled and grayed out if
the data in the corresponding
row/rows has child parent
relationship (I.e. it has
reference somewhere else in
the database.)
8.
Edit
Should function with Enter Key Cursor
“! Complete the update
Positioned on the “Edit” button or on
process”
Mouse Click.
(If the operation is already in
On clicking the edit button the row edited
Edit Mode & another Edit
should be removed from the table and the
operation is invoked)
data should be populated back on the
editable entry field.
If the data is from the repository show it
in green color text. If it is temporary data
just added show it in red color text. The
data selected for editing should be
displayed in gray. The “Add” button will
be changed to “Update” button.
9.
Save
Should function with Enter Key Cursor
For general script
Positioned on the “SAVE” button or on
validations for common
Mouse Click. On saving the data the data
functionality refer
gets saved to the database.
BPI_CAS_FSD_COMMON
Check if there is data populated for
System Error: Common
editing. If yes show a dialog box with
Text shall be followed for
message “Complete update Process.”
the System Error.
“! Do any operation to save.”
(Displayed when invoked
immediately after the screen
is loaded).
“! Complete the update
process”
(Displayed when Save is
invoked in Edit Mode).
10.
Cancel
Should reset to the previous status on
clicking the cancel button. If any of the
data has been selected for editing, the
same data should appear when cancel
button is clicked.
[0325] 3.1.5. Screen Flow
The flow of the process is as described below. (See FIG. H- 15 )
Benefit Partners Inc
Process Specification
BPI_CAS_FSD_CM — 03
1. Introduction
[0327] 1.1. Purpose
[0328] This purpose of this document is to identify the process associated with the business use case Create Rate Master. This document is the amendment of BPI_CAS_FSD_CM — 03 (Version 1.1).
[0329] 1.2. Business Use Case Specification Reference
[0000]
Business Use Specification ID
Business Use Case Name
BPI_SCOPE_CM_003
Create Rate Master
[0330] 1.3. Definitions, Acronyms & Abbreviations
[0000]
Term
Explanation
2. Process Identification
[0331] 2.1. Background
This process describes the Use Case “Rate Master”. Rate Master is used to upload all the rates for the products (Benefits) provided by individual health insurance provider (Carrier). The individual rate files are provided by PacAdvantage with the rate for all the products offered by all the carriers in a specific file format. This Process for loading the rates would be covered in the Document Reference No: BPI_CAS_FSD_EC The rates are normally classified as blended rates and raw rates. Raw rates would include only the premium rates for the products offered. Blended rate would include the sum total of the entire raw rate, admin fees, agent commission additional fees and Differential Fees. The rate classification would define the formula for calculating the blended rate for the product under offering. Using the administrative screens the classification of rates for arriving to these calculations is provided. Admin Fees: Further Admin fees can be of two types % of the premium or a fixed flat $ amount. Agent Commission: Agent commission can be a % of premium or a flat $ amount per member or a flat $ amount per group size. Additional Fees: Additional Fees can be a % premium or flat $ amount for the carrier. Differential Fees The amount type for Differential Rate should include Flat $ amount as Flat $ amount per member and also Flat $ amount per Group. When the Flat $ amount is per group it should be able to specify group size. The state is divided into several service areas based on the number of counties and their population. In the state of California there are presently 6 service areas. The Rate is based on the service area where the employees are residing. Also there are cases when the ZIP code has two or more Service Areas. Under these conditions the ZIP code should be attached to those services areas from where the rates are to be picked.
[0342] 2.2. Process Description & Flow
[0343] 2.2.1. Admin Fee
The flow of the process is as described below. 1. Input the rate type information. 2. Validate if the rate type information has the right data type. 3. If Correct then save the data to the repository. 4. Search admin fee records. 5. Select a record in modify mode 6. Edit the rate type information. 7. Validate if the rate type information has the right data type. 8. If Correct then save the data to the repository. 9. Search admin fee records. 10. Select a record in view/delete mode 11. View the selected admin fee 12. Delete the selected admin fee from the repository. Refer Process Flow Diagram FIG. 1 .
[0358] 2.2.2. Agent Fee
The flow of the process is as described below. 1. Input the rate type information. 2. Validate if the rate type information has the right data type. 3. If Correct then save the data to the repository. 4. Search agent fee records. 5. Select a record in modify mode 6. Edit the rate type information. 7. Validate if the rate type information has the right data type. 8. If Correct then save the data to the repository. 9. Search agent fee records. 10. Select a record in view/delete mode 11. View the selected agent fee. 12. Delete the selected agent fee from the repository.
Refer Process Flow Diagram FIG. 2.
[0372] 2.2.3. Additional Fee
The flow of the process is as described below. 1. Input the rate type information. 2. Validate if the rate type information has the right data type. 3. If Correct then save the data to the repository. 4. Search additional fee records. 5. Select a record in modify mode 6. Edit the rate type information. 7. Validate if the rate type information has the right data type. 8. If Correct then save the data to the repository. 9. Search additional fee records. 10. Select a record in view/delete mode 11. View the selected additional fee. 12. Delete the selected additional fee from the repository. Refer Process Flow Diagram FIG. 3 .
[0387] 2.2.4. Rate Differential
The flow of the process is as described below. 1. Input the rate type information. 2. Validate if the rate type information has the right data type. 3. If Correct then save the data to the repository. 4. Search rate differential records. 5. Select a record in modify mode 6. Edit the rate type information. 7. Validate if the rate type information has the right data type. 8. If Correct then save the data to the repository. 9. Search rate differential records. 10. Select a record in view/delete mode 11. View the selected rate differential. 12. Delete the selected rate differential from the repository. Refer Process Flow Diagram FIG. 4 .
[0402] 2.2.5. Process Flow Diagrams
(See FIG. H- 16 ) (See FIG. H- 17 ) (See FIG. H- 18 ) (See FIG. H- 19 )
3. User Interface
[0407] 3.1. User Interface Screens
[0408] 3.1.1. Screen ID's
[0000]
Corresponding HTML File
Screen ID (SID)
Screen Name
Name
rate.admin
Admin Fees
/bpi/cas/carrier/rates/AdminFee.jsp
rate.admin.search
Search Admin Fees
/bpi/cas/carrier/rates/AdminFeeSearch.jsp
rate.admin.view
View Admin Fees
/bpi/cas/carrier/rates/AdminFeeView.jsp
rate.admin.confirm
Confirm Admin Fees
/bpi/cas/carrier/rates/AdminFeeConfirm.jsp
rate.agent
Agent Commission
/bpi/cas/carrier/rates/AgentFee.jsp
rate.agent.search
Search Agent
/bpi/cas/carrier/rates/AgentFeeSearch.jsp
Commission
rate.agent.view
View Agent
/bpi/cas/carrier/rates/AgentFeeView.jsp
Commission
rate.agent.confirm
Confirm Agent
/bpi/cas/carrier/rates/AgentFeeConfirm.jsp
Commission
rate.add
Additional Fees
/bpi/cas/carrier/rates/AdditionalFee.jsp
rate.add.search
Search Additional Fees
/bpi/cas/carrier/rates/AdditionalFeeSearch.jsp
rate.add.view
View Additional Fees
/bpi/cas/carrier/rates/AdditionalFeeView.jsp
rate.add.confirm
Confirm Additional Fees
/bpi/cas/carrier/rates/AdditionalFeeConfirm.jsp
rate.ratediff
Differential Fees
/bpi/cas/carrier/rates/DifferentialRate.jsp
rate.ratediff.search
Search Differential Fees
/bpi/cas/carrier/rates/DifferentialRateSearch.jsp
rate.ratediff.view
View Differential Fees
/bpi/cas/carrier/rates/DifferentialRateView.jsp
rate.ratediff.confirm
Confirm Differential
/bpi/cas/carrier/rates/DifferentialRateConfirm.jsp
Fees
[0409] 3.1.2. User Interface ID: Rate Classification—Admin Fees
[0410] 3.1.2.1. Screen Name: Rate Classification—Admin Fees
(BPI-CAS_SCR_CM — 003 — 001) (See FIG. H- 20 )
[0411] 3.1.2.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Main Header
Text
Main Header
To give heading for the screen being navigated
rate
rate
Classification
Classification
for Admin
for Admin
Fees
Fees
Rate Type
Radio
Rate Type
To Select a rate type (Whether Blended or Non
Blended)
Rate Type
Radio
Rate Type
To Select a rate type (Whether Enroll or
Renew)
Group Type
Drop Down
Group Type
List all the Group Type Available in the system
List
Association ID
Drop Down
Association
List all the Association Type Available in the
List
ID
system
Member Type
Radio
Member Type
To Select a Member type (Whether Individual
or Association)
Percentage
Entry Field
Percentage
Entry field for entering % premium
Premium
Premium
Effective Date
Entry Field
Effective Date
To choose the date required, by calendar or
entering it
Amount
Entry Field
Amount
Entry field for entering Amount in $
Medical
Entry Field
Medical
Entry field for entering the Medical Fee in $
Dental
Entry Field
Dental
Entry field for entering the Dental Fee in $
Vision
Entry Field
Vision
Entry field for entering the Vision Fee in %
CAM
Entry Field
CAM
Entry field for entering the CAM Fee in %
Save
Button
Save
Save all the above information to the repository
(HTML
Submit
button)
Cancel
Button
Cancel
To reset the entries made in all the fields
(HTML
reset
Button)
[0412] 3.1.2.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the associated message—Success/Error Message text
[0000]
#
Element Name
Action/Validation Details
Message
1.
Rate Type
Rate Type should be selected for Adding
“Rate Type - Is required”
Admin Fees (Either one of Blended Rate
or Non Blended Rate) and (Either one of
Enroll or Renew).
2.
Group Type
Should list all the Group Type within the
“Group Type - Is required”
system
The first option should be -
-- Choose One --. Subsequent Group
Types should be listed in alphabetical
order
3.
Association Id
Should list all the Association Id within
“Association Id - Is
the system. The first option should be -
required”
-- Choose One --. Subsequent Group
Types should be listed in alphabetical
4.
Member Type
Member Type should be selected for
“Member Type - Is
Adding Admin Fees if Group Type is
required. Select either
Guaranteed Association.
Individual Member or
Association Group”
5.
Percentage
Percentage Premium should be entered if
“Percentage Premium - Is
Premium
the rate type is Blended
Required”
“Percentage Premium -
Accepts numeric value only
(0 to 100)”
6.
Effective Date
Effective Date should be selected from
“Effective Date - Is
Calendar or entered For valid Date
required”
Format Refer BPI_CAS_FSD_Common
“Effective Date - Accepts
the format in
MM/DD/YYYY”
7.
Amount
Amount should be entered if the rate type
“Amount - Is required”
is Non Blended
“Amount - Accepts
currency format only
(###.##)”
8.
Medical
Medical should be entered if the rate type
“Medical - Is required”
is Non Blended
“Medical - Accepts
currency format only
(###.##)”
9.
Dental
Medical should be entered if the rate type
“Dental - Is required”
is Non Blended
“Dental - Accepts currency
format only (###.##)”
10.
Vision
Medical should be entered if the rate type
“Vision - Is required”
is Non Blended
“Vision - Accepts numeric
value only (0 to 100)”
11.
CAM
Medical should be entered if the rate type
“CAM - Is required”
is Non Blended
“CAM - Accepts numeric
value only (0 to 100)”
12.
Save
Should function with Entry Key Cursor
For general script
Positioned on the “SAVE” button or on
validations for common
Mouse Click.
functionality refer
On saving the data the data gets saved to
BPI_CAS_FSD_COMMON
the database.
System Error: Common
Should there be any validation error on
Text shall be followed for
any of the fields. Should show the script
the System Error.
error and place the cursor on the specific
“! Do any operation to
entry field.
save.”
Check if the entries are not duplicate.
(Displayed when invoked
On Successful saving the flow should
immediately after the
reside in the same screen.
screen is loaded).
Exception: If the data selected for edition
“! Complete the update
is from the repository retain its previous
process.”
state. I.e. the data should be visible in the
(Displayed when Save is
table after saving.
invoked in Edit Mode).
Also show different text color for the
data added (temporary) and the data
picked from the repository.
13.
Cancel
Should reset to the previous state on
clicking the cancel button
[0415] 3.1.3. User Interface ID: Rate Classification—Search Admin Fees
[0416] 3.1.3.1. Screen Name: Rate Classification—Search Admin Fees
(BPI_CAS_SCR_CM — 003 — 002) (See FIG. H- 21 )
[0417] 3.1.3.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Main Header
Text
Main Header
To give heading for the screen being navigated
rate
rate
Classification
Classification
for Admin
for Admin
Fees
Fees
Rate Type
Radio
Rate Type
To Select a rate type (Whether Blended or Non
Blended)
Rate Type
Radio
Rate Type
To Select a rate type (Whether Enroll or
Renew)
Group Type
Drop Down
Group Type
List all the Group Type Available in the system
List
Association ID
Drop Down
Association
List all the Association Type Available in the
List
ID
system
Percentage
Entry Field
Percentage
Entry field for entering % premium
Premium
Premium
Effective Date
Entry Field
Effective Date
To choose the date required, by calendar or
entering it
Search
HTML
Search
Button to search the data based on inputs and
Button
displays the results in HTML table below
Table
HTML table
Table
Shows the all the data in the column format
View/Delete
Button
View/Delete
Button to view the selected record data
(HTML
Button)
Check Index
Radio
Check Index
To check the items for modify, view and
Button
deletion
Edit
Button
Edit
To edit the data against the row selected for
(HTML
edition
Button)
Cancel
Button
Cancel
To reset the entries made in all the fields
(HTML
Button)
[0418] 3.1.3.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the associated message—Success/Error Message text
[0000]
#
Element Name
Action/Validation Details
Message
1
Effective Date
Effective Date should be selected from
“Effective Date - Accepts
Calendar or entered
the format in
For valid Date Format Refer
MM/DD/YYYY”
BPI_CAS_FSD_Common
2
Search
Should function with Entry Key Cursor
On click of Search button
Positioned on the “Search” button or
checks for the above
Mouse Click.
mentioned validations
All the entries are valid. It fetches the
records from repository based on inputs
and displays the records in the table
below. Else throws error dialog box.
3
Table
Should have column header and each
subsequent row should be identified by
alternate color combinations. I.e. first
row should have color ‘x’ and the next
row should have color ‘y’. The next row
should have color ‘x’ again and so on. The
size of the text inside any cell should be
wrapped if the text becomes too long.
4
View/Delete
Should function with Entry Key Cursor
“! Select any one of the
Positioned on the “View/Delete” button
record”
or on Mouse Click.
If the user clicks on the view button
without checking any of the view radio
button should throw error message.
Success: View the current row from the
table.
5
Modify
Should function with Enter Key Cursor
Positioned on the “Modify” button or on
Mouse Click.
On clicking the modify button the row is
edited and the data should be populated.
6
Cancel
Should reset to the previous state on
clicking the cancel button
[0421] 3.1.4. User Interface ID: Rate Classification—View Admin Fees
[0422] 3.1.4.1. Screen Name: Rate Classification—View Admin Fees
(BPI_CAS_SCR_CM — 003 — 003) (See FIG. H- 22 )
[0423] 3.1.4.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Main Header
Text
Main Header
To give heading for the
rate
rate
screen being navigated
Classification
Classification
for Admin
for Admin
Fees
Fees
Rate Type
Text Field
Rate Type
Displays Blended or
Non Blended rates
Enroll
Text Field
Enroll
Displays Enroll or Renew
Renew
Renew
Group Type
Text Field
Group Type
Displays Group Type
Association ID
Text Field
Association
Displays Association Type
ID
Percentage
Text Field
Percentage
Displays % premium
Premium
Premium
Effective Date
Text Field
Effective Date
Displays Effective date
Amount
Text Field
Amount
Displays Amount in $
Medical
Text Field
Medical
Displays Medical Fee in $
Dental
Text Field
Dental
Displays Dental Fee in $
Vision
Text Field
Vision
Displays Vision Fee in %
CAM
Text Field
CAM
Displays CAM Fee in %
Delete
Button
Delete
To delete the data
(HTML
Button)
New Admin
Button
New Admin
Go to New Admin fee
fees
(HTML
fees
screen
Button)
[0424] 3.1.4.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the associated message—Success/Error Message text
[0000]
#
Element Name
Action/Validation Details
Message
1
Delete
Should function with Enter Key
“Do you want
Cursor Positioned on the
to delete the
“Delete” button or on
selected record?”
Mouse Click.
If the user clicks on the delete
button throw message box.
Success: Deletes the row from
the data base
2
New Admin
Should go to the admin fees
Fees
screen clicking the New
Admin Fees button
[0427] 3.1.5. User Interface ID: Rate Classification—Agent Commission
[0428] 3.1.5.1. Screen Name: Rate Classification—Agent Commission
(BPI_CAS_SCR_CM — 003 — 004) (See FIG. H- 23 )
[0429] 3.1.5.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Main Header
Text
Main Header
To give heading for the screen being navigated
rate
rate
Classification
Classification
for Agent Fees
for Agent Fees
Rate Type
Radio
Rate Type
To Select a rate type (Whether Blended or Non
Blended)
Rate Type
Radio
Rate Type
To Select a rate type (Whether Enroll or
Renew)
Enrolled
Check Box
Enrolled
To be checked if enrolled before 1997.
before 1997
before 1997
Group Type
Drop Down
Group Type
List all the Group Type Available in the system
List
Association ID
Drop Down
Association
List all the Association Type Available in the
List
ID
system
Member Type
Radio
Member Type
To Select a Member type (Whether Individual
or Association)
Percentage
Entry Field
Percentage
Entry field for entering % premium
Premium
Premium
Effective Date
Entry Field
Effective Date
To choose the date required by calendar or
entering
Group Size
Entry Field
Group Size
Entry field for entering group size Upper limit.
Lower Limit
Lower Limit
Amount
Entry Field
Amount
Entry field for entering Amount in $
Medical
Entry Field
Medical
Entry field for entering the Medical Fee in $
Dental
Entry Field
Dental
Entry field for entering the Dental Fee in $
Vision
Entry Field
Vision
Entry field for entering the Vision Fee in %
CAM
Entry Field
CAM
Entry field for entering the CAM Fee in %
Save
Button
Save
Save all the above information to the repository
(HTML
Button)
Cancel
Button
Cancel
To reset the entries made in all the fields
(HTML
Button)
[0430] 3.1.5.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the associated message—Success/Error Message text
[0000]
·
Element Name
Action/Validation Details
Message
1.
Rate Type
Rate Type should be selected for Adding
“Rate Type - Is Required”
Agent Fees (Either one of Blended or
Non Blended Rate and Either one of
Enroll or Renew)
2.
Enrolled before
Should be selected if enrolled before
1997
1997.
3.
Group Type
Should list all the Group Type within the
“Group Type - Is required”
system
The first option should be
-- Choose One --. Subsequent Group
Types should be listed in alphabetical
order
4.
Association Id
Should list all the Association Id within
“Association Id - Is
the system. The first option should be
required”
-- Choose One --. Subsequent Group
Types should be listed in alphabetical
5.
Member Type
Member Type should be selected for
“Member Type - Is
Adding Agent Fees if Group Type is
required. Select Individual
Guaranteed Association.
Member or Association
Group.”
6.
Percentage
Percentage Premium should be entered if
“Percentage Premium”-
Premium
the rate type is Blended
Is required
“Percentage Premium in -
Accepts numeric values
only (0 to 100)”
7.
Effective Date
Effective Date should be selected from
“Effective Date - Is
Calendar or entered
required”
For valid Date Format Refer
“Effective Date - Accepts
BPI_CAS_FSD_Common
the format in
MM/DD/YYYY”
8.
Group Size Lower
Group Size Lower Limit should be
“Group Size Lower Limit -
Limit
entered if the rate type is Non Blended
Is required”
“Group Size Lower limit -
Accepts numeric values
only (1-999)”
9.
Group Size Upper
Group Size Upper Limit should be
“Group Size Upper Limit -
Limit
entered if the rate type is Non Blended
Is required”
“Group Size Upper Limit -
Accepts numeric values
only (1-999)”
“Kindly enter Group Size
Upper limit greater than
Lower Limit”
10.
Amount
Amount should be entered if the rate type
“Amount - Is required”
is Non Blended
“Amount - Accepts
currency format only
(###.##)_”
11.
Medical
Medical should be entered if the rate type
“Medical - Is required”
is Non Blended
“Medical - Accepts
currency format only
(###.##)”
12.
Dental
Medical should be entered if the rate type
“Dental - Is required”
is Non Blended
“Dental - Accepts currency
format only (###.##)”
13.
Vision
Medical should be entered if the rate type
“Vision - Is required”
is Non Blended
“Vision - Accepts numeric
value only (0 to 100)”
14.
CAM
Medical should be entered if the rate type
“CAM - Is required”
is Non Blended
“CAM - Accepts numeric
value only (0 to 100)”
15.
Save
Should function with Enter Key Cursor
For general script
Positioned on the “SAVE” button or on
validations for common
Mouse Click.
functionality refer
On saving the data the data gets saved to
BPI_CAS_FSD_COMMON
the database.
System Error: Common
Should there be any validation error on
Text shall be followed for
any of the fields. Should show the script
the System Error.
error and place the cursor on the specific
“! Do any operation to
entry field.
save.”
Check if the entries are not duplicate.
(Displayed when invoked
On Successful saving the flow should
immediately after the
reside in the same screen.
screen is loaded).
Exception: If the data selected for edition
is from the repository retain its previous
state. I.e. the data should be visible in the
table after saving.
16.
Cancel
Should reset to the previous state on
clicking the cancel button
[0433] 3.1.6. User Interface ID: Rate Classification—Search Agent Commission
[0434] 3.1.6.1. Screen Name: Rate Classification—Search Agent Commission
(BPI-CAS_SCR_CM — 003 — 005) (See FIG. H- 24 )
[0435]
[0000]
Element
Element
Name
Type
Label
Purpose
Main Header
Text
Main Header
To give heading for the screen being navigated
rate
rate
Classification
Classification
for Agent Fees
for Agent Fees
Rate Type
Radio
Rate Type
To Select a rate type (Whether Blended or Non
Blended)
Enroll/
Radio
Enroll/
To Select a rate type (Whether Enroll or
Renew
Renew
Renew)
Group Type
Drop Down
Group Type
List all the Group Type Available in the system
List
Association ID
Drop Down
Association
List all the Association Type Available in the
List
ID
system
Effective Date
Entry Field
Effective Date
To choose the date required by calendar or
entering
Group Size
Entry Field
Group Size
Entry field for entering Group size Lower limit.
Lower Limit
Lower Limit
Group Size
Entry Field
Group Size
Entry field for entering Group size Upper limit.
Upper Limit
Upper Limit
Search
HTML
Search
Button to search the data based on inputs and
Button
displays the results in HTML table below
Table
HTML table
Table
Shows the all the data in the column format
View/Delete
Button
View/Delete
Button to view the selected record data
(HTML
Button)
Check Index
Radio
Check Index
To check the items for modify, view and
Button
deletion
Modify
Button
Modify
To edit the data against the row selected for
(HTML
edition
Button)
Cancel
Button
Cancel
To reset the entries made in all the fields
(HTML
Button)
[0436] 3.1.6.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the associated message—Success/Error Message text
[0000]
·
Element Name
Action/Validation Details
Message
1
Effective Date
Effective Date should be selected from
“Effective Date - Accepts
Calendar or entered
the format in
For valid Date Format Refer
MM/DD/YYYY”
BPI_CAS_FSD_Common
2
Group Size Lower
Group Size Lower Limit should be
“Group Size Lower limit -
Limit
entered if the rate type is Non Blended
Accepts numeric values
only (1-999)”
3
Group Size Upper
Group Size Upper Limit should be
“Group Size Upper Limit -
Limit
entered if the rate type is Non Blended
Accepts numeric values
only (1-999)”
“Kindly enter Group Size
Upper limit greater than
Lower Limit”
4
Search
Should function with Enter Key Cursor
On click of Search button
Positioned on the “Search” button or
checks for the above
Mouse Click.
mentioned validations
All the entries are valid. It fetches the
records from repository based on inputs
and displays the records in the table
below. Else throws error dialog box.
5
Table
Should have column header and each
subsequent row should be identified by
alternate color combinations. I.e. first
row should have color ‘x’ and the next
row should have color ‘y’. The next row
should have color ‘x’ again and so on. The
size of the text inside any cell should be
wrapped if the text becomes too long.
6
View/Delete
Should function with Enter Key Cursor
“! Select any one of the
Positioned on the “View/Delete” button
record”
or on Mouse Click.
If the user clicks on the view button
without checking any of the view radio
button should throw error message.
Success: View the current row from the
table.
7
Modify
Should function with Enter Key Cursor
“! Select any one of the
Positioned on the “Modify” button or on
record”
Mouse Click.
On clicking the modify button the row is
edited and the data should be populated.
8
Cancel
Should reset to the previous state on
clicking the cancel button
[0439] 3.1.7. User Interface ID: Rate Classification—View Agent Commission
[0440] 3.1.7.1. Screen Name: Rate Classification—View Agent Commission
(BPI_CAS_SCR_CM — 003 — 006) (See FIG. H- 25 )
[0441] 3.1.7.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Main Header
Text
Main Header
To give heading for the screen being navigated
rate
rate
Classification
Classification
for Agent Fees
for Agent Fees
Rate Type
Text Field
Rate Type
To Display rate type (Whether Blended or Non
Blended)
Enroll Type
Text Field
Enroll Type
To Display enroll type (Whether Enroll or
Renew)
Enrolled
Text Field
Enrolled
To Display enrolled before 1997 or not.
before 1997
before 1997
Group Type
Text Field
Group Type
To Display Group Type
Association ID
Text Field
Association
To Display Association Type
ID
Member Type
Text Field
Member Type
To Display member type (Individual or
Association)
Percentage
Text Field
Percentage
To Display % premium
Premium
Premium
Effective Date
Text Field
Effective Date
To Display Effective date
Group Size
Text Field
Group Size
To Display Group size Lower limit
Lower Limit
Lower Limit
Group Size
Text Field
Group Size
To Display Group size Upper limit
Upper Limit
Upper Limit
Amount
Text Field
Amount
To Display Amount in $
Medical
Text Field
Medical
To Display Medical Fee in $
Dental
Text Field
Dental
To Display Dental Fee in $
Vision
Text Field
Vision
To Display Vision Fee in %
CAM
Text Field
CAM
To Display CAM Fee in %
Delete
Button
Delete
To delete the data
(HTML
Button)
New Agent
Button
New Agent
To go to New Agent fees screen
Fees
(HTML
Fees
Button)
[0442] 3.1.7.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the associated message—Success/Error Message text
[0000]
·
Element Name
Action/Validation Details
Message
1
Delete
Should function with Enter Key
“Do you want
Cursor Positioned on the
to delete the
“Delete” button or on
selected record?”
Mouse Click.
If the user clicks on the delete
button throw message box.
Success: Deletes the row from
the data base
2
New Agent
Should go to the agent fees
Fees
screen clicking the New Agent
Fees button
[0445] 3.1.8. User Interface ID: Rate Classification—Additional Fees
[0446] 3.1.8.1. Screen Name: Rate Classification—Additional Fees
(BPI_CAS_SCR_CM — 003 — 007) (See FIG. H- 26 )
[0447] 3.1.8.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Main Header
Text
Main Header
To give heading for the screen being navigated
rate
rate
Classification
Classification
for Additional
for Additional
Fees
Fees
Cobra Type
Radio
Cobra Type
To Select a Cobra Type (Whether Cal Cobra or
Federal Cobra)
Additional Fee
Entry Field
Additional
Entry field for entering % Additional Fees
Percentage
Fee
Percentage
Effective Date
Entry Field
Effective Date
To choose the date required by calendar or
entering
Save
Button
Save
Save all the above information to the repository
(HTML
Button)
Cancel
Button
Cancel
To reset the entries made in all the fields
(HTML
Button)
[0448] 3.1.8.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the associated message—Success/Error Message text
[0000]
·
Element Name
Action/Validation Details
Message
1.
Cobra Type
Cobra Type should be selected for
“Kindly choose Cobra”
Adding Additional Fees
2.
Additional Fee
Additional Fee Percentage should be
“% Of Additional Fees - Is
Percentage
entered.
required”
“% of Additional Fees -
Accepts numeric value only
(0 to 100)
3.
Effective Date
Effective Date should be selected from
“Effective Date - Is
Calendar or entered
required”
For valid Date Format Refer
“Effective Date - Accepts
BPI_CAS_FSD_Common
the format in
MM/DD/YYYY”
4.
Save
Should function with Enter Key Cursor
For general script
Positioned on the “SAVE” button or on
validations for common
Mouse Click.
functionality refer
On saving the data the data gets saved to
BPI_CAS_FSD_COMMON
the database.
System Error: Common
Should there be any validation error on
Text shall be followed for
any of the fields. Should show the script
the System Error.
error and place the cursor on the specific
“! Do any operation to
entry field.
save.”
Check if the entries are not duplicate.
(Displayed when invoked
On Successful saving the flow should
immediately after the
reside in the same screen.
screen is loaded).
Exception: If the data selected for edition
is from the repository retain its previous
state. I.e. the data should be visible in the
table after saving.
5.
Cancel
Should reset to the previous state on
clicking the cancel button
[0451] 3.1.9. User Interface ID: Rate Classification—Search Additional Fees
[0452] 3.1.9.1. Screen Name: Rate Classification—Search Additional Fees
(BPI_CAS_SCR_CM — 003 — 008) (See FIG. H- 27 )
[0453] 3.1.9.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Main Header
Text
Main Header
To give heading for the screen being navigated
rate
rate
Classification
Classification
for Additional
for Additional
Fees
Fees
Cobra Type
Radio
Cobra Type
To Select a Cobra Type (Whether Cal Cobra or
Federal Cobra)
Additional Fee
Entry Field
Additional
Entry field for entering % Additional Fees
Percentage
Fee
Percentage
Effective Date
Entry Field
Effective Date
To choose the date required by calendar or
entering
Search
HTML
Search
Button to search the data based on inputs and
Button
displays the results in HTML table below
Table
HTML
Table
Shows the all the data in the column format
Table
View/Delete
Button
View/Delete
Button to view the selected record data
(HTML
Button)
Check Index
Radio
Check Index
To check the items for modify, view and
Button
deletion
Modify
Button
Modify
To edit the data against the row selected for
(HTML
edition
Button)
Cancel
Button
Cancel
To reset the entries made in all the fields
(HTML
Button)
[0454] 3.1.9.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the associated message—Success/Error Message text
[0000]
·
Element Name
Action/Validation Details
Message
1
Additional Fee
Additional Fee Percentage should be
“% of Additional Fees -
Percentage
entered.
Accepts numeric value only
(0 to 100)”
2
Effective Date
Effective Date should be selected from
“Effective Date - Accepts
Calendar or entered
the format in
For valid Date Format Refer
MM/DD/YYYY”
BPI_CAS_FSD_Common
3
Search
Should function with Enter Key Cursor
On click of Search button
Positioned on the “Search” button or
checks for the above
Mouse Click.
mentioned validations
All the entries are valid. It fetches the
records from repository based on inputs
and displays the records in the table
below. Else throws error dialog box.
4
Table
Should have column header and each
subsequent row should be identified by
alternate color combinations. I.e. first
row should have color ‘x’ and the next
row should have color ‘y’. The next row
should have color ‘x’ again and so on. The
size of the text inside any cell should be
wrapped if the text becomes too long.
5
View/Delete
Should function with Enter Key Cursor
“! Select any one of the
Positioned on the “View/Delete” button
record”
or on Mouse Click.
If the user clicks on the view button
without checking any of the view radio
button should throw error message.
Success: View the current row from the
table.
6
Modify
Should function with Enter Key Cursor
“! Selected any one of the
Positioned on the “Modify” button or on
record”
Mouse Click.
On clicking the modify button the row is
edited and the data should be populated.
7
Cancel
Should reset to the previous state on
clicking the cancel button
[0457] 3.1.10. User Interface ID: Rate Classification—View Additional Fees
[0458] 3.1.10.1. Screen Name: Rate Classification—View Additional Fees
(BPI_CAS_SCR_CM — 003 — 009) (See FIG. H- 28 )
[0459] 3.1.10.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Main Header
Text
Main Header
To give heading for the screen being navigated
rate
rate
Classification
Classification
for Additional
for Additional
Fees
Fees
Cobra Type
Text Field
Cobra Type
To Display Cobra Type (Whether Cal Cobra or
Federal Cobra)
Additional Fee
Text Field
Additional
To Display % Additional Fes
Percentage
Fee
Percentage
Effective Date
Text Field
Effective Date
To Display Effective date
New
HTML
New
Button to go to new Additional fees
Additional
Button
Additional
Fees
Fees
Delete
Button
Delete
To delete the current additional fees data
(HTML
Button)
[0460] 3.1.10.3. Front End Validations
[0000]
·
Element Name
Action/Validation Details
Message
1
Delete
Should function with Enter Key
“Do you want
Cursor Positioned on the
to delete the
“Delete” button or on
selected record?”
Mouse Click.
If the user clicks on the delete
button throw message box.
Success: Deletes the row from
the data base
2
New
Should go to the additional fees
Additional
screen clicking the New
Fees
additional Fees button
[0461] 3.1.11. User Interface ID: Rate Classification—Differential Fees
[0462] 3.1.11.1. Screen Name: Rate Classification—Differential Fees
(BPI_CAS_SCR_CM — 003 — 010) (See FIG. H- 29 )
[0463] 3.1.11.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Main Header
Text
Main Header
To give heading for the screen being navigated
rate
rate
Classification
Classification
for
for
Differential
Differential
Factor
Factor
Group Size
Entry Field
Group Size
Entry field for entering Group size Lower limit.
Lower Limit
Lower Limit
Group Size
Entry Field
Group Size
Entry field for entering Group size Upper limit.
Upper Limit
Upper Limit
Differential
Entry Field
Differential
Entry field for entering Differential Factor
Factor
Factor
Effective Date
Entry Field
Effective Date
To choose the date required by calendar or
entering
Applicable For
Radio
Applicable
To Select a Applicable For (Whether New
For
Business Only or New Business or Renewal)
Group Size
Radio
Group Size
To Select a Group Size Criteria (Whether
Criteria
Criteria
Eligible Employee or Enrolled Employee)
Save
Button
Save
Save all the above information to the repository
(HTML
Submit
button)
Cancel
Button
Cancel
To reset the entries made in all the fields
(HTML
reset
Button)
[0464] 3.1.11.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the associated message—Success/Error Message text
[0000]
•
Element Name
Action/Validation Details
Message
1.
Group Size Lower
Group Size Lower Limit should be
“Group Size Lower Limit -
Limit
entered.
Is required”
“Group Size Lower limit -
Accepts numeric values
only (1-999)”
2.
Group Size Upper
Group Size Upper Limit should be
“Group Size Upper Limit -
Limit
entered.
Is required”
“Group Size Upper Limit -
Accepts numeric values
only (1-999)”
“Kindly enter Group Size
Upper limit greater than
Lower Limit”
3.
Differential Factor
Differential Factor should be entered.
“Differential Factor - Is
required”
“Differential Factor -
Accepts numeric values
only.”
“Differential Factor -
Cannot be Zero”
4.
Effective Date
Effective Date should be selected from
“Effective Date - Is
Calendar or entered
required”
For valid Date Format Refer
“Effective Date - Accepts
BPI_CAS_FSD_Common
the format in
MM/DD/YYYY”
5.
Save
Should function with Enter Key Cursor
For general script
Positioned on the “SAVE” button or on
validations for common
Mouse Click.
functionality refer
On saving the data the data gets saved to
BPI_CAS_FSD_COMMON
the database.
System Error: Common
Should there be any validation error on
Text shall be followed for
any of the fields. Should show the script
the System Error.
error and place the cursor on the specif
“! Do any operation to
entry field.
save.”
Check if the entries are not duplicate.
(Displayed when invoked
On Successful saving the flow should
immediately after the
reside in the same screen.
screen is loaded).
[0467] 3.1.12. User Interface ID: Rate Classification—Search Differential Fees
[0468] 3.1.12.1. Screen Name: Rate Classification—Search Differential Fees
(BPI_CASE_SCR_CM — 003 — 011) (See FIG. H- 30 )
[0469] 3.1.12.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Main Header
Text
Main Header
To give heading for the screen being navigated
rate
rate
Classification
Classification
for
for
Differential
Differential
Factor
Factor
Group Size
Entry Field
Group Size
Entry field for entering Group size Lower limit.
Lower Limit
Lower Limit
Group Size
Entry Field
Group Size
Entry field for entering Group size Upper limit.
Upper Limit
Upper Limit
Differential
Entry Field
Differential
Entry field for entering Differential Factor
Factor
Factor
Effective Date
Entry Field
Effective Date
To choose the date required by calendar or
entering
Applicable For
Radio
Applicable
To Select a Applicable For (Whether New
For
Business Only or New Business or Renewal)
Group Size
Radio
Group Size
To Select a Group Size Criteria (Whether
Criteria
Criteria
Eligible Employee or Enrolled Employee)
Search
HTML
Search
Button to search the data based on inputs and
Button
displays the results in HTML table below
Table
HTML table
Table
Shows the all the data in the column format
View/Delete
Button
View/Delete
Button to view the selected record data
(HTML
Button)
Check Index
Radio
Check Index
To check the items for modify, view and
Button
deletion
Modify
Button
Modify
To edit the data against the row selected for
(HTML
edition
Button)
Cancel
Button
Cancel
To reset the entries made in all the fields
(HTML
Button)
[0470] 3.1.12.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the associated message—Success/Error Message text
[0000]
•
Element Name
Action/Validation Details
Message
1
Group Size Lower
Group Size Lower Limit should accept
“Group Size Lower limit -
Limit
numeric.
Accepts numeric values
only (1-999)
2
Group Size Upper
Group Size Upper Limit should accept
“Group Size Upper Limit -
Limit
numeric
Accepts numeric values
only (1-999)”
“Kindly enter Group Size
Upper limit greater than
Lower Limit”
3
Differential Factor
Differential Factor should accept
“Differential Factor -
numeric.[[.]]
Accepts numeric values
only.”
4
Effective Date
Effective Date should be selected from
“Effective Date -Accepts
Calendar or entered
the format in
For valid Date Format Refer
MM/DD/YYYY”
BPI_CAS_FSD_Common
5
Search
Should function with Enter Key Cursor
On click of Search button
Positioned on the “Search” button or
checks for the above
Mouse Click.
mentioned validations
All the entries are valid. It fetches the
records from repository based on inputs
and displays the records in the table
below. Else throws error dialog box.
6
Table
Should have column header and each
subsequent row should be identified by
alternate color combinations. I.e. first
row should have color ‘x’ and the next
row should have color ‘y’. The next row
should have color ‘x’ again and so on. The
size of the text inside any cell should be
wrapped if the text becomes too long.
7
View/Delete
Should function with Enter Key Cursor
“! Select any one of the
Positioned on the “View/Delete” button
record”
or on Mouse Click.
If the user clicks on the view button
without checking any of the view radio
button should throw error message.
Success: View the current row from the
table.
8
Modify
Should function with Enter Key Cursor
“! Select any one of the
Positioned on the “Modify” button or on
record”
Mouse Click.
On clicking the modify button the row is
edited and the data should be populated.
9
Cancel
Should reset to the previous state on
clicking the cancel button
[0473] 3.1.13. User Interface ID: Rate Classification—View Differential Fees
[0474] 3.1.13.1. Screen Name: Rate Classification—View Differential Fees
(BPI_CAS_SCR_CM — 003 — 0012)(See FIG. H- 31 )
[0475] 3.1.13.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Main Header
Text
Main Header
To give heading for the screen being navigated
rate
rate
Classification
Classification
for
for
Differential
Differential
Factor
Factor
Group Size
Text Field
Group Size
To Display Group size Lower limit.
Lower Limit
Lower Limit
Group Size
Text Field
Group Size
To Display Group size Upper limit.
Upper Limit
Upper Limit
Differential
Text Field
Differential
To Display Differential Factor
Factor
Factor
Effective Date
Text Field
Effective Date
To Display Effective date
Applicable For
Text Field
Applicable
To Display Applicable For (Whether New
For
Business Only or New Business or Renewal)
Group Size
Text Field
Group Size
To Display Group Size Criteria (Whether
Criteria
Criteria
Eligible Employee or Enrolled Employee)
New
Button
New
To go to Differential rate screen.
Differential
(HTML
Differential
Rate
Button)
Rate
Delete
Button
Delete
To delete the current Differential fee
(HTML
Button)
[0476] 3.1.13.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the associated message—Success/Error Message text
[0000]
Element
•
Name
Action/Validation Details
Message
1
Delete
Should function with Enter Key Cursor
“Do you
Positioned on the “Delete” button or on
want to
Mouse Click.
delete the
If the user clicks on the delete button
selected
throw message box.
record?”
Success: Deletes the row from the data
base
2
New
Should go to the agent fees screen
Differential
clicking the New Differential Fees button
Fees
[0479] 3.1.14. Screen Flow
(See FIG. H- 32 )
Benefit Partners Inc
Process Specification
1. Introduction
[0481] 1.1. Purpose
[0482] This purpose of this document is to identify the process associated with the business use case Create ZIP. This document is the amendment of BPI_CAS_FSD_CM — 04(Version 1.0).
[0483] 1.2. Business Use Case Specification Reference
[0000]
Business Use Specification ID
Business Use Case Name
BPI_SCOPE_CM_003
Create Rate Master
[0484] 1.3. Definitions, Acronyms & Abbreviations
[0000]
Term
Explanation
2. Process Identification
[0485] 2.1. Background
[0486] This process describes the Use Case “Create ZIP”. Standard ZIP is loaded into the system. Refer the document reference no. BPI_CAS_FSC_EC for process of loading ZIP Code. Also for the specific ZIP Codes the corresponding service areas are loaded. The state is divided into several service areas based on the number of counties and their population. In the state of California there are presently 6 service areas. The Rate is based on the service area where the employees are residing.
[0487] 2.2. Process Description & Flow
[0488] 2.2.1. Zip Code Search
The Screen described below has two features provided: Zip code search feature is by which the user can search for zip based on any of the selection criteria. Search for zip is based on City name, County name or a Valid Zip code. When user enters the search value, search results are displayed on a table format. There is also provision for canceling the search value. Numbers of records fetched are also displayed on the screen. There is also a feature to print the records fetched. A separate page is invoked on clicking the printer icon. The print page has the fetched records with print button. Clicking on which will invoke the printer dialog. User can view records in Normal as well as Expanded mode. Expanded mode can be invoked by clicking the gif in the table header.
[0494] 2.2.2. Zip Distance
Zip Distance feature is by which user can get the distance of the zip codes entered. Zip distance is calculated based on the geographical distribution of the area by its latitudinal & longitudinal position. The result is displayed in miles. The user interface for Zip is provided below. The two screenshots is the same screen shown to describe these two features.
[0497] 2.2.3. Process Flow Diagrams
(See FIG. H- 33 )
3. User Interface
[0498] 3.1. User Interface Screens
[0499] 3.1.1. Screen ID's
[0000]
Screen ID (SID)
Screen Name
Corresponding HTML File Name
zip.zipsearch
Zip Search
/bpi/cas/carrier/zip/ZipSearch.jsp
[0500] 3.1.2. User Interface ID: Zip Search
[0501] 3.1.2.1. Screen Name: Zip Search (BPI_CAS_SCR_CM — 004 — 001) (See FIG. H- 34 )
Zip Distance: BPI_CAS_SCR_CM — 004 — 002 (See FIG. H- 35 )
[0503] 3.1.2.2. Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Main Header
Text
Main Header
To give heading for the screen being navigated
Searching
Searching
ZIPS
ZIPS
City
Text
City
Provide Text
City
Radio
City
To choose a city for search
County
Text
County
Provide Text
County
Radio
County
To choose a county for search
ZIP
Text
ZIP
Provide Text
ZIP
Radio
ZIP
To choose a zip for search
Search Value
Entry Field
Search Value
Entering the Zip search value
Search
HTML
Search
Button to be invoked for displaying the search
Button
results based on the Entered text in Search
Value.
Cancel
HTML
Cancel
To clear the entered field.
Button
ZIP 1
Text
ZIP 1
Provide Text
ZIP 1
Entry Field
ZIP 1
Entering the Zip1 value
ZIP 2
Text
ZIP 2
Provide Text
ZIP 2
Entry Field
ZIP 2
Entering the Zip2 value
Go
HTML
Go
Button to be invoked for displaying the distance
Button
between the two zip codes entered in miles.
Cancel
HTML
Cancel
To clear the entered field.
Button
[0504] 3.1.2.3. Front End Validations
Validation Details
This section provides the front-end screen validations along with the
[0000]
#
Element Name
Action/Validation Details
Message
1.
City
Max length of the search field is set.
2.
County
Max length of the search field is set.
3.
Zip
Max length of the search field is set.
4.
Search
On click of the button, records are
“Search Value - Is
fetched from repository based on
required.”
selection criteria.
“City - Accepts alphabetic
characters only.”
“County - Accepts
alphabetic characters only.”
“ZIP - Accepts exactly 5
digit numbers only.”
5.
Cancel
On click of this button, entry field is
cleared.
6.
Go
On click of the button, distance between
“Zip1 - Is required.”
the two zip codes is displayed.
“Zip2 - Is required.”
“ZIP - Accepts exactly 5
digit numbers only.”
7.
Cancel
On click of this button, entry field is
cleared.
[0507] 3.2. Screen Flow
[0508] This section describes the screen flow for the group enrollment process. (See FIG. H- 36 )
Benefit Partners Inc
Process Specification
Cobra Enrollment
1. Introduction
[0509] 1.1 Purpose
[0510] The purpose of this document is to describe the process of COBRA Enrollment. This document identifies how the user interacts with the system, the data to be captured, the business logic to be implemented, and the output of the process.
[0511] 1.2 Business Use Case Specification Reference
[0000]
Business Use Specification ID
Business Use Case Name
BPI_SCOPE_EN
Enrollment
BPI_SCOPE_EN_OO2
COBRA Enrollment
BPI_SCOPE_EN_OO1
Group Enrollment
[0512] 1.3 Document Reference
[0000]
Document ID
Document Name
BPI_CAS_FSD_EN
Functional Specification Document-
Enrollment
BPI_CAS_FSD_EN_001
Process Flow—New Business Enrollment
BPI_CAS_FSD_EN_002
Process Flow—Enrollment Changes/Add-On
BPI_CAS_FSD_EN_003
Process Flow—COBRA Enrollment/Changes
BPI_CAS_FSD_EN_005
Process Flow—Termination/Reinstatement
[0513] 1.4 Definitions, Acronyms & Abbreviations
[0000]
Term
Explanation
2 Process Identification
[0514] 2.1 Background
[0515] California State laws and federal laws govern COBRA Rules based on whether it is Cal COBRA or Federal COBRA.
[0516] The decision whether the Group is a CAL COBRA or FEDERAL COBRA would be based on the Group size or the number of employee in the group. If the number of the employee were greater than or equal to 20 then it would be FEDERAL COBRA. If the group size were less than 20 employees then it would be Cal COBRA. This needs to be entered at the time of group enrollment. Based on applications received for group.
[0517] 2.2 Process Description
[0518] The objective of the COBRA Enrollment is to:
New Business COBRA Enrollment Existing member converting to COBRA because of the qualifying rules. Add on for COBRA members Changes to COBRA members Requalification and Open enrollment and Open enrollment for the COBRA members.
[0524] 2.3 Process Flow
[0525] Process for COBRA is based on the type of COBRA enrollment
New Business COBRA Enrollment Existing members converting into COBRA after termination
[0528] Process Flow for New Buiness COBRA Enrollment
[0529] 1) Search for the group and select the SEG Group or Alternate Group with whom the COBRA members are to be added.
[0530] 2) Specify if the Member is enrolling as COBRA member as an individual or with dependent
[0531] 3) If the member is enrolling with dependent then specify the number of dependent
[0532] 4) Enter member general information, which includes the personal information and address information.
[0533] 5) Add the dependent/dependents if the option selected is with dependent and enter the dependent/dependents information.
[0534] 6) Enter COBRA information for the member and dependents as applicable.
[0535] 7) Select the Line of coverage options for the member and dependent as applicable.
[0536] 8) List COBRA member summary and select the Benefit Level (Carrier Selection) based on the ZIP code and Service area provided.
[0537] 9) Show missing information for the COBRA enrollment.
[0538] 10) Enroll/Decline the COBRA enrollment (based on ACL).
[0539] Process Flow for new Business COBRA (See FIG. I- 1 )
[0540] Process Flow for existing Member COBRA Enrollment
[0541] 1) Search for the group and employee who need to be converted into the COBRA members.
[0542] 2) Check the term status and reasons for the Employee/dependent.
[0543] 3) Process COBRA Eligibility checks. This checks the eligibility of the Employee if termed and the reasons for the term, which form the basic for the qualifying event. Of if the employee is not termed and the dependent/dependents are termed their reasons for terms and qualifying event. If none qualify then COBRA enrollment is declined based on ACL. If either qualifies then the COBRA enrollment information is shown with option to select line of coverage for the termed members.
[0544] 4) Identify the primary member based on the criteria.
Employee is also termed and opts for COBRA then the employee becomes the primary member. If spouse is termed with children and spouse opts for COBRA coverage then spouse becomes the primary member If Children/child is termed and opts for COBRA coverage the oldest child becomes the primary member.
[0548] 5) Check if the Plan is available in the Primary members ZIP/Service area. If so then the member should select the same plan as was before. If not, pend and send quote for plans available and then allow the member to select the plan that is available in the new ZIP service area.
[0549] 6) Dependents should have the same plan as well. However they can waive any plan. (Refer the business rules for COBRA)
[0550] 7) Show Summary and missing information.
[0551] 8) Enroll/Decline member/members as COBRA group.
[0552] Process Flow for Existing COBRA conversion (See FIG. I- 2 )
3 User Interface
[0553] 3.1 User Interface Screens
[0554] 3.1.1 Screen ID's
[0000]
Screen ID (SID)
Screen Name
Corresponding HTML File Name
bpi.enrollment.cobra.new.
Group Search
/bpi/cas/enrollment/cobra/new/groupsearch/GroupSearch.jsp
search
bpi.enrollment.cobra.new.
Group Information
/bpi/cas/enrollment/cobra/new/generalinfo/GeneralInfo.jsp
general
bpi.enrollment.cobra.new.
Billing Info
/bpi/cas/enrollment/cobra/new/billinginfo/BillingInfo.jsp
billing
bpi.enrollment.cobra.new.
Coverage Info
/bpi/cas/enrollment/cobra/new/coverageinfo/CoverageInfo.jsp
coverage
bpi.enrollment.cobra.new.
Dependent Information
/bpi/cas/enrollment/cobra/new/dependentinfo/DependentInfo.jsp
dependent
bpi.enrollment.cobra.new.
CobraSearch
/bpi/cas/enrollment/cobra/new/cobrasearch/CobraSearch.jsp
searchcobra
bpi.enrollment.cobra.new.
Missing Information
/bpi/cas/enrollment/cobra/new/missinginfo/MissingInfo.jsp
missing
bpi.enrollment.cobra.new.
Group Inactivate
/bpi/cas/enrollment/cobra/new/groupinactivate/GroupInactivate.jsp
inactivate
bpi.enrollment.cobra.new.
Confirmation
/bpi/cas/enrollment/cobra/new/confirmation/Confirmation.jsp
confirmation
bpi.enrollment.cobra.existing.
Employee Search
/bpi/cas/enrollment/cobra/existing/employeesearch/EmployeeSearch.jsp
employeesearch
bpi.enrollment.cobra.existing.
Member Process
/bpi/cas/enrollment/cobra/existing/memberprocess/MemberProcess.jsp
memberprocess
bpi.enrollment.cobra.existing.
Existing General
/bpi/cas/enrollment/cobra/existing/generalinfo/GeneralInfo.jsp
general
Information
bpi.enrollment.cobra.existing.
Existing Billing Info
/bpi/cas/enrollment/cobra/existing/billinginfo/BillingInfo.jsp
billing
bpi.enrollment.cobra.existing.
Existing Coverage Info
/bpi/cas/enrollment/cobra/existing/coverageinfo/CoverageInfo.jsp
coverage
bpi.enrollment.cobra.existing.
Existing Dependent Info
/bpi/cas/enrollment/cobra/existing/dependentinfo/DependentInfo.jsp
dependent
bpi.enrollment.cobra.existing.
Existing Cobra Search
/bpi/cas/enrollment/cobra/existing/cobrasearch/CobraSearch.jsp
searchcobra
bpi.enrollment.cobra.existing.
Existing Missing Info
/bpi/cas/enrollment/cobra/existing/missinginfo/MissingInfo.jsp
missing
bpi.enrollment.cobra.existing.
Existing confirmation
/bpi/cas/enrollment/cobra/existing/confirmation/Confirmation.jsp
confirmation
bpi.enrollment.cobra.existing.
Existing Inactivate
/bpi/cas/enrollment/cobra/existing/groupinactivate/GroupInactivate.jsp
inactivate
[0555] 3.1.2 User Interface Id: BPI_SCR_EN — 002 — 001—Group Search
[0556] 3.1.2.1 Screen Name: Group Search (See FIG. I- 3 )
[0557] 3.1.2.2 Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Group Id
Text
Group Id
To provide text
Group Id
Entry Field
Group Id
Enter the group Id for Search
Group Name
Text
Group Name
To provide text
Group Name
Entry Field
Group Name
To enter group name for search
Group Phone
Text
Group Phone
To provide text
Group phone
Entry field
Group phone
Enter group phone number for search
Search
HTML
Search
Button for searching the Group
button
Table
HTML
Table
Table to display group information
Table
Select Group
Radio
Select Group
Button to select the group for Attaching the
Button
COBRA members
Single
Radio
Single
To choose if the COBRA Member is enrolling
Member
Button
Member
as a single member
Member With
Radio
Member With
To choose if COBRA Member is enrolling as a
dependent
Button
dependent
member with dependent
Dependent
Entry Field
Dependent
Field to enter the number of dependent
Member
Member
members being added to the member as
Count
Count
COBRA
[0558] 3.1.2.3 Screen Validations
[0000]
Element Name
Action/Validation Details
Message
Group ID
Enter valid group ID only
Error Dialog Box:
“Please enter valid group ID”
Group Name
Enter the group name
None
Group Phone
Enter valid phone number for the group
Error Dialog Box:
“Please enter valid phone number”
Search
On click of the search button should list
None
the groups or a single group based on the
search criteria.
Select Group
If the groups are multiple then the radio
Error Dialog Box:
button option to select the specific group
“Please select a group with whom
should be provided.
you would like to add COBRA
If the Group available is only one then it
member”
should be selected by default.
Select member Only
There should be option either to select
None
or Member with
single member or member with
dependent
dependent.
Dependent Member
If the option selected is member with
Error Dialog Box:
Count
dependent specify the number of
“Please enter the number of
dependents.
dependent as the option selected is
member with dependent.”
[0559] 3.1.2.4 Help Menu
New Business enrollment can bring in the members as COBRA. This screen is used for adding the COBRA members to the new business groups based on the selection of the group.
[0000]
Element Name
Purpose
Valid Values
Search
To search for the
Should list single or multiple
Group
groups based on the search
criteria
Single Member or
This is to specify if
None
member with
the member is
dependent
availing COBRA
benefits
individually or with
dependents
Dependent Member
Specify the count
None
Count
of the dependent
members to be
enrolled with the
primary member as
COBRA.
[0561] 3.1.3 User Interface Id: BPI_SCR_EN — 002 — 002—Group Information
[0562] 3.1.3.1 Screen Name: Group Information (See FIG. I- 4 )
[0563] 3.1.3.2
[0000]
Element
Element
Name
Type
Label
Purpose
Employer
Text
Employer
To provide text
Information
Information
Date PM
Text
Date PM
To provide text
Date PM
Entry field
Date PM
Provide entry for Date Postmarked
Date Recd
Text
Date Recd
To provide text
Date Recd
Entry field
Date Recd
Provide entry for Date Received
Salutation
Text
Salutation
To provide text
Salutation
Drop Down
Salutation
List the Salutation MR., MRS., MS.
List
First name
Text
First name
To provide text
First name
Entry field
First name
Provide entry field for the First name
Last name
Text
Last name
To provide text
Last Name
Entry Field
Last Name
Provide entry field for the Last name
MI
Text
MI
To provide text
MI
Entry Field
MI
Enter the middle initial
Suffix
Text
Suffix
To provide text
Suffix
List
Suffix
List the suffix for selection
Social
Text
Social Security
To provide text
Security
Number
Number
SSN
Entry field
SSN
Enter the SSN number
Unique ID
Text
Unique ID
To provide text
Unique ID
Entry field
Unique ID
Show the unique ID generated
(Uneditable).
Auto Generate
HTML
Auto Generate
Button to generate Unique Id if SSN is not
button
provided
Date of Birth
Text
Date of Birth
To provide text
Date of Birth
Calendar
Date of Birth
Calendar to select the birth date. Should also
allow to enter date of birth as
MM/DD/YYYY
Gender
Text
Gender
To provide text
Gender
List
Gender
List whether Male or Female
Physical Main
Text
Physical Main
To provide text
Address
Address
Street Address
Entry field
Street Address
Enter the street address
Suite/Apts.
Text
Suite/Apts.
To provide text
Suite/Apts.
Entry Field
Suite/Apts.
Enter the suite/apts. number
City
Text
City
To provide text
City
Entry Field
City
Enter the city name
State
Text
State
To provide text
State
Drop Down
State
List all the state in US
List
ZIP
Text
ZIP
To provide text
ZIP
Entry Field
ZIP
Enter zip code
Service Area
Text
Service Area
To provide text
Service Area
Entry Field
Service Area
Shows the Service Area based on the ZIP
(uneditable)
code typed
or list
Show list if the ZIP has multiple service area
County
Text
County
To provide text
County
Entry Field
County
Display the county name based on the zip and
(uneditable)
service area selected
Preferred
Text
Preferred mode
To provide text
mode of
of
correspondence
correspondence
Mode of
Drop Down
Mode of
List the mod of communication, USPS, FAX,
correspondence
List
correspondence
or email/web. Phone is not allowed.
Phone number
Text
Phone number
To provide text
Phone
Entry Field
Phone
To enter phone number
Home FAX
Text
Home FAX No.
To provide text
No.
FAX
Entry Field
FAX
To enter FAX number
Extension
Entry Field
Extension
To enter extension number
E-Mail
Text
E-Mail Address
To provide text
Address
E-mail
Entry field
E-mail Address
Enter email address
Address
Mailing
Text
Mailing
To provide text
Address
Address
Street Address
Text
Street Address
To provide text
Street Address
Text
Street Address
Enter the street address
Suite/Apts./
Text
Suite/Apts./
To provide text
PO Box #
PO Box #
Suite/Apts./
Entry Field
Suite/Apts./
Enter the suite/apts. number
PO Box #
PO Box #
City
Text
City
To provide text
City
Entry Field
City
Enter the city name
State
Text
State
To provide text
State
Drop Down
State
List all the state in US
List
ZIP
Text
ZIP
To provide text
ZIP
Entry Field
ZIP
Enter zip code
Cancel
HTML Reset
Cancel
To cancel the operation and reset for new
Button
selection
Continue
HTML
Continue
To save the data gathered in this screen and
Submit
continue to the next screen
Button
BPI_CAS_SCR_EN_002_003
[0564] 3.1.3.3 Screen Validations
[0000]
Element Name
Action/Validation Details
Message
Salutation
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
First Name
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
Last name
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
MI
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
Suffix
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
Birth date
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
SSN
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
Unique Id
Unique 9 digit ID should be generated
None
if the SSN number is not provided.
This unique ID should not be repeated
for any employee. Also unique Id
should be generated on change mode.
Number should start with 999 999
000 and start descending e.g.
999 998 999
999 998 998 and so on
Street Address
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
Suite/Apts.
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
City
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
State
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
ZIP
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
Service Area
Should pick up the service area based
None
on the Zip code number typed in the
above ZIP entry field from the
database
If there are multiple service area then
it should list the service area for
picking up the service area.
County
Show the county name based on the
none
ZIP code and Service area
combination
Mode of
List mode of communications like
Error Dialog Box:
Communication
USPS, FAX, Email/Web and others.
“Please choose the mode of
If the option selected is Email then the
communication”
Email address field cannot be blank.
Default Option should be
-- choose one --.
If none is selected should throw error
message.
Phone
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
Extension
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
FAX
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
Extension
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
E-mail Address
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
Gender
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
Street Address
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
Suite/Apts.
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
City
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
State
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
ZIP
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
Cancel
Reset Button
To reset the value in the
Entry Field to its previous
state as was on loading page
Continue
Should function with Enter Key
Error Dialog Box:
Cursor Positioned on the “Continue”
“The value entered for the
button or on Mouse Click.
FIELD NAME is erroneous.
Check for all the validation on the
Please enter valid values.”
fields
“Please choose the mode of
If any data type error throw error
communication”
message.
Allows blank entry
On Success Leads to the next page
for filling further information on the
employee.
Screen
BPI_CAS_SCR_EN_002_003
[0565] 3.1.3.4 Help Menu
This screen is used for filling up the primary COBRA member information. The information contained here is the personal information and the address information. The ZIP and the service are provided here governs the rate calculation for the COBRA member.
[0000]
Element Name
Purpose
Valid Values
Continue
On clicking the
None
button leads to
the next page for
filling up the
dependent
information if
applicable of
member
coverage
information
[0567] 3.1.4 User Interface Id: BPI_SCR_EN — 002 — 003—Dependent Information
[0568] 3.1.4.1 Screen Name: Dependent Information (See FIG. I- 5 )
[0569] 3.1.4.2 Element Name, Element Type, Label & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Salutation
Text
Salutation
To provide text
Salutation
List
Salutation
List type of salutation
Dependent
Text
Dependent
To provide text
First name
First name
First Name
Entry Field
First Name
Enter the first name
Dependent
Text
Dependent
To provide text
Last name
Last name
Last name
Entry field
Last name
Enter the last name
MI
Text
MI
To provide text
MI
Entry Field
MI
Enter the middle initial
Suffix
Text
Suffix
To provide text
Suffix
Entry Field
Suffix
Enter the suffix
Dependent
Text
Dependent
To provide text
Social
Social
Security
Security
Number
Number
SSN
Text
SSN
To provide text
SSN
Entry field
SSN
Enter the SSN number
Unique ID
Text
Unique ID
To provide text
Unique ID
Entry field
Unique ID
Show the unique ID generated
(uneditable).
Gender
Text
Gender
To provide text
Gender
List
Gender
List the gender
Relationship
Text
Relationship
To provide text
Relationship
List
Relationship
List all types of relationship like spouse,
domestic partner, child, step child others
Birth Date
Text
Birth Date
To provide text
Birth Date
Calendar
Birth Date
Calendar to choose the birth date
Add
HTML
Add
To add the above dependent Information to the
Dependent
Submit
Dependent
html table below
Button
Table
HTML
Table
Table for adding up the dependent information
Table
Delete
Button
Delete
To delete the items checked for deletion
(HTML
Button)
Check All
Text Link
Check All
To check all the check boxes in the table
Clear All
Text Link
Clear All
To un check all the check boxes checked in the
table
Delete
Check box
Delete
To check the items for deletion
Edit
Button
Edit
To edit the items against the row selected for
(HTML
edition
Button)
Disabled
Text
Disabled
To provide text
Disabled
Radio
Disabled
Temporary or permanent disability (Can be
Radio Button
Button
Radio Button
only one or the other) Default NONE.
Domestic
Text
Domestic
To provide text
Partner
Partner
Domestic
Check box
Domestic
Is Form available if so check.
Partner
Partner
Legal
Text
Legal
To provide text
Guardian
Guardian
Legal
Check box
Legal
Is Form available if so check.
Guardian
Guardian
Signature
Text
Signature
To provide text
Signature
Check box
Signature
Is signature available if check
Continue
HTML
Continue
On clicking the continue button save the
Button
information
Cancel
HTML reset
Cancel
To reset to the state as was before loading the
Button
page
[0570] 3.1.4.3 Screen Validations
[0000]
Element Name
Action/Validation Details
Message
First Name
Refer BPI_CAS_FSD_Common
Refer BPI_CAS_FSD_Common
Last name
Refer BPI_CAS_FSD_Common
Refer BPI_CAS_FSD_Common
MI
Refer BPI_CAS_FSD_Common
Refer BPI_CAS_FSD_Common
Suffix
Refer BPI_CAS_FSD_Common
Refer BPI_CAS_FSD_Common
SSN Number
Refer BPI_CAS_FSD_Common
Refer BPI_CAS_FSD_Common
Unique Id
Unique 9 digit ID should be generated if
None
the SSN number is not provided. This
unique ID should not be repeated for any
employee. Also unique Id should be
generated on change mode. Number
should start with 999 999 000 and start
descending e.g.
999 998 999
999 998 998 and so on
Birth Date
Refer BPI_CAS_FSD_Common
Refer BPI_CAS_FSD_Common
Gender
Refer BPI_CAS_FSD_Common
Refer BPI_CAS_FSD_Common
Relationship
Default option should be
Error Dialog Box:
-- Choose one --. If none is selected
“Please select the relationship of the
throw error message
dependent with the employee”
Add Dependent
On clicking the Add Dependent the
Error Dialog Box:
dependent information gets filled in the
“The value entered in the FIELD NAME is
HTML Table. All validation checks are
incorrect. Please enter valid entries”
performed on the entry field before
adding the dependent.
Table
Should have column header and each
None
subsequent row should be identified by
alternate color combinations. i.e. First
row should have color ‘x’ and the next
row should have color ‘y’. The next row
should have color ‘x’ again and so on. The
size of any text inside any cell should be
wrapped if the text becomes too long.
Note: The values inside the table on
create mode would be blank. If this
screen is reached on edit/change mode
then the values inside the table would be
green in color if retrieved from the
database. If temporarily added then it
would be red in color.
Delete
Should function with Enter Key Cursor
Error Dialog Box:
Positioned on the “Delete” button or on
“Please choose the row or rows to be
Mouse Click.
deleted.”
Delete Button should work on multiple
deletes based on the check box or boxes
selected. If the user clicks on the delete
button without checking any of the delete
check box should throw error message.
Success: Deletes the row or rows from
the HTML Table (temporary storage)
Check All
On clicking the “Check All” link should
On clicking the “Check All” link
check all the check boxes in the HTML
should check all the check boxes in the
table.
HTML table.
Clear All
On clicking the “Clear All” link should
On clicking the “Clear All” link should
uncheck all the checked check boxes in
uncheck all the checked check boxes in
the HTML table.
the HTML table.
Delete
Check box option with default
Check box option with default
“unchecked”
“unchecked”
Edit
Should function with Enter Key Cursor
On clicking the edit button the row
Positioned on the “Edit” button or on
edited should be removed from the
Mouse Click.
HTML table and the data should be
On clicking the edit button the row edited
populated back on the editable entry
should be removed from the HTML table
fields.
and the data should be populated back on
the editable entry fields.
On clicking the edit for the data that is
Green in color (permanent data) the edit
becomes disabled and the Add button
becomes Update.
On clicking edit for the red color data
(temporary data) the row with the data
disappears from the table
Domestic Partner
Default is un checked. Allow to check if
None
applicable
Legal Guardian
Default is un checked. Allow to check if
None
applicable
Signature
Default is un checked. Allow to check if
None
applicable
Continue
Should function with Enter Key Cursor
Dialog Box:
Positioned on the “Continue” button or
“Do you want to add the coverage
on Mouse Click.
information before continuing” Yes/
On success should save the data lead to
No
the next page.
Cancel
Should reset to the state as was before
None
loading the page.
[0571] 3.1.4.4 Help Menu
This screen is used for filling up the dependent COBRA member information. The information contained here is the personal information. If there are multiple ° dependent then you can add the dependent COBRA members here.
[0000]
Element Name
Purpose
Valid Values
Continue
On clicking the
none
button leads to
the next page for
filling up the
member
coverage
information
[0573] 3.1.5 User Interface Id: BPI_SCR_EN — 002 — 004—Coverage Information
[0574] 3.1.5.1 Screen Name: Coverage Information (See FIG. I- 6 )
[0575] 3.1.5.2 Element Name, Element Type, Label & Purpose
[0000]
Element
Name
Element Type
Label
Purpose
COBRA
Page sub Header
COBRA qualifying
To provide text
qualifying
Event
Event
Initial
Text
Initial COBRA effective
To provide text
COBRA
date
effective date
Date
Entry field
Date
Enter the initial effective date
COBRA End
Text
COBRA End Date
To provide text
Date
Period
Entry field
Period
Enter the COBRA effective
period
Reasons for
Text
Reasons for electing
To provide text
electing
COBRA
COBRA
Reasons for
Drop Down List
Reasons for electing
List the reasons for COBRA
electing
COBRA
election
COBRA
Where would
Text
Where would you like
To provide text
you like the
the bills to be sent
bills to be sent
Where would
Check Box
Where would you like
Check if the bill is to be sent to
you like the
the bills to be sent
the group or the member
bills to be sent
Is member
Text
Is member signature
To provide text
signature
verified
verified
Is member
Check box
Is member signature
Check if signature is verified
signature
verified
verified
Line of
HTML Table
Line of Coverage
Table to display the Member
Coverage
Selection Table
names and the Line of coverage
Selection
check boxes for picking the line
Table
of coverage for each COBRA
members
Coverage
Check Box
Coverage Selection
Check box to select the line of
Selection
coverage
Show
HTML button
Show Coverage Choice
Button to show the coverage
Coverage
choice for each line of coverage
Choice
based on the check box/boxes
checked.
Continue
HTML Button
Continue
Button to save the data and lead
to the next screen for showing
the summary and selection of
Benefit level offered by carriers
(Screen
BPI_CAS_SCR_EN_002_004)
[0576] 3.1.5.3 Screen Validations
[0000]
Element Name
Action/Validation Details
Message
Date
Defaults to system date. User can either
Error Dialog Box:
enter the date or pick the date from the
“Date cannot be future date
calendar
Please enter past date”
COBRA effective
Defaults to 18 months. Can be changed
None
period
by the user.
Reasons for electing
List the qualifying reasons for COBRA.
None
COBRA
Where would you
Option to bill either the group of the
None
like the bills to be
COBRA member based on the flag
sent
checked
Is member signature
Check if the member signature is verified
None
verified
Line of Coverage
Table to show the Line of coverage
None
Selection Table
against each member for picking the
option. The Line of coverage displayed is
based on the line of coverage selected by
the primary group.
Note: The table would display the
Member name in the following priority.
Employee as primary member
Spouse as the next member
Other members would be listed based on
the age.
Coverage Selection
Check Box to pick any combination of
None
coverage's for all the member for this
specific COBRA group
Show Coverage
On click of the Coverage choice system
None
Choice
should identify the coverage choice
based on the options checked. Whether
member only, member and spouse tec.
Continue
On clicking the continue button saves the
Dialog Box:
data and leads to the page
“Are you sure to continue”
BPI_CAS_SCR_EN_002_005
[0577] 3.1.5.4 Help Menu
This screen is used for filling up the COBRA qualifying events and the COBRA tenure for the members. Also there is an option to select the line of coverage opted for the various members.
[0000]
Element Name
Purpose
Valid Values
Continue
On clicking the
None
button leads to
the next page for
selecting the
benefit level
(Carrier)
[0579] 3.1.6 User Interface Id: BPI_SCR_EN — 002 — 006—Summary/Missing Information
[0580] 3.1.6.1 Screen Name: Missing Info (See FIG. I- 7 )
[0581] 3.1.6.2 Element Name, Element Type & Purpose
[0000]
Element
Name
Element Type
Label
Purpose
Member
Text
Member Missing
To provide text
Missing
Information
Information
Employee Tab
Expandable Tree
Employee Tab
Should be able to expand the
Employee Tab to list the
Details for the Employee
Missing and information and
Also show an expandable tab
for the Dependent Missing
Information
Enrollment
Drop Down List
Enrollment Status
List the status of enrollment.
Status
Can be Enroll or Decline
Remarks
Entry Field
Remarks
Remark for the status of
enrollment
Reasons for
Drop Down List
Reasons for Decline
List the reasons for decline
Decline
Other Reasons
Entry Field
Other Reasons
Any other reasons for decline
or others
Cancel
HTML Button
Cancel
To reset the operation
Process
HTML Button
Process Enrollment
Process the enrollment and
Enrollment
leads to the enrollment
confirmation page.
BPI_CAS_SCR_EN_001_011
[0582] 3.1.6.3 Screen Validations
[0000]
Element Name
Action/Validation Details
Message
Enrollment Status
List the status of enrollment. The default
Error Dialog Box:
option should be --choose one--
“Please choose enrollment
If the option selected is Decline.
status before continuing.”
Should list the list box containing
reasons for the decline.
If none is selected throw error message.
Remarks
Can accept any character.
Reasons for Decline
List the reasons for the decline. The
Error Dialog Box:
default option should be --choose one--
“Please choose reasons for
If none is selected throw error message.
declining before
continuing.”
Other Reasons
Can accept any character
None
Cancel
Resets to the status as was on loading this
None
page
Process Enrollment
Should function with Enter Key Cursor
Error Dialog Box:
Positioned on the “Process Enrollment”
“Please choose enrollment
button or on Mouse Click.
status before continuing.”
On success leads to the confirmation
“Please choose reasons for
page.
declining before
BPI_CAS_SCR_EN_001_011
continuing.”
It checks the eligibility rule for the
COBRA member once again. Process the
post enrollment activity like sending
emails, welcome letter. First month
invoices and email alert to GMS, Sales
and finance.
[0583] 3.1.7 User Interface Id: BPCSCR_EN — 002 — 007—Existing COBRA Employee Search
[0584] 3.1.7.1 Screen Name: Employee Search (See FIG. I- 8 )
[0585] 3.1.7.2 Element Name, Element Type & Purpose
[0000]
Element
Name
Element Type
Label
Purpose
Group ID
Text
Group ID
To provide text
Group Id
Entry field
Group Id
Enter the group id for searching
the employee
Employee ID
Text
Employee ID
To provide text
Employee ID
Entry field
Employee ID
Enter the Employee ID for
searching the employee
Employee
Text
Employee SSN
To provide text
SSN
Employee
Entry field
Employee SSN
Enter the Employee SSN for
SSN
searching the employee
Phone number
Text
Phone number
To provide text
Phone number
Entry field
Phone number
Enter the Employee Phone
number for searching the
employee
List Employee
HTML Tree
List Employee
Tree to List the Employee and
their dependent
Employee
HTML Table
Employee Table
Table to list employee
Table
information and status
Dependent
HTML table
Dependent Table
Table to list dependent
Table
information and status
Process
HTML button
Process COBRA
Button to check the COBRA
COBRA
eligibility and take to the next
page
BPI_CAS_SCR_EN_002_008 if
eligible. If not the show the same
page.
[0586] 3.1.7.3 Screen Validations
[0000]
Element Name
Action/Validation Details
Message
Group Id
Enter the Group ID or pick the group ID
Group ID can be tnered
based on the Group search
along with any other valid
fields for the employee
provided below.
Employee ID
Enter the employee Id or pick the
Note: At least one of the
employee based on the employee search
field with the search criteria
window.
for the employee must be
entered
Employee SSN
Enter the employee SSN or pick the
Note: At least one of the
employee based on the employee search
field with the search criteria
window.
for the employee must be
entered
Phone number
Enter the employee Phone or pick the
Note: At least one of the
employee based on the employee search
field with the search criteria
window.
for the employee must be
entered
List Employee
Tree to open up if dependent exist for the
None
employee
Employee Table
List the employee with status and
None
effective date
Process COBRA
Check the status and term reasons and
Embedded error if non-of
process the eligibility check for the
the member is termed or not
existing member to COBRA
qualifies for COBRA.
Note: It should check the following
status. Term Status, Term reasons
Only the member termed all eligible for
the COBRA. The reasons for term can
either decline COBRA enrollment or
define the COBRA period.
[0587] 3.1.8 User Interface Id: BPI_SCR_EN — 002 — 008—Existing COBRA Enrollment
[0588] 3.1.8.1 Screen Name: COBRA Enrollment (See FIG. I- 9 )
[0589] 3.1.8.2 Element Name, Element Type & Purpose
[0000]
Element
Name
Element Type
Label
Purpose
COBRA
Page sub Header
COBRA qualifying
To provide text
qualifying
Event
Event
Initial
Text
Initial COBRA effective
To provide text
COBRA
date
effective date
Date
Entry field
Date
Enter the initial effective date
COBRA End
Text
COBRA End Date
To provide text
Date
Period
Entry field
Period
Enter the COBRA effective
period Default to the period
based on the qualifying event
Reasons for
Text
Reasons for Term
To provide text
Term
Reasons for
Dynamic Text
Reasons for Term
Reasons for Term based on the
Term
term reasons provided
Term Date
Text
Term Date
To provide text
Term Date
Dynamic text
Term Date
Display the term date of the
member
Where would
Text
Where would you like
To provide text
you like the
the bills to be sent
bills to be sent
Where would
Check Box
Where would you like
Check if the bill is to be sent to
you like the
the bills to be sent
the group or the member
bills to be sent
Is member
Text
Is member signature
To provide text
signature
verified
verified
Is member
Check box
Is member signature
Check if signature is verified
signature
verified
verified
Line of
HTML Table
Line of Coverage
Table to display the Member
Coverage
Selection Table
names and the Line of coverage
Selection
check boxes for picking the line
Table
of coverage for each COBRA
members
Coverage
Check Box
Coverage Selection
Check box to select the line of
Selection
coverage
Show
HTML button
Show Coverage Choice
Button to show the coverage
Coverage
choice for each line of coverage
Choice
based on the check box/boxes
checked.
Continue
HTML Button
Continue
Button to save the data and lead
to the next screen for showing
the summary and selection of
Benefit level offered by carriers
(Screen
BPI_CAS_SCR_EN_002_009)
[0590] 3.1.8.3 Screen Validations
[0000]
Element Name
Action/Validation Details
Message
Date
Default to the date next to the term date.
Error Dialog Box:
Allow for making changes based on
“Date cannot be prior to the
authorization
term date. Please enter the
valid date”
Period
Default to the period based on the
none
Qualifying events. Allow to change
based on authorization
Where would you
Check the option for billing, Whether to
none
like the bills to be
the group or the member
sent
Is member signature
Check if signature is verified
none
verified
Line of Coverage
Table to show the Line of coverage
None
Selection Table
against each member for picking the
option. The Line of coverage displayed is
based on the line of coverage selected by
the primary group.
Note: The table would display the
Member name in the following priority.
Employee as primary member
Spouse as the next member
Other members would be listed based on
the age.
Check if member is
This is check if the member is not opting
None
not enrolling for
for the COBRA
COBRA
Coverage Selection
Check Box to pick any combination of
None
coverage's for all the member for this
specific COBRA group
Show Coverage
On click of the Coverage choice system
None
Choice
should identify the coverage choice
based on the options checked. Whether
member only, member and spouse etc.
Continue
On clicking the continue button saves the
Dialog Box:
data and leads to the page
“Are you sure to continue”
BPI_CAS_SCR_EN_002_009
[0591] 3.1.9 User Interface Id: BPI_SCR_EN — 002 — 009—Primary Member Information
[0592] 3.1.9.1 Screen Name: Primary Member Information (See FIG. I- 10 )
Note: This screen is pre filled with the employee information available in the employee master for all the members and the dependents belonging to this employee. Changes can be made to the information as applicable.
[0594] 3.1.9.2
[0000]
Element Name
Element Type
Label
Purpose
Main Address
Text
Main Address
To provide text
Street Address
Entry field
Street Address
Enter the street address
Suite/Apts.
Text
Suite/Apts.
To provide text
Suite/Apts.
Entry Field
Suite/Apts.
Enter the suite/apts. number
City
Text
City
To provide text
City
Entry Field
City
Enter the city name
State
Text
State
To provide text
State
Drop Down List
State
List all the state in US
ZIP
Text
ZIP
To provide text
ZIP
Entry Field
ZIP
Enter zip code
Service Area
Text
Service Area
To provide text
Service Area
Entry Field
Service Area
Shows the Service Area based
(uneditable) or list
on the ZIP code typed
Show list if the ZIP has
multiple service area
County
Text
County
To provide text
County
Entry Field
County
Display the county name based
(uneditable)
on the zip and service area
selected
Preferred mode
Text
Preferred mode of
To provide text
of
correspondence
correspondence
Mode of
Drop Down List
Mode of
List the mode of
correspondence
correspondence
communication, USPS, FAX,
email
Home Phone
Text
Home Phone number
To provide text
number
Phone
Entry Field
Phone
To enter phone number
Extension
Entry Field
Extension
To enter extension number
Home FAX No.
Text
Home FAX No.
To provide text
FAX
Entry Field
FAX
To enter FAX number
Extension
Entry Field
Extension
To enter extension number
E-Mail Address
Text
E-Mail Address
To provide text
E-mail Address
Entry field
Email Address
Enter email address
Alternate
Text
Alternate Address
To provide text
Address
Street Address
Text
Street Address
To provide text
Street Address
Entry field
Street Address
Enter the street address
Suite/Apts./
Text
Suite/Apts./PO Box #
To provide text
PO Box #
Suite/Apts./
Entry Field
Suite/Apts./PO Box #
Enter the suite/apts. number
PO Box #
City
Text
City
To provide text
City
Entry Field
City
Enter the city name
State
Text
State
To provide text
State
Drop Down List
State
List all the state in US
ZIP
Text
ZIP
To provide text
ZIP
Entry Field
ZIP
Enter zip code
Cancel
HTML Reset
Cancel
To cancel the operation and
Button
reset for new selection
Continue
HTML Submit
Continue
To save the data gathered in
Button
this screen and continue to the
next screen
BPI_CAS_SCR_EN_002_010
[0595] 3.1.9.3 Screen Validations
[0000]
Element Name
Action/Validation Details
Message
Street Address
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
Suite/Apts.
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
City
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
State
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
ZIP
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
Service Area
Should pick up the service area based
None
on the Zip code number typed in the
above ZIP entry field from the
database
If there are multiple service area then
it should list the service area for
picking up the service area.
County
Show the county name based on the
none
ZIP code and Service area
combination
Mode of
List mode of communications like
Error Dialog Box:
Communication
USPS, FAX, Email and others. If the
“Please choose the mode of
option selected is Email then the
communication”
Email address field cannot be blank.
Default Option should be--
choose one --.
If none is selected should throw error
message.
Phone
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
Extension
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
FAX
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
Extension
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
E-mail Address
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
Street Address
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
Suite/Apts.
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
City
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
State
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
ZIP
Refer Document No.
Refer Document No.
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
Cancel
Reset Button
To reset the value in the
Entry Field to its previous
state as was on loading the
page
Continue
Should function with Enter Key
Error Dialog Box:
Cursor Positioned on the “Continue”
“The value entered for the
button or on Mouse Click.
FIELD NAME is erroneous.
Check for all the validation on the
Please enter valid values._”
fields
“Please choose the mode of
If any data type error throw error
communication”
message.
Allows blank entry
On Success Leads to the next page
for filling further information on the
employee.
Screen
BPI_CAS_SCR_EN_002_010
[0596] 3.1.10 User Interface Id: BPI_SCR_EN — 002 — 010—Existing Coverage Information
[0597] 3.1.10.1 Screen Name: Coverage Information (See FIG. I- 11 )
[0598] 3.1.10.2 Element Name, Element Type, Label & Purpose
[0000]
Element
Name
Element Type
Label
Purpose
Benefit Level
HTML Table
Benefit Level (carrier
Table to display all the
(carrier
Selection)
Members in the row and The
Selection)
Benefit level selection option in
the Columns.
Member name
Link
Member name
Provide feature to edit the
member information by clicking
this link
Coverage
HTML ROW
Coverage Choice
The row get pre populated based
Choice
on the choice made in the screen
BPI_CAS_SCR_EN_002_009
Benefit Level
Link
Benefit Level Name
Link to the carrier selection for
Name
the specific line of coverage if
not available in the ZIP and
service area of the Primary
member.
PCP info
Link
PCP info (Available)
Link to edit the PCP info of the
(Available)
individual members as
applicable.
COBRA
HTML Button
COBRA Summary
Button to click for saving the
Summary
date and navigating to the next
page for displaying COBRA
summary/missing information
Cancel
HTML reset
Cancel
Button to reset to the state as
button
was on loading the page.
[0599] 3.1.10.3 Screen Validations
[0000]
Element Name
Action/Validation Details
Message
Benefit Level
Should have column header and each
None
(carrier
subsequent row should be identified by
Selection)
alternate color combinations. I.e. First
row should have color ‘x’ and the next
row should have color ‘y’. The next row
should have color ‘x’ again and so on. The
size of any text inside any cell should be
wrapped if the text becomes too long.
The Header and the Left Column should
be distinguishable.
Member name
This is a link to edit the member
None
information when on change or edit
mode.
PCP Info
This is a link to edit the PCP information
None
for the specific member. If PCP
information is not available then on
clicking the link it allows to fill in the
PCP information for the specific line of
coverage.
Coverage
Displays the dynamic text based on the
None
Choice
choices checked in the previous screen
BPI_CAS_SCR_EN_002_004
Benefit Level
Default benefit level would that the
None
Selection
employee selected when the status was
enrolled.
On clicking the Link show a minimized
window with option to select the benefit
level for the specific line of coverage.
Note the line of coverage is displayed
based on the Group options (i.e. only if
the group has selected the line of
coverage)
Also the benefit level (carrier) displayed
is based on the ZIP code/Service area of
the primary COBRA member.
Only if the prior Benefit level is not
available in the current ZIP/service are
of the primary member this is allowed to
be changed.
COBRA
On clicking the COBRA Summary
Dialog Box:
Summary
button save the content of this page into
“Are you
the repository and leads to the COBRA
sure you
summary page to display the COBRA
would like
missing information. Screen
to continue”
BPI_CAS_SCR_EN_002_006
This also does all the COBRA eligibility
checks prior to the display of summary
Page
Cancel
Resets to the state as was on loading the
none
page.
[0600] Note: the rest of the flow is common for both new Business COBRA and the Existing member conversion to COBRA.
[0601] Screen BPI_CAS_SCR_EN — 006 followed by COBRA enrollment.
[0602] 3.2 Screen Flow:
[0603] Screen Flow Diagram for COBRA Enrollment (See FIG. I- 12 )
4 Business Rule Mapping
[0604]
[0000]
Activity
Rules
New Business COBRA (NB brings
Need to know initial COBRA effective date
in COBRA)
Need to have system calculate COBRA end date (18 mo, 36 mo, or
other) based on Term Reason (Qualifying events)
For system to do this we need to have the following data captured
during the New Business COBRA Enrollment
a) Initial Effective date
b) Qualifying events
COBRA coverage
COBRA coverage has no lapse of time from the date of term &
COBRA enrollment
Exception: Death
Main subscribers coverage is terminated date of death and not the
end of the month: qualified beneficiaries (i.e. spouse/child)
effective date of COBRA is the day after the members death
Note: Since the COBRA coverage has no lapse of time it should be
basically effective from the day following the term date what ever
be the reasons.
Normal terms are always done on the end of the Month.
Death is done on the day of the death.
COBRA Election
60 days to elect COBRA coverage from the time of COBRA
notification letter.
60 days is based off the;
Date that we are notified of the termination (Postmark date for
termination)
OR
The termination date
WHICHEVER IS LATER. The decision is to be made based on
manual review by GMS personnel.
COBRA Election for Federal
If a FED COBRA group, we need to include an additional 14 days
COBRA
from termination notification date because FED Employers have 14
days to notify their employees of their rights after which they notify
the plan administrator/Pac Advantage). The decision is to be made
based on manual review by GMS personnel.
COBRA Premium Dues
COBRA members initial premium (all premiums from effective
date to current) must be made/mailed/postmarked within 45 days
from the COBRA election date (the date the application is
postmarked)
If payment is not MADE within this time frame, the COBRA
coverage is termed flat (effective date). Any partial premium
payments made will be reimbursed.
Provide over ride for 45 th day rule (ACL)
(This override needs to be available upon creating the COBRA)
COBRA Employee governed by
If main Employer group goes into possible term status or is termed,
Employer (Groups)
the COBRA will need to be notified and put in same status.
Employee will have the same coverage type, carrier & co-pay as
when termed (continue with exact coverage as before)
Cannot add dependents that were not previously covered (until o/e
or qualifying event)
Benefit Levels
Benefit level cannot change. Optional benefits and medical offered
by the group is not mandatory [Line of Coverage]
Possible extension of COBRA
Social Security disability - coverage extended to a total of 29 month
coverage
(11 mo. Extension) (all other term reasons apply)
The main subscriber does not have to elect to extend the coverage
for himself, just his dependents can elect to take the extension
Age 60 prior to loss of employment & worked for Employer for 5
consecutive years - coverage extended until the Employee turns age
65 (all other term reasons apply)
The main subscriber does not have to elect to extend the coverage
for himself, just his dependents can elect to take the extension
Also there should be a facility to grant COBRA extension if
applicable based on authority
Qualifying Events
Qualifying Beneficiaries
Continuation period
TERMINATION_OF_EMPLOYMENT
Employee, Spouse and Children
18
REDUCTION_OF_WORK_HOURS
Employee, Spouse and Children
18
CAN_NO_LONGER_AFFORD_COVERAGE
Employee, Spouse and Children
18
OBTAINED_COVERAGE_ELSE_WHERE
Employee, Spouse and Children
18
DEATH
Spouse and Children
36
ENTITLED_TO_MEDICARE
Employee, Spouse and Children
36
FRAUD_OR_MISREPRESENTATION
Employee, Spouse and Children
36
DPND_OBTAINED_COVERAGE_ELSEWHERE
Employee, Spouse and Children
18
DIVORCE_OR_LEGAL_SEPARATION
Employee, Spouse and Children
36
EMPLOYEE_CANNOT_AFFORD_SPOUSE_COVERAGE
Spouse
36
DPND_DEATH
None
18
DPND_ENTITLED_TO_MEDICARE
Dependent Spouse and Children
36
DPND_FRAUD_OR_MISREPRESENTATION
None
36
OVER_AGE_23
Dependent Child
18
NO_LONGER_AN_ELIGIBLE_DEPENDENT
Dependent Spouse and Children
18
NO_LONGER_A_DISABLED_CHILD
Dependent Child
18
EMPLOYEE_CAN_NO_LONGER_AFFORD_CHILD_COVERAGE
Child
18
OTHERS
Employee, Spouse and Children
36
There are other qualifying events, which are also considered while COBRA enrollment based on their Reason For Term.
5 User Role
[0605] The respective level of user role can over rule the following missing information.
[0000]
User Role
Level II, Level III, Level IV
S. No.,
Missing Information
Condition
1
SSN already exists
Employee SSN already exists
2
SSN already exists.
Dependent SSN already exists
Benefit Partners INC
Process Specification
Functional Design Process Specification
Add On and Change
1. Introduction
[0606] 1.1. Purpose
[0607] This document identifies how the user interacts with the system, the data to be captured, the business logic to be implemented, and the output of the process.
[0608] 1.2. Business Use Case Specification Reference
[0000]
Business Use Specification ID
Business Use Case Name
BPI_SCOPE_EN
Enrollment
BPI_SCOPE_EN_002
Enrollment Add On
[0609] Other Document Reference
[0000]
Document ID
Document Name
BPI_CAS_FSD_EN
Functional Specification Document -
Enrollment
BPI_CAS_FSD_EN_001
Process Flow - New Business Enrollment
BPI_CAS_FSD_EN_003
Process Flow - COBRA Enrollment/Changes
BPI_CAS_FSD_EN_005
Process Flow - Termination/Reinstatement
BPI_CAS_RULEBOX
RULE BOX for Add on and change
[0610] 1.3. Definitions, Acronyms & Abbreviations
[0000]
Term
Explanation
2. Process Identification
[0611] Process Flow and Description
[0612] This process is used to make changes to the Existing groups/members or dependents or add a new member/dependent to the Group or employee based on the business rules associated with changes and “Add ON's”.
[0613] 2.1. Background
[0614] 2.2. Process Description
The objective of the process
[0616] 2.3. Process Flow
This process is used to make changes to the Existing groups/members or dependents or add a new member/dependent to the Group or employee based on the business rules associated with changes and “Add ON's”.
[0618] 2.4. User Interface Screens
[0619] 2.4.1. Screen ID's
[0000]
Screen ID (SID)
Screen Name
Corresponding HTML File Name
Enrollment.addon.newemp.groupsearch
GroupSearch
/bpi/cas/enrollment/addon/newemp/groupsearch
Enrollment.addon.newemp.changerequest
ChangeRequest
/bpi/cas/enrollment/addon/newemp/changerequest
Enrollment.addon.newemp.groupgeneral
EmployeeGeneral
/bpi/cas/enrollment/addon/newemp/addemployee
Info
Enrollment.addon.newemp.employeecoverage
EmployeeCoverage
bpi/cas/enrollment/addon/newemp/employeecoverage
Info
Enrollment.addon.newemp.dependent
DependentGeneral
bpi/cas/enrollment/addon/newemp/adddependent
Info
Enrollment.addon.newemp.missing
PreEnrollment
bpi/cas/enrollment/addon/newemp/preenrollment
Enrollment.addon.newemp.summary
EnrollmentSummary
bpi/cas/enrollment/addon/newemp/enrollmentsummary
Enrollment.addon.newemp.confirmation
Confirmation
bpi/cas/enrollment/addon/newemp/confirmation
Enrollment.addon.newemp.employeesearch
Employee
bpi/cas/enrollment/addon/newemp/employeesearch
Search
Enrollment.addon.newemp.dependentsearch
Dependent
bpi/cas/enrollment/addon/newemp/dependentsearch
Search
Enrollment.addon.employeesearch
Employee
bpi/cas/enrollment/addon/adddependent/employeesearch
Search
Enrollment.addon.changerequest
Change Request
bpi/cas/enrollment/addon/adddependent/changerequest
Enrollment.addon.dependent
Dependent
bpi/cas/enrollment/addon/adddependent/dependent
General Info
Enrollment.addon.adddependentsearch
Modify
bpi/cas/enrollment/addon/adddependent/dependentsearch
dependent
Enrollment.addon.missingforadddependent
Pre-Enrollment
bpi/cas/enrollment/addon/adddepedent/preenrollment
Enrollment.addon.addconfirmation
Confirmation
bpi/cas/enrollment/addon/adddependent/confirmation
bpi.enrollment.change.group.groupsearch
Group Search
/bpi/cas/enrollment/change/group/groupsearch
bpi.enrollment.change.group.changerequest
Change Request
/bpi/cas/enrollment/change/group/changerequest
bpi.enrollment.change.group.identifychanges
Identify
/bpi/cas/enrollment/change/group/identifychanges
Changes
bpi.enrollment.change.group.general
Group
/bpi/cas/enrollment/change/group/generalinfo
GeneralInfo
bpi.enrollment.change.group.billing
Group Billing
/bpi/cas/enrollment/change/group/billinginfo
Info
bpi.enrollment.change.group.agent
Agent Info
/bpi/cas/enrollment/change/group/agentinfo
bpi.enrollment.change.group.coverage
Coverage Info
/bpi/cas/enrollment/change/group/coverageinfo
bpi.enrollment.change.group.missinginfo
Missing Info
/bpi/cas/enrollment/change/group/missinginfo
bpi.enrollment.change.group.confirmation
Confirmation
/bpi/cas/enrollment/change/group/confirmation
bpi.enrollment.change.group.groupmodifysearch
Modify Search
/bpi/cas/enrollment/change/group/groupmodifysearch
bpi.enrollment.change.employee.employeesearch
Employee
/bpi/cas/enrollment/change/employee/employeesearch
Search
bpi.enrollment.change.employee.changerequest
Change Request
/bpi/cas/enrollment/change/employee/changerequest
bpi.enrollment.change.employee.identifychanges
Identify
/bpi/cas/enrollment/change/employee/identifychanges
Changes
bpi.enrollment.change.employee.individualemployee
Individual
/bpi/cas/enrollment/change/employee/indivemployee
Employee
bpi.enrollment.change.employee.individualbilling
Individual
/bpi/cas/enrollment/change/employee/indivbilling
Billing
bpi.enrollment.change.employee.individualcoverage
Individual
/bpi/cas/enrollment/change/employee/indivcoverage
Coverage
bpi.enrollment.change.employee.individualmissing
Individual
/bpi/cas/enrollment/change/employee/indivmissing
Employee
Missing
bpi.enrollment.change.employee.employeemodifysearch
Modify Search
/bpi/cas/enrollment/change/employee/employeemodifysearch
bpi.enrollment.change.employee.employeeconfirm
Employee
/bpi/cas/enrollment/change/employee/employeeconfirm
Confirm
bpi.enrollment.change.employee.employeegeneral
Employee
/bpi/cas/enrollment/change/employee/employeegeneral
General Info
bpi.enrollment.change.employee.employeecoverage
Employee
/bpi/cas/enrollment/change/employee/employeecoverage
Coverage
bpi.enrollment.change.employee.employeemissing
Missing Info
/bpi/cas/enrollment/change/employee/employeemissing
bpi.enrollment.change.dependent.dependentsearch
Dependent
/bpi/cas/enrollment/change/dependent/dependentsearch
Search
bpi.enrollment.change.dependent.changerequest
Change Request
/bpi/cas/enrollment/change/dependent/changerequest
bpi.enrollment.change.dependent.identifychanges
Identify
/bpi/cas/enrollment/change/dependent/identifychanges
Changes
bpi.enrollment.change.dependent.dependentgeneral
Dependent
/bpi/cas/enrollment/change/dependent/dependentgeneral
General
bpi.enrollment.change.dependent.missinginfo
Missing Info
/bpi/cas/enrollment/change/dependent/missing info
bpi.enrollment.change.dependent.dependentconfirm
Confirmation
/bpi/cas/enrollment/change/dependent/dependentconfirm
bpi.enrollment.change.dependent.dependentmodify
Modify Search
/bpi/cas/enrollment/change/dependent/dependentmodify
[0620] 2.4.1.1. SID, Element Name, Element Type & Purpose
[0621] 2.4.1.1.1 SID: enrollment.addon.newemp.groupsearch
[0622] 2.4.1.1.1.1 Screen Snap Shot
Refer BPI_CAS_FSD — 01—User Interface ID
:BPI_CAS_SCR_EN — 001 — 012
[0624] 2.4.1.1.1.2 Element Name, Element Type & Purpose
Refer 3.1.13.2 of BPI_CAS_FSD_EN — 01 for the details.
[0626] 2.4.1.1.2 SID: enrollmentaddon.newemp.changerequest
[0627] 2.4.1.1.2.1 Screen Snap Shot
[0628] 2.4.1.1.2.2 Element Name, Element Type & Purpose
[0629] 2.4.1.1.3 SID: enrollmentaddon.newemp.groupgeneral
[0630] 2.4.1.1.3.1 Screen Snap Shot
Refer User Interface ID: BPI_CAS_SCR_EN — 001 — 002—Group General of BPI_CAS_FSD_EN — 01
[0632] 2.4.1.1.3.2 Element Name, Element Type & Purpose
Refer 3.1.3.2 of BPI_CAS_FSD_EN — 01 for the details.
[0634] 2.4.1.1.4 SID: enrollment.addon.newemp.employeecoverage
[0635] 2.4.1.1.4.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 007—Employee Coverage of BPI_CAS_FSD_EN — 01
[0637] 2.4.1.1.4.2 Element Name, Element Type & Purpose
Refer 3.1.8.2 of BPI_CAS_FSD_EN — 01 for the details.
[0639] 2.4.1.1.5 SID: enrollment.addon.newemp.dependent
[0640] 2.4.1.1.5.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 008—Dependent of BPI_CAS_FSD_EN — 01
[0642] 2.4.1.1.5.2 Element Name, Element Type & Purpose
Refer 3.1.9.2 of BPI_CAS_FSD_EN — 01 for the details
[0644] 2.4.1.1.6 SID: enrollment.addon.newemp.missing
[0645] 2.4.1.1.6.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 010—Missing Information of BPI_CAS_FSD_EN — 01
[0647] 2.4.1.1.6.2 Element Name, Element Type & Purpose
Refer to 3.1.11.2 of BPI_CAS_FSD_EN — 01
[0649] 2.4.1.1.7 SID: enrollmentaddon.newemp.summary
[0650] 2.4.1.1.7.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN 001 — 009—Enrollment Summary of BPI_CAS_FSD_EN — 01
[0652] 2.4.1.1.7.2 Element Name, Element Type & Purpose
[0653] Refer to 3.1.10.1 of BPI_CAS_FSD_EN — 01
[0654] 2.4.1.1.8 SID: enrollmentaddon.newemp.confirmation
[0655] 2.4.1.1.8.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 011—Enrollment Confirmation of BPI_CAS_FSD_EN — 01
[0657] 2.4.1.1.8.2 Element Name, Element Type & Purpose
Refer to 3.1.12.2 of BPI_CAS_FSD_EN — 01
[0659] 2.4.1.1.9 SID: enrollmentaddon.newemp.employeesearch
[0660] 2.4.1.1.9.1 Screen Snap ShotElement Name, Element Type & Purpose
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 013—Employee Search of BPI_CAS_FSD_EN — 01
[0662] 2.4.1.1.9.2 Element Name, Element Type & Purpose
Refer to 3.1.14.2 of BPI_CAS_FSD_EN — 01
[0664] 2.4.1.1.10 SID: enrollmentaddon.newemp.dependentsearch
[0665] 2.4.1.1.10.1 Screen Snap Shot
Refer to User interface ID: BPI_CAS_SCR_EN — 001 — 014—Dependent Search of BPI_CAS_FSD_EN — 01
[0667] 2.4.1.1.10.2 Element Name, Element Type & Purpose
Refer to 3.1.15.2 of BPI_CAS_FSD_EN — 01
[0669] 2.4.1.1.11 SID: enrollment.addon.employeesearch
[0670] 2.4.1.1.11.1 Screen Snap Shot
[0671] Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 013—Employee Search of BPI_CAS_FSD_EN — 01
[0672] 2.4.1.1.11.2 Element Name, Element Type & Purpose
Refer to 3.1.14.2 of BPI_CAS_FSD_EN — 01
[0674] 2.4.1.1.12 SID: enrollment.addon.changerequest
[0675] 2.4.1.1.12.1 Screen Snap Shot
[0676] 2.4.1.1.12.2 Element Name, Element Type & Purpose
[0677] 2.4.1.1.13 SID: enrollment.addon.dependent
[0678] 2.4.1.1.13.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 008—Dependent of BPI_CAS_FSD_EN — 01
[0680] 2.4.1.1.13.2 Element Name, Element Type & Purpose
[0681] 2.4.1.1.14 SID: enrollment.addon.adddependentsearch
[0682] 2.4.1.1.14.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 014—Dependent Search of BPI_CAS_FSD_EN — 01
[0684] 2.4.1.1.14.2 Element Name, Element Type & Purpose
Refer to 3.1.15.2 of BPI_CAS_FSD_EN — 01
[0686] 2.4.1.1.15 SID: enrollment.addon.missingforadddependent
[0687] 2.4.1.1.15.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 010—Missing Information of BPI_CAS_FSD_EN — 01
[0689] 2.4.1.1.15.2 Element Name, Element Type & Purpose
Refer to 3.1.11.2 of BPI_CAS_FSD_EN — 01
[0691] 2.4.1.1.16 SID: enrollment.addon.addconfirmation
[0692] 2.4.1.1.16.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 011—Enrollment Confirmation of BPI_CAS_FSD_EN — 01
[0694] 2.4.1.1.16.2 Element Name, Element Type & Purpose
Refer to 3.1.12.2 of BPI_CAS_FSD_EN — 01
[0696] 2.4.1.1.17 Change Screen SID
[0697] 2.4.1.1.17.1 Screen Snap Shot
Refer to User Interface ID BPI_CAS_FSD_EN — 01
BPI_CAS_RULKEBOX
[0700] 2.4.1.1.17.2 Element Name, Element Type & Purpose
Refer to User Interface ID BPI_CAS_FSD_EN — 01
BPI_CAS_RULKEBOX
[0703] 2.4.2. Screen Flow
[0704] (See FIG. I- 13 )
[0705] (See FIG. I- 14 )
[0706] (See FIG. I- 15 )
[0707] (See FIG. I- 16 )
[0708] (See FIG. I- 17 )
[0709] Change:—Group Change New Request
[0710] (See FIG. I- 18 )
[0711] Change:—Group Modify Pending Changes
[0712] (See FIG. I- 19 )
[0713] Change:—Employee Change New Request
[0714] (See FIG. I- 20 )
[0715] Change:—Employee Modify Pending Changes
[0716] (See FIG. I- 21 )
[0717] Change:—Dependent Change New Request
[0718] (See FIG. I- 22 )
[0719] Change:—Dependent Modify Pending Changes
[0720] (See FIG. I- 23 )
3. Business Rule Mapping
[0721]
[0000]
Activity
Rules
Employer Add
The rate for the employer is guaranteed for one year
On
(One year from the date of enrollment) Hence the
entire rates that is effective for the employer/group
needs to be effective for the new employees as well.
However the eligibility rules that is applicable for the
Employee at the time of enrollment. Counts for the
add-on employee can go more than 70 and up to 100 if
Small Employer Group (override based on ACL). If
Guaranteed association then there is no limit on the
employee count at any time.
Process Add on
Shows the missing information of the Add On
employee and emails the missing information to the
GMS rep.
Process Add on
On successful Add On the welcome mail is sent to the
Employer/Employee and cc to Agent. Billing
adjustment is made which would be handled in the
Finance Module.
Process Add On
Adding employee needs to check on the Waiting
(waiting Period)
Period. If the employee does not satisfy the waiting
period then it should send email to the GMS rep. Also
the employee effective date should default to the date
when the employee is actually eligible. If the
Employee satisfied the waiting period and is 60 days
past the waiting period then it should flag this as
missing information as this becomes a late
application, which needs clarification from the
employer before enrolling the employee. This
employee can be enrolled only with authorization.
The employee application form is not deemed as
“Late” if it is postmarked within 60 days from the
eligibility date. If it is postmarked within 60 days
from the eligibility date, the application is declined as
it is “Late”.
Late application can be enrolled only on the next
ROE.
[0722] Employee Add On (Adding Dependent)
[0000]
Activity
Rules
Employee Add On
The rate for the employer is guaranteed for one
year (One year form the date of enrollment) Hence
the entire rate that is effective for the employer/
group needs to be effective for the new dependent
as well. However the eligibility of the Dependent is
base on the normal eligibility rules that is applicable
for the Dependent at the time of enrollment.
Coverage Choice to be manipulated by System
automatically.
Process Add on
Shows the missing information of the Add On
Dependent and emails the missing information to
the GMS rep.
Process Add on
On successful Add On the welcome mail is sent to
the Employer/Employee/Dependent and cc to
Agent. Billing adjustment is made which would be
handled in the Finance Module.
General Rules
If the employee has selected the Employee only
option as coverage choice then it needs to be
changed for adding a dependent. System would not
allow adding dependent with Employee only status.
Employer Change
[0723]
[0000]
Activity
Rules
Demographic
Demographic change can include change in Company
changes
Name, Contact name, Address, Phone, Fax, Email,
Tax ID. All these change can be made and does not
affect the business rules except for transmission of
letter, email contacts
Billing Changes
All Billing changes are flag and email is sent to GMS
rep and Finance for Information. Billing changes
would effect the billing frequency or the mode of
payment (EFT, Credit Card or Check)
Waiting Period
Change in the waiting period would affect the
Change
Employee Eligibility criteria for all add on
employees, going forward, as the change may be.
Change in the Employee type for the waiting period
consideration would also affect the Employee
Eligibility for the New Employees ‘Add-On’, going
forward.
Waiting period would be based on the Employer
Effective date.
Effective date for changing the Waiting period should
default to the 1 st of the following month.
Waiting period can be changed only once from the
date of enrollment (effective date) to one-year cycle
for the employer.
If the waiting period changes are more than once in
the calendar year for the employer. This is to be
notified to the GMS rep and only the authorized
person can override this and allow for waiting period
change beyond 1 in employer anniversary date (one
year cycle).
Employer
Contribution would be based on the Employer
Contribution
Effective date.
Effective date for changing the Contribution should
default to the 1 st of the following month.
Contribution can be changed only twice from the date
of enrollment (effective date) to one-year cycle for the
employer.
If the Contribution changes are more than once in the
calendar year for the employer. This is to be notified
to the GMS rep and only the authorized person can
override this and allow for contribution change
beyond 1 in employer calendar year.
Note: Effective dates for Contribution changes
should be 1 st following month if the billing cycle
has not completed.
If the billing cycle is complete then it should be
effective the next billing cycle. I.e. 1 st of the month
following the next month.
Option benefits
a) Medical: No change allowed.
Changes
b) Dental Can be added only during ROE cycle.
Can be dropped any time. Note if dental is
dropped then it can be added in the ROE
following 12 month from the date of dropping the
dental plan.
c) Vision and CAM: Can be added and dropped any
time. Note if an optional benefit is dropped then
it can be added in the ROE following 12 month
from the date of dropping the optional benefit.
d) This is to be notified to the GMS rep and only the
authorized person can override this.
Employee Counts
Can be changed only at next ROE cycle.
(Number of
employee)
COBRA
Can Change any time but will effective from 1 st of the
monthly only
If this changes then any existing COBRA with this
group will change accordingly and automatically, 1 st
of the month.
Should trigger automatic transmission
TEFRA
Can be change any time but will be effective from 1 st
of the month only.
Transmit record to the carrier only if the employee is
65+
Part time
Can be change only during open enrollment or Re
coverage/
qualification and open enrollment. But should allow
Domestic partner
for overriding this feature based on authority.
Note: Any over riding function should trigger auto
email to the concerned GMS rep for making the
changes based on their authority
Agent Change
This triggers a new process flow. (Refer process flow
diagram FIG. 4.)
[0724] Note: For all changes effective date will be defaulted based on POST MARK DATE, If POST MARK date is lesser than 15th Day of month then Effective date will be 1st day of next month else it will be 1st day of next of the next month
4. User Role
[0725] The respective level of user role can over rule the following missing information.
[0000]
User Role
Level II, Level III, Level IV
S. No., Missing Information
Condition
1 SSN already exists.
Employee
2 SSN already exists.
Dependent
[0000]
Employee, Group and Dependent Changes (w.r.t. Current Date)
User Role
Condition
Level I
Reinstatement date is with in 30 days prior or later
Level II
Reinstatement date is with in 30 days prior or later
Level III
Reinstatement date is with in 60 days prior or later.
Benefit Partners Inc
Process Specification
ROE/OE Process
1. Introduction
[0726] 1.1. Purpose
[0727] The purpose of this document is to describe the process of ROE/OE Process. This document identifies how the user interacts with the system, the data to be captured, the business logic to be implemented, and the output of the process.
[0728] 1.2. Business Use Case Specification Reference
[0000]
Business Use Specification ID
Business Use Case Name
BPI_SCOPE_EN
Enrollment
BPI_SCOPE_EN_004
Enrollment - ROE
[0729] 1.3. Definitions, Acronyms & Abbreviations
[0000]
Term
Explanation
[0730] 1.4. Document Reference
[0000]
Document ID
Document Name
BPI_CAS_FSD_EN
Functional Specification Document -
Enrollment
BPI_CAS_FSD_EN_001
Process Flow - New Business Enrollment
BPI_CAS_FSD_EN_002
Process Flow - Enrollment Changes/Add-On
BPI_CAS_FSD_EN_003
Process Flow - COBRA Enrollment/Changes
BPI_CAS_FSD_EN_005
Process Flow - Termination/Reinstatement
2. Process Identification
[0731] 2.1. Background
Once a year, on the anniversary date of a group's enrollment in PacAdvantage (or for some, its July 1st, not their anniversary date), the group's participation, contribution and qualification is reviewed. This review is to ensure that the group meets the qualification requirement. The main objective of this process is to review these criteria and re qualify as needed, notify them of rate changes and provide an opportunity for employees of the group to make changes to their enrollment. This process is identified as Re-qualification and open enrollment. Also there is another process associated with this called as open enrollment where in the group has the privilege to make the changes to the plan, waiting period etc. The difference between the two processes is that for re-qualification the Group has to under go the eligibility check to qualify for their next term. For open enrollment the group need not re qualify and under go the eligibility checks. The group should already have been enrolled with the PacAdvantage and have no termination date for the ROE to be done.
[0737] 2.2. Process Description
The objective of the ROE/OE Process is to:
Annual Re qualification or open enrollment form filled by the Employer Open Enrollment Change form completed by employee, if applicable Employee Enrollment form(s) completed by employee, if applicable Dependent Enrollment fonn(s) completed by employee, if applicable
The following are the other requirements that will be supported and constraints on the proposed system:
1) The system has to initiate ROE/OE process 3 months prior to the actual anniversary date for the specific group. This process needs to be initiated by GMS personnel. 2) System has to pick up the Groups for ROE based on the rules defined below: Group Size: less than or equal to 4—All the groups needs to be re-qualified. Group Size: 5 to 9-10% of the Group needs to be re-qualified Group Size: greater than or equal to 10-1% of the group needs to be re-qualified. 3) System has to randomly pick up the groups based on the above rules for ROE based on random generator algorithm. 4) All other Group that is a part of ROE and OE needs to have their open enrollment processed. 5) Also their needs to be a facility to have manual OE process wherein the Employee or Employees are manually picked for ROE or OE process. Manual OE is usually performed based on searching the Employee based on line of coverage and plan. 6) There needs to be a feature to Finalize the ROE or OE for all the groups that have the same ROE/OE cycle.
[0753] 2.3. Process Flow
[0754] Process for ROE/OE
[0755] The process starts after manual initiation
1) Identify the group that has their anniversary date 3 months hence. 2) Based on the group size identify if the group needs to be re-qualified. 3) Randomly pick up the group for re-qualification 4) If the group is not picked for re-qualification then the group only needs to have open enrollment. 5) Send ROE/OE packets to mail house. The packet includes the Agent Packet and the group packet. 6) Also sent the packets to the COBRA members of the existing group. 7) Send reminder for the ROE/OE every month. 8) Receive the ROE/OE packets completed by the Group and enter into the system. 9) Follow up for missing information 10) Convey the Group/Agent about the ROE status on completion of the process.
[0766] Note the screens for entry of data for the ROE/OE processes are similar to the Group/Employee/Dependent Changes screen. However for the ROW/OE process the status would be identified as ROE process.
[0767] Process Flow Diagram—ROE process (See FIG. i- 24 )
3. User Interface
[0768] 3.1. User Interface Screens
[0769] 3.1.1. Screen ID's
[0000]
Screen ID (SID)
Screen Name
Corresponding HTML File Name
enrollment.roe.groupsearch
Group Search
/bpi/cas/enrollment/roe/groupsearch
enrollment.roe.request
Group Request
/bpi/cas/enrollment/roe/request
enrollment.roe.identifygroupchange
Identify Group Change
/bpi/cas/enrollment/roe/identifygroupchange
Request
enrollment.roe.groupgeneral
Group General Info
/bpi/cas/enrollment/roe/groupgeneral
enrollment.roe.groupbilling
Group Billing Info
/bpi/cas/enrollment/roe/groupbilling
enrollment.roe.groupagent
Group Agent Info
/bpi/cas/enrollment/roe/groupagent
enrollment.roe.agentsearch
Agent Search
/bpi/cas/enrollment/roe/agentsearch
enrollment.roe.groupcoverage
Group Coverage Info
/bpi/cas/enrollment/roe/groupcoverage
enrollment.roe.employeesearch
Employee Search
/bpi/cas/enrollment/roe/employeesearch
enrollment.roe.identifyemployeechange
Identify Employee
/bpi/cas/enrollment/roe/identifyemployeechange
Change Request
enrollment.roe.employeegeneral
Employee General Info
/bpi/cas/enrollment/roe/addemployee
enrollment.roe.employeecoverage
Employee Coverage Info
/bpi/cas/enrollment/roe/employeecoverage
enrollment.roe.dependentsearch
Dependent Search
/bpi/cas/enrollment/roe/dependentsearch
enrollment.roe.identifydependentchange
Identify Dependent
/bpi/cas/enrollment/roe/identifydependentchange
Change Request
enrollment.roe.dependentgeneral
Dependent General
/bpi/cas/enrollment/roe/adddependent
enrollment.roe.groupsummary
Group Summary
/bpi/cas/enrollment/roe/enrollmentsummary
enrollment.roe.groupmissing
Group Missing Info
/bpi/cas/enrollment/roe/preenrollment/
enrollment.roe.groupconfirm
Group Confirm
/bpi/cas/enrollment/roe/groupconfirm
enrollment.roe.individualemployeesearch
Indiv Employee Search/
/bpi/cas/enrollment/roe/indivemployeesearch
Indiv Group Search
enrollment.roe.indivemployeerequest
Indiv Employee Request
/bpi/cas/enrollment/roe/indivemployeerequest
enrollment.roe.identifyindivemployee
Identify Indiv Employee
/bpi/cas/enrollment/roe/identifyindivemployeechange
change
Change Request
enrollment.roe.individualemployeegeneral
Indiv Employee General
/bpi/cas/enrollment/roe/indivemployee
Info
enrollment.roe.individualbilling
Indiv Billing Info
/bpi/cas/enrollment/roe/indivbilling
enrollment.roe.individualagent
Indiv Agent Info
/bpi/cas/enrollment/roe/indivagent
enrollment.roe.individualagentsearch
Indiv Agent Search
/bpi/cas/enrollment/roe/indivagent
enrollment.roe.individualemployeecoverage
Indiv Coverage Info
/bpi/cas/enrollment/roe/indivcoverage
enrollment.roe.individualdpendentsearch
Indiv Dependent Search
/bpi/cas/enrollment/roe/indivdependentsearch
enrollment.roe.identifyindivdependent
Identify indiv Dependent
/bpi/cas/enrollment/roe/identifyindivdependentchange
change
Change Request
enrollment.roe.individualdependentgeneral
Indiv Dependent General
/bpi/cas/enrollment/roe/indivdependent/
Info
enrollment.roe.individualsummary
Indiv Enrollment
/bpi/cas/enrollment/roe/indivenrollmentsummary
Summary
enrollment.roe.individualmissing
Indiv Pre Enrollment
/bpi/cas/enrollment/roe/indivpreenrollment
bpi.enrollment.cobraroe.new.searchcobra
COBRA Search
/bpi/cas/enrollment/cobraroe/new/cobraroesearch
bpi.enrollment.cobraroe.new.request
COBRA ROE/OE
/bpi/cas/enrollment/cobraroe/new/request
Process Request
bpi.enrollment.cobraroe.new.identify
Identify COBRA ROE/
/bpi/cas/enrollment/cobraroe/new/request
changes
OE Change Request Info
bpi.enrollment.cobraroe.new.general
COBRA General info
/bpi/cas/enrollment/cobraroe/new/generalinfo
bpi.enrollment.cobraroe.new.billing
COBRA Billing Info
/bpi/cas/enrollment/cobraroe/new/billinginfo
bpi.enrollment.cobraroe.new.coverage
COBRA Coverage Info
/bpi/cas/enrollment/cobraroe/new/coverageinfo
bpi.enrollment.cobraroe.new.dependent
COBRA Dependent Info
/bpi/cas/enrollment/cobraroe/new/dependentinfo
bpi.enrollment.cobraroe.new.missing
COBRA Missing Info
/bpi/cas/enrollment/cobraroe/new/missinginfo
bpi.enrollment.cobraroe.new.confirmation
COBRA Confirmation
/bpi/cas/enrollment/cobraroe/new/confirmation
Enrollment.roe.manualroe
ROE/OE Process
/bpi/cas/enrollment/roe/manualroe
Enrollment.roe.roetransfer
ROE/OE Transfer
/bpi/cas/enrollment/roe/roetransfer
[0770] 3.1.2. SID, Element Name, Element Type & Purpose
[0771] 3.1.2.1. SID: enrollment.roe.groupsearch
[0772] 3.1.2.1.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 012—Group Search of BPI_CAS_FSD_EN — 01
[0774] 3.1.2.1.2 Element Name, Element Type & Purpose
Refer to 3.1.13.2 of BPI_CAS_FSD_EN — 01
[0776] 3.1.2.2. SID: enrollment.roe.request
[0777] 3.1.2.2.1 Screen Snap Shot (See FIG. I- 25 )
[0778] 3.1.2.3. SID: enrollment.roe.identifygroupchange
[0779] 3.1.2.3.1 Screen Snap Shot (See FIG. I- 26 )
[0780] 3.1.2.4. SID: enrollment.roe.groupgeneral
[0781] 3.1.2.4.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 002—Group General of BPI_CAS_FSD_EN — 01
[0783] 3.1.2.4.2 Element Name, Element Type & Purpose
Refer to 3.1.3.2 of BPI_CAS_FSD_EN — 01
[0785] 3.1.2.5. SID: enrollment.roe.groupbilling
[0786] 3.1.2.5.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 003—Billing of BPI_CAS_FSD_EN — 01
[0788] 3.1.2.5.2 Element Name, Element Type & Purpose
Refer to 3.1.4.2 of BPI_CAS_FSD_EN — 01
[0790] 3.1.2.6. SID: enrollment.roe.groupagent
[0791] 3.1.2.6.1 Screen Snap Shot
[0792] Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 005—Agent of BPI_CAS_FSD_EN — 01
[0793] 3.1.2.6.2 Element Name, Element Type & Purpose
Refer to 3.1.6.2 of BPI_CAS_FSD_EN — 01
[0795] 3.1.2.7. SID: enrollment.roe.agentsearch
[0796] 3.1.2.7.1 Screen Snap Shot
[0797] 3.1.2.7.2 Element Name, Element Type & Purpose
[0798] 3.1.2.8. SID: enrollment.roe.groupcoverage
[0799] 3.1.2.8.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 004—Group Coverage of BPI_CAS_FSD_EN — 01
[0801] 3.1.2.8.2 Element Name, Element Type & Purpose
Refer to 3.1.5.2 of BPI_CAS_FSD_EN — 01
[0803] 3.1.2.9. SID: enrollment.roe.employeesearch
[0804] 3.1.2.9.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 013—Employee Search of BPI_CAS_FSD_EN — 01
[0806] 3.1.2.9.2 Element Name, Element Type & Purpose
Refer to 3.1.14.2 of BPI_CAS_FSD_EN — 01
[0808] 3.1.2.10. SID: enrollment.roe.identifyemployeechange
[0809] 3.1.2.10.1 Screen Snap Shot (See FIG. I- 27 )
[0810] 3.1.2.11. SID: enrollment.roe.employeegeneral
[0811] 3.1.2.11.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 006—Employee Information of BPI_CAS_FSD_EN — 01
[0813] 3.1.2.11.2 Element Name, Element Type & Purpose
Refer to 3.1.7.2 of BPI_CAS_FSD_EN — 01
[0815] 3.1.2.12. SID: enrollment.roe.employeecoverage
[0816] 3.1.2.12.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 007—Employee Coverage of BPI_CAS_FSD_EN — 01
[0818] 3.1.2.12.2 Element Name, Element Type & Purpose
Refer to 3.1.8.2 of BPI_CAS_FSD_EN — 01
[0820] 3.1.2.13. SID: enrollment.roe.dependentsearch
[0821] 3.1.2.13.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 014—Dependent Search of BPI_CAS_FSD_EN — 01
[0823] 3.1.2.13.2 Element Name, Element Type & Purpose
Refer to 3.1.15.2 of BPI_CAS_FSD_EN — 01
[0825] 3.1.2.14. SID: enrollment.roe.identifydependentchange
[0826] 3.1.2.14.1 Screen Snap Shot (See FIG. I- 28 )
[0827] 3.1.2.15. SID: enrollment.roe.dependentgeneral
[0828] 3.1.2.15.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 008—Dependent of BPI_CAS_FSD_EN — 01
[0830] 3.1.2.15.2 Element Name, Element Type & Purpose
Refer to 3.1.9.2 of BPI_CAS_FSD_EN — 01
[0832] 3.1.2.16. SID: enrollment.roe.groupsummary
[0833] 3.1.2.16.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 009—Enrollment Summary of BPI_CAS_FSD_EN — 01
[0835] 3.1.2.16.2 Element Name, Element Type & Purpose
Refer to 3.1.10.2 of BPI_CAS_FSD_EN — 01
[0837] 3.1.2.17. SID: enrollment.roe.groupmissing
[0838] 3.1.2.17.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 010—Missing Information of BPI_CAS_FSD_EN — 01
[0840] 3.1.2.17.2 Element Name, Element Type & Purpose
[0841] Refer to 3.1.11.2 of BPI_CAS_FSD_EN — 01
[0842] 3.1.2.18. SID: enrollment.roe.groupconfinn
[0843] 3.1.2.18.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 011—Enrollment Confirmation of BPI_CAS_FSD_EN — 01
[0845] 3.1.2.18.2 Element Name, Element Type & Purpose
Refer to 3.1.12.2 of BPI_CAS_FSD_EN — 01
[0847] 3.1.2.19. SID: enrollment.roe.individualemployeesearch
[0848] 3.1.2.19.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR — 001 — 013—Employee Search of BPI_CAS_FSD_EN — 01
[0850] 3.1.2.19.2 Element Name, Element Type & Purpose
Refer to 3.1.14.2 of BPI_CAS_FSD_EN — 01
[0852] 3.1.2.20. SID: enrollment.roe.indivemployeerequest
[0853] 3.1.2.20.1 Screen Snap Shot
[0854] 3.1.2.20.2 Element Name, Element Type & Purpose
[0855] 3.1.2.21. SID: enrollment.roe.identifyindivemployeechange
[0856] 3.1.2.21.1 Screen Snap Shot
[0857] 3.1.2.21.2 Element Name, Element Type & Purpose
[0858] 3.1.2.22. SID: enrollment.roe.individualemployeegeneral
[0859] 3.1.2.22.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 006—Employee Information of BPI_CAS_FSD_EN — 01
[0861] 3.1.2.22.2 Element Name, Element Type & Purpose
Refer to 3.1.7.2 of BPI_CAS_FSD_EN — 01
[0863] 3.1.2.23. SID: enrollment.roe.individualbilling
[0864] 3.1.2.23.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR — 001 — 003—Billing of BPI_CAS_FSD_EN — 01
[0866] 3.1.2.23.2 Element Name, Element Type & Purpose
Refer to 3.1.4.2 of BPI_CAS_FSD_EN — 01
[0868] 3.1.2.24. SID: enrollment.roe.individualagent
[0869] 3.1.2.24.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 005—Agent of BPI_CAS_FSD_EN — 01
[0871] 3.1.2.24.2 Element Name, Element Type & Purpose
Refer to 3.1.6.2 of BPI_CAS_FSD_EN — 01
[0873] 3.1.2.25. SID: enrollment.roe.individualagentsearch
[0874] 3.1.2.25.1 Screen Snap Shot
[0875] 3.1.2.25.2 Element Name, Element Type & Purpose
[0876] 3.1.2.26. SID: enrollment.roe.individualemployeecoverage
[0877] 3.1.2.26.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 007—Employee Coverage of BPI_CAS_FSD_EN — 01
[0879] 3.1.2.26.2 Element Name, Element Type & Purpose
Refer to 3.1.8.2 of BPI_CAS_FSD_EN — 01
[0881] 3.1.2.27. SID: enrollment.roe.individualdependentsearch
[0882] 3.1.2.27.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 014—Dependent Search of BPI_CAS_FSD_EN — 01
[0884] 3.1.2.27.2 Element Name, Element Type & Purpose
Refer to 3.1.15.2 of BPI_CAS_FSD_EN — 01
[0886] 3.1.2.28. SID: enrollment.roe.identifyindivdependentchange
[0887] 3.1.2.28.1 Screen Snap Shot
[0888] 3.1.2.28.2 Element Name, Element Type & Purpose
[0889] 3.1.2.29. SID: enrollment.roe.individualdependentgeneral
[0890] 3.1.2.29.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN 001-008—Dependent of BPI_CAS_FSD_EN — 01
[0892] 3.1.2.29.2 Element Name, Element Type & Purpose.
Refer to 3.1.9.2 of BPI_CAS_FSD_EN — 01
[0894] 3.1.2.30. SID: enrollment.roe.individualsummary
[0895] 3.1.2.30.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 009—Enrollment Summary of BPI_CAS_FSD_EN — 01
[0897] 3.1.2.30.2 Element Name, Element Type & Purpose
Refer to 3.1.10.2 of BPI_CAS_FSD_EN — 01
[0899] 3.1.2.31. SID: enrollmentroe.individualmissing
[0900] 3.1.2.31.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 010—Missing Information of BPI_CAS_FSD_EN — 01
[0902] 3.1.2.31.2 Element Name, Element Type & Purpose
Refer to 3.1.11.2 of BPI_CAS_FSD_EN — 01
[0904] 3.1.2.32. SID: bpi.enrollment.cobraroe.new.searchcobra
[0905] 3.1.2.32.1 Screen Snap Shot
Refer to 3.1.1 Screen Shot: BPI_SCR_EN 002 — 001 of BPI_CAS_FSD_EN — 02
[0907] 3.1.2.32.2 Element Name, Element Type & Purpose
Refer to 3.1.2 of BPI_CAS_FSD_EN — 02
[0909] 3.1.2.33. SID: bpi.enrollment.cobraroe.new.request
[0910] 3.1.2.33.1 Screen Snap Shot (See FIG. I- 29 )
[0911] 3.1.2.34. SID: bpi.enrollment.cobraroe.new.identifychanges
[0912] 3.1.2.34.1 Screen Snap Shot (See FIG. I- 30 )
[0913] 3.1.2.35. SID: bpi.enrollment.cobraroe.new.general
[0914] 3.1.2.35.1 Screen Snap Shot
Refer to 3.8.1 Screen Shot: BPI_SCR_EN — 002 — 009 of BPI_CAS_FSD_EN — 02
[0916] 3.1.2.35.2 Element Name, Element Type & Purpose
Refer to 3.8.2 of BPI_CAS_FSD_EN — 02
[0918] 3.1.2.36. SID: bpi.enrollment.cobraroe.new.billing
[0919] 3.1.2.36.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 003—Billing of BPI_CAS_FSD_EN — 01
[0921] 3.1.2.36.2 Element Name, Element Type & Purpose
Refer to 3.1.4.2 of BPI_CAS_FSD_EN — 01
[0923] 3.1.2.37. SID: bpi.enrollment.cobraroe.new.coverage
[0924] 3.1.2.37.1 Screen Snap Shot
Refer to 3.9.1 Screen Shot: BPI_SCR_EN 002 — 010 of BPI_CAS_FSD_EN — 02
[0926] 3.1.2.37.2 Element Name, Element Type & Purpose
Refer to 3.9.2 of BPI_CAS_FSD_EN — 02
[0928] 3.1.2.38. SID: bpi.enrollment.cobraroe.new.dependent
[0929] 3.1.2.38.1 Screen Snap Shot
Refer to 3.3.1 Screen Shot: BPI_SCR_EN — 002 — 003 of BPI_CAS_FSD_EN — 02
[0931] 3.1.2.38.2 Element Name, Element Type & Purpose
Refer to 3.3.2 of BPI_CAS_FSD_EN — 02
[0933] 3.1.2.39. SID: bpi.enrollment.cobraroe.new.missing
[0934] 3.1.2.39.1 Screen Snap Shot
Refer to 3.5.1 Screen Shot: BPI_SCR_EN 002 — 006 of BPI_CAS_FSD_EN — 02
[0936] 3.1.2.39.2 Element Name, Element Type & Purpose
Refer to 3.5.2 of BPI_CAS_FSD_EN — 02
[0938] 3.1.2.40. SID: bpi.enrollment.cobraroe.new.confirmation
[0939] 3.1.2.40.1 Screen Snap Shot
Refer to User Interface ID: BPI_CAS_SCR_EN — 001 — 011—Enrollment Confirmation of BPI_CAS_FSD_EN — 01
[0941] 3.1.2.40.2 Element Name, Element Type & Purpose
Refer to 3.1.12.2 of BPI_CAS_FSD_EN — 01
[0943] 3.1.3. Screen Flow
[0944] (See FIG. I- 31 )
[0945] (See FIG. I- 32 )
[0946] (See FIG. I- 33 )
4. Business Rule Mapping
[0947]
[0000]
Activity
Rules
ROE Process
Identify the group randomly based on the Group
size for ROE.
ROE validation
All the eligibility rules that are applicable as
new business enrollment are applicable for the
ROE as well.
Open Enrollment
Open enrollment allows for making the changes
that are normally not possible during the normal
changes.
Billing
Bill in a normal way if the ROE/OE has a
completed status. Make the bill for the new
effective date.
If the ROE/OE has a status as pend then pend
the bill for the new effective date.
5. User Role
[0948] The respective level of user role can over rule the following missing information,
[0000]
ROE OE SEG/Alternate/Indiv Group
User Role
Level II, Level III, Level IV
S. No., Missing Information
Condition
1 SSN already exists.
Employee SSN already exists
2 SSN already exists.
Dependent SSN already exists
3 Employer Tax Id already exists.
Employer Tax Id already exists
[0000]
ROE OE COBRA Group
User Role
Level II, Level III, Level IV
S. No., Missing Information
Condition
1 SSN already exists.
Employee SSN already exists
2 SSN already exists.
Dependent SSN already exists
Benefit Partners Inc
Process Specification
Termination Reinstatement
1. Introduction
[0949] 1.1. Purpose
[0950] The purpose of this document is to identify the process associated with the business use case Termination and Reinstatement
[0951] 1.2. Business Use Case Specification Reference
[0000]
Business Use Specification ID
Business Use Case Name
BPI_SCOPE_EN
Enrollment
BPI_SCOPE_EN_005
Termination and Reinstatement
[0952] 1.3. Definitions, Acronyms & Abbreviations
[0000]
Term
Explanation
2. Process Identification
[0953] 2.1. Background
[0954] <Brief Description of the Process>
[0955] 2.2. Process Description
Process Flow for Group Term This process is used to terminate or reinstate the Group, Employee and or Dependent. The FIG. 1 shows the process flow for the group termination. The group can be termed broadly based on two reasons; Non-payment of Premium or by group request for termination. Non-payment of premium is an automated process and starts and completes the term process automatically. The employer request is a manual term process and the Group is termed manually. Automated Term process initiates the Term Process. Letter is sent to the Group with 15 days notice for reinstatement. The system holds the status as “Term Pending” although the group believes they are completely termed. The reason for this is to prevent the sending of termination then reinstatement transmissions to the carriers; which causes confusion. The finance department then processes the term to completion if the payment is not received. Finance also has ability to override the term pend status based on authority. Manual Term process is based on the request received from the group. All manual term process is notified to finance for necessary action. If the Group has a shortfall then the system notifies the finance department and finance processes the term. Term letter is send to the Group for paying through the balance premium. If the balance premium is paid then the finance department completes the term. If the balance is not paid then finance terms the group retrospectively. If the Group has a refund due them then the system notifies the finance department and finance processes the refund and completes the term process.
Process Flow for Employee Term
[0000]
Employee term is based on the Employer request to terminate the employee based on certain reasons. Based on these reasons the employee is termed and all employees who are termed needs to be sent the COBRA packets for COBRA enrollment. Billing adjustments are made for the employee term in the next invoice generated.
[0963] Process Flow for Dependent Term
Dependent term is based on the Employer/Employee request to terminate the Dependent based on certain reasons. Based on these reasons the Dependent is termed and the termed Dependent are sent the COBRA packets for COBRA enrollment. Billing adjustments are made for the Dependent term in the next invoice generated for the Group.
[0965] 2.3. Process Flow
Process flow description (See FIG. I- 34 )
3. User Interface
[0967] 3.1. User Interface Screens
[0968] 3.1.1. Screen ID's
[0000]
Corresponding HTML File
Screen ID (SID)
Screen Name
Name
enrollment.termination.groupsearch
Search Group for Termination
/bpi/cas/enrollment/termination/group/GroupSearch.jsp
enrollment.termination.grouptermination
Group Termination Request
/bpi/cas/enrollment/termination/group/GroupTerminationRequest.jsp
request
enrollment.termination.groupprocess
Group Termination Process
/bpi/cas/enrollment/termination/group/GroupProcessTermination.jsp
termination
enrollment.termination.grouptemination
Group Termination
/bpi/cas/enrollment/termination/group/GroupTerminationConfirm.jsp
confirmation
Confirmation
enrollment.termination.multiple
Multiple Group Termination
/bpi/cas/enrollment/termination/group/
groupsearch
Request
MultipleGroupTerminationRequest.jsp
enrollment.termination.multiple
Multiple Group Termination
/bpi/cas/enrollment/termination/group/
groupterminationconfirm
Confirmation
MultipleGroupTerminationConfirm.jsp
enrollment.termination.employee
Search Employee for Termination
/bpi/cas/enrollment/termination/employee/EmployeeSearch.jsp
search
enrollment.termination.employee
Employee Termination Request
/bpi/cas/enrollment/termination/employee/
terminationrequest
EmployeeTerminationRequest.jsp
enrollment.termination.employee
Employee Process Termination
/bpi/cas/enrollment/termination/employee/
processtermination
EmployeeProcessTermination.jsp
enrollment.termination.employee
Employee Termination
/bpi/cas/enrollment/termination/employee/
terminationconfirm
Confirmation
EmployeeTerminationConfirm.jsp
enrollment.termination.dependent
Search Dependent for
/bpi/cas/enrollment/termination/dependent/
search
Termination
DependentSearch.jsp
enrollment.termination.dependent
Dependent Termination
/bpi/cas/enrollment/termination/dependent/
terminationrequest
Request
DependentTerminationRequest.jsp
enrollment.termination.dependent
Dependent Process Termination
/bpi/cas/enrollment/termination/dependent/
processtermination
DependentProcessTermination.jsp
enrollment.termination.dependent
Dependent Termination
/bpi/cas/enrollment/termination/dependent/
terminationconfirm
Confirm
DependentTerminationConfirm.jsp
enrollment.reinstatement.group
Search Group for Reinstatement
/bpi/cas/enrollment/reinstatement/group/GroupSearch.jsp
search
enrollment.reinstatement.group
Group Reinstatement Request
/bpi/cas/enrollment/reinstatement/group/GroupReinstatementRequest.jsp
reinstatementrequest
enrollment.reinstatement.group
Group Process Reinstatement
/bpi/cas/enrollment/reinstatement/group/GroupProcessReinstatement.jsp
processreinstatement
enrollment.reinstatement.group
Group Reinstatement
/bpi/cas/enrollment/reinstatement/group/GroupReinstatementConfirm.jsp
reinstatementconfirm
Confirmation
enrollment.reinstatement.employee
Search for Employee
/bpi/cas/enrollment/reinstatement/employee/EmployeeSearch.jsp
search
Reinstatement
enrollment.reinstatement.employee
Employee Reinstatement
/bpi/cas/enrollment/reinstatement/employee/
reinstatementrequest
Request
EmployeeReinstatementRequest.jsp
enrollment.reinstatement.employee
Employee Process
/bpi/cas/enrollment/reinstatement/employee/
processreinstatement
Reinstatement
EmployeeProcessReinstatement.jsp
enrollment.reinstatement.employee
Employee Reinstatement
/bpi/cas/enrollment/reinstatement/employee/
reinstatementconfirm
Confirmation
EmployeeReinstatementConfirm.jsp
enrollment.reinstatement.dependent
Search Dependent for
/bpi/cas/enrollment/reinstatement/dependent/DependentSearch.jsp
search
Reinstatement
enrollment.reinstatement.dependent
Dependent Reinstatement
/bpi/cas/enrollment/reinstatement/dependent/
reinstatementrequest
Request
DependentReinstatementRequest.jsp
enrollment.reinstatement.dependent
Dependent Process
/bpi/cas/enrollment/reinstatement/dependent/
processreinstatement
Reinstatement
DependentProcessReinstatement.jsp
enrollment.reinstatement.dependent
Dependent Reinstatement
/bpi/cas/enrollment/reinstatement/dependent/
reinstatementconfirm
Confirmation
DependentReinstatementConfirm.jsp
[0969] 3.1.1.1. SID, Element Name, Element Type & Purpose
SID: enrollment.termination.groupsearch Screen Snap Shot (See FIG. I- 35 )
[0000]
Element Name
Element Type
Purpose
Group Id
Entry Field
Enter Group Id
Group Name
Entry Field
Enter Group Name
Phone Number
Entry Field
Enter Phone Number
SID: enrollment.termination.groupterminationrequest
Screen Snap Shot (See FIG. I- 36 )
[0000]
Element Name
Element Type
Purpose
Mode of
Selection Box
Entry Field for the Group Id.
Request
Postmark Date
Entry Field
Entry Field for the Group Name
Date Received
Entry Field
Entry Field for the Date Received
Authorized
Selection Box
Entry Field for the Authorized Contact
Contact
Requested
Entry Field
Entry Field for the Request Term Date
Term Date
Reason for
Selection Box
Select the Reason for Term
Term
Other Reason
Entry Field
Entry Field for the Other Reason
SID: enrollment.termination.groupprocesstermination
Screen Snap Shot (See FIG. I- 37 )
[0000]
Element Name
Element Type
Purpose
Effective Term Date
Entry Field
Entry Field for the Group Id.
Change Term Status
Select Box
Select Change Term Status
SID: enrollment.termination.groupterminationcontirm
Screen Snap Shot (See FIG. I- 38 )
SID: enrollment.termination.multiplegroupsearch
Screen Snap Shot (See FIG. I- 39 )
[0000]
Element Name
Element Type
Purpose
Postmark Date
Entry Field
Entry Field for the Group Name
Date Received
Entry Field
Entry Field for the Date Received
Requested
Entry Field
Entry Field for the Request Term Date
Term Date
Reason for
Selection Box
Select the Reason for Term
Term
Other Reason
Entry Field
Entry Field for the Other Reason
SID: enrollment.termination.multiplegroupterminationconfirm
Screen Snap Shot (See FIG. I- 40 )
SID: enrollment.termination.employeesearch
Screen Snap Shot (See FIG. I- 41 )
[0000]
Element Name
Element Type
Purpose
Group Name
Entry Field
Entry Field for the Group Name
Group Id
Entry Field
Entry Field for the Group ID
Employee
Entry Field
Entry Field for the Employee First
First Name
Name
Employee
Entry Field
Entry Field for the Employee Last
Last Name
Name
Employee Phone
Entry Field
Entry Field for the Employee Phone
Number
Number
Employee SSN
Entry Field
Entry Field for the Employee SSN
Employee ID
Entry Field
Entry Field for the Employee ID
SID: enrollment.termination.employeeterminationrequest
Screen Snap Shot (See FIG. I- 42 )
[0000]
Element Name
Element Type
Purpose
Mode of Request
Selection Box
Entry Field for the Group Id.
Postmark Date
Entry Field
Entry Field for the Group Name
Date Received
Entry Field
Entry Field for the Date Received
Authorized Contact
Selection Box
Entry Field for the Authorized
Contact
Requested Term
Entry Field
Entry Field for the Request Term
Date
Date
Reason for Term
Selection Box
Select the Reason for Term
Other Reason
Entry Field
Entry Field for the Other Reason
SID: enrollment.termination.employeeprocesstermination
Screen Snap Shot (See FIG. I- 43 )
[0000]
Element Name
Element Type
Purpose
Effective Term Date
Entry Field
Entry Field for the Group Id.
Chance Term Status
Select Box
Select Change Term Status
SID: enrollment.termination.employeeterminationconfirm
Screen Snap Shot (See FIG. I- 44 )
SID: enrollment.termination.dependentsearch
Screen Snap Shot (See FIG. I- 45 )
[0000]
Element Name
Element Type
Purpose
Employee First Name
Entry Field
Entry Field for the Employee
First Name
Employee Last Name
Entry Field
Entry Field for the Employee
Last Name
Employee SSN
Entry Field
Entry Field for the Employee
SSN
Employee Id
Entry Field
Entry Field for the Employee Id
Dependent First Name
Entry Field
Entry Field for the Dependent
First Name
Dependent Last Name
Entry Field
Entry Field for the Dependent
Last Name
Dependent SSN
Entry Field
Entry Field for the Dependent
SSN
Dependent Id
Entry Field
Entry Field for the Dependent Id
SID: enrollment.termination.dependentterminationrequest
Screen Snap Shot (See FIG. I- 46 )
[0000]
Element Name
Element Type
Purpose
Mode of Request
Selection Box
Entry Field for the Group Id.
Postmark Date
Entry Field
Entry Field for the Group Name
Date Received
Entry Field
Entry Field for the Date Received
Authorized Contact
Selection Box
Entry Field for the Authorized
Contact
Requested Term
Entry Field
Entry Field for the Request Term
Date
Date
Reason for Term
Selection Box
Select the Reason for Term
Other Reason
Entry Field
Entry Field for the Other Reason
SID: enrollment.termination.dependentprocesstermination
Screen Snap Shot (See FIG. I- 47 )
[0000]
Element Name
Element Type
Purpose
Effective Term Date
Entry Field
Entry Field for the Term Date.
Change Term Status
Select Box
Select Change Term Status
SID: enrollment.termination.dependentterminationconfirm
Screen Snap Shot (See FIG. I- 48 )
SID: enrollment.reinstatement.groupsearch
Screen Snap Shot (See FIG. I- 49 )
[0000]
Element Name
Element Type
Purpose
Group Id
Entry Field
Enter Group Id
Group Name
Entry Field
Enter Group Name
Phone Number
Entry Field
Enter Phone Number
SID: enrollment.reinstatement.groupreinstatementrequest
Screen Snap Shot (See FIG. I- 50 )
[0000]
Element Name
Element Type
Purpose
Mode of Request
Selection Box
Entry Field for the Group Id.
Postmark Date
Entry Field
Entry Field for the Group Name
Date Received
Entry Field
Entry Field for the Date Received
Authorized Contact
Selection Box
Entry Field for the Authorized
Contact
Reinstatement Date
Entry Field
Entry Field for the Request Rein
Requested
Date
Reason for
Selection Box
Select the Reason for
Reinstatement
Reinstatement
Other Reason
Entry Field
Entry Field for the Other Reason
SID: enrollment.reinstatement.groupprocessreinstatement
Screen Snap Shot (See FIG. I- 51 )
[0000]
Element Name
Element Type
Purpose
Effective Date
Entry Field
Entry Field for the Date.
Change Status
Select Box
Select Change Status
SID: enrollmentreinstatementgroupreinstatementconfirm
Screen Snap Shot (See FIG. I- 52 )
SID: enrollmentreinstatementemployeesearch
Screen Snap Shot (See FIG. I- 53 )
[0000]
Element Name
Element Type
Purpose
Group Name
Entry Field
Entry Field for the Group Name
Group Id
Entry Field
Entry Field for the Group ID
Employee First Name
Entry Field
Entry Field for the Employee
First Name
Employee Last Name
Entry Field
Entry Field for the Employee
Last Name
Employee Phone
Entry Field
Entry Field for the Employee
Number
Phone Number
Employee SSN
Entry Field
Entry Field for the Employee
SSN
Employee ID
Entry Field
Entry Field for the Employee ID
SID: enrollment.reinstatement.employeereinstatementrequest
Screen Snap Shot (See FIG. I- 54 )
[0000]
Element Name
Element Type
Purpose
Mode of Request
Selection Box
Entry Field for the Group Id.
Postmark Date
Entry Field
Entry Field for the Group Name
Date Received
Entry Field
Entry Field for the Date Received
Authorized Contact
Selection Box
Entry Field for the Authorized
Contact
Reinstatement Date
Entry Field
Entry Field for the Request Rein
Requested
Date
Reason for
Selection Box
Select the Reason for
Reinstatement
Reinstatement
Other Reason
Entry Field
Entry Field for the Other Reason
SID: enrollment.reinstatement.employeeprocessreinstatement
Screen Snap Shot (See FIG. I- 55 )
[0000]
Element Name
Element Type
Purpose
Effective Date
Entry Field
Entry Field for the Date.
Change Status
Select Box
Select Change Status
SID: enrollmentreinstatementemployeereinstatementconfirm
Screen Snap Shot
SID: enrollment.reinstatement.dependentsearch
Screen Snap Shot (See FIG. I- 56 )
[0000]
Element Name
Element Type
Purpose
Employee First Name
Entry Field
Entry Field for the Employee
First Name
Employee Last Name
Entry Field
Entry Field for the Employee
Last Name
Employee SSN
Entry Field
Entry Field for the Employee
SSN
Employee Id
Entry Field
Entry Field for the Employee Id
Dependent First Name
Entry Field
Entry Field for the Dependent
First Name
Dependent Last Name
Entry Field
Entry Field for the Dependent
Last Name
Dependent SSN
Entry Field
Entry Field for the Dependent
SSN
Dependent Id
Entry Field
Entry Field for the Dependent Id
SID: enrollmentreinstatement.dependentreinstatementrequest
Screen Snap Shot (See FIG. I- 57 )
[0000]
Element Name
Element Type
Purpose
Mode of Request
Selection Box
Entry Field for the Group Id.
Postmark Date
Entry Field
Entry Field for the Group Name
Date Received
Entry Field
Entry Field for the Date Received
Authorized Contact
Selection Box
Entry Field for the Authorized
Contact
Reinstatement Date
Entry Field
Entry Field for the Request Rein
Requested
Date
Reason for
Selection Box
Select the Reason for
Reinstatement
Reinstatement
Other Reason
Entry Field
Entry Field for the Other Reason
SID: enrollment.reinstatement.dependentprocessreinstatement
Screen Snap Shot (See FIG. I- 58 )
[0000]
Element Name
Element Type
Purpose
Effective Date
Entry Field
Entry Field for the Date.
Change Status
Select Box
Select Change Status
SID: enrollmentreinstatement.dependentreinstatementconfinn
Screen Snap Shot (See FIG. I- 59 )
[1022] 3.1.2. Screen Flow (See FIG. I- 60 )
4. Business Rule Mapping
[1023]
[0000]
Activity
Rules
Term Process (request
The person who requested the term should be the
received from)
designated contact person or agent assigned to
that group. Other persons are not authorized to
initiate the term request.
Term Process
On employer request the term process is initiated.
(Manual)
The term process should check the billing
status and the balance due or refund. If the
group has paid through and there is no
shortage or surplus then this process
should auto initiate the term process. Send
letters the Group, Employee and
dependent. Notify via mail to the GMS
rep if the group size is less than 15 and if
above 15 notify the Sales rep.
If there is a shortage then send a mail to
the finance and put the term status as term
pending. Finance should initiate follow up
for collecting the balance due and sent the
term letter and payment letter. On receipt
of payment term the Group. If the
Payment is not received then retro terms
the group.
If there is refund due to the group the
finance should process the refund and
initiate the term there after.
Note: GMS can process Term up to 30 days
(LEVEL I)
Term beyond 30 days-60 days can be
processed only by lead (LEVEL II)
Term extended beyond 60 days is based on
ultimate authority to a specified user (LEVEL
III AND IV)
Term Process
Automated term process is initiated if the group
(Automated)
does not pay the premium or there is shortage of
premium. Term letter is sent to the group on 32
day of non-receipt of payment and the Group is
given 15-day notice to repay. If the Group does
not pay within 32 + 15 days the finance should
finalize term based on authority.
General Term rules
If the group is termed then all the employees and
dependents for the group are termed. The
COBRA Members associated with the group
should also be termed. The term letter should
be sent to the entire member for the Group
including the COBRA group. EFT and auto
credit card deductions should stop on term.
Term Process
Dependent can be terminated based on various
reason provide for the employee termination.
All term should be effective end of the current
month or if the term is requested for the month
after the current month.
Dependent cannot be termed with past date
beyond 30 days.
Exception:
Death of the dependent. The dependent is termed
the on the day of the death.
Term Rules
Auto initiate Dependent terms if the age of the
dependent is 23 and the dependent other than
spouse or domestic partner are no longer eligible.
Also send the COBRA packet to the dependent if
termed.
Billing Adjustment
Make adjustment to the billing for the termed
dependent in the next billing cycle
Term Process
The person who requested the term should be
(request received
designated contact person. Other person are not
from)
authorized to initiate the term request.
Term Process
On employer request the term process is initiated.
(Manual)
The term process should check the billing
status and the balance due or refund. If the
group has paid through and there is no
shortage or surplus then this process
should auto initiate the term process. Send
letters the Group, Employee and
dependent. Notify via mail to the GMS
rep if the group size is less than 15 and if
above 15 notify the Sales rep.
If there is a shortage then send a mail to
the finance and put the term status as term
pending. Finance should initiate follow up
for collecting the balance due and sent the
term letter and payment letter. On receipt
of payment term the Group. If the
Payment is not received then retro terms
the group.
If there is refund due to the group the
finance should process the refund and
initiate the term there after.
Note: GMS can process Term up to 30 days.
(LEVEL I)
Term beyond 30 days-60 days can be
processed only by lead (LEVEL II)
Term extended beyond 60 days is based on
ultimate authority to a specified user (LEVEL
III AND IV)
Term Process
Automated term process is initiated if the group
(Automated)
does not pay the premium or there is shortage of
premium. Term letter is sent to the group on 32
day of non-receipt of payment and the Group is
given 15-day notice to repay. If the Group does
not pay within 32 + 15 days the finance should
finalize term based on authority.
General Term rules
If the group is termed then all the employees and
dependents for the group are termed. The
COBRA Members associated with the group
should also be termed. The term letter should
be sent to the entire member for the Group
including the COBRA group. EFT and auto
credit card deductions should stop on term.
Term Process
This is to complete the term process where the
term status was term pend. All auto initiated term
process has the term status as term pend. It
requires user intervention to complete the term
process based on authority.
Term Process
Employee can be terminated based on various
reason provide from the employee termination
All term should be effective end of the current
month or if the term is requested for the month
after the current month
Employee cannot be termed with past date beyond
30 days.
Exception:
Death of the employee. The employee is termed
the on the day of the death.
Process Associated
All employee terms should send term letter to the
with term
employee and group. The employee can opt for
COBRA and hence the COBRE enrollment
packet should be sent to the employee
Billing Adjustment
There should be billing adjustment in the
subsequent bill for termed employee
Term Process
Dependent can be terminated based on various
reason provide for the employee termination
All term should be effective end of the current
month or if the term is requested for the month
after the current month.
Dependent cannot be termed with past date
beyond 30 days
Exception:
Death of the dependent. The dependent is termed
the on the day of the death.
Term Rules
Auto initiate Dependent terms if the age of the
dependent is 23 and the dependent other than
spouse or domestic partner are no longer eligible.
Also send the COBRA packet to the dependent if
termed.
Billing Adjustment
Make adjustment to the billing for the termed
dependent in the next billing cycle.
Reinstatement Process
The person who requested the reinstatement
should be the designated contact person. Other
persons are not authorized to initiate the
reinstatement request.
If reinstatement cannot happen then send the
denial letter.
If reinstated notify finance
System should calculate the reinstatement fees.
Finance will reinstate on receipt of payment.
Note When the group is reinstated all the
members associated with the group are also
reinstated.
Including COBRA GROUP.
GMS can reinstate within 30 days. Any period
above this needs authorization.
Reinstatement Process
The person who requested the reinstatement
should be the designated contact person. Other
persons are not authorized to initiate the
reinstatement request.
If reinstatement cannot happen then send the
denial letter.
Note When the Employee is reinstated all the
dependents of the Employee are also reinstated.
Reinstatement Process
The person who requested the reinstatement
should be designated contact person. Other
persons are not authorized to initiate the
reinstatement request.
If reinstatement cannot happen then send the
denial letter.
If reinstated notify finance for reinstatement fees
calculation if applicable.
5. User Role
[1024] The respective level user can terminate or reinstate the dependent, employee or group based on the criteria mention in the following table. The following validations are done with respect to the current date.
[0000]
Dependent Termination
S. No.,
User Role
Condition
1
Level I
Termination date is with in 30 days prior or later
2
Level II
Termination date is within 60 days prior or later
3
Level III,
Termination date is within 90 days prior or later
Level IV
[0000]
Employee Termination
S. No.,
User Role
Condition
1
Level I
Termination date is with in 30 days prior or later
2
Level II
Termination date is within 60 days prior or later
3
Level III
Termination date is within 90 days prior or later
Level IV
[0000]
Group Termination
S. No.,
User Role
Condition
1
Level I
Termination date is with in 30 days prior or later
2
Level II
Termination date is within 60 days prior or later
3
Level III,
Termination date is within 90 days prior or later
Level IV
[0000]
Dependent Reinstatement
S. No.,
User Role
Condition
1
Level I
Termination date is with in 30 days prior or later
2
Level II
Termination date is within 60 days prior or later
3
Level III,
Termination date is within 90 days prior or later
Level IV
[0000]
Employee Reinstatement
S. No.,
User Role
Condition
1
Level I
Termination date is with in 30 days prior or later
2
Level II
Termination date is within 60 days prior or later
3
Level III,
Termination date is within 90 days prior or later
Level IV
[0000]
Group Reinstatement
S. No.,
User Role
Condition
1
Level I
Termination date is with in 30 days prior or later
2
Level II
Termination date is within 60 days prior or later
3
Level III,
Termination date is within 90 days prior or later
Level IV
Benefit Partners Inc
Proceess Specification
Appeals and Grievances
1. Introduction
[1025] 1.1. Purpose
The purpose of this document is to describe the process of Appeals and Grievances. This document identifies how the user interacts with the system, the data to be captured, the business logic to be implemented, and the output of the process.
[1027] 1.2. Business Use Case Specification Reference
[0000]
Business Use
Specification ID
Business Use Case Name
BPI_SCOPE_EN
Enrollment
SCOPE_ADD
Addendum to the Scope Document
[1028] 1.3. Definitions, Acronyms & Abbreviations
[0000]
Term
Explanation
BPI_CAS_FSD_EN
Functional Specification
Document—Enrollment
BPI_CAS_FSD_EN_001
Process Specification—New
Business Enrollment
BPI_CAS_FSD_EN_002
Process Specification—Enrollment
Changes/Add-On
BPI_CAS_FSD_EN_003
Process Specification—COBRA
Enrollment/Changes
BPI_CAS_FSD_EN_004
Process Specification—ROE/OE
BPI_CAS_FSD_EN_005
Process Specification—Termination/
Reinstatement
2. Process Identification
[1029] 2.1. Background
[1030] Any process or transaction that is performed by PacAdvantage is subject to a review process. The rule for such is defined in the PacAdvantage handbook. There are cases when the Customer is not satisfied with some of the decisions made during the administration of the program. When a customer is not satisfied with the decision made they can submit a request for Program Review. Once a decision has been made to grant or deny the request, an Appeal can then be submitted to overturn the decision of the Program Review. Not all decisions are appealable. In any case, all grievances need to be sent to PacAdvantage-Roseville, along with other certain requirements, for making a decision whether to consider the Grievances or to reject them as the case may be.
[1031] PacAdvantage-Roseville makes the decision on the initial requests or “Program Reviews” and forwards the response to the customer. Upon receipt of a second request or “Appeal”, if the decision is appealable, Pac Advantage-Roseville forwards the information to PacAdvantage-SF to make a ruling. (If the decision is not appealable, PacAdvantage-Roseville sends a letter regarding such to the customer.) PacAdvantage-SF then returns a ruling and PacAdvantage-Roseville forwards the response to the customer.
[1032] This entire process needs to be captured and tracked by the system.
[1033] Any transaction within the system has a history. The personnel handling the grievance need to review the history and generate a report regarding the grievance for review.
[1034] 2.2. Process Description
[1035] The objective of the Grievance process is to:
1) Maintain a status for all Grievances received from the customer and follow up with the decision made either by PacAdvantage-Roseville or PacAdvantage-SF.
[1037] The following are the other requirements that will be supported and constraints on the proposed system:
1) The system would track the initial request from open to close. 2) The system would track subsequent requests, if a proper appeal, from re-open to close. 3) Track subsequent requests, if not a proper appeal, for receive dates, remarks and any correspondence. 4) The system would also have a history of all the transactions to get the report for the Nature of Grievance.
[1042] 2.3. Process Flow
[1043] Process for Grievances—First Request (or “Program Review”)
1) Receive the Grievance from Group and/or Member and/or Agent representing the Group and/or Member. 2) Categorize the nature of the Grievance. 3) Review the history and collect all the relevant documents for the Grievance. 4) Make decision to approve/deny the Grievance. 5) Close the Grievance. 6) Send relevant letters. 7) If the Grievance is in favor of the group or the employee, send notification to Finance and or GMS to take necessary action (Reinstate the Group/Member).
[1051] Process for Grievances—Second Request (or “Appeal”)
1) Receive the Grievance from the Group and/or Member and/or Agent representing the Group and/or Member. 2) Categorize the nature of the Grievance. 3) Review the history and collect all the relevant documents for the Grievance. 4) Forward the document with relevant information to PacAdvantage-SF. 5) Follow up with PacAdvantage-SF regarding the decision on the Grievance. 6) On receiving the decision convey the decision to the Group and or employee. 7) Close the Grievance. 8) Send relevant letters. 9) If the Grievance is in favor of the group or the employee send notification to Finance and or GMS to take necessary action (Reinstate the Group/Member).
3. User Interface
[1061] 3.1. User Interface Screens
[1062] 3.1.1. Screen ID's
[0000]
Screen
Corresponding
Screen ID (SID)
Name
HTML File Name
bpi.enrollment.grievance.appellantsearch
Grievance
grievancesearch
Search
bpi.enrollment.grievance.grievancecreate
Grievance
grievancecreate
Create
bpi.enrollment.grievance.grievancemodify
Grievance
grievancemodify
Modify
bpi.enrollment.grievance.grievanceclose
Grievance
grievanceclose
Close
[1063] 3.1.1.1. SID, Element Name, Element Type & Purpose
[0000] SID: bpi.enrollment.grievance.appellantsearch (See FIG. I- 61 )
Element Name
[1064]
[0000]
Element
Element Name
Type
Label
Purpose
Complainant
Text
Complainant
To display text
Type
Type
appellantType
Radio
Complainant
To select the type “Group”
button
Type
or “Member”
Complainant
Text
Complainant
To display text
ID
ID
appellantId
Text Field
Complainant
To enter complainant id
ID
Company
Text
Company
To display text
Name
Name
companyName
Text Field
Company
To enter company name
Name
First Name
Text
First Name
To display text
firstName
Text Field
First Name
To enter first name
Last Name
Text
Last Name
To display text
lastName
Text Field
Last Name
To enter last name
SSN
Text Field
SSN/Tax ID
To enter SSN or Tax ID
Phone Number
Text
Phone Number
To display text
phoneNumber
Text Field
Phone Number
To enter phone number
search
HTML
Search
To perform Search
button
operation
cancel
HTML
Cancel
To reset the all search fields
button
Search Table
HTML
To list the Complainant ID,
Table
Company Name, First
Name, Last Name and
Phone number is
displayed on the screen
[1065] 3.1.1.2. SID, Element Name, Element Type & Purpose
[0000] SID: bpi.enrollment.grievance.grievancecreate (See FIG. I- 62 )
[0000]
Element Name
Element Type
Label
Purpose
Complainant Type
Text
Complainant Type
To display text
Complainant Type
Text
Complainant Type
To display complainant type
dynamically
Complainant ID
Text
Complainant ID
To display text
Complainant ID
Text
Complainant ID
To display complainant type
dynamically
Group Information
HTML Table
Group Information
To display company name,
contact name, address, phone,
effective date, ROE date, status
Postmark Date
Text
Postmark Date
To display text
postMarkDate
Calendar
Postmark Date
To enter the postmark date
Received date
Text
Received date
To display text
receivedDate
Calendar
Received date
To enter the received date
Nature of
Text
Nature of Grievance
To display text
Grievance
natureOfGrievance
List
Nature of Grievance
To list the Nature of Grievance.
Upon selection of the Nature of
Grievance, the corresponding
Grievance Type is displayed on
the screen
Subject of
Text
Subject of Grievance
To display text
Grievance
subjectOfGrievance
List
Subject of Grievance
To list the subject of Grievance
for selection
Urgent
Text
Urgent
To display text
urgent
Checkbox
Urgent
To select the option of having
urgent.
Remarks
Text
Remarks
To display text
remarks
Text Area
Remarks
to enter remarks larger area is
provided
save
HTML button
Save
Submit the data and save in the
database
cancel
HTML button
Cancel
To reset to previous status as
was on loading the page
Screen Validations
[1066]
[0000]
Element Name
Action/Validation Details
Message
Postmark Date
Should default to system date.
Error Dialog Box:
Postmark date can never be a future
“Please choose the correct date. Postmark
date and can be one day older than
date can be a future date.
current date only
Received date
Should default to system date.
Error Dialog Box:
Received date can never be a future
“Please choose the correct date. Received
date and should be equal to OR
date can be a future date.”
greater than current date.
Nature of Grievance
Default Option should be --Choose
Error Dialog Box:
One-- Should list all the types of
“Please choose the nature of grievance_”
Natures of Grievances
Subject of
Default Option should be --Choose
Error Dialog Box:
Grievance
One-- Should list all the types of
“Please choose the subject of grievance_”
subject of Grievances
Remarks
Entry Text Area to enter the
None
remarks for the Grievance. The text
area should have scrollbar if the
content within the text area grows.
Save
Should function On clicking the
Error Dialog Box:
Save Button or pressing the Enter
“The value entered for ‘FIELD NAME’ is
key with cursor on the “Save
incorrect. Please enter the correct value.”
Button”
Note: The “FIELD NAME” name should be
Save the data to the repository with
dynamically picked based on the name of
the status of the Grievance as open
the field for which the error has occurred.
Auto generate the grievance ID
Cancel
Should reset to the status as was on
None
loading the page on clicking the
cancel button
[1067] 3.1.1.3. SID, Element Name, Element Type & Purpose
[0000] bpi.enrollment.grievance.grievancemodify (See FIG. I- 63 )
[0000]
Element Name
Element Type
Label
Purpose
Search by
Text
Search by Complainant
To display text
Complainant
searchType
Radio button
Search by Complainant
To select the option of search
Search by
Text
Search by Grievance
To display text
Grievance
searchType
Radio button
Search by Grievance
To select the option of search
Grievance ID
Text
Grievance ID
To display text
grievanceID
Read only field
Grievance ID
To display Grievance ID. Ability to
search for open Grievances
Complainant ID
Text
Complainant ID
To display text
appellantId
Entry Field
Complainant ID
To enter complainant ID. Ability to
search for open Grievances for the
specific complainant.
search
Button
Search
To search for the Grievance ID or
the Complainant ID (group or
member id) with open grievances
Grievance
HTML Table
Grievance Process Table
List the grievances based on the
Process Table
search criteria.
Process
HTML Button
Process
To show the grievance selected for
further processing
Grievance
HTML Table
Grievance
Table to display Postmark Date,
Received Date, Nature of
Grievance, Subject of Grievance,
Appellant type, Appellant ID,
Grievance Status, Remarks.
Additional
Text
Additional Remarks
To display text
Remarks
additionalRemarks
Entry Field
Additional Remarks
To enter text
Forward for
Text
Forward for Approval
To display text
Approval
forwardForApproval
Check box
Forward for Approval
To check if forwarding for approval
Forward to
Text
Forward to
To display text
forwardedTo
Entry Field
Forward to
if “Forwarded for Approval” is
checked then this field must be
completed. To enter the name of
the person to whom the Grievance
is to be forwarded
Forward Date
Text
Forward Date
To display text
forwardDate
Calendar
Forward Date
If “Forward for Approval” is
checked then this field must be
completed. Enter the forward date
Batch Date
Text
Batch Date
To display text
batchDate
Calendar
Batch Date
To enter batch date
save
HTML button
Save
Save the data and save in the
database
cancel
HTML button
Cancel
To reset to previous status as was on
loading the page
Screen Validations
[1068]
[0000]
Element Name
Action/Validation Details
Message
Grievance
Entry field to enter grievance ID and on
Error Message:
tab should populate the Grievance based
“The grievance ID not available”
on the Grievance id
Complainant
Entry fields to enter Complainant ID
Error Message:
and on tab should populate all the
“Complainant ID not available”
Grievances for the specific appellant.
Search
Search for the Grievance ID or
None
Appellant ID
Grievance Process
The table gets populated based on the
None
Table
search criteria. For Grievance ID the
table shows only one grievance. For
Appellant search the table shows all the
grievances for the specific Appellant.
Process
Process the specific Row in the table
NONE
selected
Grievance
Table to display Postmark Date,
None
Received Date, Nature of Grievance,
Subject of Grievance, Appellant Type,
Appellant ID, Grievance Status,
Remarks.
Additional Remarks
Entry field for additional remarks
None
Forward for
Check box to check if forward or not.
None
Approval
Forward To
If “Forward for Approval” is checked
Error Dialog Box:
then this field must be completed. To
“Please Enter the Forwarded to persons
enter the name of the person to whom
name”
the Grievance is to be forwarded
Forward Date
Allow entering the date or picking up
Error Dialog Box:
from the calendar
“Please Enter the Forwarded Date”
if “Forward for Approval” is checked
then this field must be completed. Enter
the forward date
Batch Date
Allow entering the batch date or picking
None
up from the calendar
Save
Should function On clicking the Save
Error Dialog Box:
Button or pressing the Enter key with
“The value entered for ‘FIELD NAME’ is
cursor on the “Save Button”
incorrect. Please enter the correct
Save the data on clicking the save
value.” Note: The “FIELD NAME” name
button.
should be dynamically picked based on
the name of the field for which the error
has occurred.
Cancel
Reset to the state as was on loading the
None
page
[1069] 3.1.1.4. SID, Element Name, Element Type & Purpose
[0000] SID: bpi.enrollment.grievance.grievanceclose (See FIG. I- 64 )
[0000]
Element Name
Element Type
Label
Purpose
Search by
Text
Search by Complainant
To display text
Complainant
searchType
Radio button
Search by Complainant
To select the option of search
Search by
Text
Search by Grievance
To display text
Grievance
searchType
Radio button
Search by Grievance
To select the option of search
Grievance ID
Text
Grievance ID
To display text
grievanceID
Entry Field
Grievance ID
To enter Grievance ID. Ability to
search for open Grievances
Complainant ID
Text
To display text
complainant ID
Text
Complainant ID
To display Complainant ID. Ability
to search for open Grievances for
the specific complainant.
search
Button
Search
To search for the Grievance ID or
the Complainant ID (group or
member id) with open grievances
Grievance
HTML Table
Grievance Close Table
List the grievances based on the
Close Table
search criteria.
Grievance
HTML Table
Grievance Table
Table to display Postmark Date,
Table
Received Date, Nature of
Grievance, Subject of Grievance,
Appellant Type, Appellant ID,
Grievance Status, Remarks.
Conclusion
Text
Conclusion
To display text
conclusion
List
Conclusion
List the conclusion of appeal as
Approved, Denied, or Cancelled
Reason
Text
Reason
To display text
reason
List
Reason
List the Reason for the conclusion
otherReason
Entry Field
Other Reason
To enter reason not included in
Reason List
Batch Date
Text
Batch Date
To display text
batchDate
Calendar
Batch Date
To enter batch date
save
HTML button
Save
Save the data and save in the
database
Screen Validations
[1070]
[0000]
Element Name
Action/Validation Details
Message
Grievance
Entry field to enter grievance ID
Error Message:
“Grievance ID is required”
Complainant
Entry fields to enter Complainant ID.
Error Message:
“Complainant ID is required”
Search
Search for the Grievance ID or Appellant
None
ID
Grievance Close
The table gets populated based on the
None
Table
search criteria. For Grievance ID the
table shows only one grievance. For
Appellant search the table shows all the
grievances for the specific Appellant.
Close
Process the specific Row in the table
NONE
selected
Conclusion
Default option should be --choose one--.
None
List the conclusion for closing the
grievance as Approved, Denied or
cancelled
Reason
Default option should be --choose one--.
None
List the reasons applicable
Other Reason
If the reason selected is others the enter
None
the other reason
Batch Date
Allow entering the batch date or picking
None
up from the calendar
Submit
Should function On clicking the Submit
Error Dialog Box:
Button or pressing the Enter key with
“The value entered for ‘FIELD NAME’ is
cursor on the “Submit “Button”
incorrect. Please enter the correct
Save the data on clicking the submit
value.”
button.
Note: The “FIELD NAME” name should
be dynamically picked based on the
name of the field for which the error
has occurred.
[1071] 3.1.2. Screen Flow
(See FIG. I- 65 )
4. Business Rule Mapping
[1072]
[0000]
Activity
Rules
Appeals and
Appeals and grievance is the screen that needs to be
grievance
handled by personnel skilled with the operations of the
PacAdvantage and the governing rules.
All appeals are entered and followed up for the outcome of
the appeals. The tum around time for the appeals should be
3 days at the BPI office for entering the record and
gathering the reports and summarizing the history.
Benefit Partners Inc
Process Specification
Association Master
1. Introduction
[1073] 1.1. Purpose
The purpose of this document is to describe the process of Association Master. This document identifies how the user interacts with the system, the data to be captured, the business logic to be implemented, and the output of the process.
[1075] 1.2. Business Use Case Specification Reference
[0000]
Business Use Specification ID
Business Use Case Name
BPI_SCOPE_EN
Enrollment
SCOPE_ADD
Addendum to the Scope Document
BPI_SCOPE_EN_01
Business Use case specification - Group
Enrollment
BPI_SCOPE_EN_03
Business Use case specification - Create
Individual Association
[1076] 1.3. Definitions, Acronyms & Abbreviations
[0000]
Term
Explanation
2. Process Identification
[1077] 2.1. Background
Associations are basically a body of groups/members representing certain types of associations within the State of California. Association Groups and Association Members can participate in the Pac Advantage program similar to small employer groups or members. Associations are classified as Guaranteed, Endorsed, PEO's or Chambers. Each of the associations classified have specific business rules when participating in PacAdvantage program. This document identifies the rules and business governing the association groups and members.
[1079] 2.2. Process Description
The objective of the Association Master is to: 1) Create a master record for the association based on the classification of the association and specify the business rules associated with these classifications. 2) The master record for association includes
General information about the association Contact information Coverage Information Agent information Other information like internal work group, membership status etc.
[1088] 2.3. Process Flow
[1089] Process for Association Master
Create, modify or inactivate an association master is the basic operations that can be performed on the association master. 1) Enter general information about the association. The general information includes
Association Type Association Name Affiliation ID Address Suite City State ZIP
2) Enter contact information. The contact information includes
Salutation First Name Middle Initial Last Name Suffix Contact Phone Contact Fax Email Address
3) Enter coverage information. Coverage information includes
Line of coverage offered Domestic Partner Coverage Rate Type Admin Fees Type (Note: This are captured in Carrier Maintenance Module (Rate Classification) Agent Fees Type (Note: This are captured in Carrier Maintenance Module (Rate Classification) Additional Fees type (Note: This are captured in Carrier Maintenance Module (Rate Classification)
4) Enter other information. Other information includes
Internal Work group Membership status Contract Date Association re qualification period Special Handling
3. User Interface
[1122] 3.1. User Interface Screens
[1123] 3.1.1. Screen ID's
[0000]
Screen ID (SID)
Screen Name
Corresponding HTML File Name
enrollment.association.associationgeneral
Association
/bpi/cas/enrollment/association/associationgeneral/AssociationGeneralInfo.jsp
General Info
enrollment.association.associationcoveraeg
Association
/bpi/cas/enrollment/association/associationcoverage/AssociationCoverageInfo.jsp
Coverage Info
enrollment.association.associationother
Association
/bpi/cas/enrollment/association/associationother/AssociationOtherInfo.jsp
Other Info
enrollment.association.associationconfirm
Association
/bpi/cas/enrollment/association/associationconfirm/AssociationConfirm.jsp
Confirmation
enrollment.association.internalworkgroupsearch
Internal Work
/bpi/cas/enrollment/association/internalworkgroupsearch/InternalWorkGroupSearch.jsp
Group Search
enrollment.association.associationgeneralsearch
Association
/bpi/cas/enrollment/association/associationgeneral/AssociationGeneralSearch.jsp
Search
[1124] 3.1.1.1. SID, Element Name, Element Type & Purpose
SID: enrollment.association.associationgeneral Screen Snap Shot (See FIG. I- 66 )
[0000]
Element
Name
Element Type
Purpose
General
Header Text
To provide content for header
Information
Association
Text
To provide text
name
Association
Entry Field
Enter association name
name
Search
HTMLButton
To show pop up window to search for
the association name for editing the data
Association
Text
To provide text
Type
Association
Drop Down List
List the types of association to select
Type
from
Address
Sub Header
To provide content for sub header
Information
Address
Text
To provide text
Address
Entry field
Enter the address
Suite
Text
To provide text
Suite
Entry field
Enter the suite number
City
Text
To provide text
City
Entry field
Enter the city name
State
Text
To provide text
State
Drop Down List
List the states in USA for selection
ZIP
Text
To provide text
ZIP
Entry field
Enter the ZIP code
Contact
Sub Header for
Text for sub header content
Information
contact
information
Salutation
Text
To provide text
Salutation
Drop Down List
Select the salutation
First Name
Text
To provide text
First name
Entry field
Enter first name
MI
Text
To provide text
MI
Entry field
Enter Middle initial
Last name
Text
To provide text
Last name
Entry field
Enter last name
Suffix
Text
To provide text
Suffix
Drop down List
To select the suffix
Phone
Text
To provide text
Phone
Entry field
Enter phone number
Extension
Text
To provide text
Extension
Entry field
Enter extension number
FAX
Text
To provide text
Fax
Entry Field
Enter the Fax number
Email
Text
To provide text
Email
Entry field
Enter the email address
Continue
HTML Button
Save and continue to the next screen
BPI_CAS_SCR_EN_007_002
Cancel
Reset Button
Reset to the status as was on loading
the page
SID: enrollmentassociation.associationcoverage
[0000]
Element
Element
Name
Type
Purpose
Coverage
Header Text
To provide header for Coverage
Information
Line of
Text
To provide text
coverage
Line of
Check boxes
Check boxes to select multiple line of
Coverage
coverage offered
Domestic
Text
To provide text
Partner
Coverage
Domestic
Radio Boxes
To choose yes or no for domestic partner
Partner
coverage
Coverage
Coverage
Text
To provide text
Rate Type
Coverage
Radio Boxes
To choose if the rate type is blended or non
Rate type
blended
Continue
HTML
Submit button to save the data entered in to
Button
the. repository and navigate to the next
screen BPI_CAS_SCR_EN_007_003
Cancel
HTML reset
To reset to the status as was on loading
Button
the page
SID: enrollment.association.associationother
Screen Snap Shot (See FIG. I- 68 )
[0000]
Element
Name
Element Type
Purpose
Other
Header text
To provide text for the header
Information
Internal work
Text
To provide text
group
Internal work
Entry field
Enter the work group ID
group
Search
HTML Button
Button to search for the work group to be
attached to the association
Membership
Text
To provide text
status
Membership
Drop down list
List the membership status as active, closed or
status
frozen
Contract Date
Entry field (Calendar)
To enter or pick up the association's effective
date
Association re
Entry field (Calendar)
To enter or pick up the association's re
qualification
qualification date
period
Batch billing
Text
To provide text
Batch billing
Radio box
To specify if the association groups and
members are to billed as one batch
Desired
Text
To provide text
Association
name on the
bill
Desired
Radio Box
To specify if the Association name should be on
Association
the bill or not
name on the
bill
Continue
HTML Button
Button to save the information on this page
Clear
HTML reset Button
To reset to the status as was on loading the page
SID: enrollment.association.associationconfirm
Screen Snap Shot (See FIG. I- 69 )
SID: enrollmentassociation.internalworkgroupsearch
Screen Snap Shot (See FIG. 70 )
SID: enrollment.association.associationgeneralsearch
Screen Snap Shot (See FIG. I- 71 )
[1136] 3.1.2. Screen Flow
(See FIG. I- 72 )
4. Business Rule Mapping
[1137]
[0000]
Activity
Rules
Allow
Are eligible to enroll at any time and follow business rules
Employer
for Non-Association Small Employer Groups 2-50.
Groups 2-50
This rule applies for Guaranteed, Endorsed, PEO's and
Chambers
Allow
Must have a membership number and apply after 60 days
Individual
(read as waiting period), but within 120 days, of becoming
Members
a member of the Association or of a group sponsored for
coverage. Effective date of coverage will be within
45 days of receipt of a completed application. Declines
must wait until Open Enrollment. Waives may enroll
within 30 days of losing other employer-sponsored
coverage. The Individual Association member is required
to enroll in all lines of coverage offered by the Association
master. The Individual Association member is not eligible
for COBRA.
This is applicable only to Guaranteed association
Allow
Are eligible to enroll at any time and follow business rules
Employer
for Small Employer Groups 2-50 EXCEPT for the size of
Groups >100
the group for Guaranteed association (Group size can be
un limited for guaranteed association)
Rates
Rate for each association for various rate classification are
defined in the carrier maintenance module (Admin Fees,
Agent Commission, Additional Fees and Rate differential)
Agent
All associations have an Agency and/or Agent(s).
Commissions are applicable to both Group's an
Association Member's. For both, the agent is attached at
the Group/Association member, but can only be chosen
from the particular agents attached to the association.
Agent is selected based on the internal work group
assigned to the agent/agency.
Screen
Small employer group after identifying the association
Rules
would follow the same navigation as applicable for the
for Group
Small employer group. The Group Affiliated to an
association should also have the Membership Number and
the date of membership.
Screen
Individual association would follow the same navigation
Rules for
as applicable to the employee after selecting the
Individual
association and validating that the association is
Association
guaranteed. The only additional things needed are a
members
“Membership Number” and a “Date of Membership”.
Essentially the “Date of Membership” replaces the
employee “Date of Hire” for an employee
Benefit Partners Inc
Process Specification
Carrier Issues
1. Introduction
[1138] 1.1. Purpose
The purpose of this document is to describe the process of Carrier Issues. This document identifies how the user interacts with the system, the data to be captured, the business logic to be implemented, and the output of the process.
[1140] 1.2. Business Use Case Specification Reference
[0000]
Business Use Specification ID
Business Use Case Name
BPI_SCOPE_EN
Enrollment
SCOPE_ADD
Addendum to the Scope Document
[1141] 1.3. Definitions, Acronyms & Abbreviations
[0000]
Term
Explanation
BPI_CAS_FSD_EN
Functional Specification Document -
Enrollment
BPI_CAS_FSD_EN_001
Process Specification - New Business
Enrollment
BPI_CAS_FSD_EN_002
Process Specification - Enrollment Changes/
Add-On
BPI_CAS_FSD_EN_003
Process Specification - COBRA Enrollment/
Changes
BPI_CAS_FSD_EN_004
Process Specification - ROE/OE
BPI_CAS_FSD_EN_005
Process Specification - Termination/
Reinstatement
2. Process Identification
[1142] 2.1. Background
Various issues can arise for a member or group once enrolled with a carrier through PacAdvantage. These issues can vary from not receiving identification cards to incomplete transmission upload by the carrier. As PacAdvantage becomes aware of these issues it is their responsibility to resolve the issue in a timely manner acting as a liaison between the member and the carrier. All issues need to be tracked from start to finish by reason for issue and related carrier for reporting on performance standards as well providing information to PacAdvantage-SF regarding recurring issues within a carrier. Issues can arise at the Group level, for all members on a group and/or all members on a line of coverage. Issues can also arise at the Employee level and/or Dependent level, by member and/or by plan. Within PacAdvantage there are personnel who specifically handle all carrier related issues. Other representatives within PacAdvantage can receive the initial request, document it as needed and forward it to the Carrier Issue personnel. The Carrier Issue personnel contact the carrier to resolve the issue. They mark the documentation as needed and then close the issue and forward the resolutions back to the initial requestor (Originator). The Originator informs the member/group of resolution.
[1146] 2.2. Process Description
The objective of the Carrier Issues process is to:
1) Maintain a status for all Carrier Issues received from the customer and follow up with the carrier for resolution and inform the customer of resolution.
The following are the other requirements that will be supported and constraints on the proposed system:
1) The system would track the initial request from open to close. 2) The system would track both the reported issue and the actual issue. 3) The system would track the final resolution. 4) The system would also have a history of all the transactions to get the report for the Reported Issue.
[1154] 2.3. Process Flow
[1155] Process for Carrier Issues
1) Representative is notified of the issue by the customer and cannot resolve the issue alone. 2) Representative initiates a request either from the Group level, Employee level, or Dependent level. 3) The representative categorizes the reported issue and provides any supporting documentation. 4) The issue is marked as “Open” for the Carrier Issue personnel to handle. 5) The Carrier Issue personnel contact the carrier. 6) The Carrier Issue personnel provide the carrier with necessary information to resolve the issue. (i.e. re-transmission, e-mail of information) 7) The Carrier Issue personnel mark the issue as “Closed” and inform the Originator. 8) The originator follows-up with the member.
3. User Interface
[1164] 3.1. User Interface Screens
[1165] 3.1.1. Screen ID's
<List SID and the screen name and Corresponding HTML file for the screen.
[0000]
Corresponding
Screen ID (SID)
Screen Name
HTML File Name
bpi.enrollment.carrierissue.carrierissuesearch
Carrier Issue Search
carrierissuesearch
bpi.enrollment.carrierissue.carrierissuecreate
Carrier Issue
carrierissuecreate
Create
bpi.enrollment.carrierissue.carrierissuemodify
Carrier Issue
carrierissuemodify
Modify
bpi.enrollment.carrierissue.carrierissueclose
Carrier Issue
carrierissueclose
Close
[1167] 3.1.1.1. SID, Element Name, Element Type & Purpose
SID: bpi.enrollment.carrierissue.carrierissuesearch (See FIG. I- 73 )
[0000]
Element
Element Name
Type
Label
Purpose
Customer Type
Text
Customer
To display text
Type
clientType
Radio
Customer
To select the type
button
Type
“Group” or “Member”
Customer ID
Text
Customer ID
To display text
clientId
Text Field
Customer ID
To enter complainant id
Company
Text
Company
To display text
Name
Name
companyName
Text Field
Company
To enter company name
Name
First Name
Text
First Name
To display text
firstName
Text Field
First Name
To enter first name
Last Name
Text
Last Name
To display text
lastName
Text Field
Last Name
To enter last name
SSN
Text Field
SSN/Tax ID
To enter SSN or Tax ID
SSN
Text Field
SSN/Tax ID
To enter SSN or Tax ID
Phone Number
Text
Phone
To display text
Number
phoneNumber
Text Field
Phone
To enter phone number
Number
search
HTML
Search
To perform Search operation
button
cancel
HTML
Cancel
To reset the all search fields
button
Search Table
HTML
To list the Complainant ID,
Table
Company Name, First Name,
Last Name and Phone number
is displayed on the screen
[1169] 3.1.1.2. SID, Element Name, Element Type & Purpose
SID: bpi.enrollment.carrierissue.carrierissuecreate (See FIG. I- 74 )
[0000]
Element Name
Element Type
Purpose
Received date
Text
To display text
Received date
Calendar
To enter the received date
Reported Issue
Text
To display text
Reported Issue
List
To list the Reported Issue
Group
Entry Field
To enter Group ID if Client Type is Group. Ability to
search for Group, upon selection or entry of the Group,
the group's general information is displayed (Company
Name, Contact Name, Address, Phone, Effective Date,
ROE Date, Status)
Member
Entry Field
To enter Member ID if Client Type is Member. Ability
to search for Member, upon selection or entry of the
member ID, the member's general information is
displayed (Name, Address, Phone, Effective Date, ROE
Date, Status, Benefit Level, Coverage Choice)
Remarks
Text
To display text
Remarks
Entry Field
To enter remarks
Submit
HTML button
Submit the data and save in the database
Cancel
HTML button
To reset to previous status as was on loading the page
Cancel
HTML button
To reset to previous status as was on loading the page
[1171] Screen Validations
[0000]
Element Name
Action/Validation Details
Message
Received date
Should default to system date.
Error Dialog Box:
Received date can never be a future
“Please choose the correct date.
date.
Received date can be a future date.”
Reported Issue
Default Option should be --Choose
Error Dialog Box:
One-- Should list all the types of
“Please choose the reported issue.”
Reported Issues
Client Type
Option to choose Group or member
None
with radio button group.
Client
Entry field to enter the group ID or
None
member ID based on the Client type
selected. Based on the Client selected
Display the Group or member
information in the HTML table.
Search
Pop up window to search for the
None
Group or Member based on the Client
type selected.
Group
HTML Table to display the Group
None
Information
Member
HTML Table to display member
None
information
Remarks
Entry Text Area to enter the remarks
None
for the Carrier Issue. The text area
should have scrollbar if the content
within the text area grows.
Submit
Should function On clicking the
Error Dialog Box:
Submit Button or pressing the Enter
“The value entered for ‘FIELD NAME’
key with cursor on the “Submit
is incorrect. Please enter the correct
Button”
value.”
Save the data to the repository with
Note: The “FIELD NAME” name
the status of the Carrier Issue as open.
should be dynamically picked
Auto generate the Carrier Issue ID
based on the name of the field for
which the error has occurred.
Cancel
Should reset to the status as was on
None
loading the page on clicking the
cancel button
[1172] 3.1.1.3. SID, Element Name, Element Type & Purpose
SID: bpi.emollment.carrierissue.carrierissuemodify (See FIG. I- 75 )
[0000]
Element Name
Element Type
Purpose
Carrier Issue ID
Text
To display text
Carrier Issue ID
Entry Field
To enter Carrier Issue ID. Ability to search for open
Carrier Issues
Client
Text
To display text
Client
Entry Field
To enter client ID. Ability to search for open Issues for
the specific client
Search
Pop Up window
To search for the Carrier Issue ID or the Client ID
(group or member id) with open issues
Carrier Issue Process
HTML Table
List the issues based on the search criteria
Table
Process
HTML Button
To show the issue selected for further processing
Carrier Issue
HTML Table
Table to display Received Date, Reported Issue, Client
Type, Client ID, Issue Status, Remarks.
Additional Remarks
Text
To display text
Additional Remarks
Entry Field
To enter text
Notify Carrier
Text
To display text
Notify Carrier
Radio Button
To check if notifying to carrier
Mode of Notification
Text
To display text
Mode of Notification
List Box
If “Notify Carrier” is checked then this field must be
completed. To enter the mode of notification
Date Notified
Text
To display text
Date Notified
Calendar
If “Notify Carrier” is checked then this field must be
completed. Enter the notified date
Batch Date
Text
To display text
Batch Date
Calendar
To enter batch date
Submit
HTML button
Submit the data and save in the database
Cancel
HTML button
To reset to previous status as was on loading the page
[1174] Screen Validations
[0000]
Element Name
Action/Validation Details
Message
Carrier Issue
Entry field to enter Carrier Issue ID
Error Message:
and on tab should populate the Carrier
“Carrier Issue ID is required”
Issue based on the Carrier Issue id
Client
Entry fields to enter Client ID and on
Error Message:
tab should populate all the Carrier
“Client ID is required”
issues for the specific Client.
Search
search for the Carrier Issue ID or
None
Client ID
Carrier Issue
The table gets populated based on the
None
Process Table
search criteria. For Carrier Issue ID
the table shows only one Carrier
Issue. For Client search the table
shows all the Carrier Issues for the
specific Client
Process
Process the specific Row in the table
NONE
selected
Carrier Issue
Table to display Received Date,
None
Reported Issue, Client Type, Client
ID, Issue Status, Remarks.
Additional Remarks
Entry field for additional remarks
None
Notify Carrier
Radio button to select if notify or not
None
Mode of
If “Notify Carrier” is yes then this
Error Dialog Box:
Notification
field must be completed. To enter the
“Please Enter the Mode of
Mode of Notification for whom the
Notification”
Issue is to be forwarded
Date Notified
Allow entering the date or picking up
Error Dialog Box:
from the calendar
“Please Enter the Notified Date”
If “Notify Carrier” is yes then this
field must be completed. Enter the
notified date
Batch Date
Allow entering the batch date or
None
picking up from the calendar
Submit
Should function On clicking the
Error Dialog Box:
Submit Button or pressing the Enter
“The value entered for ‘FIELD NAME’
key with cursor on the “Submit
is incorrect. Please enter the correct
Button”
value.”
Save the data on clicking the submit
Note: The “FIELD NAME” name
button. If the Mode of Notification is
should be dynamically picked
Email, then open new message with
based on the name of the field for
appropriate information. If Mode of
which the error has occurred.
Notification is Fax, then enter
appropriate information for fax.
Cancel
Reset to the state as was on loading
None
the page
[1175] 3.1.1.4. SID, Element Name, Element Type & Purpose
SID: bpi.enrollment.carrierissue.carrierissueclose (See FIG. I- 76 )
[0000]
Element Name
Element Type
Label
Purpose
Search by
Text
Search by Customer
To display text
Customer
searchType
Radio button
Search by Customer
To select the option of search
Search by
Text
Search by Carrier
To display text
Carrier Issue
Issue
searchType
Radio button
Search by Carrier
To select the option of search
Issue
Carrier Issue ID
Text
Carrier Issue ID
To display text
carrierIssueId
Entry Field
Carrier Issue ID
To enter Carrier Issue ID. Ability to search
for open Carrier Issue
Customer ID
Text
To display text
customerId
Text Field
Customer ID
To display Customer ID. Ability to search
for open Carrier Issue for the specific
Customer
search
Button
Search
To search for the Carrier Issue ID or the
Customer ID (group or member id) with
open carrier issues
Carrier Issue
HTML Table
Carrier Issue Close
List the carrier issue based on the search
Close Table
Table
criteria.
Carrier Issue
HTML Table
Carrier Issue Table
Table to display Received Date, Reported
Table
Issue, Client Type, Client ID, Issue Status,
Remarks.
Actual Issue
Text
To display text
Actual Issue
Actual Issue
List
List the Actual Issue
Actual Issue
Retransmission
Text
Retransmission
To display text
Retransmission
Radio button
Retransmission
Select if retransmission needed or not
Resolution
Text
Resolution
To display text
Resolution
List
Resolution
List the Resolution of Issue as Verbally
Updated; Retransmitted, etc.
Resolution
Text
Resolution
To display text
Comments
Comments
Resolution
Entry Field
Resolution
To enter text
Comments
Comments
Date Carrier
Text
Date Carrier
To display text
Resolved
Resolved
Date Carrier
Calendar
Date Carrier
To enter date Carrier resolved
Resolved
Resolved
Batch Date
Text
Batch Date
To display text
Batch Date
Calendar
Batch Date
To enter batch date
Notify
Text
Notify Originator
To display text
Originator
Notify
Radio Button
Notify Originator
To select if notifying to Originator
Originator
save
HTML button
Save
Submit the data and save in the database
[1177] Screen Validations
[0000]
Element Name
Action/Validation Details
Message
Carrier Issue
Entry field to enter Carrier Issue ID
Error Message:
and on tab should populate the Carrier
“Carrier Issue ID is required”
Issue based on the Carrier Issue id
Customer
Entry fields to enter Client ID and on
Error Message:
tab should populate all the Carrier
“Customer ID is required”
Issues for the specific Client.
Search
search for the Carrier Issue ID or
None
Client ID
Carrier Issue
The table gets populated based on the
None
Process Table
search criteria. For Carrier Issue ID
the table shows only one Carrier
Issue. For Client search the table
shows all the Carrier Issues for the
specific Client.
Close
Close the specific Row in the table
None
selected
Carrier Issue
Table to display Received Date,
None
Reported Issue, Client Type, Client
ID, Issue Status, Remarks.
Actual Issue
Default option should be the same as
reported issue. List all issues.
Retransmission
Radio button to select if retransmit or
None
not
Resolution
Default option should be --choose
one--. List the resolutions for closing
the issue as Updated, Denied or
cancelled
Resolution
Entry field for additional comments
None
Comments
Date Carrier
Allow entering the date or picking up
None
Resolved
from the calendar
If “Notify Carrier” is yes then this
field must be completed. Enter the
notified date
Batch Date
Allow entering the batch date or
None
picking up from the calendar
Notify Originator
Radio button to select if notify or not.
If yes send pre-formatted email to
Originator.
Submit
Should function On clicking the
Error Dialog Box:
Submit Button or pressing the Enter
“The value entered for ‘FIELD NAME’
key with cursor on the “Submit
is incorrect. Please enter the correct
Button”
value.”
Save the data on clicking the submit
Note: The “FIELD NAME” name
button. If the Mode of Notification is
should be dynamically picked
Email, then open new message with
based on the name of the field for
appropriate information. If Mode of
which the error has occurred.
Notification is Fax, then enter
appropriate information for fax.
Cancel
Reset to the state as was on loading
None
the page
[1178] 3.1.2. Screen Flow
(See FIG. I- 77 )
4. Business Rule Mapping
[1179]
[0000]
Activity
Rules
Carrier Issues
Carrier Issue is the screen that needs to be handled by
personnel skilled with the operations of the
PacAdvantage and the coordination of data with the
Carriers.
All issues are entered and followed up for the resolution
of the issue.
Benefit Partners
Process Specification
Billing
1. Introduction
[1180] 1.1. Purpose
The purpose of this document is to describe the process of Billing. This document identifies how the user interacts with the system, the data to be captured, the business logic to be implemented, and the output of the process.
[1182] 1.2. Business Use Case Specification Reference
[0000]
Business Use Specification ID
Business Use Case Name
BPI_SCOPE_FI_001
Finance - Business use case
Specification - Billing
[1183] 1.3. Definitions, Acronyms & Abbreviations
[0000]
Term
Explanation
2. Process Identification
[1184] 2.1. Background
Billing is the process of creating the invoice for the Customers enrolled in the PacAdvantage program. The Invoice is on broad base classified into two—First Time Invoice (invoice to the group/member that has enrolled as new business) and Running invoice or periodic invoice (To the existing Group/Members).
[1186] 2.2. Process Description
The objective of the Billing process is to:
1) Generate first time invoice to the groups/members who have enrolled as new business. The invoice should get all the information about the group/member prior to invoicing. Generation of first time invoice is an automated process and should be triggered on completion of group/member enrollment. 2) Generate running invoice or periodic invoice to the existing groups/members. All the information about the existing group/members and their real time transaction details are required to invoice correctly.
This billing sub module also needs to have a feature to incorporate the following.
Suppress periodic Bill for a specific Group/Member or collective group and members Preview invoice prior to creation of actual invoice. Suppress late fee for a specific Group/Member or collective group and members Calculate Reinstatement Fee for a specific Group/Member or collective group and members Include feature to add dynamic content on the bills sent to the for a specific Group/Member or collective groups and members Calculate additional fee for Credit card transaction if applicable. Calculate adjustment when there is retrospective change in Benefit Level (for the Carrier Selected) for group/member and make adjustments in the subsequent bill. Calculate adjustment if the group/members have termed. Generate manual invoice and preview invoices before generating them. All billing transactions would be period specific (i.e. the bills would be associated with the month of coverage). Invoices would be run only on a monthly basis, whatever is the billing frequency. For example if the billing frequency opted is quarterly. The excess amount would be adjusted as credits in the subsequent month's invoices. Invoice view/preview prior to generation of invoice needs to be provided in the Enrollment module.
[1202] 2.3. Process Flow
[1203] Process for Billing—First Time Invoice
1) Enrollment is completed for the new business prior to generation of First Time Invoice. 2) All information relevant for billing (Generation of Invoice is gathered) These information are
Group ID Group Billing Address Billing information for the group like billing frequency, mode of payment and relevant information for mode of payment like EFT or Credit Card. Employees and Dependents information Member count Employer Contribution Employee Contribution Raw Rate for Each of the Benefit Level for the specific Carrier selected by the employee (for specific Age bracket, Service Area, Coverage Choice with effective date) Rate differential based on member count (Group size) with effective date Admin fees for the specific group type with effective date. Agent commission that is defined in the Agent Info tab for the group if defined. Otherwise the default agent commission specified in the Carrier Maintenance Module (Agent Commission Fees) with effective date. Additional fees if any for the specific group type with effective date.
[1218] Process for Billing—Running Invoice (Periodic Invoice)
1) Monthly or periodic invoice is sent to the existing group/members based on the Frequency selected by the group/member and the mode of communication preferred. 2) Existing billing also gathers all information relevant for billing. 3) In addition to this it also needs the previous invoice history to calculate the additional fees, late fees, reinstatement fees or as applicable. 4) The running invoice generated is for the coverage period following the previous invoice period. I.e if the previous invoice was generated in the month of Jan. 5 2002 and for the coverage period February 2002, The invoice generate on Feb. 5 2001 would be for the coverage period March 2002, 5) Billing should also calculate the Fees required for Credit Card transaction if applicable. 6) Adjustment for Add On employee/dependent or member. 7) Adjustment for Termed employee/dependent or member. 8) Reinstatement fees Termed Group, employee/dependent or member are reinstated. 9) Invoice once created by the system cannot be cancelled. An invoice is considered closed only if the invoice has been reconciled. Hence all open invoices should be considered for late fee calculation.
3. User Interface
[1229] 3.1. User Interface Screens
[1230] 3.1.1. Suppress Batch Billing
[1231] 3.1.1.1. Screen Snapshot (See FIG. J- 1 )
[1232] 3.1.1.2. Element Name, Element Type & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Bill Period
Option Box
Bill Period
Bill period for which batch billing is suppressed
Selected
Display Text
Selected Groups
Displays count of groups selected out of total
Groups
groups
Filter
Group Id
Text Box
Group Id
To filter groups based on group id
Group Name
Text Box
Group Name
To filter groups based on group name
Group Type
Option Box
Group Type
To filter groups based on group type
Group Size
Text Box
Group Size
To filter groups based on group size
ROE Date
Text Box
ROE Date - To
To filter groups based on ROE date of groups
Range
Effective Date
Text Box
Effective Date -
To filter groups based on effective date of groups
Range
To
Rate Type
Option Box
Rate Type
To filter groups based on rate type
View
Option Box
View
To filter groups based on whether batch billing is
suppressed or not
Filter
Command
Filter
Refreshes group selection table based on the filter
entered
Clear Filter
Command
Clear Filter
Clears the filter and displays all groups in the
group selection table
Groups
Selection
For selecting groups for export. Options for
Selection
Table
selection all groups, all groups in a page,
deselecting all and selection inversion are
available to the user.
New
Command
New
Clears the screen
Save
Command
Save
Saves the suppressed groups information to the
database
[1233] 3.1.1.3. Screen Validations.
[0000]
Element
Action/Validation
Name
Details
Message
Bill Period
Check to see that
“Please enter a valid billing period”
billing period is not
null
[1234] 3.1.2. Group Auto Bill Suppressing
[1235] 3.1.2.1. Screen Snapshot (See FIG. J- 2 )
[1236] 3.1.2.2. Element Name, Element Type & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Run Id
Display Text
Import Id
Displays unique system
generated id for the bill
process run
Bill Period
Option Box
Bill Period
Period for which batch billing
is run
Run By
Display Text
Run By
Displays id of user who
initiated the process
New
Command
New
Clears the screen
Process
Command
Process
Starts the batch billing process
View Status
Command
View Status
View status of batch
billing process
[1237] 3.1.2.3. Screen Validations
[0000]
Element
Name
Action/Validation Details
Message
Bill
Check to see that billing
“Please enter a valid billing period”
Period
period is not null
[1238] 3.1.3. Manual Bill
[1239] 3.1.3.1. Screen Snapshot (See FIG. J- 3 )
[1240] 3.1.3.2 Element Name, Element Tyne & Purpose
[0000]
Element
Name
Element Type
Label
Purpose
Bill Details
Bill #
Display Text
Bill #
Displays unique system generated bill #
Bill Date
Display Text
Bill Date
Displays bill date
Bill Period
Option Box
Bill Period
Period for which group is billed
Due Date
Display Text
Due Date
Displays date on which bill is due
Status
Display Text
Status
Displays the status of bill: Open or Reconciled
Reconciled
Display Text
Reconciled
Displays date on which bill was reconciled
Date
Date
Group Information
Group Id
Text Box
Group Id
Id of the group being billed
Group Type
Display Text
Group Type
Displays group type
Group name
Display Text
Group Name
Displays group name
Association
Display Text
Association
Displays name of association if group is enrolled
Name
Name
through one
Status
Display Text
Status
Displays status of group
Rate Type
Display Text
Rate Type
Displays the rate type for the group: blended or
non-blended
Billing Summary
Prior Bill
Display Text
Prior period
Displays prior period bill amount for the group
Amount
billed amount
Adjustments
Display Text
Adjustments
Displays adjustments total for the group
since prior
period
Payments
Display Text
Payments
Displays payments made by the group from
received
previous bill
Current Bill
Display Text
Current bill
Displays current bill amount
amount
Total Due
Display Text
Total due
Displays total due from the group
Employer Level Adjustments
Adjustment
Option Box
Adjustment
Type of adjustment
Type
Type
Amount
Text Box
Amount
Adjustment Amount
Period
Option Box
Period
Period for which adjustment entry is posted
Adjustments
Entry Table
Entry Table
Employee Level Adjustments
Employee
Display
Employee
Displays name of employee
Name
Column
Name
Period
Display
Period
Displays adjustment period
Column
Plan Name
Display
Plan Name
Displays the name of the plan
Column
Plan Type
Display
Plan Type
Displays plan type
Column
Coverage
Display
Coverage Type
Displays coverage option selected by the employee
Type
Column
# Members
Display
# Members
Displays member count under the employee's
Column
coverage
Premium
Display
Premium
Displays premium
Column
Admin Fee
Display
Admin Fee
Displays admin fee
Column
Agent Fee
Display
Agent Fee
Displays agent fee
Column
Total
Display
Agent Fee
Displays total premium
Premium
Column
Employee Level Detail
Employee
Display
Employee
Displays name of employee
Name
Column
Name
Plan Name
Display
Plan Name
Displays the name of the plan
Column
Plan Type
Display
Plan Type
Displays plan type
Column
Coverage
Display
Coverage Type
Displays coverage option selected by the employee
Type
Column
# Members
Display
# Members
Displays member count under the employee's
Column
coverage
Premium
Display
Premium
Displays premium
Column
Admin Fee
Display
Admin Fee
Displays admin fee
Column
Agent Fee
Display
Agent Fee
Displays agent fee
Column
Total
Display
Total Premium
Displays total premium
Premium
Column
Bill Summary
Medical
Display Text
Subtotal -
Displays medical premium subtotal
Premium
Medical
Premium
Dental
Display Text
Subtotal -
Displays dental premium subtotal
Premium
Dental
Premium
Vision
Display Text
Subtotal -
Displays vision premium subtotal
Premium
Vision
Premium
CAM
Display Text
Subtotal -
Displays CAM premium subtotal
Premium
CAM Premium
Admin
Display Text
Administration
Displays total of member level admin fee
Member Fee
Member Fee
Agent
Display Text
Agent Member
Displays total of member level agent fee
Member Fee
Fee
Admin Flat
Display Text
Administration
Displays group level admin flat fee
Fee
Flat fee
Agent Flat
Display Text
Agent Flat Fee
Displays group level agent flat fee
Fee
Current Due
Display Text
Total Due
Displays current bill amount
Current Period
Past Due
Display Text
Add Past
Displays amount due from previous bill
Amount Due
Total due
Display Text
Total Due
Displays total due from the group
New
Command
New
Clears the screen
Create
Command
Create
Creates the bill
[1241] 3.1.3.3. Screen Validations
[0000]
Element
Name
Action/Validation Details
Message
Bill Period
Check to see if bill period is not null
“Please enter
and is valid
a valid bill period”
Group Id
Check to see if group id is not null
“Please enter a
and is valid
valid group id”
Adjustment
Check to see that the value for the
“Please enter a valid
Type
filed is not null and is valid
adjustment type”
Amount
Check to see that the value for the
“Please enter a valid
filed is not null and is valid
adjustment amount”
Period
Check to see that the value for the
“Please enter a valid
filed is not null and is valid
adjustment period”
[1242] 3.1.4. Billing Adjustments
[1243] 3.1.4.1. Screen Snapshot (See FIG. J- 4 )
[1244] 3.1.4.2. Element Name, Element Type & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Adjustment Id
Display Text
Adjustment Id
Displays unique system generated id for the
adjustment
Adjustment
Text Box
Adjustment Date
Adjustment Date
Date
Status
Display Text
Status
Status of the adjustment: Open or Reconciled
Group Id
Text Box
Group Id
Id of group for which adjustment entry is made
Group Type
Display Text
Group Type
Displays group type
Group Name
Display Text
Group Name
Displays group name
Association
Display Text
Association
Displays name of association if group is enrolled
Name
Name
through one
Group Status
Display Text
Group Status
Displays status of group
Adjustment
Option Box
Adjustment Type
Type of adjustment
Type
Amount
Text Box
Amount
Adjustment Amount
Period
Option Box
Period
Period for which adjustment entry is posted
New
Command
New
Clears screen for a new adjustment entry
Save
Command
Save
Saves the adjustment entry to the database
Search
Command
Search
Provides search functionality for adjustments
[1245] 3.1.4.3. Screen Validations
[0000]
Element Name
Action/Validation Details
Message
Group Id
Check to see that the value for the
“Please enter a
filed is not null and is valid
valid group id”
Adjustment
Check to see that the value for the
“Please enter a valid
Type
filed is not null and is valid
adjustment type”
Amount
Check to see that the value for the
“Please enter a valid
filed is not null and is valid
adjustment amount”
Period
Check to see that the value for the
“Please enter a valid
filed is not null and is valid
adjustment period”
[1246] 3.2. Interface Flow
N/A
4. Business Rule Mapping
[1248]
[0000]
Activity
Rules
I - First Time Invoice
Blended
For Small Employer Group
(New Business) Note: All new business falls under blended rate
only
1.
Check All the member for Small Employer Group
2.
Check the Employee Raw Rate for the Specific Line of Coverage for the (Carrier
Selected) Benefit Level.
3.
Apply formula on the entire employee for all the line of coverage provided by the group
for the (Carrier Selected) Benefit Level (Age Bracket, Coverage Choice and Service Area
for the specific Employee). Refer Formula
4.
The Admin Fees, Agent Commission and Rare Differential Factor are governed by the
effective date. Apply the effective date for these fees with the Effective date for the Group
in deriving the Blended rate for the employees and the total amount payable by the Group.
However the Agent commission is based on the one provided at the group level in the
Agent Information Tab. It overrides the fee provided in the carrier maintenance agent
commission fees.
5.
Check if the initial payment made by the group equals the Total amount as derived above.
If not then check the difference. Allow for Reconciliation up to $2 without and authorized
intervention. For amount between $50-$3 Allow reconciliation based on security. For
amount above $50 allow reconciliation based on ultimate authority. (This rule governs if
the group can be enrolled or not. Hence there should be an invoice preview that identifies
the Cash received and the total amount due for the new business) This should be viewable
by all.
6.
The rate should be picked up based on the rules specified below:
Check the Effective date for the Group (initial enrollment date)
Check the rate from the rate table whose effective date is latest but less than the effective
date of the Group. (E.g.) Group Effective date 3/1/01. Rate effective dates 1/1/01 and
7/1/01. In this example since the group effective date is 3/1/01 the Rate picked should be
1/1/01 effective date rate.
7.
Show the Employer Contribution and the Employee Deduction in the invoice summary.
Billing Address should be picked up based on the billing address provided by the group. If
billing address is not provided, then business address should be considered for billing.
Also check the mode of communication. If the group prefers to be mailed emailed or
faxed and accordingly transmit the invoice. Refer Sample Invoice 1 for the Small
Employer Group (New Business)
Note: Small employer may bring in the COBRA members. Bill the COBRA members
separately or along with the Group based on the decision made for billing the COBRA Group.
If the COBRA members are billed separately. Generate a separate invoice for the each
subscriber COBRA members. Refer Rule for COBRA Member Invoice
However the bill for the COBRA members can be sent to the primary group if that option
is selected.
All COBRA Invoices whether billed to the primary group or the COBRA Group should
have a separate invoice for all the COBRA groups.
For COBRA Members
(New Business) Note: All new business falls under blended rate
only even for COBRA members brought by new business.
1.
Check the entire subscriber COBRA member for Small Employer Group (primary Group).
2.
Check Coverage Choice for the Subscriber member for each lines of coverage and also
note that these line of coverage are selected by the Primary group.
3.
Check what are the line of coverage picked up be each of the members including the
subscriber member and their dependent.
Note: The rate for the COBRA member should be based on the following rule.
Identify the subscriber member line of coverage selected. The age, service area and the
coverage choice provided by the subscriber member is the governing rate.
If the subscriber does not select the line of coverage that the dependent member have
selected. Check if the dependent member have relation ship as spouse or child/children. If
the Relationship is spouse then the Spouse Age should be the deciding factor for the rate
and the coverage choice opted.
If the relationship is child/children then the eldest dependent member should be the
deciding factor for the rate based on the Age.
Note however in all the above cases the Service Area is governed by the Service area of the
Subscriber COBRA member.
Note: If the Primary COBRA member is a child they have their own Group ID and their own
line of coverage and benefit level.
For Individual Association
(New Business) Note: All new business falls under blended rate
Member
even for the individual association member.
1.
Individual association member can have dependent attached to the member.
2.
The rate for the individual association member is governed by the rate applicable for the
Guaranteed association based on the effective date for the Association.
3.
The individual members can have the same line of coverage as defined by the association.
4.
The Admin Fee, Agent Commission, Additional fees and rate differential factor is as
applicable for the Association with the effective date.
5.
The calculation formula is the same as applicable for the employee of Small employer
group.
6.
The dependents for the individual association members are governed by what has been
selected by the subscriber individual association member.
Small employer Group
New Business) Note: All new business falls under blended rate
affiliated to association
even for the Small employer group affiliated to an association.
1.
Small employer groups affiliated with an association have the same rules as applicable
to the Small employer group with exception for the rate.
2.
The Admin fees, Agent commission, additional fees and Differential factor for the small
employer groups affiliated with an association are as defined for the Association with
effective date for the Association.
3.
However the Agent commission is based on the one provided at the group level in the
Agent Information Tab. It overrides the fee provided in the carrier maintenance agent
commission fees
II - First Time Invoice Formula
Blended for Small Employer Group
Blended Rate = (Raw Rate * Differential Factor)/(1 − Agent Commission % − Admin Fee %)
Example
The formula for the premium calculation for invoice Blended is as follows (Blended)
a)
Raw Rate
b)
Agent Commission
c)
Admin fee
d)
Additional Fees
e)
Differential factor
The total amount billed to group should include all the Rates after applying this formula for
all the employees/members and their line of coverage.
III - First Time Invoice Formula
Blended for COBRA Members
Example
The formula for the premium calculation for the invoice Blended for Cal COBRA is as
follows:
Cal Cobra Total Premium = Blended Rate * (1 + Additional Fees %)
The total amount billed to COBRA Subscriber member should include all the Rates after
applying this formula for all the members and their line of coverage.
IV - Running Invoice
Blended
1.
For Running invoice all that is applicable for first time invoice is applicable. In addition to
that the running invoice has the following as well:
2.
Late fee if applicable: Late fee charges are 5% on the Amount due in the prior invoices.
The late fee calculation rule is as follows:
Due Date:
Postmark date:
Received date:
If the post mark date for cash receipt is available it should fall on or before due date.
If postmark date is not available then if should check 5 calendar days backward from the
date received and see if it falls within the due date.
If the amount is received within the due date as per the above rules and is short late fee is
still applied for the shortage of premium.
If the above two conditions are not satisfied then late fee is charged for the Group or
member.
Note: Late fee is charged on the prior month's current premium
(e.g.) Due date is l st of every month or the first business day of the month. Whichever is
applicable. For example 2/1/01
Date payment received: 2/1/01 No late fee
Date payment received is 2/2/01 and post marked 1/31/01 No late fee
Date payment received is 2/3/01 and post marked 2/2/01 late fee applicable
Date payment received is 2/6/01 and postmarked date not available. Look 5 days behind for
the date for receipt, I.e 2/1/01 hence no late fees
Date payment received is 2/8/01 and postmarked date not available. Look 5 days behind for
the date for receipt. I.e 2/3/01 hence late fees applicable.
3.
Balance forward if applicable: Balance forward is the amount balance from the previous
invoice or shortage of premium.
4.
Billing Adjustment: Billing adjustments can have various categories: Note The adjustment
can be positive or negative based on the coverage period.
Employee Coverage Choice Change
Employee/Dependent Benefit Level (Selected carrier) change
Employee/Dependent Termination
Employee/Dependent Add On
Rate for the Benefit Level Offered by the carrier changes retrospectively. I.e over writing
the previous effective date that was applicable for the group.
5.
Credit Card Payment transaction fee if applicable: Credit card transaction fee is
2.5% of the total amount due for the group/member
6.
NSF Check if applicable: $25 handling fees is charged for the NSF check.
7.
Reinstatement fees: (Reinstatement fees are on the following assumption that on the date
of term all the previous balances on the group are settled.) The group needs to be
reinstated on the date next to the term date. The Amount due for the reinstatement from
the date following the term dates to the current month when the group is reinstated.
(e.g.) Group Term Dare: 2/31/01
Date when the group was reinstated 5/10/01
Effective reinstatement date is 3/1/01. Reinstatement fees is calculated for the Period 3/1/01
I.e. the month when the reinstatement occurred. The invoice contains the premium due for the
next month as well i.e. 6/1/01. However the current amount due is based on the current period
i.e. from 3/1/01 to 5/31/01. Next months period 6/31/01 and reinstatement fees
Percentage on the premium due when reinstatement occurred (The amount on which the
reinstatement fees is calculated.)
Note: Subsequent billing cycle would contain the Reinstatement Adjustments and
Reinstatement fees on reinstatement for the group/member.
A reinstatement fee is 10% of the premium due when reinstatement occurred.
V - Running Invoice
Non-Blended
Note: The difference in the rules for non-blended and blended is in the rate calculation rules.
The rest of the processes are same as for the blended.
Formula
Formula for Non-Blended Rates
The formula for the premium calculation for the invoice Non-Blended is as follows
(Non-Blended)
a)
Raw Rate
b)
Agent Commission per Member
c)
Agent Commission per Group based on group size
d)
Admin fee per Member
e)
Admin fee per Group based on group size
f)
Additional Fees
g)
Differential factor
Member Level Fees = Raw Rate + Member Count * (Agent Commission Per Member +
Admin Fee Per Member)
Note (If differential factor is applicable then Raw rate should be factored i.e Raw Rate *
Differential Factor)
Group Level Fees = Agent Commission per Group Size + Admin Fees per Group size
Total Non Blended Premium Billed to Group = Member Level Fees + Group Level Fees
Example
Raw Rate
=
$100
Agent Commission per Member
=
$10
Agent Commission per Group based on group size
=
$50 for Group size => 15
Admin fee per Member
=
$10
Admin fee per Group based on group size
=
$50 for Group size => 15
Additional Fees
=
10% on Raw Rate
Differential factor
Employee1 Member count including employee
=
3
Employee2 Member count including employee
=
2
Employee3 Member count including employee
=
4
Employee4 Member count including employee
=
5
Employee5 Member count including employee
=
1
Total Member count
=
15
Group size (=> 15)
=
15
Member Level Fee
Employee1 = 100 + 3 (10 + 10)
=
$160
Employee2 = 100 + 2 (10 + 10)
=
$140
Employee3 = 100 + 4 (10 + 10)
=
$180
Employee4 = 100 + 5 (10 + 10)
=
$200
Employee5 = 100 + 1 (10 + 10)
=
$120
Member Level Fees
=
$800
Group Level Fees
=
$50 + $50 + $100
Total Non Blended Premium Billed to Group =
Member Level Fees + Group Level Fees = $800 + $100 = $900
This formula is for the specific Benefit Level (offered by carrier) for a specific line of
coverage and a specific employed member.
The total amount billed to group should include all the Rates after applying this formula for
all the employees/members and their line of coverage.
Formula
Formula for Non-Blended Rates
Example
The formula for the premium calculation for the invoice Non Blended for Cal COBRA is as
follows:
Member Premium for Cal COBRA − Raw Rate * (1 + Additionul fee %)
Example:
Member Premium for Cal COBRA = 100 * (1 + 0.10) = $110
Amount Billed to COBRA Group = $110
This formula is for the specific Benefit Level (offered by carrier) for a specific line of
coverage and a specific employee/member.
The total amount billed to COBRA Subscriber member should include all the Rates after
applying this formula for all the members and their line of coverage.
Benefit Partners Inc
Process Specification
Cash Receipt
1. Introduction
[1249] 1.1. Purpose
The purpose of this document is to describe the process of Cash Receipt. This document identifies how the user interacts with the system, the data to be captured, the business logic to be implemented, and the output of the process.
[1251] 1.2. Business Use Case Specification Reference
[0000]
Business Use Specification ID
Business Use Case Name
BPI_SCOPE_FI_002
Finance - Business use case
Specification - Cash Receipt
[1252] 1.3. Definitions, Acronyms & Abbreviations
[0000]
Term
Explanation
EFT
Electronic Fund Transfer
2. Process Identification
[1253] 2.1. Background
Cash Receipt is the process of entering the cash received by BPI into the system. The cash receipt can be received in various modes as defined by the business process. Cash Receipt includes Lock Box receipts, Check, Credit Card, EFT and Transfer.
[1255] 2.2. Process Description
This Cash Receipt sub module also needs to incorporate the following.
1) Enter the lock box payment received as a batch process into the system 2) Enter EFT payment received as a batch process into the system 3) EFT payment made directly to Wells Fargo Bank 4) On line payment using the Credit Card and Check 5) User interface to make payment over phone by Credit card or Check 6) Credit Card payment with automatic pulling of the cash or manually on request 7) Handle negative check i.e. NSF's, Refund and Transfer. 8) Transfer of cash from one group to the other.
This Cash Receipt sub module also needs to have a feature to incorporate the following.
Batch the cash receipt based on the batch number defined. There should be ability to batch each of the modes of the payment received into a separate batch. For EFT, Credit Card, On Line Check and Lockbox payments there should be ability to upload the files into the system as one batch. Reconciliation will follow once the batch is imported and closed. In addition, prior entry of Lock box total entry made needs to tally with the lock box total.
This document details only one mode of cash entry namely, Manual Batch. Lockbox, EFT and payments through credit cards are detailed in their respective process specification documents.
[1271] 2.3. Process Flow
Cash receipts into the system can be from the following sources:
EFT Check received at BPI Lock Box file On line Credit Card Check or Credit card over phone
The cash received by any of the above mode is batched and entered into the system. The batch number is identified based on the mode of payment receipts. All batches should be identified uniquely with batch number and timestamp. The Payment received are either entered manually into the system or uploaded into the system from the files available. The batch total and sum of the entries made in each batch should tally before saving the batch. Batch date should represent the deposit date. Batch Types are:
1. Manual Batch 2. NSF Batch 3. Returns Batch 4. Positive Transfer 5. Negative Transfer 6. Lockbox Check 7. Auto-Batch EFT 8. Direct Deposit 9. Wire Transfer 10. CC over phone 11. Auto-Batch Credit Card 12. Online Credit Card
3. User Interface
[1294] 3.1. User Interface Screens
[1295] 3.1.1. Manual Cash Batch
[1296] 3.1.1.1. Screen Snapshot (See FIG. J- 5 )
[1297] 3.1.1.2. Element Name, Element Type & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Batch Information
Batch Id
Display Text
Batch Id
Displays unique system generated id for the batch
Batch Date
Text Box
Batch Date
Batch Date
Batch Total
Display Text
Batch Total
Displays total of all cash entries
Batch Type
Option Box
Batch Type
Type of manual batch. Possible options are
Manual Batch, NSF Batch, Returns Batch,
Positive Transfer, Negative Transfer
Tape Total
Text Box
Tape Total
Tape total of all cash entries
Tape Balance
Display Text
Tape Balance
Displays difference between the tape total and
total of cash entries entered
Batch Status
Display Text
Batch Status
Displays status of batch: Open or Closed
Check Information
Postmark Date
Text Box
Postmark Date
Date on which the payment was postmarked
Received Date
Text Box
Received Date
Date on which payment was received
Check #
Text Box
Check #
Check number
Check Amount
Text Box
Check Amount
Check amount
Check Distribution
Group Id
Text Box
Group Id
Group against which payment is allocated
Group Name
Display Text
Group Name
Displays name of selected group
Amount
Text Box
Amount
Amount allocated to the group out of the total
payment amount
Comments
Option Box
Comments
Standard comments for the payment, if any
Others
Text Box
Others
To enter any comments other than the standard
ones
Payment
Editable Table
Displays all payment entries for the batch for
Entries
editing
New
Command
New
Clears screen for a new batch entry
Save
Command
Save
Saves the batch information to the database
Close
Command
Close
Closes the batch. A batch can not be edited after
closing
Search
Command
Search
To search for saved batches
[1298] 3.1.1.3. Screen Validations
[0000]
Element Name
Action/Validation Details
Message
Batch Information
Batch Date
Check to see if batch date is not
“Please enter a valid
null and is valid
batch date”
Batch Type
Check to see if valid batch type is
“Please select a
selected
valid batch type”
Tape Total
Check to see if tape total is not null
“Please enter a
and is valid
valid tape total”
Check Information
Postmark Date
Check to see if postmark date is
“Please enter a valid
not null and is valid
postmark date”
Received Date
Check to see if the received date is
“Please enter a valid
not null and is valid
received date”
Check #
Check to see if check number is
“Please enter a valid
not null and is valid
check number”
Check Amount
Check to see if check amount is
“Please enter a valid
not null and is valid
check amount”
Check Distribution
Group Id
Check to see if group id is not null
“Please enter a
and is valid
valid group id”
Amount
Check to see if amount is not null
“Please enter a
and is valid
valid amount”
[1299] 3.2. Interface Flow
N/A
4. Business Rule Mapping
[1301]
[0000]
Activities
Rules
Batch Entry
Unique id should be created for each batched. The batch total should be tallied to the
individual sum before saving the batch. The batch id should be uniquely generated prior
to creation of batch. Each cash receipt should have the postmark date, date received and
the system date (I.e the date when the batch is created) and batch total. The line items
within each batch should have a feature to Split the payment for multiple group ids if
required. Batch date should be the deposit data.
Any entries made to the batch can be saved prior to completion of the batch entries.
However there would be a status for the batch which would indicate if the batch is closed
or not. Modification can be done only to the batches that are open. Any batch that is
closed cannot be modified. If there is an erroneous entry for the batch and the batch is
saved. Only Transfer can be done and it is not allowed to delete the batch that are closed.
Only the batches that are closed can be reconciled.
Batch by File
The batch that are created by uploading the files like for Lockbox, EFT or Credit Card
Uploads
will have an identification that payment for this batch was made by Lockbox, EFT or
Credit Card. These batches are always closed.
Negative
NSF would be entered into the system and there would be an indicator indicating that
Check (NSF)
this batch is a NSF batch.
Transfer
Cash transfer may be due to the reason that the Cash has been wrongly enter for the
group to which the cash does not belong. In such cased entering negative cash receipt for
the Group for whom the cash has been wrongly entered and making positive cash to the
group to whom the cash belongs makes the cash adjustment. There should be a positive
and negative cash adjustment.
Returns
Refund would be a batch and would be handled similar to the NSF Check.
Benefit Partners Inc
Process Specification
Cash Reconciliation
1. Introduction
[1302] 1.1. Purpose
The purpose of this document is to describe the process of Cash Reconciliation. This document identifies how the user interacts with the system, the data to be captured, the business logic to be implemented, and the output of the process.
[1304] 1.2. Business Use Case Specification Reference
[0000]
Business Use Specification ID
Business Use Case Name
BPI_SCOPE_FI_003
Finance - Business use case
Specification - Cash
Reconciliation
[1305] 1.3. Definitions, Acronyms & Abbreviations
[0000]
Term
Explanation
EFT
Electronic Fund Transfer
2. Process Identification
[1306] 2.1. Background
Cash Reconciliation is the process of reconciling the cash receipts to individual invoices and reconciling the amount paid by the group. The objective of the Cash Reconciliation process is to reconcile:
1) Billed amounts and cash receipt 2) Cash to negative cash 3) Adjustment to cash 4) Adjustment to billed amounts 5) Billed amount to itself if the total due results in zero 6) Adjustment to Adjustment
[1315] 2.2. Process Flow and Description
Process for Cash Reconciliation: Reconciliation is the process of matching one to one the cash received on hand and the invoices that are open. The cash are received by numerous ways as described in BPI_CAS_FSD_FI — 02 (Cash Receipt). The invoice is generated for the various groups/members based on the premium due. These invoices are matched with the cash receipts and reconciled. The rule for reconciliation should be as follows:
1. Look for the Negative Cash available and reconcile it with the positive cash (for NSF checks). 2. Look for the oldest unreconciled invoice and reconcile with the oldest cash.
The reconciliation process should look through all the invoices that have not been reconciled for a specific group and reconcile the invoice that has the earliest date with the cash received. It should also match the Cash receipt with the invoice amount. Note: reconciliation process is started automatically when the cash receipt batch is closed and it reconciles the cash received with the invoices.
Billed amounts and cash receipt: This reconciliation process is to reconcile the invoice that has not yet been reconciled for the specific group and check if the invoice is earliest un reconciled invoice for the specific group and reconcile the invoice with the cash received form the group/member. Cash to negative cash: This is the process of reconciling the negative cash with the positive cash received from the group. This case arises when there is a NSF check and the group's invoice has been reconciled. The bank usually notifies NSF check and then NSF Cash receipt entry is created in the system. Now on receipt of a replacement check against the NSF check the NSF check is reconciled with the replacement check provided the amount tallies. Adjustments to Cash: This is the process of reconciling the cash receipt with the adjustment that may be available in the next invoice. Example: If the group has received the invoice for the next month and they have an employee termed this month after the generation of invoice. The generated invoice would not identify this adjustment for the termed employees as the employee was termed after creation of invoice. But the Group may deduct the adjustments for the termed employee and send the cash that would be short as they would sent the check with the adjustments. Hence this process should identify such conditions and adjust the cash receipt for the invoice with adjustment taken in to account. The next invoice would show the cash receipt and the adjustment for the employees termed. This process can also be coined as “Reconciled but not billed”. Adjustment to billed amounts: This process identifies the invoices that are already billed to the group and any adjustments that are not made in the current invoice needs to be adjusted in the next invoice with the adjustments made. Billed amount to itself if the total due results in zero: This is process identifies if the group is termed and the invoice is already created for the group for the next month. Invoice would be created for the termed group on group termination and would adjust that with previous invoice. There would always be a final invoice for the termed groups showing adjustments that would include refund, or short fall or zero balance. Adjustment to Adjustment: This process is for adjusting the late fee with late fee is waived, Reinstatement fees with reinstatement fee waive as the case may be. If the Late fee is shown in the previous invoice that can be adjusted by waiving late fee or reinstatement fees as applicable. Example: Late fees may be $25.00 and waive late fees would be $−25.00. Here adjustment to adjustment would be $25 to $25. Also adjustment needs to be made on invoice with invoice.
3. User Interface
[1329] 3.1. User Interface Screens
[1330] 3.1.1. Manual Reconciliation
[1331] 3.1.1.1. Screen Snapshot (See FIG. J- 6 )
[1332] 3.1.1.2. Element Name, Element Type & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Group Information
Group Id
Display Text
Group Id
Displays id of the group
Group Type
Display Text
Group Type
Displays group type
Group Name
Display Text
Group Name
Displays group name
Association
Display Text
Association
Displays name of association if group is enrolled
Name
Name
through one
Status
Display Text
Status
Displays status of group
Rate Type
Display Text
Rate Type
Displays the rate type for the group: blended or
non-blended
Left to balance
Display Text
Left to balance
Displays amount left to be reconciled
Bill Information
Bill #
Display
Bill #
Column
Coverage
Display
Coverage Period
Period
Column
Due Date
Display
Due Date
Column
Bill Date
Display
Bill Date
Column
Bill Total
Display
Bill Total
Column
Total Due
Display
Total Due
Column
Adjustments Information
Adjustment Id
Display
Adj. Id
Column
Adjustment
Display
Adj. Type
Type
Column
Adjustment
Display
Adj. Date
Date
Column
User Id
Display
User Id
Column
Coverage
Display
Cvrg Month
Month
Column
Amount
Display
Amount
Column
Cash Receipts
Batch Id
Display
Batch Id
Column
Postmarked
Display
Date PM
Date
Column
Date Received
Display
Date Recd
Column
Check #
Display
Check #
Column
Batch Type
Display
Batch Type
Column
Payment
Display
Pmt Amt
Amount
Column
Unused
Display
Unused Amt
Amount
Column
Comments
Display
Comments
Column
Post
Command
Post
Post reconciliation entries
Reconciliation
Reconciliation
Clear
Command
Clear
Clears screen for a new import.
Search
Command
Search
Provides functionality to search groups
[1333] 3.1.1.3. Screen Validations
Note: Reconciliation can have any of the possible combination provided below:
1) Invoice to Invoice 2) Invoice to Cash receipt 3) Invoice to Adjustment 4) Cash receipt to cash receipt 5) Cash receipt to adjustment 6) Adjustment to adjustment
Hence, the validation for the amount left to balance is done based on any of the combination selected from the check boxes. Note: Adjustments would be shown only under special conditions where term has been initiated after generation of invoices and the group pays short taking this adjustments into account.
[1343] 3.1.2. Billing & Payments History
[1344] 3.1.2.1. Screen Snapshot (See FIG. J- 7 )
[1345] 3.1.2.2. Element Name, Element Type & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Group Information
Group Id
Display Text
Group Id
Displays id of the group
Group Type
Display Text
Group Type
Displays group type
Group Name
Display Text
Group Name
Displays group name
Association
Display Text
Association
Displays name of association if group is enrolled
Name
Name
through one
Status
Display Text
Status
Displays status of group
Rate Type
Display Text
Rate Type
Displays the rate type for the group: blended or
non-blended
Bill Information
Bill #
Display
Bill #
Column
Coverage
Display
Coverage Period
Period
Column
Due Date
Display
Due Date
Column
Bill Date
Display
Bill Date
Column
Bill Total
Display
Bill Total
Column
Total Due
Display
Total Due
Column
Adjustments Information
Adjustment Id
Display
Adj. Id
Column
Adjustment
Display
Adj. Type
Type
Column
Adjustment
Display
Adj. Date
Date
Column
User Id
Display
User Id
Column
Coverage
Display
Cvrg Month
Month
Column
Amount
Display
Amount
Column
Cash Receipts
Batch Id
Display
Batch Id
Column
Postmarked
Display
Date PM
Date
Column
Date Received
Display
Date Recd
Column
Check #
Display
Check #
Column
Batch Type
Display
Batch Type
Column
Payment
Display
Pmt Amt
Amount
Column
Unused
Display
Unused Amt
Amount
Column
Comments
Display
Comments
Column
Search
Command
Search
Provides functionality to search groups
[1346] 3.1.2.3. Screen Validations
NA
[1348] 3.2. Interface Flow
N/A
4. Business Rule Mapping
[1350]
[0000]
Activities
Rules
Automated
Automatic Reconciliation would be done on closing the batch for the cash receipt. If the
Reconciliation
cash receipt batch were closed then it would start the reconciliation process.
The following process would be auto reconciled:
Billed amounts and cash receipt
Adjustment to cash
Billed amount to itself if the total due results in zero
Adjustment to billed amounts
Reconciliation
Reconciliation process would look for the earliest un reconciled invoice and reconciles it
for the Existing
provided it is less than $ +_2.00.
Groups
Reconciliation would be as per the following sequence.
Look for the Negative Cash available and reconcile it with the positive cash (for NSF
checks).
Look for the oldest unreconciled invoice and reconcile with the oldest un-reconciled
cash and so on.
On Reconciliation the entire invoice, cash receipts would have a status as reconciled.
Manual
This process would trigger reconciliation manually based on authority or if the user is trying
Reconciliation
to reconcile and specific cash receipts with the invoice as the case may be. Manual
reconciliation can be does only for those invoices that has not reconciled automatically
Manual
Cash to negative cash
Reconciliation
Adjustment to Adjustment
Any reconciliation that is not completed by automatic reconciliation process would be
reconciled manually.
Formula for
General formula for reconciliation would be as follows:
reconciliation
Billed amounts and cash receipt = (Invoice Amount − Cash Receipt)
Adjustment to cash = (Adjustment − Cash Receipts)
Billed amount to itself if the total due results in zero = (Invoice Amount + Invoice Amount)
Adjustment to billed amounts = (Adjustment Amount + Invoice Amount)
Cash to negative cash = (Cash receipt + cash receipt)
Adjustment to Adjustment = (Adjustment + adjustment)
General formula = (Invoice Amount + Adjustment Amount − Cash Receipt Amount)
Example
Invoice = $000.00, Cash receipt = $−100.00, Cash receipt = $918.00,
Adjustment = $−100.00, Adjustment = $−80.00
Amount that can be Reconciled = 1000 − (−100) − (800) + (−100) + (−80) = 1000 + 100 − 918 −
100 − 80 = $2.00 This $2.00 is balance forward for the subsequent invoice.
New Business
Excluding COBRA and Individual Association Members who follow the reconciliation rules
Reconciliation
as per the Existing Group, the new business groups is auto reconcile if within $ +− 2.00. If
the amount is short by $100.00 the invoice and the cash receipt would be reconciled and the
short fall would be balance forward in the next invoice. PacAdvantage Fund (A Cash
Receipt Batch auto generated by the system) would adjust this short fall. This would be
based on authority (Finance/GMS).
Also for the new business the auto reconciliation process would apply to reconcile the
Invoice Generated on successful enrollment with the cash receipt as initial enrollment
payment.
Benefit Partners Inc
Process Specification
Risk Adjustment
1. Introduction
[1351] 1.1. Purpose
The purpose of this document is to describe the process of Risk Adjustment. This document identifies how the user interacts with the system, the data to be captured, the business logic to be implemented, and the output of the process.
[1353] 1.2. Business Use Case Specification Reference
[0000]
Business Use Specification ID
Business Use Case Name
BPI_SCOPE_FI_007
Finance - Business use case
Specification - Risk Adjustment
[1354] 1.3. Definitions, Acronyms & Abbreviations
[0000]
Term
Explanation
EFT
Electronic Fund Transfer
2. Process Identification
[1355] 2.1. Background
Risk Adjustment is the process of accessing the risk borne by each of the Carrier in paying for the claims submitted to them by members. Risk adjustment factor is assigned to the Carrier. Based on these factors the carrier may be classified as Payers, Receivers or None (if no factor is assigned).
Payers are the one who pays in the risk adjustment amount to the Pool. Receivers are the one who receives the Risk Adjustment amount from the pool.
These risk adjustment factors are pre-defined by PacAdvantage.
[1359] 2.2. Process Description
The objective of the Risk Adjustment process is to:
1) Provide for upload of Risk Adjustment (RA) factors in the form of text files into PX2 system
The uploaded data would subsequently be used in cash disbursement reports for suggesting the amount to be paid out to carriers after application of RA factors. The following are the other requirements that will be supported and constraints on the proposed system:
1) The system will maintain a log of all zip codes and service area imports. The log information will include the user, the day & time of import, the file path & format and the status of the import.
[1365] 2.3. Process Flow
[1366] Process for Upload of Risk Adjustment Factors
1) The import file and an effective date for import are all input from the user. 2) The system checks to see if the file data is per the format expected. If not, an error is reported. 3) If data already exists for an effective date, the system prompts to the user as to whether it should overwrite the data or cancel the import. 4) The system imports Risk Adjustment factors to its database. 3. User Interface
[1372] 3.1. User Interface Screens
[1373] 3.1.1. Risk Adjustment Factors Import
[1374] 3.1.1.1. Screen Snapshot (See FIG. J- 8 )
[1375] 3.1.1.2. Element Name, Element Type & Purpose
[0000]
Element
Element
Name
Type
Label
Purpose
Import Id
Display Text
Import Id
Displays unique id for
the import
Status
Display Text
Status
Displays status of import
Imported By
Display Text
Imported By
Displays id of user who
did the import
Import Date
Display Text
Import Date
Displays date on which
import was done
Import File
Text Box
Import File
Full path of the file to
be imported
Effective Date
Text Box
Effective Date
Date on which the RA
factors becomes effective
New
Command
New
Clears screen for a
new import.
Import
Command
Import
Starts the import process
Search
Command
Search
Provides functionality
for search of imports
[1376] 3.1.1.3. Screen Validations
[0000]
Element Name
Action/Validation Details
Message
Import File Name
Check to see that the value for
“Please enter a valid
the field is not null
import file name”
Effective Date
Check to see that the value for
“Please enter a valid
the filed is not null and is valid
effective date”
[1377] 3.2. Interface Flow
N/A
4. Business Rule Mapping
[1379]
[0000]
Activities
Rules
Risk
The formula for risk Adjustment factor is as given below:
Assessment
Raw Rate = Premium Amount (Raw Rate for Medical
Formula
Line of coverage and the benefit level for the specific
carrier opted by the member)
Adjustment Factor = Fixed dollar amount per member
count (can be negative or positive based on whether the
Carrier is receiver or payer) Positive is the receiver and
negative is the payer.
Risk Adjustment amount = Raw rate + (Risk Adjustment
factor * member count for that plan)
Example
Adjustment Factor = $ + 5.00 for Aerna (receiver)
Adjustment Factor = $ − 2.00 for Health Net (payer)
Employee 1 = $ 400 with (4 member inclusive of
employee) Aerna
Employee 2 = $ 300 with (2 member inclusive of
employee) Health net
Employee 3 = $ 200 with (1 member inclusive of
employee) Health net
For Health net
300 + (−2 * 2) + 200 + (−2 * 1) = 304 + 202 = 494.00
For Aerna
400 + (5 * 4) = $ 420.00
Note:
the adjustment factor has an effective date attach to it. Normally it is loaded once in 6 months.
Benefit Partners Inc
Process Specification
BPI_CAS_PSD_SECURITY — 01
1.1 Introduction
[0000]
This purpose of this document is to identify the processes associated with the security mechanism for core administrative system
1.2 Business Use Case Specification Reference
[1381]
[0000]
Business Use Specification ID
Business Use Case Name
NONE
NONE
1.3 Process Identification
[1382] 1.3.1 Process Description & Flow
This process describes the security framework requirements. The security framework consists of creating database for security system as well as administrator login into the system. The system also allows the administrator to create users, module, groups, and application, assign user roles and ACL etc. The system also takes care of user login into the core administrative system. The system should generate the ACL for each user when user logs in into the system. The access to any resource in the core administrative system will be decided by this ACL which will be stored in the User Profile object, stored into the session. The security system for Intranet application built for shall broadly contain following categories.
1. Definition of Realms 2. Definition of Modules 3. Definition of Applications 4. Definition of Resources 5. Definition of groups (groups can ideally be a department which has a number of users) 6. Definition of User 7. Definition of User Roles 8. Definition ACL/Permissions 9. Resources, which can be assigned to the groups. 10. User, User Role and Groups mapping 11. Overriding the group access rights.
[1396] Realms
A realm is a database of users, groups, modules, application resources and access control lists. A user must be defined in a realm in order to access any resources belonging to that realm.
[1398] Modules
The modules provide the high level classification for the applications. The module is a group of applications. The following modules have been identified in the initial stage as a part of core administrative system viz. Carrier Maintenance, Enrollment, Sales and Marketing and Finance.
[1400] Applications
A module consists of many applications. An application represents the business use case or set of related use cases. A module consists of many applications. For e.g. Carrier Maintenance module consists of following applications viz. Zip Master, Carrier Master, and M Plan etc. Each application can be further classified into the pages.
[1402] Resources
An application can be further classified into the Resources. An application can have one or more resources. Resources are the valuable items accessible from the Web server/Web Application server:
Web applications: Java.Servlet or JSP
The resources can be protected by using a single access control (ACL). The ACL specifies which users or groups are allowed to access or modify the resource. For each resource to protect, you'll specify:
An access control list (ACL)—a list defining who can use the resource
[1408] Groups
A group is a collection of users. A user can belong to multiple groups. The groups can be created based on the department where all the uses are going to perform the similar kind of operation. Groups are sets of users. Groups provide an efficient way to manage large numbers of users because an administrator can specify permissions for an entire group at one time. The resources pages can be allocated to group instead of assigning to individual user. The user gets the default access rights as a part of group. The user can override the group access rights. A person can be defined as both an individual user and as a member of a group. When an individual user also belongs to a group, the individual access permissions override any group access permissions. For e.g. a set of data entry operators can have be classified into one group. The rights can be assigned to this group as all basically going to do the data entry operation.
[1412] User Roles
In any system, there are many roles, which a particular entity plays. For e.g. in any industry role played by the manager differs from the subordinate. The roles need to be classified into the security system. A user can play multiple roles in the system. A manager can play the role as data entry as well as authorizing body. A data entry operation may not have provision to enter some critical data, which manager does enter if manager is logging into the system as manager role. The managers can login into the system as data entry operator as well. If manager is logging in as data entry operation he may not have the privileges as he was having in manager role. In such a case he will be treated as data entry operator. The security system needs to take above situations. The user roles can be
SUPER USER SENIOR MANAGEMENT MANAGER DATA ENTRY PERSONNEL PART TIME EMPLOYEE
The user roles need to be configured into the system. The user roles can be added for the future modifications. The CAS (Core Administration System) system need to be pre configured for the basic pre defined roles which will not be editable.
[1423] Users
A user is an identity that can be authenticated by the system. A user can represent a person who is working in any of the departments in Benefit Partners Inc. A user can belong to multiple groups. A user can play multiple roles
[1426] Access Rights/Permissions
Permissions represent the privileges required for accessing resources. An administrator protects resources by establishing access control lists to grant permissions to users and groups. Individual user permissions take precedence over group permissions. Individual user permission overrides the more restrictive group permission. (Even if the group permission is less restrictive than the user permission, the user permission overrides the group permission and vice versa).
[1429] List of Programs
1. Security Login
Allows the administrator to login into the security system.
2. Module Master
Allows administrator to do following operations Create Module Modify Module Delete Modules
3. Application Master
Allows administrator to do following operations Create Application Modify Application Delete Application
4. Resources
Allows administrator to do following operations Create Resources Modify Resources Delete Resources
5. Group Master
Allows administrator to do following operations Create Group Modify Group Delete Group
6. User Master
Allows administrator to do following operations Create User Modify User Delete User
7. User Role
Allows administrator to do following operations Create Role Modify Role Delete Role
8. User Access Rights 9. User, User Role and Groups Mapping 10. Group Access Rights
Allows administrator to do following operations. Assign Rights for a User. This program allows the administrator to override the access rights for a user.
11. User Login
When the system user logs in into the core administration system the separate ACL will be generated for each user. The ACL will be stored in the User Profile object, which will be stored in the user session. When user request for a particular page controller will check with the security system whether user is having access to the particular page. The user password needs to be validated as follows
The password need to be minimum 6 characters long and max 10 characters The password needs to be combination of alphabets and special characters and numbers (for e.g. Amit1$3, sriRam9#445 etc). The password is valid for 15 days, which is configurable. The system should prompt user to change the password three days (which is configurable) prior to expiry date of the password. If user changes the password then his password is valid for 15 days (which is configurable) from the date of change. In the same way administrator can configure the minimum limit for password age, which signifies that user cannot change the password for this period from the date of prior change. The minimum limit for the password age, which is configured value, cannot be greater than or equal to configured maximum limit of the password age. First time user must change his password before entering into the system. Scenario
If the user password is “123456” the for first time login user goes and change the password to “Mali5%9”. The user is created on date Jan. 4, 2002. User logs in on Jan. 5, 2002 and password expiry date for the user changes to Jan. 19, 2002 (15 calendar days) if the configured time limit is 15 days. The user needs to prompt to change password on Jan. 17, 2002 (3 calendar days prior to the expiry date). If user changes the password within stipulated time then extend the password expiry date by 15 calendar days. (New Date=Sys Date+15). All changes in the date is effective from 0000 AM
The above validation is not applicable at the time of user creation as administrator can keep the password 123456 for all. The new password in the change password is to be validated for above conditions. The old password need not be validated for above conditions. As user can have 123456 as first time as his password. The old password needs to be maintained in the history. The new password must not be equal to last five passwords. This number of history of passwords (here its 5) should be configurable. (A configurable password history where the administrator can enter value that would represent how many passwords it would remember until the user can use the same password again) The ability to enable or disable Account lockout with a configuration value for the number of user log in attempts at which point a lockout would occur. A way timer for when to reset the count of attempts before lock would be helpful. Also if it possible to make a lockout duration value that would be configurable would also be helpful. User Name cannot be a part of password.
[1484] Configurable Items
[0000]
Sr No
Item Name
Value
1
Length Of Password
Integer (Ranging From 1-n)
(Minimum Value)
Need to be set by the
administrator
2
Length Of Password
Integer (Ranging From 1-n)
(Maximum Value)
Need to be set by the
administrator
Maximum need to be greater
than minimum value
3
Expiry of the password from the
Integer (Number of days)
date of validity
Ranging from 1-n
(Maximum Range)
Need to be set by the
administrator
4
Expiry of the password from the
Integer (Number of days)
date of validity
Ranging from 1-n
(Minimum Range)
Need to be set by the
administrator
5
Password Repeat allowed value
Integer (Number of days)
This indicates that new passwords
Ranging from 1-n
can not be same as last
Need to be set by the
n passwords
administrator
6
Invalid Passwords allowed before
Integer (Number of days)
locking the account
Ranging from 1-n
If user enters the password
Need to be set by the
incorrect for n times then his
administrator
account will be locked
automatically.
7
Lock Time
Time for which account to be
locked if it is locked because
of successive invalid
passwords entry.
8
Password change prompt date
This value signifies that user
need to be intimated by 3
days prior about password
change (Value here set as 3)
[1485] 1.3. Security Framework
[1486] Process Flow Diagram (See FIG. P- 1 )
[1487] 1.3.1.1. Script for Setup
Run the basic admin script, which will create the basic administrative user for security login and minimal data into the database.
[1489] 1.3.1.2. Security Login
Security Login
Refer Process Flow Diagram FIG. 2 . The flow of the process is as described below. System allows user to login into the system. The basic user id and password validation will be done for the administrator for the security system. On successful login administrator can create modules, groups, applications, user etc.
FIG. 2 Process Flow Diagram (See FIG. P- 2 )
[1495] 1.3.1.3. Module Master
Refer Process Flow Diagram FIG. 3 , The flow of the process is as described below.
[1497] Create Modules
a) On selecting create modules option. The user needs to enter the module name and description. b) The user enters the details and clicks save. c) Upon save the data will be stored in the database. Modify Modules a) When user selects modify modules option. He will be shown all the modules in the combo box. b) The user selects the module name and clicks select. c) The user will be shown the details about the selected module. The user can modify the module details and click save. The data will be updated into database.
[1504] Delete Modules
a) When user selects the Delete option, the user will be shown all the modules where in user can select one or more access control list and click delete. b) The selected modules will be deleted from the database. FIG. 3 : Process Flow Diagram (See FIG. P- 3 )
[1508] 1.3.1.4. Application Master
Refer Process Flow Diagram FIG. 4 . The flow of the process is as described below.
[1510] Create Application
a) On selecting create application option. The user needs to enter the application details like application name, module name and description. b) The user enters the data and clicks save. c) Upon save the data will be stored in the database.
[1514] Modify Application
a) When user selects modify applications option. He will be shown all the applications in the selection box. The user selects one application and clicks select. b) The user will be shown the details about the selected application. The user can modify the application details and click save. c) The data will be updated into database.
[1518] Delete Application
a) When user selects the Delete option, the user will be shown all the applications where in user can select one or more applications and click delete. b) The selected applications will be deleted from the database. FIG. 4 : Process Flow Diagram (See FIG. P- 4 )
[1522] 1.3.1.5. Resource Master
Refer Process Flow Diagram. The flow of the process is as described below.
[1524] Create Resource
a) On selecting create resource option. The user needs to enter the resource details like resource name, application name and description. b) The user enters the data and clicks save. c) Upon save the data will be stored in the database.
[1528] Modify Resource
a) When user selects modify resource option. He will be shown all the resources in the selection box. The user selects one resource and clicks select. b) The user will be shown the details about the selected resource. The user can modify the resource details and click save. c) The data will be updated into database.
[1532] Delete Resource
a) When user selects the Delete option, the user will be shown all the resource where in user can select one or more resources and click delete. b) The selected resources will be deleted from the database. FIG. 5 : Process Flow Diagram (See FIG. P- 5 )
[1536] 1.3.1.6. Group Master
Refer Process Flow Diagram FIG. 6 . The flow of the process is as described below.
[1538] Create Group
a) On selecting create group option. The user needs to enter the group details like group name and description. b) The user enters the data and clicks save. c) Upon save the data will be stored in the database.
[1542] Modify Group
a) When user selects modify group's option. He will be shown all the groups in the selection box. The user selects one group and clicks select. b) The user will be shown the details about the selected group. The user can modify the group details and click save c) The data will be updated into database.
[1546] Delete Group
a) When user selects the Delete option, the user will be shown all the groups where in user can select one or more groups and click delete b) The selected groups will be deleted from the database. FIG. 6 : Process Flow Diagram (Sec FIG. P- 6 )
[1550] 1.3.1.7. User Creation
Refer Process Flow Diagram FIG. 7 . The flow of the process is as described below.
[1552] Create User
a) On selecting create user option. The user needs to enter the details like user name, description, address details etc. b) The user enters the data and clicks save. c) Upon save the data will be stored in the database.
[1556] Modify User
a) When user selects modify user option. He will be shown all the user details in the selection box. The user selects one-user and clicks select. b) The user will be shown the details about the selected user. The user can modify the user details and click save c) The data will be updated into database.
[1560] Delete User
a) When user selects the Delete option, the user will be shown all the users where in user can select one or more users and click delete b) The selected users will be deleted from the database. FIG. 7 : Process Flow Diagram (See FIG. P- 7 )
[1564] 1.3.1.8. User Role Creation
Refer Process Flow Diagram FIG. 7 a . The flow of the process is as described below.
[1566] Create User Role
a) On selecting create user role option. The user needs to enter the details like user role name, description b) The user enters the data and clicks save. c) Upon save the data will be stored in the database.
[1570] Modify User Role
a) When user selects modify user role option. He will be shown all the user role details in the selection box. The user selects one-user role and clicks select. b) The user will be shown the details about the selected user role. The user can modify the user details and click save. c) The data will be updated into database.
[1574] Delete User Role
a) When user selects the Delete option, the user role will be shown all the users roles where in user can select one or more users role and Click delete b) The selected user roles will be deleted from the database. FIG. 7 a : Process Flow Diagram (See FIG. P- 8 )
[1578] 1.3.1.9. User, User Role and Group Mapping
Refer Process Flow Diagram FIG. 8 . The flow of the process is as described
[1580] Assign Rights
a) On selecting the User, User Role and Group Mapping option. The user will be shown the all the users and user roles in the selection box. The user can select the combination of user and user role. b) On selection user will be shown the all the groups with already assigned groups as checked. c) The user adds or removes the group assignment and clicks save. d) Upon save the data will be stored in the database FIG. 8 : Process Flow Diagram (See FIG. P- 9 )
[1586] 1.3.1.10. Group Access Rights
Refer Process Flow Diagram. The flow of the process is as described below.
[1588] Assign Rights
a) On selecting the group access rights. The user will be shown the all the groups in the selection box. The user can select any group and click select. b) When user selects the particular group, the user will be shown the all the resources and with the access rights selection box corresponding to each module. c) User can assign one or more resources to the group and click save. d) Upon save the data will be stored in the database. FIG. 9 : Process Flow Diagram (See FIG. P- 10 )
[1594] 1.3.1.11. User Access Rights
Refer Process Flow Diagram. The flow of the process is as described below. As stated earlier, user can override the access specified to the group.
[1597] Assign User Rights.
a) On selecting the user access rights. The user will be shown the all the users in the selection box. The user can select anyone user and click select. b) When user selects the particular user, the user will be shown the all the access rights for his group for corresponding resource. c) The user can add or remove the resources. d) Upon save the data will be stored in the database.
[1602] 1.3.1.12. Configure Items
Refer Process Flow Diagram. The flow of the process is as described below. This allows administrator to configure various items like password length, expiry etc. FIG. 10 : Process Flow Diagram (See FIG. P- 11 ) FIG. 10A : Process Flow Diagram (See FIG. P- 12 )
[1606] 1.4 User Interface
[1607] 1.4.1 User Interface ID: SECURITY_SCREEN — 001 (See FIG. P- 13 )
User Interface ID: SECURITY_SCREEN — 002 (See FIG. P- 14 )
[1609] 1.4.1.1 User Interface Screen Snap Shot—Screen Name: Security Login
[1610] 1.4.1.2 Field Name, Element Type & Purpose
[0000]
Table for Screen SECURITY_LOGIN_SCREEN_001
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
Security Login
being navigated
Sub Header
Text
Text for the Login Name
Login Name
Login Name
Entry Field
Text for the entry field
Sub Header
Text
Text for the password
password
Password
Entry Field
Text for the password
Save
Button (HTML
To Save the data this button need
Button)
to be clicked
Cancel
Button (HTML
To cancel current operation.
Button)
Select the Role
Text
Text for the Role
Role
Selection Box
Selection box applicable for user
login only.
[0000]
Table for Screen SECURITY LOGIN SCREEN 002
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
Security Login
being navigated
Sub Header Login
Text
Text for the Login Name
Name
Login Name
Entry Field
Text for the entry field
Sub Header old
Text
Text for the old password
password
old Password
Entry Field
Text for the old password
Sub Header new
Text
Text for the new password
password
new Password
Entry Field
Text for the new re enter password
Sub Header re
Text
Text for the re enter password
enter password
re enter Password
Entry Field
Text for the re enter password
Select
Button (HTML
To select the current selected module
Button)
to modify.
Cancel
Button (HTML
To cancel current operation.
Button)
[1611] 1.4.1.3 Front End Validation
Validation Details
This section provides the front end screen validations along with the associated message—Success/Error Message text
[0000]
Element
#
Name
Action/Validation Details
Message
1.
Login Name
Accepts all the alphabets
Mandatory Max Length: 15
(Entry Field)
and numeric characters.
“Please Enter Login Name”
2.
Password
Accepts all the alphabets
Mandatory Max Length: 15
and numeric characters.
Min Length: 6
“Please Enter the
password”
3.
User Role
Selection Box validation
Default: Choose One
“Mandatory”
“Please choose one of the
options specified”
[1614] 1.4.2 User Interface ID: SECURITY_SCREEN — 003 (See FIG. P- 15 )
User Interface ID: SECURITY_SCREEN — 004 (See FIG. P- 16 ) User Interface ID: SECURITY_SCREEN — 005 (See FIG. P- 17 )
[1617] 1.4.2.1 User Interface Screen Snap Shot—Screen Name: Module Master
[1618] 1.4.2.2 Field Name, Element Type & Purpose
[0000]
Table for Screen SECURITY_SCREEN_003
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
Create Module
being navigated
Sub Header
Text
Text for the Module Id
Module Id
Module Id
Entry Field
Text for the entry field
Sub Header
Text
Text for the Module Name
Module Name
Module Name
Entry Field
Text for the entry field
Sub Header
Text
Text for the Module Name
Module
Description
Module
Entry Field
Text for the entry field
Description
Save
Button (HTML
To Save the data this button need
Button)
to be clicked
Cancel
Button (HTML
To cancel current operation.
Button)
[0000]
Table for Screen SECURITY_SCREEN_004
Element Name
Element Type
Purpose
Search
Gif File
Used to search the module
[0000]
Table for Screen SECURITY_SCREEN_004
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
Modify Module
being navigated
Sub Header
Text
Text for the Module Id
Module Id
Module Id
Entry Field
Text for the entry field
Sub Header
Text
Text for the Module Name
Module Name
Module Name
Entry Field
Text for the entry field
Sub Header
Text
Text for the Module Name
Module
Description
Module
Entry Field
Text for the entry field
Description
Update
Button (HTML
To Save the data this button need
Button)
to be clicked
Cancel
Button (HTML
To cancel current operation.
Button)
[0000]
Table for Screen SECURITY_SCREEN_005
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen being
Delete Modules
navigated
Sub Heading
Text
To give the sub heading for the screen
Select the
being navigated
modules
Module Names
Check Box
Check boxes for module names to be
Sales, finance
deleted.
Check Box
Check All
On clicking the “Check All” link should
check all the check boxes in the HTML
table.
Check Box
Clear All
On clicking the “Clear All” link should
uncheck all the checked check boxes in
the HTML table.
Delete
Delete
To Delete the data this button need to
be clicked
[1619] 1.4.2.3 Front End Validation
Validation Details
This section provides the front end screen validations along with the associated message—Success/Error Message text
[0000]
Action/
#
Element Name
Validation Details
Message
1
Module Name
Accepts all
Max length: 50
(Entry Field)
the alphabets
Mandatory
and numeric
BPI_CAS_FSD_COMMON
characters.
2
Module Id (Entry
Accepts all
Max length: 10
Field)
the alphabets
Mandatory
and numeric
BPI_CAS_FSD_COMMON
characters.
3
Comments (Entry
Accepts all
Max length: 250
Field)
the alphabets
BPI_CAS_FSD_COMMON
and numeric
characters.
[1622] 1.4.3 User Interface ID: SECURITY_SCREEN — 006 (See FIG. P- 18 )
User Interface ID: SECURITY_SCREEN — 007 (See FIG. P- 19 ) User Interface ID: SECURITY_SCREEN — 008 (See FIG. P- 20 )
[1625] 1.4.3.1
User Interface Screen Snap Shot—Screen Name: Group Master
[1627] 1.4.3.2 Field Name, Element Type & Purpose
[0000]
Table for Screen SECURITY_SCREEN_006
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
Create Group
being navigated
Sub Header
Text
Text for the Group Id
Group Id
Group Id
Entry Field
Text for the entry field
Sub Header
Text
Text for the Group Name
Group Name
Group Name
Entry Field
Text for the entry field
Sub Header
Text
Text for the Group Name
Group
Description
Group
Entry Field
Text for the entry field
Description
Save
Button (HTML
To Save the data this button need
Button)
to be clicked
Cancel
Button (HTML
To cancel current operation.
Button)
[0000]
Table for Screen SECURITY_SCREEN_007
Element Name
Element Type
Purpose
Search
Image
To provide search
[0000]
Table for Screen SECURITY_SCREEN_007
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
Modify Group
being navigated
Sub Header
Text
Text for the Group Id
Group Id
Group Id
Entry Field
Text for the entry field
Sub Header
Text
Text for the Group Name
Group Name
Group Name
Entry Field
Text for the entry field
Sub Header
Text
Text for the Group Name
Group
Description
Group
Entry Field
Text for the entry field
Description
Update
Button (HTML
To Save the data this button need
Button)
to be clicked
Cancel
Button (HTML
To cancel current operation.
Button)
[0000]
Table for Screen SECURITY_SCREEN_008
Element
Element Name
Type
Purpose
Main Heading
Text
To give the heading for the screen being
Delete Group
navigated
Sub Heading
Text
To give the sub heading for the screen being
Select the
navigated
Groups
Group Names
Check
Check boxes for group names to be deleted.
Sales, finance
Box
Check Box
Check All
On clicking the “Check All” link should
check all the check boxes in the HTML
table.
Check Box
Clear All
On clicking the “Clear All” link should
uncheck all the checked check boxes in the
HTML table.
Delete
Delete
To Delete the data this button need to
be clicked
[1628] 1.4.3.3 Front End Validation
Validation Details
This section provides the front end screen validations along with the associated message—Success/Error Message text
[0000]
Element
Action/
#
Name
Validation Details
Message
1
Group Name
Accepts all the
Max length: 50
(Entry Field)
alphabets and numeric
Mandatory
characters.
BPI_CAS_FSD_COMMON
2
Group Id
Accepts all the
Max length: 10
(Entry Field)
alphabets and numeric
Mandatory
characters.
BPI_CAS_FSD_COMMON
3
Comments/
Accepts all the
Max length: 255
Description
alphabets and numeric
BPI_CAS_FSD_COMMON
characters.
[1631] 1.4.4 User Interface ID: SECURITY_SCREEN — 009 (See FIG. P- 21 )
User Interface ID: SECURITY_SCREEN — 010 (See FIG. P- 22 ) User Interface ID: SECURITY_SCREEN — 011 (See FIG. P- 23 )
[1634] 1.4.4.1 User Interface Screen Snap Shot—Screen Name: Application Master
[1635] 1.4.4.2 Field Name, Element Type & Purpose
[0000]
Table for Screen SECURITY_SCREEN_009
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
Create
being navigated
Application
Sub Header
Text
Text for the Application Id
Application Id
Application Id
Entry Field
Text for the entry field
Sub Header
Text
Text for the Application Name
Application Name
Application Name
Entry Field
Text for the entry field
Sub Header
Text
Text for the Application Name
Application
Description
Application
Entry Field
Text for the entry field
Description
Sub Header
Text
Text for the Module Name
Module Name
Selection Box
Selection Box
Module Name
Save
Button (HTML
To Save the data this button need
Button)
to be clicked
Cancel
Button (HTML
To cancel current operation.
Button)
[0000]
Table for Screen SECURITY_SCREEN_010
Element Name
Element Type
Purpose
Search
Gif
To search the application
[0000]
Table for Screen SECURITY_SCREEN_010
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
Modify
being navigated
Application
Sub Header
Text
Text for the Application Id
Application Id
Application Id
Entry Field
Text for the entry field
Sub Header
Text
Text for the Application Name
Application Name
Application Name
Entry Field
Text for the entry field
Sub Header
Text
Text for the Application Name
Application
Description
Application
Entry Field
Text for the entry field
Description
Update
Button (HTML
To Save the data this button need to
Button)
be clicked
Cancel
Button (HTML
To cancel current operation.
Button)
[0000]
Table for Screen SECURITY_SCREEN_011
Element
Element Name
Type
Purpose
Main Heading
Text
To give the heading for the screen
Delete
being navigated
Application
Sub Heading
Text
To give the sub heading for the screen
Select the
being navigated
Application
Application
Check Box
Check boxes for applications names
Names
to be deleted.
Sales, Select box
for Application
Check Box
Check All
On clicking the “Check All” link
should check all the check boxes in the
HTML table.
Check Box
Clear All
On clicking the “Clear All” link
should uncheck all the checked check
boxes in the HTML table.
Delete
Delete
To Delete the data this button need
to be clicked
[1636] 1.4.4.3 Front End Validation
Validation Details
This section provides the front end screen validations along with the associated message—Success/Error Message text
[0000]
Element
Action/
#
Name
Validation Details
Message
1
Application
Accepts all the
Max length: 50
Name
alphabets and numeric
Mandatory
(Entry Field)
characters.
BPI_CAS_FSD_COMMON
2
Application
Accepts all the
Max length: 10
Id
alphabets and numeric
Mandatory
(Entry Field)
characters.
BPI_CAS_FSD_COMMON
3
Comments/
Accepts all the
Max length: 255
Description
alphabets and numeric
characters.
4
Module
Selection Box
Default: Choose One
Name
validation
BPI_CAS_FSD_COMMON
[1639] 1.4.5 User Interface ID: SECURITY_SCREEN — 012 (See FIG. P- 24 )
User Interface ID: SECURITY_SCREEN — 013 (Sec FIG. P- 25 ) User Interface ID: SECURITY_SCREEN — 0014 (See FIG. P- 26 )
[1642] 1.4.5.1 User Interface Screen Snap Shot—Screen Name: Resource Master
[1643] 1.4.5.2 Field Name, Element Type & Purpose
[0000]
Table for Screen SECURITY_SCREEN_012
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
Create Resource
being navigated
Sub Header
Text
Text for Resource Id
Resource ID
Resource ID
Entry Field
Text for the entry field
Sub Header
Text
Text for Resource Name
Resource Name
Resource Name
Entry Field
Text for the entry field
Sub Header
Text
Text for screen url
Screen URL
Screen URL
Entry Field
Text for the entry field
Resource
Text
Text for the Resource Description
Description
Resource
Entry Field
Text for the entry field
Description
Save
Button (HTML
To Save the data this button need to
Button)
be clicked
Cancel
Button (HTML
To cancel current operation.
Button)
[0000]
Table for Screen SECURITY_SCREEN_012 & Screen
SECURITY_SCREEN_013
Element Name
Element Type
Purpose
Search
Gif
To search the resource and application
[0000]
Table for Screen SECURITY_SCREEN_013
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
Create Resource
being navigated
Sub Header
Text
Text for Resource Id
Resource ID
Resource ID
Entry Field
Text for the entry field
Sub Header
Text
Text for Resource Name
Resource Name
Resource Name
Entry Field
Text for the entry field
Sub Header
Text
Text for screen url
Screen URL
Screen URL
Entry Field
Text for the entry field
Resource
Text
Text for the Resource Description
Description
Resource
Entry Field
Text for the entry field
Description
Save
Button (HTML
To Save the data this button need to
Button)
be clicked
Cancel
Button (HTML
To cancel current operation.
Button)
[0000]
Table for Screen SECURITY_SCREEN_14
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
Delete
being navigated
Resources
Sub Heading
Text
To give the sub heading for the screen
Select the
being navigated
Resources
Resources
Check Box
Check boxes for Resources to be
deleted.
Check Box
Check All
On clicking the “Check All” link should
check all the check boxes in the
HTML table.
Check Box
Clear All
On clicking the “Clear All” link should
uncheck all the checked check boxes in
the HTML table.
Delete
Delete
To Delete the data this button need to
be clicked
[1644] 1.4.5.3 Front End Validation
Validation Details
This section provides the front end screen validations along with the associated message—Success/Error Message text
[0000]
Element
Action/
#
Name
Validation Details
Message
1
Resource
Accepts all the
Max length: 50
Name
alphabets and numeric
Mandatory
(Entry Field)
characters.
BPI_CAS_FSD_COMMON
2
Resource Id
Accepts all the
Max length: 10
(Entry Field)
alphabets and numeric
Mandatory
characters.
BPI_CAS_FSD_COMMON
3
Screen URL
Accepts all the
Max length: 255
(Entry Field)
alphabets and numeric
Mandatory
characters.
BPI_CAS_FSD_COMMON
4
Comments/
Accepts all the
Max length: 255
Description
alphabets and numeric
characters.
5
Application
Selection Box
Default: Choose One
Name
validation
“Mandatory”
BPI_CAS_FSD_COMMON
[1647] 1.4.6 User Interface ID: SECURITY_SCREEN — 015 (See FIG. P- 27 )
Interface ID: SECURITY_SCREEN — 016 (See FIG. P- 28 ) User Interface ID: SECURITY_SCREEN — 017 (See FIG. P- 29 )
[1650] 1.4.6.1 User Interface Screen Snap Shot—Screen Name: User Master
[1651] 1.4.6.2 Field Name, Element Type & Purpose
[0000]
Table for Screen SECURITY_SCREEN_015
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
Create User
being navigated
Sub Header User
Text
Text for the User Id
Id
User Id
Entry Field
Text for the entry field
Sub Header
Text
Text for the Display Name
Display Name
Display Name
Entry Field
Text for the entry field
Sub Header
Text
Text for the Name
Name
Sub Header First
Text
Text for the First Name
Name
First Name
Entry Field
Text for the entry field
Sub Header MI
Text
Text for Middle Initial
Middle Initial
Entry Field
Text for the entry field
Sub Header Last
Text
Text for last name
Name
Last Name
Entry Field
Text for the entry field
Sub Header
Text
Text for the password
password
Password
Entry Field
Text for the entry field
Sub Header
Text
Text for the Phone
Phone
Phone
Entry Field
Text for the entry field
Sub Header Fax
Text
Text for the fax
Fax
Entry Field
Text for the entry field
Sub Header Extn
Text
Text for the ext
Extn
Entry Field
Text for the entry field
Sub Header email
Text
Text for the email
Email
Entry Field
Text for the entry field
Sub Header Lock
Text
Text for the lock
Lock
Check Box
Check box for lock field
Save
Button (HTML
To Save the data this button need
Button)
to be clicked
Cancel
Button (HTML
To cancel current operation.
Button)
[0000]
Table for Screen SECURITY_SCREEN_016
Element Name
Element Type
Purpose
Search
Gif
To search the user
[0000]
Table for Screen SECURITY_SCREEN_016
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
Modify User
being navigated
Sub Header User
Text
Text for the User Name
Name
Sub Header User
Text
Text for the User Id
Id
User Id
Entry Field
Text for the entry field
Sub Header
Text
Text for the Display Name
Display Name
Display Name
Entry Field
Text for the entry field
Sub Header
Text
Text for the Name
Name
Sub Header First
Text
Text for the First Name
Name
First Name
Entry Field
Text for the entry field
Sub Header MI
Text
Text for MI
MI
Entry Field
Text for the entry field
Sub Header Last
Text
Text for last name
Name
Last Name
Entry Field
Text for the entry field
Sub Header
Text
Text for the password
password
Password
Entry Field
Text for the entry field
Sub Header
Text
Text for the Phone
Phone
Phone
Entry Field
Text for the entry field
Sub Header Fax
Text
Text for the fax
Fax
Entry Field
Text for the entry field
Sub Header Ext
Text
Text for the Ext
Ext
Entry Field
Text for the entry field
Sub Header email
Text
Text for the email
Email
Entry Field
Text for the entry field
Lock
Check Box
Check box for the lock field
Update
Button (HTML
To Save the data this button need to
Button)
be clicked
Cancel
Button (HTML
To cancel current operation.
Button)
[0000]
Table for Screen SECURITY_SCREEN_017
Element
Element Name
Type
Purpose
Main Heading
Text
To give the heading for the screen
Delete User
being navigated
Sub Heading
Text
To give the sub heading for the
Select the User
screen being navigated
User Names
Check
Check boxes for User names to be deleted.
Sales. Select
Box
box for
Application
Check Box
Check All
On clicking the “Check All” link should
check all the check boxes in the
HTML table.
Check Box
Clear All
On clicking the “Clear All” link should
uncheck all the checked check boxes in the
HTML table.
Delete
Delete
To Delete the data this button need to
be clicked
[1652] 1.4.6.3 Front End Validation
Validation Details
This section provides the front end screen validations along with the associated message—Success/Error Message text
[0000]
#
Element Name
Action/Validation Details
Message
1
Display Name
BPI_CAS_FSD_COMMON
Mandatory Max Length: 30
(Entry Field)
BPI_CAS_FSD_COMMON
2
First Name (Entry Field)
BPI_CAS_FSD_COMMON
Mandatory Max Length: 25
BPI_CAS_FSD_COMMON
3
MI (Entry Field)
BPI_CAS_FSD_COMMON
Mandatory Max Length: 1
BPI_CAS_FSD_COMMON
4
Last Name (Entry Field)
BPI_CAS_FSD_COMMON
Mandatory Max Length: 35
BPI_CAS_FSD_COMMON
5
Password (Entry Field)
BPI_CAS_FSD_COMMON
Mandatory Max Length: 15
Min Length: 6
BPI_CAS_FSD_COMMON
6
Phone
BPI_CAS_FSD_COMMON
Max Length: 10
BPI_CAS_FSD_COMMON
7
Fax
BPI_CAS_FSD_COMMON
Max Length: 10
BPI_CAS_FSD_COMMON
8
Extn
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
9
Email
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
10
Lock Status
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
[1655] 1.4.7 User Interface ID: SECURITY_SCREEN — 0018 (See FIG. P- 30 )
User Interface ID: SECURITY_SCREEN — 019 (See FIG. P- 31 ) User Interface ID: SECURITY_SCREEN — 020 (See FIG. P- 32 )
[1658] 1.4.7.1 User Interface Screen Snap Shot—Screen Name: User Role Master
[1659] 1.4.7.2 Field Name, Element Type & Purpose
[0000]
Table for Screen SECURITY_SCREEN_018
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
Create User Role
being navigated
Sub Header User
Text
Text for the User Role Id
Role Id
User Role Id
Entry Field
Text for the entry field
Sub Header User
Text
Text for the User Role Name
Role Name
User Role Name
Entry Field
Text for the entry field
Sub Header User
Text
Text for the User Role Name
Role Description
User Role
Entry Field
Text for the entry field
Description
Save
Button (HTML
To Save the data this button need
Button)
to be clicked
Cancel
Button (HTML
To cancel current operation.
Button)
[0000]
Table for Screen SECURITY_SCREEN_019
Element Name
Element Type
Purpose
Search
Gif
To search the user role
[0000]
Table for Screen SECURITY_SCREEN_019
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
Modify User Role
being navigated
Sub Header User
Text
Text for the User Role Id
Role Id
User Role Id
Entry Field
Text for the entry field
Sub Header User
Text
Text for the User Role Name
Role Name
User Role Name
Entry Field
Text for the entry field
Sub Header User
Text
Text for the User Role Name
Role Description
User Role
Entry Field
Text for the entry field
Description
Update
Button (HTML
To Save the data this button need
Button)
to be clicked
Cancel
Button (HTML
To cancel current operation.
Button)
[0000]
Table for Screen SECURITY_SCREEN_020
Element
Element Name
Type
Purpose
Main Heading
Text
To give the heading for the screen
Delete User Role
being navigated
Sub Heading
Text
To give the sub heading for the screen
Select the User
being navigated
Role
User Role Names
Check Box
Check boxes for User Role names to
Sales. finance
be deleted.
Check Box
Check All
On clicking the “Check All” link
should check all the check boxes
in the HTML table.
Check Box
Clear All
On clicking the “Clear All” link should
uncheck all the checked check
boxes in the HTML table.
Delete
Delete
To Delete the data this button need to
be clicked
[1660] 1.4.7.3 Front End Validation
Validation Details
This section provides the front end screen validations along with the associated message—Success/Error Message text
[0000]
#
Element Name
Action/Validation Details
Message
1
User Role Name
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
(Entry Field)
2
User Role Id
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
(Entry Field)
3
Comments/Description
BPI_CAS_FSD_COMMON
Max length: 255
[1663] 1.4.8 User Interface ID: SECURITY_SCREEN — 021 (See FIG. P- 33 )
[1664] 1.4.8.1 User Interface Screen Snap Shot—Screen Name: Group Access Rights
[1665] 1.4.8.2 Field Name, Element Type & Purpose
[0000]
Table for Screen SECURITY_SCREEN_021
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
Group Access
being navigated
Rights
Sub Header
Text
Text for the Group Name
Select Group
Group Name
Selection Box
Selection box for the Group Name
Sub Header
Text
Text for the Application Name
Select
Application
Application
Selection Box
Selection box for the Application Name
Name
Select
Button (HTML
To select the current selected Group
Button)
to assign rights and modules.
Cancel
Button (HTML
To cancel current operation.
Button)
[0000]
Table for Screen SECURITY_SCREEN_021
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
Group Access
being navigated
Rights
Sub Header
Text
Text for the Resource Name
Resource Name
Resource Name
Check Boxes
Check boxes
Sub Header
Text
Text for Access Rights
Access Rights
Combo Box
Combo Box
Combo box for selection of access
rights.
Save
Button (HTML
To Save the data this button need to
Button)
be clicked
Cancel
Button (HTML
To cancel current operation.
Button)
[1666] 1.4.8.3 Front End Validation
Validation Details
This section provides the front end screen validations along with the associated message—Success/Error Message text
[0000]
#
Element Name
Action/Validation Details
Message
1
Group Name
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
2
Application Name
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
3
Resource Id
BPI_CAS_FSD_COMMON
BPI_CAS_FSD_COMMON
[1669] 1.4.9 User Interface ID: SECURITY_SCREEN —022 (See FIG. P- 34 )
User Interface ID: SECURITY_SCREEN — 023 (See FIG. P- 35 )
[1671] 1.4.9.1 User Interface Screen Snap Shot—Screen Name: User, Role and Group Mapping
[1672] 1.4.9.2 Field Name, Element Type & Purpose
[0000]
Table for Screen SECURITY_SCREEN_022
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen being
User Search
navigated
Sub Header
Text
Text for the User Id
Select User Id
User Id
Text Box
Text Field for the User Id
Sub Header
Text
Text for the User Name
Select User
Name
User Name
Text Box
Text Field for the User Name
Search
Button (HTML
To search the current selected User id
Button)
Cancel
Button (HTML
To cancel current operation.
Button)
[0000]
Table Screen SECURITY_SCREEN_022
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
User Search
being navigated
Sub Header
Text
Text for the User Id
Select User Id
User Id
Text Field
Text Field for the User Id
Sub Header
Text
Text for the User Name
Select User
Name
User Name
Text Field
Text Field for the User Name
Search
Button (HTML
To search the current selected User id
Button)
Cancel
Button (HTML
To cancel current operation.
Button)
Sub Heading
Text
To give the heading for the search
User Search
screen
Results
Sub Header User
Label
Text for the User Id
Id
Sub Header User
Label
Text for the User Name
Name
Data Row from
User Id
User id from database. To be
database
displayed in table
Data Row from
User Name
User name from database. To be
database
displayed in table
Cancel
Button (HTML
To cancel current operation.
Button)
[0000]
Table for Screen SECURITY_SCREEN_023
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
User Role
being navigated
Mapping
Sub Header
Text
Text for the User Id
Select User Id
User Id
Text Label
Text Label for the User Id
Sub Header
Text
Text for the User Name
Select User
Name
User Name
Text Label
Text Label for the User Name
Sub Header
Text
Text for the User Role
Select User Role
Selection box
Selection Box
Selection Box for User Role
Select
Button (HTML
To select the current selected User id
Button)
Cancel
Button (HTML
To cancel current operation.
Button)
[0000]
Table for Screen FIG. 33: Screen SECURITY_SCREEN_023
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
User Role
being navigated
Mapping
Sub Header
Text
Text for the User Id
Select User Id
User Id
Text Label
Text Label for the User Id
Sub Header
Text
Text for the User Name
Select User
Name
User Name
Text Label
Text Label for the User Name
Sub Header User
Text
Text for the User Role
Role
Text Label
Text Label
Selection Box for User Role
Sub Header
Text
Text for the Groups
Select the groups
Check Box
Check Box
Check Box for groups. User can
select one or more groups.
Select
Button (HTML
To select the current selected User id
Button)
Cancel
Button (HTML
To cancel current operation.
Button)
[1673] 1.4.10 User Interface ID: SECURITY_SCREEN — 024 (See FIG. P- 36 )
User Interface ID: SECURITY_SCREEN — 025 (See FIG. P- 37 )
[1675] 1.4.10.1 User Interface Screen Snap Shot—Screen Name: Group Access Rights
[1676] 1.4.10.2 Field Name, Element Type & Purpose
[0000]
Table for Screen SECURITY_SCREEN_024
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
User Search
being navigated
Sub Header
Text
Text for the User Id
Select User Id
User Id
Text Box
Text Field for the User Id
Sub Header
Text
Text for the User Name
Select User
Name
User Name
Text Box
Text Field for the User Name
Search
Button (HTML
To search the current selected User id
Button)
Cancel
Button (HTML
To cancel current operation.
Button)
[0000]
Table for Screen SECURITY_SCREEN_024
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
User Search
being navigated
Sub Header
Text
Text for the User Id
Select User Id
User Id
Text Field
Text Field for the User Id
Sub Header
Text
Text for the User Name
Select User
Name
User Name
Text Field
Text Field for the User Name
Search
Button (HTML
To search the current selected User
Button)
id
Cancel
Button (HTML
To cancel current operation.
Button)
Sub Heading
Text
To give the heading for the search
User Search
screen
Results
Sub Header User
Label
Text for the User Id
Id
Sub Header User
Label
Text for the User Name
Name
Data Row from
User Id
User id from database. To be
database
displayed in table
Data Row from
User Name
User name from database. To be
database
displayed in table
Cancel
Button (HTML
To cancel current operation.
Button)
[0000]
Table for Screen SECURITY_SCREEN_025
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
User Access
being navigated
Rights
Sub Header User
Text
Text for the User Name
Name
User Name
Text
Text for the User Name
Sub Header User
Text
Text for the User Id
ID
User Id
Text
Text for the User Id
Sub Header
Text
Text for the Module Name
Module Name
Selection Box
Selection Box
Selection Box for Module name
Sub Header Role
Text
Text for the Role Name
Name
Selection Box
Selection Box
Selection Box for Role name
Select
Button (HTML
To select the current selected User
Button)
assign rights for all the
application.
Cancel
Button (HTML
To cancel current operation.
Button)
indicates data missing or illegible when filed
[0000]
Table for Screen SECURITY_SCREEN_025
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen being
User Access
navigated
Rights
Sub Header
Text
Text for the Resource Name
Resource Name
Resource name
Text
Text for the Resource Name
Sub Header
Text
Text for Access Rights
Access Rights
Combo Box
Combo Box
Combo box for selection of access
rights.
Save
Button (HTML
To Save the data this button need
Button)
to be clicked
Cancel
Button (HTML
To cancel current operation.
Button)
[1677] 1.4.10.3 Front End Validation
Validation Details
This section provides the front end screen validations along with the associated message—Success/Error Message text
[0000]
#
Element Name
Action/Validation Details
Message
1
User Role
BPI_CAS_FSD_COMMON
“Please choose
the User Role”
2
Module Name
BPI_CAS_FSD_COMMON
“Please choose the
Module name”
3
Access Rights
BPI_CAS_FSD_COMMON
“Please choose the
Resource name”
[1680] 1.4.11 User Interface ID: SECURITY_SCREEN — 026 (See FIG. P- 38 )
[1681] 1.4.11.1 User Interface Screen Snap Shot—Screen Name: Configurable Items
[1682] 1.4.11.2 Field Name, Element Type & Purpose
[0000]
Table for Screen SECURITY_SCREEN_026
Element Name
Element Type
Purpose
Main Heading
Text
To give the heading for the screen
Configure Items
being navigated
Sub Header
Text
Text for the Password Length
Password Length
Password Length
Text Box
Text Field for the Password Length
Sub Header
Text
Text for the Password Length
Password Length
(Minimum)
(Minimum)
Password Length
Text Box
Text Field for the Password Length
(Minimum)
(Minimum)
Sub Header
Text
Text for the Expiry of password
Expiry of
password (Max)
Expiry of
Text Box
Text Field for the Expiry of password
password
Sub Header
Text
Text for the Expiry of password
Expiry of
password (Min)
Expiry of
Text Box
Text Field for the Prompt Date Period
password
Sub Header
Text
Text for the Prompt Date Period
Prompt Date
Period
Prompt Date
Text Box
Text Field for the Expiry of password
Period
Prompt Date Period
Sub Header
Text
Text for the Password Repeat Count
Password Repeat
Count
Password Repeat
Text Box
Text Field for the Password Repeat
Count
Count
Sub Header
Text
Text for the Invalid Passwords Count
Invalid
Passwords Count
Invalid
Text Box
Text Field for the Invalid Passwords
Passwords Count
Count
Sub Header Lock
Text
Text for the Lock Time
Time
Lock Time
Text Box
Text Field for the Lock Time
Search
Button (HTML
To search the current selected User id
Button)
Cancel
Button (HTML
To cancel current operation.
Button)
[1683] 1.4.11.3 Front End Validation
Validation Details
This section provides the front end screen validations along with the associated message—Success/Error Message text
[0000]
Action/Validation
#
Element Name
Details
Message
1
Password Length
Numeric (Integer)
Integer Length max 2
(Maximum &
For eg Min Value 6
Minimum)
Max Value 10
2
Expiry of password
Numeric (Integer)
Integer Length max 2
(Min)
For eg Min Value 1
Max Value 99
3
Expiry of password
Numeric (Integer)
Integer Length max 2
(Max)
For eg Min Value 0
Max Value 99
Should be greater than
Expiry of password (Min)
4
Password Repeat
Numeric (Integer)
Integer Length max 2
Count
For eg Min Value 1
Max Value 10
5
Invalid Passwords
Numeric (Integer)
Integer Length max 2
Count
For eg Min Value 1
Max Value 10
6
Lock Time
Numeric (Integer)
Integer Length max 2
(Minutes)
For eg Min Value 10
Max Value 36000
7
Password Length
Numeric (Integer)
Integer Length max 2
(Minimum)
For eg Min Value 6
Max Value 10
Less than maximum length
of password
8
Prompt Date
Numeric (Integer)
Less than maximum limit
Period for
for expiration date
expiration
For eg Min Value 1
Max Value 10
[1686] 1.4.12 User Login
When the system user logs in into the core administration system the separate ACL will be generated for each user. The ACL will be stored in the User Profile object, which will be stored in the user session. When user request for a particular page controller will check with the security system whether user is having access to the particular page. When any user requests a particular page in the core administrative system, the controller will ask the security system about the security rights for the application. If user is having rights he will be allowed to perform the current operation. For e.g. If user request for create carrier master. The carrier master is registered into the system with system with id as 0001. The controller will check the access rights for the carrier master. If the rights for carrier master is write then user will have access to create carrier master as the user rights are higher than requested one. If user is having access rights as read for carrier master then he would not be able to access because it is having lower rights than requested one.
[1690] Password Validation
Password validation to be done as per the requirements specified before. The following items need to be configured as per requirements.
[1692] 1.5 Business Rules
[0000]
Activity
Rules
Delete Rule
For Deleting referential integrity need to be
considered.
A group can be deleted if no user is referring to the
group
Same applies to other hierarchy
Module
Application
Resource
[1693] 1.6 Help Menu
Help to be provided for all the screens. Help should contain following details.
Basic Functionality Description Description about the screen fields.
[1697] 1.7 Process-Data Structure
This section describes the likely data structure that would contain the data for/by executing the process
[0000]
BPI_MODULES
Data Element Name
Data Element Type
Constraints
MODULE_ID
Varchar (10)
PK Not Null
MODULE_NAME
Varchar (50)
Not Null
DESCRIPTION
Varchar (255)
CREATED_BY
Varchar (25)
CREATED_DATE
Timestamp
MODIFIED_BY
Varchar (25)
LAST_MODIFIED_DATE
Timestamp
STATUS
NUMBER
1- Active
0- Inactive
[0000]
BPI GROUPS
Data Element Name
Data Element Type
Constraints
GROUP_ID
Varchar (10)
PK Not Null
DESCRIPTION
Varchar (255)
Not Null
GROUP_NAME
Varchar (50)
CREATED_BY
Varchar (25)
CREATED_DATE
Timestamp
MODIFIED_BY
Varchar (25)
LAST_MODIFIED_DATE
Timestamp
STATUS
NUMBER
1- Active
0- Inactive
[0000]
BPI APPLICATIONS
Data Element Name
Data Element Type
Constraints
APPLICATION_ID
Varchar (10)
PK Not Null
APPLICATION_NAME
Varchar (50)
Not Null
DESCRIPTION
Varchar (255)
MODULE_ID
Varchar (10)
FK Refers
BPI_MODULES
CREATED_BY
Varchar (25)
CREATED_DATE
Timestamp
MODIFIED_BY
Varchar (25)
LAST_MODIFIED_DATE
Timestamp
STATUS
NUMBER
1- Active
0- Inactive
[0000]
BPI RESOURCES
Data Element
Data Element Name
Type
Constraints
RESOURCE_ID
Varchar (10)
PK Not Null
RESOURCE_NAME
Varchar (50)
Not Null
DESCRIPTION
Varchar (255)
APPLICATION_ID
Varchar (10)
FK Refers
BPI_APPLICATIONS
CREATED_BY
Varchar (25)
CREATED_DATE
Timestamp
MODIFIED_BY
Varchar(25)
LAST_MODIFIED_DATE
Timestamp
STATUS
NUMBER
1 Active
0- Inactive
[0000]
BPI ACL
Data Element Name
Data Element Type
Constraints
ACL_ID
Varchar (10)
PK Not null
ACL_NAME
Varchar (50)
Not null
CREATED_BY
Varchar (25)
CREATED_DATE
Timestamp
MODIFIED_BY
Varchar(25)
LAST_MODIFIED_DATE
Timestamp
STATUS
NUMBER
1 Active
0- Inactive
[0000]
BPI ROLES
Data Element Name
Data Element Type
Constraints
ROLE_ID
Varchar (10)
PK Not null
ROLE_NAME
Varchar (50)
Not null
CREATED_BY
Varchar (25)
CREATED_DATE
Timestamp
MODIFIED_BY
Varchar(25)
LAST_MODIFIED_DATE
Timestamp
STATUS
NUMBER
1 Active
0- Inactive
[0000]
BPI USERS
Data Element Name
Data Element Type
Constraints
USER_ID
Varchar (10)
PK Not null
PASSWORD
Varchar (30)
Not null
ADDRESS 1
Varchar (30)
ADDRESS 2
Varchar (30)
CITY
Varchar (25)
STATE
Varchar (25)
ZIP
Varchar (25)
COUNTRY
Varchar (25)
PHONE 1
Varchar (25)
PHONE 2
Varchar (25)
PHONE 3
Varchar (25)
CREATED_BY
Varchar (25)
CREATED_DATE
Timestamp
MODIFIED_BY
Varchar (25)
LAST_MODIFIED_DATE
Timestamp
STATUS
Number
1 Active
0 Inactive
PASSWORD_EXPIRY_DATE
Timestamp
LOCK_STATUS
Number
[0000]
BPI GROUP ACCESS
Data Element
Data Element Name
Type
Constraints
GROUP_ID
Varchar (10)
Not null Refers
BPI_GROUPS
RESOURCE_ID
Varchar (105)
Not null Refers
BPI_RESOURCES
APPLICATION_ID
Varchar (10)
Not null Refers
BPI_APPLICATIONS
ACL_ID
Varchar (10)
Not null Refers
BPI_ACL
CREATED_BY
Varchar (25)
CREATED_DATE
Timestamp
MODIFIED_BY
Varchar (25)
LAST_MODIFIED_DATE
Timestamp
STATUS
Number
1 Active
0 Inactive
[0000]
BPI USER ROLES
Data Element Name
Data Element Type
Constraints
USER_ID
Varchar (10)
Not Null Refers
BPI_USERS
ROLE_ID
Varchar (10)
Not Null Refers
BPI_ROLES
GROUP_ID
Varchar (10)
Not Null Refers
BPI_USGROUPS
CREATED_BY
Varchar (25)
CREATED_DATE
Timestamp
MODIFIED_BY
Varchar (25)
LAST_MODIFIED_DATE
Timestamp
Status
Number
1 Active
0 Inactive
[0000]
BPI USER ACCESS
Data
Element
Data Element Name
Type
Constraints
RESOURCE_ID
Varchar (10)
Not Null
Refers BPI_RESOURCE
USER_ID
Varchar (25)
Not Null Refers
BPI_USERS
ACL_ID
Varchar (10)
Not Null Refers BPI_ACL
ROLE_ID
Varchar (10)
CREATED_BY
Varchar (25)
CREATED_DATE
Timestamp
MODIFIED_BY
Varchar (25)
LAST_MODIFIED_DATE
Timestamp
Status
Number
1 Active
0 Inactive
[0000]
BPI USER PASSWORD HISTORY
Data Element Name
Data Element Type
Constraints
USER_ID
Varchar (10)
Not Null Refers
BPI_USERS
PASSWORD
Varchar (10)
Not Null
CREATED_BY
Varchar (25)
CREATED_DATE
Timestamp
MODIFIED_BY
Varchar (25)
LAST_MODIFIED_DATE
Timestamp
Status
Number
1 Active
0 Inactive
[1699] 1.8 Back End Validations
This subsection provides the field element name and corresponding back end validation if applicable. Back end validations are those validations where the validations have got to be necessarily done using the database. As a general rule backend validations should be done for all the validation checks that are being carrier on the front end.
[1703] 1.9 Non-Functional Requirements
This subsection corresponds to the requirements that do not relate to the user function. It provides information on the system requirements—Ideally identifies the present problems in the existing system from a non-functional perspective and avoiding the same in the new system
[0000]
Non Functional
Requirement
Details
Performance
Performance criteria should be established based
on the data size and the page size.
System Exception
All system exceptions should be handled grace
fully throwing a error page with relevant exception
information and action to be taken for resolving the
exception
[1705] 1.10 Access Control List
This section describes the classification of users who can access the process under definition
[0000]
User ID
Job Description
Functionality
Access Level
Benefit Partners Inc
Process Specification
Common Functional Features
1. Introduction
[1707] 1.1. Purpose
The purpose of this document is to describe the common functional features available across all the modules. This document is identified as Common Functional Features. This document identifies how the user interacts with the system, the data to be captured, the business logic to be implemented, and the output of the process for the common functional features.
[1709] 1.2. Business Use Case Specification Reference
[0000]
Business Use Specification ID
Business Use Case Name
BPI_SCOPE
Scope Document
BPI_SCOPE_ADD
Addendum to scope
[1710] 1.3. Definitions, Acronyms & Abbreviations
[0000]
Term
Explanation
2. Process Identification
[1711] 2.1. Background
Common functional feature is to identify the common functionality across all the modules that have the same usage. This would help in standardization and reuse of the components.
[1713] 2.2. Process Description
The objective of the Common Functional Features process is to:
1) Identify the Common functional features across all the modules:
[1716] 2.3. Process Flow
Not applicable
3. User Interface
[1718] 3.1. User Interface Screens
[1719] 3.1.1. Not Applicable
[1720] 3.1.2. Not Applicable
[1721] 3.1.3. Element Name, Element Type & Purpose
[0000]
Element Name
Element Type
Purpose
First name
Entry Field
Enter the First name
Last name
Entry Field
Enter the last name
Middle name (MI)
Entry Field
Enter the middle Name
Suffix
Drop Down List
List the Suffix
Salutation
Drop Down List
List the Salutation
Title
Entry Field
Enter the Job Title
Address
Entry Field
Enter the first detail about the address
Suite/Apt. #
Entry Field
Enter the suite/Apartment or PO BOX number
City
Entry Field
Enter the name of the city
State
Drop Down List
List all the States in UAS
ZIP
Entry Field
Enter the ZIP Code
Phone #
Entry Field
Enter the Phone number
Fax #
Entry Field
Enter the FAX number
Phone Extension
Entry Field
Enter extension number
FAX Extension
Entry Field
Enter extension number
Email Address
Entry Field
Enter the email address
Credit Card Number
Enter the Credit Card
Entry Credit Card number
Number
Credit Card Type
Drop Down List
List the type of Credit Card
(Date) Current Date
Calendar/Entry Field
Entry field to type the date or Calendar to pick the
(System Date)
date
(Date) Past Date (1900
Calendar/Entry Field
Entry field to type the date or Calendar to pick the
to system date)
date
(Date) Future Date
Calendar/Entry Field
Entry field to type the date or Calendar to pick the
(System date to 100 Yr.
date
hence)
(Date) Default 1 st of
Calendar/Entry Field
Entry field to type the date or Calendar to pick the
Following Month (eg.
date
System date is Dec. 2, 2001
should default to
Jan. 1, 2002)
(Date) Default 1 st of
Calendar/Entry Field
Entry field to type the date or Calendar to pick the
the current Month (e.g.
date
System date is Dec. 2, 2001
should default to
Dec. 1, 2001)
(Date) Default End of
Calendar/Entry Field
Entry field to type the date or Calendar to pick the
current Month (eg.
date
System date is Dec. 2, 2001
should default to
Dec. 31, 2001)
(Date) Credit Card
Drop Down List
List all the Months in a year
Date (should only
accept future date.)
Month
Date) Credit Card
Drop Down List
List the year 25 years ahead
Date (should only
accept future date.)
Year
Social Security
Entry Field
Enter the Social Security number
Number
TAX Identification
Entry Field
Enter the Tax Identification Number
Number
Mode of
Drop Down List
List Various modes of communication
Communication
Browser Back Button
Button
Validate the back button
Browser Forward
Button
Validate the forward button
Button
Refresh Button
Button
Validate Refresh button
Address Bars
Tool Bars
Hide Address bar
Link Bar
Tool Bars
Hide Link bar
Standard Button
Tool bars
Hide standard bars
Window Close
Browser Window
Validate Close
Window Minimize
Browser Window
Validate minimize
[1722] 3.1.4. Screen Validations
Note: Validation provided here are the default validations. However if the module functionality has specified different validations for these element described then that would override the default validations provided here.
[0000]
Element Name
Action/Validation Details
Message
First name
Entry Field with 40 Character long.
Can accept only Alpha characters.
Arnold
Last name
Entry Field with 40 Character long
Can accept only Alpha characters.
Schwarzenegger
Middle name (MI)
Entry Field with 1 Character long
Can accept only Alpha characters.
M. A etc.
Suffix
List should include Jr., Sr., I., II.,
III., IV., and V.
Salutation
List should include Mr., Mrs., Ms.
Title
Entry Field with 20 Character long
Can accept Alpha and numeric
character and blank space between
character (Example Administrator 1)
Address
Entry Field with 40 Character long
3013 Douglas Boulevard,
Can accept free form entry with any
character.
Suite/Apt. #
Entry Field with 20 Character long
Example 200 or 1 D etc.
Can accept free form entry with any
character.
City
Entry Field with 20 Character long
Alpha only and Blank between
words allowed
Roseville, San Jose, San Diego
State
List all the States in USA in
abbreviated form as CA, IL, OH, NY
etc.
ZIP
Entry Field with 5 Character long
Should allow maximum and
minimum of 5 Numbers only. Whole
Number Field.
Phone #
Entry Field with 10 Character long
Should allow maximum and
minimum of 10 Numbers only.
Whole Number Field.
3 for Area code, 7 for the number.
Fax #
Entry Field with 10 Character long
Should allow maximum and
minimum of 10 Numbers only.
Whole Number Field.
3 for Area code, 7 for the number.
Phone Extension
Entry Field with 5 Character long
Should allow maximum of 5 and
minimum of 1. Blanks fields are
acceptable.
Whole Number Field.
FAX Extension
Entry Field with 5 Character long
Should allow maximum of 5 and
minimum of 1. Blanks fields are
acceptable.
Whole Number Field.
Email Address
Entry Field with 40 Character long
Allow entering more than 40
character.
Validate for a Valid Email Address.
Credit Card
Entry Field with 20 Character long
Number
Minimum and maximum value
should be 16. Allow only Whole
Number. Numeric Field
For Amex allow 20 as min and max
value.
Credit Card Type
List Credit Card type as
Visa, Master, Discovery, Amex etc
(Date) Current
Entry Field or Calendar with default
Date (System Date)
system date in the Entry Field and
calendar.
(Date) Past Date
Entry Field or Calendar with default
(1900 to system
system date − 1 in the Entry Field
date)
and calendar. Do not allow for
Current date and future date
(Date) Future Date
Entry Field or Calendar with default
(System date to
system date in the Entry Field and
100 Yr. hence)
calendar. Do not allow for past date
(Date) Default 1 st
Entry Field or Calendar with default
of Following
first of the following month date in
Month (eg. System
the Entry Field and calendar.
date is Dec. 2, 2001
should default to
Jan. 1, 2002)
(Date) Default 1 st
Entry Field or Calendar with default
of the current
first of the current month date in the
Month (e.g. System
Entry Field and calendar.
date is Dec. 2, 2001
should default to
Dec. 1, 2001)
(Date) Default End
Entry Field or Calendar with default
of current Month
end of the current month date in the
(eg. System date is
Entry Field and calendar.
Dec. 2, 2001 should
default to
Dec. 31, 2001)
(Date) Credit Card
List to show all the months in a year
Date (should only
accept future date.)
Month
Date) Credit Card
List the years from current year to
Date (should only
100 years forward hence.
accept future date.)
Validate The Credit Card month and
Year
year together. Should not have past
month as credit card entry.
Social Security
Entry Field with 9 Character long
Number
Should allow maximum of 9 and
minimum of 9.
Whole Number Field.
TAX Identification
Entry Field with 9 Character long
Number
Should allow maximum of 9 and
minimum of 9.
Whole Number Field.
Mode of
List various modes of
Communication
Communication like Fax, Phone,
Email, USPS
Browser Back
Disable the browser back button and
Button
hide the back button
Browser Forward
Disable the browser forward button
Button
and hide the forward button
Refresh Button
Disable the browser refresh button
and hide the refresh button
Address Bars
Disable the address bar so that user
cannot type the URL to navigate to
the respective screen
Link Bar
Disable the link bar
Standard Button
Disable the browser standard button
Window Close
Catch windows close event with
Java script and show the message.
Window Minimize
Allow to minimize the window
[1724] 3.1.5. Interface Flow
N/A
[1726] 3.1.6. Help Menu
[0000]
Element Name
Purpose
Valid Values
4. Business Rule Mapping
[0000]
Not Applicable
[0000]
Activity
Rules
1.
5. Data Structures
[0000]
Not Applicable
[0000]
Data Element Name
Data Element Type
[1729] 5.1. Back End Validations
Not Applicable
[0000]
Field Element Name
Back End Validation
6. Non-Functional Requirements
[0000]
Not Applicable
[0000]
Non Functional Requirement
Details
7. Access Control List
[0000]
Not Applicable
[0000]
User ID
Job Description
Functionality
Access Level
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An automated benefit administration system and methods of use and doing business. The full system includes a wide range of features including application of business rules to enrollment, eligibility, and maintenance data input, making of business decisions based on the specific data entered, and issuing of notices based on business rule discrepancies including notices to third parties when deemed appropriate. The full system also is secure while providing remote access, including through the Internet, limits access based on user hierarchy, allows user customization of various features including communications vehicles (e-mail, letter correspondence, or facsimile) and of the format of certain communications, provides automatic enrollment in Cobra without re-entry of beneficiary data, accomplishes various types of financial reconciliation, accommodates differing organizational structures and groupings of entities, provides business rule over-ride capability for certain users, and provides robust information about carriers and their services.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to the inking of high-speed web printing presses. High-speed web printing is a widely used printing technique where the inked image is transferred from a plate to a rubber blanket, then to the printing surface. Some advantages of high speed web printing compared to other printing methods are consistent high image quality and production of sharper, cleaner images and type than letterpress printing for the reason that the rubber blanket conforms to the texture of the printing surface. Additionally, the production of the printing plates is quick and easy and the printing plate life is longer than on direct lithographic presses, since there is no direct contact between the plate and the printing surface.
[0002] The present invention is an oscillating ink form, which is designed as an intermediary roller between the inking roller and the high speed plate. The oscillating ink form is designed differently than prior inking forms. The present invention is permitted to move freely back and forth within preset lateral motion limiters, to allow a more even distribution of the ink onto the high speed plate that prints on the paper.
[0003] One problem with earlier ink forms is that these ink forms were static, i.e., locked in a single position, and thus, unable to laterally move within the confines of the horizontal dimensions of the press. In this manner, ink being deposited on the intermediate roller or on the rubber blanket was unevenly distributed across the printing surface. Due to the non-oscillating nature of earlier ink forms “ghosting” occurred on the printed page, which is a slightly offset secondary image of the primary image. “Ghosting” can occur because the thickness of the deposited ink diminishes during transference. Therefore a need exists for an ink form that prevents the occurrence of “ghosting” by employing a laterally offset motion for the indirect transference of the ink for the high speed presses to avoid ink thickness differences on either the secondary transfer roller or the rubber blanket.
[0004] A need also exists for an ink form roller that achieves a more uniform inking of the inking transfer roller, and ultimately the printing plate (or rubber blanket) by allowing for a slight lateral motion of the inking form along its axis. This will achieve a more even distribution of ink onto the printing plate in a continuing, consistent manner and is especially useful in preventing horizontal and vertical lines that form when the ink thickness diminishes. Moreover, a need also exists for an ink form that prevents the fading of bold letter characters and reprinted photos. The present invention will permit minimal lateral displacement of the inking form along its axis (support shaft) within preset motion limiters to create the more uniform distribution of ink across the width of the press assembly.
SUMMARY OF THE INVENTION
[0005] The present invention is an oscillating ink form used in place of the standard large ink form, or the outside ink form, in the ink train of a high-speed printing press. The benefit of using an oscillating ink form is to create a more uniform distribution of ink across the width of the print rollers of the press and to reduce or eliminate “ghosting” resulting in better print quality.
[0006] The ink form roller is assembled using a hollow core, an elongated shaft, a pair of washers, two split collar motion limiters, a pair of linear rotary bearings and a pair of snap rings. A rubber covering is applied to the outer surface of the core to form the ink form roller. The ink form roller is mounted on a stationary solid shaft that runs through the hollowed middle of the ink form roller. When installed in the ink train of the high-speed press, the shaft is bolted to the frame, so that the roller can spin freely about the pair of linear rotary bearings, as well as travel back and forth, i.e., oscillate, along the rotational axis of the ink form roller within lateral motion limits set by the pair of split collar motion limiters. This is accomplished without any movement of the static shaft, although the ink form roller rotates at press speed.
[0007] It is an object of the present invention to have the pair of split collar motion limiters positioned at substantially identical distances outward of the ink form roller core along the stationary shaft to allow the ink form roller to freely oscillate back and forth within the distance limited by the collars to provide a more uniform ink distribution to the transference roller and to the printing form. The ink form roller will rotate at machine speed, oscillating between the collars in following the associated drive roller, to distribute the ink along the desired ink width of the ink transference rollers of the press.
[0008] It is another object of the present invention to have an ink form roller where the amount of the oscillation is adjustable in accordance with the placement of the paired split collar motion limiters so that the ink form roller may oscillate within a range of ¼ of an inch to 1 inch or more, according to the needs of the user.
[0009] Other features and advantages of the invention are described below.
BRIEF DESCRIPTION OF THE DRAWING
[0010] For the purpose of illustrating the invention, there is shown in the drawing a form which is presently preferred; it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
[0011] FIG. 1 is a partial cutaway side view of the oscillating ink form roller assembly of the present invention.
[0012] FIG. 2 is a schematic view of the series of rollers from the ink fountain roller to the plate and blanket cylinder rollers.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The following detailed description is of the best presently contemplated mode of carrying out the invention. The description is not intended in a limiting sense, and is made solely for the purpose of illustrating the general principles of the invention. The various features and advantages of the present invention may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawing.
[0014] As illustrated in FIG. 1 , the oscillating ink form system 10 is assembled using a hollow core 14 , which is cylindrical in shape, about which a rubber cover 16 is applied to create the ink form or roller 12 . A solid elongated shaft 18 , about which the hollow core 14 and rubber covering 16 will rotate, extends through the core 14 . In order that the ink form or roller 12 can rotate about the shaft 18 , a pair of linear rotary bearings 20 a, 20 b are press-fitted into the cylindrical hollow space within the core 14 a predetermined distance inward from the respective rims of both ends of the core 14 and a pair of snap rings 22 a, 22 b are positioned into respective slots precut inside the core 14 to retain the liner rotary bearings 20 a, 20 b in their predetermined positions during use of the form or roller 12 .
[0015] Completing the assembly of the oscillating ink form system 10 , the shaft is inserted through the hollow core 14 of the ink form or roller 12 , through the central aperture of each of the linear rotary bearings 20 a, 20 b. The ink form or roller 12 is centered on the shaft 18 and a pair of motion permitting washers or spacers 24 a, 24 b, are placed outward and at either side of the ink form or roller 12 along the shaft 18 . Finally, a pair of split collar motion limiters 26 a, 26 b are positioned along the shaft 18 outward from the ink form or roller 12 a predetermined distance such that the ink form or roller 12 is capable of both free rotation about, and limited lateral motion along the shaft 18 . The motion limiters 26 a, 26 b can be located at any desired distance away from the ends of the ink form or roller 12 to permit the free oscillation within the limited lateral distance between the motion limiters 26 a, 26 b. It is preferred, although not required, to position the motion limiters 26 a, 26 b at positions that are equidistant from either the center or the ends of the shaft 18 so that the ink form or roller 12 performs its rotational translation symmetrically along the length of the shaft between the motion limiters 26 a, 26 b. If non-symmetrical oscillation is required, the motion limiters 26 a, 26 b may be positioned at unequal distances to accommodate this requirement.
[0016] The ink form or roller 12 , which is rotationally mounted about the elongated shaft 18 that runs through the hollow center of the ink form or roller 12 , is installed onto the press by bolting the opposite ends of the shaft 18 to the high-speed printing press frame. With reference to FIG. 2 , there may be a number of placements for the ink form rollers 12 of the present invention in the roller series for inking high-speed presses. Starting in the upper left with the ink fountain roller 32 , this roller transfers the ink from the fountain (not shown) to one or more of ink transfer rollers 34 utilizing intermediary ink oscillator rollers 36 . These ink oscillator rollers also are intermediate the ink transfer rollers 34 and the one or more ink form rollers 12 of the present invention. The ink form rollers 12 , in turn, contact the printing plate cylinder roller 38 , transferring the ink so that “ghosting” does not occur when the ink is transferred to the blanket roller 40 for printing on the desired print surface.
[0017] Each of any ink form rollers 12 present in the ink train system for the press is driven rotationally by the adjacent ink oscillator roller 36 and also laterally as the ink oscillator rollers 36 move laterally in accordance with the preferred scope of motion set for the individual print job. In this manner the ink form or roller 12 will freely rotate at press speed, without impediment, about the fixed, stationary shaft 18 and oscillate back and forth along the shaft 18 within the limited lateral spacings of the motion limiters 26 a, 26 b. It is important to not that the lateral motion of the ink form roller 12 may be set to mimic the ink oscillator rollers 36 or be set to limit to lateral motion of the roller. The lateral, oscillating motion of the ink form or roller 12 provides for the more even distribution of ink within the ink train of the high-speed press.
[0018] The linear rotary bearings 20 a, 20 b that are used to mount the may ink form or roller 12 to the shaft 18 are preferred to be made of aluminum alloy or stainless steel, are cylindrical in shape with a hollowed out core, are capable of self alignment when placed in the desired position, and may range in length (for the present application) from 3 inches up to 8 inches. The overall distance between each of the motion limiters 26 a, 26 b is larger than the overall length dimension of the ink form or roller 12 and the washers 24 a, 24 b to permit the uninhibited lateral motion, i.e., the free rotational oscillation, of the ink form or roller 12 .
[0019] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, the described embodiments are to be considered in all respects as being illustrative and not restrictive.
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The present invention is an adjustable oscillating ink form or roller that moves freely back and forth along its axis of rotation to create a more efficient inking of the printing plate of a high-speed web printing press by allowing for a more even distribution of ink onto the printing plate in a more consistent manner. The back and forth oscillation is especially useful in preventing image “ghosting” that forms on the printed page when the ink thickness diminishes.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is related to co-pending and commonly assigned U.S. patent application Ser. No. 516,413 filed Apr. 30, 1990, now U.S. Pat. No. 5,031,188.
TECHNICAL FIELD
This invention relates to semiconductor devices and, more particularly, to devices employed as transmitters and receivers in lightwave communication systems.
BACKGROUND OF THE INVENTION
Wavelength-division-multiplexing (WDM) affords bidirectional communications and multiple channel communications over a single optical fiber link in a lightwave communication system. For an exemplary bidirectional system between two end stations, each station transmits at an assigned wavelength. See, for example, Elect. Lett., Vol. 21, No. 20, pp. 928-9 (1985). In order to receive signals from the remote end station, the receiver must operate at a wavelength different from the assigned transmitter wavelength. Separate waveguides connect the transmitter and the receiver to the optical fiber. Wavelength blocking filters and wavelength selective or routing couplers have been used to direct lightwave signals from the optical fiber to the receiver and from transmitter to the optical fiber.
By employing WDM, it is possible to design around crosstalk between signals of significantly differing strengths, namely, the high optical power signal from the transmitter and the relatively low optical power signal to the receiver. Unfortunately, receiver interference is caused by near end crosstalk from Fresnel reflections and Rayleigh backscattering of lightwave signals from the optical fiber. Receiver interference degrades receiver sensitivity and impairs WDM system performance. While WDM techniques offer the potential for bidirectional transmission on a single optical fiber, it is clear that realization of a WDM system is costly and architecturally complex. Both cost and complexity combine to make these techniques unattractive for communication systems having a large number of stations such as local area networks and "fiber to the home" applications.
SUMMARY OF THE INVENTION
Full duplex lightwave communications is achieved in a diplex transceiver realized in a semiconductor photonic integrated circuit having an inline interconnecting waveguide integral with the transmitting and receiving portions of the transceiver. Semiconductor lasers and detectors operating in different wavelength regimes permit diplex or wavelength-division-multiplexed operation. In the transceiver, lightwave signals from the laser propagate through the detector without interfering with the detector operation or the lightwave signals being detected.
In one exemplary embodiment, a longer wavelength laser or source is integrated with a shorter wavelength detector. The longer wavelength lightwave signals of the laser propagate in a direction contrary to the shorter wavelength signals for the detector in the region of the detector without affecting detector operation. This permits outgoing signals to be transmitted from the same end (facet) of the transceiver as incoming signals are received.
BRIEF DESCRIPTION OF THE DRAWING
A more complete understanding of the invention may be obtained by reading the following description of a specific illustrative embodiment of the invention in conjunction with the appended drawing in which:
FIG. 1 shows a simplified block diagram of a wavelength-division-multiplexed lightwave communication system realized in accordance with the principles of the present invention;
FIGS. 2, 3, and 5 show cross-sectional views of exemplary semiconductor heterostructure arrangements for realizing the inline diplex lightwave transceiver in accordance with the principles of the present invention; and
FIG. 4 shows an exemplary transition from an active device to a passive waveguide as employed in the arrangements of FIGS. 2, 3, and 5.
It should be noted that the drawings have not been drawn to scale in order to achieve more clarity and understanding witrh respect to the features of the present invention.
DETAILED DESCRIPTION
A bidirectional lightwave communication system having at least two end stations is shown in simplified block diagram form in FIG. 1. Each end station modulates a lightwave signal at one wavelength with data while receiving a lightwave signal from the remote end station at a different wavelength.
End station 1 comprises lightwave transmitter 10, lightwave receiver 11, and wavelength selective coupler 12. End station 2 comprises lightwave transceiver 20 which is realized in accordance with the principles of the invention as described in more detail below. End station 1 communicates with end station 2 over single optical fiber 3. Bidirectional transmission over the optical fiber is achieved because the end stations are transmitting lightwave signals to each other at two mutually exclusive wavelengths, namely, λ 1 and λ 2 . That is, λ 1 is not equal to λ 2 . An exemplary system could be realized with λ 1 at 1.3 μm and λ 2 at 1.5 μm. The relative directions of signals at wavelengths λ 1 and λ 2 are shown by directed arrows under optical fiber 3.
Wavelength selective coupler 12 is employed to direct the lightwave signal received on optical fiber 3 from transceiver 20 at wavelength λ 2 to lightwave receiver 11. Also, wavelength selective coupler 12 serves as an interface for lightwave signals at wavelength λ 1 from lightwave transmitter 10 to optical fiber 3.
In accordance with the principals of invention, lightwave transceiver 20 is realized as a photonic integrated circuit in which the lightwave transmitter and lightwave receiver are individually integrated in an inline geometry with a single waveguide. The single waveguide supports propagation of lightwave signals at wavelengths λ 1 and λ 2 . For the exemplary embodiments shown below, λ 1 is chosen to be a shorter wavelength than λ 2 . It should be clear from the description provided below especially with reference to FIGS. 2, 3, and 5 that lightwave signals at both wavelengths counter propagate through the waveguide at least in the region associated with the lightwave receiver shown as a 1.3 μm detector. In the FIGS. cited above, the long wavelength lightwave transmitter is shown as a 1.5 μm laser. In general, lightwave signals enter through an emanate from one and only one end of the waveguide in the photonic integrated circuit comprising lightwave transceiver 20.
In the various embodiments described herein, the photonic integrated transceiver circuit incorporates all the processing simplicity of a single laser, and puts all the optics needed at one end station of a λ 1 /λ 2 bidirectional link onto a single chip with a single waveguide fiber coupling port. The transceiver has successfully operated in 200 Mb/s bidirectional lightwave communications link with only a ˜1 dB crosstalk penalty and sufficient margin for transmission over more than 30 km using only 50Ω amplifiers connected directly to the detector portions of the transceivers.
A basic exemplary design for lightwave transceiver 20 is shown FIG. 2. This embodiment includes a long wavelength laser and a short wavelength detector. In order to achieve the desired transmit and receive functions for this transceiver, material absorption properties are utilized by a judicious arrangement of different semiconductor materials to form the single waveguide underlying and integrated with the transmit and receive devices. This is contrast to prior art technologies in which different wavelength signals were separated onto physically separate waveguides by interferometric or grating-based wavelength routing techniques.
Conventional semiconductor heterostructure growth techniques are employed to form the photonic integrated circuit shown in FIG. 2 as well as those shown in the subsequent figures. One such technique is described in U.S. patent application Ser. No. 237,251 filed Aug. 26, 1988. The teachings of this application are expressly incorporated herein by reference. This technique has also been described in the following technical article: Technical Digest of the Topical Meeting on Integrated and Guided Wave Optics, paper MDD2 (1989).
The semiconductor heterostructure shown in FIG. 2 comprises a plurality of layers wherein substrate and lower cladding layer 201 is an n + InP layer having a thickness of ˜1.35 μm and a dopant concentration of approximately 10 18 cm -3 ; inline waveguide layer 202 is a substantially undoped InGaAsP having a thickness of ˜0.3 μm and a set of mole fractions x and y (In 1-x Ga x As y P 1-y ) suitable for achieving a photoluminescence peak substantially at the shorter wavelenght λ 1 ; gain layer 203 in the laser section is a substantially undoped InGaAsP layer having a thickness of ˜0.07 μm and a set of mole fractions suitable for achieving a photoluminescence peak substantially at the longer wavelength λ 2 ; upper cladding layer 204 is a p + InP layer having a thickness of ˜1.5 μm and a dopant concentration of approximately 5×10 17 cm -3 ; and electrical isolation layer 206 includes semi-insulating InP to a sufficient thickness for achieving electrical isolation between the detector and the laser. It is understood that each cladding layer comprises material having a lower refractive index than the inline waveguide layer in order to form a low loss optical waveguide.
In the laser portion of the transceiver, electrical connection is made through contacts 211 and 200; in the detector portion of the transceiver, electrical connection is made through contacts 213 and 200. Standard metallic contacts are contemplated for use in this device. Conventional photolithographic masking and contact deposition techniques are employed to form contacts 200, 211, and 213. Signals for the longer wavelength laser are applied to the laser via lead 208. Signals from the shorter wavelength detector are received via lead 209. While data signals are depicted in the FIG., it is understood that analog and digital signals, either separately or in combination, are anticipated for use with the present invention.
The laser cavity is defined in the present embodiment by end facet 212 and diffraction grating 210. While end facet 212 may be uncoated or passivated, it is contemplated that the end facet may also be coated with standard metallic or dielectric coatings to increase or decrease the reflectivity from end facet 212.
The laser shown in FIG. 2 is a distributed Bragg reflector laser. Diffraction grating 210 is a distributed Bragg reflector grating which is patterned on the upper surface of inline waveguide layer 202 using conventional techniques such as holographic resist exposure and wet chemical etching. Placement of the grating is also contemplated to be on the upper surface of substrate and lower cladding layer 201 in the same position longitudinally as shown in the FIG. In the latter configuration, the grating is positioned beneath the inline waveguide layer. When the grating length is relatively short compared to several Bragg lengths, diffraction grating 210 is partially transmitting and functions as an output coupler of the 1.5 μm laser. In this configuration, the laser injects its lightwave signal at λ 2 into the shorter wavelength passive inline waveguide at λ 1 . Eventually the longer wavelength lightwave signal emerges from end facet 214, which is preferably coated with anti-reflection coating material shown as layer 205, for transmission on an optical fiber, for example, of a bidirectional communications link. Anti-reflection coating is desirable to avoid formation of an additional reflector for the laser signals at λ 2 and to eliminate loss due to Fresnel reflections for signals at λ 1 which are entering the waveguide.
Groove 207 is formed in the upper cladding layer to provide electrical isolation for the contact 211 and termination for the gain region so that the diffraction grating 210 remains substantially unpumped. This groove is formed by various methods such as wet etching or reactive ion beam processing.
Electrical isolation between transmitter contact 211 and detector contact 209 is desirable in a photonic integrated circuit such as this. Electrical isolation can be achieved in a number of ways such as ion implantation, or by channel etching, or by growth of a semi-insulating material layer between the laser and detector sections. In particular, this latter technique is employed without additional crystal growth steps by using a processing sequence such as the previously described in U.S. patent application Ser. No. 237,251. Semi-insulating InP (Fe or Ti doped) upper cladding layers can be formed in certain regions as shown while the same semi-insulating material growth provides lateral current blocking in certain other regions such as lateral regions around the laser. While it is important to provide materials for good electrical isolation, it is preferred to utilize materials which substantially match the refractive index properties of the upper cladding layer so that unwanted perturbations of the propagating signals are avoided along the inline waveguide.
It should be understood that, for processing simplification, layer 203 includes a thin (˜200Å) InP stop-etch layer separating the two quaternary layers to allow selective removal of the gain layer quaternary material by using conventional masking and material selective etching techniques.
In an alternative embodiment, layer 203 comprises multiple quantum wells where the barrier (wide bandgap) material is InGaAs and the well (narrow bandgap) material is InGaAsP having the proper mole fractions to achieve a photoluminescence peak substantially at λ 2 . One exemplary embodiment of this alternative structure includes the InGaAs/InGaAsP multiple quantum well stack consisting of four 80Å wells and 100Å barriers which is positioned on top of a 1.3 μm bandgap InGaAsP inline waveguide. The multiple quantum well stack provides gain through its overlap with the edge of the optical mode in this multi-layer waveguide in the longitudinal sections which contain the multiple quantum well stack. It is desirable to separate the multiple quantum well stack from the 1.3 μm quaternary inline waveguide by a thin (˜200Å) InP etch-stop layer which allows the selective removal of the stack using simple material-selective wet chemical etches.
As presently understood, the principle used in this bidirectional photonic integrated transceiver circuit is based on a fundamental property of the wide bandgap passive inline waveguide. This property is the ability of this guide to be a low loss transmitting or transparent waveguide at the longer wavelength λ 2 =1.5 μm but, concurrently, to be strongly absorbing for incoming signals at the shorter wavelength of λ 1 =1.3 μm. As a result, when the incoming signal is coupled into the inline waveguide from end facet 214 adjacent the detector, it is absorbed within a short distance L, where L is inversely proportional to the material absorption coefficient α at the wavelength of interest, that is, for 1.3 μm material at 1.3 μm wavelength. Typically, L is less than approximately 100 μm. Absorption constitutes the generation of electron-hole pairs across the bandgap. If the end region is properly contacted and biased in a p-n junction configuration as shown, this end section will constitute a shorter wavelength (1.3 μm) waveguide photodetector. Due to its small junction area, such detectors can be made with low capacitance for high speed and high sensitivity operation. At the same time that the waveguide photodetector is detecting the weaker incoming signal at wavelength λ 1 , it experiences the higher intensity local transmitting signal at wavelength λ 2 passing directly through the detector absorbing layer. In accordance with the principles of the present invention, properly sequencing of materials having appropriate band edge absorption properties allows an intimate integration of lightwave transmitter and receiver functions in a simple in-line geometry without interference, wherein the transmitter and receiver are designed for different wavelength operating regimes.
While it is expected that the detector (p-i-n) structure and the distributed Bragg reflector laser structure are desirable, many different structures for the laser are contemplated. These structures include Fabry-Perot and distributed feedback (DFB) lasers as shown in FIGS. 3 and 4, respectively. Although not shown in the drawing, it is contemplated that the distributed Bragg reflector structure in FIG. 1 be modified to include an additional Bragg reflector in place of the end facet. Also, many of the multi-electrode and multi-section DBR and DFB laser structures are contemplated for use herein.
A simpler version of the photonic integrated transceiver circuit can be made to include a simple Fabry-Perot laser cavity. In this version, the end facets cannot be anti-reflection coated, at least at the longer wavelength λ 2 (1.5 μm). End facet 305 is required for the laser feedback/output coupler mirror. A narrowband wavelength anti-reflection coating at the shorter wavelength λ 1 (1.3 μm) could be applied to end facet 305 to permit this facet to remain reflective at the longer wavelength λ 2 (1.5 μm). In the event that no coating is applied to this end facet, it is expected that there will be a small loss for the incoming signal as a result of facet reflection. In this implementation the short wavelength detector is actually inside the cavity of the long wavelength transmitter laser. Simplification gained by eliminating diffraction gratings comes at the expense of possibly higher crosstalk penalties due to the larger optical power density for the long wavelength signal as it traverses the short wavelength detector. Other anticipated losses may come from the above-mentioned potential Fresnel losses for the incoming signal.
The semiconductor heterostructure shown in FIG. 3 comprises a plurality of layers wherein substrate and lower cladding layer 301 is an n + InP layer; inline waveguide layer 302 is a substantially undoped InGaAsP having a set of mole fractions x and y (In 1-x Ga x As y P 1-y ) suitable for achieving a photoluminescence peak substantially at the shorter wavelength λ 1 ; gain layer 303 in the laser section is a substantially undoped InGaAsP layer having a set of mole fractions suitable for achieving a photoluminescence peak substantially at the longer wavelength λ 2 ; upper cladding layer 304 is a p + InP layer; and electrical isolation layer 306 includes semi-insulating InP to a sufficient thickness for achieving electrical isolation between the laser and detector. It is understood that each cladding layer comprises material having a lower refractive index than the inline waveguide layer in order to form a low loss optical waveguide.
In the laser portion of the transceiver, electrical connection is made through contacts 311 and 300; in the detector portion of the transceiver, electrical connection is made through contacts 313 and 300. Signals for the longer wavelength laser are applied to the laser via lead 308. Signals from the shorter wavelength detector are received via lead 309.
A cutaway view of an exemplary distributed feedback laser section is shown in FIG. 4. This laser may be substituted in the photonic integrated transceiver circuit shown in FIG. 2. In this laser structure, grating 404 could be either above or below the guide in the longitudinal region containing the gain layer.
The portion of the semiconductor heterostructure shown in FIG. 4 comprises a plurality of layers wherein substrate and lower cladding layer 407 is an n + InP layer; inline waveguide layer 403 is a substantially undoped InGaAsP having a set of mole fractions x and y (In 1-x Ga x As y P 1-y ) suitable for achieving a photoluminescence peak substantially at the shorter wavelength λ 1 ; gain layer 401 in the laser section is a substantially undoped InGaAs/InGaAsP quantum well stack layer having a set of mole fractions suitable for achieving a photoluminescence peak substantially at the longer wavelength λ 2 ; layer 409 may be a thin etch-stop InP layer for permitting placement of grating 404; upper cladding layer 406 is a p + InP layer; and a thin etch-stop layer 402 of InP between the gain layer and the inline waveguide layer. It is understood that each cladding layer comprises material having a lower refractive index than the inline waveguide layer in order to form a low loss optical waveguide. The optical mode of the signal from the laser and its direction are designated with reference numerals 405 and 408, respectively. The active/passive butt-coupling shown is capable of achieving 95% coupling efficiency.
In an example from experimental practice, the photonic integrated transceiver circuit was integrated in a somewhat more complex photonic integrated circuit than the ones shown in the preceding FIGS. This exemplary embodiment is shown in FIG. 5. In the embodiment shown in FIG. 5, the photonic integrated circuit includes the transceiver along with an amplifier and adiabatic mode expansion taper. The adiabatic mode expansion (AME) taper is designed for expanding the optical mode at the input/output facet thereby allowing easy fiber coupling. The adiabatic mode expansion taper has been described in allowed U.S. patent applications Ser. Nos. 389,087 (Koch Case 11-6) and 389,074 (Koch Case 12-7), both of which are commonly assigned herewith. The teachings of these references are expressly incorporated herein by reference.
The semiconductor heterostructure shown in FIG. 5 comprises a plurality of layers wherein substrate and lower cladding layer 501 is an n + InP layer; inline waveguide layer 502 is a substantially undoped InGaAsP having a set of mole fractions x and y (In 1-x Ga x As 1-y P y ) suitable for achieving a photoluminescence peak substantially at a wavelength which is shorter than λ 1 , for example, 1.1 μm; another guiding layer 503 is a substantially undoped InGaAsP layer having mole fractions suitable for achieving a photoluminescence peak substantially at the shorter wavelength λ 1 ; gain layer 514 in the laser section is a substantially undoped InGaAsP layer having a set of mole fractions suitable for achieving a photoluminescence peak substantially at the longer wavelength λ 2 ; another guiding layer 515 is a substantially undoped InGaAsP layer having mole fractions suitable for achieving a photoluminescence peak substantially at the shorter wavelength λ 1 ; upper cladding layer 504 is a p + InP; and electrical isolation is provided by grooves 506, 507 and 517. It is understood that each cladding layer comprises material having a lower refractive index than the inline waveguide layer in order to form a low loss optical waveguide.
Diffraction grating 510 for the distributed feedback laser is positioned on layer 515. The backside facet for the photonic integrated transceiver circuit is end facet 512.
In the laser portion of the transceiver, electrical connection is made through contacts 511 and 500; in the amplifier portion of the transceiver, electrical connection is made through contacts 516 and 500; and in the detector portion of the transceiver, electrical connection is made through contacts 513 and 500. Signals for the longer wavelength laser are applied to the laser via lead 508 and emanate from the device via facet 505. Signals from the shorter wavelength detector are received via lead 509 and are received to the device through facet 505.
Evaluation of the performance of this photonic integrated transceiver circuit was accomplished by installing it in a bidirectional fiber link communicating with a complementary hybrid end station. This hybrid was formed using a simple non-wavelength-selective fiber directional coupler with a 1.3 μm DFB transmitter laser on one arm and a p-i-n detector on the other arm. In this link, the detector on the photonic integrated transceiver circuit was connected directly to 50Ω 6 dB noise figure amplifiers. Even with the fiber coupling loss into the waveguide detector on the photonic integrated transceiver circuit and the very low sensitivity of the front end amplification, this link had ˜7 dB of margin at 200 Mb/s and 10 -9 bit-error-rate to potentially permit >30 km of fiber transmission. Included in these results is the penalty due to crosstalk between the high intensity longer wavelength (1.5 μm) transmitter signal passing directly through the shorter wavelength (1.3 μm) detector, which was only ˜1 dB. Since most of the crosstalk appears to be related to the mount, at least at these margin levels, the integration technology is quite sound.
Although not shown in the FIGS., it is understood that lateral (transverse) confinement of the waveguides may be accomplished through standard mask and etch techniques. Typical lateral dimensions for the waveguides are approximately 0.5 μm to several μm.
Additional information concerning the multiple quantum well lasers employed in the photonic integrated transceiver circuits is found in Electronics Letters, Vol. 25, No. 19, pp. 1271-2 (1989).
By using bandgap discrimination in a proper sequence for each transmit/receive bidirectional wavelength-division-multiplexed end station, it has been shown how the transmitted light can actually pass through the operating detector without interference or cross-talk. By offering a simple geometry and combining all the optical devices onto a single chip with one fiber connection, photonic integrated circuits of this type should be attractive for cost-sensitive applications such as fiber to the home.
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Full duplex lightwave communications is achieved in a diplex transceiver realized in a semiconductor photonic integrated circuit having an inline interconnecting waveguide integral with the transmitting and receiving portions of the transceiver. Semiconductor lasers and detectors operating in different wavelength regimes permit diplex or wavelength-division-multiplexed operation. In the transceiver, lightwave signals from the laser propagate through the detector without interfering with the detector operation or the lightwave signals being detected.
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FIELD OF THE INVENTION
The present invention is related to an apparatus and method for communicating optical signals to an electronic device enclosed within a flip-chip package.
ART BACKGROUND
Commonly available electronic devices exist in the form of a thin sheet of semiconductor material, or die, with electronic circuitry disposed thereon by way of various photolithographic processes. To protect the circuitry from damage, the die is often enclosed in a package designed to facilitate the attachment of the electronic device to a printed circuit board of a computer system or other electronic system.
Within some electronic devices are components meant to produce optical signals to be transmitted outside of the package, or to receive optical signals to be received from outside of the package. Packages have been used that provide a window through which such signals may pass. The window of such packages typically faces outwardly from the package in a direction that is generally meant to face away from the printed circuit board to which the electronic device is to be attached. One of the most common examples of such electronic devices enclosed within such a package is an ultaviolet-eraseable programmable read-only memory or UV-EPROM.
FIG. 1 is a cross-sectional view of a prior art package of the dual inline pin (DIP) type. The exterior or package 100 is comprised of window 110 and shell 112 . Die attach 114 attaches die 130 to an inner surface of shell 112 , thereby securing die 130 to the interior of package 100 . Bonding wires 120 provide part of the electrical connections between die 130 and solder balls 122 . Die 130 is positioned within package 100 such that the surface on which electronic circuitry (not shown) has been disposed is caused to face window 110 to allow the transmission or receipt of optical signal 132 . Pins 122 are used to attach package 100 to printed circuit board 140 through which are holes to receive the pins, and as a result, window 110 faces away from printed circuit board 140 .
The use of such packages, however, is based on a long-standing practice of having the surface of the die on which electronic circuitry is disposed facing away from the printed circuit board to which the electronic device is attached, thereby making this surface of the die accessible to optical signals passing through the window of the package. More recently, however, flexibility in power consumption and die size, as well as improvements in electrical signal characteristics, have been realized through the use of packages, such as the “flip-chip” or the “controlled collapsed chip connection” (C4) package, in which the surface of the die on which electronic circuitry is disposed now faces towards the printed circuit board to which the electronic device is to be attached.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects, features, and advantages of the present invention will be apparent to one skilled in the art in view of the following detailed description in which:
FIG. 1 is cross-sectional view of a prior art ball grid array package.
FIG. 2 cross-sectional view of one embodiment of the present invention.
FIG. 3 is a cross-sectional view of another embodiment of the present invention.
FIG. 4 is a cross-sectional view of yet another embodiment of the present invention.
DETAILED DESCRIPTION
In the following description, for purposes of explanation, numerous details are set forth in order 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. In other instances, well known electrical structures and circuits are shown in block diagram form in order not to obscure the present invention unnecessarily.
The present invention concerns “flip-chip” or “controlled collapsed chip connection” (C4) packages for integrated circuits, wherein the surface of a die on which electronic circuitry has been disposed is positioned such that it faces towards the circuit board to which the package will be attached during use of the electronic circuitry. The present invention further concerns the addition of a window to such a package on the side of the package that faces towards the circuit board to enable the transmission of optical signals to and from the electronic circuitry.
FIG. 2 is a cross-sectional view of one embodiment of the present invention. The exterior of package 200 is comprised of shell 210 and substrate 212 . Die attach 214 holds die 230 in place within package 200 such that the surface of die 230 on which electronic circuitry has been disposed faces towards substrate 212 . Underfill 220 and solder balls 222 attach die 230 to substrate 212 , with solder balls 222 providing electrical connections between die 230 and substrate 212 . Substrate 212 is a printed circuit board with conductors forming electrical connections between solder balls 222 and solder balls 224 . Mounted within and through substrate 212 is window frame 219 , in which window 218 is mounted, which allows optical signal 232 to pass between the exterior of package 200 and exposed die portion 231 of die 230 where electronic circuitry capable of interacting with optical signal 232 has been disposed.
In one embodiment, exposed die portion 231 comprises less than all of the surface of the die that faces window 218 , while in an alternate embodiment, exposed die portion 231 comprises the entire surface of the die that faces window 218 .
In one embodiment, die attach 214 is a thermal grease, such as silicone, and shell 210 is a heatsink made of material capable of conducting heat away from die 230 , such as copper or aluminum.
In one embodiment, window 218 is made of glass, while in alternative embodiments, window 218 is made of plastic or a combination of glass and plastic. In one embodiment, the material of which window 218 is made is chosen to be transparent for optical signals of a specific frequency or frequencies, while in an alternative embodiment, the material of which window 218 is made is chosen to be transparent for a substantially wider range of frequencies.
In one embodiment, the external surface of window 218 is mounted flush with the external surface of window frame 219 . In an alternative embodiment, window 218 is recessed within window frame 219 to permit the insertion of an optical conductor, an assembly of lenses, an optoelectronic device, or other apparatus protruding through the opening in printed circuit board 240 . In still another alternative embodiment, a micromechanical device for manipulating optical signal 232 , such as a micromirror (not shown), is positioned within window frame 219 , either behind or in place of window 218 .
In one embodiment, window frame 219 is made of ceramic material having a thermal coefficient substantially similar to that of die 230 . In this embodiment, shell 210 and window frame 219 cooperate to restrict the expansion of substrate 212 in response to heat emanating from die 230 during operation of the electronic circuitry disposed onto die 230 . This ensures that substrate 212 maintains its shape and remains correctly aligned with die 230 .
In one embodiment, window 218 , window frame 219 , underfill 220 and exposed die portion 231 define a cavity through which optical signal 232 is transmitted. In one embodiment surface tension from the edges of the die and the inner edge of window frame 219 prevents underfill 220 from overflowing and thereby blocking exposed die portion 231 . Alternatively, exposed die portion 231 is treated with a low surface energy coating, such as a flour-carbon (CFx) deposition. Regardless of whether surface tension or a low surface energy coating is used, underfill 220 may be of a material commonly used as underfill in typical flip-chip or C4packages.
In one embodiment, adhesive 216 and solder balls 224 attach package 200 to printed circuit board 240 . Solder balls 224 provide electrical connections between substrate 212 and electrical contacts disposed on printed circuit board 240 . In a further embodiment, an opening is provided through printed circuit board 240 to permit optical signal 232 to pass therethrough, thereby enabling the exchange of optical signals between die 230 and other devices (not shown) positioned on the opposite side of printed circuit board 240 .
In one embodiment, printed circuit board 240 is a rigid laminate of electrically conductive materials and electrical insulators. In an alternative embodiment, printed circuit board 240 is a flexible laminate of such materials. In another alternative embodiment, printed circuit board 240 is replaced with solid piece of electrical insulator upon which electrical contacts are disposed for making electrical connections with solder balls 224 .
In one embodiment, circuitry comprising the core logic (e.g., random access memory controller, bus interface, I/O device interface, or timers) of a microcomputer system is disposed on a surface of die 230 with circuitry capable of interacting with optical signals being disposed on exposed die portion 231 . In another embodiment, circuitry comprising a central processing unit of a microcomputer system is disposed on a surface of die 230 with circuitry capable of interacting with optical signals being disposed on exposed die portion 231 .
In one embodiment, package 200 is assembled by first designing and fabricating package 200 with an opening in substrate 212 for window frame 219 . Then by fitting window frame 219 and window 218 into substrate 212 . Then by attaching die 230 to substrate 212 by way of solder balls 222 using a typical C4process. Then by filling the area among solder balls 222 with underfill 220 and curing underfill 220 .
In one embodiment, package 200 is attached to printed circuit board 240 by first attaching package 200 via solder balls 224 to printed circuit board 240 by way of typical surface mount soldering techniques. Then by applying die attach 214 to surface of die 230 that is to be attached to shell 210 . Then by applying adhesive 216 to the surface of shell 210 that is to be attached to printed circuit board 240 . Then by attaching shell 210 to both die 230 and printed circuit board 240 and curing adhesive 216 .
FIG. 3 is a cross-sectional view of another embodiment of the present invention. Most of the numbered elements of FIG. 3 substantially correspond to those of FIG. 2 with the exception that window frame 219 and window 218 have been replaced with window 318 . Just as window frame 219 and window 218 served to allow die 230 to interact with optical signal 232 in the embodiment depicted in FIG. 2, window 318 serves to allow die 330 to interact with optical signal 332 in the embodiment depicted in FIG. 3 . However, unlike the embodiment of FIG. 2, where window 218 , window frame 219 , underfill 220 and exposed die portion 231 defined a cavity, as earlier described, no such cavity is defined in FIG. 3 .
In one embodiment, window 318 is made of a material with a thermal coefficient substantially similar to that of die 330 , and window 318 cooperates with shell 310 to restrict the expansion of substrate 312 in the same way in which window frame 219 and shell 210 restricted the expansion of substrate 212 in FIG. 2 .
FIG. 4 is a cross-sectional view of another embodiment of the present invention. Most of the numbered elements of FIG. 4 substantially correspond to those of FIG. 2 with the exception that pins 424 have been substituted for solder balls 224 of FIG. 2 . However, unlike printed circuit board 240 of FIG. 2, additional openings (e.g., plated through-holes) have been provided in printed circuit board 440 to receive pins 424 . In one embodiment, printed circuit board 440 is a rigid laminate of electrically conductive materials and electrical insulators. In an alternative embodiment, printed circuit board 440 is a flexible laminate of such materials. In another alternative embodiment, printed circuit board 440 is replaced with solid piece of electrical insulator through which electrical contacts are disposed for making electrical connections with pins 424 .
Just as solder balls 224 of FIG. 2 served to attach package 200 to printed circuit board 240 , pins 424 serve to attach package 400 to printed circuit board 440 . Also, just as solder balls 224 served as electrical contacts providing a portion of the electrical connections between die 230 and electrical contacts disposed on printed circuit board 240 , pins 424 serve as electrical contacts providing a portion of the electrical connections between die 430 and electrical contacts disposed through printed circuit board 440 .
In the depicted embodiment, package 400 is attached directly to printed circuit board 440 . However, in an alternate embodiment, a socket (not shown) that is designed to receive pins 424 is interposed between package 400 and printed circuit board 440 . In one embodiment, this socket would, in turn, be comprised of pins by which it would be attached to printed circuit board 440 , just as package 400 would have been.
The invention has been described in conjunction with the preferred embodiment. It is evident that numerous alternatives, modifications, variations and uses will be apparent to those skilled in the art in light of the foregoing description. It will be understood by those skilled in the art, that the present invention may be practiced in support of other combinations of functions in a computer system.
The example embodiments of the present invention are described in the context of ball grid array and pin grid array packages for electronic devices that are comprised of components for sending or receiving optical signals. However, the present invention is applicable to a variety of package types and to a variety of electronic, microelectronic, optical, optoelectronic and micromechanical devices. The term optical should not be taken to be limited to encompassing only signals with frequencies within the visible spectrum of light, for the present invention is applicable to use with light of a variety of frequencies, including infrared and ultra-violet. Although the present invention is described in the context of packages attached to rigid printed circuit boards that are commonly in use, the present invention is also applicable to packages being attached to sheets of flexible material or other surfaces providing electrical connections. Also, although the present invention is described in the context of having electronic circuitry disposed onto a single surface of a die composed substantially of semiconductor material, thereby requiring that single surface to be oriented to face the window of the package, it will be understood by those skilled in the art that electronic circuitry may be positioned within a package using a variety of means and in a variety of orientations without departing from the spirit of the invention as hereinafter claimed. Furthermore, although the present invention is described in the context of packages that enclose a single die on which electronic circuitry is disposed, the present invention is applicable to packages enclosing multiple separate dies, and/or dies comprised of smaller dies.
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An apparatus and method for enabling interaction between electronic circuitry and optical signals with a package for enclosing the electronic circuitry having contacts and a window for the passage of optical signals disposed about a face of the package that becomes substantially inaccessible when the package is used.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to earlier-filed and commonly owned U.S. Provisional Patent Application, Ser. No. 61/019,487, filed on Jan. 7, 2008, the disclosure of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present disclosure relates generally to tools and devices for remotely actuating rescue devices and assisting in rescues.
BACKGROUND
[0003] In many trench rescue situations, extendable struts or braces may be used to aid in shoring up potentially unstable walls to secure the area for rescue workers to assist victims who may have been trapped and/or injured in the trench. Until such bracing and shoring can be accomplished, often the rescue workers are unable to enter the trench to assist the victims.
[0004] A variety of struts or braces are being used currently by trench rescue teams and are available from numerous manufacturers and resellers. Many of these struts may be positioned within the trench in a collapsed state in conjunction with other shoring materials such as sheets, beams, cribbing, etc. When in place, the struts can be remotely extended through mechanical, pneumatic or hydraulic means to engage the shoring materials and/or the trench walls. However, a common characteristic of the operation of these conventional devices is that a person needs to visit the strut once extended remotely to engage a mechanical safety lock to secure the strut in the desired extended position. This permits the extension means to be disconnected from the strut and provides a safer, more secure rescue environment. During the locking process, a worker is required to enter the unsecured and potentially unstable and hazardous area of the trench to engage the lock.
[0005] The same or similar struts may also be used to secure unstable structures or features adjacent an industrial or transportation accident scene. For example, in a rollover car crash, where the car is left inverted and unstable on its roof, struts can be positioned to support and stabilize the vehicle while the rescue of the vehicles occupants is carried out. Once the struts are positioned and extended to their desired length, a worker must move under the vehicle to engage the locks of the strut and remove the actuation means connection.
[0006] Any of these workers accessing and actuating the locks of the strut may be exposed to unnecessary hazards due to the unsecured nature of the work site until the struts are locked.
[0007] Improvements to the locking of the extended struts in the desired position are desirable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The accompanying drawings, which are incorporated in and constitute a part of the description, illustrate several aspects of the invention and together with the description, serve to explain the principles of the invention. A brief description of the drawings is as follows:
[0009] FIG. 1 is a photograph of conventional struts used to shore up a trench.
[0010] FIG. 2 is a diagrammatic cross-section of a trench with shoring forms, supports and struts positioned between opposing walls of the trench.
[0011] FIG. 3 is a side view of a tool head according to the present disclosure.
[0012] FIG. 4 is a top view of the tool head of FIG. 3 .
[0013] FIG. 5 is a side view of an alternative embodiment of a tool head according to the present disclosure.
DETAILED DESCRIPTION
[0014] Reference will now be made in detail to exemplary aspects of the present invention which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
[0015] FIG. 1 illustrates a trench rescue setting where a variety of struts or extendable braces have been used in conjunction with beams, sheets and other shoring materials to support and stabilize the sides of the trench. This stabilization will permit rescue workers to safely access a location of a victim within the trench to provide emergency care and rescue services as needed.
[0016] In FIG. 2 , a trench 10 may have one or more exposed earthen walls 12 extending from an upper edge 14 to a trench bottom 16 . If a worker is trapped on or near bottom 16 , walls 12 may need to be braced to support the walls while treatment and rescue of the worker takes place. As shown in FIG. 1 , a plurality of sheets or forms 18 may be placed against walls 12 to support them against collapse. One or more vertical supports 20 may be placed along forms 18 or may be positioned to extend horizontally along the forms. A plurality of extendable struts 22 extend between supports 20 on opposite walls 12 to press the supports and forms against walls 12 .
[0017] To place the forms and supports in position to support walls 12 , struts 22 are extendable, with a first section 26 and a second section 28 positioned within and slidable in first section 26 . A locking ring 24 is positioned about second section 28 and may be threaded about the second section to allow it to moved along the exposed length of second section 28 . To place the struts within trench 10 , second section 28 would be slid into first section 26 so that the length of strut 22 is less than the width of trench 10 at the point the strut will be placed. An actuation connection 30 may also be attached to the strut at this time. Once positioned within trench 10 , actuation line 30 may provide pressure to slide second section 28 outward from first section 26 until the extreme ends of the two sections engage the supports or forms within the trench and are exerting a desired amount of force against trench walls 12 . Actuation line may be connected to a pneumatic pressure source or a hydraulic pressure source, depending on the configuration of struts 22 .
[0018] Once the strut is extended as desired, locking ring 24 is moved along second section 28 until it engages an inner end of first section 26 . With the locking ring threadably engaging second section 28 and engaging an inner end of first section 26 , strut 22 is now fixed into the desired length providing pressure against trench walls 12 and the actuation line 30 can be removed from the strut.
[0019] Conventional approaches to moving locking ring 24 into position to fix the extension of strut 22 involve rescue workers entering the trench and positioning the threads by hand. Until the rings are positioned, any failure of the actuation system may permit the strut to retract and potentially permit a partial or complete collapse of trench walls 12 , possibly onto the rescue worker within the trench.
[0020] Referring now to FIGS. 3 and 4 , a tool head 50 according to the present disclosure permits a rescue worker to rotate and position locking rings 24 without having to enter trench 10 . Tool head 50 includes a handle mounting end 52 for mounting an extended handle (not shown). Such a handle might provide for a length adjustment permitting use of tool head 50 is a variety of trenches of differing depth or arrangement. A shorter handle may be required to access locking ring 24 in narrow, shallow or obstructed trenches. A longer handle may be desired for deeper trenches or for situations when it is not possible to closely approach the strut to be locked.
[0021] A lock ring engagement face 54 is included along a central portion 62 of tool head 50 between handle mounting end 52 and distal end 60 . Positioned along at least a portion of the length of face 54 may be a plurality of ring engagement teeth 56 . Often, an outer surface of locking ring 24 will be knurled or may include a plurality of evenly spaced recesses. Teeth 56 are preferably configured to engage the features of the outer surface of locking ring 24 so that tool head 50 may be used to rotate locking ring 24 about threads on an outer surface of second section 28 to engage an inner end of first section 26 . The teeth 56 shown are illustrative only and it is anticipated that a variety of configurations of teeth may be used to engage the locking ring of the particular strut used.
[0022] In addition, there some configurations of struts 22 that may include a locking pin that is positioned through second section 28 through one of a plurality of opening extending through the section. The pin is preferably inserted in the opening closest to the inner end of first section 26 . Lock ring 24 may be threaded to an outer surface of first section 26 and rotated along the threads over the inner end until the locking ring engages the pin to fix the length of the strut. Such a lock ring about the first section may be similarly configured and positioned with tool head 50 as described above. To aid in the positioning of the pin through the second section, tool head 50 may include a pin hook 58 adjacent distal end 60 . The pin may include a loop to slip over pin hook 58 . Tool head 50 could then be used to position the pin within the desired opening through second section 28 and then be used to rotate the locking ring into position using face 54 and teeth 56 .
[0023] Use of tool head 50 with an appropriate handle will allow a rescue worker to secure struts 22 within trench 10 without having to enter the trench before the walls 12 are braced and secured.
[0024] As described above, tool head 50 may also be used to position locking ring 24 away from an inner end of first section 26 to permit strut 22 to be collapsed for removal from trench 10 , again, without requiring a rescue to be within a potential unsupported trench. Alternatively, tool head 50 could be used to retract a locking ring positioned about a first section engaging a locking pin, and then used to remove the locking pin, permitting the strut to be collapsed and removed from the trench.
[0025] It is anticipated that tool head 50 may be configured differently than illustrated herein, with angles and curves designed to more closely match the particular size and shape of the strut being used. While the tool head is described only with regard to its configuration to address particular uses with struts, it is understood that the tool head may also be configured to useful as a multipurpose pulling or reaching tool. No particular claim is made to the materials used to construct the tool head according to the present disclosure. The tool head may be used to actuate other devices beyond rescue struts. No particular claim is made to a particular size of the tool head.
[0026] FIG. 5 illustrates a second embodiment of a tool head 100 according to the present disclosure. Tool head 100 includes handle mounting end 102 and a distal end 110 . As shown above with regard to tool head 50 , handle mounting end 52 may be configured to receive an end of a handle to which tool head 50 may be mounted. As shown in FIG. 5 , handle mounting end 102 may be configured to be received within an end of a handle to which the tool head may be mounted.
[0027] A central portion 112 includes a face 104 on which are positioned a plurality of teeth 106 . It is anticipated that face 104 may be concave to enable more positive engagement of locking rings of struts to be engaged by tool head 100 , as shown in the non-limiting examples above. However, it is also within the scope of the present disclosure to have other configurations of face 104 or 54 which may be flat or convex, providing the teeth positioned on the faces are configured to engage and actuate locking elements of struts or other emergency response equipment.
[0028] Opposite face 104 , a hook 108 may be positioned adjacent distal end 110 . Hook 108 may be configured to engage elements of the emergency equipment such as the struts illustrated in FIGS. 1 and 2 , above. In addition, hook 58 may be sized or configured to permit tool head 100 to be used to engage, move and lift other equipment or objects that may be in or around the emergency response site. Tool head 100 may be incorporated into a multipurpose tool that may be used in other situations where struts or similar emergency equipment is not utilized. By making tool head 100 from a suitable durable material, the tool head may be used as a general purpose pike during typical fire or rescue operations and then used as a strut engaging tool in below ground operations. More than one hook or strut engagement device may be mounted to the tool head within the scope of the present disclosure.
[0029] Tool heads 50 and 100 may be constructed as a single unitary piece or may be assembled by the durable connection of a plurality of smaller components. It is anticipated that any suitable material may be used to construct tool heads 50 and 100 , provided the material is sufficiently rigid to resist deformation and permit actuation of the struts or other emergency devices. As the tool heads may also be incorporated into general purpose fire or rescue tools, it may be desirable that the tools head be made of a durable material that is resistant to heat or solvents as well, and that the hook opposite the strut engagement face may be sufficiently rigid or resistant to deformation to permit adequate pressure to be applied to locking pins or for lifting or pushing other objects.
[0030] No dimensions or sizing is implied in the present disclosure. Struts and other rescue devices to be engaged by the tool heads of the present disclosure may vary in size and in the nature of the lock rings or pins to be actuated. It is anticipated that the size of the tool head and number of teeth incorporated into the tool head may be adapted for the particular strut or other device to be actuated, and that such adaptations are within the scope of the present disclosure.
[0031] Various alternatives and embodiments are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter regarded as the invention.
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A tool for engaging and actuating support struts that may be used during or as part of a below ground rescue. The struts to be engaged may also be used to support unstable structures that must be entered or accessed during emergency response situations. The tool may include a tool head with a face including a plurality of teeth configured to remotely engage a locking mechanism of the struts or other devices. Other possible features of the tool head may include hooks or other structures for engaging or moving other objects.
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This is a division of application Ser. No. 597,203 filed Oct. 11, 1990, now U.S. Pat. No. 5,062,480.
BACKGROUND OF THE INVENTION
The present invention is drawn to an improved inlet valve assembly for use in subsurface sucker rod operated reciprocating piston pumps used in the petroleum industry for pumping oil from a downhole well to the surface.
Typically, subsurface sucker rod operated reciprocating piston pumps comprise a pump barrel having any inlet check valve and an outlet check valve and a pump plunger which is reciprocated within the barrel via a sucker rod. The intake valve is generally located at the entrance to the pump barrel and allows for the flow of well fluids into the pump barrel. The discharge valve is commonly located in the plunger and permits the flow of well fluids out of the pump barrel and up to the surface. Upon reciprocation of the pump plunger by the sucker rod, the coordinated action of both the intake valve and the discharge valve results in fluid flow from the well to the surface.
In order for the reciprocating piston pumps to operate properly they must be anchored within the production tube of the deep well. Thus, during normal pumping operations from the well the reciprocating piston pump is anchored within the production tube. However, during well maintenance, repair and stimulation operations, such as, steam injection or diluent injection, it is necessary to stop the normal pumping operation and to remove the subsurface reciprocating pump from its anchored position in the production tube as no fluids could flow down through the pump when in its anchored position. While the pump must be unanchored in order to carry out fluid injection and the like as aforesaid, it is highly desirable that the reciprocating piston pump remain within the production tube in order to avoid the cost and lost time associated with bringing the subsurface reciprocating pump and sucker rod string to the surface during the aforesaid operations. Accordingly, it is common practice in the prior art to unanchor the subsurface reciprocating pump by pulling the sucker rod string from the surface and move the pump a short distance from its anchored position to an enlarged section of the production tube. In this position, specific fluids from the surface can be injected downhole into the well for maintenance, repair and recovery stimulation.
During the injection of the aforesaid fluids into the well it is extremely important not allow any flow through the pump barrel of the subsurface reciprocating pump as the fluids being injected generally carry particles which are known to damage the pump plunger and pump barrel surfaces. Accordingly, in existing systems one must choose between removing the reciprocating pump entirely from the production tube or suffer the consequences of passing a portion of the aforesaid injected fluid through the pump barrel of the pump thus resulting in the aforesaid damage to same.
Naturally, it would be highly desirable to provide a system wherein the reciprocating piston pump may be maintained in the production tube of a downhole well and at the same time insure that no fluids which would damage the pump will pass through the pump during the maintenance, repair and stimulation operations as set forth above.
Accordingly, it is the principal object of the present invention to provide an improved inlet valve assembly for use in subsurface sucker rod operated reciprocating piston pumps.
It is a particular object of the present invention to provide an intake valve assembly as aforesaid wherein the inlet valve to the reciprocating piston pump is locked in its closed position when the pump is in its unanchored, non-pumping position within the production tube of a deep well.
It is a further object of the present invention to provide an inlet valve assembly as aforesaid wherein the inlet valve is freely moveable between its open and closed position when anchored within the production tube of the deep well for pumping fluid from the well to the surface. It is a further object of the present invention to provide an inlet valve assembly as aforesaid which is effective in service and relatively inexpensive to manufacture.
Further objects and advantages of the present invention will appear hereinbelow.
SUMMARY OF THE INVENTION
In accordance with the present invention the foregoing objects and advantages readily obtained.
The present invention is drawn to an improved inlet valve assembly for use in combination with a sucker rod operated reciprocating subsurface pump which is disposed within the production tube of a deep well for pumping oil from the well to the surface. In accordance with the present invention the sucker rod operated reciprocating subsurface pump is selectively positioned between a first position wherein the pump is anchored in the production tube for pumping fluid from the well and a second position wherein said pump is unanchored in said production tube for non-pumping operations such as maintenance, repair and recovery stimulation operations. The reciprocating subsurface pump comprises a pump barrel having a first valve seat defining an inlet to the pump barrel and a second valve seat defining an outlet port from the valve barrel. An inlet valve is provided for selectively sealing the inlet port by seating on a surface of the first valve seat. Likewise, an outlet valve is provided for selectively sealing the outlet port from the valve barrel. A pump plunger is mounted for reciprocal movement via a sucker rod within the pump barrel for pumping fluid from the inlet port to the outlet port when the pump is anchored in the production tube. In accordance with the present invention the inlet valve of the present invention includes means for locking the inlet valve against the inlet port for sealing same against pressure downhole in the well when the pump is in its second unanchored position so as to prohibit passage of fluid into the pump barrel. The inlet valve further includes means for unlocking the inlet valve so as to allow for selective sealing and unsealing of the inlet port to the pump barrel when the pump is in its first anchored position for pumping fluid from the well.
In one preferred embodiment of the present invention the mechanism for locking the inlet valve includes a mechanical biasing mechanism which biases the inlet valve against the inlet port. In a further embodiment the mechanism for locking the inlet valve against the inlet port includes a flow control mechanism for sealing off the flow of fluid to the inlet port and accordingly the inlet valve of the subsurface pump.
By providing an arrangement as aforesaid the sucker rod operated reciprocating subsurface pump may be maintained within the production tube when in its unanchored position without fear of fluid passing through the inlet valve and through the pump barrel and damaging same.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial sectional view of a deep well pump assembly in its unanchored position in the production tube and illustrating an inlet valve of the present invention in its locked position.
FIG. 2 is a partial cross sectional view similar to FIG. 1 showing the subsurface pump in its anchored positioned within the production tube wherein the inlet valve is free to move between its open and closed positions.
FIG. 3 is a partial cross sectional view similar to FIG. 2 showing the position of the inlet valve of the present invention on the upstroke of the plunger.
FIG. 4 is a partial cross sectional view similar to FIG. 3 showing the position of the inlet valve of the present invention on the downward stroke of the pump plunger.
FIG. 5 is a cross sectional view of a second embodiment of an inlet valve in accordance with the present invention showing the valve in its locked position.
FIG. 6 is a further cross sectional view of the valve of FIG. 5 showing the inlet valve in its unlocked position.
FIG. 7 is a cross sectional view of a third embodiment of an inlet valve in accordance with the present invention shown in its locked position.
FIG. 8 is a cross sectional view of the inlet valve of FIG. 7 shown in its unlocked position.
DETAILED DESCRIPTION
With reference to the drawings and, more particularly, FIGS. 1 through 4 there is illustrated a sucker rod operated reciprocating subsurface pump located within the production tube of a deep well. The reciprocating subsurface pump 10 comprises a pump barrel 12 having a piston 14 mounted therein for reciprocal movement via sucker rod 16. As can be seen in FIG. 3, the pump barrel 12 is provided with an inlet valve assembly 18 for drawing fluid into the pump barrel during the upward stroke of the pump piston 14 via the sucker rod 12. The pump piston 14 carries a discharge valve 20 which, as can best be seen in FIG. 4, opens for passing fluid from the pump barrel and up the well production tube 22 on the downward stroke of the pump piston 14.
In accordance with the present invention a first embodiment of inlet valve assembly 18 is illustrated in FIGS. 1 through 4. The inlet valve assembly includes a valve seat 24 formed within the pump barrel and defining a sealing surface 26 upon which valve sealing element 28 seals when the valve 18 is in its closed position. The assembly further includes an extension portion 30 which extends from the valve seat 24 upstream of valve sealing element 28. Portion 30 has either integrally therewith or secured thereto a sealing portion 32 provided with a seal or friction ring 34 for sealing the extension and therefor the pump barrel in seating nipple 36 in a manner to be described in more detail hereinbelow. In accordance with the embodiment of inlet valve of the present invention as illustrated in FIGS. 1 through 4, a connection portion 38 extends from the sealing element 28 and connects to a vane guide member 40 which consists of, for example, four vane members 42 located 90 degrees apart with respect to the axis of the connecting element 38.
As can be seen most clearly in FIG. 1, a locking member 44 in the form of a hollow substantially cylindrical tube is mounted within extension portion 30 and 32. The locking member includes a bore 46 defined by radial flange 48. The connecting portion 38 of the valve 18 penetrates the bore 46. The vanes 42 of valve portion 40 abut radial flange 48 as shown in FIG. 1. The locking mechanism 44 has an annular rib 50 located intermediate the ends of the locking mechanism. The end of the locking mechanism 44 opposite radial flange 48 is provided with a flange 52 which abuts the locking nipple 36 when the pump is in its anchored position within the production tube 22 in a manner to be discussed in greater detail hereinbelow. A coil spring 54 is provided in an annular chamber 56 defined by extension portion 30 and locking mechanism 44. The coil spring contacts the underside of valve seat 24 and biases against annular rib 50 on locking mechanism 44 for biasing the locking mechanism downward. As can be seen in FIG. 1, the coil spring 54 biases the locking mechanism 44 downward so that radial flange 48 abuts the vanes 42 of vane guide portion 40 of valve 18. In turn, the valve sealing element 28 is likewised carried by the locking mechanism 44 downward so as to lock the valve sealing element 28 against the sealing surface 26 of valve seat 24.
With further reference to FIGS. 1 through 4 the operation of the inlet valve assembly and sucker rod operated reciprocating subsurface pump will be described in detail. As noted above, when the well is being serviced and no pumping is being carried out by the reciprocating subsurface pump, it is desirable to maintain the pump within the well tube in an unanchored position. The unanchored position of the pump within the well tube 22 is illustrated in FIG. 1. As illustrated in FIG. 1 the pump barrel 12 is held in this position by the sucker rod 16 which is connected to piston 14. The piston 14 abuts an annular abutment 60 provided on the pump barrel. In this manner the pump 10 is suspended within the well tube. In order to prohibit the flow of fluid into the pump barrel 12 when in its unanchored suspended position, valve sealing element 28 is held against the sealing surface 26 of the valve seat 24 by locking member 44 which is biased downwardly by coil spring 54. The locking mechanism 44 abuts valve portion 40 and assures that the valve sealing element 28 seals on the valve seat 24. In this manner fluids are prohibited from flowing into the valve barrel. The biasing force of the coil spring 54 is selected in order to insure that the valve remains in its sealed position against the pressures which will be created downhole in the well during servicing, maintenance and the injection of fluids for well stimulation.
When maintenance of the well is complete and pumping from the well is again desired the pump 10 is lowered via the suction rod 16 into seating nipple 36 wherein friction ring or sealing means 34 seals on the annular wall 62 of the seating nipple 36. Upon anchoring the pump within the seating nipple 36 flange 52 of the locking member 44 abuts the bottom surface 64 of the annular chamber defined in seating nipple 36. As can be seen in FIG. 2, as the pump is lowered the locking means 44 is pressed upward against the force of spring 54 and frees valve portion 40 thereby allowing the valve to act as a conventional check valve. As can be seen in FIGS. 3 and 4 on the upward stroke of the pump piston 14 the valve is moved upward so that element 28 unseals from valve seat 24 so as to draw fluid into the pump barrel 12. On the downward stroke (FIG. 4) the fluid is compressed in the pump barrel 12, the valve is closed as a result of compression of fluid in the barrel and outlet valve 20 provided in pump piston 14 opens allowing the fluid to pass from the pump barrel up the production tube 22.
FIGS. 5 and 6 illustrate a second embodiment inlet valve assembly in accordance with the present invention. With reference to FIG. 5, the pump barrel 12' has secured thereto by means of threads 70 an extension 30' which carries friction ring or seals 34' in a manner similar to the embodiment discussed above with regard to FIGS. 1 through 4. The pump barrel 12' is provided with a rib extension 72 on which a valve seat 24' rests. The valve seat 24' is held against rib 72 by cage member 74 which includes ports 76 for communicating fluid to the interior of pump barrel 12' via valve sealing element 28'. Cage member 74 is held against valve seat 24' by extension member 30' which is screwed to the valve barrel 12' by threads 70 as noted above. The cage member 74 is provided with a receptacle 78 which receives spring element, 54'. Locking member 44' is mounted within bore 79 of extension element 30'. Locking member 44' includes on one end thereof a piston element 80 provided with annular recess 82 in which seal 84 seats. Piston 80 is contacted by spring 54' for biasing the locking member 44' in the downward direction where intermediate rib portion 86 abuts annular ridge 88. In this position the piston 80 is sealed within passage 78 thereby prohibiting flow of fluid up hollow conduit 92 in locking elements 44' and radial passages 94 to valve sealing element 28'. Thus, in the position shown in FIG. 5 locking element 44' insures that no fluid from the well bore reaches the valve element 28' and thereby insures no fluid flows into the pump barrel 12'. The position of the valve in FIG. 5 is that position which the valve will assume when the pump is suspended in the production tube as discussed above with reference to FIG. 1.
Upon seating of the pump in seating nipple 36' the valve of FIG. 5 assumes the position illustrated in FIG. 6. As discussed above with regard to FIG. 2, element 52' on locking member 44' abuts the seating nipple and accordingly compresses spring 54' upon anchoring of the valve pump within the seating nipple as shown in FIG. 6. The compression of the spring element 54 allows the ports 94 to communicate with annular chamber 96 and thereby allows fluid to pass up through conduit 92 into annular chamber 96 through ports 76 to the valve sealing element 28'. In this position the valve now functions as a conventional check valve and will open and close in the same manner as discussed above with regard to FIGS. 3 and 4.
FIGS. 7 and 8 illustrate a third embodiment of inlet valve in accordance with the present invention. The inlet valve of FIGS. 7 and 8 is similar construction to that of the inlet valve assembly FIGS. 5 and 6 discussed above. In the embodiment of FIGS. 7 and 8, the locking mechanism is provided with a piston portion 80' which has a sealing radial peripheral surface 100 adapted to seal on sealing surface 102 provided in extension portion 30". Accordingly, as can be seen in FIG. 7, when the pump is in its unanchored position within the production tube the spring element 54" biases piston portion 80' downwards so that it seals on sealing surface 102 thereby preventing flow of fluid up through conduit 92' and into annular space 96'. In this manner it is insured that fluid cannot pass through inlet valve seating element 28" and into the pump barrel 12". When the pump is anchored within seating nipple 36" of the production tube, element 54" of the locking mechanism 44" abuts the seating nipple and thereby compresses spring 54" so as to establish communication between conduit 92' and annular chamber 96' via ports 94' provided in locking element 44". Thus, as was the case with the embodiments discussed above, when the pump is anchored within the seating nipple the valve assembly of the present invention acts as a normal check valve for pumping fluid from the deep well in the manner previously discussed with regard to FIGS. 3 and 4.
It is to be understood that the invention is not limited to the illustrations described and shown herein, which are deemed to be merely illustrative of the best modes of carrying out the invention, and which are susceptible of modification of form, size, arrangement of parts and details of operation. The invention rather is intended to encompass all such modifications which are within its spirit and scope as defined by the claims.
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The present invention is drawn to an inlet valve assembly for a subsurface sucker rod operated reciprocating piston pump and, more particularly an inlet valve assembly which is locked in its closed position when the pump is in its unanchored, non-pumping position within the production tube of a deep well. When the subsurface piston pump is anchored within the production tube of the deep well of the inlet valve assembly is freely movable between open and close positions upon reciprocation of the piston.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a rotary head type reproducing apparatus and more particularly to a rotary head type reproducing apparatus of the kind obtaining a reproduced signal through a rotary transmitter.
2. Description of the Related Art
FIGS. 1(a), 1(b) and 1(c) of the accompanying drawings schematically show rotary transmitters arranged, for example, in two channels. Each channel is provided with coils 11a and 11b or 12a and 12b. The coils 11a and 12a are disposed on the side of a rotor 23 while coils 11b and 12b are disposed on the side of a stator 24. A motor shaft 22 is secured to the rotor 23 and to a rotary upper drum which is not shown but is provided with reproducing heads. The stator 24 is secured to a stationary lower drum 25. A short-circuit ring 26 is arranged to suppress a cross-talk between the two channels.
With the transmitters arranged within a reproducing apparatus, a plurality of reproducing rotary heads reproduce signals from a recording medium. The reproduced signals are respectively produced through the rotary transmitter 11a and 11b and the other rotary transmitter 12a and 12b. The efforts to reduce a crosstalk which takes place between the channels of rotary transmitters during reproduction have been directed solely to improvement in the characteristics of the rotary transmitters. However, the attainable degree of such improvement is limited. It has been thus impossible to have these channels completely unaffected by each other.
SUMMARY OF THE INVENTION
It is a general object of this invention to solve the above-stated problem of the prior art.
It is a more specific object of this invention to provide a rotary head type reproducing apparatus which is capable of eliminating the adverse effect of a cross-talk between a plurality of channels of rotary transmitters on reproduced signals solely by means of an external circuit without having recourse to improvement in characteristics of the rotary transmitters.
To attain this object, a rotary head type reproducing apparatus embodying this invention comprises a plurality of rotary heads arranged to reproduce signals recorded on a record bearing medium by tracing on the medium; a plurality of rotary transmitters which are arranged to receive signals reproduced by the rotary heads respectively; level adjusting means arranged to produce output signals of the plurality of rotary transmitters by adjusting their levels relative to each other; and computing means for computing the output signals of the rotary transmitters after these signals are level adjusted by the level adjusting means.
Further objects of this invention will become apparent from the following detailed description of preferred embodiments thereof taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1(a), 1(b) and 1(c) schematically show the arrangement of rotary transmitters arranged in two channels. FIG. 1(a) is a plan view, FIG. 1(b) a sectional view and FIG. 1(c) a circuit diagram of the transmitters.
FIG. 2 is a block diagram showing a reproducing apparatus arranged as an embodiment of this invention.
FIG. 3 is a block diagram showing another reproducing apparatus arranged as another embodiment of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2 shows in a block diagram a reproducing apparatus arranged as an embodiment of this invention. The illustration includes a reproducing head 1 which is provided for a channel A. Another reproducing head 2 is provided for a channel B. The heads 1 and 2 are arranged to trace a record bearing medium respectively. Rotary transmitters 3 and 4 are respectively arranged for the channels A and B. Amplifiers 5 and 6 are arranged to amplify reproduced signals of the channels A and B which are obtained via the rotary transmitters 3 and 4. A mixer 7 is arranged to mix the outputs of the amplifiers 5 and 6. A reference numeral 9 denotes an attenuator. Subtracters 8 and 10 are arranged to subtract the output of the attenuator 9 from the outputs of the above-stated amplifiers 5 and 6 respectively.
With the reproducing apparatus arranged as described above, the amplifier 5 produces an output which is expressed as A+KB and the amplifier 6 an output which is expressed as B+K'A. In these formulas, A represents the output of the head 1, B that of the head 2, K'A a cross-talk output of the head 1 coming to the rotary transmitter 4, KB a cross-talk output of the head 2 coming to the rotary transmitter 3, and K and K' the rates of the cross-talks, respectively. With the output levels of the amplifiers 5 and 6 mixed by the mixer 7, the mixer 7 produces an output at a level which can be expressed as follows:
A+KB+B+K'A
Generally the rates of cross-talks may be regarded as K=K'. The output level of the mixer 7 then can be expressed as: (1+K)(A+B). The attenuator 9 is arranged to have its attenuating degree set at 1/(1+K). Then, the output level of the attenuator 9 becomes: A+B. Accordingly, the output level of the subtracter 8 becomes: A+B- (A+KB)=B-KB=B(1-K) while that of the other subtracter 10 becomes:
(A+B)-(B+K'A)=A(1-K')
As apparent from the foregoing, no cross-talk component is included in the signal components A and B thus obtained.
While the embodiment described is arranged to have two channels, the invention is likewise applicable to other arrangement to have three or more channels by just increasing the computing stages. The output of such modification also can be obtained without including any cross-talk component therein.
FIG. 3 shows in a block diagram a reproducing apparatus arranged as another embodiment of this invention. This embodiment includes a reproducing head 1 for a channel A; another reproducing head 2 for another channel B; rotary transmitters 3 and 4 for these channels A and B; amplifiers 5 and 6 which are arranged to amplify reproduced signals of the channels A and B obtained via the rotary transmitters 3 and 4; an attenuator 17; and a differential amplifier 18.
With the reproducing apparatus arranged as described above, the amplifier 5 produces an output which can be expressed as A+KB, and the amplifier 6 an output which can be expressed as B+KA. In these formulas, A represents the output of the head 1, B that of the head 2, KA a cross-talk output of the head 1 coming to the rotary transmitter 4, KB a cross-talk output of the head 2 coming to the rotary transmitter 3, and K the rate of the cross-talk, respectively.
Assuming that the attenuator 17 is arranged to have its attenuating degree set at K, the output level of the attenuator 17 becomes:
K(B+KA)=KB+K.sup.2 A≠KB
Since K 2 A is at a very low level, it is ignorable in this instance.
The differential amplifier 18 is arranged to have the output of the amplifier 5 supplied to its noninverting input terminal and the output of the attenuator 17 to it inverting input terminal. Therefore, the output of the differential amplifier 18 becomes: A+KB-KB=A. Thus, the cross-talk from the head 2 is removed and the output of the head 1 alone can be taken out excluding the cross-talk component.
While the output of the head of the channel A is alone described in the foregoing, the circuit arrangement can be made in the same manner for the output of the head of the other channel B.
In the specific embodiment described, the differential amplifier is employed for the purpose of removing the cross-talk component. However, this arrangement may be changed to invert either one of the input signals and to use a simple mixer.
Further, in the embodiments described, two channels are arranged. However, a reproduced signal free of any cross-talk component is likewise obtainable by suitably combining the computing arrangement described even in the case of three or more channels.
In accordance with this invention, as described in the foregoing, the cross-talk between the rotary transmitters can be removed by a simple arrangement.
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A rotary head type reproducing apparatus having a plurality of rotary transmitters which respectively receive signals reproduced from a record bearing medium by a plurality of rotary heads is arranged to eliminate any cross-talk between the rotary transmitters by adjusting the levels of signals produced from these transmitters relative to each other and then by performing a computing operation on the adjusted signal levels.
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BACKGROUND OF THE INVENTION
The field of the invention is vapor degreasers and the invention relates more particularly to vapor degreasers having a tank with a liquid solvent in the bottom which is heated to provide a solvent vapor zone used to remove soluble material from an object being degreased.
Conventional vapor degreasers are shown in U.S. Pat. No. 4,246,116 which was invented by the inventor of the present invention.
U.S. Pat. No. 5,048,548 shows a vapor degreaser with a three stage condenser/heat exchanger configuration for assisting in removal of solvent vapors so that they do not escape from the degreaser.
A door closure system for a vapor degreaser is shown in U.S. Pat. No. 5,261,736.
The solvents commonly used for vapor degreasing include methylene chloride, perchloroethylene, 1,1,1-trichloroethane, trichloroethylene, and trichlorotrifluoroethane. The vapors of some of these solvents are best eliminated as much as possible from the outside of the confines of a vapor degreaser. Although the solvents are heavier than air in the vapor state and tend to stay within the tank walls, breezes or drafts can cause the vapor to escape above the top of the tank walls. Past systems for preventing this have either been expensive or not sufficiently effective.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved vapor degreaser which essentially eliminates the escape of solvent vapor during the degreasing process.
The present invention is for an improved vapor degreaser of the type having a degreaser tank with a bottom, a front wall, a back wall, a right side wall, and a left side wall. The degreaser has a liquid solvent in the bottom which is heated to provide a solid vapor zone above the liquid solvent. First means for cooling the solvent vapor zone are provided which creates a first freeboard area above the solvent vapor zone. The improvement of the present invention comprises an upper tank zone above the first freeboard area. The upper tank zone has a second means for cooling a second freeboard area above the first freeboard area and any solvent vapor which has escaped into the second freeboard area from the first freeboard area. A first cover is provided between the first freeboard area and the second freeboard area and a second cover is provided over the second freeboard area. The covers are preferably reciprocating covers comprised of two halves which meet in the middle and permit a chain to hold a part below the lower cover, said chain being positioned between each of the two cover halves. Preferably, the degreaser tank separates into an upper tank portion and the more conventional lower tank portion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded cross-sectional view showing the right and left sides and back wall of the improved vapor degreaser of the present invention.
FIG. 2 is a cross-sectional view of the vapor degreaser of FIG. 1 with the upper tank portion connected to the lower tank portion and showing the front and back walls and the left side wall.
FIG. 3 is a cross-sectional view analogous to FIG. 2, except showing the cover mounted in the upper tank portion.
FIG. 4 is a cross-sectional view showing the upper tank portion slid to one side of the lower tank portion for servicing.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The vapor degreaser of the present invention is shown in FIG. 1 in an exploded cross-sectional view where the degreaser has a lower tank portion 10 and an upper tank portion 11. Lower tank portion 10 has a left side wall 12, a right side wall 13, a back wall 14 and a front wall 15. A bottom 16 completes the lower tank portion 10. A liquid solvent 17 is held at a solvent depth 18 in the bottom of the tank. A heating coil 19 provides a source a heat to cause the liquid solvent to boil. The solvent vapor thus created provides a solvent vapor zone 20. Lower cooling coils 21 create a solvent vapor level 22 at the top of the solvent zone 20. If the surroundings of the tank were always quiescent, this system which is relatively conventional would be adequate. However, in reality, there are always some breezes and drafts and, thus, the solvent vapor level does not completely contain all of the solvent vapor and a small amount rises above the solvent vapor level 22 into a first freeboard area 23 in lower tank portion 10.
Upper tank portion 11 also has an upper left side wall 24, an upper right side wall 25, an upper back wall 26 and an upper front wall 27. The bottom flange 28 on upper tank portion 11 mates with a top flange 29 at the top of lower tank portion 10. A water separator 30 is conventional and the heavier solvent is returned to the liquid solvent 17. The water separator 30 is fed from trough 31 in the upper tank zone and trough 32 in the lower tank zone.
Upper tank portion 11 has second means for cooling comprising cooling coils 33. This second set of cooling coils provides a very low air temperature in the second freeboard area 34 and removes by condensation any vapor which may have escaped the first freeboard area 23. Coils 33 can be subzero coils to provide an exceptionally low temperature, and, thus, an exceptionally low vapor level. This upper tank zone 35 is thus maintained at a very low solvent vapor level.
To further reduce the solvent vapor molecules in the second freeboard area 34, a first cover 36 tends to hold most escaped solvent molecules in first freeboard area 33. First cover 36 is a reciprocating type of cover which has a front half 37 and a back half 38. These two halves permit a chain 39 to pass between the two cover halves 37 and 38 so that the first freeboard area 23 is essentially covered with only a small gap between the two cover halves. First cover 36 is shown in the drawings mounted in lower tank portion 10. It is also possible to mount cover 36 in the bottom of upper tank portion 11. By doing this, the upper half 11 can be added as an after-market add-on to provide all the benefits of the degreaser of FIG. 2.
Furthermore, the upper tank zone 35 is covered with a second cover 30 consisting of front half 41 and back half 42. This similarly permits chain 39 through the second cover 40 with almost complete closure. The result is a vapor degreaser which has essentially no drafts within the first freeboard area 23 or the second freeboard area 34. The first cover 36 also permits the second freeboard area 34 to be held at a much lower temperature than the first freeboard area 23. This is the result of the second set of cooling coils 33 combined with the action of the two covers.
Another advantage of a covered upper tank zone 35 is the ability to maintain a very low temperature in the upper tank zone. For instance, the AQMD requires that the upper tank zone be 30% of the boiling point of the solvent. Thus, if the solvent boils at 250° F., the upper zone must be as low as 75° F. The construction of the degreaser of the present invention permits this upper tank zone to be as low as 40° F., thus, providing a much greater degree of safety as compared to the conventional 75° F.
Alternatively, the object being degreased 43 can be placed on horizontal rods 44 and equally degreased without any drafts disturbing the first and second freeboard areas. The second freeboard 34 is, thus, a chilled freeboard area. Another advantage of providing an upper half 11 separate from lower tank portion 10, is that it can be much easier to service. By providing clamps around flanges 28 and 29 it is possible to slide the upper tank portion as much as 75% off from lower tank portion 10. It is then possible to provide a great deal of service without draining the tank.
In FIG. 3 an alternative mounting of first cover 36 is shown where first cover 36 is mounted in upper tank portion 11. Also, a pair of clamps 45 are shown around flanges 28 and 29. These clamps 45 permit the upper tank portion to be slid so that it extends over lower tank portion 10 as shown in FIG. 4. In FIG. 4 where the upper tank portion 11 is slid to the right. It is to be understood that this upper tank portion can as easily be slid to the left. The clamps 45 are sufficient so that the upper tank 11 can be extended approximately 75% past lower tank 10. This permits the servicing of the upper tank portion without the necessity of draining the tank and airing it out for a prescribed amount of time.
The present embodiments of this invention are thus to be considered in all respects as illustrative and not restrictive; the scope of the invention being indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
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An improved vapor degreaser with a tank having a conventional lower portion with a solvent which is heated and cooling coils which largely combine the solvent vapor zone to a solvent vapor level. An upper tank portion rests above the conventional tank and has a second set of cooling coils. A first cover is placeable between the conventional tank and the upper tank portion. A second cover is placeable over the upper tank portion to provide a vapor degreaser with a much lower chance of any vapors escaping the degreaser.
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BACKGROUND TO THE INVENTION
The invention relates to duckboards.
A duckboard is a length of board laid, in use, on a surface--such as the ground--over which men, materials and/or equipment have to walk, be dragged and/or wheeled.
The purpose of conventional duckboards is to make the passage of the men, materials and/or equipment easier and/or safer than it would be without the use of the board. For example, the ground-engaging wooden duckboard gives a man a firm-footed passage over boggy ground, and reduces the dangers of him slipping or sinking if the board were not present. And as a similar example, the conventional roof crawling board spreads a man's weight over a greater area than that of the roof struts which, without the board present, could not withstand the pressure of his weight on their own relatively small area.
These conventional duckboards are widely used. But their use is largely confined to the building industry. They are essentially rigid structures, and they are also relatively heavy. They tend to be quite large. For all these reasons, they are not easily portable, nor can they be stacked or transported in relatively confined spaces.
The commercial building industry accepts that its equipment will, in general, be heavier, more bulky, and less easily carried, than the equipment which the amateur "do it yourself" builder or gardener seeks to use. Building has always been essentially a heavy labouring job. The rigidity, weight, and size of conventional duckboards has therefore not received any inventive attention. Whether they are used outdoors, (as in the two examples given above) or indoors (in a gymnasium for example), duckboards have always been relatively rigid, large, and heavy; and there has been no reason to think of altering these basic qualities.
The commerical builder may accept readily enough that duckboards are one of the items of equipment in which he must invest, and which he must be prepared to carry around with him from site to site. The amateur builder or gardener, without the muscle power or the storage space available to the professional, does not view them in the same light. There are many instances when he could use the advantages of a duckboard or a line of duckboards laid end-to-end. For example, when barrowing earth across his lawn to and from his garden compost heap. He may to so far as to use planks, laid end-to-end, if he has these available to protect his lawn. He is more likely, either not to have them available, or to be unwilling to wrestle with them every time he needs to run a heavy barrow over his turf.
There is, in the example just given, a clear need for some form of duckboard which the amateur would be willing to buy and to use. But it is equally clearly a need to which conventional duckboards provide no solution. They are too heavy, too big, and too rigid to be used by the amateur. But the professional who does use them sees no good reason why he should seek to alter them for his purposes.
In a situation where an amateur builder or gardener requires the use of a duckboard, if it is to be of use to him it will have to be light enough for him to be able to readily lift and transport manually the whole assembly himself.
An embodiment of the duckboard of the invention may be used in situations where a temporary roadway may be required over a poor surface such as for use in tranporting emergency relief in third world countries. In such cases, the duckboard can usefully be heavier than that used by a gardener but still needs to be light enough to be easily lifted by a few men and easily transported by a lorry also carrying other goods. In the following specification the term "relatively portable" will be taken to mean light enough to be portable and useful for its required intended purpose.
SUMMARY OF THE INVENTION
The invention provides a duckboard which comprises a succession of treads linked so as to rest, in use, in generally parallel non-co-axial corresponding-end-alignment along the ground or other surface on which the board is placed; and characterized by the features, firstly that the board is flexible enough to be rolled end-to-end; secondly, that it is light enough to be relatively portable; and thirdly, that the means linking the treads are resilient enough and/or rigid enough to tend to maintain the parallelism and the end-alignment of the treads in use.
Such a board differs from a conventional wooden ground-engaging duckboard by virtue of its flexibility and its relatively light weight, irrespective of whether or not the conventional duckboard--as it may have--has parallel end-aligned treads. It differs from the conventional roof crawling board in the same respects. And it differs from, say, a conventional rope ladder laid in use on the ground, in that the ropes linking the treads of such a ladder are neither resilient enough nor rigid enought to tend to maintain the parallelism and the end-alignment of the ladder treads when subject to the use for which the duckboard is intended. It is therefore new.
Such a duckboard also does not form any obvious development of the state of the art in duckboards generally. Taking the known art, and the problem that it presents, in the terms already reviewed, provides no apparent basis for arriving at the present invention. Conventional duckboards are neither readily stored nor readily portable for the amateur, but the professional has never had any need to change either of these features. Rope ladders have been known for as long as conventional duckboards, and are easily rolled for storage and light in weight for easy portability. But they are quite unsuited to use as a duckboard and therefore there is no obvious reason to consider the teachings that they represent when one has been told to try to modify the conventional duckboard. And even if one is told to consider applying the features of the rope ladder to the conventional duckboard, there is no immediately apparent means of doing so with advantage.
The invention, therefore, is believed to involve an inventive step over the most relevant art currently known to the applicant.
In a duckboard embodying the invention, the means linking the treads may comprise lengths of resilient material spacing the treads one from another in use. This allows compact rolling of the duckboard, possibly "carpet-fashion" (i.e. end-over-end instead of just end-to-end).
It is preferred that the treads and the means linking the treads are arranged such that they can be readily coupled together in situ to allow the assembly of the duckboard. This allows sale of the duckboard in self-assembly "flat-pack" form; and ready assembly of any desired length of duckboard.
Conveniently when the means linking the treads are lengths of resilient material, these "linking strips" snap-fit into bores in the treads.
Alternatively the means linking the treads may comprise conventional saw-tooth plastics cable straps which can be readily used to couple two treads together in situ. Once such straps are in position, they can only be disconnected by cutting the straps and thus, in this case, once the duckboard is assembled it cannot readily be dismantled.
Where the connection between the treads and the linking strips is a snap-fit, it is preferred that the snap-in ball is coupled to the linking strip by a stalk of cross-section smaller than the cross-section of the bore in the tread. This enables the linking strip and hence adjacent treads to move with limited movement relative to one another, irrespective of the flexibility/rigidity of the linking strip itself.
It has been found that a stalk of square cross-section is preferred to a stalk of circular cross-section.
Preferably the bore in the tread is tapered. This allows for a smooth snap-action but tends to retain the ball in place. It is possible to arrange the snap-fit so as to be readily detachable or such that once connected the disconnection is difficult or impossible.
In a preferred arrangement the stalk of the snap-in ball is longer than the bore of the tread. This allows the linking strip to float up and down in relation to the tread to accommodate irregularities in ground surface.
Preferably each tread also includes means to link it with a further tread arranged co-axially with the tread so that not only can the duckboard have its length increased but it can also have its width increased by adding another run of treads.
One or more of the treads may incorporate, or be adapted to incorporate, ground-engaging pegs. Where a duckboard embodying the invention is laid along the ground, it will tend to sink into the ground and stay in place with repeated use. But pegging its end tread (for example) will help to ensure that it does stay in place during use.
The ground-engaging surface of each tread is preferably either generally concave or substantially flat. Whilst the ground-engaging surface could, within the broadset aspect of the invention, be convex--for example, the treads could be circular-cylindrical-section bars--a concave substantially flat ground-engaging tread surface will grip the ground better in use; and the duckboard will tend more to stay in place.
The top surface (i.e. the non-ground-engaging surface) of each tread may be partially or substantially wholly ribbed or otherwise treated to improve the grip of whatever or whoever contacts that surface in use. The advantages of such surface treatment are self-evident in themselves. But it is not obvious to apply them to a duckboard embodying the invention, in which it would more naturally be thought that the provision of successive individual treads would in itself provide sufficient grip for whatever travels over them in use.
The bottom surface (i.e. the ground-engaging surface) of each tread may with advantage be treated to improve the grip of the tread on the ground in use. Here again, the advantages of such treatment are known in themselves, but using it to improve a duckboard embodying the invention involves an inventive step; because separate treads would normally be assumed to sink in use into the ground and so to be already sufficiently gripping the duckboard into place.
Preferably the treads and the means linking the treads are injection moulded plastics. In one embodiment of the invention the tread comprises a foamed plastics core surrounded by a harder wearing plastics outer shell, for example a polyurethane shell surrounding a cellular plastics core.
The invention also includes within its scope a tread intended for use as part of a duckboard embodying the invention in any of the aspects summarized above.
BRIEF DESCRIPTION OF THE DRAWINGS
Two duckboards in accordance with the invention, together with possible modifications thereof will now be described by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 of the drawings shows in "exploded" perspective, one tread and several adjacent lengths of tread-linking material, forming a portion of a first duckboard embodying the invention;
FIGS. 1A and 1B show respectively, in sectioned part-elevation features of the tread in FIG. 1;
FIG. 2 shows a portion of the first duckboard diagrammatically, in elevation in use along the ground;
FIG. 3 likewise shows in diagrammatic perspective another aspect of the use of the duckboard;
FIG. 4 shows the duckboard rolled end-to-end;
FIG. 5 shows a longer duckboard, again embodying the invention, rolled carpet-fashion;
FIG. 6 shows a section through a modification of the tread shown in FIG. 1;
FIG. 7 is a schematic plan view of two treads of a second duckboard;
FIG. 8 is a sectional elevation along line I--I of FIG. 7;
FIG. 9 is an enlarged perspective view of a feature of the means linking the treads of FIG. 7;
FIG. 10 is an enlarged plan view of a feature of the duckboard of FIG. 7;
FIG. 11 is an enlarged schematic view of a feature of the duckboard of FIG. 7;
FIGS. 12A and 12B show schematically the means for linking the treads of the second duckboard together, and,
FIG. 13 is a schematic perspective view of an alternative means for linking the treads together.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The duckboards shown in the drawings are only examples of forms which the invention might take within its broadest aspect.
The first duckboard, shown in FIGS. 1 to 5 consists essentially of a succession of flat elongate treads 11 linked, and spaced apart, ladder-fashion by lengths of resilient material 12 which are readily detachable from the treads and are sold, initially, in a self-assembly "flat-pack" packaged bundle with the treads.
As FIG. 1 shows, each tread 11 is rectangular in plan, and generally rectangular but with rounded ends in end elevation. That surface of the tread which, in use, will engage the ground, is ribbed as indicated at 13. The non-ground-engaging surface of the tread is overlaid with a roughened coating 14. The ribs 13 are spaced apart across the bottom surface of the tread, and run parallel along the length of that surface. The roughened coating 14 comprises a gritted sheet wich is glued firmly to the tread top surface and which covers substantially the whole of that surface.
Each tread 11 such as the one illustrated is adapted to incorporate ground-engaging pegs, by virtue of two holes 15 each running through the tread from its top surface to its bottom surface. The centre line of each of these holes 15 lies on the longitudinal axis about which the tread 11 is symmetrical in plan. And as FIG. 1B shows, the holes 15 taper regularly from the top surface to the bottom surface of the tread 11 to accept respective conical pegs 16 in use.
The treads 11, of which there are as many as is desired to constitute an adequate overall length of duckboard, are recessed as indicated at 17 in FIG. 1 to accept the ends of the resilient strips 12. Each of these strips 12 is rectangular, elongate and substantially flat. Each end of each such strip has a ball 18 formed integrally with the strip and projecting from the underside of the strip. The ball is a snap-fit in a hole 19 formed in the recess 17 which accepts the strip end.
The treads 11 are moulded from relatively rigid plastics material. The strips 12 are also relatively rigid plastics strips but, because they are thin in comparison with the thickness of the tread 11, each strip can flex resiliently to a limited extend about an axis running across the strip, whilst remaining substantially inflexible about the longitudinal axis of the strip.
When the strip 12 are snap-fitted into the treads 11, to link successive treads in parallel spaced-apart corresponding-end-alignment, the frictional fit of each ball 18 into its hole 19 is sufficient for the strips not to spring out of the recesses 17 (unless of course the assembly of treads and strips is flexed quite abnormally beyond its intended useage). But a determined pull on any individual strip-end will dislodge the ball 18 from the hole 19 so that the strips can be readily detached from the treads.
Because the strips 12 are substantially inflexible about their respective longitudinal axes, and are also substantially not distortable from their elongate rectangular form; and because the side walls 21 of each recess 17 are long enough to contact an appreciable portion of each rectangular strip-end; then the overall result is that the resilient strips 12 allow the overall assembly to flex to a limited extent but tend to maintain the treads 11 in parallelism and in end-alignment.
As FIGS. 2 and 3 show, when the duckboard comprising the assembly of treads 11 and strips 12 is laid along the ground, the wheel 22 of a garden barrow (not shown) can be run along it without damaging the ground itself. As FIG. 4 shows, a basic length of duckboard can be rolled end-to-end. And as FIG. 5 shows, a longer length can be rolled carpet-fashion.
The duckboard described and illustrated can be used to run garden barrows across lawns, up curbs, and to form a track across any other soft but not wholly waterlogged terrain. It could be permanently left in place, in certain circumstances, and grass growing up around it could be mown to just above the level of the tread surfaces 14 by a ground-cushion-travelling mower of the FLYMO kind (FLYMO is a trade mark).
It could equally possible be used as a track against which the driven wheels of a bogged-down vehicle, stranded for example in mud or in snow, could grip.
In practical use, preferably the treads 11 are sufficiently close to one another that the wheel of the barrow or other item of equipment using the duckboard does not contact the ground in between successive treads as it travels along the duckboard.
In cases where the duckboard is to be used to support trucks or lorries, the treads have to be strong. They can therefore have the construction shown in FIG. 6. Here each tread comprises a core 23 of cellular plastics with a hardwearing outer shell 24 of polyurethane. The treads may typically here be 6 ft or 8 ft (1.83-2.44m) long.
In cases where the duckboard is to be used in gardens only the treads can be much shorter (for example 0.25-0.5m) to make them easier to handle. They can also be made of a hollow shell since they only have to support the weight of a man, or a garden barrow.
The second duckboard shown in FIGS. 7 to 12B is suitable for use in a garden. The duckboard is made up of a plurality of treads 25 which are elongate and generally rectangular in plan. These treads 25 are linked by lengths 26 of resilient material.
The linking strips 26 and treads 25 can readily be connected together and are sold initially in a self-assembly flat pack. If the duckboard needs to be extended either lengthways or widthways, further flat packs can be bought and readily connected to the existing duckboard.
Each tread 25 and linking strip 26 is made from injection moulded plastics material. Each tread 25 is ribbed in construction as can be seen in FIG. 8 and consists of three open edged channels 27 coupled by linking members 28.
This gives a good gripping surface on the ground engaging surface and the non-ground engaging surface. The non-ground engaging surface has a plurality of slight projections 29 which serve to roughen this surface to provide a non-slip surface.
Each tread 25 includes six bores 30. The tread includes a portion of thickened cross-section 31 wherever a bore is to be cut. Into each portion 31 is cut a slot 32. This allows the end of the linking strip 26 to sit beneath the upper surface of the tread as is shown in FIG. 8.
The tread includes two spaced-apart bores 30 along each of its elongate edges, and when two linking strips 26 extend between two pairs of bores 30 of adjacent treads 25, the treads 25 are held in a generally parallel non-coaxial corresponding-end-aligned relationship.
When the duckboard needs to have its width extended the bores 30 at the ends of each tread can be used to couple a further run of treads to the existing duckboard.
FIG. 9 shows in detail the end of a linking strip 26. Each strip 26 has integrally moulded at each of its ends a projection 33, consisting of a stalk 34 of square cross-section and a ball 35.
The ball 35 is a snap-fit into bore 30 as shown in detail in FIGS. 12A and 12B.
The bore 30 tapers to tend to retain the ball 35 in position.
The cross-section of stalk 34 is smaller than the diameter of bore 30, as shown in FIG. 10 and therefore the linking strip 26 can "waggle" about relative to the tread 25 as shown in FIG. 12B.
The swivel allowed by the rotation between stalk 34 and bore 30 is limited by the strip 26 bearing against the wall of the slot 32 as shown in FIG. 11.
The length of stalk 34 is longer than bore 30 to allow each strip 26 to be able to float up and down with respect to the tread 25.
The arrangement is such that once the ball 35 has been snapped through bore 30, it is not readily removeable in fact in many cases it is impossible. Thus there is no danger of the duckboard coming apart in use.
In an alternative embodiment, the means linking the treads 25 can be provided by saw-tooth plastics cable straps 36 as shown in FIG. 13. These can readily be coupled to the treads and once in position would have to be cut in order to dismantle the duckboard.
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A duckboard comprising a succession of treads (11) linked so as to rest, in use, in generally parallel non-co-axial corresponding-end-alignment along the ground or other surface on which the board is placed: and characterized by the features, firstly that the board is flexible enough to be rolled end-to-end; secondly, that it is light enough to be relatively portable; and thirdly, that the means (12) linking the treads (11) are resilient enough and/or rigid enough to tend to maintain the parallelism and the end-alignment of the treads (11) in use.
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BACKGROUND OF THE INVENTION
The invention relates to a method for reducing vibrations of a machine element and/or of a workpiece in a machine tool, production machine and/or in a machine which is embodied as a robot. The invention also relates to a machine of said type.
In machines such as, for example, machine tools, production machines and/or in robots, vibrations often occur during a machining process, which vibrations are generated by the machining process or by a fault, in machine elements of the machine and/or in the workpiece to be machined by the machine. In machine tools in particular, so-called chatter vibrations occur for example during cutting machining processes such as for example turning or milling, which chatter vibrations reduce the machining process quality and the machining speed which can be reached. Chatter vibrations are generated for example if the tool used and/or the workpiece are incited to vibrate at their natural frequency by the forces which occur during the machining process. Occurring vibrations of the tool and/or of the workpiece leave behind a corrugated surface on the workpiece, wherein the corrugated surface can further amplify the vibrations in the event of renewed contact with the tool.
One known measure for reducing vibrations and in particular chatter vibrations is that of the possibility, in the event of vibrations occurring, of reducing the rotational speed with which the tool or the workpiece rotates in the event of the chatter vibrations occurring.
The German laid-open specification DT 25 20 946 A1 discloses a method for preventing or eliminating chatter vibrations of a working spindle of machine tools and a device for carrying out said method.
DE 698 04 982 T2 discloses a device and a method for recommending dynamically preferable machining speeds.
The laid-open specification DE 44 05 660 A1 discloses a method and an arrangement for operating a cutting machine tool, in particular a circular saw, milling or grinding machine or the like.
The laid-open specification DE 102 29 134 A1 discloses a device and a method for workpiece machining using rotating tools, in which, in order to reduce vibrations, a rotating tool is moved dynamically with respect to the driveshaft by means of an adjusting unit which is fitted in a rotating system between the driveshaft and tool.
The laid-open specification DE 198 25 373 A1 discloses a chucking arrangement of a tool in a tool holder, with occurring vibrations being reduced by means of a flexible element which has a high degree of damping and which is inserted into the force flow between the tool and the tool holder.
The laid-open specification DE 102 20 937 A1 discloses a method and a device for damping an occurring chatter vibration in a machining machine.
SUMMARY OF THE INVENTION
The invention is based on the object of reducing vibrations, which occur during a machining process, of a machine element and/or of a workpiece.
Said object is achieved by means of a method for reducing vibrations of a machine element and/or of a workpiece in a machine tool, production machine and/or in a machine which is embodied as a robot, wherein, in the event of the vibrations occurring, a clamping force which is used to lock the workpiece and with which a workpiece holding device acts on the workpiece is varied.
Said object is also achieved by means of a machine, with the machine being embodied as a machine tool, production machine and/or as a robot, with the machine having a workpiece holding device, with the machine being designed such that, in the event of vibrations of a machine element and/or of a workpiece occurring, a clamping force which is used to lock the workpiece and with which the workpiece holding device acts on the workpiece is varied.
Advantageous embodiments of the invention can be gathered from the dependent claims.
Advantageous embodiments of the method are provided analogously to advantageous embodiments of the machine and vice versa.
It has proven to be advantageous if the clamping force is varied by means of a piezo element. The clamping force can be varied in a particularly simple manner by means of a piezo element.
It has also proven to be advantageous if the clamping force is varied by means of a hydraulic element. The clamping force can be varied in a simple manner by means of a hydraulic element.
It has also proven to be advantageous if the clamping force is varied by means of a linear motor. The clamping force can likewise be varied in a simple manner by means of a linear motor.
It has also proven to be advantageous if the clamping force is present in the form of a torsional clamping force which generates a torsional stress in the workpiece. In particular in the case of elongate workpieces, it is possible by introducing a torsional clamping force to obtain particularly good locking of the workpiece.
In this connection, it has proven to be advantageous if the torsional clamping force is generated and varied by means of a rotary drive, since the torsional stress can then be varied in a simple manner.
It has also proven to be advantageous if the torsional clamping force is varied, with the workpiece being clamped into the workpiece holding device at two points of the workpiece and being twisted by means of a rotary drive assigned to each point. By means of said measure, it is possible to obtain particularly good locking of the workpiece, in particular in the case of elongate workpieces, wherein if the workpiece is rotatably clamped into the workpiece holding device at two points, the workpiece can be rotated during the machining process, but by means of corresponding activation of the two drives, the torsional clamping force is maintained and can be varied.
In this connection, it has proven to be advantageous if the rotary drive is embodied as a direct drive. Said measure permits a simple construction of the workpiece holding device.
It has also proven to be advantageous if the clamping force is composed of a linear clamping force and a torsional clamping force, with the linear clamping force being varied by means of a piezo element, a hydraulic element and/or a linear motor, and the torsional clamping force being varied by means of a rotary drive, with it being possible for the rotary drive to be embodied as a direct drive.
It has also proven to be advantageous if the occurrence of vibrations is determined by virtue of the signal of a vibration sensor being monitored and/or by virtue of a drive variable being monitored. The use of vibration sensors and/or monitoring a drive variable, such as for example a drive current, represent simple possibilities for determining occurring vibrations.
It has also proven to be advantageous if the clamping force is varied until the amplitudes of the vibrations are at a minimum. The occurring vibrations can be minimized by means of said measure.
BRIEF DESCRIPTION OF THE DRAWING
Two exemplary embodiments of the invention are illustrated in the drawing and are explained in more detail below. In the drawing:
FIG. 1 shows a machine according to the invention and
FIG. 2 shows a further machine according to the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates, in the form of a schematic illustration, a machine 1 which is embodied as a machine tool within the context of the exemplary embodiment. The machine 1 has a displaceable drive 9 for driving a tool 6 in rotation, with the drive 9 being displaceable in the vertical direction, as indicated by an arrow 4 .
The machine 1 also has a workpiece carriage 7 which is displaceable in the direction of the arrow 3 and on which a workpiece 5 to be machined is locked by means of a workpiece holding device. Within the context of the exemplary embodiment, the workpiece holding device comprises a first clamping jaw 2 a which is fixedly connected to the workpiece carriage 7 , a second clamping jaw 2 b which is arranged so as to be movable on the workpiece carriage 7 in the horizontal direction, and a force element 2 c which generates a clamping force F. The force element 2 c exerts a clamping force F on the second clamping jaw 2 b and presses the latter against the workpiece, such that the workpiece 5 is thereby locked. Furthermore, the machine has a vibration sensor 10 in order to determine occurring vibrations, in particular chatter vibrations on a machine element which is embodied within the context of the exemplary embodiment as a drive 9 . Furthermore, the machine 1 has a control and/or regulating device 8 for controlling and/or regulating the machine 1 . Within the context of the exemplary embodiment, the tool 6 is embodied as a milling cutter.
Now, if vibrations, in particular chatter vibrations, occur during the machining process, that is to say in this case during the milling process, then said vibrations are detected by the vibration sensor 10 and a corresponding vibration signal is supplied to the control and/or regulating device 8 . According to the invention, in order to reduce vibrations which occur during the machining process, the clamping force F which is used for locking the workpiece 5 and with which the workpiece holding device acts on the workpiece is varied by virtue of the clamping force F being increased or decreased. This takes place by means of the force element 2 c which can for example be embodied as a hydraulic element or as a linear motor. However, the force element 2 c can also, for variations in the clamping force, have a piezo element or be embodied as a piezo element, by means of which the clamping force F can be varied. By means of the control and/or regulating device 8 , the variation of the clamping force F is controlled by virtue of the force element 2 c being correspondingly activated. Here, it is advantageous for the clamping force F to be varied within permissible and possible limits until the amplitudes of the vibrations are at a minimum.
It is of course also conceivable for the force element to be formed from a combination of a linear motor and/or hydraulic element and/or piezo element.
The vibration sensor 10 can of course also be attached in the vicinity of the workpiece and thereby detect vibrations occurring in the workpiece. Alternatively or in addition, occurring vibrations can however also be determined by monitoring the drive currents of the drive 9 or of the drive, which has not been illustrated in FIG. 1 for clarity, of the workpiece carriage 3 .
The embodiment illustrated in FIG. 2 substantially corresponds in terms of its basic design to the above embodiment described in FIG. 1 . Identical elements are therefore provided with the same reference symbols in FIG. 2 as in FIG. 1 . The significant difference of the embodiment as per FIG. 2 in relation to the embodiment as per FIG. 1 is that the tool holding device is designed such that the clamping force which acts on the workpiece and which is varied is present in the form of a torsional clamping force which generates a torsional stress in the workpiece. For this purpose, the workpiece holding device as per FIG. 2 has two rotary drives 11 a and 11 b, with the rotary drive 11 a driving a clamping jaw 2 d in rotation and the rotary drive 11 b driving a further clamping jaw 2 e in rotation. The workpiece is clamped into the workpiece holding device at the points A and B, wherein in order to lock the workpiece, a torsional clamping force is generated by virtue of the workpiece 5 being twisted by means of the rotary drives 11 a and 11 b.
In the exemplary embodiment, the drive 11 b is activated in such a way that the latter maintains its position, while the drive 11 a is rotated by a small angle, as indicated by an arrow 12 , in order to generate a torsional stress in the workpiece. In contrast to the embodiment as per FIG. 1 , therefore, inter alia a torsional clamping force is used for locking the workpiece in the embodiment as per FIG. 2 . If vibrations occur in a machine element and/or in the workpiece during the milling process of the workpiece, then the torsional clamping force generated by the drive 11 a is varied and the vibrations are thereby reduced. The embodiment as per FIG. 2 is advantageous in particular in the case of an elongate workpiece which, if no locking of the workpiece by means of a torsional clamping force is carried out, cannot be correctly locked since it otherwise starts to bend under the forces which act during the machining process.
The embodiment of the workpiece holding device illustrated in FIG. 2 also offers the advantage that, during the machining process, the workpiece can be rotated by means of the two drives 11 a and 11 b in the same direction, but with the drives 11 a and 11 b being activated in such a way that the torsional clamping force is maintained during the rotary movement and can be varied in the event of vibrations occurring.
The drives 11 a and 11 b are embodied in the exemplary embodiment as direct drives, in particular as torque motors, which permits a simple structural mechanical design of the workpiece holding device.
it is of course also possible for the torsional clamping force to be varied by means of only one single rotary drive by virtue, for example, of the drive 11 b being omitted and the clamping jaw 2 e being positionally fixedly connected to the workpiece carriage 7 .
In the embodiment as per FIG. 1 , the clamping force F is present in the form of a linear clamping force which acts on the workpiece in a linear direction, while in the embodiment as per FIG. 2 , the clamping force is present in the form of a torsional clamping force which generates a torsional stress in the workpiece. It is of course also possible for the two embodiments to be combined, with the clamping force in this case being composed of a linear clamping force and a torsional clamping force, with it being possible for the drive 11 a as per FIG. 2 to also exert a linear clamping force on the workpiece 5 in the linear direction, for example by means of a suitable hydraulic element as used in FIG. 1 .
As a result of the reduction of the vibrations, the machining speed and the feed depth into the material can be increased, as a result of which an increase in productivity can be obtained and/or the machining quality can be improved.
It should be noted at this point that, within the context of the invention, for example a tool which is clamped into the machine is also considered to be a machine element.
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The invention relates to a method for reducing vibrations of a machine element ( 9 ) and/or a workpiece ( 5 ) in a machine tool, a production machine and/or in a machine which is embodied as a robot. A clamping force (F), which is used to lock the workpiece ( 5 ) and which makes the workpiece holder ( 2 a, 2 b, 2 c, 2 d, 2 e, 11 a, 11 b ) act upon the workpiece ( 5 ), is modified when vibrations occur. The invention also relates to a corresponding machine. Due to said invention, vibrations of a machine element ( 9 ) and/or a workpiece ( 5 ), which occur during a machining process, are reduced.
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BACKGROUND OF THE INVENTION
The invention relates to a shift device for a transmission, consisting of a shift sleeve, displaceable in the direction of the axis of a transmission shaft, for the driving connection of transmission members, of a shift fork engaging into the shift sleeve, and of, as actuator, an element which is rotatable on a shift shaft arranged transversely to the transmission shaft and which cooperates with a foot part of the shift fork.
It is known from WO 01/59331-A to adopt, as actuator a pinion which meshes with a corresponding toothing on the foot part of the shift fork, the shift shaft being driven by an electric gear motor.
This has some disadvantages: the step-up of this movement transmission is constant, which, as a rule, does not correspond to the profile desired for shifting and to the characteristic of the electric motor; especially not when the shift sleeve has synchronization. There are no stops, and the toothing has no blocking action, that is to say it cannot retain the shift sleeve in the respective position. Both factors, however, are particularly important in the case of an electromotive drive. The motor is, of course, to remain currentless after a completed changeover and is even to be capable of being uncoupled in specific applications, even when changeover took place counter to the ever-acting force of a spring. Furthermore, to simplify the control, the motor is to be capable of being moved up against a stop, in order to manage without position or speed sensors.
In order to remedy this, the object of WO 01/59331-A is to provide a detent disk firmly connected to the rotating element and a detent member engaging into a detent recess. Said detent member holds the rotating element after the uncoupling of the electric motor and ensures that this is possible only after a defined end position is reached. However, this remedy is highly complicated and is also not entirely satisfactory in functional terms. Due to the moments acting on the element and consequently on the detent disk (which emanate, for example, from the synchronization or from chamfers of the teeth in order to secure the sleeve against a stop), friction arises which obstructs or completely prevents the changeover. This may also occur when the two elements to be coupled are in an unfavorable relative position. The other gear in each case then cannot be engaged, and the sleeve remains set in the neutral position, which may lead to hazardous driving situations and therefore should not happen. Moreover, due to the long tolerance chain, positioning is inaccurate.
The object of the invention, therefore, is to propose a simple and reliable control which satisfies all functional requirements, in particular safety requirements.
SUMMARY OF THE INVENTION
The foregoing object is according to the invention, by means of the following:
a) the rotatable element is a cam which has two flanks extending from a minimum to a maximum radius and a flattening at the maximum radius,
b) two lantern wheels cooperating with the cam are provided at a fixed distance from one another on the foot of the shift fork,
c) so that one lantern wheel bears against one flank and the other lantern wheels bears against the other flank and, in at least one end position, one lantern wheel bears against the flattening and the other lantern wheel bears exactly against the minimum radius.
The cooperation of the cam of one member with the two lantern wheels of the other member, the two members having defined poles (one may be infinitely remote), provides a desmodromic control. In this context, the flattening is formed. Thus, one lantern wheel, together with a flattening, brings about a detention of the shift fork in an end position, and the other lantern wheel at the smallest radius gives rise to a stop. As a result, two functions, which it has been possible to fulfill only by means of two different pairs of members according to the prior art, are combined in a single pair of members, this being such that shifts can take place even counter to considerable holding forces. The lantern wheel pressing onto the flattening of the cam under the force of the coupling spring does not, of course, exert any torque on the cam. Furthermore, by the configuration of the cam shape, the step-up can be adapted to the shift requirements (in contrast to a conventional lantern wheel toothing in which the step-up must of course be constant).
In a preferred embodiment, the shift fork is a two-armed lever pivotable about an axis fixed with respect to the housing and the lantern wheels are cylinders, the axes of which are parallel to the axis of the shift shaft. This affords an accurate kinematic guidance of the two members, along with low friction; the latter to an especially great extent when the lantern wheels are rotatable about their axes. Furthermore, the flanks of the cam are enveloping curves of the lantern wheels when there is a common rolling movement of cam and lantern wheels. In this case, the step-up ratio of the rolling movement can be determined by means of the configuration of one flank of the cam, that of the other flank then arising from this.
In an advantageous development with a shift shaft driven by an electric motor, a shoulder is provided at the point of minimum radius on at least one flank. The electric motor can consequently be controlled automatically without path or speed regulation.
In order to ensure reliable shifting, further measures may advantageously be taken: when the shift fork surrounds a shift sleeve with a large diameter, the foot part of the shift fork is appended at the lowest point of the latter, the shift force thereby being introduced symmetrically into the shift fork. When there is the risk that the shift sleeve cannot be engaged in the case of a tooth-on-tooth position, the shift fork contains an elastic element, so that the foot part can move back. When the tooth position is favorable, shifting then takes place somewhat later by means of the force of the elastic element.
The invention is also concerned, particularly with regard to the power divider for motor vehicles, with an off-road gear step which can be shifted due to the axial displacement of one of its elements by means of a shift fork as a result of rotation of a shift shaft arranged transversely to the axial direction. In the case of a power divider, the problems referred to initially arise in a particularly disturbing way. They are eliminated by the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described and explained below with reference to figures in which:
FIG. 1 illustrates a vertical section through a power divider having the shift device according to the invention,
FIG. 2 illustrates a section according to CC in FIG. 1 ,
FIG. 3 illustrates a detail of FIG. 2 , enlarged and varied,
FIG. 4 illustrates a view according to IV in FIG. 3 ,
FIG. 5 illustrates the same as FIG. 4 in one end position,
FIG. 6 illustrates the same as FIG. 4 in the other end position,
FIG. 7 illustrates another embodiment in a view similar to that of FIG. 4 .
DETAILED DESCRIPTION
In FIG. 1 , the housing of a power divider is designated as a whole by 1 , an input shaft coming from the drive unit, not illustrated, of the vehicle by 2 , a first output shaft drive-connected to the rear axle by 3 and a second output shaft drive-connected to the front axle, likewise not illustrated, by 4 . The second output shaft 4 , by means of a first toothed-belt wheel 5 , drives, below the input shaft 2 , a second toothed-belt wheel 6 which is seated on a driven shaft 7 for the drive of the front axle.
To distribute the torque to the two output shafts 3 , 4 , a differential, designated in summary by 10 , is provided. Furthermore, a control unit 11 below the differential 10 and a blocking clutch 12 for blocking the differential 10 are provided. In the exemplary embodiment shown, the blocking clutch is combined structurally with the differential 10 . It could, however, also be arranged separately, indeed even anywhere else in the power divider or in the drive train. The differential itself may also have a widely differing design within the framework of the invention.
FIG. 1 and FIG. 2 show an exemplary and particular version of the power divider. Inside a differential housing 16 , which serves here at the same time as a planet carrier, are located a sun wheel 17 connected fixedly in terms of rotation to the input shaft 2 , planet wheels 18 of the off-road gear step, which are mounted rotatably in the differential housing 16 , and first compensating wheels 21 and second compensating wheels 22 . The former ( 21 ) are connected fixedly in terms of rotation to the first output shaft 3 and the latter ( 22 ) are connected fixedly in terms of rotation to the second output shaft 4 . The differential housing 16 is surrounded by a ring wheel 19 which is axially displaceable and, in the off-road gear, is connected fixedly in terms of rotation to the differential housing 16 . This special embodiment of the differential 10 is the subject of Austrian patent 405 157 and is described in more detail there in terms of type of construction and functioning.
The blocking clutch 12 is actuated by means of two ramp rings 31 , 32 rotatable relative to one another. The first ring 31 possesses a first ramp lever 35 , and the second ring 32 possesses a second ramp lever ( 36 ), said ramp levers projecting downward and possessing rollers 39 at their free ends 37 , 38 . Between the two rollers 39 is located a rotatable control disk 40 . During the rotation of this control disk, the rollers 39 are moved apart from one another and, via the ramp levers 35 , 36 moved in a scissor-like manner, the rings 31 , 32 are rotated relative to one another.
In FIG. 2 , 47 is a motor output shaft of an electric gear motor, not illustrated, said motor output shaft rotating with a corresponding step-down when the motor is running. Connected fixedly in terms of rotation to this motor output shaft is a carrier shaft 48 which is slipped onto the latter in a sleeve-like manner and which is mounted on both sides in the housing 1 . The hub 49 of the control disk 40 and a cam 50 are mounted rotatably on the carrier shaft 48 . Between the hub 49 and the cam 50 , a changeover sleeve 52 is mounted fixedly in terms of rotation, but displaceably in the longitudinal direction, on the carrier shaft 48 by means of a longitudinal ball guide 51 . The changeover sleeve 52 is displaced by means of a changeover fork 53 which is actuated by a changeover magnet 54 ( FIG. 1 ) via a lever mounted in a changeover fork axis 55 ( FIG. 1 ). The changeover sleeve 52 , at its two axial ends, has first shift teeth 56 for rotationally fixed connection to the hub 49 and second shift teeth 57 for rotationally fixed connection to the cam 50 . The shift teeth 56 , 57 are coupling teeth with a deflecting pressure angle. If only one gear shift or only one blocking clutch is to be actuated, a changeover sleeve 52 is not necessary.
It can be seen in more detail in FIG. 3 that the cam 50 cooperates in a way still to be described with lantern wheels 60 , 61 which are arranged on the foot part 64 of a shift fork 63 which is pivotable about an axis of oscillation 62 in the housing and by means of which the ring wheel 19 is displaced in the axial direction for changeover into the off-road gear. For this purpose, a sliding block 66 is provided on each of the two sides of the ring wheel. An elastically flexible intermediate zone 65 may be provided in the foot part 64 .
In the exemplary embodiment shown, the cam 50 and the lantern wheels 60 , 61 are duplicated (cams 50 * and lantern wheels 60 *, 61 *) for reasons of lateral guidance, and the foot part 64 of the shift fork 63 is tied to the lowest point of the latter, hence in its axis of symmetry. By virtue of the latter aspect, the deformations of the two halves of the shift fork 62 are equal, so that they cannot become jammed.
In FIG. 4 , the kinematics of the cooperation of cam and lantern wheels 60 , 61 can be seen. The lantern wheels 60 , 61 are arranged at a fixed distance 70 from one another on the foot part 64 of the shift fork 63 . Here, they are circular cylinders (other shapes may also be envisaged, see FIG. 7 ) with axes 71 which either are only geometric axes or are axes of rotation for the lantern wheels, on which they can rotate and thus roll on the cam 50 , in order to minimize friction. The cam is rotatable with its shaft about an axis 72 and possesses a first flank 73 , a second flank 74 , at a maximum distance from the axis 72 a flattening 75 , and at a minimum distance from the axis 72 , that is to say at a minimum radius, valleys 76 , 77 which shoulders 78 , 79 adjoin. The flanks 73 , 74 are shaped in such a way that in all the middle positions, such as, for example, in FIG. 4 , the lantern wheel 60 always bears against the flank 73 and the lantern wheel 61 always bears against the flank 74 . These flanks are therefore enveloping curves of the two lantern wheels. In contrast to a toothing, by means of a suitable shaping of the flanks 73 , 74 , different step-ups can be implemented as a function of angle. It can also be seen directly in FIG. 4 how, for example, a rotation of the cam 50 clockwise about its axis 72 causes a pivoting of the shift fork 63 counterclockwise about its axis of oscillation 62 .
In FIG. 5 , the cam 50 ′ is in one end position. The lantern wheel 61 ′ has run through the valley 77 ′ and reached the stop 79 ′. As a result, the electric motor driving the cam has been stopped and reversed, so that, when switched on again, it rotates in the opposite direction. In this position, the other lantern wheel 60 ′ is supported on the flattening 75 ′. Since the supporting force, illustrated by an arrow 80 , is directed toward the axis 72 ′ of the cam 50 ′, no torque is in this case exerted on the cam 50 ′. The shift fork can thus be held in the position shown without action upon the motor and without locking. If appropriate, for safety purposes, a spring, not illustrated, is provided or a coupling spring, present in any case, acts as such. The other end position of FIG. 6 differs from that of FIG. 5 only in that the lantern wheels 60 ″, 61 ″ have exchanged their rollers, and in that the cam 50 ″ is rotated clockwise approximately through a right angle. The shift fork is retained, here, in the other end position.
The possibility of providing an elastic zone 65 in the foot part 64 of the shift fork 63 was mentioned further above. When the ring wheel cannot be engaged in the case of a tooth-on-tooth position, the elastic zone allows the cam 50 to execute its adjusting movement as far as the end position, but without the fork itself being moved in this case. Only when the teeth of the ring wheel have been displaced somewhat with respect to its counterwheel is the ring wheel engaged by means of the force stored in the elastic zone.
In the variant of FIG. 7 , the cam 150 is to a very great extent widened and thickened. It cooperates kinematically with the lantern wheels 160 , 161 which are not cylindrical here, but bar-shaped, and are provided with suitably shaped sliding surfaces 178 , 179 . Here, too, between the two members a desmodromic movement transmission prevails, in which the two contact surfaces 178 , 179 are always in contact with the cam 150 .
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A shift device for a transmission, which comprises a sliding sleeve, a shift fork engaging in the sliding sleeve, and an actuator that can rotate on a shaft that is disposed at an angle to the transmission shaft. In order to provide a simple and reliable control that satisfies all functional requirements, a cam having two flanks and a flattened section on the maximum radius is disposed on the shaft. On the base of the shift fork, two interacting pushrods are disposed at a fixed distance so that one pushrod rests against the one flank and the other pushrod rests against the other flank and one pushrod rests against the flattened section in at least one extreme position.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a digital control method and device for an internal combustion engine and more particularly to improvements in a digital control method and device suitable for use in an engine of a motor vehicle having an electronic fuel injection device, wherein the engine is digitally controlled in response to engine condition signals that have been read out from sensors for detecting the conditions of the engine.
2. Description of the Prior Art
Heretofore, there has been put into practical use a digital control method for an internal combustion engine, wherein various sensors including a coolant temperature sensor, an intake air temperature sensor, an intake air pressure sensor, an intake air flow rate sensor, an engine rotation sensor and the like for detecting the conditions of the engine are provided on various portions of an internal combustion engine such as motor vehicle engine or the like, and fuel injection time of fuel injected into a combustion chamber of the engine, ignition timing, idle rotation speed and the like are digitally controlled in response to the engine condition signals including an engine coolant temperature, an intake air temperature, an intake air pressure, an intake air flow rate, a crank angle and the like which have been read out from the aforesaid sensors. In a digital control device for performing the aforesaid digital control, normally, an analogue signal from each sensor, for example, a coolant temperature sensor 10 for detecting an engine coolant temperature is, as shown in FIG. 1, converted into a digital signal by an Analogue-Digital Converter (hereinafter referred to as an "A/D converter") 14 in a digital control circuit 12, and thereupon, taken into a Central Processing Unit (hereinafter referred to as "CPU") 16 for performing various calculating operations. More specifically, a voltage from a battery 22 is applied to the aforesaid coolant temperature sensor 10 through a voltage regulator 18 having an output voltage Vc of 5 V, for example, and a resistor 20, whereby a change in voltage by a change in resistence of the coolant temperature sensor 10 due to a change in the engine coolant temperature is taken into the A/D converter 14 as an analogue signal indicating the engine coolant temperature.
The above-described digital control method features that the engine is accurately controllable. However, heretofore, a signal from each sensor, for example, a coolant temperature signal read out of an output from the coolant temperature sensor 10 has been taken in at a constant cycle of 1 or 2 seconds and converted into a digital signal in the A/D converter 14, without synchronizing with the rotation of the engine. Hence, for example, when a power supply voltage from the battery 22 drops greatly and the supply voltage Vc of the coolant temperature sensor 10 also drops during start and the like, an output voltage from the coolant temperature sensor 10 also drops. Thus, for example, when a thermistor type temperature sensor is used as the coolant temperature sensor 10, a temperature higher than the actual temperature is detected. As the result, there have been cases where too short fuel injecton time during start results in start failure, an insufficient increase after the start leads to unsatisfactory drivability, and, worst of all, an engine stall is caused.
SUMMARY OF THE INVENTION
The present invention has been developed to obviate the above-described disadvantages of the prior art, and has as its first object the provision of a digital control method for an internal combustion engine wherein accurate engine condition signals are obtainable regardless of a battery voltage drop, whereby the engine driving conditions during start and after the start are maintained properly, so that satisfactory start performance and drivability can be obtained.
The present inventiton has as its second object the provision of a digital control method for an internal combustion engine, capable of reading out outputs from sensors for detecting the conditions of the engine at a proper crank angle.
The present invention has as its third object the provision of a digital control method for an internal combustion engine, capable of obtaining accurate engine condition signals from outputs fed from a temperature sensor sensitive to the influence of a battery voltage drop.
The present invention has as its fourth object the provision of a digital control device for an internal combustion engine, capable of achieving the above-described objects.
To achieve the first object, according to the present invention, in a digital control method for an internal combustion engine, wherein the engine is digitally controlled in response to engine condition signals read out from sensor for detecting the engine conditions, the sensor outputs are read out in synchronism with the rotation of the engine at a crank angle where an engine load is low and a battery voltage is high, and turned into the engine condition signals.
To achieve the second object, according to the present invention, in a digital control method for an internal combustion engine, the crank angle for reading out the sensor outputs is made to be a crank angle very close to the bottom dead center.
To achieve the second object, according to the present invention, in a digital control method for an internal combustion engine, the crank angle for reading out the sensor outputs is made to be a crank angle within +20 degrees CA from the bottom dead center.
To achieve the third object, according to the present invention, in a digital control method for an internal combustion engine, the sensors are temperature sensors for detecting an engine coolant temperature, an intake air temperature and the like.
To achieve the fourth object, according to the present invention, the digital control device for an internal combustion engine comprises:
an intake air temperature sensor for detecting the temperature of the intake air taken in by an air cleaner;
a throttle sensor including an idle switch for detecting whether a throttle valve is within the range of idle opening or not and a potentiometer for generating a voltage output in proportion to an opening of the throttle valve;
an intake air pressure sensor for detecting an intake air pressure from pressure in a surge tank;
injectors for injecting fuel into the engine;
a top dead center sensor and a crank angle sensor for respectively outputting a top dead center signal and a crank angle signal in accordance with the rotation of the engine;
a coolant temperature sensor for sensing an engine coolant temperature; and
a digital control circuit for extracting a basic injection time in accordance with the intake air pressure fed from the intake air pressure sensor and the engine rotational speed obtained from the crank angle signal fed from the crank angle sensor, and correcting the basic injection time in accordance with an output from the throttle sensor, the intake air temperature fed from the intake air temperature sensor and the engine coolant temperature fed from the coolant temperature sensor, both of which are read out at the crank angle close to the bottom dead center in synchronism with the rotation of the engine, and the like, so as to determine a fuel injection time and feed valve opening time signals to the injectors.
The present invention is based on the fact that the battery voltage is periodically varied in accordance with the engine load, and hence, even when the battery voltage drops, a relatively high battery voltage is generated at a crank angle where the engine load is low. According to the present invention, even when the battery voltage drops, accurate engine condition signals can be read in, and hence, the engine operating conditions during start and after the start can be maintained properly, thus enabling satisfactory start performance and drivability.
BRIEF DESCRIPTION OF THE DRAWINGS
The exact nature of this invention, as well as other objects and advantages thereof, will be readily apparent from consideration of the following specification relating to the accompanying drawings, in which like reference characters designate the same or similar parts throughout the figures thereof and wherein:
FIG. 1 is a block diagram showing an example of arrangement of a digital control circuit used in a digital control device for an engine of motor vehicle in the prior art;
FIG. 2 is a sectional view, partially including a block diagram, showing the arrangement in an embodiment of the intake air pressure sensing type (so-called D - J type electronic fuel injection device for a motor vehicle engine, wherein the digital control method for an internal combustion engine according to the present invention is applied;
FIG. 3 is a block diagram showing the arrangement of the digital control circuit used in the aforesaid embodiment;
FIG. 4 is a flow chart showing a portion of an Analogue-Digital conversion ending interrupt routine used in the digital control circuit;
FIG. 5 is a flow chart showing a portion of a 30 degrees CA interrupt routine; and
FIG. 6 is a diagram showing an example of the relations between the crank angle, battery voltage and the output voltage from the voltage regulator in the aforesaid embodiment.
DETAILED DESCRIPTION OF THE INVENTION
Detailed description will hereunder be given of an embodiment of the intake air pressure sensing type (D - J type) electronic fuel injection device for a motor vehicle engine, wherein the digital control method for an internal combustion engine according to the present invention is applied, with reference to the drawings.
As shown in FIG. 2, the present embodiment is of such an arrangement that, in a D - J type electronic fuel injection device for a motor vehicle engine 30, comprising: an air cleaner 32 for taking in atmospheric air; an intake air temperature sensor 34 for detecting a temperature of the intake air taken in through the air cleaner 32; a throttle valve 38 provided on a throttle body 36 and openable in association with an accelerator pedal provided about a driver's seat, not shown, for controlling the flow rate of the intake air; a throttle sensor 40 including an idle switch for detecting whether the throttle valve 38 is within the range of idle opening or not and a potentiometer for generating an output voltage in proportion to the opening of the throttle valve 38; a surge tank 42 for preventing the intake air interference; an intake air pressure sensor 43 for detecting an intake air pressure from pressure in the surge tank 42; a bypass passage 44 bypassing the throttle valve 38; an idle speed control valve 46 provided in the intermediate portion of the bypass passage 44 for controlling an opening area of the bypass passage 44 to control idle rotation speed; injectors 50 provided on an intake manifold 48 for injecting fuel into intake ports of the engine 30; an oxygen concentration sensor (hereinafter referred to as an "O 2 sensor") 54 provided on an exhaust manifold 52 for detecting an air-fuel ratio from a residual oxygen concentration in the exhaust gas; a three-way catalytic converter 58 provided in the intermediate portion of an exhaust pipe 56 at the downstream side of the exhaust manifold 52; a distributor 60 having a distributor shaft rotatable in association with the rotation of a crankshaft of the engine 30; a top dead center sensor 62 and a crank angle sensor 64, both of which are incorporated in the distributor 60 for respectively outputting a top dead center signal and a crank angle signal in accordance with the rotation of the distributor shaft; a coolant temperature sensor 10 provided on an engine block for detecting an engine coolant temperature; and a digital control circuit 12 for extracting a basic injection time per one process of the engine in accordance with the intake air pressure fed from the intake air pressure sensor 43 and an engine rotational speed obtained from the crank angle signal fed from the crank angle sensor 64, correcting the basic injection time in accordance with the output from the throttle sensor 40, the air-fuel ratio fed from the O 2 sensor 54, the engine coolant temperature fed from the coolant temperature sensor 10, the voltage from the battery 22 and the like, so as to determine a fuel injection time and feed valve opening time signals to the injectors 50, determining an ignition timing in accordance with the engine operating conditions, feeding an ignition signal to a coil 66 with an igniter, and further, controlling the idle speed control valve 46 during idling, in the aforesaid digital control circuit 12, the outputs from the coolant temperature sensor 10 and the intake air temperature sensor 34 being read out at a crank angle very close to the bottom dead center in synchronism with the rotation of the engine.
As shown in detail in FIG. 3, the digital control circuit 12 comprises: a Central Processing Unit (CPU) 16 such as a microprocessor for performing various calculating operations; an A/D converter 14 with a multiplexer for converting analogue signals fed from the battery 22, the coolant temperature sensor 10, the intake air temperature sensor 34, the potentiometer of the throttle sensor 40, the intake air pressure sensor 43, the O 2 sensor 54 and so forth into digital signals and taking the digital signals into the CPU 16 successively; a voltage regulator 18 for applying a constant voltage Vc to the coolant temperature sensor 10, the intake air temperature sensor 34, the potentiometer of the throttle sensor 40, the intake air pressure sensor 43 and so forth; a digital input port 70 for taking the digital signals fed from the idle switch of the throttle sensor 40, the top dead center sensor 62, the crank angle sensor 64 and so forth into the CPU 16 at predetermined timings; a Read Only Memory (hereinafter referred to as a "ROM") 72 for storing control programs, various constants and the like; a Random Access Memory (hereinafter referred to as a "RAM") 74 for temporarily storing calculation data and the like in the CPU 16; a backup Random Access Memory 76 supplied with voltage from an auxiliary power supply when the engine is out of operation for maintaining memory; a digital output port 78 for feeding the results of operation in the CPU 16 to the idle speed control valve 46, the injectors 50, the coil 66 with the igniter and so forth at predetermined timings; and a common bus 80 for connecting the above-described components to one another.
Description wil now be given of an exemplary best node.
Firstly, the digital control circuit 12 extracts the basic injection time TP in accordance with the intake air pressure PM fed from the intake air pressure sensor 43 and the engine rotational speed NE calculated from the crank angle signal fed from the crank angle sensor 64.
Further, the basic injection time TP is corrected in response to the signals fed from the various sensors through the following equation, whereby the fuel injection time TAU is calculated out.
TAU=TP*F (1)
where F indicates a correction factor. When F is larger than 1, an increase correction is meant, and when F is smaller than 1, a decrease correction is meant.
The valve opening time signals corresponding to the fuel injection time TAU thus determined are fed to the injectors 50, and the injectors are opened in synchronism with the rotation of the engine, whereby fuel is injected into the intake manifold 48 of the engine 30.
The following is the process of read-in of the output from the coolant temperature sensor 10 in the present embodiment.
As shown in FIG. 4, in Step 101 of an Analogue-Digital conversion ending interrupt routine, it is determined whether the present conversion value is that of an engine coolant temperature or not. If this determination is positive, then the process goes forward to Step 102, where it is determined whether a signal read-in flag is set or not. If this flag is set, then the process goes forward to Step 103, where the signal read-in flag is rest (i.e., cleared) to zero. Then, the process goes forward to Step 104, where the present Analogue-Digital conversion value established as a read-in signal THW of the engine coolant temperature. Upon completion of Step 104, or when the determination in the aforesaid Step 102 is negative and not suitable for signal read-in, this program is terminated. On the other hand, when the determination of the aforesaid Step 101 is negative, the process goes forward to Step 105, where other signals such the intake air temperature are treated, to complete this program.
The signal read-in flag used in Step 102 of FIG. 4 is set by a 30° CA interrupt routine as shown in FIG. 5. More specifically, in Step 201 of the 30° CA interrupt routine, it is determined whether a crank angle suitable for signal read-in, i.e., the bottom dead center, is obtained or not. That is, in the case of a six-cylinder engine, it is determined whether interruption is to be made at 60°, 120° or 300° after the top dead center or not. In the case of a four-cylinder engine, it is determined whether the interruption is to be made at 60° and 240° or 90° and 270° after the top dead center or not. If this step 201 determination is positive, the process goes forward to Step 202, where the signal read-in flag tested in step 102 is set. Upon is ending of Step 202, or when the determintion of Step 201 is negative, the process goes forward to the succeeding Step of the 30° CA interrupt routine.
As described hereinabove, the sensor outputs are read in at a crank angle synchronized with the engine rotation, as shown in FIG. 6, where the voltage regulator 18 functions satisfactorily to allow to obtain a stable constant voltage Vc, so that Analogue-Digital conversion values of an accurate engine coolant temperature and the intake air temperature can be obtained. In contrast thereto, heretofore, even in a section A shown in FIG. 6, wherein the constant voltage Vc drops, read-in of the engine coolant temperature and the like has been performed, thus presenting the disadvantages.
In the above-described embodiment, read-in of the engine coolant temperature is performed at a crank angle very close to the bottom dead center, however, the crank angle for read-in need not be limited to this, but it is possible to perform read-in at a crank angle within ±20° in the proximity of the bottom dead center in addition to the above.
In the above-described embodiment, the present invention is applied to read-in of the engine coolant temperature fed from the coolant temperature sensor and the engine intake air temperature fed from the intake air temperature sensor, however, the scope of application of the present invention need not be limited to this, but the present invention is applicable to read-in of outputs fed from sensors other than the above.
In the above-described embodiment, the present invention is applied to the motor vehicle engine having the D - J type electronic fuel injection device, however, the scope of application of the present invention need not be limited to this, but it is apparent that the present invention is also applicable to the motor vehicle engine having an intake air flow sensing type (so-called L - J type) electronic fuel injection device, or to the digital control device for the general internal combustion engine.
It should be apparent to those skilled in the art that the above-described embodiment is merely representative, and only represents applications of the principles of the present invention. Numerous and varied other arrangements can be readily devised by those skilled in the art without departing from the spirit and the scope of the invention.
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In a control method and device for a digitally controlled internal combustion engine, engine condition signals are read out from sensors for detecting conditions of the engine, with selected sensor outputs read out in synchronism with rotation of the engine at a predetermined crank angle empirically corresponding to a low engine load and resulting high battery voltage, the predetermined crank angle being within at least 20 crank angle degrees of bottom dead center.
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FIELD OF THE INVENTION
[0001] The present invention relates to a label comprising a substrate having a face side and a rear side, and an adhesive layer arranged on the rear side of the substrate, the adhesive layer being non-tacky but activatable to become tacky. The invention also relates to a method for attaching the label to an item.
BACKGROUND OF THE INVENTION
[0002] A number of known label decoration technologies are available and each of them possesses various advantages and disadvantages.
[0003] Self-adhesive or pressure-sensitive labels are well-known and widely used in the industry. They suffer, however, from a number of disadvantages which include the fact that the production process is rather complex. Firstly a release liner is coated on one side with a release agent, typically silicone, and then on top of this cured silicone layer, a layer of pressure-sensitive tacky adhesive is applied which remains tacky for an unlimited time throughout the lifetime of the product. A paper or filmic print-carrier is then laminated to the adhesive coated release liner, at which point the adhesive is preferably transferred to the print carrier. Rolls of such a pressure-sensitive laminate are then supplied for printing the face side and die-cutting the labels to the required shape and finally removing the waste matrix of the face side. The labels are then ready to be applied to the item to be labelled, and at this point the removable liner becomes a waste product which is a major disposal issue for users of such labels and the industry at large as well as the whole environment.
[0004] Another known alternative is the use of wet-glue labels in which pre-printed and die-cut paper labels are coated with a wet adhesive and applied to the substrate. Typically, such wet-glue label operations are very messy with a large amount of time being lost for clean-up, set-up and changing of label formats. In addition, such wet-glue labels almost always exhibit the unattractive gripper marks of the “label-box” on the finished labelled object (the label-box is a device which holds the paper labels prior to the application of the adhesive and their application to a surface). Furthermore, wet-glue labels are not available with clear films due to the technical problem that the water cannot evaporate and escape from such labels in a completely satisfactory manner resulting in unattractive bubbles in the label.
[0005] Another decoration technology is that of shrink-sleeves, in which case the total applied cost is very high and the production process is complex. Shrink-sleeve films are normally printed on wide-web gravure or flexographic presses with solvent-based inks, which could be an environmental and safety hazard. In a separate offline process after printing, the film is formed into a tube and the seams are adhered together by the use of a solvent welding process. This tube is then cut into shorter lengths and dropped over the article to be labelled which is then fed through a shrink-tunnel at high temperature causing the film to shrink and fit the shape of the container. Although this technology has produced a number of eye-catching and appealing results for some target market segments, it has a number of disadvantages. These include the fact that by definition, a shrink-sleeve covers the whole surface of the object to be labelled, and therefore 180° decoration or a label covering only part of the container surface is not possible. The visibility of unattractive seams on shrink-sleeve labels is also a negative issue. It is not possible to use shrink-sleeves for containers with flat sides or with containers with handles. It is not possible to use paper labels with shrink-sleeves; nor is it possible to have a variety of textures or tactile effects. It is also not possible to have spot labels, multiple labels on a container or unique label shapes when using shrink-sleeves. Neither is it possible to achieve the so-called “no-label” look with shrink-sleeves, that is, it is not possible to have the label blend with the container colour and material as if the label was not there and that the container was pre-printed.
[0006] Another widely-used label technology is that of wrap-around labels. Wrap-around labels can be produced from either paper or film and can be fed from stationary magazines or directly from reels. Typically, a hot-melt adhesive is applied to the leading edge of the label which is tightly wrapped around the container being rotated at a controlled speed, with the trailing edge being fixed in place by a second narrow strip of hot-melt adhesive. The major markets for such labels are soft drinks and mineral waters due to the lack of premium look and therefore the marketing appeal of the labels. It is not possible in this case to achieve the “no-label” look. The choice of materials is very limited and design variety is restricted to that of simple cylindrical shapes.
[0007] Publication US 2007/0014985 discloses compositions having a structured morphology. When triggered or activated by a suitable action, the morphology changes, causing a corresponding predetermined change in the property of the composition. Examples range from non-tacky to tacky, from uncured to cured, including change in colour, change in intensity of presence of fragrance, odour or smell, ranging from non-reactive to reactive and from stable to non-stable. The publication also discloses non-tacky films which become tacky in consequence of heating. Such activation by heating thus results in change of the tackiness of the film, but this tackiness is preserved upon cooling and the end result is similar to a pressure sensitive adhesive that remains tacky for an unlimited time.
SUMMARY OF THE INVENTION
[0008] It is an aim of the invention to provide a novel label that eliminates the above-mentioned drawbacks of the labels. In detail, the label according to the invention, among other things, does not require a release liner, which not only saves vital resources and manufacturing complexity but also avoids the major drawback of pressure-sensitive labels which is the disposal of the release liner after the application of the labels. In this case, there is no release liner to dispose of, nor is there any silicone involved or applied to the facestock in order to prevent blocking in the rolls, which could interfere with the subsequent printability of the facestock.
[0009] The aim of the present invention is also to provide a label which makes possible a firm joint between the label and the surface which the label has been attached.
[0010] Further advantages which relate to a novel label according to the invention are:
It is possible to label very sensitive materials that do not tolerate hot adhesives even for a short time, labelling machines become simpler because the activation section of the adhesive may be placed further away from the section where the label is attached to a surface, and manual labelling is also possible because labels may cool down before the attachment of the labels.
[0014] To achieve the above-mentioned aims and advantages, the label according to the invention comprising a substrate having a face side and a rear side, and an adhesive layer arranged on the rear side of the substrate, the adhesive layer being non-tacky but activatable to become tacky, is characterized in that the adhesive layer comprises a polyurethane composition which is reversibly changeable from the non-tacky state to the tacky state.
[0015] In the labels according to the invention, the temporal tackiness period of the adhesive is not directly linked with the duration of the activation period. For example, if the activation from non-tacky to tacky is performed with heating, the tackiness is preserved a certain time also outside the cooling period. In other words, the already cooled down adhesive maintains its tackiness over a certain period of time after the temperature has equalized with the ambient temperature. According to one embodiment of the invention, the adhesive coating may remain tacky for up to 15 minutes which is more than adequate for it to be applied to a target item after activation.
[0016] The adhesive layer of the label can be altered from tacky to non-tacky, i.e. after the attachment of the label the adhesive changes to a non-tacky state.
[0017] This happens after the label has been attached to a surface, and thus a firm joint is formed and it would be difficult to remove the label from its place.
[0018] A characteristic feature of the adhesive is that it is non-tacky at room temperature. The adhesive becomes tacky when it is activated by external energy and becomes non-tacky after a certain period of time after the external energy source has been removed. Thus, following the above-mentioned principle, the adhesive becomes tacky when it is heated and it becomes non-tacky after a certain period after cooling. However, the adhesive can be re-heated to become tacky again. Therefore, the polymer composition is reversibly changeable from the non-tacky state to the tacky state. By the mechanism of the adhesive, the non-tacky highly crystalline polymer melts when heated and changes to a largely amorphous tacky state.
[0019] Compared to the pressure-sensitive adhesives, the present adhesive has, for example, better bond strength, water resistance, solvent and heat resistance.
[0020] The label according to the invention comprises a substrate and an adhesive layer. The substrate has a face side and a rear side. The adhesive layer is situated on the rear side of the substrate. However, it is possible that this particular adhesive layer is not the closest layer of the rear side of the substrate but other layers may exist between the rear side of the substrate and the adhesive layer. The substrate may consist of one layer, or it may comprise several layers which may be, for example, co-extruded or laminated layers. The substrate may be made of paper or plastic or a combination of them. The plastic layer comprises polymers or co-polymers, such as polyester, polyolefin, polystyrene, polyurethane, polylactic acid, cyclic olefin copolymer, polyamide or combinations of these. The face side may serve as a printing substrate but it is also possible that the face side remains unprinted. The face side may also be treated so that the surface properties become more suitable for printing. The substrate may be a plastic film which may be clear or opaque. Also “no label” look labels can be manufactured. It is possible that the substrate or at least one layer of the substrate is metallised, coloured, or textured.
[0021] The adhesive of the adhesive layer is non-tacky in its initial state, i.e. the label may be manufactured without a release liner. However, the adhesive of the adhesive layer is activatable so that it becomes tacky when external energy is exerted on the adhesive layer. The adhesive comprises a polyurethane composition which is reversibly changeable from the non-tacky state to the tacky state. The adhesive may also comprise other polymers in addition to the polyurethane composition. The adhesive may include polymers, such as acrylic polymers, polyvinyl alcohol, ethylene/vinyl acetate copolymers or styrene/acrylate copolymers. The adhesive may also comprise inert fillers, tackifiers and/or plasticizers together with the polymer composition, such as the polyurethane composition. The external energy may comprise, for example, heat, infra-red radiation, microwaves, laser, or some other external energy which is capable of activating the adhesive layer. As one possibility, the adhesive layer is activated by heating it to a temperature between 50 to 90° C.
[0022] The face side of the label may be printed by any type of printing process, such as UV-flexo, UV-letterpress, water-based-flexo, gravure, offset, litho, screenprocess, thermal-transfer, direct-thermal hot- or cold-foil stamping. After printing, the labels may be die-cut and supplied to the application point in pre-cut form in any shape or design-format required. Alternatively, the labels may be supplied in rolls to the application point, where they could be die-cut, for example, using laser and transferred to a vacuum drum, of the type typically used for wrap-around labels, where the non-tacky dry coating on the reverse side of the facestock would be activated by heat, IR radiation or another energy source to produce a coating with sufficient “hot-tack” in order for it to be applied to the container and remain firmly in place during or after cooling.
[0023] The invention also relates to a method for attaching the label according to the invention to an item. The method is characterized in that the method comprises at least the steps of:
activating the non-tacky adhesive layer of the label to become tacky, and attaching the label to the item so that the tacky adhesive layer comes in contact with the surface of the item.
[0026] The label of the invention may be attached to any type of item, container or surface which may be made of, for example, plastic, glass, metal, or cardboard.
DESCRIPTION OF THE DRAWINGS
[0027] In the following, the invention will be explained by an example and by referring to the appended drawings, in which
[0028] FIG. 1 shows raw materials for the production of polyurethane dispersions,
[0029] FIG. 2 shows the stabilization of dispersion particles by hydrate shells which are formed due to anionic groups,
[0030] FIG. 3 shows the preparation of polyurethane dispersions by using the acetone process,
[0031] FIG. 4 shows the preparation of polyurethane dispersions by using the melt dispersion process,
[0032] FIG. 5 shows the drying and film formation of a polymer dispersion, and
[0033] FIG. 6 shows the heat activation of polyurethane adhesives with crystalline polyester soft segments measured by TMA.
DETAILED DESCRIPTION OF THE INVENTION
[0034] In the following, the invention will be explained in more detail.
Preparation of the Adhesive Layer
[0035] In the following, one possibility to prepare an adhesive for an adhesive layer will be explained.
[0036] Polyurethane adhesives are generally produced by reacting long-chain polyols with aromatic or aliphatic isocyanates using the diisocyanate polyaddition process. Among the polyurethane heat-activatable adhesives, the polymer backbone is primarily based on crystalline polyester polyols, but amorphous polyester polyols have also been used for the production of heat-activatable adhesives (see FIG. 1 which shows raw materials for the production of polyurethane dispersions).
[0037] In the production of polyurethane dispersions by the acetone process or the melt-dispersion process, use is made of emulsifiers integrated in the polymer chain. Hydrophilic modification can be carried out through the covalent integration of ionic groups in the polymer chain, or through long polyether units at the ends of the chains. The dispersion particles are then surrounded by a stabilizing hydrate shell, with ionic and non-ionic hydrophilic groups generally acting synergistically (see FIG. 2 ).
[0038] Compared with the use of external emulsifiers, the incorporation of hydrophilic centers brings a number of advantages, such as self-dispersibility, high dispersion stability and good film-forming properties. Added to this is the fact that the covalent link prevents any diffusion of the emulsifier to the polymer surface.
[0039] With the acetone process (illustrated in FIG. 3 ), the first reaction stage—the so-called prepolymer-forming reaction—involves reacting the diisocyanate with the polyol in the melt to form a prepolymer terminated with isocyanate groups. In the second reaction stage—the chain extension reaction—after the addition of acetone, the molecular weight increases further through the addition of suitable chain extenders carrying ionic groups. Through the addition of water to the acetone solution, a fine dispersion is formed and, at the last stage, the acetone is distilled off. Because of the homogeneous structure of the polymer, the acetone process produces particularly high-quality dispersions.
[0040] The melt dispersion process (illustrated in FIG. 4 ) has become established as a simpler alternative production procedure. In the prepolymer-forming reaction, the polyols are reacted with the diisocyanates to form an isocyanate-terminated prepolymer. Following dispersion in water, during which a fine dispersion forms spontaneously due to the internal hydrophilic character of the prepolymer, a high molecular weight polyurethane is produced by means of a short-chain diamine in the chain extension reaction. Both processes result in dispersions with good storage life and solids contents of 40 to 50% by weight, in which the polymer is present in discrete particles of 100 to 200 nm diameter. Unlike solvent-based systems, this means that low application viscosities can also be achieved with high solids contents, and it is even possible to produce branched or crosslinked polyurethanes.
[0041] The dispersion produces a homogeneous adhesive film on the substrate after the water has evaporated (see FIG. 5 ). Although the drying process with adhesive dispersions is initially regarded as a rather problematic procedure, it is possible, with the correct choice of temperature, to achieve a drying rate for waterborne adhesives similar to that of solvent based systems.
Drying and Bonding of the Adhesive
[0042] In the following, the drying and bonding behaviour of the adhesive described above will be explained.
[0043] An important bonding process with polyurethane adhesives, both solvent-based and dispersion-based, is by heat activation. After applying the adhesive to the substrate, non-blocking films are obtained. The films only become tacky upon activation in a heat tunnel or under an infrared lamp through melting of the crystalline polyester segments at temperatures above the minimum activation temperature (see FIG. 6 ). The period of time during which the polymer film has sufficient tackiness for bonding is called the hot-tack life. During this time, which can range from seconds to minutes depending on the polymer structure, the substrates can be joined. It should be noted that the hot-tack life is not directly related to the temperature of the adhesive. The hot-tack period, the period when the adhesive is tacky, may extend beyond the period after which the adhesive has reached ambient temperature.
[0044] Through cooling of the adhesive film and crystallization of the polyester segments, a high initial bond strength is obtained.
[0045] Another characteristic of heat-activatable polyurethane adhesives is that, because of their high molecular weight and segmented polymer structure, the heat stability is higher than the decrystallization temperature of the polyester segments. This means that the adhesives only begin to slow down the thermoplastic flow to a considerable extent at temperatures significantly higher than the minimum activation temperature.
Use of the Labelstock According to the Invention
[0046] A labelstock according to the invention was manufactured. The reverse side of the facestock was coated with the polyurethane coating described above. The coating was dried at an elevated temperature. After drying, the coating was completely tack-free and non-sticky and, therefore, in comparison to pressure-sensitive labelstock, it did not require a release liner.
[0047] After coating and drying of the polyurethane coating on the facestock, the labelstock was wound into reels and then supplied to printers for further processing.
[0048] The facestock may be printed with any type of printing process such as UV-flexo, UV-letterpress, water-based-flexo, gravure, offset, litho, screenprocess, thermal-transfer, direct-thermal hot- or cold-foil stamping.
[0049] After printing, the labels may be die-cut, for example, by using laser and supplied to the application point in pre-cut form in any shape or design-format required. Alternatively, the labels may be supplied in rolls to the application point, where they could be die-cut using laser and transferred to a vacuum drum, of the type typically used for wrap-around labels, where the non-tacky dry coating on the reverse side of the facestock would be activated by heat, IR radiation or another energy source to produce a coating with sufficient “hot-tack” in order for it to be applied to the container and remain firmly in place whilst cooling. Typically, the polyurethane coating could by activated by heating it to a temperature between 50 and 90° C. for only a few seconds.
[0050] However, even due to the short heating period, the coating will typically remain tacky for up to 15 minutes which is more than adequate for it be applied to the container after activation. After that, the coating is no longer tacky and forms a permanent bond to the container and displays good heat-resistance. Using this technique, any paper or filmic facestock may be chosen together with any label shape and printed by any known printing process. Clear labels with a “no-label” look can also be achieved.
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A label including a substrate having a face side and a rear side. An adhesive layer is arranged on the rear side of the substrate. The adhesive layer is non-tacky but activatable to become tacky adhesive. The adhesive layer includes a polyurethane polymer composition that is reversibly changeable from the non-tacky state to the tacky adhesive state. A method for attaching a label to an item.
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This application is a continuation, of application Ser. No. 659,819, filed 10/10/84, now abandoned.
FIELD OF THE INVENTION
There are provided compounds containing spiropyran and mesogenic moieties and a process for the production of such compounds.
There are provided orientated quasi-crystalline films produced from such compounds, based on the partial thermoconversion of the spiropyran into the merocyanine form and stabilization of the quasi-liquid crystalline state by the application of a suitable electrostatic field, resulting in an alignment of the film. The films thus obtained can be used in a wide variety of devices employing second harmonics or other non-linear optical effects.
BACKGROUND OF THE INVENTION
The following U.S. Patents and publication in scientific literature are of relevance to the subject matter of the present invention:
3,922,485-11/1975 Starkweather et al. 178/7.6
4,040,096-8/1977 Starkweather 358/302
4,405,733-9/1983 Williams et al. 430/345
D. Chemla, J. L. Oudar and J. Zyss, L'Echo des Rescherches (Intern. issue) 47, (1981).
D. J. Williams, Ed. Non linear Optical Properties of Organic and Polymeric Materials, ACS Publish, (1983).
A. Dulcic and C. Flytzanis. Opt. Com. 25, 402 (1978).
G. R. Meredith, V. A. Krongauz and D. J. Williams. Chem. Phys. Lett., 87, 289 (1982).
F. P. Shvartsman and V. A. Krongauz. Nature, 309, 608-611 (1984).
H. Kelker and R. Hatz. Handbook of Liquid Crystals, Chemie, Weinheim, (1980).
Gale, D. J. Wilshire, J. F. K., J. Soc. Dyers Colour 90, 97 (1974).
Tarbell, D. S. Yamomoto, Y., Pope, B. M., Procl. Natl. Acad, Sci., USA 69, 730 (1972).
Itoh, M., Hagiwara, D., Kamiya, T., Bull Chem. Soc. Jpn. 50, 718, (1977).
Hinnen, A., Audic, C., Gautron, R., Bull. Soc. Chim. France, 5, 2066, (1968).
Lundt, B. F., Johansen, N. L., Volund, A., Makussen, J., Int. J. Pept. Protein Res., 12, 258, (1978).
Hassner, A., Alexanian, V., Tetrahedron Letters, 46, 4475, (1978).
Orahovats, A. S., Radeva, T. Zh., Spassov, S. L., Comp. Rend. Acad. Bulg. Sci., 26(5), 663, (1973).
When light is propogated through an optical dense medium, the induced electronic polarization of the material in an electric field E can be represented by the following expression:
P=χ.sup.(1) E+χ.sup.(2) E.sup.2 +χ.sup.(3) E.sup.3 +
P=P.sub.1 +P.sub.2 +P.sub.3 +
where the χ's are coefficients of successive powers of the field, and χ.sup.(n) is usually about 10 5 χ.sup.(n+1). This means that the high order terms will be important only at very high fields. P 1 is the linear polarization and P 2 is the first non-linear polarization. Symmetry considerations require that P 2 =0) if the material has a center of symmetry associated with it. Finite values of P 2 gives rise to new phenomena with considerable practical importance in laser-related technologies, optical communications and information processing (D. Chemla, J. H. Oudar and J. Zyss, L'Echo des Recherches (Intern. issue) 47, (1981). Materials with high second-order non-linear properties (χ.sup.(2) >>0) are generally based on molecules having high first hyperpolarizabilities. Originally only inorganic crystals were used in optical devices based on these properties. However, recent research has led to the discovery of some organic crystals which have second-order non-linear optical coefficients several orders of magnitude larger than those of the conventional inorganic ones, and with much larger damage thresholds (D. J. Williams, ed., Nonlinear Optical Properties of Organic and Polymeric Materials, ACS Publish., 1983).
One example is 2-methyl-4-nitroaniline crystals with χ.sup.(2) =1.25×10 -6 esu. However, it is difficult to grow single crystals of this material of good quality, and not feasible to prepare thin films.
Recently it was shown that the molecular hyperpolarizability of some merocyanine dyes is surprisingly high (A. Dulcic and C. Flytzanis, Opt. Com. 25, 402 1978). If one uses this value and assumes that the merocyanine molecules are aligned in the bulk phase such that the material is noncentrosymmetric and that all of the molecular dipoles point in the same direction, χ.sup.(2) would be approximately 10 -5 esu. This would be the largest known value for nonlinear optical material and would enable the use of these materials in a variety of practical devices.
One of the most useful effects for investigation of optical non-linearity of material is second harmonic generation, SHG, which manifests itself as the conversion of light frequency 2ε on propagation through a suitable material.
There is known an electro-optical modulator, containing usually Pockel's cell which can be used in scanning devices. Such a device can transfer video information to a scanned medium by a scanning system, see for example, U.S. Pat. Nos. 3,922,485 and 4,040,096. The materials which may be used in such electro-optical modulators include crystals of KHPO 4 , LiTaO 3 , LiNbO 3 , BSN, etc. The property of these materials which make them useful in a device such as the Pockel's cell is their first non-linear polarization.
SUMMARY OF THE INVENTION
The invention relates to novel spiropyran-merocyanine compounds, containing mesogenic groups, which compounds are of the general formula ##STR1## and which compounds comprise a mesogenic group, a bridging group X, a spiropyran moiety and a terminal group R, as marked in the above formula, and wherein the mesogenic group may contain bridging groups A, wherein the spiropyran moiety comprises a 2H pyran ring, the 2-carbon of which is involved in a spiro linkage and a group Y and a cyclic moiety Z, each of which is an aromatic, heteroaromatic or cycloaliphatic ring or ring system, which ring or rings may bear non-interfering substitutes, wherein the ring structures Q and Q' of the mesogenic group are aromatic, heterocyclic or cycloaliphatic moieties, said bridging groups X and A being selected from --HC═N--, --ON═N--, --N═N--, --OC--O--, --C.tbd.C--, --CH═CH--, --OC--NH--, --CH 2 --CH═N--, --CH═CH--OC--O, --CH═N--N═CH--, --OOC--(CH 2 )n--COO--, --N═C═N--, --CH═CH--OC--, --CH═N--NH--, --CH═CH--CH═CH--, --O--(CH 2 ) n --O----N═CH--CH═N--, --NH--(CH 2 )n--NH-- --OC--O--N═CH--, or --CH 2 --NH--, --CH 2 O--, --(CH 2 ) n -- --(CH 2 ) n --COO--; the terminal group R being selected from --OR', --R', --COOR', --OOCR', --OOCOR', --CN, --Cl, --NO 2 , --COR', --CH═CH--COOR', --F, --Br, --I, --NC, --NC═O--, --N═C═S, --N 3 , --R", --OH, --OR", --COOR", --OCOR", --NH 2 , --NHR", --NR" 2 , wherein --R' is straight chain alkyl and wherein R" is branched alkyl or alkenyl, and wherein R 1 and R 2 are alkyl and n is an integer.
Preferred groups Q and Q' are phenyl, biphenyl, substituted phenyl, substituted biphenylene, 5- or 6- membered heterocyclic rings with one or more nitrogen, oxygen or sulfur atoms and cycloaliphatic rings. There are known a multitude of mesogenic moieties from literature and essentially all of these are suitable for coupling with the spiropyran moiety to result in compounds of use for the purpose of the present invention.
The invention further relates to a process for the preparation of compounds of the type defined above, and to the production from such compounds of aligned quasi-liquid crystalline films which are useful in a variety of electro-optic devices. The main object of the present invention is to provide a novel product, provided in the form of the oriented quasi-liquid crystalline thin film having exceptional non-linear optical properties, which make possible a variety of applications.
The novel materials exhibit some features of liquid crystals (birefringence, orientation in an electric field), but have different structures. It is suggested to call them "quasi-liquid crystals" (QLC) (Shvartsman, F. P. and Krongauz, V. A., Nature, 309, 608,611, (1984). The spiropyrans of the general formula as hereinbefore defined, are thermo- and photo-chromic in solution.
Yellow crystals of these compounds, obtained by slow crystallization from suitable solvents, have sharp melting points (Table 3) and give green or greenish-blue isotropic melts. The change in color on melting is associated with a shift of the thermal equilibrium (eq 1) to the right. The thin amorphous films of spiropyrans obtained as described above also change their color on heating. The relatively slow rate of transformation of the metastable films is associated apparently with the presence, at low concentrations, or merocyanine molecules, even at room temperature. The merocyanine acts as an impurity, retarding crystallization of the films. On heating, the amorphous films give the anisotropic structures observable under the polarization microscope through their birefringement textures. The appearance of this texture coincides with a substantial change in the film color, from yellow to bright green or greenish-blue. At a still higher temperature, this texture disappears: above this clearing point total extinction of light is observed through cross polarizers.
The temperature range in which the textured structure exists is much lower than the melting point of the crystals. For example, for spiropyran, [V], with R═CH 3 O--, the mp is 198°-203° C., while the temperature range for the birefringent texture is 50°-130° C. The material above 130° C. is an isotropic liquid which is metastable above the melting point of the crystal. The texture, which disappears above 130° C., reappears on cooling below 130° C. However, this process is not completely reversible due to the competitive crystallization process, which is slow at low temperatures but proceeds faster at higher temperatures. It looks as if the mesophase is "hidden" beneath the crystal phase and appears when we destroy the crystal lattice by dissolving the crystalline spiropyrans. However, this is not the case because the isotropic material obtained by heating spiropyran crystals above the melting point gives, on cooling, isotropic glass, which does not exhibit birefringence on being reheated from room temperature, i.e. the system does not exhibit properties of a monotropic mesophase.
Orientation of the QLC occurs when the films are placed in a constant electric field or more than 0.5 kV/mm as described in the Experimental Section. For example, films of compounds [VI] with R═n--C 6 H 13 O-- at 100° C. and E═1.5 kV/mm gave nearly homogenous birefringence and uniaxial alignment expanded from electrodes during 20-30 sec. after evaporation of the solvent (FIG. 1). Dichroic contrast due to merocyanine alignment was observed when the film was viewed with a single polarizer, perpendicular and parallel to the applied field. The higher the field and the temperature (below the clearing point) the better and more uniform was the orientation. Orientation does not occur in an electric field at temperatures above the clearing point, but does when the film is cooled below this temperature in the field. Orientation in an electrostatic field was observed also on the hydrophobic surface obtained by treating the slide with a solution of octadecyltrichlorosilane in bicyclohexyl. The most remarkable effect of the electrostatic field is the stabilization of the quasi-liquid crystalline state which accompanies the orientation of the films. Spontaneous crystallization no longer occurs. In the supercooled conditions at room temperature the orientation and glass-like state were preserved without change for at least one year after the field was switched off. Both scanning electron microscope and optical microscope observations showed the absence of crystals. The extinction coefficient of merocyanines in the visible absorption maxima (Σ mer) obtained from different spiropyrans lie in the rather narrow range (3-5)×10 4 ×liter× mole -1 ×cm -1 . Assuming these coefficients to be valid for the films, and knowing the extinction coefficients of the spiropyrans, we can estimate the ratio of the concentrations of merocyanine and spiropyran in these films from the absorption spectra (FIG. 2):
Cmer/Csp=(εsp/εmer)×(Dmer/Dsp), where Dmer and Dsp are the absorbances of merocyanine and spiropyran, respectively. The estimate is that the extent of conversion of spiropyran into merocyanine for most films is only 3-10%. A further most surprising fact, is that the absorption spectra of the films are dichroic only in the region of the merocyanine absorption band (λ max approximately 600 nm), while in the region of spiropyran absorption band (λ max approximately 370 nm) the degree of linear dichroism is vanishingly small. This means that only the merocyanine molecules are aligned in the electric field, while the bulk of the material, which consists of spiropyran molecules, is unaligned. The order parameter of the merocyanines is given by S=(D.sub.∥ -D.sub.⊥)/(2D.sub.⊥ +D.sub.∥), where D.sub.∥ and D.sub.⊥ are, respectively, the absorption parallel and perpendicular to the electeric field. This parameter depends on the field strength, the temperature and the film thickness. Under optimum conditions the order parameter is S=0.4. The direction of the long molecular axis, coincident with the direction of maximum absorption of polarized light, is parallel to the field for all examined compounds and mixtures. Measurements of the linear dichroism of orientated QLC films were also carried out in the presence of the dye additives 4-dimethylamino-4'-nitrostilbene (DANS) and 1,6-diphenylhexatriene (DPH). This allowed us to estimate the order parameters of the merocyanines (FIG. 2).
Simple considerations lead to the conclusion that orientation of separate merocyanine molecules is inconceivable in an electric field as weak as 1-1.5 kV/mm. Only assemblies of the interacting molecules, having large dipole moments, can be orientated in such a field. It is also inconceivable that weak interactions, determined by the anisotropy of the molecular polarizabilities of mesogenic groups and responsible for the occurrence of the liquid crystalline state of material, would keep together the merocyanine molecules in such assemblies. Indeed, the concentration of merocyanines in the isotropic bulk is low (3-10%) and the intense birefringence of the QLC, which indicates ordering of the material, the characteristic temperature behaviour and the response to an electric field, all characterize the bulk material as a nematic mesophase. Lack of uniaxial alignment of the spyropyrans in the field impede formation of a regular nematic structure by the mesogenic groups. One may suggest that the spiropyrans form domains with a structure similar to that of the axially symmetric micelles in liotropic liquid crystals located closely and interacting with each other.
The fact that QLC appear only in films cast from solution and never from spiropyran melt, may indicate some latent preorganization or aggregation developing on evaporation of solvent.
The novel quasi-liquid crystals are organized in polar structures, and thus exhibit non-linear optical properties. Indeed, experiments on the SHG from thin films of this material showed a very high efficiency of optical frequency-doubling.
The following are some of the many possible applications of the novel quasi-liquid crystalline films:
Non-linear optics: Hyperpolarizability of mero-cyanine molecules and their complexes, uniform orientation on a molecular level, degree of orientation and optical transparency of quasi-liquid crystalline films are more pronounced, in QLC films than in the known quasi-crystals (Meredith, G. R., Krongauz, V. A., and Williams, D. J., Chem. Phys. Lett., 87, 289,294 (1982), U.S. Pat. No. 4,405,733. This determines non-linear optical effects and related applications, such as: second harmonic generation (frequency doubling)--useful in frequency conversion for near IR solid state lasers and frequency mixing--useful in parametric amplification, infrared up conversion and optical gating; Pockels anisotropy--useful in variable retardation, Q-switch, pulse, and extractors (shutters); electro-optic effect--useful in modulators and detectors; and optical rectification--useful to achieve optical bistability.
Ferroelectrics: Due to the high permanent dipole moment of the merocyanine, certain QLC's exhibit fero-electric properties. Applications include information storage, displays and capacitors.
Pyroelectrics: Changes in the separation of centers of positive and negative change caused by temperature changes can be utilized in the construction of thermal detectors.
Piezoelectrics: A relationship exists between the change in the separation of the centers of positive and negative charge and expansion or contraction of the QLC. Uses of this effect include microphones, headphones, phonograph cartridges and ultrasonic cleaners, etc.
Photoconductors: QLC's may be used in devices based on photoconductivity and photovoltaic effect, such as electrophotography devices, photodetectors and devices for solar energy conversion.
Substrates upon which QLC films of the present invention may be cast include glass, silicone or polymeric support material.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows the optical texture of QLC film, prepared from spiropyran [VI] with R═n--C 6 H 13 O-- and aligned in electrostatic field (E=1.5 kV/mm, at 100° C., distance between electrodes-11 mm), viewed through crossed polarizers, when light is polarized parallel (a) and perpendicular (b) to the long molecular axis. The black parallel strips on the picture are areas of the interdigital electrodes.
FIG. 2 shows the absorption spectra (1-3) and order parameter S (4-6) of orientated QLC films; 1,5-mixture of spiropyrans [V] which R═CH 3 O-- and [VI] with R═n--C 6 H 13 O-- in ratio 3:1 (by weight); 2,6-1% by weight of DPH in the same mixture of spiropyrans; 3,4-1% by weight of DANS in the same mixture of spiropyrans.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The following description is intended to illustrate the invention and to exemplify it. It is to be construed in a non-limitative manner. The process for the preparation of the novel compounds defined above is essentially a coupling reaction of the mesogenic entity with the spiropyran entity, to result in the desired compound. Such coupling reactions, illustrated in the following Table 1, are based on the use of the respective reactive groups of these entities which can be used for such couplings.
TABLE 1__________________________________________________________________________Examples of coupling reactions ##STR2## ##STR3##wherein B C D [E] X__________________________________________________________________________ COH NH.sub.2 Mol. sieves [H.sub.2 O] OHN NHOH ON NaOH [H.sub.2 O] ONN X = ONN H.sub.2 [H.sub.2 O] NN COCl HO Pyridine [HCl] OCO COCl NH.sub.2 Pyridine [HCl] OCNH MgBr HONH [Mg(OH)Br] NH CH.sub.2 OH HO H.sup.+ [H.sub.2 O] OH.sub.2O OH HO ClOC(CH.sub.2).sub.nCOCl [2HCl] OOC(CH.sub.2).sub.nCOO NH.sub.2 NH.sub.2 ClOC(CH.sub.2).sub.nCOCl [2HCl] NH(CH.sub.2).sub.nNH10. CH.sub.2 OH CH.sub.2 OH H.sup.+ [2H.sub.2 O] CHCH__________________________________________________________________________
It is stressed that it is possible to prepare a wide variety of similar compounds based on the same and analogous coupling reactions of mesogenic entities of the type illustrated for example in Kelker, H., Hatz, R., Handbook of Liquid Crystals, Chemie, Weinheim, 1980, with suitable spiropyran structures, of the type set out above and in the examples. A person versed in the art is able to produce such compounds based on the teachings of these specific examples, without any problem or difficulty as the mesogenic structures are known, or can be prepared in an analogous manner, and as the coupling reaction with the spiropyran moiety does not involve any difficulty. The surprising properties of the novel compounds makes possible a wide variety of uses, as is illustrated hereinbefore. A typical coupling reaction of this type is set out in the enclosed reaction scheme which illustrates the preparation of the spiropyran moiety and its coupling with the mesogenic group.
Properties of these novel spiropyran-merocyanine compounds are shown in the following Table 2 and full description of the procedure is given below.
Reaction scheme for preparation of the novel spiropyran-merocyanine compounds, containing mesogenic groups ##STR4##
TABLE 2__________________________________________________________________________Properties of novel spiropyran-merocyanine compounds containing mesogenicgroups Analyses %Compound Molecular Yield Melting* Calculated FoundNo. Formula Weight % Point, °C. C H N C H N__________________________________________________________________________I C.sub.12 H.sub.16 N.sub.2 188.27 75 98-100 76.56 8.57 14.88 76.00 8.65 14.91II C.sub.17 H.sub.24 N.sub.2 O.sub.2 288.40 93 R.sub.f = 0.3 Plates-DC-Aiufolien, Kieselgel 60F 254 (red spot) Eluant --CH.sub.3 OH:CH.sub.2 Cl.sub.2 = 1.15III C.sub.24 H.sub.27 N.sub.3 O.sub.5 237.50 78 200-203 65.89 6.22 9.60 66.05 6.34 9.68IV C.sub.19 H.sub.19 N.sub.3 O.sub.3 337.38 55 148-150 67.64 5.68 12.45 67.75 5.61 12.52V C.sub.34 H.sub.29 N.sub.3 O.sub.6 575.63 37 198-203 70.95 5.08 7.30 71.06 5.12 7.35VI C.sub.39 H.sub.39 N.sub.3 O.sub.6 645.76 45 165-168 72.54 6.09 6.51 72.50 6.08 6.53VII C.sub.34 H.sub.25 N.sub.4 O.sub.5 570.60 48 210-214 71.57 4.59 9.82 71.64 4.60 9.78VIII C.sub.15 H.sub.12 O.sub.4 256.25 80 83-85 70.31 4.72 70.33 4.75IX C.sub.20 H.sub.22 O.sub.4 326.40 76 57-58 73.60 6.79 73.58 6.83X C.sub.15 H.sub.9 NO.sub.3 251.25 68 260-262 71.71 3.61 5.57 71.77 3.64 5.63__________________________________________________________________________ *not corrected
Example of preparation of spiropyran-merocyanine compounds, containing mesogenic groups
5-amino-1.3.3-trimethyl-2-methyleneindoline [amino-Fisher's base (I)] was prepared by the method described in Gale, D. J., Wilshire, J. F. K., J. Soc. Dyers Colour., 90, 97-100(1974).
5-Amino-N-tert-butyloxycarbonyl-1.3.3-trimethyl-2-methyleneindoline [BOC-amino-Fischer's base (II)] (Tarbell, D. S., Yamamoto, Y., Pope, B. M., Procl. Natl. Acad. Sci., U.S.A., 69, 730,735(1972) (Itoh, M., Hagiwara, D., Kamiya, T., Bull. Chem. Soc. Jpn., 50, 718-723(1977).
The solution of amino-Fischer's base (3.76 g, 0.02 mole), di-tert-butyldicarbonate (4.3 g, 0.02 mole) and triethulamine (TEA) (2.02 g, 0.02 mole) in 100 ml dry tetrahydrofyran (THF) which was passed through Al 2 O 3 /basic, was allowed to stand overnight at room temperature.
The THF and TEA were evaporated and the oily residue was dissolved in 50 ml of CH 2 Cl 2 . The solution was extracted (3×50 ml 5% CH 3 COOH) to take out the BOC-amino-Fisher's base (II) in the form of its quaterney acetate salt. The water fraction with salt was washed (2×50 ml ether) and made alkaline (pH=9-10) with cooling and stirring. The white precipitate was extracted (3×50 ml CH 2 Cl 2 ), dried with MgSO 4 , filtered and then the solvent was evaporated to give 5.35 g (93%) of very viscous oil (II), rapidly becoming reddish. This product was used directly in the following step without further purification.
5-amino-N-tert-butyloxycarbonyl-1.3.3-trimethyl-6'-nitrospiro(indoline-2.2'-[2H-1] benzopyran) [BOC-amino-spiropyran(III)] (Heinnen, A., Audic, C., Gautron, R., Bull. Soc. Chim. France, 5, 2066-2074(1968).
A mixture of BOC-amino-Fischer's base (5.35 g, 0.018 m) and 5-nitrosalicylaldehyde (3.1 g, 0.018 mole) in 100 ml of methanol (analytical) was refluxed for 0.5 h. The brilliant green precipitate was separated and washed with cold methanol. After recrystallization (from hexane:benzene=1:2) the yield of yellow crystals (III) was 6.3 g (78%).
5-amino-1.3.3 trimethyl -6'-nitrospiro (indoline-2,2'-[2H-1] benzopyran) [amino-spiropyran (IV)] (Lundt, B. F., Johansen, N. L., Volund, A., Markussen, J., Int. J. Dept. Protein Res., 12, 258,265 (19878)
BOC-amino spiropyran (6.3 g. 0.014 mole) was dissolved in 20 ml CF 3 CO 2 H and the solution was allowed to stand for 1 h. The yellow solution was then made alkaline (pH=11-12) with cooling and good stirring, and the brown precipitate of IV was taken up in CH 2 Cl 2 . The solution was washed thoroughly with water, dried with MgSO 4 and filtered, and then the solvent was evaporated. After two reprecipitations (from CH 2 Cl 2 /hexane) of the brown crude product, the yield of dark cherry-red crystals (IV) was 2.7 g (55%).
4-(4'-Methoxybenzoyloxy) benzaldehyde (VIII), 4-(4'-hexoxybenzoate)-benzaldehyde (IX) and 4-(4'benzonitrile) benzaldehyde (X) listed in Table 2, were synthesized by the direct room temperature esterification of the corresponding 4-methoxybenzoic acid, 4-hexoxybenzoic acid and 4-cyanobenzoic acid, respectively, with 4-hydroxybenzaldehyde, as is described in Hassner, A., Alexanian, V., Tetrahedron Letters, 46, 4475-4478(1978).
5-(4'-Methoxybenzoyloxy)-benzylidenamino-1.3.3-trimethyl 6'-nitrospiro (indoline-2.2'-[2H-1]benzopyran) (V),5-(4'hexoxybenzoate)benzylidenamino-1.3.3-trimethyl-6'-nitrospiro(indoline-2.2'-[2H-1]benzopyran) (VI) and 5-(4'benznitrile)benzylidenamino-1.3.3-trimethyl-6'nitrospiro(indoline-2.2'-[2H-1] benzopyran) (VII) were obtained by the Method A described in Orahovats, A. S., Radeva, T. Zh., Spassov, S. L., Comp. Rend. Acad. Bulg. Sci., 26,(5), 66-665(1973), in dry 1.2-dimethoxyethane as solvent, and repricipitated ferom benzene/hexane.
Example of preparation of orientated quasi-liquid crystalline films for observations of the second harmonic generation.
Solutions of spiropyrans in benzene (10 g/1) were used for film preparation. The preparation of orientated QLC film was carried out by casting a spiropyran solution onto a slide bearing vacuum-deposited electrodes, the spacing between electrodes was 1 mm. The casting was performed at a temperature of 100° C. and an electrostatic field of strength 1.5 kV/mm. The resultant films were then cooled to room temperature in the electric field. Orientated QLC films prepared in this way proved to be rigid, stable, transparent and birefringent. Characteristics of the original spiropyrans, containing mesogenic groups and quasi-liquid crystals obtained from these compounds are shown in the following Table 3.
TABLE 3__________________________________________________________________________Characteristics of spiropyrans and quasi-liquid crystals ##STR5## ##STR6## MixtureandCompound °C.*PointMelting ##STR7##__________________________________________________________________________V 198-203 50 130VI 165-168 45 110VII 210-214 80 170I:II = 3:1 -- 50 135I:III = 1:1 -- 60 140__________________________________________________________________________ *not corrected
The slide with the resultant quasi-liquid crystalline film was placed in the beam of a Nd 3+ /YAG laser which produced pulses of 1.06 μm light. The resulting 532 nm harmonic was detected by an EMI 9558Q photomultiplier placed behind a monochromator and Shott KG-3 filtering assembly for effectivee f/16 collection optics centered on laser beam. A 5-fold increase in detected harmonic was achieved by covering the QLC films with a low vapor pressure liquid such as dodecane or petroleum jelly (Vaseline) with a cover slip placed over this combination. This increase was interpreted as in increase both in harmonic generation and in collection efficieny.
As set out above, a wide variety of devices can be constructed which make use of the novel quasi-liquid crystal films of the present invention. Among possible use there are devices based on the ferrelectric properties of such orientated films, devices based on pyroelectric effects, devices based on piezoelectric effects and devices based on photoconductivity.
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There are provided compounds which give quasi-liquid crystals, which comprise a mesogenic group, which can contain bridging groups, a bridging group and a spiropyran moiety having a 2H pyran ring, a terminal group being attached to the mesogenic group. The mesogenic group contains two aromatic, heterocyclic or cycloaliphatic ring structures. The compounds are prepared by a coupling reaction of mesogenic groups with a spiropyran compound via a suitable bridging group. There is provided a process for producing quasi-liquid crystalline (QLC) films which are useful for producing a wide variety of devices based on the optical non-linearity of generation of second harmonics by such films. Such devices can also be based on ferroelectric, pyroelectric, piezoelectric effects and photoactivity of such oriented QLC films.
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This is a divisional of U.S. patent application Ser. No. 08/688,628, filed Jul. 29, 1996, now U.S. Pat. No. 5,802,842.
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates generally to rocket thrusters and more particularly, to small regeneratively cooled rocket thruster engines having a dimensionally stable throat insert installed therein.
2. Discussion
In a regeneratively cooled bipropellant rocket motor the thruster is cooled using the latent heat of vaporization of the oxidizer flowing through coolant passages in the wall of the thruster chamber. In this type of cooled thruster design, there exists a large thermal gradient between the inner wall of the thruster chamber and the coolant passages. The thermal gradient is particularly large at the throat of the rocket thruster where heat loads and operating temperatures are at their greatest. These large thermal gradients cause local yielding of the material between the throat surface and the surface of the cooling passages. As a result of this yielding, there is a phenomena created called thermal ratcheting. Thermal ratcheting results in a radically inward shrinkage of the throat of the thruster after each firing or thermal cycle of the thruster. A reduction in throat area of up to forty-five percent has been observed within only sixty thermal cycles. Reductions in the throat area of this magnitude are clearly unacceptable after so few thermal cycles, particularly when considering that this type of thruster is often required to complete 700 cycles over the life of the thruster.
The problem of thermal ratcheting has proven to be difficult to overcome. Thermal gradients can be reduced by using materials having high thermal conductivity, but the yield strength and oxidation resistance of such materials is generally below that necessary for this type of application. Conversely, high strength materials which are more resistant to thermal ratcheting and exhibit good oxidation resistance typically have low thermal conductivities. The low thermal conductivity of such materials actually results in higher thermal gradients and related stresses, which may ultimately cause yielding and some thermal ratcheting.
While thermal ratcheting is not solely unique to bipropellant rocket thrusters, monopropellant thrusters are much less susceptible to thermal ratcheting because the thermal gradients are not as severe. However, any improvement in the reduction of thermal ratcheting which is developed for bipropellant rocket thrusters can of course be applied when the thrusters are operated as a monopropellant thruster, even though the need is not as great.
SUMMARY OF THE INVENTION
In accordance with the teachings of the present invention, there is disclosed a dimensionally stable throat insert and a method of making and using the throat insert. The throat insert has a thin walled shell made from a high strength, oxidation resistant material. The shell has a throat of reduced cross-section and a radially extending annular stiffening ring located at the throat. A casing is molded around an outer surface of the shell and has a generally cylindrical exterior surface which allows the throat insert to be installed in a thruster rocket engine. The casing is made from a material having a thermal conductivity at least 10 times greater than that of the shell. The shell resists yielding and oxidation caused by the extreme temperatures of rocket fuel combustion products passing through the throat insert, while the casing acts to efficiently transfer heat from the shell to the cooling passages.
BRIEF DESCRIPTION OF THE DRAWINGS
The various advantages of the present invention will become apparent to one skilled in the art upon reading the following specification and by reference to the drawings in which:
FIG. 1 is a cross-sectional view of a regeneratively cooled bipropellant rocket thruster incorporating a throat insert made in accordance with the teachings of the present invention;
FIG. 2 is a detailed cross-sectional view of a throat insect made in accordance with the teachings of the present invention; and
FIG. 3 is a cross-sectional view of an in-process assembly employed in the method of producing a throat insert of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following description of the preferred embodiment is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
Referring to FIG. 1, there is shown a cooled bipropellant rocket thruster 10 having a throat insert 12 incorporated therein. Thruster 10 has a hydrazine (N 2 H 4 ) decomposition chamber 14. Hydrazine, utilized as a fuel for thruster 10, flows from the inlet line 16 through a control valve 18 to a catalytic bed of active material 20, such as iridium coated alumina oxide which promotes exothermic decomposition of the hydrazine within decomposition chamber 14. The highly exothermic decomposition of hydrazine results in the product gasses ammonia, hydrogen, and nitrogen. This decomposition process takes place at a temperature of approximately 1,700 degrees fahrenheit. The product gasses are communicated by injectors 22 to a second reaction chamber defined as a thruster chamber 24 contained within thruster housing 26.
A liquid oxidizer, such as nitrogen tetroxide (N 2 O 4 ) or liquid oxygen, is supplied to thruster 10 by inlet line 28 and passing through a control valve 30. The liquid oxidizer enters a central portion 32 of thruster chamber 24, and is distributed to a cooling passage 33 having a first passage portion 34 and other passage portions 36. While FIG. 1 shows only two cooling passages 33, it will be understood by one skilled in the art that any number of cooling passages 33 could be spaced around thruster chamber 24 in thruster housing 26 as required to properly cool thruster housing 26.
The liquid oxidizer acts as a coolant by flowing through passage 33, entering at inlet 35 and exiting at outlet 37, within thruster housing 26 and absorbing heat which is created in thruster chamber 24 by the combustion of the product gasses and the gassified oxidizer. While absorbing heat the liquid oxidizer is transformed from the liquid state to a heated gas phase. When the oxidizer has travelled the entire length of cooling passage 33 and reached the outlet 37, it should be substantially 100% gas. The latent heat of vaporization of the oxidizer will have absorbed the heat transferred from the hot product gasses in thruster chamber 24 and will have accomplished the majority of cooling of thruster housing 26.
The heating and phase change, from liquid to gas, accomplished in cooling passage 33 is assisted by use of flow swirlers 40 and 42. One skilled in the art would understand that flow swirlers 40 and 42 are used to swirl the mixture of liquid and gas in order to transfer more heat to the liquid and to help remove the gas from the passage walls. One skilled in the art would further understand that although two cooling passage portions 34 and 36 are represented in the present embodiment, more passage portions may be required to adequately cool thruster housing 26 and transform the liquid oxidizer into a fully gaseous state.
The oxidizer, having been transformed to a gaseous state, is superheated to approximately 250 degrees to 300 degrees fahrenheit and is communicated from the outlet 37 of cooling passage 33 to oxidizer injector 44. Oxidizer injector 44 directs the flow of gaseous oxidizer such that it is mixed with the product gasses passing through injectors 22. The product gasses and gaseous oxidizer secondarily react to produce a strongly exothermic reaction at approximately 5,000 degrees fahrenheit.
There exists a large thermal gradient between the inner wall 46 of thruster chamber 24 and cooling passage 33 contained in thruster housing 26. This thermal gradient is particularly severe at the throat 48 of nozzle 50. The large thermal gradient can cause local yielding of the material of thruster housing 26 between the inner surface 52 of throat 48 and cooling passage 33. This localized yielding can result in a phenomena called thermal ratcheting, which is an inward shrinkage of throat 48 after each thermal cycle.
With reference now to FIGS. 1 and 2, throat insert 12, shown in detail in FIG. 2, is constructed of a thin walled shell 54 made of a material having a high yield strength and a high oxidation resistance. Several alloys, for example, those having nickel, chrome, and cobalt therein, are known to exhibit properties meeting these criteria, as are other alloys or superalloys. Materials which are currently available and which would be appropriate for making shell 54 include, but are not limited to, materials available under the Commercial Designations WASPALOY, RENE 41, INCONEL ALLOY 625, HASTELLOY X (Note-HASTELLOY 8), and UDIMET. These alloys are available from Cabot Corp., Carpentio Technology, Cyclops Corp., and Simmonds Steel Corp. These materials have relatively low thermal conductivity and hence shell 54 must be relatively thin to prevent large thermal differentials.
A casing 56 of material having a high thermal conductivity relative to that of shell 54 is therefore molded to the outer surface 58 of shell 54 to transfer the heat from shell 54 to the thruster housing 26 and ultimately to cooling passage 33. The thermal conductivity of casing 56 is at least 10 times greater than that of the shell 54. Materials such as pure copper, silver, gold, nickel, and other materials having a thermal conductivity similar to those listed, are appropriate materials for this application. A thin plating (0.002 to 0.005 inches thick) of material, such as sulfamate nickel, may be added to the outer surface 58 of shell 54 to improve the wettability of the high thermal conductivity material of casing 56 to the high yield strength, high oxidation resistant material of shell 54. The nickel plating may also be used to reduce gain boundary attack of the shell 54 by the casing material 56 during high temperature vacuum casting. Casing 56 has an exterior surface 59 which is generally cylindrical such that it can be mated with and furnace brazed to thruster housing 26.
To further reduce any potential effects of thermal ratcheting, an annular stiffening ring 60 is formed in shell 54 at the throat 48 of throat insert 12. The stiffening ring 60 provides a structurally stable throat diameter by resisting the radially inward forces created by any local yielding that may occur near inner surface 52 due to thermal cycling. In effect, the hoop stresses that occur due to the local yielding are counteracted by the circumferential forces of stiffening-ring 60.
The shell 54 of throat insert 12 further includes an annular braze ring groove 62 which is utilized to assure proper retention and sealing of throat insert 12 to thruster housing 26. Throat insert 12 is furnace brazed into thruster housing 26 using high temperature vacuum brazing techniques or other processes which result in a joint with high temperature capability.
With reference now to FIG. 3, there is shown an in-process assembly 70 utilized in fabricating throat insert 12. High temperature vacuum casting is a preferred method in the present embodiment. A preform 72 is fabricated from the high strength, oxidation resistant material which will later be machined to form the thin walled shell 54 (shown in FIGS. 1 and 2). Specific contours are formed within preform 72 which will correlate to the annular stiffening ring 60 and to outer surface 58 of shell 54. These contours are indicated by reference numerals 60' and 58' in FIG. 3. After fabrication, preform 72 is plated with a thin plating of material, such as sulfamate nickel plating, to improve wettability of the high thermal conductivity material which will form casing 56. This thin plating also protects the material of preform 72 from grain boundary attack during the casting process which follows. Preform 72 also contains holes 74 and 76 which are used in subsequent machining operations in the formation of throat insert 12. Holes 74 and 76 may be masked during the plating process in order to insure their dimensional accuracy for reference during the subsequent machining process.
Three fillers 78, 80, and 82 are positioned around preform 72, and are made of a high thermal conductivity material (such as pure copper, silver, gold, or nickel) which will constitute the material of casing 56 upon completion of the manufacture of throat insert 12. Preform 72 and fillers 78, 80, and 82 are placed in a housing 84 designed to position preform 72 and contain fillers 78, 80, and 82 during the casting process. Housing 84 may be fabricated from steel or any other compatible material.
Once preform 72 and fillers 78, 80, and 82 are placed in housing 84, thereby creating in-process assembly 70 as shown in FIG. 3, they are placed in a high temperature vacuum brazing furnace or other similar furnace such as an inert gas or hydrogen brazing furnace. A high temperature insulator (not shown) is placed over the top of assembly 70 such that assembly 70 is heated and cooled from a lower surface 86 of housing 84. The intent of providing a high temperature insulator is to insure that upon cooling, the molten fillers 78, 80, and 82 solidify from the bottom toward the top. This assures that any shrinkage voids which may occur are outside of the throat insert 12 when completed.
Thermocouple 88 is attached to housing 84 to monitor the temperature of assembly 70 as it is heated and later cooled. The furnace temperature is set at approximately 2,100 degrees fahrenheit and the temperature of assembly 70 is monitored by way of thermocouple 88. Fillers 78, 80, and 82 melt at approximately 2,000 degrees fahrenheit, the exact temperature depending upon the specific material selected, and during this time the monitoring thermocouple 88 is locked at the melt temperature. After melting is complete, the temperature is slightly increased, to approximately 2,050 degrees fahrenheit, and the furnace is turned off allowing assembly 70 to cool and the fillers 78, 80, and 82 to solidify. The molten fillers 78, 80, and 82 wet the plated preform 72 like a brazing alloy and fill the cavity machined into preform 72.
Once assembly 70 is completely cooled preform 72 and the material which made up fillers 78, 80, and 82, now molded to preform 72, is removed from housing 84. Machining operations utilizing holes 74 and 76 as dimensionally stable locating points are conducted to form the final throat insert 12 shown in FIG. 2. Throat insert 12 is then vacuum furnace brazed using a brazing alloy, such as gold/nickel, into thruster chamber 24 of thruster housing 26. The brazing alloy used should have a melt temperature below that of the material used for fillers 78, 80, and 82, which now constitutes casing 56.
The foregoing discussion discloses and describes a preferred embodiment of the present invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that various changes, modifications, and variations can be made therein without departure from the true spirit and fair scope of the invention as defined in the following claims.
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A thruster rocket engine throat insert (12) has a thin walled shell (54) made from a high strength, oxidation resistant material. The shell (54) having a throat (48) of reduced cross-section and a radially extending annular stiffening ring (60) located at the throat (48). A casing (56) made from a material having a thermal conductivity at least 10 times greater than that of shell (54) is molded around an outer surface (58) of shell (54) and has a generally cylindrical exterior surface (59). Shell (54) resists yielding and oxidation caused by the extreme temperatures of rocket fuel combustion products passing through the throat insert (12), while the casing (56) acts to efficiently transfer heat from the shell (54).
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] U.S. provisional application No. 62/131,819 dated Mar. 11, 2015 the contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention is in the field of mobile entertainment systems and methods of manufacturing for luxury executive vehicles.
BACKGROUND
[0003] Many present day in-vehicle entertainment systems include an in-dash mounted radio frequency (RF) receiver, CD/DVD player, and a universal serial bus (USB) port for the system to download program source data from a thumb drive or similar memory device. A vehicle passenger may use portable electronic device (PED) such as smart phone, tablet, or media player (e.g. an I-POD®) to access program source data previously stored on the PED. Entertainment systems for automobiles are well known. As such, many advances have been made in the development of entertainment systems that make the otherwise tedious task of riding in an automobile almost bearable. In addition to the development of overhead systems pioneered by the present inventor, a variety of systems and techniques for integrating entertainment systems within an automobile have been developed.
[0004] Limitation to the modification to accommodate in a custom vehicle. Not going to try to invent 48 inch in a standard vehicle. Modify without making the modification obvious from the outside. From average observer perspective the outside is not modified, the width is not modified. The height is modified to accommodate.
[0005] For example, headrest entertainment systems have been developed and allow multiple individuals to view a variety of different video sources within the same vehicle. However, some automobiles are not suited for the utilization of headrest entertainment systems and, therefore, are unable to take advantage of this advancement in technology. Similarly, only larger vehicles can take advantage of the overhead systems commonly found in automobiles. But even these do not make entertainment centers for luxury travel.
[0006] With this in mind, alternate techniques for implementing entertainment systems within automobiles are needed. The present invention attempts to add to the choices consumers have by providing an automobile entertainment system that can give the user a “wow” experience.
[0007] Although various improvements are known to the art, all, or almost all of them suffer from one or more than one disadvantage. Therefore, there is a need to provide an improved entertainment system and method of installation in executive vehicles.
RELEVANT ART REFERENCES
[0008] U.S. Pat. No. 5,918,183 issued to Jansky et al., discloses a concealed mobile communications system.
[0009] U.S. Pat. No. 7,163,251 issued to Sitzler et al., discloses a seat back storage system for a vehicle entertainment system.
[0010] U.S. Pat. No. 7,604,291 issued to Vitito discloses a vehicle entertainment system incorporated within the armrest/console of a vehicle with a swivel monitor mounting structure.
[0011] U.S. patent application Ser. No. 10/225,674 disclosed by lmamura et al., discloses an in-vehicle monitor support structure.
[0012] U.S. patent application Ser. No. 11/874,684 disclosed by Revelino et al., discloses a flat screen television bracket for a vehicle.
[0013] U.S. patent application Ser. No. 11/571,223 disclosed by Handa discloses a panel driven apparatus.
[0014] U.S. patent application Ser. No. 13/652,566 disclosed by Kelly disclosed an in-vehicle entertainment system for providing program source data to a portable electronic device.
[0015] These publications and all other referenced patents are incorporated herein by reference in their entirety. Furthermore, where a definition or use of a term in a reference, which is an incorporated reference here, is inconsistent or contrary to the definition of that term provided herein the definition of the term provided herein applies and the definition of that term in the reference does not apply.
SUMMARY OF THE INVENTION
[0016] In view of the shortcomings of the prior art, it is the object of this invention to provide an awesome entertainment center in a vehicle without completely customizing a mobile movie theater.
[0017] It is further an object of the invention that the installation be performed with a skilled crew but that the current disclosure be sufficient for one skilled in the art to achieve awesome results.
[0018] It is further an object of the invention that the system be mobile.
[0019] It is to be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not to be viewed as being restrictive of the present invention, as claimed. Further advantages of this invention will be apparent after a review of the following detailed description of the disclosed embodiments and in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 shows a preferred embodiment of a frame for installing into a sport utility vehicle modified for receiving a monitor flat screen of fifty inches measured by the diagonal.
[0021] FIG. 2 shows a preferred embodiment of a frame for installing into a sport utility vehicle modified for receiving a monitor flat screen of fifty inches measured by the diagonal in the raised position.
[0022] FIG. 3 shows a preferred embodiment of a frame for installing into a sport utility vehicle modified for receiving a monitor flat screen of fifty inches measured by the diagonal in the raised position.
[0023] FIG. 4 shows a preferred embodiment of a frame installed into a sport utility vehicle modified for receiving a monitor flat screen of fifty inches measured by the diagonal.
[0024] FIG. 5 shows a preferred embodiment of a frame for installing into a sport utility vehicle modified for receiving a monitor frame between a driver seat and passenger seat.
[0025] FIG. 6 shows a preferred embodiment of a frame installed into a van for receiving a monitor flat screen.
[0026] FIG. 7 shows a preferred embodiment of a frame for installing into a van for receiving a monitor frame between a driver seat and passenger seat.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0027] Referring now to the drawings wherein the showings are for purposes of illustrating a preferred embodiment of the present invention and not for purposes of limiting the same, A first embodiment of the invention is a monitor frame adapted for insertion into a vehicle. The frame may be made of various materials comprising metal, polymer, and wood to achieve a strong, light weight, and sturdy support for a monitor in a moving vehicle. The dimensions are given with respect to accommodate a 48 to 50 inch television in a Cadillac Escalade®. However, additional dimensions are described for different embodiments. The frame 10 is rectangular in shape having a top 1 , a bottom 2 , a right side 3 and a left side 4 . The frame 10 is mountable to a vehicle via frame mounts 5 that provide a fixed and stable platform for the frame 10 to attach to a vehicle. The vehicle frame 10 has a monitor mount 6 that is generally rectangular and is mounted to at least one vertical guide member 7 between the sides of the frame 10 and the monitor mount 6 of the vehicle frame 10 . The vertical guide member 7 provides a platform for the monitor mount 6 to raise and lower with in the vehicle frame 10 . The monitor mount 6 is operable via an electric motor to raise and lower depending upon an Executive's operating preferences. See FIGS. 1-3 . FIG. 2 shows a preferred embodiment in the open position and FIG. 3 shows a preferred embodiment in the closed position wherein a monitor is in a viewable position.
[0028] FIGS. 4 and 5 show a vehicle frame 10 maybe further be incorporated into a partition or divider between a driver seat 20 and a passenger seat 30 of an SUV vehicle. When the monitor mount 6 is in the closed position the driver cannot directly visualize any executives in a passenger portion of the vehicle. A driver would have to utilize an audio or audio and visual communication means like speakers and or video feed to communicate with an executive when the monitor mount 6 is in the closed position. This provides a measure of privacy and security to the executive. For example, the executive could turn off audio monitoring with the driver for private conversations in the vehicle or for phone calls or for teleconference calls on a monitor mounted on the monitor mount 6 . Alternatively, an executive could open the partition between the driver portion and passenger portion of a vehicle by operating the monitor mount 6 to secrete into a partition and thus open a fluid space between the executive and the driver to communicate directly. In a preferred embodiment the driver seat 20 is mounted to the floor 21 of a sport utility vehicle (“SUV”) and in particular the rear mount hole 22 is used to bolt the driver's seat. A partition (not shown in FIG. 5 ) with a decorative facade encapsulates frame 10 and is located between five inches and thirty inches away from the rear mount hole 22 . In order to accommodate a large monitor the SUV ceiling must be adapted such as by raising six inches on the roof exterior 26 and interior ceiling 27 . In an SUV preferred embodiment it is sometimes necessary to raise the roof exterior 26 and interior ceiling 27 but this relatively modest modification allows the vehicle to accommodate a relatively large monitor of fifty inches without the need to augment or modify the side exterior panels 24 or side interior 25 . This modification limited to the roof exterior 26 and interior ceiling 27 keeps the cost of manufacture relatively inexpensive and complies with Department of Transportation regulations. FIG. 5 shows a profile of an SUV interior. In a preferred embodiment a driver seat 20 is bolted to an SUV floor 21 via a bolt in bolt hole 22 . A passenger seat 30 would be mounted to the SUV floor in a conventional manner. A partition housing a monitor frame 10 would be positioned between the driver portion and passenger portion of the SUV. In a preferred embodiment the frame mounts 5 would be positioned between five and thirty inches from the bolt hole 22 of a driver seat 20 in a vehicle. For the sake of clarity it is intended that a monitor 33 be firmly attached to or within the monitor mount 6 . In the preferred embodiment the monitor 33 would be at least twenty inches above the SUV floor 21 to be visible and no more than six inches from the interior ceiling 27 . FIG. 5 shows center of the rear bolt hole 22 of the driver seat 20 . Additionally, frame sides 3 , 4 are disposed between two and fourteen inches from an SUV side interior 25 .
[0029] FIGS. 1-3 show the frame and dimensions for a preferred embodiment that includes the installation into a vehicle with an unmodified width and a modified height of between three to six inches to accommodate a fifty inch monitor in a partition between a driver portion and an executive portion. While in the closed position the frame supports the monitor in a viewable position that blocks off visual communication between the driver and executive unless other video camera means are used. While in the open position the frame is secreted in the partition so that an executive and a driver could communicate the same as a common person would in a taxi cab.
[0030] FIGS. 6 and 7 show an alternative embodiment of the present invention, a roof modification is not needed for a van, for example a Mercedes Benz Sprinter® has a relatively high roof 67 compared to a typical SUV. The frame 50 is rectangular in shape having a top 51 , a bottom 52 , a right side 53 and a left side 54 . The frame 50 is mountable to a vehicle via frame mounts 55 that provide a fixed and stable platform for the frame 50 . The vehicle frame 50 has a monitor mount 56 that is generally rectangular and is mounted to at least one vertical guide member 57 between the sides of the frame 50 and the monitor mount 56 of the vehicle frame 50 . The vertical guide member 57 provides a platform for the monitor mount 56 to raise and lower with in the vehicle frame 50 . The monitor mount 56 is operable via an electric motor to raise and lower depending upon an Executive's operating preferences.
[0031] The vehicle frame 50 maybe further incorporated into a partition or divider between a driver portion and a passenger portion of a vehicle. When the monitor mount 56 is in the closed position the driver cannot directly visualize any executives in a passenger portion of the vehicle. A driver would have to utilize an audio or audio and visual communication means like speakers and or video feed to communicate with an executive when the monitor mount 56 is in the closed position. This provides a measure of privacy and security to the executive. For example, the executive could turn off audio monitoring with the driver for private conversations in the vehicle or for phone calls or for teleconference calls on a monitor mounted on the monitor mount 56 . Alternatively, an executive could open the partition between the driver portion and passenger portion of a vehicle by operating the monitor mount 56 to secrete into a partition and thus open a fluid space between the executive and the driver to communicate directly. In a preferred embodiment the driver seat 60 is mounted to the floor 59 of a van and in particular the rear mount hole 58 is used to bolt the driver seat 60 . A partition (not shown in FIG. 7 ) with a decorative facade encapsulates frame 50 and is located between five inches and thirty inches away from the rear mount hole 58 . In order to accommodate a large monitor the van ceiling 67 need not be modified. FIG. 7 shows a profile of a van interior. In a preferred embodiment a driver seat 60 is bolted to a van floor 59 via a bolt in bolt hole 58 . A passenger seat 70 would be mounted to the van floor 59 in a conventional manner. A partition housing a monitor frame 50 would be positioned between the driver seat 60 and passenger seat of the van. In a preferred embodiment the frame mounts 5 would be positioned between five and thirty inches from the bolt hole 22 of a driver seat 20 in a vehicle. For the sake of clarity it is intended that a monitor 33 be firmly attached to or within the monitor mount 56 . In the preferred embodiment the monitor 33 would be at least twenty inches above the van floor 59 to be visible and no more than twenty four inches from the interior ceiling 67 . FIG. 7 shows center of the rear bolt hole 58 of the driver seat 60 . Additionally, frame sides 53 , 54 are disposed between two and fourteen inches from a van interior side 65 .
[0032] A partition and monitor frame 50 can be adapted to hold curved or flat monitors by simply adjusting the thickness of the frame. The Sprinter® is capable of having a seventy inch monitor without having to modify the interior side 65 of the vehicle. The monitor frame 50 in a Sprinter® would be mounted between one and twelve inches from the vehicle interior side 65 or for example from a passenger window. In the Sprinter® embodiment the top of the monitor viewable portion would be limited to between one inch to twenty-four inches from the ceiling of the vehicle. The monitor frame in a typical SUV would be between four and thirteen inches from a passenger window without the vehicle sides being modified.
[0033] Monitors are used for watching movies, security cameras, conference calling and other entertainment.
[0034] Vertical guides can be made of simple rail systems the purpose of the vertical guides is to provide a stable platform to raise and lower the monitor frame. The vertical guides can be made of metal, wood, or polymer, or in combination thereof. The vertical guides may have chains, tracks, wires or other attachment means to allow low friction movement of the monitor mount between the monitor left and right sides.
[0035] The foregoing description is, at present, considered to be the preferred embodiments of the present discovery. However, it is contemplated that various changes and modifications apparent to those skilled in the art, may be made without departing from the present discovery. Therefore, the foregoing description is intended to cover all such changes and modifications encompassed within the spirit and scope of the present discovery, including all equivalent aspects. Additional modifications and improvements of the present invention may also be apparent to those skilled in the art. Thus, the particular combination of parts described and illustrated herein in intended to represent only one embodiment of the invention, and is not intended to serve as limitations of alternative devices within the spirit and scope of the invention.
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An entertainment system for a luxury vehicle that is mounted in a partition that separates a driver from a back seat passenger. The partition provides privacy and the ability to encase large television screens or monitors. The mounted monitor can be lowered to allow for communication with a driver or let the passenger see out the windshield.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims the benefit of U.S. Provisional Application Ser. No. 60/395,042, filed Jul. 11, 2002, which is incorporated herein by reference in its entirety.
FIELD OF INVENTION
[0002] The present invention relates to the field of bi-directional communication devices. More specifically, the present invention relates to upgrading application level gateways and firewall rule sets for bi-directional communication devices.
DESCRIPTION OF THE BACKGROUND ART
[0003] Field upgradeable products are becoming more prevalent in the broadband market today. Devices, such as cable modems and other bi-directional communication devices, may have application level gateways (ALGs) and/or firewall rule sets downloaded remotely to them while in a customer's home or office. Downloading files containing such ALGs and/or firewall rule sets places the device at higher risk for downloading improper file versions, corrupted files, non-authorized files, files that are too large, incompatibility with the device's hardware and/or software, among others.
[0004] Downloading an incompatible or corrupted ALG file to a cable modem may cause the cable modem to hang up or crash. Once a cable modem hangs up or crashes, the cable modem becomes inoperable and, typically, requires a service call, illustratively from a multiple systems operator (MSO) service representative or the like, to repair the cable modem.
[0005] Therefore, there is a need to validate proper application level gateway files or firewall rule set files being downloaded to a bidirectional communication device such as a cable modem.
SUMMARY OF INVENTION
[0006] The disadvantages heretofore associated with the prior art, are overcome by the present invention of an apparatus and method for validating application level gateway (ALG) files or firewall rule sets. The method and apparatus include receiving an ALG file from a service provider, and validating at least one compatibility parameter of the ALG file with features of a bidirectional communications device receiving such ALG file. In an instance where all of the compatibility parameters are validated, the ALG file is stored at the bi-directional communications device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The teachings of the present invention can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which:
[0008] FIG. 1 depicts a high-level block diagram of a cable communications system over which an exemplary embodiment of the present invention is utilized;
[0009] FIG. 2 depicts a block diagram of an exemplary application level gateway (ALG) file, in accordance with the principles of the present invention; and
[0010] FIG. 3 depicts a flow diagram of a method for validating a upgraded ALG file in accordance with the principles of the present invention;
[0011] To facilitate understanding of the invention, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures.
DETAILED DESCRIPTION OF THE INVENTION
[0012] The present invention comprises a bi-directional communication device (BCD) operating in a bidirectional communications environment and method for downloading application level gateway (ALG) files or firewall rule sets to a BCD. For purposes of simplicity and better understanding of the invention, the present invention is illustratively discussed in terms of a cable communications distribution system. However, the principles of the present invention are also applicable to other bi-directional communication environments, such as satellite communication systems, ADSL, DSL, Dial-up, wireless systems, or any other bidirectional communication environment capable of providing bi-directional communications (e.g., data, multimedia content, and other information) to a plurality of subscriber devices.
[0013] The bi-directional communication device is, in one embodiment, a CableLabs Certified CableModem™ compliant cable modem that may be used to provide bi-directional communications between a cable television system operator (and Internet service providers (ISPs)) deploying DOCSIS-based products, such as cable modems, and a plurality of subscriber devices, such as personal computers, and the like. CableLabs Certified CableModem™ (previously known as DOCSIS (data over cable service interface specifications) is funded by leading CATV operators who establish specifications that specify modulation schemes and the protocols for exchanging bi-directional signals over cable. The various versions of DOCSIS are incorporated herein by reference in their entirety.
[0014] FIG. 1 depicts a block diagram of a cable modem communication system 100 in which an exemplary embodiment of the present invention may be utilized. The bi-directional communications system (e.g., cable modem system) 100 comprises a multiple systems operator (MSO, i.e., cable operator) 110 and a plurality of subscriber premise equipment 170 , which are coupled to the service provider 110 via an access network 108 .
[0015] The subscriber premise equipment 170 comprises a plurality of user devices 172 1 , through 172 N (collectively user devices 172 ) respectively coupled to a plurality of bidirectional communication devices (e.g., cable modems) 130 1 through 130 N (collectively cable modems 130 ) of which only one cable modem 130 is shown in FIG. 1 . The user devices 172 may be any type of device capable of processing a digitized stream comprising audio, video, and/or data, such as a personal computer (PC), laptop computer, television set, hand-held device, or any other device capable or transmitting and/or receiving data. Each user device 170 is coupled to the access network 108 via a cable modem 130 , which connects the user device 172 to an IP network 102 (e.g., the Internet) via the local cable television provider (i.e., MSO 110 ).
[0016] It is noted that in FIG. 1 , a plurality of user devices 172 is illustratively shown as being coupled to a single cable modem 130 via a hub 174 . However, one skilled in the art will appreciate that each user device 172 may alternatively be coupled to a respective cable modem or grouped in any configuration to provide bidirectional communications between the user devices 172 and the MSO 110 .
[0017] The cable modem 130 allows the subscriber to download information from the service provider 110 at speeds much faster than a telephone dial-up modem. For example, a cable modem 130 can provide connectivity at a rate of three or more megabits per second, as compared to 56 kilobits per second for a telephone modem. One type of cable modem illustratively used in the system 100 is a DCM305 model, manufactured by Thomson Inc., of Indianapolis, Ind. It is noted that cable modems (and modem functionality) provided by other manufacturers that are DOCSIS compliant may also be implemented in the system 100 as well.
[0018] The service provider 110 may be any entity capable of providing low, medium and/or high-speed data transmission, multiple voice channels, video channels, and the like. In particular, data is transmitted via radio frequency (RF) carrier signals by the service provider 110 in formats such as the various broadcast formats (e.g., Digital Broadcast Satellite (DBS)), cable transmission systems (e.g., high definition television (HDTV)), digital video broadcasting ((DVB-C) (i.e., European digital cable standard)), and the like. The service provider 110 provides the data over the cable transport network 108 .
[0019] The service provider 110 typically comprises a plurality of head-ends 112 (only one head end shown in FIG. 1 ), which are deployed in various geographic regions to provide connectivity, services, and support to subscribers located in such regions. For example, one or more head-ends 112 may be located in proximity to a large subscriber base, such as a city (e.g., San Francisco, Calif.). Other head-ends 110 may be provided by the MSO 110 to support other cities or regional areas as required.
[0020] Each head-end 112 comprises at least one termination system (e.g., cable modem termination system (CMTS)) 114 , a file server 116 , among other support servers 118 , such as a dynamic host configuration protocol (DHCP) server, a trivial file transfer protocol (TFTP) server, an Internet time protocol (ITP) server, web caching servers, MSO or ISP content delivery servers, and the like.
[0021] The file server 116 provides a means by which files such as the downloadable application level gateway (ALG) files or firewall rule sets may be transferred from the MSO 110 to the cable modem 130 . Specifically, the file server 116 is coupled to an ALG database 120 , which stores a plurality of ALG files pertaining to various protocols and devices, such as the cable modems 130 . The file server 116 retrieves a particular ALG file from the ALG file database 120 and sends such file to the bi-directional device 130 as required and discussed below with regard to method 300 of FIG. 3 .
[0022] The other support servers 118 are used to establish connectivity between the cable modems 130 and the IP network 102 during cable modem initialization. Specifically, the other support servers 118 deliver a configuration file and the current date and time to a cable modem 130 each time it initializes. Further, the other servers 118 such as web caching servers, MSO or ISP content delivery servers and the like provide regionalized worldwide web content, redundant connectivity, and the like. Moreover, the DHCP server centrally-manages and automatically assigns IP addresses to the host devices (i.e., cable modems) coupled to the IP network 102 . For example, when a cable modem 130 is added, replaced, or moved in the system 100 , the DHCP server automatically assigns a new IP address for that cable modem 130 .
[0023] The CMTS 114 exchanges digital signals with cable modems 130 on the cable network 100 . The quantity of CMTSs 114 disposed at each head-end 112 is dependent on the number of subscribers being served in a particular geographic region. A single CMTS 114 typically provides connectivity for up to about 8000 cable modems 130 . In instances where a geographic region has more than 8000 subscribers, the head-end 112 is provided with additional CMTSs 114 , as required.
[0024] A data service (e.g., multimedia content) and ALG upgrade files are delivered to the cable modem 130 through an RF path (i.e., channels) over the Access Network 108 via a transmission medium (e.g., a conventional bidirectional hybrid fiber-coax (HFC) cable network, such as specified under the North American or European DOCSIS standards), coupled to the cable modem 130 . It is noted that the cable modem 130 may be installed externally or internally to a subscribers computer or television set 172 , and is connected by a Local Area Networking medium supported by the cable modem 130 and computer or television set (e.g. Ethernet, Universal Serial Bus (USB), 802.11b wireless, Home Phoneline Networking Alliance (HPNA)).
[0025] One channel is used for downstream signals from the CMTS 114 to the cable modem 130 , while another channel is used for upstream signals from the cable modem 130 to the CMTS 114 . When a CMTS 114 receives upstream signals from a cable modem 130 , the CMTS 114 processes these signals into Internet Protocol (IP) packets, which are routed over the IP network 102 to a particular destination (e.g., a server having a desired content or a web site). When a CMTS 114 sends downstream signals to a cable modem 130 , the CMTS 114 modulates the downstream signals for transmission across the access network 108 to the cable modem 130 . The cable modem 130 converts the modulated signal to a baseband signal for processing by the user device 172 .
[0026] The exemplary cable modem 130 is utilized to provide downstream broadband data signals from the service provider 1 10 to the user device 172 of a data communications system 100 . Additionally, the exemplary cable modem 130 is utilized to transfer upstream baseband data signals from the illustrative user device 172 back to the service provider 110 .
[0027] The cable modem 130 comprises a processor 132 , support circuits 134 , 1 / 0 circuits 142 , storage devices such as an EEPROM 138 and FLASH memory 140 , as well as volatile memory 136 . The processor 132 may be a cable modem processor, such as a single chip BCM3345 device manufactured by Broadcom Inc., of Irvine, Calif., which includes a modulator and demodulator (not shown).
[0028] The EEPROM and FLASH memories 138 and 140 are non-volatile memory devices used to permanently store application program files, data files, and other program code that may be executed, illustratively, by the processor 132 . For example, a firewall, a plurality of application level gateway files, and a routine for validating the application level gateway files may all be permanently stored in the EEPROM 138 and/or FLASH 140 memories.
[0029] The volatile memory 136 may be random access memory (RAM), which is used during operation to store all or portions of the programs stored in the non-volatile memory 138 and 140 for quick retrieval and execution. As shown in FIG. 1 , a firewall program 150 , a plurality of application level gateway files 152 (e.g., files ALG- 0 through ALG-m, and routine 300 , which is used for validating upgrades for the application level gateway files 152 (as discussed below in further detail with regard to FIG. 3 ), is depicted being stored in the volatile memory 136 . Other programs that may be stored in memory 136 typically include process stacks, heap, transient data such as ALGs and firewall rule sets under discrimination, executing applications copied from Flash, startup constant data, a kernel and application code, and other data (not shown).
[0030] The processor 132 cooperates with conventional support circuitry 134 such as power supplies, clock circuits, cache memory and the like as well as circuits that assist in executing the software routines stored in the memory 136 . As such, it is contemplated that some of the process steps discussed herein as software processes may be implemented within hardware, for example as circuitry that cooperates with the processor 132 to perform various steps. The cable modem 130 also comprises input/output (I/O) circuitry 142 that forms an interface with the various functional elements communicating with the user devices 172 . The physical layers between the cable modem 130 and user devices 172 may illustratively include Ethernet, coaxial cables, FDDI, ISDN, ATM, ADSL, CAT 1 - 5 cabling, USB, HomePNA, wireless data links (e.g., 802.11 or Bluetooth standard wireless links), a power line carrier, among others.
[0031] Furthermore, the cable modem 130 comprises signal processing circuitry 144 , which further comprises downstream processing circuitry 146 and upstream processing circuitry 148 . The signal processing circuitry 144 is coupled to the processor 132 and an interface 143 , which is coupled to the access network 108 .
[0032] In operation, the CMTS 114 converts digital data to a modulated RF signal and provides such modulated signals downstream, via the HFC transport (access) network 108 to the cable modem 130 , where the RF signals are received, tuned, and filtered to a predetermined intermediate frequency (IF) signal. The IF signal is then demodulated into one or more respective baseband signals, and otherwise processed into, illustratively, data packets. The data packets are further transmitted, illustratively, through cabling (e.g., Ethernet, universal serial bus (USB), coaxial cable, and the like) 175 to the user device 172 .
[0033] Similarly, a user of the user device 172 may send data signals to the cable modem 130 via the cabling 175 . The cable modem 130 receives data signals from the user device 172 , and then modulates and upconverts the data signals onto a RF carrier for upstream transmission back to the service provider 110 , via the cable transport network 108 .
[0034] The downstream processing circuitry 146 typically includes various components, such as a tuner, filters, demodulator, a controller, and other downstream processing circuitry, such as a medium access controller (MAC), which is also used for upstream processing. Typically, the downstream signals are either 64 QAM or 256 QAM signals having a frequency range of approximately 91 MHz to 860 MHz. The downstream processing circuitry 146 selectively tunes, demodulates, and otherwise “receives” at least one of a plurality of downstream data signals from the CMTS 114 in response to a selection signal provided by the controller. A high-pass filter (HPF) passes all downstream data signals to the tuner, which downconverts the received downstream RF signals from the HPF to a predetermined IF frequency signal. The IF signals are demodulated by the demodulator circuitry to provide one or more respective digital baseband signals. The digital baseband signals are sent to the medium access controller (MAC), where the received signals (e.g., MPEG packets) are de-encapsulated and formed into a bitstream for subsequent transport to the user device 172 , as managed by the controller.
[0035] Prior to transport to the user device 172 , the packets are sent either to an internal TCP/IP stack or to the firewall program 150 for examination, as discussed In further detail below. Once the packets are deemed to comply with the firewall program rules, the MAC, controller, and other digital circuitry may further process the packetized data (e.g., attach or encapsulate in appropriate transport packets as required) and then distribute the processed, packetized data to the user device 172 (or other information appliance). In particular, the MAC sends the packetized bitstream to the controller, where the data is processed (e.g., formatted) for interface with the user device 172 . The controller transfers the formatted packetized bit stream (via cabling) to the user device 172 for further processing (e.g., extraction and upconversion of the data).
[0036] The upstream processing circuitry 148 typically includes various components such as, the upstream physical layer elements, an upstream medium access controller, a modulator, a low-pass filter, and other upstream processing circuitry (amplifiers, voltage regulators, and the like). The cable modem 130 receives signals (e.g., data signals) from the user device 172 for subsequent transmission to the service provider 110 . In particular, a user sends data, data requests, or some other user request to the service provider 110 via the cable modem 130 . The cable modem 130 receives the user requests, where the MAC and upstream processing circuitry format, encapsulate, and upconvert the signals (e.g., 5 MHz to 54 MHz frequency range) for transport. The modulator modulates (e.g., QPSK or 16 QAM) the upconverted signals along the upstream signal path to the CMTS 114 .
[0037] The firewall program 150 is capable of examining and filtering data packets (e.g., IP data packets) sent from an originating source node (e.g., file server on a WAN) to a destination node (e.g., local computer on a LAN). In particular, the firewall program 150 comprises a set of related programs that protect the resources of a private network from users from other networks. The firewall program 150 examines some or all of the network packets to determine whether to forward the packets to its destination. That is, the firewall program 150 operates at the network level. Data is only allowed to pass through the communications device 130 containing the firewall program 150 if the packet configuration does not violate specified rules.
[0038] The firewall program rules are established, for example, by an administrator of a LAN (default rules may also be used), for example, at the service provider 110 . The rules reflect policy considerations by an organization to provide security by prohibiting unwanted data from entering the organizations local area network/wide area network (LAN/WAN). For example, an organization may decide that particular Internet web sites should not be viewed by the organization's employees, or that some employees should be denied any Internet access. In one embodiment, the firewall rules are defined in application level gateway files such as the exemplary ALG file shown in FIG. 2 . As such, the rules include programming to restrict some or all hypertext transfer protocols (HTTP). Additional rules include restricting data packets that may be deemed harmful to the LAN and end-users, such as worms, as well as unauthorized persons (i.e., “hackers”) trying to infiltrate the LAN.
[0039] The ALG files are stored in a database 120 coupled to the TCP/IP file server 116 , which are located at the service provider 110 . When a system administrator updates the ALG files, the cable modems 130 will also require a file upgrade. In one embodiment, the ALG files may be provided to the cable modems 130 by a user requesting a download over the access network 108 . In a second embodiment, the firewall 150 may periodically poll the ALG database to identify upgraded files at the service provider 110 . Alternatively, the MSO 110 may command the cable modem 130 to obtain new firewall rule set or ALG data via a protocol such as Simple Network Management Protocol (SNMP). Once an upgraded ALG file is identified, the service provider 110 automatically retrieve the upgraded files and sends them to the cable modems 130 . In a third embodiment, the upgraded ALG files may be stored on a non-volatile storage device, such as a CD-ROM, disk drive, floppy drive, and the like, in which the user may upload the new and/or upgraded ALG files to their cable modem 130 via their user device 172 .
[0040] FIG. 2 depicts a block diagram of an exemplary application level gateway (ALG) file 200 of the present invention. The ALG file 200 comprises an ALG body 202 (payload) and a header 210 . The ALG file 200 comprises executable code that the firewall program 150 executes in order to determine how to handle a particular protocol. That is, the ALG body 202 contains programming code that is protocol specific. For example, one ALG file 200 may comprise code to allow the passage of information utilizing an http protocol, while a second ALG file 200 contains executable programming code specific for blocking data utilizing FTP (file transfer protocol). Other ALG files 200 may be utilized to control traffic flow for other types of protocols, such as TFTP, SNMP, RLOGIN, and the like.
[0041] The ALG header 210 comprises header data fields such as header format version 216 , header size 218 , expected header CRC 220 , payload authentication signature 222 , payload size 224 , expected payload CRC 226 , compatible hardware and software version families 228 and 230 , and other header data 212 such as compression parameters, copyright notices, and/or the date/time the payload was created, among other information. In one embodiment of the invention, many of these ALG header 210 components may be utilized as ALG file validity fields 214 , which are used by the cable modem 130 to determine whether an upgraded or new ALG file 200 received by the cable modem 130 has been corrupted during file transfer, as well as compatible with the cable modem hardware and software. Although FIG. 2 is discussed in terms of an ALG file 200 , the inventive ALG file should not be considered as limiting. For example, a similar header 210 may be appended to a file comprising firewall rules.
[0042] In particular, the validity fields 214 comprise a header format version field 216 , a header size 218 , a header expected CRC (cyclic redundancy check) 220 , an ALG authentication signature 222 , an ALG body size field 224 , an ALG body expected CRC 226 , a compatible hardware version family field 228 , and a compatible software version family field 230 . Each validity field 214 is checked by the cable modem 130 using method 300 , as discussed below with regard to FIG. 3 .
[0043] The header format version field 216 provides information regarding the order and length of the fields of the data in the header 210 . Specifically, the header format version field 216 comprises a predefined number that corresponds to a known format. This predefined number will typically start at one (1) and increment each time a field is added, a length is changed or fields are rearranged in the header. The header format version field 216 prevents a misinterpretation by software that is unfamiliar with a new format. In one embodiment, the header format version field 216 may be 1 byte to 4 bytes in length, and in one specific embodiment is 2 bytes In length. The header size field 218 identifies the size of the header 214 . In one embodiment, the header size field 218 may be 1 byte to 4 bytes in length, and in one specific subset of that embodiment is 2 bytes in length. The header expected CRC field 220 identifies a 16 or 32 bit polynomial that is appended to the header 210 and used for detecting errors (loss data) in the header 210 .
[0044] The ALG authentication signature field 222 provides information regarding cryptographic authentication that a source (e.g., company, 3rd party entity, and the like) that generated a trusted firewall rule set or ALG. In one embodiment, the ALG authentication signature field 222 may be 1 byte to 1024 bytes in length, and in one specific subset of that embodiment is 128 bytes in length. The ALG body size field 224 identifies the size of the ALG body 202 . In one embodiment, the ALG body size field 224 may be 1 byte to 4 bytes in length, and in one specific subset of that embodiment is 4 bytes In length. It is noted that the ALG body size field 224 refers to the length of the size field in the header. The actual ALG or rule set data files are typical in the order of a few thousand bytes. The ALG body expected CRC field 220 identifies a 16 or 32 bit polynomial that is appended to the header 210 and used for detecting errors (loss data) in the ALG body 202 .
[0045] The compatible hardware version field 228 provides information regarding the set of hardware version(s) on which this file will execute (ALG) or operate (rule set) with no expected problems. In one embodiment, the compatible hardware version field 228 may be 1 byte to 8 bytes in length, and in one specific subset of that embodiment is 4 bytes in length. The compatible software version field 230 provides information regarding the set of application software version(s) on which this file will execute (ALG) or operate (rule set) with no expected problems. In one embodiment, the compatible software version field 230 may be 1 byte to 8 bytes in length, and in one specific subset of that embodiment is 4 bytes in length. It is noted that the illustrative sizes of each of the above mentioned fields should not be considered as limiting, and the fields may be any length suitable to provide the required information in an efficient manner (e.g., bandwidth considerations). It is further noted that the same type of header may be added to a firewall rule set to apply the same discrimination algorithm.
[0046] FIG. 3 depicts a flow diagram of a method 300 for validating a new or upgraded ALG file 200 (or firewall rule set) in accordance with the principles of the present invention. Method 300 may be utilized when a new or upgraded ALG file 200 is stored in memory of the cable modem 130 for execution by the firewall 150 therein. Method 300 comprises checking various parameters for compatibility issues and loss of data during file transfer. It is noted that the types of parameters and the specific order shown in FIG. 3 for validating the various parameters are merely illustrative, and should not be construed as being so limiting.
[0047] In particular, method 300 starts at step 302 , and proceeds to step 304 , where an ALG file 200 is sent to the cable modem 130 and buffered in the volatile memory 136 . In one embodiment, the firewall 150 periodically polls a central location (i.e., the ALG database 120 ) at the service provider 110 for new or upgraded ALG files 200 . The new or upgraded ALG files 200 are then downloaded from the TCP/IP file server 116 at the head end 112 via the access network, as required.
[0048] In a second embodiment, a configuration file is downloaded to the cable modem 130 from the service provider 110 . The configuration file provides bi-directional network policy information used to establish a managed connection. The cable modem application (e.g., firewall 150 ) checks the configuration file and determines whether to download the ALG file 200 . If the firewall 150 executing this discrimination algorithm determines the ALG file 200 is appropriate for the cable modem 130 , then the firewall 150 sends a request to the file server 116 to send the ALG file 200 . The file server 116 then downloads the ALG file to the cable modem 130 via the access network 108 .
[0049] In a third embodiment, the ALG files 200 may be loaded into the cable modem 130 by a user on their user device 172 . In this instance, the ALG file 200 is stored on a non-volatile medium, such as a floppy disk, CD-ROM, disk drive, and the like. As such, step 304 of method 300 encompasses any the three embodiments described above. The method 300 then proceeds to step 306 .
[0050] At step 306 , the header format version field 216 in the header 210 of the received ALG file 200 is checked. If at step 308 , the header format version is not known, then the method 300 proceeds to step 350 , where the ALG file 200 is rejected. That is, the ALG file 200 is not stored in the non-volatile memory 138 and/or 140 or used by the firewall 150 , and at step 399 , the method 300 ends. If, at step 308 , the header format version is known; then the method 300 proceeds to step 310 .
[0051] At step 310 , the ALG header size field 216 and ALG body size field 224 in the header 210 of the received ALG file 200 are checked. If at step 312 , the ALG file 200 exceeds the capacity of the non-volatile memory 136 , then method 300 proceeds to step 350 , where the ALG file 200 is rejected as discussed above. If at step 312 , the ALG file 200 does not exceed the capacity of the non-volatile memory 136 , then method 300 proceeds to step 314 .
[0052] At step 314 , the expected header CRC field 220 in the header 210 of the received ALG file 200 is checked. At step 316 , the CRC for the header 210 is calculated such that the cable modem 130 applies the same polynomial to the data (header 210 ) and compares the result with the CRC result appended by the service provider 110 . If, at step 318 , the calculated CRC and the appended header CRC do not match, then method 300 proceeds to step 350 , where the ALG file 200 is rejected as discussed above. If, at step 318 , the calculated CRC and the appended header CRC match, then method 300 proceeds to step 320 .
[0053] At step 320 , the expected body CRC field 226 in the header 210 of the received ALG file 200 is checked. At step 316 , the CRC for the ALG body 202 is calculated such that the cable modem 130 applies the same polynomial to the data (ALG body 202 ) and compares the result with the CRC result appended by the service provider 110 . If, at step 324 , the calculated CRC and the appended body CRC do not match, then method 300 proceeds to step 350 , where the ALG file 200 is rejected as discussed above. If, at step 324 , the calculated CRC and the appended body CRC match, then method 300 proceeds to step 326 .
[0054] At step 326 , the ALG authentication signature field 222 in the header 210 of the received ALG file 200 is checked. At step 328 , an authentication operation is performed on the signature. For example, authentication may be provided by Rivest Shamir Adelman (RSA) signature algorithm with Secure Hash Algorithm-1 (SHA-1), or other conventional authenticating techniques as is known in the art. If at step 330 , the ALG file 200 is not from an authenticated source, then method 300 proceeds to step 350 , where the ALG file 200 is rejected as discussed above. If at step 330 , the ALG file 200 is from an authenticated source, then method 300 proceeds to step 332 .
[0055] At step 332 , the hardware version family field 228 in the header 210 of the received ALG file 200 is checked. If at step 334 , the ALG file 200 is not compatible with the hardware version of the cable modem 130 , then method 300 proceeds to step 350 , where the ALG file 200 is rejected as discussed above. If at step 334 , the ALG file 200 is compatible with the hardware version of the cable modem 130 , then method 300 proceeds to step 336 .
[0056] At step 336 , the software version family field 230 in the header 210 of the received ALG file 200 is checked. If at step 338 , the ALG file 200 is not compatible with the software version of the cable modem 130 , then method 300 proceeds to~step 350 , where the ALG file 200 is rejected as discussed above. If at step 338 , the ALG file 200 is compatible with the software version of the cable modem 130 , then method 300 proceeds to step 340 .
[0057] Once the ALG file 200 has been checked for compatibility issues and corrupted data, at step 340 , the ALG file 200 is loaded into the non-volatile memory 136 of the cable modem 130 , and at step 399 , the method 300 ends. Method 300 provides a routine to validate the compatibility of an ALG file 200 or firewall rule set while receiving the ALG file 200 or rule set, and prior to using such received file or rule set. If the validation algorithm indicates the ALG file or firewall rule set is not compatible with the hardware or software of the cable modem 130 , then the received file or rule set may be safely rejected. As such, the risk of inducing a non-recoverable error condition by implementing a non-compatible ALG file 200 or rule set is substantially reduced.
[0058] Although various embodiments that incorporate the teachings of the present invention have been shown and described in detail herein, those skilled in the art may readily devise many other varied embodiments that still incorporate these teachings.
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Method ( 300 ) and apparatus for validating application level gateway files or firewall rulsets. The method and apparatus include receiving at a bidirectional communications device, an application level gateway file, and comparing at least one compatibility parameter of said ALG file with features of said bi-directional communications device. In an instance where all of the compatibility parameters compare favorably, the ALG file is stored at the bidirectional communications device.
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BACKGROUND OF THE INVENTION
This invention relates to a device for the self-feeding of pet animals, particularly, but not exclusively, cats.
As to those who are familiar with house pets, and particularly cats, will readily recognize, pet feeding is not an inconsequential matter from the points of view of both the owner and the pet. From the owner's point of view the feeding of the pet is a chore which, if the desire of the pet to be fed is to be taken into account (and the pet usually sees to it that it is a matter of immediate concern), not only occurs frequently but often at inconvenient hours, so that sometimes it is a matter of debate as to who is really in charge. From the pet's point of view the problems of obesity and lack of exercise afflict pets today, just as those matters often concern their owners. In addition, just as with humans, if a pet does not have to work for its dinner or get sufficient exercise it tends to become apathetic, and hence less healthy and less pleasing to its owner.
It is very easy for pets to over-eat because owners, with the best of intentions, tend to load the feeding dish with an excess of food and the pet, like some owners, tend to eat all that is put in front of it even after the need for additional sustenance actually has been satisfied.
It is therefore highly desirable to provide means by which the feeding of a pet is controlled without requiring the supervision of the owner and which is under the control of, and actually powered by, the pet itself.
SUMMARY OF THE INVENTION
The present invention accomplishes those ends by providing a supply of food, usually in the form of pellets or other particles, and dispensing that food to the pet only when the pet wants the food, requiring physical effort on the part of the pet to get the food, and with the amount of food to be provided entirely under the control of the pet. Consequently, the pet, after a brief period of training, will be able to control its own feeding without having to seek any assistance on the part of its owner, with physical effort being required on the part of the pet in order to gain access to the food. Optionally structure to inhibit ready access to the dispensed food may also be provided, providing an additional challenge and requiring additional physical activity on the part of the pet before the food particles may be obtained and eaten.
In accordance with the present invention the food particles are contained within a container capable of moving, preferably in full or limited rotation, and provided with one or more protrusions which the pet may engage with its paw to cause the container to move. The movement agitates the food pellets or other particles in the container and causes them to tend to escape from the containers through an opening at the rear of the container, from which the pellets drop to the area below the container to which the pet has access. The size of the exit opening or openings may be adjustable, thereby to vary the amount of food which will escape from the container opening or openings, for a particular movement thereof. In a preferred embodiment the container is so mounted and arranged that it has a preferred standby position from which it can be moved in either direction to only a limited extent, so that the feeding movement of the container is more readily controlled by the pet. As an added feature the device of the present invention may have a floor onto which the pellets fall from the container which may be corrugated and/or provided with spaced obstructions extending thereacross, thus presenting physical challenges to the pet to gain access to the food. In its preferred form the container is of drum-shape loaded from the top through a relatively wide opening which, when the cover provided is not in place, gives the pet access to the food in the container through that top opening, a feature helpful in training the pet to use the device. The drum is preferably mounted to rotate or oscillate about an axis which is slightly forwardly and upwardly inclined. This facilitates the escape of the food particles through the exit passage or passages in the back of the drum. The drum may be mounted on its axis so as to tend to come to a normal stationary position, as by being counterweighted or mounted on an axis offset from the center of the cross-section of the drum.
DESCRIPTION OF THE DRAWINGS
The preferred embodiments of the present invention as described in the appended detailed description are shown in the accompanying drawings, in which:
FIG. 1 is a three-quarter front perspective view of a preferred embodiment;
FIG. 2 is a three-quarter rear exploded perspective view of the embodiment of FIG. 1 ;
FIG. 3 is a fragmentary perspective view of the rear of a food container;
FIG. 4 is a side view of the embodiment of FIG. 1 partially broken away;
FIG. 5 is a view similar to FIG. 3 but showing the position of the parts when the feeder is to be deactivated;
FIG. 6 is a three-quarter perspective view showing one way in which a pet may manipulate the device to obtain food;
FIG. 7 is a view similar to FIG. 1 but showing an alternate embodiment of the invention; and
FIG. 8 is a three-quarter rear perspective exploded view of the embodiment of FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
In its preferred form, shown in FIGS. 1–6 , the feeder comprises a food container generally designated 2 mounted on a supporting structure generally designated 4 so as to pivot about an axis generally designated 6 . The supporting structure 4 which is here specifically disclosed comprises a floor 8 connected to an upstanding wall 10 . Extending out from the wall 10 and slightly inclined upwardly is a shaft 12 . The container 2 comprises a front wall 14 , a generally cylindrical side wall 16 and a rear wall 18 . The shaft 12 extends through the rear wall 18 into the interior of the container 2 , the rear wall being provided with a sleeve 20 through which the shaft 12 extends. Thus the container 2 is mounted on the upstanding wall 10 so as to be rotatable about the shaft 12 , which defines the axis 6 . The rear wall is provided with a food exit opening 34 at what will be its lower portion.
The rear wall 18 is provided on its exterior with a pair of cleats 22 , and the control piece 24 is designed to be slideable beneath the cleat 22 between upper and lower positions, as shown in FIGS. 4 and 5 , respectively, and as indicated by the arrows 26 to FIGS. 3 and 5 . The piece 24 is provided with an elongated slot 28 through which the shaft 12 passes, thus permitting and limiting the up and down movement of the piece 24 . The upper portion of the piece 24 is provided with a manually accessible part 30 for moving the piece 24 up and down. In its lower position, shown in FIG. 5 , the food exit opening 32 at the bottom of the piece and the food exit opening 34 in the rear wall 18 of the container 2 are out of alignment so that no food can escape through the opening 34 . However, when the piece 24 is in its upper position, as shown in FIGS. 2 and 6 , the openings 32 and 34 will register and food can then escape from the container 2 . Movement of the piece 24 need not be rectilinear to bring the two feed openings into and out of registration, and the piece 24 may have a plurality of different size openings 32 which, when selectively brought into registration with the feed opening 34 in the container, will produce different rates of food dispensing.
The cleats 22 are shown as provided with outstanding lugs 36 and 38 , and the upper portion 10 of the rear wall 10 is provided with ledges 40 , one on each side, in line with lugs 36 and 38 respectively. The container 2 is provided with outward protrusions 42 which, as shown in FIG. 6 , may be engaged by the pet's paw in order to turn the container 2 in one direction or the other, and in the embodiment of FIGS. 1–6 that movement will continue until one or the other of the lugs 36 or 38 engages a stop, here shown in the form of a ledge 40 , as shown in FIG. 6 . Since that limits rotation of the container 2 (180° of rotation is appropriate, but not required), the pet will release the protrusions 42 and the container 2 will then rotate back to its normal standby position, either because of the weight of the mass of food particles 42 in the container 2 or because the container may be counter-weighted or because the axis of shaft 12 is somewhat above the center of gravity of the container itself or because of some other arrangement. Thus for each manipulation of a protrusion 42 by the pet a small amount of food will escape from the container and fall onto the floor 8 as indicated by the food mass 44 in FIG. 4 .
As illustrated, the front wall 14 of the container 2 may be ornamental to represent the face of a cat, the protrusion 42 may simulate the cat's ears and the upstanding handle portion 30 of the piece 24 may simulate a cat's tail. Other forms of ornamentation will suggest themselves, preferably in the form of interchangeable panels or sheets.
As may best be seen in FIG. 2 , the container 2 is provided at its top with a large filling opening 46 with a slideable cover 48 . The opening 46 preferably extends substantially the full length of the container 2 not only to facilitate filling the container 2 with the desired amount of food particles, but also to assist in training the pet to use the device. At the outset the food particles will be placed in the container 2 and the cover 48 will be removed. This provides an opening through which the pet can see the food in the container 2 and through which the pet can insert its paw to get the food. In so doing it will usually cause the container 2 to rotate. This will cause some food to fall from the container 2 when the exit opening 34 is exposed, and the pet will thus learn that by turning the container 2 food is made available on the floor, where it is more readily available than in the container 2 . After a brief learning period the cover 48 will be put in place, and then the pet will use what it has learned to get food when the container 2 is moved.
While the device as thus far described will, particularly when the container cover 48 is in place, force the pet to “work for its dinner”, certain additional work-requiring features may be present. Thus, as shown in FIGS. 1 and 2 , the floor 8 may be provided with a corrugated upper surface 50 , and optional rods 52 may be mounted to extend over the floor 8 , with or without the corrugated surface 50 , as by passing through apertures 54 in side walls 56 upstanding from the floor 8 , thus making access to the food particles 44 on the floor more difficult to the pet. The periphery of the upstanding wall 4 on which the shaft 12 is mounted preferably tapers upwardly so that the pet has ready access to the protrusions 42 .
FIGS. 7 and 8 show an alternate embodiment of the present invention in which the container 2 1 is fully rotatable about the axis defined by the shaft 12 , in this instance the shaft 12 extends through the front wall 14 1 of the container 2 1 , the container 2 1 being retained on the shaft 12 by any appropriate structure, here shown as a nut 52 screwed onto the tip 54 of that shaft 12 . Because the container 2 1 is rotatable on the shaft 12 without restriction it is provided with protrusion 42 1 throughout its periphery. Its rear wall 18 1 is provided with one or more exit openings 34 1 , which may be of different sizes, and which are selectively provided with closing plugs 24 1 , selection of which of the plugs 24 1 to remove from the rear wall 18 1 determining the rate at which food will fall from the container 2 1 when it is rotated.
It will be understood that, particularly but not exclusively with the embodiment of FIGS. 7 and 8 , the supporting structure 4 as specifically disclosed may be completely eliminated, the supporting shaft 2 extending from any desired generally vertical supporting structure.
From the above it can be seen that the problems resulting from the tendency of pet owners to make food too easily available to their pets, and the problems involved in pets nagging their owners to feed them at inconvenient times are eliminated through use of the device disclosed. The pets must work for their food, but they do so on their own timetable and without inconveniencing their owners. Since they have to work for their food they will tend not to overeat, and hence the obesity problem is minimized. Moreover, because the pet must exercise its intellect in order to get fed the pet will tend to be more interested and therefore more interesting.
While but a limited number of embodiments have been here specifically disclosed, it will be apparent that many variations can be made therein, and that many of the disclosed features are optional and may be used in various combinations, all within the scope of the present invention as defined in the following claims.
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A pet feeding device comprising a container for pet food from which food is controllably provided through action by the pet itself in moving the container.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This is a U.S. national phase application under U.S.C. §371 of International Patent Application No. PCT/JP2006/324248 filed Dec. 5, 2006. The International Application was published on Jun. 12, 2008 as International Publication No. WO/2008/068845 under PCT Article 21(2) the contents of which are incorporated herein in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to a pallet conveyance device that moves pallets that support a substrate, and to substrate inspection device that contain this pallet conveyance device; and this substrate inspection device can be applied to a liquid crystal substrate inspection device for inspecting liquid crystal substrates used in liquid crystal displays, organic EL displays, and the like.
BACKGROUND OF THE INVENTION
[0003] Liquid crystal substrates and thin film transistor array substrates (TFT array substrate) constitute TFT arrays, in which thin film transistors (TFT) are arranged in a matrix shape on a substrate such as glass substrate, and signal electrodes that supply drive signals to these thin film transistors; and the thin film transistors are driven by signals from scanning signal electrode terminals and video signal electrode terminals.
[0004] Substrate inspection devices such as TFT array inspection devices and liquid crystal substrate inspection devices are known as devices that inspect TFT arrays formed on substrate and liquid crystal substrates. Substrate inspection devices are composed of probers and an inspection circuit for inspecting the electrical connections of scan signal electrode terminals and video signal electrode terminals. The inspection circuit applies a specified voltage to the inspection probers, detects the flow of current caused by that application of voltage, and investigates for short circuits between the gate and source, point defects, disconnected lines, and the like.
[0005] TFT arrays formed on liquid crystal substrate come in a variety of sizes and specifications, differ in layouts, and have differing drive electrodes formed on the liquid crystal substrate depending on the layout. For those reasons, substrate inspection devices used to inspect liquid crystal substrate set up the electrode positions of the inspection prober electrodes corresponding to the TFT array layout, and inspections are conducted by substituting these positions corresponding to the liquid crystal substrate to be inspected.
[0006] When inspecting liquid crystal substrates, a prober frame is stacked from above or below the liquid crystal substrate, the probe pins provided on the prober frame make contact with the electrodes of the liquid crystal substrate, and this contact between the probe pins and the electrodes makes electrical contact between the liquid crystal substrate and the prober.
[0007] Inspection of semiconductor substrates, which is not limited to the liquid crystal substrate described above, is conducted in an inspection chamber. To inspect substrate in this inspection chamber, the substrate is mounted on a pallet, this pallet is conveyed from a load lock chamber into the inspection chamber, and the inspected substrate is discharged together with the pallet.
[0008] Pallets can be conveyed between the inspection chamber and the load lock chamber by conveyance rollers provided respectively in the inspection chamber and the load lock chamber. By providing conveyance rollers in these chambers, the pallets can be moved in the chambers, and the pallets can be transferred between the inspection chamber and the load lock chamber.
[0009] In order to heighten the efficiency of substrate conveyance in the inspection process, a configuration can be adopted in which several pallets are arranged up and down in the load lock chamber, and pallets are switched with the conveyance rollers by moving the pallets up and down.
[0010] When moving the pallets up and down to switch the pallets with conveyance rollers, the pallets accelerate when changing from a static state to a drive state, or when changing from a drive state to a static state. Meanwhile, when a substrate is mounted on a pallet, the substrate is no more than simply placed on the pallet, and therefore, when the pallet is moving, the inertia of the substrate generates a discrepancy between the movement of the pallet and the movement of the substrate, and the substrate is subjected to impact.
[0011] In this kind of configuration, when heightening the velocity of the up and down movement of the pallet in order to quicken the substrate conveyance process and to improve the processing approach of the substrates, acceleration of pallets becomes greater. Therefore, the substrates are subjected to a greater impact and there is the risk of substrates being damaged by this impact.
[0012] Thus, to address the aforementioned problems of the past, an object of the present invention is to reduce damage to substrates caused by impact generated by pallet drive when conveying substrates using pallets in pallet conveyance devices and in substrate inspection devices containing pallet conveyance devices.
SUMMARY OF THE INVENTION
[0013] In addition to a mechanism to move the pallets that support the substrate, the pallet conveyance device of the present invention is also equipped with a lifting mechanism to move the pallets up and down. This lifting mechanism is equipped with an impact cushioning mechanism that cushions the impact to which the substrate that is supported on the pallet is subjected during the lifting operation.
[0014] As previously described, when moving a pallet up and down using a lifting device, the inertia of the substrate generates a discrepancy between the movement of the pallet and the movement of the substrate, and may thereby be subjected to impact.
[0015] For example, if a pallet on which a substrate is mounted is lifted by a lifting mechanism, the velocity of the pallet is decelerated when stopping the lifting operation, but the velocity of the substrate mounted on the pallet is maintained by inertia at that time. For that reason, the substrate moves in a direction to separate from the pallet, and afterwards lands on the pallet by the force of gravity. The substrate is impacted by the pallet at this time.
[0016] Moreover, when the lifting mechanism lowers a pallet on which a substrate is mounted, the velocity of the pallet is accelerated downward from the stop position, and the substrate mounted on the pallet attempts to remain stationary at that time by the force of inertia. For that reason, the substrate temporarily moves toward separation from the pallet, and afterward lands on the pallet by the force of gravity. At that time, the substrate is impacted by the pallet.
[0017] In operations when the pallet impacts the substrate as described above, the impact cushioning mechanism of the present invention cushions the impact imparted to the substrate supported on the pallet by controlling the lifting operation of the lifting mechanism.
[0018] The impact cushioning mechanism of the present invention is a mechanism that switches the drive velocity of the lifting mechanism, switches the drive velocity of the pallet to low speed after beginning operation and before ending operation of the lifting mechanism, and switches the drive velocity of the pallet to high speed in drive periods other than the low speed periods. Here, the periods of switching the pallet drive velocity to low speed are the periods when the velocity changes during start up and termination of the drive operation, and are the periods when velocity discrepancies are generated between the pallet and the substrate. In this period the extent of velocity change is reduced and the positional discrepancy between the pallet and substrate is decreased by decelerating the pallet drive velocity, thereby reducing the impact on the substrate.
[0019] For example, during the lifting operation of the lifting mechanism, the lifting operation is begun at the high-speed drive velocity and the drive velocity is switched to low-speed prior to completing the lifting operation. By switching and controlling this drive velocity in the lifting operation of the lifting mechanism, the pallet drive velocity is decreased prior to stopping the lifting operation, and the impact imparted to the substrate when stopping the pallet can be reduced by conducting the stop operation from the low-speed state. Further, when beginning the lifting operation, upward facing force acts on the substrate from the pallet, and therefore there is little velocity discrepancy between the substrate and the pallet and no impact is imparted to the substrate by positional discrepancy between the pallet and the substrate.
[0020] Meanwhile, during the lowering operation of the lifting mechanism, the lowering operation is begun at the low-speed drive velocity, and then after having passed through a specified period from the beginning of the lowering operation, the drive velocity is switched to high-speed. By switching and controlling this drive velocity in the lowering operation of the lifting mechanism, the impact imparted to the substrate when lowering the pallet can be reduced by decelerating the pallet drive velocity when beginning the lowering operation.
[0021] Further, when stopping the lowering operation, upward facing force acts from the pallet to the substrate, and therefore there is little velocity discrepancy between the substrate and the pallet and no impact is imparted to the substrate by positional discrepancy between the pallet and the substrate.
[0022] An air cylinder mechanism that is driven by pneumatic pressure is used as one configuration of the lifting mechanism of the present invention. This impact cushioning mechanism has two compressed air line systems, a high-speed compressed air line and a low-speed compressed air line, which supply gas at differing flow rates into the air cylinder mechanism.
[0023] In these 2 compressed air line systems the flow rate of gas that the low-speed compressed air line supplies to the air cylinder mechanism is set up to be less than the flow rate of gas that the high-speed compressed air line supplies to the air cylinder mechanism.
[0024] When supplying gas to the air cylinder system using the low-speed compressed air line, the supply rate of gas supplied to the air cylinder mechanism per unit time is small, and therefore the drive velocity of the air cylinder mechanism is low-speed, and the movement velocity of the pallet that is driven by this air cylinder is low-speed. Meanwhile, when supplying gas to the air cylinder system using the high-speed compressed air line, the supply rate of gas supplied to the air cylinder mechanism per unit time is large compared to that of the low-speed compressed air line, and therefore the drive velocity of the air cylinder mechanism is high-speed, and the movement velocity of the pallet that is driven by this air cylinder is high-speed.
[0025] The lifting mechanism is not limited to the aforementioned air cylinder mechanism, and may be a motor-driven mechanism ancillary to the device. In a motor-driven mechanism, for example, adjusting the drive current can control the pallet movement velocity.
[0026] Moreover, the impact to the substrate is cushioned by switching the pallet drive velocity between high speed and low speed; and the pallet conveyance time can be shortened and the substrate conveyance time can be shortened by switching to high-speed drive.
[0027] The lifting mechanism of the present invention can be applied to pallet conveyance devices that move multiple pallets supporting substrates. In this aspect, the device is composed of the aforementioned lifting mechanism and of a conveyance mechanism that moves one of the multiple pallets horizontally. The lifting mechanism can individually move the multiple pallets up and down or can move and switch a pallet to and from the conveyance mechanism, and the pallet is moved and switched by moving up and down and to and from the conveyance mechanism.
[0028] Further, the pallet conveyance device of the present invention can be applied to a substrate inspection device. In the aspect of a substrate inspection device of the present invention, the substrate inspection device is composed of an inspection chamber for inspecting substrates, and a load lock chamber for conveying substrates to and from the inspection chamber; and the load lock chamber constitutes the pallet conveyance device of the present invention. The conveyance mechanism is composed of a first set of conveyance rollers provided in an inspection chamber for inspecting substrates, and a second set of conveyance rollers provided in the load lock chamber for conveying substrates in and out of the inspection chamber. The multiple pallets that the lifting mechanism supports in the load lock chamber are conveyed to and from the first set of conveyance rollers by sharing the second set of conveyance rollers.
[0029] When conveying substrates using pallets, a pallet conveyance device according to the present invention, and a substrate inspection device composed of this pallet conveyance device, can reduce substrate damage caused by impact generated by pallet drive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a schematic diagram for explaining a pallet conveyance device of the present invention and a substrate inspection device composed of this pallet conveyance device;
[0031] FIG. 2 is a diagram for explaining an example of the configuration of a lifting mechanism of the present invention;
[0032] FIG. 3 is a flowchart for explaining the low-speed switching operation when operation of the lifting mechanism of the present invention is stopped;
[0033] FIGS. 4( a )- 4 ( d ) are operational diagrams for explaining low-speed switching operations while stopping during the lifting operations of the lifting mechanism of the present invention;
[0034] FIGS. 5( a )- 5 ( d ) are operational diagrams for explaining the low-speed switching operations while starting during lowering the lowering operations of the lifting mechanism of the present invention;
[0035] FIGS. 6( a )- 6 ( c ) are diagrams for explaining the drive of just the high-speed line;
[0036] FIGS. 7( a )- 7 ( e ) are perspective diagrams for explaining an example of the operation of the conveyance mechanism and lifting mechanism of the present invention;
[0037] FIGS. 8( a )- 8 ( c ) are cross-sectional diagrams for explaining an example of the operation of the conveyance mechanism and lifting mechanism of the present invention;
[0038] FIGS. 9( a )- 9 ( c ) cross-sectional diagrams for explaining an example of the operation of the conveyance mechanism and lifting mechanism of the present invention;
[0039] FIG. 10 is a flowchart for explaining an example of the operation of the pallet conveyance device of the present invention;
[0040] FIG. 11 is a flowchart for explaining an example of the operation of the pallet conveyance device of the present invention;
[0041] FIGS. 12( a )- 12 ( d ) are operational charts for explaining an example of the operation of the pallet conveyance device of the present invention;
[0042] FIGS. 13( a )- 13 ( d ) are operational charts for explaining an example of the operation of the pallet conveyance device of the present invention;
[0043] FIGS. 14( a )- 14 ( d ) are operational charts for explaining an example of the operation of the pallet conveyance device of the present invention;
[0044] FIGS. 15( a )- 15 ( e ) are operational charts for explaining an example of the operation of the pallet conveyance device of the present invention;
[0045] FIGS. 16( a )- 16 ( d ) are operational charts for explaining an example of the operation of the pallet conveyance device of the present invention;
[0046] FIGS. 17( a )- 17 ( c ) are operational charts for explaining an example of the operation of the pallet conveyance device of the present invention;
[0047] FIGS. 18( a )- 18 ( c ) are operational charts for explaining an example of the operation of the pallet conveyance device of the present invention;
[0048] FIGS. 19( a )- 19 ( c ) are operational charts for explaining an example of the operation of the pallet conveyance device of the present invention; and
[0049] FIGS. 20( a )- 20 ( c ) are operational charts for explaining an example of the operation of the pallet conveyance device of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0050] Aspects of implementing the present invention will be explained in detail below while referring to the diagrams.
[0051] FIG. 1 is a schematic diagram for explaining a pallet conveyance device of the present invention and a substrate inspection device composed of this pallet conveyance device. Further, part of the configuration of the substrate inspection device is also indicated here.
[0052] A substrate inspection device 100 is composed of an inspection chamber 3 where the introduced substrate (not indicated in the diagram) is inspected, a load lock chamber 2 from which the substrates are conveyed into and out of the inspection chamber 3 , and a gate valve 4 that can freely seal and open between the inspection chamber 3 and the load lock chamber 2 .
[0053] The inspection chamber (MC) 3 is a chamber for inspecting semiconductor substrate such as liquid crystal substrate, and the substrate, which is mounted on a pallet, is conveyed onto the conveyance rollers 31 inside the inspection chamber though the gate valve 4 . The substrate that has been conveyed into inspection chamber 3 is inspected, and after inspection has ended, the substrate, which is mounted on a pallet, is conveyed out through the gate valve 4 by the conveyance rollers 31 .
[0054] An example of the inspection of a liquid crystal substrate conducted in the inspection chamber will be explained below. Further, the configuration to be explained below is not indicated in FIG. 1 .
[0055] The liquid crystal substrate inspection device is composed of a charged particle source that irradiates a charged particle beam on the liquid crystal substrate targeted for inspection, a detector that detects secondary electrons emitted from the liquid crystal substrate based on the irradiation of these charged particles, and other parts such as a stage that supports and two-dimensionally scans the liquid crystal substrate targeted for inspection; and substrate inspection is conducted based on scan images obtained by the detector.
[0056] The liquid crystal substrate constitutes, for example, a TFT array formed on a glass substrate. The layout, electrodes, routing pattern, and the like of the TFT array formed on this liquid crystal substrate may be set up in a variety of ways corresponding to the size of the liquid crystal panel and the specifications. Thin film transistors formed in a matrix and signal electrode terminals (for example, scan signal electrode terminals, video signal electrode terminals), which drive the thin film transistors, are formed in the TFT array on the liquid crystal substrate. Moreover, an electrode is formed outside of the array on the liquid crystal substrate for electrically connecting with a unit exterior to the liquid crystal substrate.
[0057] In addition, the liquid crystal substrate inspection device is composed of a prober (not indicated in the diagram) that supplies inspection signals to the liquid crystal substrate. The prober is composed of a prober frame (not indicated in the diagram) for electrically connecting with the electrodes of the liquid crystal substrate and conducting inspections, and of probe pins (not indicated in the diagram) for electrically connecting with the electrodes of the liquid crystal substrate.
[0058] In order to inspect the liquid crystal substrate, the probe frame is arranged on the liquid crystal substrate that is mounted on a pallet. The probe pins coming into contact with the electrodes make an electrical connection between the liquid crystal substrate and the prober frame, and inspection signals are supplied to the TFT array through the connection between the probe pins and the electrodes. Moreover, the connection between the prober framer and the pallet or stage is made by a connector (not indicated in the diagram) provided on the prober frame and the pallet.
[0059] Further, the pallet can move freely by being mounted on a stage (not indicated in the diagram). The electrical connection between the pallet and the stage can be made by a pallet-side connector provide on the pallet and a stage-side connector provided on the stage side.
[0060] The inspection device and the conveyance rollers 31 provided inside the inspection chamber 3 are controlled by an inspection device control unit 43 , which is controlled by a control unit 40 .
[0061] The load lock chamber 2 is a chamber where substrates are introduced from the outside, substrates mounted on a pallet are conveyed into the inspection chamber 3 , inspected substrates mounted on pallets are conveyed out from the inspection chamber 3 , and the substrates are returned to the outside; and load lock chamber 2 has a configuration in which multiple pallets can be arranged up and down in order to efficiently convey substrates in and out of the inspection chamber 3 .
[0062] A pallet conveyance device 1 , which moves the multiple pallets horizontally as well as up and down, is provided inside the load lock chamber 2 . This pallet conveyance device 1 is composed of a conveyance mechanism 10 , which has a set of conveyance rollers 11 that moves pallets horizontally and conveys pallets in and out of the inspection chamber 3 , and a lifting mechanism 20 that moves and switches pallets with the conveyance rollers 11 by moving pallets up and down.
[0063] The conveyance rollers 11 of the conveyance mechanism 10 constitute a mechanism that moves pallets horizontally in the load lock chamber 2 , and conduct operations to introduce and discharge substrates between the load lock chamber 2 and the outside, and operations to convey substrates in and out of the inspection chamber 3 . This conveyance mechanism 10 is controlled by a conveyance roller control unit 41 that is controlled by a control unit 40 .
[0064] The lifting mechanism 20 is provided above and below with multiple pallet support parts 22 A, 22 B that support pallets, and is driven by an air cylinder mechanism (not indicated in FIG. 1 ) by pneumatic pressure. The air cylinder mechanism of this lifting mechanism switches lifting velocities using an impact cushioning mechanism 24 . Switching lifting velocities using this impact cushioning mechanism 24 is conducted by switching the flow rate of gas supplied to the air cylinder. This lifting mechanism 20 is controlled by controlling the impact cushioning mechanism 24 using a lifting mechanism control unit 42 that is controlled by the control unit 40 .
[0065] Moreover, the gate valve 4 , which opens and closes between the load lock chamber 2 and the inspection chamber 3 is controlled by a valve control unit 44 that is controlled by the control unit 40 .
[0066] An example of a configuration of the lifting mechanism 20 will be explained using FIG. 2 . Further, one of the multiple pallet support parts 22 provided in the lifting mechanism 20 is indicated in FIG. 2 .
[0067] The lifting mechanism 20 is composed of multiple pallet support parts 22 that support a pallet and a mount 21 that maintains the aforementioned pallet support parts 22 for being driven up and down. The air cylinder 23 freely moves the mount 21 up and down.
[0068] This air cylinder drives by being supplied gas from a gas supply source (not indicated in the diagram) through the impact cushioning mechanism 24 . The impact cushioning mechanism 24 is composed of a high-speed compressed air control circuit 24 a , which configures a high-speed line, and a low-speed compressed air control circuit 24 b , which configures a low-speed line; and the lifting velocities of the mount 21 and the pallet support parts 22 are controlled by switching between the high-speed line and the low-speed line.
[0069] The high-speed compressed air control circuit 24 a is configured by a linear connection of a electromagnetic valve 25 a and a flow rate adjuster 26 a , while the low-speed compressed air control circuit 24 b is configured by a linear connection of a electromagnetic valve 25 b and a flow rate adjuster 26 b.
[0070] One or the other of the high-speed line or the low-speed line is connected to the air cylinder 23 by exclusively switching between the electromagnetic valve 25 a and the electromagnetic valve 25 b . The flow rate regulator 26 a and the flow rate regulator 26 b regulate the flow rate of the gas supplied to the air cylinder 23 . The flow rate regulator 26 a of the high-speed compressed air control circuit 24 a regulates the flow rate such that more gas is supplied than with the flow rate regulator 26 b of the low-speed compressed air control circuit 24 b . The air cylinder 23 drives at a speed corresponding to the flow rate set up by the flow rate regulator 26 a or the flow rate regulator 26 b.
[0071] Further, the configuration of the lifting mechanism 20 indicated in FIG. 2 indicates that the air cylinder 23 has mainly been driven upward by the compressed air supplied by the high-speed line or the low-speed line.
[0072] Meanwhile, the air cylinder 23 can be driven downward by reducing the pressure in the air cylinder 23 , and the lowering velocity can be controlled by adjusting the flow rate by which gas inside the cylinder 23 is suctioned. The suctioning flow rate can be regulated by connecting a suction pump through the linear connection of the electromagnetic valve and the flow rate regulator in the same way as the impact cushioning mechanism 24 . In this case as well, a high-speed line and a low-speed line with differing flow rates based on regulation by flow rate regulators are provided, and the downward drive velocity of the air cylinder 23 can be switched by exclusively selecting the high-speed line or the low-speed line.
[0073] Next, the operation of the impact cushioning mechanism will be explained using FIG. 3 through FIG. 6 .
[0074] FIG. 3 is a flowchart of the low-speed switching operation when operation of the cylinder is being stopped, and FIG. 4 is an example of low-speed switching operations when operation of the cylinder is being stopped. This example is applicable to impact cushioning when raising a pallet. An example of the operation when raising a pallet will be described below.
[0075] When raising begins (S 1 ), the air cylinder 23 is driven from the low position of the mount 21 by the high-speed line (A in FIG. 4( a )), and the mount 21 rises at high speed (B in FIG. 4( c )). Operation of the high-speed line is conducted by leaving the electromagnetic valve 25 b of the low-speed compressed air control circuit 24 b shut, and releasing the electromagnetic valve 25 a of the high-speed compressed air control circuit 24 a thereby supplying gas (for example, air) into the air cylinder 23 at a high flow rate (S 2 ).
[0076] As this mount 21 begins to rise, the pallet accelerates rapidly (C in FIG. 4( d )), but no positional discrepancy between the pallet and the pallet support part is generated because this acceleration works in the direction of pushing the pallet onto the pallet support part.
[0077] Immediately before stopping the air cylinder 23 (S 3 ), the air cylinder 23 is driven by switching from the high-speed line to the low-speed line (D in FIG. 4( b )), and the mount 21 is switched to low-speed (E in FIG. 4( c )). Operation of the low speed line is conducted by closing the electromagnetic valve 25 a of the high-speed compressed air control circuit 24 a , opening the electromagnetic valve 25 b of the low-speed compressed air control circuit 24 b , and lowering the flow rate of gas (for example, air) supplied to the air cylinder 23 (S 4 ).
[0078] When stopping the mount 21 , the velocity of the pallet support part is lower than that of the pallet mounted thereon, which attempts to maintain velocity through inertia, and therefore that lower velocity operates in a direction to create a positional discrepancy between the pallet and the pallet support part. By switching to this low-speed line, however, the force operating to make the pallet float up from the pallet support part becomes small compared to the force of gravity, and no positional discrepancy is generated between the pallet and the pallet support part.
[0079] When lifting reaches the end position (S 5 ), the electromagnetic valve 25 b of the low-speed line is closed, and the gas supply to the air cylinder 23 is stopped (S 6 ).
[0080] FIG. 5 is an example of the operation of switching to low speed when beginning operation of the cylinder, and can be applied to cushioning impact when lowering the pallet. An example of the operation to lower pallets will be explained below.
[0081] When lowering pallets, with the mount 21 in the upper position, the air cylinder 23 is driven by the low-speed line (G in FIG. 5( a )), and the mount 21 is lowered at low speed (H in FIG. 5( c )). Operation of the low-speed line is conducted by leaving the electromagnetic valve 25 a of the high-speed compressed air control circuit 24 a shut, and releasing the electromagnetic valve 25 b of the low-speed compressed air control circuit 24 b thereby limiting the flow rate of gas into the air cylinder 23 .
[0082] When beginning to lower mount 21 , the mount operates in a direction to create a positional discrepancy between the pallet and the pallet support part. However, the pallet accelerates slowly (I in FIG. 5( d )), and the force operating to cause the pallet to fly up from the pallet support part is small compared to the force of gravity, and therefore, no positional discrepancy is generated between the pallet and the pallet support part.
[0083] After the air cylinder 23 begins to descend, the air cylinder is driven by switching from the low-speed line to the high-speed line (J in FIG. 5( a )), and the mount 21 is switched to high speed (K in FIG. 5( c )). Operation of the high-speed line is conducted by closing the electromagnetic valve 25 b of the low-speed compressed air control circuit 24 b , opening the electromagnetic valve 25 a of the high-speed compressed air control circuit 24 a , and increasing the flow rate of gas (for example, air) supplied into the air cylinder 23 .
[0084] When stopping the mount 21 (M in FIG. 5( a )), the velocity of the pallet support part is lowered in relation to that of the pallet mounted thereon, which attempts to maintain velocity through inertia (N in FIG. 5( c )). That acceleration operates in a direction to press the pallet onto the pallet support part (O in FIG. 5( d )), and therefore no positional discrepancy is generated between the pallet and the pallet support part.
[0085] FIG. 6 is a diagram for explaining the drive of just the high-speed line without using the impact cushioning mechanism to switch between the high-speed line and the low-speed line.
[0086] With the mount 21 in the low position, the air cylinder 23 is driven by the high-speed line (P in FIG. 6( a )), and the mount 21 is driven at high speed (Q in FIG. 6( b )). When beginning to drive this mount 21 , the pallet is accelerated rapidly (R in FIG. 6( c )). In addition, when stopping the air cylinder 23 (S in FIG. 6( a ) and T in FIG. 6( b )), the pallet is also accelerated rapidly (U in FIG. 6( c )).
[0087] As described above, when driven only by the high-speed line, the pallet undergoes great acceleration when beginning drive and when stopping drive. If the direction of this acceleration is opposite to the direction of gravity, the substrate mounted on the pallet moves in a direction of separation from the pallet because of inertia, and a positional discrepancy may be generated between the pallet and the pallet support part.
[0088] In contrast, as indicated in FIG. 4 and FIG. 5 , the acceleration to which the pallet is subjected is decreased by switching to the low-speed line, and even if the substrate mounted on the pallet moves in the direction of separation because of inertia, no positional discrepancy between the pallet and the pallet support part is generated.
[0089] Next, in an operational example of the conveyance mechanism 10 and the lifting mechanism 20 , the operation of placing a pallet on the conveyance rollers after having been lifted by the lifting mechanism 20 will be explained using FIG. 7 to FIG. 9 . Further, FIG. 7 is a perspective drawing, and FIG. 8 and FIG. 9 are cross-sectional diagrams.
[0090] Initially, let the pallet support parts 22 be positioned below the conveyance rollers 11 , and let a pallet 50 be supported on these pallet supports 22 . At this time, the space between the conveyance rollers 11 on the two sides is the distance at which pallet 50 is placed ( FIG. 7( a ), FIG. 8( a )). Because the space between the conveyance rollers 11 on the two sides is the distance at which pallet 50 is placed, if the pallet 50 , which is supported on the pallet support parts 22 , is lifted by the lifting mechanism 20 in this state, the pallet 50 will bump into the conveyance rollers 11 . Therefore, pallet 50 cannot be placed on the conveyance rollers 11 .
[0091] Thus, the conveyance rollers 11 are moved to the outside, broadening the space between the rollers, such that the pallet support parts 22 and the pallet 50 can pass between the rollers ( FIG. 7( b ), FIG. 8( b )). After the distance between the rollers has been widened, the pallet support parts 22 are raised by the lifting mechanism 20 and pass between the rollers, and the pallet 50 is moved to a position above the conveyance rollers 11 ( FIG. 7( c ), FIG. 8( c )). After the pallet support parts 22 and the pallet 50 have been moved to a position above the conveyance rollers 11 , the space between the roller is narrowed by moving the conveyance rollers 11 to the inside, setting up a space at which the pallet 50 can be placed on the conveyance rollers 11 ( FIG. 7( d ), FIG. 9( a )). Afterwards, the pallet support parts 22 are lowered, and the pallet 50 is placed on the conveyance rollers 11 ( FIG. 7( e ), FIG. 9( b )). After the pallet 50 is supported on the conveyance rollers 11 , the pallet support parts 22 can be lowered further, and the pallet 50 can be conveyed by the conveyance rollers 11 ( FIG. 9( c )).
[0092] Next, an example of the operation of a pallet conveyance device of the present invention will be explained using the flowcharts in FIG. 10 and FIG. 11 , and the operational explanatory diagrams in FIG. 12 to FIG. 20 .
[0093] In one embodiment the conveyance device 10 in the load lock chamber 2 is provided with one set of conveyance rollers 11 , two pallets are housed positioned above and below, and pallet switching is conducted to and from conveyance rollers 11 . Moreover, as the initial state, assume that inside the 2 pallet support parts provided inside the load lock chamber two the upper pallet 50 u is supported on the upper pallet support part, no pallet is supported on the lower pallet support part, nor is a pallet housed inside the inspection chamber 3 . Further, assume that the upper pallet 50 u is positioned above the conveyance rollers 11 .
[0094] Initially, the upper pallet 50 u is lowered by driving the lifting mechanism 20 , and the substrate 60 to be supported is placed on the upper pallet 50 u (S 11 ) ( FIG. 12( a )). Gate valve 4 is opened, the conveyance rollers 11 are driven, and the upper pallet 50 u mounted on the conveyance rollers 11 is conveyed from the load lock chamber 2 into the inspection chamber 3 . At that time, the lower pallet 50 d is supported in a position below the conveyance rollers 11 (S 12 ) ( FIG. 12( b )).
[0095] After the upper pallet 50 u has been conveyed into the inspection chamber 3 , the gate valve 4 is closed, and the substrate 60 mounted on the upper pallet 50 u is inspected inside the inspection chamber 3 (S 13 ) ( FIG. 12( c ), FIG. 17( a )).
[0096] While substrate inspection is being conducted in the inspection chamber 3 , on the load lock chamber 2 side preparations are being conducted to convey the lower pallet 50 d into the inspection chamber 3 .
[0097] In the load lock chamber 2 the rollers of the conveyance rollers 11 are moved to the outside to widen the distance between rollers so that the lower pallet 50 d can be moved upward between the rollers of the conveyance rollers 11 (S 14 ) ( FIG. 17( b )). The lower pallet 50 d is raised and passed through the spread rollers of the conveyance rollers 11 (S 15 ) ( FIG. 12( d ), FIG. 17( c )).
[0098] A substrate targeted for inspection is introduced from the outside, and is placed on the lower pallet 50 d that has been raised above the conveyance rollers 11 (S 16 ) ( FIG. 13( a ), FIGS. 18( a ), ( b )).
[0099] After substrate inspection has been completed in the inspection chamber 3 , the gate valve 4 is opened, the upper pallet 50 u is conveyed from the inspection chamber 3 to load lock chamber 2 through this gate valve 4 (S 17 ) ( FIG. 13( b ), FIG. 18( c )). After the upper pallet 50 u that has been conveyed out has been moved onto the conveyance rollers 11 in the load lock chamber 2 , the gate valve 4 is closed (S 18 ) ( FIG. 13( c )).
[0100] The upper pallet 50 u is moved and switched onto the conveyance rollers 11 . The moving and switching onto the conveyance rollers 11 can be conducted by supporting the upper pallet 50 u using the pallet support part ( FIGS. 19( a ), ( b )), and then moving the rollers outward ( FIG. 19( c )).
[0101] After the upper pallet 50 u has been lowered through the opened rollers (S 19 ) ( FIG. 20( a )), the rollers of the conveyance rollers 11 are moved to the inside (S 20 ) ( FIG. 20( b )), the lower pallet 50 d is lowered and placed on the conveyance rollers 11 (S 21 ) ( FIG. 13( d ), FIG. 20( b )).
[0102] The gate valve 4 is opened, and the lower pallet 50 d is conveyed into the inspection chamber 3 through this gate valve 4 (S 22 ) ( FIG. 14( a ), FIG. 20( c )). After the lower pallet 50 d has been conveyed into the inspection chamber 3 , the substrate is inspected inside the inspection chamber 3 (S 23 ) ( FIG. 14( b )).
[0103] While the substrate mounted on the lower pallet 50 d is being inspected in the inspection chamber 3 , in the load lock chamber 2 , the upper pallet 50 u is raised ( FIG. 14( c )), and the inspected substrate mounted on the upper pallet 50 u is discharged (S 25 ) ( FIG. 14( d )). A substrate targeted for inspection is introduced and placed on the upper pallet 50 u (S 26 ) ( FIG. 15( a )).
[0104] Moving the rollers of the conveyance rollers 11 on the load lock chamber 2 side to the outside to widen the distance between rollers makes it possible for the upper pallet 50 u to move up and down through the rollers of the conveyance rollers 11 by (S 27 ). The upper pallet 50 u is then lowered and passed through the spread rollers of the conveyance rollers 11 (S 28 ) ( FIG. 15( b )).
[0105] Gate valve 4 is opened, the lower pallet 50 d in the inspection chamber 3 is conveyed out from the inspection chamber 3 into the load lock chamber 2 (S 29 ) ( FIG. 15( c )), and gate valve 4 is closed (S 30 ) ( FIG. 15( d )). The lower pallet 50 d is raised by the lifting mechanism 20 on the load lock chamber 2 side ( FIG. 16( a )), and the inspected substrate is discharged to the outside ( FIG. 16( b )) (S 31 ). A substrate targeted for inspection is introduced and placed on the lower pallet 50 d (S 32 ) ( FIGS. 16( c )), ( d )).
[0106] Further, in the example of the above configuration, an air cylinder mechanism was used as the lifting mechanism, but the present invention is not limited to an air cylinder mechanism. A mechanism driven by a motor ancillary to the conveyance device may also be used, and switching the pallet movement velocity between high-speed and low-speed may be controlled by regulating the drive current.
[0107] The pallet conveyance device of the present invention is not limited to conveyance of liquid crystal substrates, and can be applied to conveyance of semiconductor substrates.
[0108] The substrate inspection device of the present invention is not limited to inspection of liquid crystal substrates, and can be applied to inspection of semiconductor substrates.
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A pallet conveyance device has, besides a mechanism for moving a pallet for supporting a substrate, a lifting mechanism for vertically moving the pallet. The lifting mechanism has an impact cushioning mechanism for cushioning an impact applied to the substrate supported on the pallet. When an impact is applied to the substrate from the pallet, the impact cushioning mechanism controls a vertical motion of the lifting mechanism to cushion the impact applied to the substrate supported on the pallet. The impact cushioning mechanism is a mechanism that changes the drive speed of the lifting mechanism. The impact cushioning mechanism changes the drive speed to a low speed at at least either the start of operation of the lifting mechanism or before the end of the operation, and in a drive period excluding a low speed period, the impact cushioning mechanism changes the drive speed to a high speed.
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BACKGROUND OF INVENTION
The invention relates to a method and apparatus for correcting DC offset problems found in high-speed transceiver systems.
Conventional transceiver systems commonly must switch back and forth between transmit and receive modes. As the speed of data transmission increases, the time allowed for switching between the Transmit (Tx) and Receive (Rx) modes becomes smaller. One conventional type of receiver is known as a Direct Conversion zero intermediate frequency (IF) receiver. In this type of receiver a local oscillator is tuned to the carrier frequency of the incoming signal. These types of receivers commonly have multiple stages in which the incoming signal is down converted and processed using a local oscillator (LO) circuit. These IF type receivers create in phase (I) and 90 degrees out of phase quadrature (Q) signals from the received signal. Large DC offsets are produced in the down converter outputs of Zero IF receivers due to LO leakage at the RF ports of the down converters. Additional DC offsets exist along the I and Q paths that include low-pass channel filters and automatic gain control (AGC) circuits with large gains. Therefore each of these DC coupled stages introduces a DC offset error into the signal. In an orthogonal frequency division multiplexing (OFDM) system, a difference between the local oscillator (LO) frequency and the incoming signal frequency causes DC offset errors within the system to profoundly degrade the SNR after demodulation. These unwanted DC errors may also cause the amplifiers used in the I and Q branches to saturate. Once the amplifier is in a saturated state, the received data signal cannot be processed and amplified correctly so the received data signal is lost.
Prior art attempts to deal with the above problems have been only semi-successful. Stroet et al.'s article entitled “A Zero-IF Single Chip Transceiver for up to 22 Mb/s QPSK 802.11b Wireless LAN” shows that these offset errors may be reduced or settled in 25 microseconds. The reduced DC offset is still too high for OFDM systems and takes too long to settle. As mentioned above, with an increase in data speeds, this prior art system is not useable in today's transceiver environments.
All known prior art techniques used to reduce these DC offset errors have drawbacks in one form or another. For example, AC coupling signals with high frequency cut off values may reduce response time, but has an unacceptable signal to noise ratio or an unacceptable effect on the signal itself Further, automatic gain control is also only useable when the DC offset level is very small. The end result is that these DC offset values can not be reduced in an acceptable amount of time.
SUMMARY OF THE INVENTION
The instant invention uses an automatic gain controller AGC and a digital signal processor along with zero IF transceiver circuitry to create I and Q signals to process and remove DC offset signals in acceptable time periods. Using a combination of techniques such as AC and DC coupling, automatic gain control, and digital signal processing, the DC offsets are removed to insignificant levels. The main features or steps of the invention are: 1) dynamically changing the cut off frequency of an AC coupling stage; 2) computing a DC signal error over a time period in which the I and Q signals complete a single or multiple cycles, 3) subtracting the estimated DC errors from the I and Q signals, and 4) high-pass filtering the resultant signal so that residual DC errors are removed. The implementation and timing of these steps allows for DC offset control that is far superior to prior art systems.
In a second embodiment a D/A converter is used in each of the I and Q branches to significantly reduce the DC offset, and then steps 2 – 4 as mentioned above are followed. The DSP does a coarse DC correction with the D/A converter, and maintains a list of correction values for all combinations of antenna diversity, LNA amplifier gains and AGC gains. This ensures that DC offset correction values are maintained for all combinations of antenna diversity and low noise amplifier gains. In the second embodiment, the DSP controls the system so that the DC offset error is reduced when AGC gain is reduced.
In a third embodiment, the transceiver frequency error is further removed in the receiver by changing the voltage controlled oscillator crystal (VCXO) frequency that is used for the local oscillator (LO) frequency synthesizer. This also ensures that the effect of the DC offset error is minimized after demodulating an OFDM signal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the transceiver circuit of a first and second embodiment of the present invention.
FIG. 2 shows a timing diagram of the present invention.
FIG. 3 shows a frequency adjust circuit employed in a third embodiment of the invention.
FIG. 4 shows one embodiment of an automatic gain control circuit of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Using a combination of techniques such as AC and DC coupling, automatic gain control, and digital signal processing, the DC offsets are removed to insignificant levels. The main features or steps of the invention are dynamically changing the cut off frequency of an AC coupling stage; computing a DC signal error over a time period in which the I and Q signals complete a single or multiple cycles, subtracting the estimated DC errors from the I and Q signals, and high-pass filtering the resultant signal so that residual DC errors are removed. The implementation and timing of these steps allows for DC offset control that is far superior to prior art systems.
In a second embodiment a D/A converter is used in each of the I and Q branches to significantly reduce the DC offset, and the steps as mentioned above are followed. The DSP does a course DC correction with the D/A converter, and maintains a list of correction values for all combinations of antenna diversity and LNA amplifier gains. This ensures that DC offset correction values are maintained for all combinations of antenna diversity and low noise amplifier gains. In the second embodiment, the DSP controls the system so that the DC offset error is reduced when AGC gain is reduced.
In a third embodiment, the transceiver frequency error is further removed in the receiver by changing the voltage controlled oscillator crystal (VCXO) frequency that is used for the local oscillator (LO) frequency synthesizer. This also ensures that the effect of the DC offset error is minimized after demodulating an OFDM signal.
FIG. 1 shows a diagram of the transceiver 10 as a zero intermediate frequency radio device according to the present invention. The transceiver 10 comprises a receive branch Rx and a transmit branch Tx. A transmit power amplifier 14 is coupled to a Tx/Rx switch 13 . The Tx/Rx switch 13 is coupled to an antenna 11 . The transmitting branch is well known in the art and is not shown in detail here. The receiver branch further includes a variable gain low noise radio frequency amplifier (LNA) 15 that is coupled to the Tx/Rx switch 13 . The LNA 15 amplifies an input signal that corresponds to an incoming radio frequency signal that is received by the antenna 11 .
The output of the LNA 15 is coupled to a frequency down converter 34 for down converting the radio frequency signal to a zero intermediate frequency (IF) signal. The present invention employs a quadrature frequency down converter. The frequency down converter 34 which contains mixers 16 and 17 in respective quadrature and in-phase mixer paths that provide filtered and amplified quadrature signals Q and I. The frequency down converter 34 further includes controllable AC couplers 22 and 23 , and channel filters 24 and 25 . The AC couplers 22 and 23 are coupled between the mixers 16 and 17 and the zero IF amplifiers filters 24 and 25 .
Control signals for the automatic gain control AGC 31 are provided by a DSP baseband processor 30 . The baseband processor 30 contains processing means for providing cut-off frequency control signals and signals to the AGC unit 31 . Signal line 35 controls the automatic gain controlling data, while signal line 36 contains frequency cutoff information. Also shown is a State Machine 9 . The State Machine 9 is connected to capacitors 22 – 23 and 32 – 33 . The State Machine is used to change the AC coupling frequency from 10 MHz to 500 KHz as will be explained in greater detail below. The operation and functions of the DSP 30 will also be described in detail with reference to FIG. 2 below.
In another embodiment, the baseband circuit 30 further employs analog to digital converters 20 and 21 for canceling the DC offset in the quadrature signals I and Q. The sampled I and Q DC correction signals are supplied by the digital signal processor (DSP) 30 .
The transceiver 10 further comprises a PLL 19 for generating local oscillator signals for the receive branch Rx and for the transmit branch Tx. As is well known in the art, the PLL comprises a voltage controlled oscillator (VCO), a loop filter, and an integrator. A reference oscillator signal, as shown in more detail in FIG. 3 , is supplied to the PLL. In order to generate the I and Q signals, a ninety degrees phase shifter is used in conjunction with the LO signals that are fed to the mixers 16 and 17 . The transceiver 10 does not use the D/A converters in the first embodiment but does employ them in a second embodiment.
As described above, the problems with prior art transceiver systems are the unwanted DC offset values that are produced by the system components.
FIG. 2 shows a timing diagram according to one preferred embodiment of the invention. This timing diagram shows the durations of the AC and DC coupling stages necessary to reduce the DC offset errors. Also shown in FIG. 2 are the lower cut off frequencies of the filters during these AC coupling stages.
The invention implements both AC and DC coupling in the receiver I and Q base band paths. Temporary AC coupling is used to remove DC offsets that could otherwise saturate the receiver outputs due to the large gain in the base band paths from the down converters outputs to the I and Q outputs. The AC coupling is implemented as a cascade of one or more first order high pass filters 24 and 25 , with a particular lower 3 dB cut off frequency (f lower).
With reference to FIG. 2 , upon entering the receive (RX) mode at time zero, (step 1 ) the AC coupling cutoff frequency (f lower) is momentarily kept at 10 Mz for 0.15 usec. This is done automatically by a state machine 9 in the receiver. This quickly removes all the DC offset in the receiver I and Q base band paths. After 0.15 microseconds (f lower) is automatically reduced to 500 kHz, and remains at this cut off value until the DSP removes the AC coupling and introduces DC coupling. With the 500 kHz AC coupling, DC offset changes (with AGC gain changes) are quickly removed before the signal is sampled or the next AGC iteration. It is during this stage of step 1 that automatic gain control is performed on the signal. The gains of amplifiers 26 , 27 , 28 and 29 are changed by the DSP to adjust the IQ signals to a desired level at the AID input. FIG. 2 shows 3 distinct time periods of adjustment, however more periods could be used as necessary. In the example shown in FIG. 2 , the DC coupling (step 2 ) is switched on at 1.05 microseconds.
The DC coupling is actually an AC coupling with a very low value of (f lower) which is less than 100 Hz. With such a low cut off frequency, it may be considered DC coupling even for long IEEE802.11a data packets that may be up to 5–6 milliseconds in duration.
It should be noted that whenever the LNA 15 gain is changed, there is a change in logic level at the antenna select input, and the state machine 9 changes (f lower) to 10 MHz for 0.15 microseconds and then returns (f lower) to 500 kHz.
It should also be noted that when the state machine 9 changes (f lower) from 10 MHz to 500 kHz, there is a step in the I and Q DC levels that may be as large as the peak signal level. This step quickly decays away to very low levels within about 0.8 microseconds. Simulations show that with 500 kHz AC coupling for IEEE802.11a, if a moving average signal power estimate is computed by the DSP 30 (averaged over 0.8 microseconds), then the error is within 2 dB after the first 0.8 microseconds of the RF burst. For a coarse signal level estimate, a 150 nanosecond averaging window (samples at 40 or 80 MHz AID) is sufficient.
When the DSP 30 changes the receiver base band AGC gain in step 1 , it must wait for up to 300 nanoseconds before sampling the I and Q signals for computing the signal power. This is because of the transient settling of the receiver AGC DC levels that takes less than 300 nanoseconds to settle for a 500 kHz AC coupling. For small changes in AGC gain settings, the transient settling time is less than 300 nanoseconds. All changes in LNA and AGC gain settings should be done in order to get the proper signal level and allow the DC errors to be removed before making the decision for the next gain setting.
After finally adjusting the receiver AGC gain, the DSP 30 changes the receiver paths to DC coupling (step 2 ). When this is done, there is a small change in the I and Q DC levels, and it can not be avoided. It is less than about −5 dB relative to the peak signal level and is due to the AC coupling acting on the signal itself (not related to the actual DC error in the circuit). This DC error remains nearly constant during the rest of the receive burst that may be up to 6 ms long. In this preferred embodiment, this static DC error should be removed digitally by the DSP 30 , only after the I and Q A/D conversion takes place. This will ensure not to degrade the signal to noise ratio (SNR) after the fast Fourier transform (FFT) in the receiver, especially when there are large relative frequency offsets between the Transmitting and Receiving modes in the transceivers.
In step 3 of the preferred embodiment the DSP 30 computes the DC offsets in the I and Q remaining parts of the signal. The average values of the I and Q signals are calculated by the DSP 30 . The computed average DC offsets should then be subtracted from their respective signals for the rest of the packet. It is important to calculate the DC offset error at this point while the signal is DC coupled, so as to get an accurate indication of the offset error. After this subtraction, a first order high pass filtering should be done on the following I and Q signals digitally by the DSP 30 , which represents step 4 of the preferred embodiment. This process significantly improves the SNR of the signal. This is because the estimated DC offset is not the true DC offset when the transmitter-receiver frequency offset is present. A residual DC error remains and it must be removed. Simple high pass digital filtering in the DSP 30 is sufficient. A lower cutoff frequency of 1 kHz is optimum for this digital filtering.
This process as shown in FIG. 2 allows the DC offset error to be reduced to acceptable levels within 8 microseconds. In this preferred embodiment it is assumed that the DSP 30 takes 150 nsec to compute the signal power and program the AGC. Actual time for worst case AGC setting will depend on the exact processing delay of the DSP, and the total number of AGC set iterations, and whether or not antenna diversity is used.
In another preferred embodiment, instead of computing the DC error in the DSP and subtracting it, the DSP can instead ramp down the value of (f lower) the AC coupling cut off frequency, from 500 kHz to less than 100 Hz over about 4 microseconds. This avoids the sudden step in DC offset that is associated with abruptly changing the cut off frequency.
FIG. 3 shows a third embodiment of the present invention, wherein a frequency adjust signal is applied to the voltage controlled crystal oscillator 50 to change the frequency of the LO. A signal (F adjust) is applied to the voltage controlled crystal 50 from the DSP controller. The phase locked loop contains conventional components such as a charge pump multiplier 51 , a low pass filter 52 , an integrator 53 and voltage controlled oscillator 54 . The function of this circuit shown in FIG. 3 is to ensure that the frequencies of the local and received carriers are the same. When the frequency error is significantly reduced, even a large DC offset does not degrade the SNR after demodulation of the OFDM signal. Therefore the DC estimation and subtraction, and removal of residual DC error, is not required.
FIG. 4 shows one embodiment of how the automatic gain control circuit (AGC) and AC coupling may be implemented. This feedback circuit contains two amplifiers 60 and 61 with respective gains of G and A respectively. A low pass filter (integrator) 62 is also added after the feedback amplifier 61 . This type of connection allows the transfer function from input to output to be frequency dependent. By changing the gains of the amplifiers 60 and 61 , the cutoff frequency of this circuit may be varied. The −3 db lower cutoff frequency of the AC coupling is 2piAG. The product of AG must be maintained constant when changing the signal path gain G, in order to keep a constant cutoff frequency. In this manner automatic gain control may be implemented while keeping a constant lower cut-off frequency. As mentioned above the AC coupling provided by this circuit may be effectively changed to DC coupling by making the value of A very small, so that 2piAG is less than 100 HZ.
In view of the foregoing, it will be evident to a person skilled in the art, what various modifications may be made in the embodiments given, such as digital signal processing, gain control, channel filtering, and reduction of cut off frequencies. Further the invention is thus not limited to the examples provided.
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This invention describes how to quickly cancel DC offsets that are present in the two quadrature paths of a zero intermediate frequency transceiver. Previously known techniques are not suitable for the 5 GHz WLAN standards because of the very short transmit to receive turn around times and extraordinarily large dc offsets in these systems. This invention solves the above problems. The present invention uses both AC and DC coupling along with automatic gain control techniques to remove unwanted DC offsets within an acceptable time period. The invention further uses a digital signal processor to estimate and subtract out the DC offset errors using time averaged signals. The digital signal processing circuit is capable of further AC filtering and Analog to Digital conversions.
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CROSS-REFERENCE TO RELATED APPLICATIONS
(Not applicable)
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
(Not applicable)
REFERENCE TO SEQUENTIAL LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISC
(Not applicable)
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to concrete construction utilizing foam block forms, more specifically to improvements to the foam sidewalls used to create a longitudinally bi-directional system, improved form sidewall spacing ties which create enhanced concrete flow, enhanced strength, and enhanced fire-break properties, and a corner form that can be used as a right-hand or left-hand form.
2. Description of the Related Art
Concrete forms made of a polymeric foam material are known. Such forms basically comprise a pair of laterally spaced-apart sidewalls presenting a cavity therebetween. A number of these forms are connected to present longitudinally and vertically aligned cavities for pouring concrete therein.
One such form is shown in U.S. Pat. No. 3,788,020, issued on Jan. 29, 1974. This patent discloses a concrete form with a pair of sidewalls, end walls and intermediate partition walls. A plurality of these forms are connected to present vertical cavities for pouring concrete therein to form a plurality of vertical concrete columns or piers. These vertical columns are connected by a horizontal concrete beam formed by filling a channel with concrete, the channel presented upon placing one row of concrete forms atop another.
One problem with existing concrete forms is that the sidewalls must be immobilized so as to resist pressures on the walls during transport and, more importantly, during concrete pouring and curing. If not, the form sidewalls may shift in lateral and/or vertical and/or longitudinal directions. Such displacements make it difficult to easily connect the forms. Also, the forms may separate along the joints respectively presented along the zones of connection between longitudinally and vertically adjacent forms. If the forms are not sufficiently braced, the concrete can cause these joints to separate. The industry refers to such separations as “blow outs”.
During the pouring of the concrete, a hydraulic concrete load acts on the sidewalls of each form as well as on any structure spanning such sidewalls. The load urges the sidewalls from their proper vertical, lateral and longitudinal spatial relationships. Also, during form transport to the job site, the sidewalls may be displaced due to the weight of other forms stacked thereon. In some cases the distance between the sidewalls may vary. Accordingly, problems will arise when attempting to longitudinally and vertically connect forms as the mating lap joint surfaces and/or tongue/groove elements will not be properly aligned.
The closest related publications known to the inventor are U.S. Pat. No. 4,223,501 granted to DeLozier Sep. 23, 1980 and Published U.S. Application 2004/0045237 invented by Coombs et al and published Mar. 11, 2004. Each of these publications shows concrete forms made of opposing panels. The panels are held in spaced relationship by ties. In the patent publication, the tie contains inadequate open space to allow for the free flow of concrete necessary during a pouring operation in order to avoid air pockets which will weaken the resulting wall. In both of these publications, the tie is a single piece bent at each side to form an anchor. This allows for lateral movement during shipping and a corresponding loss of alignment. When this happens the units do not fit together properly on the construction site.
Also, in both of these publications, the tie is made of metal, which conducts heat and can be a mode of transmitting heat during fire. Additionally, in both of these publications there is no predetermined space for connecting the form to studs.
As seen from the above, various devices in the forms of braces and permanent tension members have been proposed so as to maintain the sidewalls in place to preclude such shifting and/or “blow outs” during concrete pouring and subsequent curing. However, such devices have been relatively complex in construction requiring the sidewalls to have special configurations so as to receive the braces and/or ties and have lacked desirable features.
In prior art systems, corners present some problems. Typically a wall form is extended to the end of the wall and a piece of foam plastic is secured over the end of the wall form by wire or the like.
This type of end is difficult to secure to the wall form, frequently breaks during concrete pouring, and is not securely fastened to the wall form. This creates unnecessary labor in fixing breaks, setting up the forms, and affixing exterior sheathing to the corner of the wall.
In another prior art approach, the specific corner form is provided, but it is preformed for a certain specific job and must be either a right-hand corner or a left-hand corner. Right-hand or left-hand orientation is always determined from a top plan view because these forms have by necessity a top end and a bottom end. Therefore, a right-hand corner form cannot be substituted for a left-hand corner and visa versa. This doubles the number of types of molds required to produce the corner forms, doubles the types of corner forms needed in inventory, increases delivery costs, and so forth.
Therefore, there is a need for a corner form for a concrete wall that is universal, that is, can be used for either a right-hand or left-hand wall corner; that can be securely and easily attached to the wall form; that does not break during concrete pouring; and that is securely fastened to the wall form.
BRIEF SUMMARY OF THE INVENTION
The present invention is directed to maintaining the positive aspects of the advances already made by the prior art while eliminating the problem areas. Thus, the inventor has invented improvements in concrete forms.
A particular object of this invention is to provide a concrete form bi-directional system which enhances on-site assembly of the concrete form walls. This improvement takes the form of a bi-directional insulating concrete form system having novel upper, lower, and side surfaces that provide one-hundred eighty degree rotation of the form creating a bi-directional orientation for corresponding insulating concrete forms. Forty-five and ninety degree corner blocks are also part of this invention.
One improvement disclosed in this invention is a corner form for a concrete wall. This form creates a universal corner form, that is, it can be used to create right-hand or left-hand wall corners in concrete walls. Another feature of this corner form is that it can be securely and easily attached to the wall form. Another feature of this corner form is that it can provide a corner form for a concrete wall that does not break during concrete pouring. This corner form for a concrete wall is securely fastened to the wall form.
Another improvement over the prior art is a form tie, more particularly, novel form ties for maintaining the sidewalls of a concrete form in desired longitudinal, vertical and laterally spaced-apart relationships that also serve as a fire-break. Each form tie generally comprises a pair of plastic vertical side pieces with a pair of metal horizontal pieces spanning the form sidewalls. The ties are formed by connecting a pair of plastic vertical side pieces with a pair of metal horizontal pieces. The horizontal pieces are located at the upper and lower ends of the vertical pieces. The vertical side pieces are embedded in the sidewalls of the forms during the molding process with the horizontal pieces spanning the facing interior surfaces of the sidewalls. The ties preclude lateral, vertical and longitudinal shifting of the sidewalls during transport and use. The ties of the present invention find use in concrete forms and effectively interface with the form sidewalls so as to maintain the walls in a desired spatial relationship during transport as well as concrete pouring and curing. The forms of the present invention also automatically present a longitudinally enhanced fire-break resulting from the innovative use of metal band horizontal pieces and thermoplastic vertical side pieces. During a fire, the thermoplastic vertical side pieces melt and do not conduct heat to the horizontal pieces. Thus, the heat stays on one side of the enclosed concrete. Also, the ties are oriented to reduce downward stress on the ties, as a whole, during the pouring of plastic concrete in the cavity formed between the sidewalls.
The ties resist loads that impart tension, compression, bending, twisting and lateral stresses acting thereon. The ties also diminish the lateral, vertical and longitudinal displacement of adjacent sidewalls of a concrete form during transport and use. The ties of the present invention further enhance on-site assembly of the concrete forms, inclusive of the installation of exterior finish materials attached thereto. These ties effectively resist the forces arising from concrete flow but without interference with the concrete flow in the cavity between the form sidewalls and between adjacent forms.
Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, now preferred embodiments of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational perspective view of an elongated concrete form of the present invention.
FIG. 2 is an elevational top view of the elongated form shown in FIG. 1 .
FIG. 3 is an elevational perspective view of one embodiment of an elongated form sidewall of this invention.
FIG. 4 is an elevational end view of the elongated form sidewall of FIG. 3 .
FIG. 5 is an elevational top view of the elongated form sidewall of FIG. 3 .
FIG. 6 is an elevational side view showing the inside of the elongated form sidewall of FIG. 3 .
FIG. 7 is an elevational perspective view of another embodiment of an elongated form sidewall of this invention.
FIG. 8 is an elevational end view of the elongated form sidewall of FIG. 7 .
FIG. 9 is an elevational top view of the elongated form sidewall of FIG. 7 .
FIG. 10 is an elevational side view of the elongated form sidewall of FIG. 7 .
FIG. 11 is an elevational end view of an elongated form of this invention.
FIG. 12 is an elevational perspective view of a part of an elongated form sidewall showing a male connection.
FIG. 13 is an elevational perspective view of a part of an elongated form sidewall showing a female connection.
FIG. 14 is an elevational perspective view of an elongated form of the present invention showing the contours of the form.
FIG. 15 is an elevational top view showing a corner form of this invention in place.
FIG. 16 is an enlarged elevational top view of a portion of a first sidewall shown in FIG. 15 , showing the male connection in detail.
FIG. 17 is an enlarged elevational top view of a portion of a second sidewall shown in FIG. 15 , showing the female connection in detail.
FIG. 18 is an elevational perspective view of a corner form of this invention.
FIG. 19 is an enlarged detail view of the corner of the form of FIG. 18 .
FIG. 20 is an elevational side view of the open side of the form of FIG. 15 .
FIG. 21 is an elevational side view of the closed side of the form of FIG. 15 .
FIG. 22 is an elevational side view of the form of FIG. 15 from the right end of the form.
FIG. 23 is an enlarged detail view showing the top end of the form as seen in FIG. 22 .
FIG. 24 is an enlarged detail view showing the bottom end of the form as seen in FIG. 22 .
FIG. 25 is an elevational top view of a corner form sidewall of this invention.
FIG. 26 is an enlarged elevational top view showing the male edge of the form sidewall of FIG. 25 .
FIG. 27 is an enlarged elevational top view showing the female edge of the form sidewall of FIG. 25 .
FIG. 28 is an elevational perspective view of a corner form sidewall of the present invention.
FIG. 29 is an enlarged elevational perspective view showing the top corner of the corner form sidewall of the present invention.
FIG. 30 is an elevational side view of a corner form sidewall of this invention.
FIG. 31 is an enlarged side elevational view of the top portion of the corner form sidewall shown in FIG. 30 .
FIG. 32 is an enlarged elevational side view of the bottom portion of the corner form sidewall shown in FIG. 30 .
FIG. 33 is an elevational side view of a first corner sidewall section for a form of this invention.
FIG. 34 is an enlarged elevational side view of the top end of the section of FIG. 33 showing detail.
FIG. 35 is an enlarged elevational side view of the bottom end of the section of FIG. 33 showing detail.
FIG. 36 is an elevational end view of a corner sidewall of this invention.
FIG. 37 is an enlarged elevational end view of the corner shown in FIG. 36 showing detail.
FIG. 38 is an elevational perspective view of a corner sidewall.
FIG. 39 is an elevational perspective view of a top corner section of a corner sidewall shown in FIG. 38 showing detail.
FIG. 40 is an elevational top view of a corner sidewall of this invention.
FIG. 41 is an elevational top view of a first end of the corner sidewall of FIG. 40 showing detail.
FIG. 42 is an elevational top view of a second end of the corner sidewall of FIG. 40 showing detail.
FIG. 43 is an elevational side view of a tie of the present invention
FIG. 44 is an elevational front view of a tie of the present invention
FIG. 45 is an elevational perspective view of a tie of the present invention.
FIG. 46 is a top cross-sectional view of a form of one embodiment having ties attached thereto.
FIG. 47 is a front cross-sectional view of a form of one embodiment having ties attached thereto.
FIG. 48 is an end cross-sectional view of a pair of concrete form sidewalls of this invention having ties attached thereto.
FIG. 49 is an elevational perspective view of a sidewall of one embodiment of this invention having ties attached thereto.
FIG. 50 is an elevational perspective view of a wall using the forms of this invention under construction.
FIG. 51 is an elevational perspective view showing the placement of a bottom layer of forms in a wall.
FIGS. 52 and 53 are cross-sectional views of the forms of this invention having rebars passing through poured concrete and inner and outer finishing.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention will now be described with reference to the above drawings wherein like reference numerals refer to like parts throughout the description.
Turning more particularly to the drawings, FIGS. 1-14 , show one type of longitudinal concrete form 2 which comprises a pair of rectangular sidewalls 4 . These sidewalls 4 are preferably made of fire-resistant foamed plastic. Each sidewall 4 has upper 6 and lower 8 longitudinal surfaces as well as a pair of opposed vertical surfaces 10 . Each sidewall 4 has an inner surface 12 and an outer surface 14 . When the longitudinal form 2 is assembled, the inner surfaces 12 of the sidewalls 4 cooperate to form a plurality of vertical cavities 16 and a vertical slot 18 . The slot 18 longitudinally spans the length of the form 2 and connects the cavities 16 . The outer surface 14 is flat and serves to receive facing or studs.
As shown best in FIG. 11 , each sidewall 4 ′, 4 ″ has a raised portion 20 and a non-raised portion 22 along the upper surface 6 which mate with a complementary non-raised portion 22 and raised 20 portion located along the lower surface 8 of an overlying form 2 . In each sidewall 4 ′ 4 ″, the vertical surfaces 10 ′, 10 ″ as shown best in FIG. 2 are made up of a tongue 24 and groove 26 . For a first (outer) sidewall 4 ′, a first vertical surface 10 ′ has a tongue 24 and the second vertical surface 10 ″ has a corresponding groove 26 . For the second (inner) sidewall 4 ″ of a form 2 , the sidewall 4 ″ opposite the first sidewall 4 ′, the first vertical surface 10 ′ has a groove 26 and the second vertical surface 10 ″ has a tongue 24 as best seen in FIGS. 12 and 13 . Accordingly, the forms 2 may be connected in longitudinally extending courses and stacked one atop the other. In the above, “outer” and “inner” are related to the exterior or interior of the building. This is best shown in FIGS. 50 and 51 .
Referring to FIGS. 50 and 51 , the first course of longitudinal forms 2 is positioned atop a footing 28 and held in place by various materials such as plastic roof cement. It is understood that other types of connection of the first row of longitudinal forms 2 to the footing 28 may be utilized, such as placing the forms 2 in a wet footing 28 and allowing the footing 28 to subsequently dry. Upon reaching a desired height of the forms 2 , wet concrete is poured between the form sidewalls 4 . From FIG. 50 , it is seen that the forms 2 are staggered among rows so as to preclude formation of a continuous vertical joint among the form rows. The poured concrete fills the vertical cavities 16 and longitudinally extending vertical slot 18 of each form 2 . Also, upon stacking a second course of forms 2 atop the first course of forms 2 , a horizontal channel is formed which spans the upper and lower forms 2 . The poured concrete will fill the channel of the form 2 . Thus, a concrete wall within the interior of the forms 2 is presented. The forms 2 are left in place for insulating the resulting concrete wall. Wall clips (not shown) may be used for attaching exterior siding thereto. Such clips are the subject of a separate patent application by the inventor.
It is known that the courses of the forms 2 may be selectively configured so as to present walls of various configurations. Also, door frames, window frames, bucks, bulkheads, and the like may interrupt the courses of forms 2 so as to provide openings for insertion of doors, windows and the like therein while precluding spillage of poured concrete from the forms 2 .
Referring to FIGS. 15-42 , corner forms 30 of this invention will be described. There is shown a universal corner form 30 for concrete walls. By universal corner form 30 , it is intended to mean that there is an open left-hand side 32 of the corner form 30 or an open right-hand side 34 which can fit onto either end of the forms 2 of the present invention.
As can best be seen in FIGS. 15-17 , the vertical surfaces 36 of the corner form 30 are the same as the vertical surfaces 10 of the sidewall forms 2 . Also, the upper 6 and lower 8 longitudinal surfaces of the corner pieces 30 are configured identically to the upper 6 and lower 8 surfaces of the sidewall forms 2 .
With reference to the sidewall form 2 shown in FIG. 14 , it may be assumed that the sidewall 4 which has the tongue 24 on the vertical surface 10 is the outer sidewall 4 ′ while the sidewall 4 which has the groove 26 on the vertical surface 10 is the inner sidewall 4 ″.
In order to make a left corner using the above form, the open right-hand side 34 of the corner form 30 as shown in FIG. 15 is connected to the above form 2 . Similar straight forms 2 may then be connected to the open left-hand side 32 of the corner form 30 . In such an arrangement, the upper longitudinal surface 6 of both the straight forms 2 and the corner forms 30 will contain raised portions 20 along the outer surface 14 and non-raised portions 22 along the inner surfaces 12 .
In a like manner, to form a right corner using the above corner form 30 , the open left-hand side 32 of the corner form 30 shown in FIG. 15 is connected to the above straight form 2 . Again, straight forms 2 may be connected to the free end of the corner form 30 . In such an arrangement, the upper longitudinal surface 6 of both the sidewalls 4 and the corner pieces will contain raised portions 20 along the outer surface 14 and non-raised portions 22 along the inner surfaces 12 .
Should the straight form 2 be in place such that the outer sidewall 4 ′ contains an upper longitudinal surface 6 having a raised portion 20 along inner surface 12 and a non-raised portion 22 along the outer surface 14 , the corner form 30 may simply be turned over so that the former upper longitudinal surface 6 is now the lower longitudinal surface 8 . The corner form 30 will then have an outer sidewall 4 ′ which contains an upper longitudinal surface 6 having a raised portion 20 along inner surface 12 and a non-raised portion 22 along the outer surface 14 . This allows the corner form 30 of the present invention to be a universal corner form as it can form a left corner or right corner regardless of the configuration of the vertical surfaces of the sidewalls 4 of the form 2 .
Referring to FIGS. 43-49 , the ties 38 of this invention are described. Each tie 38 presents an overall square or rectangular configuration. The tie 38 comprises first and second laterally spaced-apart vertical thermoplastic side pieces 40 with two connecting metal horizontal pieces 42 therebetween.
Each side piece 40 generally comprises a vertical holder 44 having a proximal edge 46 and a distal edge 48 . The proximal edge 46 is of lesser length than the distal edge 48 . The vertical holder 44 contains a plurality of holes 50 to allow the passage of polystyrene beads and to avoid the buildup of air pockets in the vicinity of the tie 38 . The side piece 40 contains a vertical flange 52 laterally displaced from each side of the proximal edge 46 of the vertical holder 44 . The presence of two flanges 52 gives added dimensional stability and strength to the prepared form 2 .
A horizontal piece 42 in the form of a thin metal band extends between approximately the midline between the proximal edge 46 and the distal edge 48 of a first vertical holder 44 and approximately the corresponding midline of a second vertical holder 44 at the lower ends 54 thereof. Likewise, upper ends 56 of first and second vertical holders 44 are similarly joined by a metal horizontal piece 42 . The horizontal pieces 42 may be secured to the vertical holders 44 by common fastening devices, preferably rivets. Dimensional stability may be assured by having the horizontal pieces 42 fit into grooves 58 in the vertical holders 44 . Complimentary notches 60 and protrusions 62 in the horizontal pieces 42 and the vertical holders 44 serve to increase lateral and vertical dimensional stability of the tie 38 and any form 2 containing the tie 38 . The thin metal band horizontal piece 42 is located such that the upper 64 and lower surfaces 66 are narrow and the two side surfaces 68 are wide.
In the event of a fire on a first side of a concrete wall prepared using the ties 38 and forms 2 of the present invention, the thermoplastic side pieces 40 melt and cannot transfer sufficient heat to the metal horizontal pieces 42 to allow the fire to spread to the opposite side of the concrete wall.
As is known in the prior art, two bipartite molds are used for forming the sidewalls of the polymeric concrete form. Polystyrene beads are blown into the respective sidewall molds at a first temperature with the beads expanding upon cooling so as to fill the mold. Upon the beads being reheated at an elevated temperature, a second expansion occurs so that the foam fills the mold. Upon removal of the mold the sidewalls 4 are presented.
One problem which has arisen with the use of form ties is that the sidewall molds must have openings therein to allow for insertion of the ends of the tie in each mold and extension of the tie between the sidewall molds. In turn, the expanding foam may escape from these mold openings. Such a leakage/seepage of the foam from the mold may impair form integrity and lead to undesirable ruptures, cracks, etc. in the forms. Such defects may not be visibly apparent until the form sidewalls are subjected to the hydraulic loads presented by the poured concrete between the form sidewalls.
In response to such a problem, the vertical side pieces 40 of the ties 38 of this invention are configured to seal the mold openings. The forms 2 are prepared as a unit with the ties 38 being embedded in the sidewalls 4 . Thus, the vertical side pieces 40 preclude escape of the expanding polystyrene foam from the mold. Also, the distance between these vertical side pieces 40 defines the length of the horizontal pieces 42 and thus the resulting lateral displacement between the sidewalls 4 . Accordingly, the coplanar relationship of the opposed, interior surfaces 12 of the sidewalls 4 presents a visual gauge of a common lateral displacement between the sidewalls 4 of the forms 2 .
Thus, the horizontal pieces 42 fix and maintain a desired lateral distance between the interior surfaces 12 of the sidewalls 4 of the form 2 . This common lateral modularity assures the builder that the stacked forms will present even exterior surfaces
As best shown in FIGS. 46-49 , the ties 38 are embedded in the sidewalls 4 of the form 2 . As such, they resist any forces acting thereon which may disrupt the monolithic structure of the sidewall 4 . The horizontal pieces 42 span the sidewalls 4 . As such, a plurality of horizontal pieces extends between the sidewalls 4 so as to maintain the distance therebetween in the presence of hydraulic concrete loads. It is noted that the horizontal pieces 42 are so arranged as to present a minimal amount of surface to a longitudinal concrete flow through the form 2 .
The ties 38 , as above described, resist tension, compression, bending, twisting and lateral forces acting thereon during transport as well as during concrete pouring and curing.
Thus, longitudinal shifting of the sidewalls 4 of the form 2 is particularly precluded. Such preclusion also contributes to the elimination or reduction in the width modularity during form use.
Referring to FIGS. 52 and 53 , following construction of the form wall and prior to the pouring of the concrete, horizontal rebars 70 are placed on the upper surface 64 of one lower horizontal piece 42 and the corresponding surface 64 of the other lower horizontal pieces 42 of the ties 38 . Following the installation of horizontal rebars 70 , vertical rebars 72 are installed offset from the center of the form 2 to lend support to the concrete wall. Following the installation of vertical rebars 72 , the vertical 72 and horizontal 70 rebars are tied into place.
As best seen in FIGS. 3-10 , some of the inner sidewalls 4 ″ contain notches 96 on the upper longitudinal surface 6 thereof. These notches 96 may hold the short side of L-shaped pieces (not shown). The long side of such pieces will fit against the outer surface 14 of the sidewalls 4 . The configuration of the short side of the L-shaped piece is such that it completely fills the notch 96 . The configuration of the long side of the L-shaped piece is such that it will lie flat along the outer surface 14 of the inner sidewall 4 ″. The long side presents a solid surface to aid in nailing studs to the inner sidewall 4 ″. To this end, the distance between the notches 96 is equal to the conventional distance between studs.
It is to be understood that while certain forms of this invention and dimensions have been illustrated and described, the invention is not limited thereto except insofar as such limitations are included in the following claims and allowable functional equivalents thereof.
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An insulating concrete form foam block bi-directional system comprises a pair of opposed and parallel foam sidewall panels spaced using a plurality of plastic and metal band ties that act as a fire-break between the two exterior finished concrete wall surfaces. Each tie comprises nearly full sidewall height, plastic flanges which engage the sidewalls and a metal band cross-connecting vertical holders of the ties. The metal band forms a wide opening to enhance concrete flow. The tie results in a minimal downward stress impact on the tie during concrete placement. The top and bottom surfaces of each sidewall are formed with raised areas and non-raised areas which interlock with adjacent blocks. The side surfaces of each sidewall are formed with vertical tongues and grooves which interlock with like tongues and grooves of corner pieces which are adapted to form right or left-hand corners.
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BACKGROUND OF THE INVENTION
[0001] Embodiments of the present invention relate to composite materials, and more particularly to processes for fabricating composite materials that comprise a reinforcement fabric infiltrated with a polymeric resin.
[0002] A key component of a high-bypass gas turbine engine is the fan section and its blades. The fan blades are the distinctive feature of the engine when viewed from the front (looking aft), and are the first component of the engine to contact incoming air. As such, fan blades must be capable of performing at the speeds, altitudes and inlet temperatures demanded of high-bypass aircraft engines. In addition, fan blades must be capable of mitigating a variety of adverse environmental effects, while withstanding and operating through bird impacts and other foreign object damage (FOD) at high speeds. As a result, an operational requirement of a fan blade is a high degree of impact resistance.
[0003] Due to additional requirements of aircraft engines, fan blades are also relatively lightweight, durable, and tough. Significant research and development has been invested in improving blade operation and construction so as to improve engine performance by having lower rotating mass, greater damage tolerance, greater vibratory damping, and increased aerodynamic efficiency. When improving blade toughness, generally the goal is to improve blade durability and impact strength so that the blade can be reduced in thickness while maintaining or improving its overall resistance to fracture and impact damage. Lighter blades lead to improved aerodynamic efficiency and reduce the weight, cost, and efficiency of the engine as a whole.
[0004] Recently, much progress has been made in the integration and application of composite materials in aircraft components, including engine fan blades. Fan blades made from polymeric matrix composite (PMC) materials include two main components: a polymer resin material and a fiber reinforcement material impregnated by the resin to provide strength and structure to the composite. Thermoset epoxy PMC materials have also been considered, such as epoxy laminates reinforced with carbon (graphite) fibers or fabrics, as they offer advantages including the ability to meet aerodynamic criteria and reduce weight, which promote engine efficiency and improve specific fuel consumption (SFC).
[0005] Composite fabrication involves not only impregnation, but also a lay-up process. During the lay-up process, a prepreg comprising a resin-impregnated reinforcement material is cut and drawn into plies or sheets of material. The plies may then be cut, stitched or pressed into layers to produce a resin-impregnated laminate composite structure, which can be shaped according to the operation and purpose of the composite.
[0006] Although fan blades manufactured with thermoset epoxy PMC provide impact resistance characteristics and can produce thin blades, improvements are needed to continue engine performance gains.
BRIEF DESCRIPTION OF THE INVENTION
[0007] Embodiments of the present invention provide processes suitable for fabricating thermoplastic resin/fiber composites, particular but nonlimiting examples of which include aircraft engine fan blade airfoils including fan blades of high-bypass gas turbine engines.
[0008] According to a first aspect of the invention, a process for fabricating a thermoplastic-fiber composite includes heating a thermoplastic resin to a liquid state, unidirectionally orienting fibers, optionally coating the fibers to improve composite damage tolerance, impregnating the fibers with the thermoplastic resin in the liquid state to produce composite laminae, and performing an machine lay-up process to produce a composite laminate comprising a plurality of the composite laminae.
[0009] Other aspects of the invention include fan blade airfoils produced by a process comprising the steps described above.
[0010] Other aspects and advantages of this invention will be better appreciated from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 represents a fan blade of a type that may be fabricated with a polymer matrix composite material.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Embodiments of the present invention relate to processes for the fabrication of thermoplastic resin/fiber composites for use in aircraft engine fan blade airfoils, including fan blades of high-bypass gas turbine engines.
[0013] A difference between thermoset and thermoplastic resins is that thermoset resins exist as a liquid at room temperature, whereas thermoplastics exist as a solid at room temperature. Thermoplastics provide two distinct advantages over thermosets: they have a greater impact resistance to comparable thermoset composites, and they are reformable, allowing them to be reused or repaired more easily than comparable thermosets. Their greater impact resistance makes them desirable for use in fan blade fabrication. However, there are complications to using thermoplastics in reinforced composite fabrication. Because thermoplastics are solid at room temperature they require reheat to make them formable for manufacture. Typically, this process is more time-consuming and possibly cost-prohibitive than a similar impregnating process involving a comparable thermoset resin.
[0014] Briefly, an embodiment of such a process involves orienting unidirectional pre-impregnation (prepreg) of a reinforcement material with a thermoplastic resin to produce composite plies. A nonlimiting example is carbon (graphite) fibers as a unidirectional reinforcement material that is impregnated with the thermoplastic resin, for example, poly ether ether ketone (PEEK), though other thermoplastics could be used, nonlimiting examples of which include polyetherketoneketone (PEKK), polyphenylene sulfide (PPS), polyamideimide (PAI), and polyetherimides (PEI). A decoupling agent may be applied as a coating on the reinforcement material to further improve composite damage tolerance of the resulting fan blade. Another step of the process is machine lay-up, in which the composite plies are cut and removed from the bulk. This machine process is an improvement over hand lay-up methods. A consolidation process or autoclave cure step is then performed, in which the composite plies are shaped and solidified.
[0015] The unidirectional prepreg process constructs a composite material from the thermoplastic resin and reinforcement material. The thermoplastic resin is heated to a liquid state, then the reinforcement material is impregnated with the resin to form a reinforced polymer matrix. As noted above, the reinforcement material comprises unidirectional (fibers), more particularly continuous carbon (graphite) fibers and glass fibers. As used herein, continuous refers to reinforcement (fiber) material made up of fibers or fiber bundles (tows) that are sufficiently long to be capable of being oriented to have a specified orientation (unidirectional) within a matrix material of a composite, for example(but not limiting), parallel to the load direction on the composite, in contrast to discontinuous fiber reinforcement materials made up of shorter fibers that are typically randomly dispersed in a matrix material of a composite. In an embodiment of the present invention, the fibers are suitable for being unidirectionally impregnated, such that all the impregnated fibers are and remain orientated substantially parallel to each other. This process yields a composite material that exhibits desirable structural and mechanical properties.
[0016] The decoupling process, as embodied by the invention, involves the application of a coating to the unidirectional reinforcement fibers. The coating may be applied before the prepreg process and enables the fibers to better interface as a reinforcement material with the thermoplastic matrix. The result of this coating is a distributed damage mechanism in the composite matrix to further improve composite toughness during impact damage.
[0017] The machine lay-up process, as embodied by the invention, involves cutting and drawing the composite material into plies and shaped into laminae, which are then stacked and shaped to produce a laminate. As used herein, the term laminae refer to complete plies, ply segements, and portions of plies in shapes and strips. The process may also involve ultrasonically-assisted stitching processes, in which reinforcement fibers may be inserted through multiple ply layers, improving the qualities of the laminate as a whole. The machine lay-up process saves labor cost when considered in contrast to conventional lay-up processes that use manual skill and labor to cut the plies and construct and shape the laminae.
[0018] Finally, the process may use an in-situ consolidating process or autoclave cure to shape and cool the laminate to yield a composite article. A consolidating process more particularly uses consolidating forces to press the laminate and its plies/laminae into the desired shape and is generally a part of the lay-up process. An autoclave cure places a laminate in a high-pressure device to shape the final composite. Suitable autoclave temperatures include temperatures from about 600° F. to about 840° F., preferably from about 680° F. to about 760 ° F., which is higher than typical thermoset autoclaving temperatures. One composite article would be a fan blade 10 as depicted in FIG. 1 .
[0019] While the invention has been described in terms of specific embodiments, it is apparent that other forms could be adopted by one skilled in the art. For example, composite components other than fan blades could be produced, processing parameters could be modified, and appropriate materials could be substituted for those noted. Accordingly, it should be understood that the invention is not limited to the specific disclosed embodiments. It should also be understood that the phraseology and terminology employed above are for the purpose of disclosing the invention, and do not necessarily serve as limitations to the scope of the invention. Finally, while the appended claims recite certain aspects believed to be associated with the invention, they do not necessarily serve as limitations to the scope of the invention.
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A process for fabricating a thermoplastic-fiber composite includes heating a thermoplastic resin to a liquid state, unidirectionally orienting fibers, impregnating the fibers with the thermoplastic resin in the liquid state to produce composite laminae, and performing an automated machine lay-up process to produce a composite laminate comprising a plurality of the composite laminae.
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[0001] This application claims priority on U.S. Provisional Patent Application Ser. No. 60/817,623 filed on Jun. 29, 2006 the disclosures of which are incorporated herein by reference. This application is also a continuation in part of U.S. application Ser. No. 11/478,322 also filed Jun. 29, 2006 which claims priority on U.S. Provisional Patent Application Ser. No. 60/757,704 entitled “Micro Vein Enhancer” filed on Jan. 10, 2006 which are also incorporated by reference herein.
SUMMARY OF THE INVENTION
[0002] A laser based imaging system that can image veins, arteries, or other organs containing blood, and can generate three dimensional images representative thereof.
BACKGROUND OF THE INVENTION
[0003] It is known in the art to use an apparatus to enhance the visual appearance of the veins and arteries in a patient to facilitate insertion of needles into those veins and arteries as well as other medical practices that require the identification of vein and artery locations. Such a system is described in U.S. Pat. Nos. 5,969,754 and 6,556,858 incorporated herein by reference as well as publication entitled “The Clinical Evaluation of Vein Contrast Enhancement”. Luminetx is currently marketing such a device under the name “Veinviewer Imaging System” and information related thereto is available on their website, which is incorporated herein by reference.
[0004] The Luminetx Vein Contrast Enhancer (hereinafter referred to as LVCE) utilizes a light source for flooding the region to be enhanced with near infrared light generated by an array of LEDs. A CCD imager is then used to capture an image of the infrared light reflected off the patient. The resulting captured image is then projected by a visible light projector onto the patient in a position closely aligned with the image capture system. The light source for flooding the region to be enhanced does not deeply penetrate into the patient, and therefore, only the veins on the surface of the patient are imaged. Further, the image representative of the veins which is rendered onto the patient is two dimensional and does not provide any depth information. Still further, there is no method using such technology to display blood flowing at a given depth in the patient.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 shows a perspective view of the optical apparatus for the laser based vein enhancer of the present invention.
[0006] FIG. 2 is a control block diagram of the controlling elements of the optical apparatus of FIG. 1 .
[0007] FIG. 3A is a side cutaway view of a patient's arm, illustrating the veins within the patient's arm.
[0008] FIG. 3B is a top view of the veins in the arm of the patient in FIG. 3A .
[0009] FIG. 3C is a side view of the veins in the arm of the patient in FIG. 3A .
[0010] FIG. 4A is a side view of the veins in the arm of the patient in FIG. 3A , showing the scan depth lines from N=1 through N=17.
[0011] FIG. 4B shows 17 images for N=1 through N=17 of the arm of the patient in FIG. 3A that are stored in the image memory if laser based vein enhancer of the present invention.
[0012] FIG. 5 is a flow chart illustrating an embodiment of the image formatter of the optical apparatus of FIG. 2 .
[0013] FIG. 6 is a top view of the veins in the arm of the patient in FIG. 3A , utilizing different patterns to differentiate between the various different veins and arteries.
[0014] FIG. 7 is a flow chart of another embodiment of the image formatter of the optical apparatus of FIG. 2 .
[0015] FIG. 8 is a flow chart of a third embodiment of the image formatter of the optical apparatus of FIG. 2 .
[0016] FIG. 9 shows a top front perspective view of an embodiment of the image formatter of the optical apparatus of FIG. 2 .
[0017] FIG. 10 shows the projection plane of the laser based vein enhancer of the present invention on a cross section of a patient's arm.
[0018] FIG. 11 is an illustration of how an embodiment of the laser based vein enhancer of the present invention accurately projects the correct vein size regardless of the depth of the veins within the patient's arm.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Preliminary application 60/757,704, incorporated herein by reference, described a miniature laser based system for imaging a patient's veins and arteries and then rendering them onto the surface of the patient's skin. Tests of such a system has shown that the laser based imaging system can penetrate and image very deeply into the patients body, and in some cases, such as the hand or arm, can image entirely through the hand or arm. Further, it has been found that the depth of penetration of the imaging is a function of the amount of laser power applied. Using these principals, a three dimensional imaging system is now described.
[0020] FIG. 1 . shows the optical apparatus for a laser based vein enhancer. A single colored laser 180 , for example a 630 nm semiconductor red laser, is projected into combiner 181 . A semiconductor laser 183 is also projected into the combiner 181 . Laser 183 may have a frequency from 700 nm to 1000 nm, with a preferred frequency of 740 nm. An illustrative example of a semiconductor 740 nm laser is Sacher Lasertechnik's Fabry Perot Diode Laser 740 nm, 10 mw, model number FP-0740-10. The combiner 181 outputs a combined laser beam 184 which is the combination of the 630 nm red and the 740 nm laser beams. Combiners for combining two lasers of different frequencies are well known in the art and will not be further described herein. The combined laser beam 184 is positioned to hit off mirror 172 and then to hit the MEMS scanner 173 . The MEMS scanner moves in a raster pattern thereby causing the combined laser beam to move along optical path 5 forming a raster pattern at the field of view 4 . A photodetector 182 which is responsive to the 740 nm frequency is provided and receives 740 nm light reflected off objects in the field of view. The photodetector 182 outputs an analog signal representing the amount of 740 nm light received. An illustrative example of a photodetector is Roithner Lasertechnik's model number EPD-740-1.
[0021] FIG. 2 shows a control block diagram for controlling the elements in FIG. 1 to form a three dimensional imaging system. An electronic block 192 for driving the MEMS driver and for sensing the position of the raster scanner is provided. This block 192 generates the signals required to drive the MEMS scanner 173 in a raster pattern, and also determines the exact instantaneous location of the MEMS scanner and communicates this information to an image memory array 191 A- 191 N. This electronic block 192 also generates output signals indicating the frame count and communicates such signals to image memory array 191 A- 191 N, image formatter 300 , image memory two 196 , and laser intensity block 301 .
[0022] Assuming the frame rate is sixty frames per second, the frame count will cycle from one through sixty. The operation is as follows. The MEMS scanner 173 is driven in a raster pattern. The first full frame after achieving a stable raster pattern will be identified as frame one by the frame counter. Thereafter each subsequent frame will increase the frame counter by one, up to sixty, and thereafter the frame counter will reset to one and then start the cycle again. Laser intensity block 301 drives the laser drivers 195 at a select one of sixty levels depending upon the current frame counter level. More particularly, the laser intensity block 301 drives the laser drivers 195 in such a manner that the power output from the 740 nm laser 183 linearly increases in sixty steps as the frame counter increments from one to sixty. During the first sixty frames of operation the laser drive 194 for the 630 nm laser 180 is turned off. The light from the 740 nm 183 is reflected off the patient and absorbed by the blood in the veins in a patient's body and the reflected light is sensed and converted into an analog signal by 740 nm photo detector 182 . The analog signal is then passed through an A/C converter 190 which outputs a digital representation to image memory 191 A- 191 N, wherein in this example A=1 and N=60. Image memory 191 A- 191 N receives instantaneous position information from the electronic block 192 , and based upon such information, the digital representation for each pixel is stored in a memory location corresponding to a particular pixel. This is repeated for each pixel within a frame. In this manner, each frame is stored in an associated image memory. Upon completion of the first sixty frames, the image memory 191 A- 191 N contains sixty images of the veins within the field of view of the 740 nm laser 183 , wherein each sequential image memory contains an image which has been obtained with increased laser intensity. After the completion of the sixtieth frame, the image memory is forwarded to an image formatter 300 , which in turn forms an image which is transferred to image memory two 196 . During each of the next sixty frames of the cycle, the data in the image memory two 196 is read out as a function of the instantaneous position information provided by the electronic block 192 and provided to a D/A converter 193 which outputs an analog signal to laser drive 194 which drives the 630 nm laser 180 . In this manner, the image that was stored in image memory two 196 is projected by the 630 nm laser 180 onto the patient. In this manner, the veins that are in the field of view become visible to the practitioner.
[0023] While in the above embodiment, the frame count (number of slices of images taken) was sixty, the frame count could be more or less than sixty. Also, the laser intensity 301 was indicated to go up linearly. It is also possible to have a look-up table or algorithm which provides for non-linear step-ups in power. To simplify the discussion, the power changes have been described in a “step-up” fashion. The order in which the various steps are taken are unimportant, it is the capture of the vein signal at various intensities is what is important to the process.
[0024] The operation of image formatter 300 will now be described in greater detail. To simplify the Figs. shown, a maximum frame count of 17 (N=17) is illustrated as opposed to the frame rate of 60 (N=60) previously described. Accordingly, for the purpose of the illustrations the laser will cycle through 17 frames at 17 different increasing power levels. Referring to FIG. 3A , a three dimension illustration of a patient's arm 309 is shown. The arm has a top vein 310 which is closest to the top surface and bottom vein 312 which is the deepest as viewed from the top surface and middle vein 311 which is between the two. FIG. 3B shows a top view 308 of the veins 310 , 311 and 312 as viewed from the top of the arm if the arm was transparent and the veins were not. FIG. 3C shows a side view 307 of the veins 310 , 311 and 312 as viewed from the side of the arm (assuming again for the moment the arm is transparent and the veins are not).
[0025] The laser based vein enhancer of FIG. 1 and FIG. 2 is positioned so that the field of view corresponds with the top view 308 of the patient's arm 309 shown in FIG. 3 . FIG. 4A again shows the side view 307 but also includes along the right edge scan depth lines 314 N=1 through N=17. These scan depth lines 314 indicate how deeply the laser light penetrates into the arm at each respective laser intensity level N=1 through N=17. FIG. 4B shows 17 images N=1 through N=17 that are stored in image memory 191 A- 191 N. Referring to the image memory associated with frame one (N=1), the intensity of the laser only penetrates the patient arm to the depth shown by the N=1 scan depth line 314 . Since this depth does not reach vein 310 , 311 or 312 as shown in FIG. 4A , the image stored for the first frame N=1 is blank. The same applies to the second frame N=2. The third frame N=3 reaches partly into vein 310 and accordingly the image stored in image memory associated with the third frame (where N=3) begins to faintly show vein 310 . Frames 4 , 5 and 6 each penetrate successively deeper into vein 310 and therefore the image of vein 310 gets successively darker in the image memory 191 A- 191 N associated with frames 4 , 5 and 6 (N=3, 4 and 5). Similarly, starting with frame 7 (N=7), the middle vein 311 begins to appear and then starting with frame 11 (N=11) the deepest vein 312 begins to appear. By frame 14 the laser light penetrates all the way through veins 310 , 311 , and 312 and therefore the images for frames 14 through frame 17 are approximately the same and show all the veins.
[0026] If the image for frame 17 (N=17) were to be projected onto the patients arm, there would be no way for the practitioner to determine the relative depths of veins 310 , 311 or 312 . Accordingly the image needs to be reformatted so as to provide additional information to the practitioner before projecting on the patients arm.
[0027] Referring to FIG. 5 , an illustrative embodiment of the image formatter 300 of FIG. 2 is flow-charted. The frame counter N is set at 0 in step 2 and all previously stored vein/artery images are cleared. In step 3 the counter N is increased by one. In step 4 the frame counter is tested to see if all 17 frames are completed. Accordingly, step 5 will be reached for each of the 17 successive images (N=1 through N=17). In step 5 the image N is recalled from the appropriate image memory 191 A- 191 N. In step 6 all previously stored vein/artery pattern are subtracted. During the first frame N=1 there will be no previously stored vein/artery pattern to be subtracted since they were cleared at step 2 . At step 7 , image processing is performed to detect whether a vein or artery pattern is found. Since it is know that veins and arteries are tube shaped and have a length much greater than their diameter, relative straightforward computer processing can be used to identify such a pattern. If a new pattern is detected at step 8 the new vein/artery pattern is stored at step 9 and the program returns to step 3 . If there is no new pattern detected in step 8 the program returns to step 3 .
[0028] Now applying step 1 through step 8 to the images shown in FIG. 4B , assuming that image N=3 represents the first time step 7 detects a vein 310 , the image of the vein 310 is stored at step 8 . Thereafter, in each subsequent image processed, the image of vein 310 is removed from the image at step 6 . Then assuming when the N=7 the second vein 311 is detected in step 9 , the image of vein 311 is stored and accordingly removed the next time the program reaches step 6 . Finally when the N=11 the deepest vein 312 is detected in step 9 , the image of vein 312 is stored and accordingly removed the next time the program reaches step 6 . After completing the last frame 17 , the program moves to Step 9 wherein each stored vein/artery pattern is replaced with a unique pattern. For example, the pattern of vein 310 can be replaced with a diagonally striped pattern, the pattern of vein 311 can be replaced by a checked pattern, and the pattern of vein 312 can be replaced with a light grey pattern. At step 10 each of the now unique patterns for each of the stored vein/artery patterns are layered on top of each other, with the first found pattern falling on the top, the second pattern in the middle and the third pattern on the bottom. In step 11 , the image of step 10 is transferred to image memory two 196 (See FIG. 2 ). The image of step 10 is then projected by the visible laser onto the patients arm.
[0029] FIG. 6 shows the resulting image 320 projected onto the patients arm. As can be seen, vein 310 is represented by the diagonally striped pattern, vein 311 represented by the checked pattern, and vein 312 by a light grey pattern. It is clear to the practitioner that vein 310 is positioned above veins 311 and 312 since the diagonally striped pattern at the intersection points of the respective veins. Similarly it is clear that vein 311 is positioned above vein 312 since the checked pattern appears at the intersection point of veins 311 and 312 .
[0030] In FIG. 6 , diagonal striped patterns, checked pattern, and a light grey pattern were utilized for differentiating between the various different veins/arteries, however, the invention is not limited thereto. Varying patterns, such as dotted lines having different dot-space characteristics could have been utilized to represent veins at different depths. Alternatively, solid images having different intensities could have been utilized, wherein, for example, those veins closer to the surface are represented by dark projections and deeper veins by lighter projections. Still further, the red laser 180 could be replaced by multiple color lasers, for example red, green and blue, all arranged so that their projections are aligned coaxially. By mixing the amount of each laser, color images can be projected. Accordingly, each different depth vein can be represented by a different color.
[0031] A further embodiment is shown with reference to FIG. 7 . In this embodiment, the capturing of the vein/artery image is the same as shown previously with reference to FIG. 2 and the resulting image gets stored in image memory 191 A- 191 N. However, in this embodiment, the image is not transmitted back onto the patient, but instead is transfer to a computer 325 and is then displayed on a three dimension (3D) display 326 . More specifically, three dimensional computer software is known in the art, such a CAD (computer aid design) software or medical imaging software, for manipulating and outputting 3D images. One example of such CAD software is SolidWorks. An example of medical imaging software is an Advanced 3D Visualization and Volume Modeling software from Amira. SeeReal Technologies provides a stereo 3D display (Model C-s Display) which receives image information over a DVI connection from a graphics card of a Windows based computer and allows the user to view such 3D image without necessitating special glasses. Such Windows based computer must be fitted with a special graphics card, such as NVidea Open GL Video card, to enable the driving of the display.
[0032] Utilizing the computer 325 and 3D display 326 , the practitioner can view the veins in 3 dimensions. The 3 dimensional images can be rotated by the CAD software, and cross-section slices of the 3 dimensional images can be performed. Still further, it is possible to utilize a 2 dimensional display with CAD software converting the 3D image into meaningful 2D displays.
[0033] FIG. 8 shows a still further embodiment wherein the visible laser projection onto the patient of FIG. 2 is combined with the 3D display 326 described with reference to FIG. 7 . In this case, the image is projected onto the patient by the 630 nm laser 180 while concurrently being displayed in 3D on screen 326 . In this manner the practitioner can find the exact positioning of the veins as projected on the patient and can also view a 3D representation of the veins/arteries under the surface.
[0034] FIG. 9 shows an embodiment similar to that shown in FIG. 15A of preliminary application No. 60/757,704.
[0035] In this embodiment the Miniature Vein Enhancer (MVE) 150 includes a small display 325 , having attached thereto an attachment piece 154 and a Miniature Projection Head (MPH) 2 . Although the attachment is shown at a right angle to the stem extending vertically from the vial, the stem can be at an angle to the vial and the display angle can vary, as well. A needle protector 156 , connects to a vial holder 7 . The attachment piece 154 receives the top of the needle protector and temporarily locks the MVE to the needle protector 156 which in turn attaches to the vial holder 7 . The MPH 2 is attached to the small display 151 and is oriented so that the optical path 5 is such that the field of view 4 covers the point of the needle 14 . The MPH 2 outputs the image of the veins 11 onto the field of view 4 on the patient (not shown). The MPH 2 also provides the image signal to the display 151 to be viewed on the display 151 . The image signal includes both the veins and the needle 14 . The display 151 includes image processing capabilities that detects the position of the tip of the needle and displays a predetermined number of pixels of the image around the tip of the needle on the display. In FIG. 14C , both the image of the needle 153 and the image of the vein 152 are shown.
[0036] The unit of FIG. 9 is driven by the electronics (not shown) describe previously in FIG. 8 , wherein the computer 325 , including the graphics card logic and 3D software, are miniaturized and housed in the MVE 150 and wherein the display is a small 3D display 326 attached to the MVE 150 . Accordingly, when this device is used, the practioner can view the projected image on patient, as well as the three dimensional image on the 3D display 326 .
[0037] With reference to FIG. 10 , a correction methodology is now described. The projection/imaging optical cone 445 of the MVE unit originates at the mirror of the MVE and diverges from there. The projection angle, for example, could be 60 degrees. A cross section of a patient's arm 446 is shown with a cross section of a first vein 443 shown at a first imaging plane 441 and a cross section of a second vein 444 shown at a second imaging plane 441 . A projection plane 440 is also shown, which is approximately on the top surface of the arm 446 of the patient and represents where the image is displayed on the patient. In this example, the first imaging plane 441 is half way between the projection plane 440 and the second imaging plane 442 . Due to the projection angle, the second imaging plane 442 is wider than the first imaging plane 441 which in turn is wider than the projection plane 440 . In this example, the first vein and the second vein are each the same size. The first vein 443 as viewed at the first imaging plane 441 is one quarter the width of the first image plane 441 . The second vein 444 as viewed at the second imaging plane 442 is one sixth the width of the second image plane 442 . Accordingly when the images of the first and second veins are projected on the arm 446 on projection plane 440 , the first vein 443 will appear to be one quarter the width of the projection plane 440 , and the second vein 444 will appear to be one sixth the width of the projection plane 440 . It should be noted that neither the projected image of the first vein 443 nor the projected image of the second vein 444 is accurately representative of the actual vein size.
[0038] In accordance with the present invention, a scaling process can be performed prior to transmitting the image of the veins onto the projection image plane 440 . As previously described, the laser power of the 740 nm laser can be sequentially increased for each frame. A depth table correlating the depth of penetration of the 740 nm laser as a function of laser power can be pre-stored in memory. This depth information can then be used to correct the actual image size of the veins 443 and 444 prior to projecting their images onto projection plane 440 . The correction algorithm can be straight forward trigonometry and therefore is not described herein.
[0039] FIG. 11 describes an embodiment which accurately projects the correct vein size regardless of the depth of the veins 443 and 444 within the patients arm. The optical path diverges at an angle 447 and hits a parabolic mirror 448 which is arranged to have a shape so that the optical beam 449 exiting off the mirror 448 is parallel and does not diverge. In this manner, the image of the veins 443 and 444 are both the same size, and when they are projected onto projection plane 440 , the size of the vein images exactly matches that of the actual veins. As an alternative embodiment, a lens could be used instead of a parabolic mirror 448 for converting the diverging optical path to a parallel path.
[0040] As yet a further embodiment, it has been determined that increasing the wavelength of the laser light emitted from the laser 183 increases the depth of penetration into the flesh of the patient. This effect can be used to construct three dimensional images by increasing the wavelength of laser light emitted on sequential frames, thereby allowing the system to determine the depth of the veins (this is similar to the previous embodiment where the laser intensity was increased to obtain greater penetrations).
[0041] It should be noted that all embodiments herein have been described with a 740 nm laser 183 for imaging the veins/arteries. However, a broader range of wavelengths (700 nm to 1000 nm) could be utilized. Similarly, in the event a broader range of wavelengths are emitted by laser 183 , the 740 nm photo detector 182 could be changed to a different wavelength to receive the associated wavelength (700 nm-1000 nm). Still further, the 630 nm (red) laser 180 has been utilized for displaying the image on a patient. The 630 nm (red) laser 180 could be replaced with any visible laser (generally in the range of 400 nm-700 nm). Still further, the single (red) laser 180 could be replaced with multiple lasers configured so that they project coaxially. For example, if red, green and blue lasers are utilized, full color images can be rendered.
[0042] It also should be noted that often description is made of identifying vein, and in some cases veins and/or arteries. The invention is not limited thereto. Any portion of the body containing blood would be appropriately imaged by the devices of this invention.
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An apparatus and method for creating a three dimensional imaging system is disclosed. There is a first source of laser light and a second source of laser light having a wavelength different from the wavelength of the laser light of the first source. The laser light from the first and second sources are combined, and the combined laser light is transmitted to a scanner. The scanner further transmits the combined light to a surface to be imaged.
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BACKGROUND AND OBJECTS OF THE INVENTION
This invention relates to an improved method and apparatus of providing a daily cover to overlie and, in effect, seal dumped waste such as trash, garbage, fly ash and bottom ash in a landfill or other dump area.
It is common in landfill or dump operations which receive garbage, trash and/or ash deposits during the day to provide a covering layer of compacted earth approximately six inches to two feet deep at the end of the day. This earth layer is to prevent the escape of odors, the blowing of papers and other trash into the adjacent area, the proliferation of pests such as flies, rodents, and birds, and the leaching of toxic or disagreeable components from the dumped material. This cover material provision often termed "daily cover" is frequently required by municipal, state, and/or federal regulations which govern such landfill or dump operations.
The task of placing and compacting an earth "daily cover" represents a very significant portion of the landfill operating cost since it employs significant labor and heavy equipment. Such compacted earth cover performs its principle function only for a day or so, that is, each day's garbage or trash layer is covered at the end of the day and further garbage and trash layers are then piled directly on top of the previous day's "daily cover."
Besides the cost of applying the compacted earth cover, it is recognized that multiple earth fill layers used in this way consume a significant volume of the valuable landfill space which might otherwise be used for receiving garbage or trash. It is well known that many areas are rapidly exhausting their available landfill acreage and reducing the consumption rate of the available landfill volume is, accordingly, desirable.
An alternate solution to the provision of such compacted earth cover has been proposed and described in U.S. Pat. Nos. 4,421,788 and 4,519,338 in which means are disclosed for coating the landfill surface with a non-biodegradable plastic foam spray which, in effect, provides the "daily cover." Such process, however, utilizes high pressure spray equipment which tends to blow away the debris. Although this foam spray method reduces the volume consumed by the compacted earth layer alternative, such method still adds a small amount of undesirable volume to the landfill. In addition, the proposed plastic spray solution is expensive, and its applicability limited to dry climates and may even add its own contamination to the landfill depending on the plastic foam utilized.
Accordingly, it would be desirable to provide a "daily cover" for such landfills which utilizes no additional space therein and accomplishes its overall objectives in a straightforward, relatively inexpensive and low tech manner. These and other objects of the present invention are accomplished by the provision of a daily cover for a working face of a landfill having a surface roughly defined by a front laterally extending edge and a rear edge longitudinally separated therefrom, comprising providing a sheet-like member in a compacted form, said member having an extended length and width to cover at least a substantial portion of said working face, said member having a laterally extending trailing edge, fixedly positioning said trailing edge onto said landfill working face at a position longitudinally remote from said front edge thereof and thereafter moving the remaining portions of said member towards said front edge so as to extend said member and cover said working face.
Other objects, features and advantages of the invention shall become apparent as the description thereof proceeds when considered in connection with the accompanying illustrative drawings.
DESCRIPTION OF THE DRAWINGS
In the drawings which illustrate the best mode presently contemplated for carrying out the present invention:
FIG. 1 is a top plan view showing a landfill and a working face thereof with the device of the present invention in position;
FIG. 2 is a schematic elevational view of FIG. 1 showing the manner in which the cover member of the present invention may be applied to the working face of the landfill;
FIG. 3 is top plan view of the carriage which houses the rolled cover member; and
FIG. 4 is an enlarged sectional view showing the manner in which specially provided pegs or stakes may be utilized to fix the trailing edge of the member to the landfill.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings and more particularly FIGS. 1 and 2 thereof, a landfill 10 or a portion thereof is depicted including a working face 12. By working face, it is meant that landfill portion 10 that is being worked at the present time, that is, the normally downwardly sloping face onto which trash, garbage and like is dumped and thereafter compacted. Normally such compacting is done periodically through the landfill working day and then prior to end thereof a working cover provided thereon such that loose trash such as papers and the like are not blown away overnight and some protection is provided against scavengers and from run off inherent in the dumped mass itself or from wet weather conditions. The extent of such working face 12 is, of course, dependent on the particular landfill being considered, but normally it is somewhere between forty and two hundred feet in lateral extent with the longitudinally sloping dimension dependent upon the particular site but generally within the range of fifty and two hundred feet. In addition while the present invention will be described in relationship to a sloping working face 12, it should be brought out that the working face need not be sloping but may be even a flat portion of an overall landfill, the important aspect being that it is the portion of the landfill being worked which causes the problems the present invention solves.
The crux of the present invention is the provision of a rolled sheet-like member 14 which in its extended position acts as a cover for all or a substantial portion of the working face 12 such that it may be substituted for the normal "daily cover" now provided in such landfill sites, that is, an additional layer of dirt to provide such cover.
The member 14 is preferably of heavy-duty canvas material and exhibits a trailing edge 16 which is adapted to be pinned or otherwise secured to a rear landfill edge 18 and then extended to cover the working surface thereof such that a portion of the member thereafter overlies the front laterally extending landfill edge 20. Stated differently, it is the overall intent for the member 14 to cover the working face 12 of the landfill with the proviso that it is, of course, possible with large working faces that two or more members 14 may be laid laterally side by side with some overlap to assure the desirable features of the present invention are accomplished. Generally, such canvas or other material should be waterproof and flame retardant so as to meet existing state, etc. requirements for a dirt cover although in some environments may be of an open mesh or net-like construction. Also, the material sheet may be formed from suitable plastic resin materials such as polypropylene.
The trailing edge 16 of the member 14 (as well as the side edges in some cases) is preferably provided with a series of reinforced eyelets or openings 22 which extend through the body of the member 14 in a laterally extending line and used for a purpose which will hereinafter be more fully defined. The member 14 is normally presented in a rolled form upon a device such as a carriage 30 provided for such purpose such that at the conclusion of the landfill working day, the member 14 in rolled form is positioned adjacent the inner edge 18 of the working face 12. Thereafter, the trailing edge 16 thereof is placed on the landfill surface after which transversely extending elongated members such as pieces of wood 40 are laid parallel to the line of openings 22 and thereafter stakes 42 driven through the openings 22 to force the wooden members 40 into pinning contact with the member 14 upper surface. The stakes 42 besides exhibiting a normal body 44 having a pointed end 46 include an inwardly extending generally L-shaped head 46 which terminates in a downwardly extending point 48 adapted to extend into but not through the wooden member 40 such that the desired pinning contact with the member 14 is effected without tearing such member. It should also be pointed out that the stakes 42 may have a more conventional flattened upper head 46, the under surfaces of which are smooth and provide the pinning contact between the member 14 upper surfaces and the landfill supporting surface 10.
Thereafter, the remaining rolled or otherwise compacted portions of the sheet-like member 14 are extended downwardly across the working face 12 until reaching the front edge thereof; thus, in effect, providing a substitute "daily cover" for the working face 12. The member 14 remains in such position until just prior to the subsequent working day when it is removed such that additional trash and garbage may be piled and compacted against the working face 12 thus forming a new working face which is then recovered at the end of the next day and so on.
Turning again to the drawings and particularly FIG. 3 thereof, the carriage 30 of the present invention is best shown. Such carriage 30 includes an open frame 32 comprising a pair of laterally opposed side pieces 34 in turn integrally attached to a front beam 36 and a rear beam 38. A roller 50 extends between the side pieces or beams 32 and is mounted for rotation with respect thereof. Such rotation may be free or by means of a gear or other power-driven system not shown. The member 14 leading edge (not shown) is conventionally fixed to the roller 50 and thence the remainder of the member 14 wound thereon to present an enlarged roll adapted to be suspended between the lateral extents of such frame 32. The front beam 36 is further provided with a hitch 52 such that the carriage 30 may be attached to and maneuvered into the desired position by a tractor or other commonly used landfill compacting and trash/earth moving equipment. Such beam may also include a crank or otherwise operated landing gear 53 or other support, leg or the like such that the front end of the carriage may be supported at a predetermined height to facilitate connection of the hitch 52 to a tractor or other piece of equipment.
Also, a tool box 54 is conveniently provided between two adjacent beams and as shown in FIG. 3 extends above the member 14 as its trailing edge downwardly is, in effect, threaded below the rear beam 38 to assume its position adjacent the rear edge 18 of the working face 12. After the trailing edge 16 is so positioned, the tractor via the hitch 52 will slowly move the carriage 30 down the working face 12 into the position shown by the dotted lines in FIG. 2 where it remains until the subsequent landfill working day is to commence whereupon the tractor is now utilized to push the carriage slowly up the working face 12 while the roller 50 is simultaneously manually or mechanically wound to take up the member 14 extending across the working face and reroll the member upon the roller 50. In this regard, the rear beam 38 may be provided with brushes (not shown) or other mechanisms downwardly and upwardly extending therefrom to contact either one or both member 14 surfaces to remove trash, garbage and the like therefrom prior to being rerolled and stored. In the instructional example shown in the drawings, however, such brushes are omitted and the rear beam 38 lower surface in effect by contacting the member 14 upper surface as the carriage is forced up the working face 12 tends to dislodge any such trash or garbage that may adhere to the under face of the member 14.
In order to facilitate the above described movement of the carriage 30, the frame 30 is provided with wheels 56 which downwardly extend from opposite sides of the side pieces 34 via trunnion members 58. It should also be pointed out that various reinforcing beams or pieces (not shown) may be utilized to strengthen or assure the frame is of satisfactorily rigid construction for the intended purpose.
While there is shown and described herein certain specific structure embodying this invention, it will be manifest to those skilled in the art that various modifications and rearrangements of the parts may be made without departing from the spirit and scope of the underlying inventive concept and that the same is not limited to the particular forms herein shown and described except insofar as indicated by the scope of the appended claims.
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A method and apparatus for applying a "daily cover" to the working face of a landfill. A sheet-like member preferably of imperforate construction such as canvas and the like is positioned at the end of a working day at one edge of the working face such that one edge of the member is adjacent thereto. The member is then fixed to the landfill and then unrolled to its extended position to cover at least a significant portion of the working face and thus obviate the need for a conventional "daily cover" in the form of six inches to two feet of compacted earth.
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[0001] This application claims the benefit under 35 U.S.C. 119(e) of the filing date of Provisional U.S. Application Ser. No. 61/556,128, entitled Systems and Methods for Percutaneous Intravascular Access and Guidewire Placement, filed on Nov. 4, 2011. This application is also related to commonly owned U.S. patent application Ser. No. 13/161,183, entitled Systems and Methods for Creating Arteriovenous (A Fistulas, and U.S. patent application Ser. No. 13/161,356, entitled Intravascular Arterial to Venous Anastomosis and Tissue Welding Catheter, both filed on Jun. 15, 2011. All of the foregoing applications are expressly incorporated herein by reference, in their entirety.
BACKGROUND OF THE INVENTION
[0002] In the body, various fluids are transported through conduits throughout the organism to perform various essential functions. Blood vessels, arteries, veins, and capillaries carry blood throughout the body, carrying nutrients and waste products to different organs and tissues for processing. Bile ducts carry bile from the liver to the duodenum. Ureters carry urine from the kidneys to the bladder. The intestines carry nutrients and waste products from the mouth to the anus.
[0003] In medical practice, there is often a need to connect conduits to one another or to a replacement conduit to treat disease or dysfunction of the existing conduits. The connection created between conduits is called an anastomosis.
[0004] In blood vessels, anastomoses are made between veins and arteries, arteries and arteries, or veins and veins. The purpose of these connections is to create either a high flow connection, or fistula, between an artery and a vein, or to carry blood around an obstruction in a replacement conduit, or bypass. The conduit for a bypass is a vein, artery, or prosthetic graft.
[0005] An anastomosis is created during surgery by bringing two vessels or a conduit into direct contact. The vessels are joined together with suture or clips. The anastomosis can be end-to-end, end-to-side, or side-to-side. In blood vessels, the anastomosis is elliptical in shape and is most commonly sewn by hand with a continuous suture. Other methods for anastomosis creation have been used including carbon dioxide laser, and a number of methods using various connecting prosthesis, clips, and stents.
[0006] An arterio-venous fistula (AVF) is created by connecting an artery to a vein. This type of connection is used for hemodialysis, to increase exercise tolerance, to keep an artery or vein open, or to provide reliable access for chemotherapy.
[0007] An alternative is to connect a prosthetic graft from an artery to a vein for the same purpose of creating a high flow connection between artery and vein. This is called an arterio-venous graft, and requires two anastomoses. One is between artery and graft, and the second is between graft and vein.
[0008] A bypass is similar to an arteriovenous graft. To bypass an obstruction, two anastomoses and a conduit are required. A proximal anastomosis is created from a blood vessel to a conduit. The conduit extends around the obstruction, and a second distal anastomosis is created between the conduit and vessel beyond the obstruction.
[0009] As noted above, in current medical practice, it is desirable to connect arteries to veins to create a fistula for the purpose of hemodialysis. The process of hemodialysis requires the removal of blood from the body at a rapid rate, passing the blood through a dialysis machine, and returning the blood to the body. The access to the blood circulation is achieved with (1) catheters placed in large veins, (2) prosthetic grafts attached to an artery and a vein, or (3) a fistula where an artery is attached directly to the vein.
[0010] Hemodialysis is required by patients with kidney failure. A fistula using native blood vessels is one way to create high blood flow. The fistula provides a high flow of blood that can be withdrawn from the body into a dialysis machine to remove waste products and then returned to the body. The blood is withdrawn through a large access needle near the artery and returned to the fistula through a second large return needle. These fistulas are typically created in the forearm, upper arm, less frequently in the thigh, and in rare cases, elsewhere in the body. It is important that the fistula be able to achieve a flow rate of 500 ml per minute or greater, in order for the vein to mature or grow. The vein is considered mature once it reaches >4 mm and can be accessed with a large needle. The segment of vein in which the fistula is created needs to be long enough (>6 cm) to allow adequate separation of the access and return needle to prevent recirculation of dialysed and non-dialysed blood between the needles inserted in the fistula.
[0011] Fistulas are created in anesthetized patients by carefully dissecting an artery and vein from their surrounding tissue, and sewing the vessels together with fine suture or clips. The connection thus created is an anastomosis. It is highly desirable to be able to make the anastomosis quickly, reliably, with less dissection, and with less pain. It is important that the anastomosis is the correct size, is smooth, and that the artery and vein are not twisted.
SUMMARY OF THE INVENTION
[0012] The present disclosed invention eliminates the above described open procedures, reduces operating time, and allows for a consistent and repeatable fistula creation.
[0013] The present invention comprises a device to allow passage of a guidewire from a primary blood vessel to an adjacent secondary blood vessel, which comprises a main body having a primary lumen and a secondary lumen and a piercing member disposed in the secondary lumen, and configured to be moved distally out of the secondary lumen, and to pierce through tissue while being distally moved. A third lumen located within the piercing member is configured to allow placement of a guidewire from the primary blood vessel to the adjacent secondary blood vessel.
[0014] In one embodiment, the secondary lumen is constructed out of superelastic material, such as Nitinol, that is shaped such that the distal tip is oriented toward the adjacent secondary blood vessel. The secondary lumen may have a “J” shape heat set into the secondary lumen; however, different shapes may be used depending upon the type of anatomy that is being accessed. The primary lumen is configured with a stiffness such that it has the ability to straighten the shape of the secondary lumen. Either advancing or retracting the primary lumen relative to the secondary lumen can adjust the rise, or shape, of the secondary lumen. Shaping the primary lumen can further modify the angle at which the piercing member exits the secondary lumen. In an alternative embodiment, the shape of the secondary lumen may be modified using a tendon wire. In still another embodiment, the piercing member is designed to remain in a substantially straight configuration.
[0015] In another aspect of the invention, the distal tip of the secondary lumen has a feature to make it such that it will not perforate the primary lumen as it is being placed into a desired position within the body. In the first embodiment noted above, the tip has a large diameter polymer tip that has a rounded distal edge and is atraumatic. This distal tip also has features that make it visible under different imaging techniques, such as ultrasound, fluoroscopy, CT, or MRI. There is a coil constructed of a radiopaque material, embedded in the polymer tip. Small particles of air or other radiopaque materials known to those skilled in the art can also be used to increase the radiopacity of the tip.
[0016] The hollow piercing member has a sharp point on the distal tip that exits from the primary vessel by puncturing its wall and enters into the secondary vessel in the same manner. In one embodiment, the sharp distal point is constructed using a lancet point. The primary bevel is ground at an angle between 12 and 20 degrees with a secondary angle between 5-20 degrees, with a rotation angle between 25-45 degrees. The needle grind is designed such that it pierces through the vessel wall and does not core, or cut a plug, through the vessel wall, to minimize bleeding between vessels when removed after the guidewire is placed into the secondary vessel. The outer diameter of the piercing member is also minimized to further reduce bleeding. The piercing member is oriented within the secondary lumen such that the tip of the lancet point is directed toward the adjacent secondary vessel. Other piercing mechanisms, or needle point grind configurations, known to those skilled in the art may be provided.
[0017] More particularly, there is provided a device for creating intravascular access and guidewire placement, which comprises a main body having a first lumen, a piercing member disposed in that lumen, and configured to be moved distally out of said lumen and to pierce through tissue while being distally moved, and a handle attached to the main body and having an actuator for moving the piercing member. A second lumen is disposed within the piercing member. A guidewire is disposed in the second lumen for delivery into a desired site from a distal end of the second lumen. The piercing member has a sharp point on one end thereof.
[0018] In one disclosed embodiment, a third lumen is disposed within the main body, outwardly of the first lumen. The piercing member is retractable into the first lumen. The third lumen is defined by a needle guide having shape memory properties, the needle guide being actuatable to a curved orientation by adjustment of a position of the main body to create an incrementally adjustable radius of curvature on the needle guide. The piercing member has shape memory properties, and is actuatable to create an incrementally adjustable radius of curvature.
[0019] The actuator for moving the piercing needle linearly comprises a slide. In the curved embodiment, a second actuator is disposed on the handle for actuating the needle guide to a curved orientation. This actuator comprises a rotatable knob. In both embodiments, the first lumen is defined by a needle guide having an atraumatic distal tip having a relatively large diameter. The atraumatic distal tip is comprised of a polymer material and further comprises radiopaque materials. Preferably, the radiopaque materials comprise a plurality of coils constructed of a radiopaque material.
[0020] The sharp point preferably comprises a lancet point and primary bevels.
[0021] In another aspect of the invention, there is disclosed a method of creating intravascular access and guidewire delivery, which comprises steps of positioning the main body of a device within a primary vessel and manipulating a distal end of the device to engage an inner wall of the primary vessel and to push the primary vessel into close engagement with an adjacent secondary vessel. Yet another step comprises extending the piercing member distally from the main body, through the wall of the primary vessel, and through an adjacent wall of the secondary vessel, so that the end of the piercing member is disposed within the secondary vessel for creating a communicating aperture on the opposing walls of the primary and secondary vessel.
[0022] In one embodiment, the method comprises a further step of incrementally adjusting a radius of curvature of the piercing member. In both embodiments, the positioning step is performed percutaneously.
[0023] The method further comprises a step of advancing a guidewire distally through a lumen in the piercing member from the primary vessel into the secondary vessel, and a step of withdrawing the device from the vessel, thus leaving the guidewire in place and crossing from the primary vessel to the secondary vessel through said communicating aperture.
[0024] In still another aspect of the invention, a method of creating a passage between adjacent primary and secondary blood vessels is disclosed, comprising a step of positioning a main body of the device within the primary vessel and extending a piercing member distally from the main body, through the wall of the primary vessel, and through an adjacent wall of the secondary vessel, so that the piercing member is disposed within the secondary vessel. The secondary lumen is linearly actuated to move relative to a distal end of the piercing member for articulating the distal end of the piercing member for cutting a small communicating aperture from the primary blood vessel to the adjacent secondary blood vessel. The method further comprises the step of advancing a guidewire distally within the piercing element to pass from the primary blood vessel, while maintaining position substantially within the primary blood vessel, to the adjacent secondary blood vessel.
[0025] The invention, together with additional features and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying illustrative drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 a is a view of one embodiment of the device of the present invention, wherein the device has been percutaneously or surgically positioned at a desired location in a blood vessel;
[0027] FIG. 1 b is a view, similar to FIG. 1 a, of another embodiment of the device of the present invention, wherein the device has been percutaneously or surgically positioned at a desired location in a blood vessel;
[0028] FIG. 2 a is a view of the FIG. 1 a embodiment of the present invention, illustrating the distal piercing element in isolation;
[0029] FIG. 2 b is a view, similar to FIG. 2 a , of the embodiment of FIG. 1 b, illustrating the distal piercing element in isolation;
[0030] FIG. 3 a is a view similar to FIG. 2 a , wherein the distal piercing element of FIG. 2 a has been advanced distally to push the blood vessel in which it is disposed into contact with the adjacent blood vessel;
[0031] FIG. 3 b is a view similar to FIG. 2 b , wherein the distal piercing element of FIG. 2 b has been advanced distally to push the blood vessel in which it is disposed into contact with the adjacent blood vessel;
[0032] FIG. 4 a is a view similar to FIG. 3 a , wherein the piercing element is advanced from the primary blood vessel into the adjacent secondary blood vessel;
[0033] FIG. 4 b is a view similar to FIG. 3 b , wherein the piercing element is advanced from the primary blood vessel into the adjacent secondary blood vessel;
[0034] FIG. 5 a is a view similar to FIG. 4 a , wherein a guidewire is extended from the primary blood vessel and into the adjacent secondary blood vessel;
[0035] FIG. 5 b is a view similar to FIG. 4 b , wherein a guidewire is extended from the primary blood vessel and into the adjacent secondary blood vessel;
[0036] FIG. 6 illustrates the small communicating aperture and the guidewire placement created by the device and methods of the present invention after either embodiment of the inventive device of FIGS. 1 a - 5 b has been withdrawn from the procedural site; and
[0037] FIG. 7 illustrates an isolated detail view of the distal tip of the piercing element for the illustrated embodiments.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0038] Referring now more particularly to the drawings shown in FIGS. 1 a - 7 , there are illustrated several embodiments of a device and system constructed in accordance with the principles of the present invention. As illustrated in FIG. 1 a, one embodiment of the device 10 comprises a handle or handpiece 2 and a main body shaft 12 having a primary lumen 18 and a secondary lumen 14 ( FIG. 2 a ). To begin the inventive method of intravascular access and communication, the practitioner selects an appropriate procedural site having each of a primary blood vessel 24 and a secondary blood vessel 26 ( FIG. 1 ) in close proximity to one another. In currently preferred approaches, the primary blood vessel 24 comprises a vein, and the secondary blood vessel 26 comprises an artery, but the invention is not limited to this arrangement. The main body 12 is inserted into primary vessel 24 so that the distal end 32 thereof ( FIG. 2 a ) lies within the blood flow passage of the primary vessel. Preferably, this insertion step is performed using percutaneous technique, but open surgery may also be employed.
[0039] With reference now to FIG. 2 a , a piercing element 20 comprises a needle guide 34 , lumen 22 , and a distal tip 36 , and can be adjustably oriented axially within the secondary lumen 14 of a needle guide 16 . These elements are further adjustably oriented axially within lumen 18 of the needle guide 16 , and lumen 22 provides an externally communicating passage. A distal end 40 of the needle guide 16 comprises a blunt large diameter atraumatic tip, comprised of a polymer material, having a rounded distal edge. This distal tip 40 also has features that make it visible under different imaging techniques, such as ultrasound, fluoroscopy, CT, or MRI. There is a coil 42 constructed of a radiopaque material, embedded in the polymer tip 40 . Small particles of air or other radiopaque materials known to those skilled in the art may also be used to increase the radiopacity of the tip.
[0040] Referring to FIGS. 2 a and 3 a , the blunt tip 40 is manipulated to contact an inner wall of the primary vessel and to push it into desired engagement with the adjacent wall of the secondary vessel, as shown in FIG. 3 a . The position of desired engagement is arranged to optimize the piercing step to be next described. The distal tip 36 of the piercing element 20 may be longitudinally extended with respect to the needle guide 34 , between a range of the radius of curvature along axis 35 of needle guide 34 , using a slide 8 on the handle 2 . A first, or retracted, position is illustrated in FIG. 2 a , where the distal tip 36 is within the secondary lumen 14 of needle guide 16 . As will be described more fully below, the retracted orientation is utilized during the initial device insertion steps, as well as the device withdrawal steps, while variable extended orientations are the operative orientation for creating the communication passageway and guidewire placement. Needle guide 34 of piercing element 20 is fabricated of a material that has shape memory properties that allow it to be held in an essentially axial position indefinitely by needle guide 16 , while in the orientation shown in FIG. 2 a , and can achieve an incremental increase in the radius of curvature as distal tip 36 is extended beyond the end of needle guide 16 as shown in FIG. 3 a . This variable orientation of the radius of curvature may be desirable by the practitioner to more effectively aim the distal tip 36 of the piercing element 20 in order to achieve a more desirable orientation for access from primary vessel 24 to secondary vessel 26 . In one version of this embodiment, the needle guide 34 is fabricated of a superelastic material, such as Nitinol, to achieve this curvature effect. However, it should be noted that the needle guide 34 need not necessarily be made of a superelastic material for this embodiment to function. Since the shape of the needle guide comes from the secondary lumen 14 , its shape is determined by moving the primary lumen 18 axially.
[0041] Referring again to FIG. 3 a , once the main body 12 is inserted into primary vessel 24 and advanced to the desired site determined by the practitioner using ultrasound or fluoroscopic imaging, as previously described, it may be desired to adjust the radius of curvature of needle guide 34 to increase the angle of the axis of distal tip 36 by rotating knob 4 of handle 2 . Since piercing distal tip 36 is configured to have echogenic and radiopaque properties to allow the practitioner to visualize the orientation of piercing tip 36 under real time imaging guidance, and the main body 12 of device 10 is incrementally rotatable about its axis, this will allow the practitioner to more effectively aim piercing tip 36 through direct visualization as secondary blood vessel 26 is “nudged” by the atraumatic tip of the needle guide 16 of the device 10 as the main body is incrementally rotated and the radius of curvature as desired, to allow more accurate penetration from primary blood vessel 24 to secondary blood vessel 26 .
[0042] With reference now to FIG. 4 a , once the practitioner has oriented piercing tip 36 as desired for optimal penetration, knob 4 of handle 2 is advanced to penetrate from primary blood vessel 24 through the primary vessel wall 44 to secondary blood vessel 26 through the secondary vessel wall 46 . This may be done under direct imaging guidance to verify complete penetration without extending beyond the flow passage of blood vessel 26 . The practitioner may also verify acceptable penetration through direct visualization of blood that flows through lumen 22 and exits aperture 4 of handle 2 as shown in FIG. 1 .
[0043] With reference now to FIG. 5 a , once penetration from primary blood vessel 24 to secondary blood vessel 26 has been achieved, a guidewire 28 , preferably having a diameter of 0.014″ or less, is advanced through an aperture 6 of the handle 2 until the guidewire is positioned in the blood flow path of blood vessel 26 sufficiently to allow device 10 to be removed while retaining its position in blood vessel 26 . With reference now to FIG. 6 , once guidewire 28 is sufficiently in position as previously described, the practitioner withdraws the device 10 completely from the body, thus leaving the guidewire in the desired position and crossing from primary vessel 24 to secondary vessel 26 .
[0044] FIG. 7 illustrates a detail view of the configuration of the piercing tip 36 utilized in both of the illustrated embodiments. The tip is configured to have a lancet point 48 to enhance the penetration from primary blood vessel 24 to secondary blood vessel 26 . A primary bevel 50 is ground at an angle between 12 and 20 degrees with a secondary angle between 5-20 degrees, with a rotation angle between 25-45 degrees. The needle grind is designed such that it pierces through the vessel wall and does not core, or cut a plug, through the vessel wall, to minimize bleeding between vessels when removed after the guidewire is placed into the secondary vessel. The outer diameter of the piercing member is also minimized to further reduce bleeding. The piercing member is oriented within the secondary lumen such that the tip of the lancet point is directed toward the adjacent secondary vessel. Other piercing mechanisms, or needle point grind configurations, known to those skilled in the art may be provided.
[0045] The embodiment of FIGS. 1 b, 2 b, 3 b, 4 b, and 5 b (the “B” embodiment) is similar in most respects to that of FIGS. 1 a, 2 a, 3 a, 4 a, and 5 a (the “A” embodiment), differing only in the details to be explained below. All common elements to those in the A embodiment are identified by common reference numerals in the figures illustrating the B embodiment, and the method sequencing shown in FIGS. 2 b , 3 b , 4 b , and 5 b is similar to that shown in FIGS. 2 a , 3 a , 4 a , and 5 a . FIGS. 6 and 7 are common to both embodiments.
[0046] The major difference between the A and B embodiments is that in the B embodiment the primary lumen 14 has been eliminated. This is because, in this embodiment, the shape of the needle guide 34 is not adjustable. Thus, it remains straight, and need not be fabricated of superelastic material. This arrangement is possible because the blunt tip 40 may be manipulated by the practitioner to ensure that the adjacent vessel walls of the primary and secondary vessel may be pierced by an axial advancement of the piercing member, as shown in FIG. 3 b . As a result of this change, the knob 4 has also been eliminated, since control of the curvature of needle guide 34 is not required.
[0047] Accordingly, although an exemplary embodiment and method according to the invention have been shown and described, it is to be understood that all the terms used herein are descriptive rather than limiting, and that many changes, modifications, and substitutions may be made by one having ordinary skill in the art without departing from the spirit and scope of the invention.
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A device for allowing passage of a guidewire from a primary blood vessel to an adjacent secondary blood vessel includes a main body having a primary lumen and a secondary lumen, and a piercing member disposed in the secondary lumen, and configured to be moved distally out of the secondary lumen, and to pierce through tissue while being distally moved. A third lumen located within the piercing member is configured to allow placement of a guidewire from the primary blood vessel to the adjacent secondary blood vessel. In one embodiment, the secondary lumen is configured to allow articulation of the distal end of the piercing element. The piercing member has a sharp point on one end to facilitate cutting a small communicating aperture from the primary blood vessel to the secondary blood vessel.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 12/440,008, filed Nov. 6, 2009, which claims the benefit of International Application No. PCT/EP2007/058476 filed Aug. 15, 2007 and which claims the benefit of Finland Patent Application No. 20065557, the disclosures of all applications being incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for filling and cleaning a pulp tower. The invention is most suitable for filling and cleaning high-consistency pulp towers, bleaching towers, storage tanks and similar towers containing fiber suspensions, within the wood-processing industry.
Pulp towers within the wood-processing industry are in most cases tanks containing high-consistency pulp, whose consistency is about 10-20 percent, occasionally also pulp of low consistency, and which are used, e.g., for pulp storage or processing. Moreover, pulp towers are used as a blow tank for some devices or to store, e.g., pulp arriving periodically from batch digesters, which pulp is used as a steady flow in following processing devices. In other words, it is characteristic of the towers of the invention that they are basically large (diameter is generally on the order of 4-12 meters, and their height around 20-30 meters, although both smaller and larger towers exist), and that their surface level varies greatly, even if in most cases they have an optimal surface level, and it is generally desired to maintain the pulp surface at that level.
Many problems have been observed concerning the use of these towers or tanks. They relate mainly to the filling or emptying of the towers, or the inside fouling of the tower due to the stored or processed material adhering to the wall of the tower. In the following, the focus will be on discussing how the tower is filled and its fouling prevented, which is the subject matter of the present invention.
Many different solutions for filling the towers of the type mentioned above are previously known. The oldest known methods consist in pumping pulp to the top of the tower and allowing it to fall more or less directly downward. If pulp is allowed to fall directly downward on top of existing pulp, it is obvious that the pulp falling from above will pass through the surface of the pulp layer in the tower and penetrate deep into the old pulp. This gives rise to many disadvantages. First of all, if pulp dilution is performed at the tower bottom, as is very often the case, the pulp fed into the tower may penetrate as far as to the dilution zone. Hence pulp is discharged uncontrollably into the dilution zone, and dilution uniformity no longer corresponds to the requirements of the apparatus downstream of the tower. Another problem is that the pulp penetrating into the old pulp drifts closer to the tower discharge opening than does the pulp already in the tower, so that the content of the tower will not be evenly changed—instead a part of the pulp is carried out of the tower in a few minutes while a part of the pulp remains in the tower in the worst case even for days or weeks. More problems ensue in turn from this. First of all, it is impossible to imagine that pulp staying in the tower for days or even weeks may retain a quality similar to that of fresh pulp. Secondly, performing a complete change of grade in such towers may take days, or at best several hours, whereby the pulp discharged from the tower during the change period is a mixture of the new and old pulp grade. Depending on the subsequent use of the pulp, this so-called intermediate pulp may, in the worst case, be completely useless. Furthermore, old pulp remaining for a longer period in the same place in the tower, and new pulp flowing therethrough and deeper into the tower, gradually allow liquid to seep away from the surface of the pulp layer, whereby the surface layer hardens and may become more easily decayed. At the same time, old pulp also adheres more easily to the tower walls, from which it may detach as large solid pieces, which no longer disperse properly at the dilution zone of the tower.
Of course, the pulp may also be discharged into a distributor, e.g. a rotating disk arranged on top of the tower (e.g., SE-B-463 030), which distributes the pulp more evenly over the whole cross-section of the tower. While the distributor disperses the pulp flow into droplets, or at least relatively small-sized particles, a considerable amount of air is bound to the pulp as it descends, which air must be removed at a later stage of the process by vacuum pumps or by similar systems consuming a great deal of energy. In some towers, the pulp is carried from below to the bottom of a rotating disk provided with vanes (SE-C-502,971) so that the vanes spread the pulp over the cross-section of the tower. The publication states that the rotational speed of an electric motor used to rotate the disk may be changed in order to obtain the various degrees of spreading, whatever this means. This procedure is affected by the same problems as the rotating disk; i.e., the pulp forms droplets and a great deal of air is bound to the pulp. Another problem that may be mentioned is that rotating disks or the like described in the prior art do not allow for surface level variations in the tower, and instead are only suitable at some constant surface level, which practically in most cases means a full tower, whereby the disk or the like is placed only a little above the surface of the pulp in the tower. In an emptier tower the rotating disk throws the pulp against the wall of the tower, whereby it at the latest falls into drops and absorbs a great amount of air.
U.S. Pat. No. 4,278,496 discloses a filling arrangement for a bleaching tower within the pulp industry, wherein pulp is delivered to the tower through a rotating pipe fitting such that the pulp is spread in layers in the tower. However, this is a continuous process, where the surface level in the tower remains practically constant, and it is not critical that the pulp be spread out completely evenly into the tower, since the consistency of the pulp delivered to the tower is in the HC [high-consistency] area, in other words according to the publication, between 35 and 50 percent. With such high consistencies, there is no substantial danger of the pulp permeating deep into the pulp layer already in the tower, when the direction of pulp feed is not completely vertical. Nor is the mixing of the air into the pulp of any significance, since high-consistency pulp inherently contains large amounts of air.
A further problem that is not addressed concerns the storage of the bleached pulp. In some cases, it is namely of paramount importance that the pulp be discharged from both the bleaching tower and a possibly following storage or blow tank to ensure that the time the pulp stays in the tower or tank is kept constant. In other words, no part of the pulp may be left standing in the tower, since this will compromise its quality in one way or another. It was found, among other things, that the brightness of the pulp is reduced when the surface in the tower is lowered. This means in practice that the longer the pulp stays in the tower, the lower its brightness will be, or in the optimal case, the aim would be to discharge pulp from the tower in exactly the same order as it was fed in, or to maintain the time the pulp stays in the tower constant. It was furthermore observed that restarting the filling of the tower according to a prior-art method (direct blow via the top of the tower) increases the brightness of the pulp removed from the tower very quickly again. The only explanation for this would be that the blow coming from the tower continues almost directly to the tower discharge opening, whereby the pulp remaining in the tower will stay at the areas closer to the tower wall and not reach the tower discharge in time for removal.
Finnish patent application 971330 deals with a feed device, which aims to solve as efficiently as possible the problems of the previously described prior art devices. The apparatus in question includes a rotating feeder means arranged in connection with the upper part of the pulp tower, preferably its top or cover, preferably a central shaft relative to the tower, devices for its rotation, devices for delivering the pulp to the feeder means, as well as devices for controlling the operation of the feeder means. The devices for delivering pulp to the tower, except for the pipe leading through the cover, may also consist of a pipe extending through the side wall of the tower substantially to the central shaft of the tower, or the like. A pulp feeder means according to a preferred embodiment of the invention discussed in the publication consists of an elbow pipe arranged at the bottom end of a vertical pulp pipe or a similar entering the tower from above, the discharge opening of the elbow being substantially directed toward the wall of the tank or pulp tower. An important feature of the feeder means of the preferred embodiment described above is that its form does not disperse the pulp flow, i.e. produce sprinkles—instead the aim is to keep the pulp flow uniform, preventing as much as possible the binding of air among the pulp. It is not essential for the invention described in the publication that the discharge opening of the elbow pipe is in the horizontal direction, or tilted slightly up or down, but the direction of the pulp discharged from the discharge opening, along with the rotational speed of the feeder means, should ensure that under all operating conditions of the tower, pulp is discharged also to the proximity of the tower wall. The rotating device for the feeder means is preferably an electric motor with adjustable rotational speed, and optionally provided with a reduction gear. The control devices mentioned for the operation of the feeder means consist of a level sensor and a control unit, as standard equipment for each tower.
Thus it is possible with at least one or perhaps more of the devices mentioned above to feed pulp into the tower such that the tower is filled evenly from above, and the pulp fed to the tower cannot penetrate directly from the feed into the dilution zone.
Another problem with towers is, as pointed out previously, the adhesion of pulp to the tower wall. In practice, this always occurs, i.e. regardless of whichever device is used to feed pulp to the tower. When the pulp has adhered to the wall of the tower, it gradually dries and hardens, whereby it detaches as hard flaky lumps. These lumps do not necessarily disperse sufficiently in the dilution zone, but are instead carried forward to the pump and through it further into the process, where they hamper the process. Another disadvantage, which these cakes of pulp adhered to the wall of the tower may cause, is pulp deterioration. If the pulp remains in the tower for a sufficiently long period, the favorable conditions in the tower, i.e. temperature and moisture, promote deterioration of the pulp due to the influence of various microbes. The deterioration of the pulp may lead to greater pulp lots being deteriorated and also compromise the quality of the end product, unless the problem is noticed and corrected in a timely fashion.
For the above reasons, among other things, the cleanliness of the pulp towers is checked periodically, and the towers are cleaned either manually or by various washing devices arranged in the pulp towers, the washing operation being either continuous or intermittent. Among the washing methods used, manual washing, usually performed with a pressure washer, is the traditional way of handling this. This, however, involves problems of its own. First of all, it is almost impossible to perform washing when the process is ongoing, so that in practice cleaning is limited only to any downtime. Moreover since washing is manual, it is expensive and also somewhat hazardous work.
Thus, to clean the tower, various mechanical devices are proposed, most of which are based on the use of pressurized water or, more broadly, pressurized washing liquid in the washing of the tower. In principle, the devices come in three basic types. There are fixed nozzles and spray pipes, from which washing liquid is sprayed onto the desired portion of the tower wall. Moreover, there are rotating nozzle devices in connection with the cover of the tower, preferably arranged at the central shaft of the tower, where there generally are a large number of pressure liquid nozzles fixed on one or more stems producing the desired washing action in the tower. Further, fixed washing devices are known, consisting of a more or less round distributing chamber, a large number of nozzles being provided at its walls in such a way that they will cover the area to be washed in the inner surface of the tower.
The solutions known from the prior art, however, have their own problems. First of all, the fixed nozzles placed on separate sides of the tower have a relatively complex design requiring ramified liquid piping and numerous attachments, or in some cases, even numerous inlets through the cover of the tower. Also, when using the rotating feed devices known from the patent publications mentioned above, there is the risk of a pulp jet discharging from the feed devices breaking the nozzle pipes, or at least clogging the nozzles. A similar problem also concerns other solutions, in which the nozzle devices are exposed to a pulp jet. Thus, no matter how the washing devices according to the prior art are placed in the tower, there is great risk that they will either become clogged and/or break down due to the action of the pulp that is fed into the tower. Moreover, when the tower filling devices are located at the tower centerline, prior art nozzle solutions to be placed in the same way at the tower centerline, whether rotating or fixed, cannot be placed at the same point, but instead they need to be installed at the side of the tower centerline, thus in turn becoming exposed to the pulp jet.
SUMMARY OF THE INVENTION
The various problems of the previously described prior art solutions may be solved by the method and apparatus according to our invention.
Using the method and apparatus according to the invention, the filling and cleaning of the pulp tower may be done almost without any supervision at all. The washing apparatus is placed so that the pulp jet may neither break nor clog the washing device or its nozzles. The apparatus according to the invention is simple because it exploits already existing structures, as much as possible. Hence, if the tower already has a rotating feed device, its drive mechanism, and the attachment, sealing and bearings provided for it at the cover of the tower, may also be used when installing the device according to the invention.
The invention will be described below in more detail in reference to the attached drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
The FIGURE is an elevational view of an exemplary apparatus for filling and cleaning a pulp tower.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The apparatus according to the invention comprises, according to the FIGURE, a filling unit 12 provided at the top of the pulp tower, preferably at the cover of the tower 10 , preferably placed centrally to the shaft of the tower, the filling unit being provided with a lid 14 , and one or more connections 16 located at the side of the unit for a pipe or pipes delivering pulp to the tower. Inside the unit 12 below this connection there is situated preferably, but not necessarily, a baffle 18 or a funnel guiding pulp entering the tower from the connection 16 in the direction of the shaft of the tower. The lid 14 of this filling unit is provided with a seal and a bearing 20 on a shaft 22 , below which there is fastened a scooping feeder means 24 , which may be, e.g., an elbow pipe, whose discharge opening or edge is substantially directed toward the wall of the tank or pulp tower. An important feature of a feeder used in connection with the invention is that in terms of its form, it does not disperse, i.e. sprinkle, the pulp flow—instead the aim is to keep the pulp flow uniform and prevent as much as possible binding of the air among the pulp. It is not essential, for the feeder means according to the present invention, whether the direction of feed of the feeder means 24 is horizontal, or titled slightly up or down, but the direction of the pulp discharged from the discharge opening, along with the rotational speed of the feeder means 24 , should ensure that under all operating conditions of the tower, pulp is discharged also to the proximity of the tower wall. The rotating device 26 of the feeder means, which according to a preferred embodiment of the invention is preferably a speed-adjustable electric motor, which may optionally be provided with a reduction gear, is arranged outside the tower either in connection with the unit 12 or at a distance from it (as shown in the FIGURE).
This feeder means 26 according to a preferred embodiment of the invention is rotated, e.g. so that the rotational speed of the feeder means is changed both relative to the tower diameter and according to the surface level in the tower. Thus, with each pulp surface level in the tower, the rotational speed of the feeder means is changed such that the feeding of the pulp to the tower occurs at its maximum distance to the vicinity of the tower wall, without the pulp jet hitting the tower wall, and at its minimum close to the shaft of the tower. When the surface level decreases from the one described above, the rotational speed of the feeder means is reduced, since already with the lower rotational speed the pulp jet discharging from the feeder means extends to the vicinity of the tower wall. Similarly, when the surface level rises, the rotational speed is increased.
The apparatus according to the invention includes furthermore an axial channel 28 arranged in the shaft 22 of the feeder means 24 , at the upper end of which channel there is a rotating coupling arrangement 30 for delivering washing liquid to the channel 28 . This coupling arrangement may be such, as represented in the FIGURE, that at a suitable point along the length of the shaft, there is a substantially radial opening in the shaft arranged for carrying washing liquid to a preferably, but not necessarily, central washing-liquid channel of the shaft, or the coupling arrangement may optionally be placed at the upper end of the shaft. It is, of course, possible also to arrange this channel outside the shaft, even if the technical implementation is significantly more complex. Similarly, the shaft 22 is equipped at its lower section with devices 32 for carrying washing liquid from the shaft channel 28 to nozzles. By means of washing-liquid jets discharging from the nozzles either the tower walls or the tower ceiling or both are kept clean. These devices 32 carrying washing liquid are formed by one or more pipes permanently fastened to the shaft or the feeder means 24 , which pipe/s is/are provided with nozzles preferably so that they will not directly contact the pulp that is fed into the tower. One possibility is therefore, as shown in the FIGURE, to place both the devices 32 carrying washing liquid and the nozzles at the back, so that in practice the feeder means 24 feeds the pulp in the opposite direction relative to the washing nozzles.
Depending on the size of the tower, the washing arrangement of the tower according to the invention may also, except for the nozzle pipe 32 in connection with the nozzle arrangement shown in the FIGURE, consist of a solution in which one or more pipes are fastened on the shaft 22 or the feeder means (when the pipe is fastened on the feeder means 24 , devices for carrying washing liquid from the channel 28 of the shaft 22 to the pipe are needed), the pipe/s carrying the washing liquid to a proper nozzle system located further away from the shaft, and the pipes at the same time acting as supports for the nozzle system—or of a solution where one or more nozzles are arranged in direct connection with the feeder means 24 , and by means of the nozzle/s, both the walls and the ceiling of the tower, or either one of them, may be kept clean. The nozzle arrangement mentioned above may, e.g., be a larger chamber located at the end of one or more pipe/s delivering washing liquid, several nozzles having been fastened at the walls of the chamber—or one or more transversal pipe/s provided with one or more nozzles, the pipe/s having been fastened to one or more pipe/s at its/their opposite end/s with regard to the shaft 22 or in proximity thereof.
As a further embodiment of the invention, an apparatus may be devised where in connection with the top of the tower, regardless of whether the tower is provided with a ceiling or a cover, or whether the tower is open at the top, there is arranged a feeding and washing device, which is either continuously or intermittently rotating. This device may preferably, but not necessarily, consist of, e.g., a vertical pipe located in the middle of the tower, the bottom of the pipe being sealed except for a few (e.g., three or four) feed pipes arranged at regular intervals to the circumference of the pipe, from which pipes pulp is discharged at a desired distance toward the side wall of the tower. Between the relevant feed pipes either directly in contact with a vertical pipe or arranged via a stem at a distance therefrom there is arranged a suitable nozzle apparatus, with which the space surrounding the feeding and washing apparatus of the tower is washed. This space refers either to the tower wall, the suspension device of the feeding and washing apparatus, the ceiling of the tower, or any other structure inside the tower, or some combination thereof. The relevant feeding and washing apparatus may be rotated continuously, and at a variable speed, whereby the device is essentially operated the same way as in the previous embodiment; i.e., the distance at which pulp is fed depends on the rotational speed of the feed device.
This embodiment also affords the possibility of keeping the feed device stationary for a while, which, of course, is also possible with the previously discussed embodiment shown in the FIGURE. The idea is now that the tower is filled a few sectors at a time, at the same time as the space surrounding the feed and washing device is washed from the area of the remaining sectors. Characteristic of both this and the prior embodiments of the invention is that the washing process need not be continuous, instead the washing may be pre-set to occur in a desired way, e.g. according to the degree of fouling of the tower.
A feed device feeding in several directions may, except for the previously described sealed-pipe, also be of the open scoop type, as shown in the FIGURE, in which there are several scoops, however. Thus, the washing devices are placed between the scoops, and the feeding of the washing liquid occurs in different directions relative to the directions in which the pulp is fed.
It should be further noted that the washing arrangement according to the invention may be suspended in a tower without any ceiling or cover. This means that both the pulp feeder arrangement and the washing apparatus for the tower walls are suspended either on the tower walls or on a special support structure arranged either in connection therewith or outside thereof.
As can be understood from the above a new method and apparatus for filling/cleaning pulp towers has been designed which corrects the numerous drawbacks of prior art apparatus and methods. However, only a few advantageous embodiments of the invention have been described above, which do not limit the scope of the invention from what has been defined in the appended patent claims.
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The present invention relates to a method and apparatus for filling and cleaning a pulp tower. The invention is most suitable for filling and cleaning high-consistency pulp towers, bleaching towers, storage tanks and similar towers containing fiber suspensions, of the wood-processing industry. The apparatus and method according to the invention for filling and cleaning a pulp tower, in which method pulp is fed into the pulp tower either through its cover ( 10 ) or at least feed devices ( 24 ) arranged at its top, are characterized in that the space surrounding the feed device ( 24 ) is washable at the same time as the pulp is fed into the tower by means of washing devices ( 28, 30, 32 ) arranged in connection with the feed devices.
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BACKGROUND OF THE INVENTION
With the recent advent of aerobic type exercises such as swimming, cycling, jogging and tennis there has been a corresponding upsurge in the rate of deaths relating to cardiovascular exertion. The frequency of heart failures occurring, for example, in winter months due to the exertion on the heart by the over zealous snow shoveler is now occurring throughout the remaining seasons due to heart exertion caused by physical fitness enthusiasts. A person following the current fashion of weight reduction by early morning jogging may lose as much as 20 pounds in a month and may also lose his life. The sudden and continued exertion above a critical limit upon the heart caused by the tremendous amount of blood transport and oxygen consumption required results in a breakdown of the heart structure and, if immediate medical attention is unavailable, death may result. The unfortunate factor common for most cases of coronary failure due to overexertion is that the victim never knows when to stop and death in most cases could have been avoided if the victim didn't continue his exercise.
The heart muscle, like any other vital organ, can build up tolerances to long and continued exertion if given time to develop sufficient cellular structure to accommodate the added workload and to provide for the increased blood handling capacity. By gradually exposing the heart to periods of temporary exertion over increasing periods of time, the body as a whole adapts to a lower oxygen consumption requirement and the heart readily supplies the increased demands for blood flow.
Several devices are currently available for monitoring the pulse rate activity of the human heart. For example, U.S. Pat. No. 3,792,700 describes a technique for indicating the pulse rate of an inactive user by electrodes placed under the armpits of a user. This technique provides an indication of the pulse rate of an inactive user and signals when a coronary problem exists. U.S. Pat. No. 3,802,698 incorporates a pulse rate measuring device with a stationary exercise control system and signals when a particular pulse rate value is reached. U.S. Pat. Nos. 3,742,937; 3,807,388 and 3,863,626 describe miniature pulse monitoring devices that can be worn by persons undergoing physical fitness activities to indicate when a predetermined pulse rate has been exceeded.
The aforementioned examples of the prior pulse rate indicators provide some means for detecting and monitoring the pulse rate of a person undergoing physical exertion and for indicating when the exertion is excessive, but are not tailored to the individual physiological characteristics of the user.
SUMMARY OF THE INVENTION
A pulse rate indicator is mounted to detect the heart pulse rate of a user. The indicator determines the average pulse rate of a user at rest and utilizes this rate as a reference to indicate the pulse rate at a safe exercise level as well as the pulse rate at a dangerous level.
In one embodiment of the invention, the three conditions of pulse rate are displayed in color that is analogous to a traffic control pattern. Consequently, green is selected to represent a rest pulse rate, amber is selected to represent a safe exercise pulse rate level and red represents a dangerous pulse rate level.
In another embodiment of the invention, the pulse rates are digitally displayed in number form as well as in color. Thus, the optimum pulse exercise rate for each individual user is displayed. Since the optimum pulse exercise rate varies from user to user depending on the particular physiological characteristics of each user, the indicator is tailored to each individual user.
Further embodiments utilize an audible alarm to alert the user in a manner analogous to the color display.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graphic representation of an electrocardiogram display of the surface potential changes of a heart in a person at rest;
FIG. 1A is a graphic representation of the normal pulse displayed in FIG. 1;
FIG. 2 is a graphic representation of an electrocardiogram display of the surface potential changes in a heart in the abnormal condition of tachycardia, which is an excessive heartbeat rate;
FIG. 2A is a graphic representation of the electrical pulses generated in the circuit of the intant invention representing the abnormal pulse rate as shown in FIG. 2;
FIG. 3 is a graphic representation of the pulse rate for a normal distribution of male population;
FIG. 4 is a schematic circuit diagram of the pulse rate indicator of the instant invention;
FIG. 5 is a top perspective view of one embodiment of the invention wherein the pulse rate is displayed in digital form;
FIG. 6 is a top perspective view of a second embodiment of the invention wherein the pulse rate is displayed in color;
FIG. 7 is a side perspective view of the embodiment of FIG. 6; and
FIG. 8 is a pictorial representation of other embodiments of the invention.
GENERAL DESCRIPTION OF THE INVENTION
FIG. 1 shows normal pulses as displayed upon an electrocardiogram and with the standard points P Q R S and T indicated. For the purpose of this invention, the pulse rate is defined to be the number of times the R pulse point repeats itself over a given period of time. As shown, R' is the second occurrence of the R pulse point within a short time increment. The medical diagnostician measures the period of time between the occurrences of R and R' as an indication of the condition of a heart. The R pulse rate is related to the pressure exerted by the blood upon one of its chambers, and this in turn is an indication of the pressure exerted by the blood upon the particular artery where the pulse rate is being sensed. It is therefore common in the medical diagnostic field to attach a sensor such as a strain gauge or the like, which is responsive to pressure to produce an electrical pulse having the same frequency and intensity as the pulse shown in FIG. 1. The waveform of FIG. 1A is the electrical counterpart of the pulse R of FIG. 1 and represents the electrical variation in intensity pressure exerted by the heart. The normal pulse rate of FIG. 1 indicates that there is sufficient time between pulse R and pulse R' for the heart to recover in its continuing sequence of expansions and contractions. These expansions and contractions force the blood from one chamber to the other and through the large multiplicity of arteries and veins throughout the body.
FIG. 2 illustrates an electrocardiogram display of a pulse rate in a state of excessive exertion known in the medical field as tachycardia. Here the time between successive pulses is very short and therefore allows the heart muscles very little time to expand and contract to perform the necessary functions of blood transport. The distance between recurrent R pulses therefore is very small and the pulse rate is much higher than the normal condition depicted in FIG. 1.
FIG. 2A illustrates how the more rapid pulse rate under the condition of tachycardia is translated by this invention into a series of electrical pulses having the same pulse rate frequency as the pulse rate corresponding to the pulse rate occurring within the human body. The normal pulse rate for an adult male is designated as ranging from between 70-72 beats/minute and for an adult female as from 78-82. Pulse rates in both men and women rarely exceed 150 beats/minute in normal everyday activity and pulse rates in excess of 175 beats/minute may be fatal. The condition of tachycardia as portrayed in FIG. 2 corresponds to a pulse rate of 170 beats/minute. The condition of tachycardia therefore presents an excessive burden upon the heart muscle since the heart muscle is required to perform an excessive amount of work in a very short period of time.
The pulse rate for humans varies over a wide range as the human progresses throughout life. Table I, as shown below, illustrates the pulse rate as a function of age where the pulse rate varies from as high as 150 in the early stages of life as to as low as 50 in the seventieth year.
TABLE I______________________________________AGE PULSE RATE______________________________________Embryo 150At Birth 140-130First Year 130-115Second 115-100Third 100-90Seventh 90-85Fourteenth 85-80Fiftieth 75-70Seventieth 65-50______________________________________
This wide spread in pulse rates is also seen in the adult male population as shown in FIG. 3. Here the pulse rate is illustrated as a bell-shaped distribution of the healthy adult male population. The average pulse rate, for example, is 70 and some men have normal pulse rates as high as 90 and some men have normal pulse rates as low as 50. This distribution of so-called normal pulse rates from 50 to 90 indicates that the pulse rate of every individual must be exactly determined before any type of physical exertion is imparted to the heart. Tachycardia, described earlier as excessive heart pulse rate, occurs at approximately 170 pulses/minute. The person with the lower pulse rate of 50 would have to strain his heart to a substantial degree before the tachycardia pulse rate of 170 would occur. The person with the so-called normal pulse rate of 90 would reach the tachycardia condition of a pulse rate of 170 in a substantially shorter period of time. If a normal distribution is plotted for the onset of tachycardia based on the 170 pulse value then the range in population would be that depicted in FIG. 3. It is evident that persons with higher rest pulse rates would be more prone to the onset of tachycardia than those with lower rest pulse rates. The problem that this invention directs itself to is to determine the accepted pulse rate for exercising that would permit a particular individual to condition his body without excessive strain on the heart and to determine for each particular individual the particular pulse rate at which such physical strain would be excessive.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 5 illustrates one embodiment of the programmable indicator 1 which includes a wristband 2 supporting an indicator face 3 that displays digital pulse rate 4. The indicator 1 is supported on a wrist 5 of a user and the indicator 1 includes a housing 6 that contains the programmable electrical components. The user can at any time see what his pulse rate is during any part of his physical exercise program.
Referring to FIG. 7, the indicator 1 includes a contact type pulse detector 7 which extends from the indicator 1. The detector 7 contacts the radial artery in the vicinity of the user's wrist and relays the detected pulses to the programmable integrated circuit within the housing 6. The pulse detector 7 shown as depending from the indicator 1 can also be part of the wristband 2 since the band would provide a larger surface for detection purposes. The detected pulse rate is digitally displayed upon the viewing indicator face 3.
A traffic control analogy may be utilized to display cnditions of pulse rates. FIG. 6 shows such an embodiment which includes red, amber and green indicating lights on the viewing indicator face 3. The indicator 1 activates the red, amber and green lights in the following manner. When the start and reset knob 10 is depressed energy is supplied by means of a miniature disc-shaped battery contained in the indicator 1 (not shown) and successive heart pulse beats are detected by detector 7 and processed within the indicator 1. The green light indicates that an average rest pulse rate has been determined. This is similar, for example, to the common traffic signal indicator where the green light indicates "go" and the presence of the green light insures the operator that the pulse is being detected and that the battery is operational.
When the user begins to exercise moderately the pulse rate is detected and counted and an optimum exercise pulse rate for the particular average rest pulse rate is determined. For the example given earlier of the medium normal pulse rate of 70, the optimum exercise pulse rate should be 50 greater than the average rest value. Thus, for the 70 rest rate a pulse rate of 120 is the optimum exercise pulse rate for the user and an amber light begins to glow at this rate. The green light would therefore become extinguished at this value and the exerciser is instructed that he has reached the optimum safe exercise pulse rate period. Thus, the optimum safe exercise pulse rate calculated on the basis of 50 beat/minute above the rest value pulse rate indicated by the amber glow continues until a pulse rate of 150 pulses/minute is achieved. At this point the amber light is extinguished and the red light begins to glow indicating to the exerciser that the danger pulse rate condition has been reached and that the exerciser must slow down in order to extinguish the red light and regenerate the amber light.
Table 2, shown below, illustrates the color conditions of green, amber and red along with the corresponding rest, optimum exercise, and dangerous pulse rates for the normal pulse conditions. Although the optimum exercise pulse rate for each group is determined by the addition of 50 pulses or beats/minute above the rest rate, to avoid the onset of tachycardia a red signal is energized to glow at a reduced safety pulse rate of 150 pulses/minute.
TABLE 2______________________________________ GREEN AMBER RED (Rest Rate) (Exercise Rate) (Danger Rate)Low Normal 50 100 150Normal 70 120 150High Normal 90 140 150______________________________________
The color pattern can be utilized in the digital display embodiment shown in FIG. 5. Here the numeric display characters themselves can be caused to glow green, amber or red depending upon the pulse rate condition during exercise. The numerals indicating the average high normal rest rate of 90, in the example of Table 2 can be made to glow green. When the safe optimum exercise rate is reached the numerals glow in an amber color indicating to the user that this particular numerical value is his optimum safe exercise pulse rate. Although higher numerical pulse rates remain amber as exercise continues the user knows that he has exceeded the optimum safe pulse rate and should begin to slow down. If he doesn't slow down, and the pulse rate reaches 150, then numerals indicating this dangerous pulse rate are displayed in red. If he does not slow down at this stage of exercise, the tachycardia may occur.
The visual display indicators depicted in both FIGS. 5 and 6 can have different degrees of light intensity and may have other attention directing characteristics. The amber light, for example, might be caused to blink at the optimum safe exercise pulse rate so that the operator, for example, by looking at the face of the indicator 1 would know that he is exercising within the safe condition of pulse rate. By practice he could pace himself by observing that his particular pulse is beating at the rate of the blinking light. By breaking his stride he could lower his pulse rate to remain at the optimum. Other attention directing means may be incorporated within the indicators of FIGS. 5 and 6 which could include an audible beep device which could be made to vary in frequency in accordance with the pulse rate. The rest condition green, for example, would require no indicating tone and the amber condition would require an auditory beep merely to indicate to the exerciser how fast his pulse rate is going with no possible indication of alarm. The dangerous condition indicated by the pulse rate occurring when the indicator is glowing red would have a rapidly repeating beep and the red light simultaneously could be caused to blink at the same rate to alert the exerciser to slow down.
FIG. 8 depicts alternate embodiments of the pulse sensor of this invention. Here a jogger depicted generally at 21 could carry an indicator unit 1 mounted within a sweatband 23. Here the sensor 7 would contact the vicinity of temporal artery for receiving and recording pulse rates as described earlier. This particular embodiment would require only an audible indicator and the aforementioned red, amber and green indicator lights could be absent. Here the only requirement is that when the pulse rate of 150 is reached then the indicator 1 would begin to beep and the user would summarily have to slacken his pace until the sound disappears. A simplified embodiment is also depicted by the wristband 22. Here again the indicator 1 would contain the same necessary circuit elements to provide an audio beep when the pulse rate detected from the radial artery reaches 150 pulses/minute.
Alternate embodiments within the scope of this invention include audible and visual low pulse level indication when the pulse rate falls below the recorded rest rate average value. This feature would indicate an abnormal physiological condition to the user. Since the pulse rate is lower when sleeping or lying down the long distance driver, for example, would receive an indication that he is starting to doze at the wheel and the audible and visual alarm would alert him of a very dangerous situation.
The digital readout display device of FIG. 5 may serve the health conscious executive who is under a condition of emotional and mental stress even when in a sedentary position at his office. The visual indication of a rising pulse and the occurrence of an amber light in the absence of physical exercise would indicate to the user that his emotions are interferring with his cardiovascular activity. Keeping within the scope and teachings of the instant invention several safety features may be further incorporated within the indicator 1 depicted within the embodiments of FIGS. 5 and 6. Should the exerciser fail to heed the occurrence of the blinking light and the loud and intermittent beep emanating when the pulse rate exceeds 150 then after a time delay the beep is caused to increase in intensity and begin to sound the Morse Code Mayday audio alarm. This would direct a rescuer to the danger, for example, if the user should succumb to heart disease similar to arrythmia and becomes disabled. If the dangerous condition persists for an additional time period then the Mayday distress call also becomes transmitted within the citizens and police broadcast bands in order that immediate help be directed to the stricken individual. The operation of the inventive pulse indicator of FIG. 4 may be explained as follows.
A block diagram of the electric circuit of the indicator is illustrated in FIG. 4. This circuit includes a detector or sensor 7 which may, for example, comprise a thin silicon metal piezoelectric transducer or a piezoelectric strain gauge consisting of barium titanate or barium zirconate. The detector 7 may be attached to the wrist or head of a jogger 21 as designated in FIG. 8 and is included in the indicator 1. The sensor 7 produces an electric output signal as shown in FIGS. 1A and 2A at every pulse beat as shown in FIGS. 1 and 2. The electrical output signal is amplified in the amplifier 210 and then peak detected in the shaper circuit 222. The shaper circuit 222 may, for example, comprise a peak detector and a squarer circuit that detects the peak of the R pulse 211 in the Q R S waveform shown in FIG. 1. The shaper circuit 222 is made variable to tailor it to the individual physiological characteristics of a user because the peak amplitudes of Q R S pulses vary from individual to individual.
The shaped output pulse is applied to a counter 230 where the pulses are counted. At the end of a predetermined period, which may, for example, comprise 15 seconds or alternatively one minute, the count in the counter 230 is transferred through transfer gates 240 to a storage device 260 by a pulse from a clock or timer 270. The clock or timer may, for example, comprise the timer on the wristwatch worn by the jogger. After a slight delay, the counter 230 is reset by the clock 270 via delay 250. The storage device 260 may, for example, comprise a plurality of storage circuits such as shift registers. The count in the first storage circuit is transferred to the second storage circuit when the second count in the counter 230 is transferred through the transfer gates 240 to the storage circuit. At the end of a predetermined number of counts, an averaging circuit 280 adds the pulse counts stored in the storage device 260 and divides by the number of counts to determine the average rest pulse rate over a predetermined period. This average pulse rate is applied to a comparator circuit 290 and displayed in a display device 200. Thus, the display device 200 displays the average or rest pulse rate of the jogger. The display device 200 may, for example, display in green, amber or red and may include light-emitting devices that digitally display the pulse rate. The average rest pulse rate is usually displayed in green.
The averaging circuit 280 also includes a set element 218 to fix or set the average of the pulse rate so that this figure remains constant during jogging. Alternatively, if an individual knows accurately his rest pulse rate, this rate may be set into the averaging circuit 280 by the manual set 220. Both the switch and set element 218 and the manual set 220 are coupled to the knob 10 shown in FIGS. 5 and 6. During the jogging period, the pulse rate is applied through the transfer gates 240 to the comparator 290. The average rest pulse rate stored in the averaging circuit 280 is, as explained previously, incremented by the number 50 to set the optimum safe exercise pulse rates. During a period when exercise is being done, the display device 200 may, for example, digitally display the pulse rate at that particular moment. When the pulse rate reaches the established optimum safe pulse rate number, this number is digitally displayed in amber and an audible indicator 300 may beep as described earlier. When the pulse rate reaches the danger pulse rate of 150 the comparator 290, set to detect this critical number, causes the display device 200 to glow red. Additionally, audible indicator 300 may beep at an increased rate.
The time delay 250 connected to the counter 230 also provides the alternate safety function that when the circuit is first energized by means of knob 10 connecting energy source 278 to the circuit components the time delay 250 will not allow the sensor 7 to energize the aforementioned green light until a sufficient time span has occurred so that a representative average rest pulse rate can be determined. This is important since it is possible that an impatient jogger may upon early waking, when the pulse rate is at its lowest, immediately commence jogging and receive a false amber indication as to the optimum exercise pulse rate since the aforementioned rest rate average was excessively low. The time delay, for example, would give the user adequate time to provide sufficient sample pulse counts to the counter so that a true rest rate pulse average can be determined before the go ahead signal is indicated by means of the aforementioned green light. The components of the circuit depicted in FIG. 4 may comprise an integrated circuit. However, it is not necessary that the detector 7 be directly connected within the circuit. An alternate embodiment, for example, could consist of a sensor which incorporates an ultrasonic transmitter and the other circuit components could be at a remote location from the sensor.
A heavily bundled snow shoveler wearing gloves may be unable to hear the audible alarm indicated from the pulse sensor and audible alarm on the wrist but would clearly hear an audible alarm generated within the sweatband embodiment described earlier as in contact with the temporal artery due to the proximity of the temporal artery and the ear. In the event that the snow shoveler may be reluctant to wear the complete sensor contained within the sweatband similar results could be achieved by locating the detector and transmitter portion of the circuit within a wristband proximate the radial artery and locating a simple receiver in the vicinity of the ear by means of a sweatband or similar device. Here the excessive pulse rate would be detected in the ultrasonic region and regenerated in close proximity to the ear within audible range. It is to be further noted that energy source 278 may be a self-contained battery of the rechargeable type and may provide power to each and every circuit element as required including the green, amber and red display elements which for their purpose of size and efficiency may comprise light emitting diodes.
Although several limited embodiments have been described as operative examples of the inventive pulse rate indicator this is by way of example only and is in no way intended to limit the scope of this invention to these specific examples.
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A pulse rate indicator automatically indicates a person's pulse rate and changes in this rate. The indicator is individually programmed for each user to account for the overall physiological characteristics of the user. The indicator may be mounted on a wristband and the pulse count is averaged over a time increment, stored and displayed as a reference or rest value. As the user undergoes physical exercise, the subsequent pulse rate is visually indicated and compared with the reference or rest value. When the pulse rate increases, but not to a dangerous level, the color of the indicator changes to inform the user that continued exercise is permissible. When an excessive pulse rate is reached, the indicator changes color and an audible alarm is sounded. The programmable feature therefore allows each person to exercise up to his particular limits for physical fitness tailored to his own physiological makeup, with sufficient advance warning to avoid excessive strain on the heart.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the field of mobile application development, and more particularly to the field of Mobile Information Device Applet (MIDlet) emulation in a desktop environment.
[0003] 2. Description of the Related Art
[0004] Mobile application development has evolved in time from proprietary coding schemes in which applications were developed for a particular host device and stored in fixed media such as a read-only memory (ROM), to portable coding schemes in which an application can be coded in a general purpose programming language and packaged for distribution to any number of compatible mobile devices through a mere extension to a conventional programming environment. The Java™ language MIDlet represents one well-known mobile application development environment. A MIDlet is a Java™ language program for embedded devices, more specifically the Java™ Micro Edition (ME) virtual machine.
[0005] Like other Java programs, MIDlets are write once, run anywhere. To facilitate write once, run anywhere, the basic components of any MIDlet suite include a Java Application Descriptor (JAD) file and a Java Archive (JAR) file. The JAD file describes a MIDlet suite including the name of the MIDlet suite, the location and size of the JAR file, and the configuration and profile requirements. The JAD file optionally can include other attributes defined by the Mobile Information Device Profile (MIDP), by the MIDlet developer, or both. The JAR, by comparison, contains one or more MIDlets, specified in the JAD. Finally, a manifest file can be provided within the JAR. The manifest can include the same syntax as the JAD file and can share the same attributes. In addition to the Java class files and the manifest, the JAR file can include other resources including images that the MIDlet can load using the createImage(String) method. The MIDlet can also use getResourceAsStream(String) to access any resource in the JAR file as an InputStream. In both cases, the String argument can include a pathname identifying a resource in the JAR file.
[0006] Though MIDlets intend to be executed in a mobile device, MIDlets can be executed on the desktop within an emulation environment. The emulation environment can be fixed in terms of display space and the MIDlet can be contained within the fixed display space. Permitting a MIDlet to execute outside of the display space, however, would be highly desirable given the apparent popularity of desktop widgets in modern computing. In this regard, to deploy a widget in a desktop environment normally requires the presence of a widget engine enabled to process the markup language specified user interface and logic of a widget. In the absence of a widget engine, widgets cannot operate in the desktop environment.
[0007] To enable the deployment of a MIDlet in a desktop environment to emulate a widget, first a clip region must be established to provide for event handling for the MIDlet relative to the remainder of the desktop environment. Yet, to enable widget like behavior for MIDlet applications in a desktop environment would require integration with the diaphanous feature of the emulation environment—namely determining how to provide a degree of transparency about the perimeter of the MIDlet application while maintaining a defined clip region for event handling of the MIDlet application in the desktop environment.
BRIEF SUMMARY OF THE INVENTION
[0008] Embodiments of the present invention address deficiencies of the art in respect to MIDlet execution in a desktop environment and provide a novel and non-obvious method, system and computer program product for clip region definition for a MIDlet region space. In one embodiment of the invention, a method for clip region definition for a MIDlet region space can be provided. The method can include extracting a raster image from a MIDlet, computing a clip region from the extracted raster image for the MIDlet, deploying the MIDlet to a desktop environment through an emulator, and applying the clip region to the MIDlet through the emulator to deploy the MIDlet as a widgetized application in the desktop environment.
[0009] In one aspect of the embodiment, computing a clip region from the extracted raster image for the MIDlet can include scanning the raster image line by line, pixel by pixel seeking out an opaque pixel initiating the line segment and a transparent pixel terminating the line segment. In this regard, a pixel can be considered to be transparent if the pixel is a given color such as red and otherwise the pixel can be determined to be opaque. Each line can be clipped between the opaque pixel and the transparent pixel. Additionally, each clipped line can be merged with one another to create a clipped region. Finally, in another aspect of the embodiment, applying the clip region to the MIDlet through the emulator to deploy the MIDlet as a widgetized application in the desktop environment can include setting a parent window for a diaphanous feature of the emulator to the clip region, and setting a child window for the diaphanous feature to the MIDlet. Notably, the foregoing technique further can be applied to an applet executing in a desktop environment.
[0010] Additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The aspects of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention. The embodiments illustrated herein are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown, wherein:
[0012] FIG. 1 is a pictorial illustration of a process for clip region definition for a MIDlet region space;
[0013] FIG. 2 is a schematic illustration of a desktop user interface data processing system configured for clip region definition for a MIDlet region space; and,
[0014] FIG. 3 is a flow chart illustrating a process for clip region definition for a MIDlet region space.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Embodiments of the present invention provide a method, system and computer program product for clip region definition for a MIDlet region space. In accordance with an embodiment of the present invention, a raster image of a MIDlet application can be selected from a MIDlet suite and a clip region can be computed for the raster image including red-green-blue (RGB) data. Subsequently, the club region can be utilized as the parent window for a diaphanous feature of the MIDlet emulator while the MIDlet application can be drawn in the child window of the MIDlet emulator. Finally, transparency can be applied to the parent window according to alpha values in the RGB data for the clip region. In this way, the clip region can be defined for the MIDlet application by reference to the raster image deployed in the MIDlet suite in order to enable clipped region widgets in the desktop environment.
[0016] In illustration, FIG. 1 pictorially depicts a process for clip region definition for a MIDlet region space. In accordance with an embodiment of the invention, a MIDlet 100 can be packaged for deployment into a desktop environment 170 configured to support not only general application instances 180 bounded by a corresponding application user interface, but also a widgetized application 190 unbounded by an emulator user interface. The MIDlet 100 itself can include JAD 110 and JAR 120 . The JAD 110 can include a descriptor 130 of the content of the MIDlet 100 including a manifest of the JAR 120 . The JAR 120 , in turn, can include different logical files 140 defining the operational functionality of the MIDlet 100 as well as one or more supporting resources, including a raster image 150 of the MIDlet user interface.
[0017] In order to support the deployment of the MIDlet 100 into a desktop environment 170 unbounded by an emulator user interface, a clip region 160 can be established for the MIDlet 100 . In this regard, the clip region 160 can be computed from the raster image 150 within the MIDlet 100 by differentiating between that portion of the raster image 150 that is to be opaque in nature and that portion of the raster image 150 that is to be transparent in nature so as to blend with the background of the desktop environment 170 . The clip region 160 in turn can be provided when computing the window for the widgetized application 190 such that user interface events occurring within the window can be attributed to the widgetized application 190 , while user interface events occurring outside of the window can be attributed elsewhere.
[0018] In further illustration, FIG. 2 is a schematic illustration of a desktop user interface data processing system configured for clip region definition for a MIDlet region space. The system can include a support computing platform 205 including an operating system 210 for providing a desktop computing environment 215 . The desktop computing environment 215 can support the execution of one or more applications 220 bound by respective graphical user interfaces. The desktop computing environment 215 further can be coupled to a virtual machine 225 enabled to process platform neutral program code, such as that conforming to the Java™ programming language. In this way, platform neutral program code can execute within the confines of the virtual machine 225 in the desktop computing environment 215 .
[0019] Notably, an emulator 230 can be provided. The emulator 230 can be enabled to emulate to operation of a MIDlet 235 as if the MIDlet 235 were executing in a pervasive device environment such as a cellular telephone or personal digital assistant despite the desktop environment 215 . The MIDlet 235 itself can include both a JAD 240 and JAR 245 as is well known in the art. The JAR 245 , in turn, can include both logic files 250 such as Java™ classes, in addition supporting resources including a raster image 260 for the MIDlet 235 .
[0020] The emulator 230 further can be coupled to clip region computation logic 300 . The logic 300 can include program code enabled to compute a clip region from the raster image 260 in the MIDlet 235 . In this regard, the program code can identify the raster image 260 in the JAD 240 which can include a reference to the raster image 260 in the JAR 245 . Thereafter, the raster image 260 can be scanned line by line, pixel by pixel seeking out an opaque pixel initiating the line segment and a transparent pixel terminating the line segment and clipping the line. Each clipped line can be ORed with each other clipped line to create a clipped region. In one aspect of the embodiment, the opacity of a segment can correspond to non-red pixels for opacity and red-pixels for transparency (red color freeing to a selected color as the opaque pixel).
[0021] Once a clip region has been computed for the MIDlet 235 , the clip region can be applied to the parent window of the diaphanous feature of the emulator 230 , while the use interface of the MIDlet 235 itself can be drawn in the child window of the diaphanous feature of the emulator 230 . Optionally, the raster image 260 can be used as a background image of the MIDlet 235 . In that circumstance, the alpha component of the RGB data for the raster image 260 can be used to signal transparency. In this way, the MIDlet 235 can be deployed into the desktop environment unbounded by the user interface of the emulator 230 as a widgetized application.
[0022] In even yet further illustration, FIG. 3 is a flow chart illustrating a process for clip region definition for a MIDlet region space. Beginning in block 305 , a raster image can be retrieved from a MIDlet suite for a MIDlet and a clip region can be initialized for the MIDlet. In block 315 , a first row of the raster image can be selected for processing and in block 320 a first pixel in the row can be selected for processing. In block 325 , the RGB data for the pixel can be retrieved and in block 330 , an alpha value for the pixel can be determined. Thereafter, in decision block 335 it can be determined whether the pixel is transparent. If so, the segment for the row can be clipped and merged with a clip region for the raster image.
[0023] In decision block 345 , if more pixels remain to be processed for the row, in block 350 a next pixel can be selected for processing and in block 325 , once again the RGB data for the pixel can be retrieved and in block 330 , an alpha value for the pixel can be determined. Thereafter, in decision block 335 it can be determined whether the pixel is transparent. When no further pixels remain to be processed, in decision block 350 it can be determined whether additional rows of the raster image remain to be processed. In so, in block 355 a next row can be retrieved for processing and the process can repeat through block 320 . Otherwise, in decision block 350 when the complete raster image has been processed, in block 360 a clip region can be returned for use in rendering the MIDlet in the desktop environment.
[0024] Embodiments of the invention can take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment containing both hardware and software elements. In a preferred embodiment, the invention is implemented in software, which includes but is not limited to firmware, resident software, microcode, and the like. Furthermore, the invention can take the form of a computer program product accessible from a computer-usable or computer-readable medium providing program code for use by or in connection with a computer or any instruction execution system.
[0025] For the purposes of this description, a computer-usable or computer readable medium can be any apparatus that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device. The medium can be an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system (or apparatus or device) or a propagation medium. Examples of a computer-readable medium include a semiconductor or solid state memory, magnetic tape, a removable computer diskette, a random access memory (RAM), a read-only memory (ROM), a rigid magnetic disk and an optical disk. Current examples of optical disks include compact disk-read only memory (CD-ROM), compact disk-read/write (CD-R/W) and DVD.
[0026] A data processing system suitable for storing and/or executing program code will include at least one processor coupled directly or indirectly to memory elements through a system bus. The memory elements can include local memory employed during actual execution of the program code, bulk storage, and cache memories which provide temporary storage of at least some program code in order to reduce the number of times code must be retrieved from bulk storage during execution. Input/output or I/O devices (including but not limited to keyboards, displays, pointing devices, etc.) can be coupled to the system either directly or through intervening I/O controllers. Network adapters may also be coupled to the system to enable the data processing system to become coupled to other data processing systems or remote printers or storage devices through intervening private or public networks. Modems, cable modem and Ethernet cards are just a few of the currently available types of network adapters.
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Embodiments of the present invention address deficiencies of the art in respect to MIDlet execution in a desktop environment and provide a method, system and computer program product for clip region definition for a MIDlet region space. In one embodiment of the invention, a method for clip region definition for a MIDlet region space can be provided. The method can include extracting a raster image from a MIDlet, computing a clip region from the extracted raster image for the MIDlet, deploying the MIDlet to a desktop environment through an emulator, and applying the clip region to the MIDlet through the emulator to deploy the MIDlet as a widgetized application in the desktop environment.
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This is a continuation of application Ser. No. 403,091, filed July 29, 1982, abandoned.
SUMMARY OF THE INVENTION
A highly effective hydrophilic denture adhesive composition is provided comprising a substantially anhydrous mixture of from about 20 to about 35 percent by weight of the total composition (i.e. w/w) of ethylene oxide homopolymer as the sole adhesive component and a hydrophilic vehicle comprising from about 65 to about 80 percent w/w of a polyethylene glycol fraction with average viscosity of from about 44 to about 25,600 centipoises at about 60° C. Various forms of the subject compositions are available, for example, liquids, creams and powders. Optionally, up to about one-half of the polyethylene glycol fraction may be substituted with glycerin in the non-powder forms of the subject compositions. The denture adhesive composition may also have present colorants, flavoring agents, odorants, sweeteners and other additives in amounts generally employed for their respective intended purposes.
BACKGROUND OF THE INVENTION
Denture adhesive cream formulations have heretofore been comprised mainly of natural or synthetic polymeric adhesives suspended in an anhydrous oleagenous vehicle system generally consisting of mineral oil and/or petrolatum. These hydrophobic formulations have viscosities ranging from moderately thick to very thick making them difficult to squeeeze out evenly and fluidly from the generally employed collapsible tubes or containers. However, this thickness range is necessary to prevent syneresis (i.e., phase separation) from occurring due to the solid adhesive particles being only suspended in the hydrophobic vehicle.
More recently, liquid denture adhesives have been reported containing sodium carboxymethylcellulose and ethylene oxide homopolymer as the solid adhesives suspended in mineral oil (e.g. see U.S. Pat. No. 4,280,936). Examples of such hydrophobic denture adhesives are the products commercially available from Block Drug Company, Inc. in the United States under the trademark "Dentrol" and in West Germany under the trademark "Cedenta", which are believed to contain about 41-45% w/w of sodium carboxymethylcellulose and ethylene oxide homopolymer in a mineral oil base. However, upon standing, considerable phase separation occurs thus requiring a "shake well" indication on the container.
Furthermore, whereas such formulations may be effective in securing dentures quickly within the oral cavity, it may be necessary to apply more than one application per day to obtain sufficient adhesion throughout the day, depending on the fit of the denture and the psychological need of the denture wearer. Such multiple applications are inconvenient and at times impractical or impossible and, therefore, these heretofore known denture adhesive liquids are not totally acceptable and in some cases undesirable.
Whereas these conventional types of denture adhesive creams and liquids have provided good stabilizing/hold properties to denture wearers, some organoleptic negatives have also been perceived with these products. Some of these commonly perceived negatives are, for example, unpleasant mouth feel, bad taste, grittiness, oily sensation in the mouth and difficulty of application and removal from dentures. Another disadvantage is that the salivary fluids have to penetrate a hydrophobic vehicle in order to reach and hydrate the adhesive system. This hydrophobic barrier may cause a time lag before the adhesive is hydrated and starts to work. Due to such slowed rate of hydration of adhesive components, there results a lack of immediate denture hold.
It has therefore been desirable to provide a denture adhesive of superior adherent properties over prolonged periods of time. Such is accomplished with the denture adhesive compositions herein described, a novel and unique combination of an adhesive in a hydrophilic vehicle system which eliminates many of the aforementioned disadvantages found with deture adhesives having conventional oleagenous vehicle systems. For example, the hydrophilicity of this unique combination facilitates the penetration of the saliva to the adhesive gum system, thereby allowing quicker hydration, and, therefore, quicker hold. Test results hereinafter demonstrate the stronger hold of the subject compositions. Furthermore, they are available in forms with variable consistencies, for example, liquids, creams and powders.
In our copending application Ser. No. 361,631, filed Mar. 26, 1982, entitled "Hydrophilic Denture Adhesive", the use of a polymeric adhesive system comprising sodium carboxymethylcellulose in admixture with an ethylene oxide homopolymer in specified ratios together with a hydrophilic PEG vehicle was described. In contrast, the instant compositions elimate the need for said sodium carboxymethylcellulose and utilize ethylene oxide homopolymer as the sole adhesive component.
DETAILED DESCRIPTION OF THE INVENTION
This invention relates to a hydrophilic denture adhesive composition which, when in contact with saliva, hydrates within the oral cavity to provide superior adherent properties. The composition comprises two essential components. The first is from about 20 to about 35 percent w/w of ethylene oxide homopolymer as the sole adhesive ingredient. The second is a hydrophilic vehicle comprising from about 65 to about 80 percent w/w of a polyethylene glycol fraction with average viscosity of from about 44 to about 25,600 centipoises when measured at about 60° C., generally 60°±2° C.
The ethylene oxide homopolymers employed in the compositions of the invention are water soluble nonionic poly(ethylene oxide) homopolymers having molecular weights of from about 100,000 to about 5,000,000. The polymers have the structure --O--CH 2 CH 2 ) n wherein n represents the degree of polymerization and has a value of from about 2,000 to about 100,000. These polymers are white powders. When moistened, they become hydrated and tacky or gummy in consistency with adhesive characteristics.
Poly(ethylene oxide) homopolymers of this type are more fully described in "Polyox", 1978, published by Union Carbide Corporation, 270 Park Avenue, New York, New York 10017, as Technical Bulletin F-44029B.
As examples of commercially available powdered poly(ethylene oxide) homopolymers suitable for use in this invention there may be mentioned those polymers sold by Union Carbide Corporation under the trademark POLYOX as grades WSR N-10, WSR N-80, WSR N-750, WSR N-3000, WSR -205, WSR -1105 and WSR -301. Preferred for use in this invention in POLYOX WSR -301 homopolymer.
In the compositions of this invention, the adhesive component comprises from about 20 to about 35 percent w/w and preferably from about 30 to about 35 percent w/w of ethylene oxide homopolymer.
With regard to the hydrophilic vehicle component, the polyethylene glycols suitable for use in the compositions of the invention are also well known and commercially available, for example, those marketed by Union Carbide Corporation under its trademark "Carbowax".
Polyethylene glycols are polymers of ethylene oxide with the generalized formula HOCH 2 (CH 2 OCH 2 ) n CH 2 OH wherein n represents the average number of oxyethylene groups. These polyethylene glycols, which are designated by a number that represents the average molecular weight, range from clear viscous liquids at room temperature (e.g., PEGs 200, 300, 400 and 600) to soft solids (e.g., PEGs 1000 and 1450) to waxy solids available in the form of flakes or powders (e.g., PEGs 3350 and 8000) to granular solids (e.g., PEG 14,000). All these polymers dissolve in water to form clear solutions and this water solubility feature imparts a hydrophilic characterisitc to the compositions of this invention.
The subject compositions comprise from about 65 to about 80 percent w/w and preferably from about 65 to about 70 percent w/w of a polyethylene glycol (PEG) fraction, comprising one or more polyethylene glycols each having an average molecular weight of from 200 to 20,000, with an average viscosity when measured at about 60° C. of from about 44 to about 25,600 centipoises (cps), preferably from about 44 to about 2,500 cps, and most preferably from about 44 to about 300 cps, as determined, for example, by an instrument such as the Brookfield RVT Viscometer. Either individual polyethylene glycols or blends of two or more polyethylene glycols within this viscosity range may be utilized. For example, and without being limited thereto, a blend of liquid PEG 400 or PEG 600 and solid PEG 8000 in a respective weight ratio of from about 9:1 to about 33:1 has been found particularly suitable for the lotion-like liquids and soft creams of this invention.
The data presented in following Table 1 illustrates the variety of final product consistencies obtainable according to this invention by varying the make-up of the PEG fraction in a particular formulation. In Example 4, hereafter, a formulation is described which contains 35% w/w poly(ethylene oxide) homopolymer, 10% w/w glycerin and 54.59% w/w PEGs, the latter made up of PEG 400 and PEG 8000 in an approximate 9:1 ratio, respectively. By substituting an equivalent amount of total PEG but in the indicated varying ratios, the following results are approximated.
TABLE 1______________________________________Vehicle Ratio PEG Fraction(PEG 400: Viscosity ProductPEG 8000) (cps @ 60° C.) Consistency______________________________________100:0 56 liquid lotion98:2 (49:1) 44 liquid lotion97:3 (32.3:1) 61 liquid lotion94:6 (19:1) 72 liquid lotion92:8 (11.5:1) 94 liquid lotion90:10 (9:1) 94 soft cream80:20 (4:1) 170 cream70:30 (2.3:1) 315 thick cream60:40 (1.5:1) 600 very thick cream0:100 (PEG 8000*) 2,500 powder0:100 (PEG 14000*) 25,600 powder______________________________________ *The 10% w/w glycerin replaced by an equal amount of PEG.
By blending members of the PEG series, different viscosities within the defined range may be obtained, as desired. For example, by utilizing increasing amounts of higher molecular weight PEGs, i.e. more solids than liquids, the resultant viscosity of the polyethylene glycol fraction will also increase (assuming other ingredients in the denture adhesive composition are maintained constant) so that one can readily obtain embodiments of the subject compositions ranging in consistency from viscous liquids to creams to powders. For example, with about 32 percent w/w of the poly(ethylene oxide) homopolymer adhesive and 10 percent w/w of glycerin, a polyethylene glycol fraction having a viscosity at about 60° C. of about 44-95 cps affords a final product with a liquid lotion to soft cream consistency; whereas a polyethylene glycol fraction having a viscosity of about 100-300 cps affords a cream type of final product, whereas a polyethylene glycol fraction above 300 affords a thick creamy product; and whereas without glycerin a polyethylene glycol fraction having a very high viscosity of about 2500-25,600 cps affords a final product in powder form.
This ability to adjust the fluidity of the final product is a particularly advantageous feature of the invention since it affords commercialization of final product forms with consumer acceptable consistencies such as (i) liquids and soft creams, which are readily extrudable from appropriate containers, for example, pump action bottles, squeezable tubes and the like, (ii) thicker creams and (iii) powders, all of which forms are suitable for easy application to dentures.
With regard to the liquid and cream compositions of this invention, one particular ingredient that is preferred and recommended as a substitute for part of the polyethylene glycol fraction is glycerin which has a known soothing effect on oral gum tissue and also affords a pleasant mouth feel and sweetening taste to the finished composition. Due to its humectant character, glycerin also contributes to the hydrophilicity of the finished composition, thereby allowing quicker hydration on contact with moisture or saliva. Thus, although glycerin in not an essential component of the hydrophilic vehicle or of the finished composition, it does enhance the latter's esthetic appearance and acceptability.
It has been found that a significant amount of glycerin can be substituted for the polyethylene glycol fraction, for example, up to about one-half of the latter may be so substituted without any significant detriment to the overall adhesive ability of the finished composition. However, due to the increased cost incurred with high amounts of the relatively expensive glycerin, about 25% w/w of glycerin is recommended as the upper limit with about 5 to about 15 percent w/w being preferred and about 10 percent w/w most preferred.
Any suitable flavoring agent, colorant, odorant, natural or synthetic sweetener, deodorant, antimicrobial agent, tissue healing agent or other optional ingredient generally employed as an additive in denture adhesives may be utilized in the compositions of this invention, if so desired, so long as such addition is not detrimental to the overall adhesive ability of the compositions. Preferably, up to about 1.0% w/w of such additives may be utilized.
Typical of the compositions encompassed in the present invention are the formulations exemplified in Table 2. The "% w/w" indicates the weight of each ingredient based on the total weight of the particular composition.
TABLE 2______________________________________Formulation Examples in % w/w Ex. 1 Ex. 2 Ex. 3 Ex. 4______________________________________Poly(ethylene 35.0 20.0 30.0 35.0oxide)homopoly-mer type WSR-301PEG 400 49.2PEG 600 65.0 80.0PEG 8000 70.0 5.39Glycerin 10.0Color: FD & C 0.01Red No. 3Flavor: Premix 0.4of mint oilsTotal % w/w 100.0 100.0 100.0 100.0Form: lotion lotion powder soft cream______________________________________
The compositions of this invention can be produced by standard compounding techniques. For example, the liquid and cream compositions are readily prepared by heating with stirring the polyethylene glycol fraction to about 65°-70° C. at which temperature any solid or semi-solid polyethylene glycols which may be present are liquified and the fraction has a syrupy gel-like consistency. The poly(ethylene oxide) homopolymer is added to the polyethylene glycol fraction, slightly cooled to about 50°-55° C., with constant stirring to obtain a uniform adhesive/vehicle mixture. Any optional additives such as flavor, color and the like may then be incorporated into the adhesive/vehicle mixture. It is recommended, however, that the adhesive/vehicle mixture be cooled to about or slightly below 40° before incorporation of any such additives of a volatile character, for example, aromatic flavors, in order to preserve their characteristic essences.
When glycerin is to be included in the final product, it is advantageously added to and mixed into the slightly cooled (about 50°-55° C.) polyethylene glycol fraction prior to admixture with the adhesive component. The glycerin addition step may also be utilized as a way of carrying any compatible optional additive such as a sweetener, colorant and the like into the final product by simply mixing or dissolving the desired additive in the glycerin beforehand.
The powder compositions of this invention are readily obtained by simple admixture of the ethylene oxide homopolymer powder with the powder PEG fraction of the hydrophilic vehicle component. The preferred polyethylene glycol for making the powder compositions is PEG 8000 alone. It is recommended that granular forms of polyethylene glycol, such as PEG 14,000, be pulverized to a fine powder prior to admixture with the ethylene oxide homopolymer.
The denture adhesive compositions of this invention possess superior and unexpected adhesion/cohesion properties as measured by the Texturometer evaluation test. The term Texturometer is a trademark for an instrument manufactured and sold by C. W. Brabender Instruments, Inc. of Hackensack, N.J. which enables a quantitative measurement of textural parameters of products. The instrument mechanically simulates the chewing motions of the human jaws. A plunger is driven through the test sample (approx. 3 ml) held in a sample holder under which there is a strain-gauge hooked up to a high-speed chart recorder. The instrument draws force-time curves which are indicative of cohesive/adhesive ability of the test sample. The plunger is driven through the test sample at the rate of 12 times per minute and the chart paper speed is 1500 mm per minute.
The test sample is prepared by uniformly mixing the product to be tested with distilled water in a small mortar and pestle at a ratio of one part by weight of product to four parts by weight of water. The areas under the cohesion and adhesion parts of the force-time curves are measured and these areas are a measure of the cohesive/adhesive abilities of the hydrated adhesive formulation, i.e., the larger the areas, the greater such abilities. After the initial measurement, the test sample is kept undisturbed in a tightly covered petri-dish (to prevent evaporation) for 5 hours at 25° C. and then retested. Accordingly, in Table 3 hereafter, the tabulated numbers indicating the observed Texturometric evaluations represent areas under the cohesion/adhesion Texturometric curves.
The unexpected superiority of the compositions of the present invention is demonstrated by the Texturometer evaluation data set forth in Table 3 wherein the compositions of Examples 1 and 2 are tested and compared with a conventional commercial product available under the brand name "Dentrol" which has a hydrophobic mineral oil vehicle rather than the hydrophilic PEG vehicle of this invention. The adhesive/cohesive properties of the tested hydrated products are evaluated initially and again after 5 hours.
TABLE 3______________________________________Texturometric Evaluations* COHESION ADHESION (sq. mm.) (sq. mm.)Test After AfterProduct Initial 5 Hours Initial 5 Hours______________________________________Dentrol 279 568 71 37Ex. 1 147 642 174 775Ex. 2 147 241 200 134______________________________________ *Numbers represent areas under cohesion/adhesion Texturometric curves.
The data listed in Table 3 shows clearly the unexpected and superior nature of the cohesion and adhesion parameters obtained with compositions of this invention. Particularly noteworthy is the marked cohesion and adhesion abilities of the subject compositions even after 5 hours. In contrast, the measured adhesion of the comparative commercial product decreased significantly, almost 50% after 5 hours. This cohesion and adhesion after keeping for 5 hours, characteristic of the subject compositions, is even more surprising since it might be expected that with passing of time the water of hydration, considering the hydrophilicity of the subject compositions, might weaken rather than strengthen the structure of such compositions.
When in contact with moistened denture plates, gums and saliva, the subject compositions hydrate within the oral cavity to provide superior denture stabilizing properties not possessed by heretofore known denture adhesives, the latter generally having hydrophobic vehicles for the adhesive components rather than hydrophilic vehicles as with the subject compositions. In general, furthermore, the subject compositions will form a clear gel-like mass (upon mixing with water or saliva) whereas conventional products with hydrophobic vehicles form an opaque, very oily mass. Esthetically, the clear gel-like mass is more acceptable to the user.
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An improved denture adhesive containing poly(ethylene oxide) as the sole adhesive component in a hydrophilic vehicle comprising certain polyethylene glycols (PEG) and, as an optional component in certain forms of the subject adhesives, glycerin, for enhancing pharmaceutical elegance of the final product.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from European Serial No. 04027709.7, filed Nov. 22, 2004.
TECHNICAL FIELD
[0002] The present invention is related to systems and methods for manufacturing dental prostheses, such as bridges and crowns. In particular, the present invention is directed to novel methods for managing machining jobs for manufacturing dental prostheses in a system having a plurality of machining devices.
BACKGROUND OF THE INVENTION
[0003] Prostheses are commonly used in the dental industry for replacing or reconstructing teeth. Generally, such dental prostheses can be in the form of implants, crowns, bridges, onlays and inlays. Since such prostheses have to be designed precisely in order to ensure proper fit, manufacturing methods for such products have to meet certain criteria in terms of accuracy in designing and machining. It is recognized in the art that computer aided design (CAD) and computer aided manufacturing (CAM) can be viable options for providing flexibility, ease and accuracy in designing and manufacturing such prostheses.
[0004] For example, U.S. Pat. No. 6,287,121 describes a device for determining the shape of a duplicate of a remaining tooth area to be provided with a dental prosthesis and an arrangement for producing the dental prosthesis. The described arrangement for producing the prosthesis comprises a shape determination device and a machining device for the actual production of the dental prosthesis, and an electronic data processing (EDP) installation. The EDP installation couples the shape determination device with the machining device, and also includes a memory unit for the results of the shape determination device, and a control unit for controlling the machining device. U.S. Pat. No. 6,287,121 primarily relates to a three serial module arrangement consisting of the shape determination device, EDP installation and machining device. All control and monitoring functions take place in the EDP installation, so that the shape determination device and the machining device need not have individual EDP units. This provides central control and monitoring of the entire production of the dental prosthesis at the EDP installation. Such an arrangement may be efficient for cases where only one machining device is needed. However, such an arrangement may prove disadvantageous in terms of efficiency for relatively large scale production of dental prostheses, e.g. in a production lab having a plurality of machining devices connected in a network with various workstations. In such a network, one may have a plurality of machining jobs, each corresponding to a particular dental prosthesis to be machined and may want to have the machining devices run independently with minimal user intervention. Thus, a system and method specifically suited for such applications would be desirable.
[0005] WO 01/37756 discloses an arrangement for a system for manufacturing dental products having a plurality of production units. The manufacturing system comprises various coordination units which receive and register orders from different customers. The coordination units distribute the orders to production units. The various units are updated by data replications in conjunction with changes to system functions, system application and system structure. The data contained in the databases of the production units are entered in memory elements which are arranged for accessing program contents when executing data replications via one or more interfaces. In the arrangement described, a production job for a particular dental product is assigned to a particular production unit by one of the coordination units. The data is then replicated from the coordination unit to that particular production unit.
[0006] There are some practical disadvantages associated with such an arrangement. For example, if a particular production unit becomes disabled or inoperative after assignment of the production jobs, the production jobs have to be re-assigned to another production unit. Further, when manufacturing dental prostheses, it is desirable to tailor the machining of the prosthesis to the material characteristics of the material to be machined. To this end, a particular material blank having certain material characteristics may be assigned to a particular prosthesis or production job. If the production job is assigned to a particular production unit for machining, the operator has to make sure that the material blank is placed in the production unit assigned to that production job. If the material blank is placed in the wrong production unit, delays would be caused in the manufacturing process.
[0007] Hence, there is a need for a more flexible and robust method and system for manufacturing dental prostheses in an environment having a plurality of production devices. It would be advantageous to provide a system in which it is not necessary to allocate a particular production unit for a particular production job, so that inconveniences associated with such allocation can be eliminated and production jobs can be done in a more autonomous fashion.
SUMMARY OF THE INVENTION
[0008] The present invention provides systems and methods that are particularly suitable for manufacturing dental prostheses in an arrangement having a plurality of machining devices. A system according to the present invention comprises essentially at least one workstation having data processing means configured for designing a dental prosthesis using a digital image of a situation of a person's teeth area and a plurality of machining devices for machining the framework for the dental prosthesis from a material blank using machining data generated at the at least one workstation, wherein the machining devices of the system are configured to read an identification code associated with the material blank and to retrieve the machining data corresponding to the identification code of the material blank.
[0009] The system may further comprise at least one scanning means for producing a digital image of the situation of a person's teeth area. For example, a scanning means can be provided which can produce a digital image of the situation of a person's teeth by directly scanning an area of a person's teeth or by scanning a working model of an area of a person's teeth. The situation of a person's teeth area refers to the area of the person's teeth, in which the dental prosthesis should be placed.
[0010] In the case where a working model is scanned, a working model is provided by a dentist, a dental technician, or other customer. The working model is normally based on an impression made from an area of a person's teeth, in which the dental prosthesis should be placed.
[0011] The working model is preferably placed within the scanning means where a digital image is made of the working model. The digital image representing the working model is received by the data processing means of a workstation. Preferably, the data processing means uses a CAD/CAM modeling software, such as Lava™ System (commercially available from 3M-ESPE AG, Seefeld, Germany) to design a framework for the dental prosthesis using the digital image as a basis.
[0012] For manufacturing the dental prosthesis, a material blank is typically used. The material blank can be any biocompatible material that is suitable for use in dental prosthetic applications. For example, suitable biocompatible materials may comprise polymer-based materials, precious metals and titanium. Preferably, the material blank is a pre-sintered ceramic, such as pre-sintered zirconium oxide or zirconia, respectively. The material blank may be in any suitable form for machining. For example, the material blank may be in the form of a cylindrical solid block.
[0013] Preferably, a material unit is used for securely holding the material blank during machining. Each material unit has a unique identification code which identifies the material unit. This identification code may be a serial number or any code which allows the material unit to be singularly identified. Preferably, the material unit also has a lot identification number which provides information on the characteristics of the material of the blank. For example, the lot identification number could indicate information on the manufacturing of the material and sintering shrinkage properties. This information could be used for designing the dental prosthesis and for determining the specific machining path instructions for the machining devices. Machining could then be tailored for each material blank which in turn provides greater accuracy in the machining process and inevitably an optimal fit for the dental prosthesis.
[0014] For each dental prosthesis to be designed and machined, a machining job is established for machining the framework for the dental prosthesis. The machining job is represented electronically by machining data comprised in a machining data file or files. The machining data indicates the machining path instructions and the material unit assigned to that machining job. The machining path instructions are based on the desired parameters for the prosthesis and the material characteristics of the material blank. The machining path instructions can be determined using CAM software.
[0015] Each machining device comprises data processing means having a storage unit for storing machining data files and preferably a receiving means for receiving a plurality of material units. The material unit can comprise a means for ensuring proper orientation of the material unit in the receiving means of the machining device. The machining device has reading means for reading the identification code of the material unit. Once the identification code of the material unit is read, the machining device is designed to retrieve the machining data associated with the identification code of the material unit. This is particularly advantageous in that it is not necessary for the operator to place the material unit in a particular machining device or for machining data to be pre-assigned to a particular machining device. This also avoids errors associated with placing the material unit in the wrong machining device. Also, if a machining device is disabled, machining data files do not have to be re-assigned to a different machining device. The operator only has to place the material unit in another machining device. Machining jobs can be completed in a more automated fashion.
[0016] The machining device may be any suitable machining device that provides appropriate machining of the material blank to form the framework for a dental prosthesis. Such machining devices may include milling devices, grinding devices laser devices and the like. The machining device is preferably configured to machine the material blank according to the instructions in the machining data file(s) in order to form a dental prosthesis. Preferably, the machining device is so configured that a plurality of material units can be loaded, and finished material units for dental prostheses can be removed while machining continues. Further, the machining device is preferably configured to orientate the material units for machining and to change machining tools according to the specifications of the machining data without intervention from an operator.
[0017] In one aspect of the invention, the machining data files generated by a workstation are first stored in a central storage. For example, the central storage could be a network attached server or the like. Each machining device and each workstation has access to the central storage. Once a machining device of the system reads the identification code of a material unit, the data processing means of the machining device is configured to search for the corresponding machining data file in the central storage. The machining device then machines the framework of the prosthesis from the material blank as the machining data is being read from the central storage. After the dental prosthesis has been machined, the machining data is then preferably deleted from the central storage.
[0018] In a second aspect of the invention, the machining device is configured to first save the machining data file in the storage unit of the device and then machine the material blank as the machining data file is read from its own storage unit. This is particularly advantageous in that the machining is performed independent of the central storage. For instance, if the central storage means was disabled, it would not affect the machining process of a blank being instantaneously machined. After the machining of the blank is complete, the corresponding machining data file is preferably deleted from the central storage and the storage unit of the machining device.
[0019] A third aspect of the invention relates to a product for managing the machining data files. The product has code designed to ensure proper deleting, retrieving and saving of the machining data files in the machining devices, workstations and central storage of the system. For example, the product can have code to ensure that the machining data files are deleted when the corresponding machining job is completed, especially in cases when components of the system are inactive at the time of file deletion.
[0020] In a fourth aspect of the invention, a central storage is not used. The data processing means of the workstation is configured to distribute all machining files generated on its computer to all other computers in the system, e.g. to the data processing means of other workstations and to the storage units of each machining device. After the material blank has been successfully machined, the data processing means of the machining device is configured to preferably place a request to delete the corresponding machining data files from the other computers in the network, for example by writing the identification code of the material unit into a designated file. The files in the designated file are automatically deleted from all storage locations in the system, e.g. from the storage means of the workstations and the storage units of the machining devices. This aspect of the invention would also be insensitive against a possible network failure of the system during machining.
[0021] A fifth aspect of the invention relates to a product for managing machining data files in a system according to the fourth aspect of the invention. For example, such a product could have code to make sure that files are properly copied and preferably deleted on all computers of the network and to take into account that not all computers may be running at the same time or all the time.
[0022] With regard to the various described aspects of the invention, it should be noted that the method steps do not have to be in the specific order described in the preferred embodiments and figures. For example, the step of generating the machining data for a particular blank may take place after or simultaneously with the step of placing the material blank in a machining device or the step of the machining device reading the identification code.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Preferred embodiments of the present invention will be further described by the following description and drawings:
[0024] FIG. 1 is a diagram of a system according to the first and second aspects of the invention;
[0025] FIG. 2 is an example of a material unit used in the present invention;
[0026] FIG. 3 is a flow chart of a method according to the first aspect of the invention;
[0027] FIG. 4 is a flow chart of a method according to the second aspect of the invention;
[0028] FIG. 5 is a diagram of a system according to the fourth aspect of the invention; and
[0029] FIG. 6 is a flow chart of a method according to the fourth aspect of the invention.
DETAILED DESCRIPTION
[0030] Referring to FIGS. 1 and 5 , the system using the method of the present invention generally comprises at least one workstation 201 , 202 , 203 and a plurality of machining or milling devices 301 , 302 , 303 , preferably forming a local area network or the like. The system may further comprise at least one scanning means 101 , 102 , 103 electronically connected to at least one of the workstations 201 , 202 , 203 .
[0031] The scanning means 101 , 102 , 103 is configured to scan a model representing the area of a person's teeth in which the dental prosthesis should be placed and to form a digital image of the model. The scanning means 101 , 102 , 103 is preferably a non-contact 3-D optical scanner.
[0032] The workstation 201 , 202 , 203 comprises an electronic data processing means. Preferably, the workstation is a computer having storage means, a data processor, a monitor, keyboard, mouse and/or touchpad or the like. The data processing means of workstation 201 , 202 , 203 is configured to store and process digital images received from a scanning means or other external source. Other external sources could include digital images of situations of teeth received via modem, network or read from external storage media. The digital images are processed using CAD/CAM software for designing dental prostheses and for determining the milling data. For example, the dental prosthesis can be designed using a CAD modeling software such as Lava™ System (commercially available from 3M-ESPE AG, Seefeld, Germany). For each dental prosthesis to be designed and milled, a milling job is established for milling the framework for the dental prosthesis. The milling job is represented electronically by milling data comprised in a milling data file or files. The milling data file indicates the milling path instructions and the material blank assigned to that milling job. The milling path instructions are based on the desired parameters for the prosthesis and the material characteristics of the material blank. Preferably, the milling path instructions are determined using the CAM software, for example LAVA™ CALC software (commercially available from 3M-ESPE AG, Seefeld, Germany).
[0033] The material blank for the dental prosthesis consists of a biocompatible material. Preferably, the material blank consists of a pre-sintered ceramic material. Most preferably, the material blank consists of pre-sintered zirconium oxide. The material blank may be in any suitable form for milling. For example, the material blank may be in the form of a cylindrical solid block.
[0034] Preferably, the material blank 22 is contained in a material unit 20 having the form shown in FIG. 2 . The material unit serves to securely hold the material blank during machining or milling. Further, the material unit may have codes or numbers identifying the material blank and its material characteristics. Other suitable material units are described in WO 01/97707 (assigned to 3M-ESPE AG, Seefeld, Germany).
[0035] In FIG. 2 , the material unit 20 comprises a material blank 22 and a support body 24 for holding the material blank 22 . In the example shown, a framework for a dental prosthesis 30 has been milled from the material blank 22 . Further, the material unit 20 has a unique identification code 26 . Each material unit has a different identification code. This identification code can be a serial number or any code which allows the material unit to be singularly identified. At the workstation 201 , 202 , 203 , a material unit is assigned to each milling job for a dental prosthesis and is associated with milling data for that particular material unit.
[0036] Further, the material unit 20 may comprise a material lot number or code 28 which indicates material properties and manufacturing characteristics specific to that particular material blank 22 contained in the material unit 20 . Such information could be useful, for example, in calculating sintering shrinkage or suitable machining tools.
[0037] The machining or milling devices 301 , 302 , 303 mill the material blank 22 in order to form the framework of the dental prosthesis 30 . The milling devices 301 , 302 , 303 are configured to receive a plurality of material units 20 , for example in a loading area or the like. Each milling device 301 , 302 , 303 has a data processing means including a storage unit for storing milling data files and reading means for reading the identification codes 26 of the material units 20 . The milling data file contains milling path instructions for the milling devices 301 , 302 , 303 .
[0038] FIG. 3 shows a flow chart of a method according to the first aspect of the invention. In this aspect, the milling data files generated by workstation 201 , 202 , 203 are first stored in a central storage 10 as shown in FIG. 1 . For example, the central storage 10 could be a network attached server or the like. Each milling device 301 ,. 302 , 303 and each workstation 201 , 202 , 203 has access to the central storage 10 , thereby being able to save to, retrieve from or delete files from the central storage 10 . Once a milling device 301 , 302 , 303 reads the identification code 26 of a material unit 20 , the data processing means of the device 301 , 302 , 303 is configured to search for the corresponding milling data file in the central storage 10 . The milling device 301 , 302 , 303 then mills the framework of the prosthesis 30 from the material blank 22 , as the milling data file is being read from the central storage 10 . After the framework for the dental prosthesis 30 has been milled, the milling data file is then preferably deleted from the central storage 10 . This aspect of the invention is particularly advantageous in that the milling data file does not have to be previously assigned at the workstation 201 , 202 , 203 to a particular milling device 301 , 302 , 303 . Material units 20 can be placed in any milling device 301 , 302 , 303 of the system.
[0039] FIG. 4 shows a flow chart of a method according to the second aspect of the invention. In this aspect, the milling device 301 , 302 , 303 is configured to first save the milling data file in the storage unit of the device 301 , 302 , 303 and then mill the material blank 22 as the milling data file is read from its own storage unit. This is particularly advantageous in that the milling is performed independent of the central storage 10 . After the milling of the blank 22 is complete, the corresponding milling data file is preferably deleted from the central storage 10 and the storage unit of the milling device 301 , 302 , 303 .
[0040] The third aspect of the invention relates to a product for managing the milling data files using methods and systems according to the first and second aspect of the invention. The product has code designed to ensure proper deleting, retrieving and saving of the milling data files in the milling devices 301 , 302 , 303 , workstations 201 , 202 , 203 and central storage 10 of the system. The system of the invention may also be accessed externally, for example by providing modem connection or the like to the central storage 10 and/or workstations 201 , 202 , 203 .
[0041] FIGS. 5 and 6 relate to the fourth aspect of the invention, wherein a central storage is not used. The data processing means of the workstation 201 , 202 , 203 is configured to distribute all milling data files generated on its computer to all other computers in the network. After successful milling of the material blank 22 of a material unit 20 , the data processing means of the milling device 301 , 302 , 303 is preferably configured to place a request to delete the corresponding milling data files for the material unit 20 , for example by writing the identification code 26 of the material unit 20 into a designated file. Preferably, the milling data files in the designated file are read and automatically deleted from all storage locations in the system. The method of this aspect also comprises steps to take into account that not all computers may be running at the same time or all the time. For example, such steps could comprise maintaining lists of the files copied and deleted on all computers. A solution like this would also be insensitive against a possible network failure during milling.
[0042] The fifth aspect of the invention relates to a product for managing milling data files in a system according to the fourth aspect of the invention.
[0043] The various embodiments presented in the specification are used for the sake of description and clarification of the invention, and thus should not be interpreted as limiting the scope of the invention as such. Moreover, the present invention is realized by the features of the claims and any obvious modifications thereof.
LIST OF REFERENCE NUMERALS
[0000]
101 , 102 , 103 scanning means
201 , 202 , 203 workstation
301 , 302 , 303 milling device
10 central storage
20 material unit
22 material blank
24 support body
26 identification code
28 material lot number
30 framework for a dental prosthesis
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The present invention is related to systems and methods for manufacturing dental prostheses, such as bridges and crowns. In particular, the present invention is directed to novel methods for managing machining jobs for manufacturing dental prostheses in a system having a plurality of machining devices.
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TECHNICAL FIELD
[0001] The present invention relates to compositions for the prevention or removal of insoluble salt deposits. The present invention further relates to use of compositions for the prevention or removal of insoluble salt deposits. The present invention further provides a method for the manufacturing of compositions for the prevention or removal of insoluble salt deposits and to a method to prevent or remove insoluble salt deposits using compositions according to the invention.
[0002] The present invention relates to the use of a composition comprising itaconic acid, its anhydride, succinic acid, its anhydride, and or lactide and combinations thereof for the prevention or removal of insoluble salt deposits.
[0003] The present invention further relates to a toilet block, comprising a composition comprising itaconic acid, its anhydride, succinic acid, its anhydride, and or lactide and combinations thereof.
[0004] The present invention further relates to an effervescent tablet comprising a composition comprising itaconic acid, its anhydride, succinic acid, its anhydride, and or lactide and combinations thereof.
[0005] The present invention further relates to an acid gel comprising a composition comprising itaconic acid and or succinic acid combined with a rheology modifier.
[0006] Also, this invention relates to a composition comprising itaconic acid, its anhydride, succinic acid, its anhydride, and or lactide and combinations thereof for the prevention or removal of insoluble salt deposits
BACKGROUND
[0007] Water insoluble salts such as calcium and magnesium carbonates or silicates or sulfates commonly referred to as limescale, but also barium sulfate, calcium oxalate, calcium phosphate, iron oxide and the like are readily formed in watery solutions when the conditions are right and may each represent particular challenges in relation to their removal.
[0008] Limescale or limestone is the hard, off-white, chalky deposit found in kettles, hot-water boilers and the inside of inadequately maintained hot-water central heating systems. It is also often found as a similar deposit on the inner surface of old pipes and other surfaces where “hard water” has evaporated.
[0009] These types of limescale differ slightly due to their origins. The type found deposited on the heating elements of water heaters, laundry machines, etc. has a main component of calcium carbonate, precipitated out of the (hot) water. Hard water contains calcium (and often magnesium) bicarbonate and/or similar salts.
[0010] Calcium bicarbonate is soluble in water, however at temperatures above 70° C. the soluble bicarbonate is converted to poorly-soluble carbonate, leading to deposits in places where water is heated. Local boiling “hot spots” can also occur when water is heated, resulting in the concentration and deposition of salts from the water. Likewise calcium sulfate is a common component of fouling deposits in industrial heat exchangers, due to its decreased solubility with increasing temperature. Silicate containing laundry and automatic dishwashing products may cause a calcium or magnesium silicate deposit, which is especially difficult to remove (in contrast to calcium carbonate) from glassware.
[0011] The type found on air-dried cooking utensils, dripping taps and bathroom tiling consists of calcium carbonate mixed with all the other salts that had been dissolved in the water, prior to evaporation. It can also be found on taps and water reservoirs (such as in the toilet) where hard water has been continually running through and has deposited calcium carbonate.
[0012] The presence of limescale presents several problems. Other than being unsightly and harder to clean, limescale can impair the operation of various components or damage them. In kettles, limescale acts as an insulator, impairing heat transfer. Additionally, it can damage the heating element, which overheats due to accruing limescale. Limescale can build up inside tubing, thus reducing water flow and necessitating higher electrical consumption for the circulation pumps, and eventually blocking the tubing. Expresso machine manufacturers recommend to descale the machine (depending on the water hardness) every month or trimester in order to avoid bitter taste development, machine malfunction and slowing down.
[0013] Other types of deposits formed by insoluble salts are beerstone and milkstone. Calcium oxalate forms a major component of beerstone, a brownish precipitate that tends to accumulate within vats, barrels and other containers used in the brewing of beer. Beerstone is composed of calcium and magnesium salts and various organic compounds left over from the brewing process; it promotes the growth of unwanted microorganisms that can adversely affect or even ruin the flavor of a batch of beer. Calcium oxalate is also formed during carbonation of raw sugar beet juice before it undergoes crystallization. First, the juice is mixed with hot milk of lime (a suspension of calcium hydroxide in water). This treatment precipitates a number of impurities, including multivalent anions such as sulfate, phosphate, citrate and oxalate, which precipitate as their calcium salts and large organic molecules such as proteins, saponins and pectins, which aggregate in the presence of multivalent cations.
[0014] Milkstone is a layer of scale mainly formed by cations like calcium and magnesium originating from both milk and hard water. Besides giving the equipment an unclean appearance, milkstone could harbour and protect micro organisms always present in raw milk and ready to multiply at a high rate. Since milk products are some of the most perishable major foods, cleaning and sanitization in that industry generally require the highest standards. The main part of milk residue is easily removed by rinsing with water. However, the last part comprising the milkstone is often harder to get rid of.
[0015] Several methods and products have been developed in order to remove some or all of these different types of deposits by insoluble salts, such as limescale.
[0016] Generally, different types of descaling agents are used to remove deposits by insoluble salts. Descaling agents are either acids or complexing agents or both in one (e.g. carboxylic acids). They remove insoluble deposits such as limescale by respectively dissolving the limescale and or complexing its cationic constituents. Acids used as descaling agents can be either mineral acids or organic acids. Below in table 1, the properties of some organic and mineral acids that are used or can be potentially useful for descaling are shown.
[0000]
TABLE 1
Properties of some organic and mineral acids used or potentially useful for descaling.
Solubility
Solubility
Trivial name
water
calcium salt
physical
of acid
20° C.
g/100 ml
form
Sourcing
descaling
pKa
smell
Compatibility
label
oxalic
14%
0.0007
powder
Petro
1.3/4.3
++
C, Xn
maleic
>40%
2.9
powder
Petro
1.9/6.3
+−
Xi/Xn
malonic
>90%
No data
powder
Petro
2.9/5.7
+−
Xn
tartaric
+−60%
0.04
powder
Ferm
3/4.3
++
Xi
fumaric
64%
1.4,
2% b
powder
Petro
3/4.4
++
Xi
citric
60%
5%
(1.Ca)
powder
Ferm
−
3.1/4.8/6.4
++
++
Xi
0.09%
(2-3.Ca)
malic
>80%
0.8% b
powder
Petro
+
3.4/5.1
+−
−−
Xn
formic
100%
17
liquid
Petro
++
3.8
−−
−−
C, Xn
glycolic
100%
1.2%
powder
Petro
−−
3.9
+−
−−
C, Xn
itaconic
9.5%
No data
powder
Ferm
3.9/5.1
++
Xi
lactic
100%
7%,
3.1% b
liquid
Ferm
+
3.8
++
++
Xi
gluconic
>50%
3,
3% b
powder
Ferm
3.9
−−
Xn
succinic
7.7%
0.004% b
powder
petro/ferm
4.2/5.6
++
C, Xn
glutaric
50%
Soluble
powder
Petro
4.3/5.4
++
Xi
Acetic
100%
33.8
liquid
petro/ferm
+
4.8
−−
−−
C, Xn
Lactide a
Insol. a
a
Powder
Ferm
/
++
++
Xi
phosphoric
100%
0.03
liquid
Min
++
2.2/6.8/12.4
+
−
C, Xn
sulfamic
29%
No data
powder
Min
++
0.1
+−
+−
C, Xn, N
hydrochloric
>40%
75
liquid
Min
−9.3
−−
C, T, N
sulfuric
100%
0.3
liquid
Min
−3
+−
C, T
b Lactide is a dimeric ester rather than an acid but readily hydrolyses to lactic acid. Data obtained from presentations by Purac and complemented with various literature data. Properties listed include the solubility in water (pH 7, 20° C.), the solubility of the calcium salt (mono, di, tri-salts,
b as % anhydrous at 25° C.), their physical form, descaling effectiveness (Purac data), pKa value(s), smell, overall material compatibility (Purac data) and labeling according to EU legislation.
[0017] Table 1 documents among other characteristics the water solubility of di- and tri-salts of polybasic carboxylic acids which tends to be (very) limited as compared to that of monocarboxylic acids, with maleic and glutaric acids as an exception to this apparent rule. No literature data were found regarding the calcium salt of itaconic acid. Whereas the monocalcium salt of citric acid is water soluble (5%), the disalt and trisalts are only sparingly or practically insoluble (0.09 g/l).
[0018] The majority of acids commercially used for descaling are mineral acids such as phosphoric, sulfamic, hydrochloric and sulfuric acid (cf table 1). These are however classified as corrosive to the skin and the eyes and as environmentally hazardous or in case of phosphoric acid represent a substantial eutrophication potential. Moreover they tend to be either fuming or cause a pungent smell and their overall material compatibility is limited.
[0019] Organic acids have one, two or three carboxyl groups (note the pKa values in table 1) and are usually less aggressive which is why acetic, citric and formic and more recently glycolic and lactic acid found their way to the market.
[0020] Organic acids can be sourced from fermentation or from petrochemical synthesis. Citric and lactic acid for example are obtained by fermentation from renewable feedstock (typically molasses). The fact that many of these organic acids suitable for descaling action are renewable is increasingly considered an environmental advantage as illustrated in life cycle analyses. However, some of these organic acids still show disadvantages.
[0021] For example, the iron and calcium salts of citric acid are said to be less soluble than those of glycolic acid, so they may precipitate onto the treated surfaces, diminishing cleaning effectiveness of citric acid.
[0022] Acetic and formic acid have a pungent smell that is hard to cover with fragrance, which is a serious disadvantage.
[0023] Acetic acid, which may be sourced from fermentation or from petrochemical synthesis, is renowned for its corrosivity to copper which leads to the formation of toxic copper acetate (a fungicide) thus rendering acetic and vinegar unsuited for descaling coffee and expresso machines which often have a copper mounting tube for hot water or steam. Acetic acids will thus also be unsuited for all other surfaces comprising cupper.
[0024] Furthermore, the descaling activity of many organic acids is quite weak. Many organic acids either show efficiency in fast descaling or in descaling upon prolonged contact, but not both. Moreover a limited number of organic acids is available as a solid. These are huge disadvantages as they put a restriction onto the development of descaling agents that offer an overall better efficiency.
[0025] There is a need for a descaling agent which is renewable, and which shows a better efficiency than the existing products.
[0026] One specific application of descaling agents is their use in toilet blocks, since toilets often suffer from severe insoluble salt deposits. Traditionally toilet blocks in the past where designed to mask odors and have a slight cleaning effect in the toilet. The two main types manufactured and marketed up until the late 1980's were the so called rim and the in-cistern blocks, applied in the toilet bowl and the water cistern respectively. During the 1990's several new developments have been marketed, with the liquid rim containers coming on the market which has greatly increased the flexibility and number of ingredients available to formulate with, and the solid block formulations have also been expanded with products that have special properties (i.e. lime scale inhibition, bleaching, cleaning efficiency, etc.).
[0027] There are different challenges to the formulation and manufacture of toilet and cistern blocks as these are dependent on most of the ingredients being supplied as practically water free chemicals, otherwise they might have a negative influence on the chemical properties of the block as well as the stability and compatibility with other ingredients included. The main manufacturing process for such blocks is by extrusion of a pre-made dry mixture of all the ingredients. A crucial property for the manufacture of solid blocks however has been the extrusion properties of the anionic surfactants and in particular dry LAS (Linear Alkyl Benzene sulfonate). The sodium salt of LAS in dry form is available as a very hygroscopic powder, which means that precaution has to be taken in terms of handling and storage, but it is also this product characteristic that makes it an excellent main ingredient in formulating solid extrude toilet blocks. The hygroscopic nature of LAS ensures that once the final product is exposed to water in the toilet bowl or in the cistern it will create an outer layer or membrane that slows down the overall solubility of the block thereby imparting a controlled release of all the active ingredients in the block (source: Toilet block introductory Leaflet by Unger, 2008). Formulating rim and in-cistern blocks among others implies selecting solubility retarding or “matrix” ingredients with a melting point at or just above the extrusion temperature, which upon cooling will form a homogenous solid block that will gradually and evenly set free its actives over time, typically during several weeks for 50 to several hundreds of flushes, more typically up to 500-800 flushes. Such formulas contain 25-50% LAS (typically 40%), 0-8% fatty alcohol sulfate (mainly C 12-14 , some C 16 in cistern blocks) or 0-5% highly ethoxylated fatty alcohol (e.g. C 16-18 with up to 50 mol ethylene oxide), 0-3.5% Coconut monoethanolamide, 1% foam enhancing fatty alcohol ether sulfate, 0.05% paraffin oil, 5-6% fragrance and dyes and sodium sulfate as a filler. Low amounts of acids (e.g. 2% lactic acid or 10-20% citric acid anhydrate) have been incorporated as well as polymers. US2007191245A1 for example describes the use in toilet blocks of polysuccinimide for preventing or dispersing urine scale.
[0028] Effervescent toilet descaling tablets form an alternative approach for descaling, targeting fast tablet disintegration (as opposed to toilet blocks) but long contact times (e.g. overnight). They are produced by tabletting and always contain an acid (usually sulfamic or citric acid) for dissolution of the immersed limescale and a carbonate source for the effervescent system (sodium carbonate, bicarbonate, percarbonate, . . . ). Formulating such tablets is all about finding the balance between fast dissolution on one hand and tablet strength and stability on the other. Low moisture content is of paramount importance, especially when the formula contains percarbonate bleach. A typical formula contains 1-2% lauryl sulfoacetate or FAS, 1% FAEO C 16-18 8EO, 40-50% citric or sulfamic acid, 20-30% sodium carbonate, some polyethylene glycols, fragrance, dye, and sulfate as a filler. Some formulations additionally contain about 2% percarbonate bleach.
[0029] Products dedicated to periodical cleaning and descaling of automatic dishwashing machines usually are based on citric acid and a small amounts of FAEO (e.g. C 9-11, 4 EO), and additionally may contain some corrosion inhibitor, solvents, PEG, phosphonates, fragrance and dye.
[0030] There is a need for a renewable low moisture and stabile descaling agent that can be used in descaling block or tablet formulations and has a better efficiency than the existing descaling agents used in toilet blocks and tabs.
[0031] It is an object of the present invention to provide a new descaling agent which is made of renewable material and which shows a better overall efficiency than the descaling agents known from the prior art.
[0032] It is also an object of the present invention to find a toilet block comprising a descaling agent, which is made of renewable material, is low moisture and stabile with a better efficiency than the existing descaling agents used in toilet blocks.
SUMMARY OF THE INVENTION
[0033] The present invention aims to provide a solution for at least one of the problems mentioned.
[0034] The first object is achieved by a composition of claim 1 . In particular, the present invention provides a composition for the prevention or removal of insoluble salt deposits comprising:
a) an organic acid with two carboxylic acid functional groups obtainable by fermentation, selected from the list of itaconic acid, itaconic acid anhydride, succinic acid, succinic anhydride and combinations thereof, and b) at least one compound determining the release of said acid from said composition, said compound is selected from the list comprising: i) a hygroscopic compound, ii) a carbonate source, iii) an acid solubility retarding compound, iv) a compound with melting point situated between 60° C.-95° C., and combinations thereof.
[0041] The inventors found that an acid as described under a) could be combined with compounds acting as acid release regulating means as described under b). This is advantageous as it allows the manufacturing of compositions for both fast and slow release based an acid of renewable resources, in particular itaconic acid and/or succinic acid. In a preferred embodiment, the anhydride form is used. The acids and anhydrides prescribed are interesting from an ecological point of view as they are readily degradable and obtainable from renewable resources. The acids are remarkably compatible with the functional compounds under b). The combination of a) and b) provides a synergistic effect. The acids under a) do not impact the functionality of compounds under b). This has for effect that they can be used as mixing partners. Selections of a compound from the list under b) will provide access to compositions with either slow or fast release of the acid under b). Both fast and slow release compositions for itaconic acid, itaconic acid anhydride, succinic acid, succinic acid anhydride have become available.
[0042] In a preferred embodiment, the organic acid is itaconic acid.
[0043] Itaconic Acid (CH 2 :C(COOH)CH 2 COOH, CAS 97-65-4, also called Methylene Succinic Acid, Butanedioic acid, Methylene Butanedioic acid, Propylenedicarboxylic acid; 2-Propene-1,2-dicarboxylic acid;) is a white anhydrous (<0.3%) hygroscopic crystalline dicarboxylic acid with a melting point of 166° C. It is soluble in water, ethanol and acetone. Its chemical structure is similar to that of succinic acid but with a methylene group substituted onto the carbon chain, the unsaturated double bond forming a conjugated system with the carbonyl group.
[0000]
[0000] Itaconic can be converted into its anhydride as described in U.S. Pat. No. 5,260,456. Itaconic anhydride (CAS 2170-03-8,2-Methylenesuccinic anhydride) white crystals have a slightly acidic odor and a melting point of 67-69° C. In contact with water the anhydride will hydrolyze back to itaconic acid.
[0044] Itaconic acids primary application is in the polymer industry where it is employed as a co-monomer at a level of 1-5% in styrene butadiene resins and in acrylic latexes for textile, paper, and paint applications. It is furthermore used to prepare acrylic fibers and rubbers, reinforced glass fiber, artificial diamonds and lens.
[0045] Itaconic acid was discovered as a distillation product of citric acid, but is now typically produced in a fungal fermentation at relatively small scale. Magnuson and Lasure (2004) give an extensive overview of the history and current status of itaconic acid. The first reported biological source of itaconic acid was the descriptively named Aspergillus itaconicus . Shortly thereafter, it was discovered that A. terreus produced itaconic acid. An efficient process for the fermentation of sucrose in molasses to itaconic acid using A. terreus was patented in 1962. The reported yield is 70%,
[0046] Magnuson J K, and L L Lasure. 2004. “Organic Acid Production by Filamentous Fungi.” Chapter 12 in ADVANCES IN FUNGAL BIOTECHNOLOGY FOR INDUSTRY, AGRICULTURE, AND MEDICINE, ed. Jan S. Tkacz and Lene Lange, pp. 307-340. Kluwer Academic/Plenum Publishers, New York, N.Y.
[0047] The inventors have surprisingly found that itaconic acid in a composition according to an embodiment of the invention shows excellent descaling activity and an overall excellent activity in the removal and prevention of insoluble salt deposits.
[0048] Furthermore, itaconic acid in a composition according to an embodiment of the invention is a very strong descaling agent in both fast descaling as well as descaling upon prolonged contact.
[0049] Furthermore, It can be produced through fermentation, and it is a fully renewable descaling agent. Furthermore, it is non-corrosive and has a neutral smell.
[0050] Furthermore, itaconic acid can be used as a solid state, stabile, low moisture ingredient for descaling activities, allowing polyvalent use.
[0051] Furthermore itaconic anhydride can be used as an agent releasing the above itaconic acid upon contact with water, a property especially useful in toilet blocks.
[0052] In a preferred embodiment, the compound selected from list b) is the hygroscopic compound. More preferably, the hygroscopic compound is lactide, an anionic surfactant, or combinations thereof. In a preferred embodiment the hygroscopic compound is lactide. An example of a hygroscopic anionic surfactant is alkyl benzene sulfonate. In a preferred form, itaconic acid is in substantially dry form, i.e. with a water content of at most 5%, preferably at most 3%, more preferably at most 1%, most preferably at most 0.5%.
[0053] Lactide (CAS 4511-42-6 and 95-96-5, also called cyclic dimer of lactic acid, Dilactide, L-Lactide, DL-Lactide, 3,6-Dimethyl-1,4-dioxane-2,5-dione) on the other hand contains two molecules of natural L(+)-lactic acid in the form of a ring. While mixed with water, the ring is hydrolyzed back into two free L(+)-lactic acid molecules that allow a delayed acidification of the medium, the pH drop to pH2 being completed after two hours. The inventor observed complete dissolution at room temperature to require at least 3 hours while stirring. The strong acidity released by lactide is due to the low pKa of lactic acid and to the release of two acidic functions per mole. It is a white, almost odorless, virtually water-free (<30 ppm) very hygroscopic powder with a melting point of 94-99° C.
[0000]
[0054] Lactide is produced by double condensation of L(+)-lactic acid molecules obtained by fermentation of natural sugar. After several solvent-free purification steps, small white flakes of pure 3,6-dimethyl-1,4-dioxane-2,5-dione are obtained (solid lactic acid). There are several methods to prepare lactic acid. Among the biological routes is a process employing R. oryzae . The organism imports glucose and exports lactate, an acid that is not a component or by-product of the citric acid cycle. Lactate is produced by the organism aerobically, and the commercial process requires agitation and aeration just as the other fungal organic acid processes do. The substrate for the R. oryzae process is glucose, and the manufacturers are corn-processing companies with readily available low-cost glucose. Lactic acid is recovered by the technologies used for the other organic acids, including precipitation from an alcoholic extract. In aqueous solution, lactic acid dimerizes to form lactide, an intermediate for the biodegradable plastic, polylactic acid (PLA). Until recently, lactic acid was used primarily in the food industry as a preservative, flavor enhancer, and acidulant. The dedicated Nebraskan PLA (“NatureWorks”) production site alone has a production capacity of 140.000 tons and PLA use in packaging is currently rapidly growing.
[0055] The inventor has surprisingly found that also lactide shows excellent descaling activity and an overall excellent activity in the removal and prevention of insoluble salt deposits.
[0056] In a preferred embodiment, a composition according to the invention comprises 1-20% lactide, preferably 1-20% slow-release lactide as measurable by the pH-development of a 0.1 w/v % solution of the slow-release lactide in demineralized water at 25° C. and the curve depicting the pH versus time displaying a pH of 3.7 after 5 minutes, 3.2 after 10 and 2.5 after 120 minutes.
[0057] Furthermore, It can be produced through fermentation, and it is a fully renewable descaling agent.
[0058] Furthermore, it is also non-corrosive and has a neutral smell and can be used as a solid state, stabile, low moisture ingredient for descaling activities, allowing polyvalent use.
[0059] Lactide and Itaconic acid or its anhydride can be used separately as a descaling agent but they also show a highly efficient descaling activity when used in combination with each other.
[0060] Preferably, the insoluble salts deposits are selected from a group consisting of lime scale, beer stone, milk stone, barium sulfate, calcium oxalate and combination thereof.
[0061] Preferably, itaconic acid, its anhydride and or lactide and combinations there is present in the composition in a concentration of 5-60% m/m, preferably 20-40% m/m.
[0062] In such a concentration range, the composition of the present invention, is most effective.
[0063] In a preferred embodiment, the composition further comprises one or more other acids.
[0064] Combined with other acids, the composition comprising lactide, itaconic acid and/or anhydride can be even more efficient.
[0065] In a preferred embodiment, the compound selected from list b) is the carbonate source. More preferably, the carbonate source is sodium carbonate, bicarbonate or percarbonate.
[0066] In a preferred embodiment, the compound selected from list b) is the acid solubility retarding compound. More preferably, the acid solubility retarding compound is an ethoxylated surfactant with C16-C22 carbon chain length and an ethoxylation degree of 30-40 ethylene oxide groups, a thickener, or combinations thereof.
[0067] Suitable thickeners for use in the above described invention may be of synthetic or biobased, preferably biobased. A suitable synthetic thickener, is for example a polyacrylate. Suitable biobased thickeners are for instance hydrocolloids such as pectin, agar, carrageenan, alginate, starch, locust bean gum, gelatin, guar gum, gum Arabic, xanthan gum, 12-hydroxy stearic acid. Derivatives of the previously listed compounds may also be used. They include carboxymethylcellulose, carboxymethyl guar gum. Evidently, combinations of the thickeners listed above may also be used.
[0068] In a preferred embodiment, the compound selected from list b) is the compound with melting point between 60° C.-95° C.; preferably between 60°-90° C., more preferably between 60°-80° C., most preferably between 60°-75° C. Preferably the compound iv) is a nonionic sucrose ester with melting point between 60° C.-75° C. In another preferred embodiment, compound iv) is a lactide with melting point of approximately 95° C., or combinations thereof.
[0069] In a preferred embodiment, a composition of the invention has a reduced level of alkyl benzene sulfonate. More preferably, the composition is free of alkyl benzene sulfonate. The inventors found that fatty alcohol sulfate is a good substitute for at least part or all of the alkyl benzene sulfonate. In a preferred embodiment of the invention, at least part or all of the alkyl benzene sulfonate in the composition is replaced by fatty alcohol sulfate. The reduction of the use of alkyl benzene sulfonate is advantageous as alkyl benzene sulfonate is a petrochemical which upon aerobic biodegradation leaves stable metabolites and is not degradable in anaerobic conditions. The use of fatty alcohol sulfate in a composition of the invention is advantageous as it has a better ecological profile than alkyl benzene sulfonate. It provides good foam. Foam functions as an indicator to a consumer that the composition is working. The inventors also found that the extrudability of a composition according to the invention comprising a fatty alcohol sulfate is improved.
[0070] In a preferred embodiment, a composition of the invention comprises lactide, preferably slow-release lactide. The lactide will liberate lactic acid which will further enhance the lime scale removal claimed in/subject to this invention. Lactic acid is released from a slow-release lactide as follows. A 0.1 w/v % solution of the slow-release lactide in demineralized water at 25° C. is characterized by a curve depicting pH versus time, wherein the pH is 3.7 after 5 minutes, the pH is 3.2 after 10 minutes, and the pH is 2.5 after 120 minutes. Slow-release lactide is commercially available from the company Galactic, Belgium. Use of slow-release lactide is advantageous as it has the effect that the release of acid from a composition, i.e. lactide and other acids present, for the prevention or removal of insoluble salt deposits can be tuned further.
[0071] In a preferred embodiment, the composition is formulated as a virtually water-free powder, tablet or block.
[0072] In such a formulation, the solid state acids used in the present invention allow prolonged exposure either due to the product form or through delayed acidification. This makes the composition very suitable for applications such as toilet blocks.
[0073] The invention further provides several type compositions for use in the prevention or removal of insoluble salt deposits, including toilet rim, cistern or urinal block; tablets and gels.
[0074] In a preferred embodiment, the composition is a toilet rim, cistern or urinal block, comprising: 3-30 weight % itaconic acid, itaconic anhydride, succinic acid, succinic anhydride or a combination thereof, 20-50 weight % linear alkyl benzene sulfonate and/or fatty alcohol sulfate, and the remainder formulation auxiliaries. Preferably the formulation auxiliaries comprise or consist of a perfume or fragrance.
[0075] In a more preferred embodiment, the toilet rim, cistern or urinal block as previously described comprises an acid solubility retarding sucrose derivative. In a preferred embodiment, the solubility retarding sucrose derivative is a sucrose behenate, sucrose stearate and/or a fatty acid derived sucrose ester with melting point between 60° C.-75° C. The latter is commercially available from P&G, under the trade name Sefose. Use of a sugar based compound in a formulation according to the invention has for effect that the amount of compounds derived from renewable resources is increased further. Sugar based molecules provide an improve degradability. The degree of biobased materials used is increased even further.
[0076] In a preferred embodiment, the blocks as described above have a life expectancy of at least 50 flushes, preferably at least 100 flushes, most preferably at least 200 flushes.
[0077] To a person skilled in the art tests are available for determining the life expectancy characterizing a batch of products. A test can be carried out as follows: A product is weighed. It is set in a toilet near the water supply means, at a precisely defined place. The toilet is fed with 35° THF hard water reproducing unfavorable but realistic conditions. The toilet is flushed at irregular time intervals. The test is carried out until the product is completely consumed. From the number of flushes required to consume the product, the product life expectancy is obtained. The life expectancy can be expressed in number of flushes, number of days or number of weeks.
[0078] In another preferred embodiment of the invention, the composition as previously described is provided in the form of an effervescent tablet. In particular, the effervescent tablet comprises: 7-75% itaconic acid, itaconic anhydride, succinic acid, succinic anhydride or a combination thereof, 5-25% of a carbonate source, selected from the list of sodium carbonate, bicarbonate, percarbonate and combinations thereof, and the remainder formulation auxiliaries. Preferably the formulation auxiliaries comprise or consist of a perfume or fragrance.
[0079] In a preferred embodiment of the invention, a 20 gram tablet dissolves in one liter of water in under 15 minutes and the pH of the resulting water comprising the dissolved table is at most 4.5, preferably at most 4.0, more preferably at most 3.5. Preferably the pH-development provided by the tablet does not go below 2.0.
[0080] In another preferred embodiment of the invention, the composition as previously described is provided in the form of a toilet gel. In particular, the toilet gel, comprises: 1-30% itaconic acid, succinic acid, or a combination thereof, 2-40% an ethoxylated nonionic surfactant with an ethoxylation degree of 30-40 ethylene oxide units, a thickener such as a polyacrylate, a hydrocolloid, a derivative of a hydrocolloid, or a combination thereof, and the remainder formulation auxiliaries. Preferably the formulation auxiliaries comprise or consist of a perfume or fragrance.
[0081] In a further aspect of the invention uses for the compositions of the invention are provided. In a preferred embodiment, a composition according to an embodiment of the invention is used for the prevention or removal of lime scale, beer stone, milk stone, barium sulfate, calcium oxalate and combinations thereof.
[0082] Preferably the used described previously is one wherein the prevention or removal is directed to a toilet, a laundry machine, a dishwashing machine, a boiler, a kettle, a coffee-maker, an espresso machine, a dairy equipment, a food processing equipment, a beverage processing equipment, an industrial water system, or a well.
[0083] In another preferred embodiment of the present invention, the composition described here above, is used the removal of insoluble salt deposits upon prolonged exposure of the insoluble salts to the composition.
[0084] The invention is however not limited to prolonged exposure of the composition, all other types of exposure known by the person skilled in the art, can also be used. The composition according to the present invention is for example also very effective in fast descaling. If however the composition is applied during prolonged exposure, it is very effective for heavy duty removal of thick deposits of insolubles, which is an advantage.
[0085] In a third aspect of the invention, a method for the manufacturing of compositions according to the invention is provided. In a preferred embodiment, a method for manufacturing compositions for the prevention or removal of insoluble salt deposits comprises the step of:
[0086] selecting an organic acid with two carboxylic acid functional groups obtainable by fermentation and available in substantially dry powder form, from itaconic acid, itaconic acid anhydride, succinic acid, succinic anhydride or a combination thereof,
[0087] mixing the selected organic acid with at least one compound determining the release of said acid from said composition, said compound is selected from a list comprising: i) a hygroscopic compound, ii) a carbonate source, iii) an acid solubility retarding compound, iv) a compound with melting point situated between 60° C.-95° C., and combinations thereof, -extruding or melt casting the mixture obtained at a temperature between 60° C.-95° C., -obtaining the composition for the prevention or removal of insoluble salt deposits in a desirable form such as a block, tablet or gel.
[0088] In a final aspect, the invention provides a method for the prevention or removal of insoluble salt deposits comprising the step of:
[0089] connecting a composition according to an embodiment of the invention to a supply means of water,
[0090] contacting the composition with water from said supply means thereby lowering the pH of the water to a pH below 5,
[0091] leading the water with pH below 5 over a surface in need of treatment, thereby preventing insoluble salts to deposit on the surface or thereby removing from the surface insoluble salts deposited on the surface. In a preferred embodiment, the pH is below 4.5; preferably below 4.0; more preferably below 3.5; and not below pH 2.
[0092] Preferably, the composition according to the present invention is used for the prevention or removal of insoluble salts in toilet, sanitary, bathroom, laundry and automatic dishwashing machine, boiler, kettle, coffee-maker, dairy equipment, food and beverage processing equipment, industrial water systems and wells, concrete removers and the like. However, the composition is also suitable for other descaling activities known by the person skilled in the art.
[0093] The second object is achieved by a toilet block a composition comprising itaconic acid, its anhydride and or lactide and combinations thereof.
[0094] Such a product shows a higher descaling activity than the products known in the state of the art.
[0095] The invention further relates to an effervescent tablet comprising a composition comprising itaconic acid, its anhydride and or lactide and combinations thereof.
[0096] Such an effervescent tablet can be used for descaling in several applications, such as a toilet or a dishwashing machine, or any other application known by the person skilled in the art. The solid character of lactide and itaconic acid offers a substantial advantage in the formulation of these tablets. However, these tablets will still be able to dissolve quickly upon contact with water. Also, the fact that the acids used in the composition according to the present invention are so efficient upon prolonged contact, offers a huge advantage for the different applications making use of this effervescent tablet.
[0097] This invention also relates to a composition comprising itaconic acid, its anhydride and or lactide and combinations thereof for the prevention or removal of insoluble salt deposits.
[0098] The present invention uses a composition comprising itaconic acid, its anhydride, succinic acid or its anhydride and or lactide and combinations thereof, for the prevention or removal of insoluble salt deposits.
[0099] The invention is further illustrated and described in more detail in the description and examples given below.
DETAILED DESCRIPTION OF THE INVENTION
[0100] All of the organic acids shown in table 1 were tested in order to find a renewable acid that had potential as a descaling agent, both in terms of fast descaling and descaling upon prolonged contact. Furthermore, it was important that the potential descaling agent had a neutral smell, was non-corrosive, and had a solid structure.
[0101] When screening various non-corrosive and non-pungent smell acids for their applicability in descaling products, the inventors surprisingly found a substantially different ranking in acid descaling performance for short as compared to prolonged exposure.
[0102] As described here above, using non-corrosive acids with a non-pungent or even neutral smell offers clear advantages in the production and use phase, but this fact reduces table 1 to 10, respectively 7 potential candidates. Selecting non-corrosive, non-pungent smell acids obtained from fermentation narrows the selection down to 6, 5 of which are solid state acids, which allows more flexibility in formulating either a liquid end product, a powder or a tablet. This selection is as follows; tartaric, citric, lactic, succinic and itaconic acid as well as lactide, succinic acid and itaconic acid being the subject of the present invention and offering clear advantages over all other acids as illustrated in the description of the invention. In contrast with citric, gluconic and lactic acid, itaconic acid is used exclusively in non-food applications. The recently increased commercial availability of itaconic acid and lactide make this invention all the more attractive.
[0103] When a substantial limescale deposit is attacked by a polybasic carboxylic acid is it reasonable to assume that provided the deposit “survives” this acid attack i.e. is thick enough to last for several hours, the calcium concentration at its surface will be high enough as to allow the formation of disalts (or trisalts in the case of citric and phosphoric acid) and the contact time long enough for these often insoluble salts to deposit on the surface, thus forming a greasy layer. Without wanting to be bound by theory the inventors assume this layer slows down further descaling due to inhibited access to the calcium carbonate underneath. From this and from table 1 one would expect that although non-corrosive and having a neutral smell, tartaric, citric and succinic acid will be less suited for the job due to the insolubility of their calcium disalts, whereas glycolic and lactic should be better suited. This proved not to be correct.
[0104] Among the acids that were tested, all featuring the aforementioned desirable properties, glycolic acid is very efficient in fast descaling but is far less efficient in prolonged descaling (in example 4, even more or less failing in example 2). This is attributed to the observed formation of a greasy layer (as is the case with tartaric and citric acid), but is in contradiction to what one would expect from the high water solubility of the calcium salt (table 1) and in contradiction to what its manufacturer claims. Lactic acid does a mediocre job in fast descaling, but is second best upon prolonged contact. Succinic acid performs reasonably well in both fast and prolonged descaling, although its calcium salts are insoluble. The inventors furthermore surprisingly found itaconic acid, although not as yet described as such in patent literature, to be the best solid acid in fast descaling as well as upon prolonged contact. Likewise lactide, known to fully hydrolyze into lactic acid, was shown to be very effective against limescale, which was never described before.
[0105] Thus the inventors selected two non-corrosive neutral-smell ingredients, which moreover are fully renewable and are solid state ingredients, allowing polyvalent use; itaconic acid, its anhydride and lactide can be used as such in waterless solid compositions or, in case of itaconic acid, used as a liquid compositions, either alone or in combination with other acids. These products are particularly well suited for heavy duty removal for insoluble salt deposits, i.e. requiring prolonged exposure for complete removal.
[0106] Stable effervescent toilet descaling tablets containing substantial amounts of itaconic acid were formulated and shown to be very effective. Preliminary tests showed lactide-itaconic based tablets to be even more effective, but present the challenge of gelling due to the high hygroscopy of lactide. As it happens this property is very beneficial in formulating toilet rim blocks by extrusion where it will cause an outer layer or membrane that slows down the overall solubility of the block thereby imparting a controlled release of the fragrance and the surfactant in the block. Moreover the melting point of lactide is anticipated to assist in the extrusion process and cause it to function as a solubility retarder. Finally of course it will act as a slow release agent of lactic acid shown to be very effective in removing lime scale.
[0107] These advantages can be complemented with the excellent limescale removing capacity of itaconic acid, which is sufficiently but substantially less water soluble than most other acids, a property which again is a benefit in retarding the complete dissolution of the toilet rim block. Using itaconic anhydride which slowly releases acid upon contact with water, may present further benefits in that its melting point is 67-69°, well within the extrusion temperature range, as opposed to succinic anhydride (120° C.), maleic (53° C.) and glutaric anhydride (47-57° C.).
[0108] As said here above, the present invention entails solid and liquid toilet rim blocks. Other products for removing insoluble salt deposits according to the present invention include solid in-cistern blocks, urinal blocks, effervescent toilet tablets, toilet gels, bathroom cleaners, liquids removing limescale from hard surfaces, periodic cleaners for automatic dishwashing and laundry machines, boiler cleaners, treatment products for water wells, boiler systems and tubing, cleaners for dairy and food equipment, concrete cleaners and removers.
[0109] The present invention, in various forms or shapes, is shown to be much more effective than the commonly used citric acid for preventing and removing insoluble salts (e.g. Ca, Mg, limescale) while having neutral odor and color, being non fuming, free of phosphorus, non corrosive to the skin, non toxic to aquatic life and obtained by fermentation as a fully renewable product. Moreover it is non corrosive to the treated surfaces among others since it's free of chlorides, thus not representing the risk of possible chloride cracking of stainless steel or embrittlement sometimes experienced in acid chloride systems, nor will it cause spallation (in case of itaconic based formulations).
[0110] In order to find a renewable and highly efficient descaling agent according to the present invention, the inventors screened various acids from Table 1 for their potential application as descaling agents.
EXAMPLES
Example 1
[0111] Tartaric (Sigma-Aldrich), malic (Sigma-Aldrich), glycolic (Dupont Chemicals), itaconic (Alfa Caesar), lactic (Purac), succinic (Sigma-Aldrich) and citric (Brenntag) acid were tested according to the protocol found in the article “Empfelungen zur Qualitätsbewertung fur saure WC-reiniger” (Qualitatsempfelung des Industrieverbandes Korperpflege -und Washmittel e.V. (IKW), Referat Putz -und Pflegemittel, Frankfurt a.M., paragraph 6 Gebrauchswertprüfung. SÖFW-journal, 120, Jahrgang 13:94) for their descaling efficiency upon short exposure.
[0112] For each product, five oven-dry marble plates (Carrara marble, 75×150×5 mm, bought at Van Houten Malle) are weighted on a high precision balance and subsequently completely immersed during 10 seconds in a glass beaker holding 950 milliliter of a 5% active matter acid solution. The plates are then removed from the liquor, and put in upright position for 10 minutes during which the acid is allowed for further action. The plates are subsequently rinsed-off during 30 s with softened tap water, dried at 105° C., allowed to cool in a desiccator and again weighted. The weight loss due to the exposure to the acid is used as a measure for its descaling performance. The 0.14766 gram weight loss due to the exposure to the itaconic acid is used as a measure for its descaling performance.
[0000]
Prod-
Weight (g)
uct
Plate
Before
After
Difference
Ita-
1
154.7922
154.6747
0.1175
Average
0.14766
conic
(g)
acid
2
149.244
149.1075
0.1365
standard
0.029775
deviation
3
151.8382
151.6805
0.1577
variation
4.959201
coeffi-
cient (%)
4
150.6909
150.4966
0.1943
5
153.6839
153.5516
0.1323
[0113] The same approach was simultaneously followed for the other acids. Finally the average descaling efficiency, the standard deviation and variation coefficient was calculated for all other acids leading to the following comparative table:
[0000]
Average
variation
weight
standard
coefficient
Acid
loss (g)
deviation
(%)
Tartaric acid
0.09632
0.035235
2.733622
Malic acid
0.14574
0.029364
4.963268
Glycolic acid
0.16294
0.01914
8.512848
Itaconic acid
0.14766
0.029775
4.959201
Lactic acid
0.12784
0.00771
16.58122
Succinic acid
0.13764
0.063322
2.173656
Citric acid
0.10496
0.013478
7.787259
[0114] From this table it follows that tartaric and citric acid are not particularly well suited for fast descaling, whereas glycolic is performing best, as claimed by its manufacturer. Itaconic acid outperforms all tested solid acids and all acids obtained from fermentation.
Example 2
[0115] Similar to example 1 the descaling efficiency upon prolonged contact to the same range of acids is determined. This is done in duplicate with fully immersed marble blocks ((Carrara marble, 20×30×30 mm, bought at Van Houten Malle) according to the modified protocol of “Qualitätsnormen für saure WC-reiniger” (Qualitätsnormen des Industrieverbandes Putz- and Pflegemittel e.V. (IPP), Frankfurt/M (Fassung 1987)), again monitoring weight loss but this time after 24 hours immersion in the acid solution, followed by rinse-off and drying.
[0000]
Acid
Average weight loss (g)
Tartaric acid
0.3141
Malic acid
8.73535
Glycolic acid
2.62915
Itaconic acid
9.6414
Lactic acid
9.05985
Succinic acid
9.30385
Citric acid
3.8461
[0116] Tartaric acid fails again, but this time glycolic and citric acid under perform as well. The other tested acids are more or less equivalent, but again itaconic acid is performing best among the tested solid acids, in fact best of all the tested acids. The marble blocks exposed to tartaric and citric acid, but also albeit to a lesser extent that exposed to glycolic acid were observed to be covered with a greasy layer, assumed to be water insoluble calcium salts of the acid.
Example 3
[0117] The experiments of example 1 and 2 were repeated with the same set of blocks and plates for itaconic acid (5%), lactide (3%), lactide (5%), citric acid (5%) and succinic acid (5%). Solutions were allowed to stand until complete dissolution of the lactide before the descaling test was started.
[0118] The following results were obtained for short contact time descaling of plates and prolonged contact descaling of blocks (average values and 95% confidence intervals):
[0000]
Weight
Weight
Weight
Weight
Weight
difference
difference
Weight
difference
difference
difference
plates (g)
plates (g)
difference
blocks (g)
blocks (g)
Descaling agent
plates (g)
−95%
+95%
blocks (g)
−95%
+95%
Itaconic acid 5%
0.1115
0.088464
0.134616
7.1586
6.2838
8.0334
Lactide 5%
0.1365
0.100986
0.171974
6.0445
5.4793
6.6097
Lactide 3%
0.1129
0.082268
0.143572
2.9844
2.1723
3.7964
Citric acid 5%
0.0782
0.059637
0.096683
3.3186
2.7113
3.9259
Succinic acid 5%
0.0899
0.060463
0.119297
7.2479
6.6405
7.8552
[0119] Lactide and itaconic acid again prove to be very efficient descaling agents as compared to citric acid both in fast and prolonged exposure conditions, 3% lactide thereby matching the performance of 5% citric acid. As in example 2, succinic acid performs very well upon prolonged exposure, somewhat less so at short exposures.
Example 4
[0120] A non factorial, central composite design experiment was set up, combining citric acid, succinic acid, lactic acid, itaconic acid and glycolic acid and testing the descaling efficiency of the mixtures both at short contact times (on marble plates, protocol as in ex.1) and prolonged contact (on marble blocks, as in ex.2). The required volumes for filling the beakers were prepared as 3% active matter solutions, 20 hours prior to the test. Also the formation of an insoluble layer surrounding the blocks was monitored, scoring no visible layer with a score of 0 and a clearly distinctive layer with a score of 1. The experimental setup and descaling results were as follows (sorted on the visual presence of an insoluble layer):
[0000]
cit-
suc-
lac-
ita-
gly-
Pres-
ric
cinic
tic
conic
colic
Weight loss
Weight loss
ence of
acid
acid
acid
acid
acid
plates (g)
blocks (g)
layer
0
0
0
3
0
0.10074
5.41945
0
0
3
3
0
3
0.19384
16.7526
0
0
0
3
3
3
0.18188
15.313051
0
0
3
3
3
0
0.12942
13.6005
0
3
0
3
0
3
0.17068
13.381
0
0
3
0
0
0
0.08734
4.705
0
0
0
3
0
0
0.09616
5.2176
0
3
3
3
3
3
0.26504
19.6414
0
0
3
0
3
3
0.19244
10.1536
1
1.5
1.5
1.5
1.5
1.5
0.13584
10.4738
1
1.5
1.5
1.5
1.5
1.5
0.1304
9.784
1
3
0
0
3
3
0.13424
12.7577
1
3
3
0
3
0
0.16276
6.7325
1
3
3
3
0
0
0.1333
9.3773
1
3
0
3
3
0
0.14288
13.0694
1
3
3
0
0
3
0.1672
10.8451
1
3
0
0
0
0
0.05778
2.2648
1
0
0
0
0
3
0.11152
4.2873
1
[0121] These data were examined using statistical software Statistica (Statsoft, Statistica version 9).
[0122] For the short exposure of the plates the following multiple regression model with a correlation coefficient (adjusted R 2 ) of 0.902 was obtained:
[0000]
Regressn
Coeff.
Std. Err.
P
Mean/Interc.
0.042892
0.010743
0.003146
(1)citric acid
0.003786
0.003936
0.361202
(2) succinic acid
0.013192
0.005328
0.035219
(3)lactic acid
0.014675
0.004718
0.012515
(4)itaconic acid
0.013405
0.002841
0.00109
(5)glycolic acid
0.015795
0.004718
0.008556
1 by 2
0.002217
0.001894
0.271693
2 by 3
−0.00293
0.001894
0.155759
2 by 5
0.002077
0.001894
0.301121
3 by 5
0.002299
0.001894
0.255727
[0123] Succinic, lactic, itaconic and glycolic acid seem to be equally effective at descaling, contrary to citric acid which is ineffective as already illustrated in Ex.1. No significant interactions amongst the acids (synergy or antagonism) were noted.
[0124] For the prolonged exposure of the blocks the following multiple regression model for the descaling efficiency was obtained with an correlation coefficient (adjusted R 2 ) of 0.994:
[0000]
Regressn
Coeff.
Std. Err.
P
Mean/Interc.
0.317877
0.354173
0.46416
(1)citric acid
0.645604
0.132453
0.039607
(2)succinic acid
1.459004
0.132453
0.008141
(3)lactic acid
1.629871
0.132453
0.006539
(4)itaconic acid
1.697154
0.132453
0.006036
(5)glycolic acid
1.319771
0.132453
0.009923
1 by 2
−0.27364
0.03949
0.020198
1 by 3
−0.09582
0.03949
0.136041
1 by 4
0.078019
0.03949
0.186854
1 by 5
0.211589
0.03949
0.033112
2 by 3
0.130106
0.03949
0.081079
2 by 4
−0.36003
0.03949
0.011818
2 by 5
0.089156
0.03949
0.152536
3 by 4
0.1093
0.03949
0.109508
3 by 5
0.136147
0.03949
0.074812
4 by 5
−0.12937
0.03949
0.081891
[0125] All acids significantly contribute to descaling, albeit that the effect of citric acid again is only half or less that of the other acids. Itaconic acid performs best as in example 2. Succinic acid combined with citric or itaconic seems to worsen the descaling, whereas glycolic acid positively interacts with citric acid.
[0126] In the latter experiment with the blocks the formation of an insoluble layer around the blocks after 24 hours exposure was scored 0 for no appreciable deposit and 1 for a clearly distinctive layer. The following multiple regression model with an correlation coefficient (adjusted R 2 ) of 0.83 was obtained for the formation of an insoluble layer:
[0000]
Regressn
Coeff.
Std. Err.
P
Mean/Interc.
0.055556
0.148032
0.71528
(1)citric acid
0.333333
0.04969
0.000053
(2)succinic acid
0
0.035136
1
(3)lactic acid
0
0.04969
1
(4)itaconic acid
0
0.035136
1
(5)glycolic acid
0.333333
0.060858
0.00027
1 by 5
−0.11111
0.023424
0.000788
3 by 5
−0.11111
0.023424
0.000788
[0127] Citric acid alone and 8 out of 10 of the citric acid containing combinations result in a distinctive separate layer, as opposed to 4 out of 10 for lactic acid and 5 out of 10 for the other acids. Itaconic acid on the other hand does not cause an insoluble layer to be formed and nor do succinic and lactic acid. Contrary to the claims of its manufacturer, and contrary to what one might expect from the solubility of its calcium salts, glycolic acid also caused an insoluble layer on itself and in combinations with other acids, unless it is combined with lactic acid. The model further identifies a significant negative interaction of citric and glycolic acid, which in this case implies a desirable effect, i.e. less insoluble layer when combining glycolic acid with citric acid, probably causing the significant descaling synergy described above.
Example 5
[0128] Effervescent 35 gram tablets F1-F8 with the followed compositions were tableted at press forces of 2-5 ton.
[0000]
Ingredient
Supplier
F1
F2
F3
F4
F5
F6
F7
F8
F43
F444
citric anhydrous
80
57
10
10
56
0
10
56
56
41
Itaconic acid
0
20
67
50
20
74
58.35
20
20
35
Lactide (Galacid
Galactic
0
0
0
17
0
0
0
0
0
0
LDPW L50)
FAS (Sulfopon 12 G)
Cognis
5
5
5
5
5
5
5
5
5
5
APG (Glucopon 215)
Cognis
0.25
0.25
0.25
0.25
0
0
0.25
0.25
0
0
Desintegration aid
2
2
2
2
2
2
2
2
2
2
Tabletting aid
2
2
2
2
2.25
1.25
2
2
3.25
3.25
Sodium carbonate
11.35
11.35
11.35
11.35
11.35
15.35
0
11.35
6.35
11.35
Sodium bicarbonate
0
0
0
0
0
0
20
0
5
0
Sodium percarbonate
2
2
2
2
2
2
2
0
2
2
Potassium persulfate
FMC
0
0
0
0
0
0
0
2
0
0
perfume pine
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
Friability (%)
94
96
99
98
97
97
95
95
98
98
Desintegration
11
12
4
19
10
5
′/
19
>20
10
time (s) after
4 ww climate
Vol. exp. (%)
4
1
24
−1
5
35
′/
3
8
2
4 ww climate
Vol % 8 ww
5
32
50
Wet
7
/
Tab
13
10
2
climate
sticky
strength
insuffic
[0129] High concentrations of itaconic acid seem to negatively influence tabletting characteristics, in particular the volume expansion upon climate chamber storage tests, but it is possible to formulate a stable product (e.g. F5, F444) with at least 20% itaconic (e.g. F5) or at least 35% itaconic acid (e.g. F444). Lactide-itaconic based tablets present the additional challenge of gelling, probably due to the high hygroscopy of lactide. Using itaconic anhydride may further improve stability.
[0130] These 35 gram tablets were tested for their long exposure descaling efficiency as in example 2 but dosing one tablet per liter. They were compared with 2 market reference tablets, reference 1 being based on sulfamic acid (31 g tablet) and reference 2, a 25 gram tablet, both adjusted to 35 grams for testing the descaling at equal dosage.
[0000]
F1 (35 g): 80% citric acid
0.2415
F2 (35 g): 57% citric acid + 20% itaconic
0.4084
T
F3 (35 g): 10% citric acid + 67% itaconic
0.7367
F4 (35 g): 10% citric acid + 50% itaconic + 17%
0.9614
lactide
F6 (35 g): 74% itaconic
1.13
Market reference product 1 (35 g)
1.0269
Market reference product 2 (35 g)
0.6621
[0131] These examples clearly demonstrate the descaling superiority over citric acid of itaconic acid and lactide and in particular of their combination. Using itaconic acid and or lactide allows to match the performance of the market reference products while refraining from corrosive or environmentally hazardous ingredients.
Example 6
[0132] Toilet rim block formulations “Rim1” and “Rim2” are taken for reference from the Unger guideline recipes for extrusion of 40 gram rim blocks at 70-90° C. In formulas Rim3 to 8 the solubility retarding coconut MEA and FAEO are replaced by sucrose esters with a comparable melting point and with lactide (which has a somewhat higher mp) or itaconic anhydride (with a comparable melting point). In addition to the acid releasing itaconic anhydride and lactide, itaconic acid is formulated in Rim4 and Rim8 against limescale (similar to the best descaling effervescent tablet of the previous example). Furthermore polysuccinimide and persulfate bleach or calcium peroxide slow release bleach are added to Rim3 and Rim8.
[0000]
Rim
Rim
Rim
Rim
Rim
Rim
Rim
Rim
Ingredient
Ingredient
Supplier
Function
1
2
3
4
5
6
7
8
FAS 1218
UFAROL
Unger
Extrusion aid
31.5
24
31.5
24
24
24
24
24
TCT 90 P
and improved
soft water
foaming (mp
>200° C.)
AOS
Ufapore
Unger
Dry foam
1.5
1.5
1.5
1.5
1.5
1.5
TCO
booster
FAEO (*)
TP716
Unger
Combined
16
16
extrusion aid
and solubility
retarder
FAEO
Emulgator
Unger
Surface finish
0.5
0.5
0.5
0.5
F8
improver and
extrusion aid
Sodium Chloride
/
/
Filler for
12.5
12.5
12.5
12.5
12.5
7.5
increased
block hardness
Sodium Sulphate
/
/
Filler
49.25
49
39.5
35
42.5
42.5
42.5
35.5
Calcium carbonate
/
/
Filler -
1
Compactation
agent
LES70
Foam enhancer
Unger
Liquid foam
0.5
0.5
booster
Pine fragrance
Pine fragrance
/
Fragrance
3
3
3
3
3
3
3
3
Coconut MEA
Ufanon MK
Unger
Solubility
3.25
Eur-amid
EOC
retarding
FMCM/FL
Surfac-
mp 75° C.
tants
Polysucinimid
Baypure
Lanxess
Hydrolyses
4
DSP
to lime dis-
grinded
persing agent
Calcium Peroxide
Ixper 75C
Solvay
Slow release
4
bleach
K-persulfate
/
FMC
Bleach
4
Sodium citrate
Complexing
5
agent
Itaconic anhydride
Slow release
20
(*)
descaler,
solubility
retarding
(hygroscopic
and mp
67-69° C.)
Itaconic acid
Descaling
10
agent
Lactide (*)
Slow release
5
16
16
16
16
descaler,
solubility
retarding
(hygroscopic
and mp
94-99° C.)
sucrose behenate
Sefose
PG
Solubility
0.5
2275C
Chemicals
retarding
mp 65° C.
sucrose stearate
Sefose
PG
Solubility
0.5
1618H
Chemicals
retarding
mp 71° C.
(*) Cooling of the extruder head will be necessary when using high amounts of coconut MEA, TP 716, itaconic anhydride or lactide to maintain pressure in the extruder and avoid the block becoming too soft for cutting. Recipe adjustments due to local variations in requirements and extruder properties will have to be considered.
Example 7
[0133]
[0000]
Trial
Trial
Trial
Trial
Trial
Composition
1
2
3
4
5
Fatty alcohol sulphate 1218
37
30
30
30
30
Sucrose ester from fatty
10
5
5
5
5
acid, melting point 65° C.
Itaconic acid
5
5
5
5
5
Slow release Lactide
2.7
2.7
2.7
7.5
2.7
Persulfate
0
0
0
0
10
Water
1.3
1.3
1.3
1.3
0.5
NaCl
16
16
16
16
16
Sulfate
25
36
36
31.2
25.5
Fragrance
3
4
4
4
5.3
Total
100
100
100
100
100
Diameter (mm)
42
42
25
25
25
[0134] Tablets produced by extrusion of the compositions listed in Example 7 (Trials 1 to 5) provided hard tablets of consistent composition and homogeneous and consistent appearance. These tablets lasted well above 50 flushes. Tablets made according to the above described compositions wherein the slow-release lactide was replaced by standard lactide showed needle like protrusions, probably caused by lactide crystals.
Example 8
[0135] Formulation for dishwashing machine, in analogy with a commercial dishwashing machine composition sold under the brand name Finish, comprises:
[0000] 85% itaconic acid (replacing citric acid),
10% low foaming non-ionic surfactant,
0.5% fragrance and
4.5% additives, such as phosphonates and/or calcium silicate
Suitable surfactants for use in the above formulation are PPG-15 C12-18 and PPG-5 Laureth-5 with fatty alcohol alkoxylate
By the term low foaming as described herein it is meant, producing no foam or a foam which disappears after build up within less than 5 minutes.
Example 9
[0136] Formulation comprising itaconic acid and between 1-20% of slow-release lactide, in the form of powder or a 30% solution, for the treatment of insoluble salt deposits in expresso machines.
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The present invention provides compositions, in particular blocks, tablets and gels, for the prevention or removal of insoluble salt deposits comprising: a) an organic acid with two carboxylic acid functional groups obtainable by fermentation, selected from the list of itaconic acid, itaconic acid anhydride, succinic acid, succinic anhydride and combinations thereof, and b) at least one compound determining the release of said acid from said composition, said compound is selected from a list comprising: i) a hygroscopic compound, ii) a carbonate source, iii) an acid solubility retarding compound, iv) a compound with melting point situated between 60° C.-95° C., and combinations thereof. The invention further provides uses of the compositions for the prevention or removal of insoluble salt deposits. The invention also provides a method of manufacturing such compositions and a method for the prevention or removal of insoluble salt deposits with a product of the invention.
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DESCRIPTION
1. Technical Field
This invention relates to a safety assembly for an escalator which serves to shut the escalator off in the event that an object becomes wedged between the escalator step treads and the exit landing combplate. More particularly, this invention relates to such an assembly which is activated by upward movement of the combplate relative to the steps.
2. Background Art
Escalators and moving walkways are commonly provided with passenger supporting steps or pallets that have cleated treads. At the exit landing, the treads pass beneath a landing plate that is provided with combteeth which pass through the gaps between the tread cleats. The possibility exists that an object can be carried with the treads beneath the combplate and be trapped or wedged between the tread and the combplate. The prior art has recognized this problem and has devised a number of systems which can detect the presence of an object between the tread and combplate, and can sound an alarm and/or shut the escalator or walkway off in certain cases. U.S. Pat. Nos. 3,233,717 to Jin et al; 3,913,723 to Johnson; 3,934,699 to Saito et al; 4,088,219 to Binns; and 4,629,052 to Kitamura are illustrative of such prior art combplate safety systems.
DISCLOSURE OF INVENTION
This invention relates to a combplate safety system for an escalator or moving walkway which employs a power interruption switch having heightened sensitivity which is responsive to upward movement of the combplate that results from the wedging action of an object between the treads and combplate. Where necessary due to the weight of the combplate, and especially in older units in the field, the assembly includes a device for preloading the combplate upwardly so as to reduce the effective weight of the combplate. This weight reduction will cause the safety switch to be activated by a lesser wedging force than would be needed to operate the switch in the absence of the upwardly directed preload. The system is thus rendered operable at lower wedging forces, thus becoming inherently safer to passengers.
The safety switch includes a finely threaded combplate sensor which can be very precisely adjusted relative to the combplate. The sensor is mounted on a pivoting rocker which includes a switch-contacting arm that acts as a multiplier of the extent of movement of the combplate sensor. If the sensor is lifted 1 mm by upward movement of the combplate, the switch-contacting arm will move 2 mm; or 3 mm, as desired. Thus a relatively minute degree of movement of the combplate can activate the switch and shut the escalator off.
The upward preloading of the combplate is accomplished by combplate supports which have a controlled spring component that is stressed by the combplate. The spring component is one that when compressed to a certain degree will create a predictable preload reaction that lowers the effective weight of the combplate by a known value. Thus, a one hundred pound combplate can be vertically preloaded to impart thereto an effective weight of ninety pounds, for example. In this manner, new safety code changes can be met by relative slight modifications of older equipment, without completely replacing such equipment. The preferred form of combplate preloading device is a curved steel washer, termed a "wave washer" which is presently used to preload bearings.
It is therefore an object of this invention to provide an improved combplate safety assembly which reacts to a foreign object becoming wedged between the treads and combplate of an escalator or moving walkway.
It is an additional object of this invention to provide a safety assembly of the character described which can shut off the escalator or walkway in certain instances.
It is a further object of this invention to provide a safety assembly of the character described which responds to upward movement of the combplate.
It is another object of this invention to provide a safety assembly of the character described where the effective weight of the combplate is reduced to increase operational sensitivity of the assembly.
These and other objects and advantages of the invention will become more readily apparent from the following description of a preferred embodiment of the invention when taking in conjunction with the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a fragmented perspective view of the landing area of an escalator or moving walkway which is equipped with the safety assembly of this invention;
FIG. 2 is a side elevational view, partially in section, of the landing area shown as viewed from the path of movement of the steps of the escalator or walkway;
FIG. 3 is an end elevation view of the landing area, partially in section, as seen from the left hand end of FIG. 2;
FIG. 4 is a fragmented sectional view of the combplate support/preload assembly which is used to lower the effective weight of the combplate showing the preload assembly in its unloaded condition; and
FIG. 5 is a fragmented sectional view of the combplate and its support assembly showing the latter in its loaded condition; and
FIG. 6 is a schematic view of an escalator which includes the stop switch assembly of this invention.
BEST MODE FOR CARRYING OUT THE INVENTION
Referring first to FIG. 6, an escalator is shown schematically. The escalator includes a step chain 1 which is mounted on sprockets 3 and 5, with the sprocket 3 being a drive sprocket powered by an electric motor 7. A plurality of steps 9 are mounted on the chain 1 between balustrades 11, the steps 9 moving along a passenger-conveying path of travel toward an exit landing 2. A motor control stop switch 24, which will be described in greater detail hereinafter, is connected to the motor 7 via a line 25.
Referring now to FIGS. 1-3, the exit landing area of an escalator or moving walkway is shown and is denoted generally by the numeral 2. The escalator truss 4 has a U-shaped member 6 secured thereto via bolts 8. The member 6 extends from the truss 4 toward the area 10 on the escalator through which the escalator steps (not shown) travel. A U-clamp 12 connects a bracket 14 to the member 6, the bracket 14 including a first upwardly turned switch assembly support flange 16 and a second downwardly depending L-shaped combplate support 18. The combplate support 18 has a lower horizontal platform 20 which carries a vertical threaded stud 22 welded thereto.
The flange 16 has mounted thereon an electrical switch assembly 24 which is a component of the electrical circuit for the escalator or walkway power source. The switch 24 is preferably a "normally closed" switch which includes spring-biased button 26 which, when pressed, opens the switch 24. When the switch 24 is closed, the escalator or walkway is powered, or "on", and when the switch 24 is opened, the escalator or walkway is shut off. Obviously, the opposite mode of operation of the switch 24 would provide an equivalent control for the operation of the safety assembly. A switch control rocker 28 is mounted on the flange 16 for pivotal movement about a pin 30. The rocker 28 has a horizontal arm 32 and a vertical arm 34. The horizontal arm 32 has a finely threaded adjustment screw combplate sensor 36 therein which contacts an angle iron 38 that is welded to one side edge of the combplate 40 outboard of the path of travel 10 of the steps. The adjustment screw 36 is properly set so as to position the rocker vertical arm 34 against the switch button 26, whereby appropriate upward movement of the combplate 40 and angle iron 38 will cause the rocker arm 34 to depress the switch button 26 and actuate the switch 24 to interrupt power to the escalator. The switch-actuating upward movement of the combplate 40 will result from wedging of objects between combplate 40 and the steps. The switch 24 is preferably a micro plunger make/break switch which is a component of a conventional safety circuit that can interrupt prior to the conveyor. Preferably, the switch will be one that must be manually reset after it has been actuated.
A pair of jam nuts 42 are mounted on the stud 22 and are spaced apart from the angle iron 38 by a distance D which defines the maximum extent of possible upward movement of the combplate 40. The distance D is preferably no more than 2 mm so as to limit the extent of possible upward movement of the combplate. The distance D also defines the degree of switch-actuating movement of the adjustment screw 36. It will be noted that the distance between the centerline of the adjustment screw 36 and the pivot pin 30 is one half the distance between the centerline of the switch button 26 and the pivot pin 30. The length of the vertical arm 34 thus serves to create a switch-actuating stroke which is a multiple of the distance D. In this manner, a relatively small upward movement of the combplate 40 will serve to actuate the switch 24.
As previously noted, when the combplate 40 is a relatively heavy piece, a preloading support assembly will be provided to lessen the amount of wedging force that must be present to actuate the switch 24. Details of a preferred embodiment of such a support assembly are shown in FIGS. 4 and 5. The stud 22 has a pair of lower jam nuts 44 mounted thereon, which support a cup 46. The cup 46 has a through bore 48 that receives the stud 22, and an enlarged counterbore 50 in which a curved washer 52 is seated. A flat washer 54 is disposed on the top surface 56 of the cup 46 and provides a contact surface for the angle iron 38. FIG. 4 shows the support assembly in its unloaded configuration, and FIG. 5 shows the loaded configuration. As will be noted from FIG. 4, when there is no downwardly directed force imposed on the assembly, the curved washer 52 will project above the top surface 56 of the cup 46, and the flat washer 54 will rest on the curved washer 52, and be elevated above the top surface 56 of the cup 46. It will be noted that the curved washer 52 rests on the bottom surface 49 of the counterbore 50 and is constrained by the side wall 51 of the counterbore 50. The depth of the counterbore 50 is the factor which controls the extent to which the curved washer 52 will preload and reduce the effective weight of the combplate 40. As noted, these curved washers are used to preload bearings, and can be obtained from Associated Spring Co., Bristol, Conn. The washers are sold with tables that specify and equate washer deformation with preload values. The preloaded combplate support assembly described above can support a 130 lb. combplate and reduce its effective weight to only 105 lb.
It will be readily appreciated that the combplate stop switch assembly can operate with a minimal amount of upward movement of the combplate. The assembly can be included in new equipment or can be retrofitted onto older equipment in the field. The preloading of the combplate supports allows older, heavier equipment to be rendered operable with minimal upward wedging forces, and brings such equipment into compliance with modern code requirements which require more sensitive stopping systems.
Since many changes and variations of the disclosed embodiment of the invention may be made without departing from the inventive concept, it is not intended to limit the invention otherwise than as required by the appended claims.
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A power switch assembly is operably connected to the combplate of an escalator for selectively shutting off the escalator in the event of entrapment of some object between the steps and combplate. When an object becomes wedged between the steps and combplate, the latter will be lifted or pushed upwardly away from the steps. The upward movement of the combplate operates a power interruption switch to stop further movement of the steps and handrail. The combplate is supported on the truss by spring assemblies which serve to effectively lower the weight of the combplate so that upward movement of the latter is more readily accomplished. The assembly can be retrofitted onto older existing escalators with heavier combplates than are found in newer equipment.
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FIELD OF INVENTION
This invention relates to compounds of organic acids and to methods of making and using the same.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 3,722,504 describes a screen for testing pharmaceutical compounds based at least partly on their ability to increase the negative surface charge of the vascular system. U.S. Pat. No. 3,722,504, by way of example, discloses a pharmaceutical compound which prevents thombosis by modifying the intimal surface charge of the vascular system.
Para amino benzoic acid increases the net negative surface charge of blood vessels and blood cells. It produces a marked increases in the current-induced occlusion time in rat mesentery vessels (see U.S. Pat. No. 3,956,504). It produces no measurable effect on blood coagulation studies. It has a limited effect on blood vessel wall pores as shown by electro-osmotic studies.
Para amino benzoic acid, further, has good anti-thrombotic characteristics but tends to have relative little anti-coagulant activity as shown by its lack of effect on the coagulation studies including partial thromboplastin time, thrombin time and recalcification time. It is therefore a very useful antithrombotic drug.
Para amino benzoic acid has various very significant properties as a drug:
1. It is inexpensive;
2. It is known to be non-toxic in humans;
3. It can be used for long periods of time without significant incidence of pathological manifestations:
4. The material can be taken orally in large dosage without significant toxicity.
In man, dosages have been administered, for example, as high as 12 to 24 grams a day without significant side effects. It has furthermore been used for a large number of diseases in man including the therapy of Ricketsial diseases before the development of anti-biotics, for tuberculosis in very large dosage and in the treatment of certain protozoan diseases and other infestation. It has long been thought to be a mild anti-inflammatory agent.
In humans with arteriosclerotic peripheral vascular disease, para amino benzoic acid has been shown to increase blood flow in ischemic limbs as measured by Barcroft plethysmographic studies and Doppler blood flow measurements. Studies which were carried out in approximately fifty patients resulted in an approximate doubling of blood flows in patients in which para amino benzoic acid salt was effective. U.S. Pat. No. 3,956,504 has been issued on the effect of para amino benzoic acid on blood flow in man.
The long term effects of vitamin C on scurvy in man is a primary event of historical interest in medicine. The effects of vitamin C to prevent scurvy are extraordinarily well documented throughout the world. Man, deprived of vitamin C for periods longer than approximately sixty days, starts to display evidence of capillary fragility and bleeding into all tissues and organs.
Vitamin C has the following characteristics:
1. It is a co-enzyme in the Kreb's cycle.
2. It is a reducing agent and electron donor in all known biological systems.
L-ascorbic acid or vitamin C has a variety of biological functions some of which are not completely understood (Ziten et al 1964). Large doses of L-ascorbic acid appear to have value in prevention and symptom reduction in the common cold and other viral diseases (Linus Pauling 1974). Recent experimental evidence indicates that L-ascorbic acid is effective in reducing serum chloresterol levels. C. Spittle (The Lancet, July 28, 1973; pp. 199-201 and Dec. 11, 1971; pp. 1280-1281) suggested that dosages of 1 to 2 grams of vitamin C per day can be beneficial in the prevention of deep vein thrombosis as well as in reducing the incidence of atherosclerotic complications in man. Recent research indicates that ascorbic acid may reduce the incidence of myocardial infarction (Knox, E. G., The Lancet, pp. 1465, June 30, 1973). L-ascorbic acid, further, appears to offset the thrombogenic effects of oral contraceptives as demonstrated by prolongation of occlusion times in the mesenteric vessels.
Good results were obtained in a pilot study using seven volunteer subjects to determine the effects of ascorbic acid on (1) plasma coagulation characteristics (2) serum cholesterol levels (3) platelet aggregability and (4) surface charge characteristics of red cells and platelets. Vitamin C in these subjects was shown to decrease platelet aggregability and increase the electrophoretic mobility of all the tested cells.
There has been little evidence to indicate that vitamin C effects measured blood coagulability as demonstrated by partial thromboplastin time, thrombin times and thrombin recalcification times.
Spittle et al have tested vitamin C in a randomized group of patients with thrombophlebitis. The protective effect of vitamin C against thrombosis has been shown by a randomized double-blind trial using patients who were shown to be prone to deep venous thrombosis. In a total of fifty-three patients, it was observed that the incidence of deep venous thrombosis was 33% in patients dosed with L-ascorbic acid compared to 60% in the placebo groups (Spittle, C. R., The Lancet pp. 199, July 28, 1973). The dose given was 1 gram per day. This correlation between the intake of vitamin C and reduction in the number of thrombotic episodes has been confirmed by other sources. In burn patients, where it is customary to use large doses of vitamin C to speed healing, there has been an apparent demand for treatment of deep-vein thrombosis. This information is based on the experience of one hospital over a five and one-half year period during which time 159 patients over forty years of age were treated with large doses of vitamin C (Spittle, C. R., The Action of Vitamin C on Blood Vessels, Amer. Heart J. 88:387, 1974).
SUMMARY OF THE INVENTION
It is an object of the invention to provide a synergistic combination of para amino benzoic acid and L-ascorbic acid.
It is another object of the invention to provide an improved pharmaceutical compound having improved utility for extended periods following administration.
Yet another object of the invention is to provide improved methods for the treatment of hosts and the prevention of vascular conditions.
Still another object is to promote the development of useful compounds based on organic acids and the like.
A further object of the invention is to provide new methods for the development of pharmaceutical compounds.
To achieve the above and other objects of the invention, there is provided a method comprising reducing thrombotic tendencies in a host by administering to the host a compound derived from two organic acids.
According to one embodiment of the invention, one of the acids is L-ascorbic acid and the other is para amino benzoic acid.
The compound which is derived may be a salt and this compound may be administered in a dosage of 1-100 mg./kg. of body weight. The dosage is preferably administered orally, although it can be administered parenterally.
The compound may be formed by mixing solutions of L-ascorbic acid and para amino benzoic acid and evaporating the thusly resulting mixture and recovering the thusly resulting solid. The acids are preferably used in a ratio of 1:1 on a molar basis. The solid may be recovered in crystal form or may be recovered as a cake.
The invention includes, as one aspect thereof, compounds prepared according to the above method or specifically salts of L-ascorbic acid and para amino benzoic acid.
BRIEF DESCRIPTION OF DRAWING
The sole FIGURE of the drawing is a chart demonstrating the prolonged activity of dosages of the compound of the invention.
DETAILED DESCRIPTION
Hereinabove, reference had been made to para amino benzoic acid. The formula for this organic acid is as follows: ##STR1##
Reference has also been made to L-ascorbic acid or vitamin C, the formula for which is: ##STR2##
The present invention relates to compounds derived from these organic acids, namely, salts, esters and amides thereof, the synthesization of the same and the applicability thereof to the treatment of the vascular system, notably in rats, dogs and human hosts requiring such treatment.
The formula for the salt is as follows: ##STR3##
The original approach was to prepare a salt of ascorbic acid with para amino benzoic acid. Such a salt can be shown in two forms -- one using the open form of ascorbic acid, the other using the enol form.
Two manufacturing procedures used are described below. Because of the ease of oxidation of ascorbic acid, it is essential to perform all operations under nitrogen and free of water and air. In one case, substantial darkening of the product resulted. It was believed this was due to the presence of moisture.
EXAMPLE I
1. A solution of para amino benzoic acid in a mixture of 50% acetone and 50% methanol was prepared with gentle heating. The concentration was approximately 100 grams per liter.
2. A similar solution was prepared with L-ascorbic acid.
3. The two solutions were mixed. Water was excluded to the extent possible.
4. The mixture was evaporated under vacuum, with nitrogen being utilized to flush the system. As the material concentrated, crystals began to appear.
5. When the solution was evaporated, until it was a thick slurry, the material was filtered through a coarse filter paper and allowed to drain as dry as possible. The surface was blanketed with nitrogen, with great care to exclude all filtered water.
6. The resultant solid was dried under high vacuum at room temperature. The ratio of L-ascorbic acid to para amino benzoic acid used was one to one on a molar basis.
EXAMPLE II
1. An alternative method of preparation used was to evaporate the solvent with careful exclusion of water and air to the point where a solid semi-dry cake was obtained in the container in which the evaporation was conducted.
2. This moist cake was then transfered to an appropriate container and dried under high vacuum. All operations are protected against exposure to air and moisture.
Other solvent systems will undoubtedly work. The above were used largely as a matter of convenience. An odor develops in the process which is removed with high vacuum drying, but must represent a by-product which is formed during the process. It must also be volatile, since it can be removed.
The first salt shown above, theoretically, only requires the removal of a molecule of water to form the amide. In general, this does not happen too readily. The distillation of the solvents may help pull off water.
Initial studies were directed toward determining the toxicity of the above indicated compound in mammalia. A very high dosage per kilogram of body weight in rats and dogs has been shown essentially non-toxic.
The new compound was next tested to determine its effect on rat-mesentery occlusion studies. Half lives of para amino benzoic acid have been shown to approximate one day. Half lives of vitamin C approximate 12 hours to a maximum of 1 day. The half lives of the new compound have been shown to approximate 4 to 5 days with a tail. A single dose lasts approximately 14 days. Mechanical mixing of para amino benzoic acid and L-ascorbic acid have been shown to have a maximal tail of approximately 5 to 6 days indicating by direct logic that the new compound is biologically different from the two components mixing together mechanically. Specifically, the compound derived appears to be more potent than the starting materials mixed together in a 50/50 ratio. If the agents are mixed together in the same ratio as used when making the new compound, the mechanical mixture is still not as potent as the compound derived.
The new compound has been evaluated in rat-mesentery studies. In the rat-mesentery, the new compound has been shown to prolong coagulation 3 to 4 times the normal rat-mesentery thrombosis time. The result is dramatic and prolonged since the effect of a single dose appears to extend out to 14 days before rat-mesentery occlusion times return to a normal level. This result is based on 26 rats.
Blood cells of male dogs fed with the new compound, display an increase in negative surface charge which increases sequentially from the third day to approximately the 14th day, so that at 14 days there is a doubling of electrophoretic mobility over the effects seen on the fifth, sixth and seventh day.
The available evidence suggests that, as with most normal pharmacologic agents, the new compound will not produce super normality. It will, however, return toward normal any grossly abnormal measurements concerning the electrokinetic characteristics of blood cells and blood vessels in dogs.
The available evidence indicates that the new compound derived from L-ascorbic acid and para amino benzoic acid is a rather potent anti-thrombotic agent. Its effect is cumulatively greater than the effect of either of its components even when they are mechanically mixed together and given orally to rats and/or dogs. The compound is an elegant example of an electron donor compound which is useful in treating the vascular system.
The following are some results of tests comparing the new compound with a mixture of the starting materials and with the starting materials individually:
TABLE I__________________________________________________________________________Dosages - Oral Route DURATIONMATERIAL RANGE MGS/KG/DAY ADMINSTRATION TOXICITY EFFECT__________________________________________________________________________ Minimum MaximumPABA (X) 1 10 Indefinite Low cutaneous Relatively manifestation. limitedL-Ascorbic 0.25 10 Indefinite Low cutaneous Critical inAcid (Y) mgs. manifestation. maintenance Gastritis. Some of tissue evidence dis- integrity turbence gene particularly pool in massive vascular tree dosage. Catalytic oxidizer Krebs cycle essential vitamins.X + Y 1 100mg/kg Unknown Very low gas- Prolonged rat(mixture) rats long term tritis in one mesentery rat, in high occlusion dosage 1mg/gm time. Single body weight dose run dosage. (day 1): 170±20 min. Tail - 7 days.X - Y 2 100mg/kg May be Very low Prolonged.(compound) given long gastritis. Longer tail term than X + Y Tail - 14 days Occlusion time: 206 = 24 min.__________________________________________________________________________ X - Y tail - minimum 14 days in experimental animals X + Y tail - minimum 7 days in experimental animals
The following additional data was obtained relative to the utility of the new compound:
______________________________________EFFECT OF NEW COMPOUND ON ELECTRICALLY IN- -DUCED THROMBOSIS IN RATMESENTERIC VESSELS______________________________________SINGLE LOADING DOSE20mg/100g B.W. MALEMELTING POINT - 147° C.1 DAY AFTER SINGLE LOADING DOSE1 Rat The occlusion time was 240 minutes3 DAYS AFTER SINGLE LOADING DOSE1 Rat The occlusion time was 150 minutes2 Rat The occlusion time was 195 minutes______________________________________
The following data relates to rat-mensentery occlusion time:
______________________________________RAT-MESENTERY OCCLUSION TIME OCCLUSION TIME CONTROL______________________________________PABA35 mg p.o./d × 3 d (F) 95 min (1F) 45+5 min (3F)35 mg p.o./d × 3 d (M) 53±13 min (7M)L-ASCORBIC ACID10mg/100g body weight/per day × 3 days (F) 112±18 min (5F) 45±5 min (2F)10mg/100g body weight/per day × 3 days (M) 135±14 min (2M) 38±10 min (3M)PABA +L-ASCORBIC ACID35 mg + 10mg/100g bodyweight 108±23.0 min (6F) 45±5 min (2F) 128±18.0 min (2M) 38±10 min (3M)10 mg + 10 mg 160 min (2F) 50 minutes (1F)(3M + 3F) 175 min (3M) 55 minutes (1M) AF + 3MPABA -L-ASCORBIC ACIDSALT(NEW COMPOUND)20 mgs/100 grams 1 day after Single Loading Dose 240 min (1F) 3 days after Single Loading Dose 150 min (1M) 195 min (2F)______________________________________
The following data relates to the occlusion time tail in female rats:
______________________________________(X - Y) - NEW COMPOUND - SINGLE DOSE/ P.O.100mg/100g body weight Average Occluding Time______________________________________1 day 206 ± 24.0 min (5F) 5 days 143 ± 9.5 min (5F) 9 days 137 ± 12.0 min (5F)11 days 127 ± 34.0 min (4F)14 days 67 ± 4.5 min (4F) Control - 48 ± 1.1 min (5F)______________________________________
Below are tabulated some physical characteristics of batches of the compound which were made:
______________________________________ MELTING POINT SOLUBILITY______________________________________Batch 1 157° C. Sparingly Soluble; 1gm/100cc. H.sub.2 OBatch 2 157° C. SameBatch 3 147° C. Same______________________________________
Referring next to the sole FIGURE of the drawing, it is seen that there is illustrated the effects of a single loading dose on a number of rats. A control is provided in the form of five animals and it is noted from the chart in the drawing that the control provides a rat-mesentery occlusion time relative to electrically-induced thrombosis which is at the outset, less than a single loading dose of the new compound after 14 days.
More particularly, it will be noted that five animals were sacrificed after one day following administration of the new compound, five animals were sacrificed after five days, five more animals were sacrificed after nine days, four additional animals were sacrificed after 11 days and finally, four animals were sacrificed after 14 days. The occlusion time (in minutes) after the first day is markedly greater than that of the controls. After five days, the occlusion time is reduced but is still more than double that of the controls. Similarly, after nine days, the occlusion time is substantially greater than the controls and has reduced only very slightly from the fifth day measurements. Similarly, after 11 days, there is very little reduction in occlusion time which is still at least twice as great as that of the controls.
After 14 days, measurement of four sacrificed animals still reveals an occlusion time which is greater than that of the controls.
The measurements in the drawing are based upon an administration of the compound in a dosage of 100 mg/100 g of body weight and single loading doses are employed for both the controls and the animals to which the new compound has been administered. This shows a substantial tail inures to the benefit of administration of the new compound and this is important with respect to the treatment of humans wherein oral administration of the new compound is expected to lead to a scheduled administration which provides for spaced-oral dosages over a period of days, such as, for example, one oral administration per week.
There will now be obvious to those skilled in the art, many modifications and variations of the above methods and compounds. These modifications and variations will not depart from the scope of the invention if defined by the following claims or if generally equivalent thereto.
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A solution of L-ascorbic acid and a solution of para amino benzoic acid are mixed and the mixture evaporated to permit recovery of a solid compound. The compound is adminstered to a host to reduce thrombotic tendencies.
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[0001] This continuation application claims the benefit of U.S. patent application Ser. No. 12/315,485, entitled APPARATUS FOR DETERRING MODIFICATION OF SPORTS EQUIPMENT, to George W. Burger, filed Dec. 3, 2008.
BACKGROUND OF THE INVENTION
[0002] (a) Field of the Invention
[0003] The present invention relates to an apparatus for playing ball sports, such as, for example, softball. More particularly, the present invention relates to an apparatus for deterring the modification of ball bats.
[0004] (b) Background of the Invention
[0005] In the field of ball bat technology, a known problem is “rolling”. An issue presently exists in softball where players will purchase a softball bat and then modify that bat such that its performance ability is altered and may exceed the standards of the Amateur Softball Association of America (ASA). Persons will perform a process known as “rolling” where they will take a fiber bat and “squeeze” the barrel between large rolling tubes separated by a distance smaller than the diameter of the bat being rolled. The bat is rolled back and forth between these tubes fracturing fibers within the bat so that the bat becomes softer and more elastic. A bat that is so rolled is referred to as “hot” because it has the capacity to send the ball from the bat at a faster pace than a bat not so rolled. Certain regulations are in place under the ASA that make such rolled bats improper for use in any ASA regulated competition. Tests are conducted under the authority of the ASA to determine the rate of speed at which a ball will exit a bat when struck by a batter. Those bats with exit speeds in excess of 98 miles per hour (mph) when using the ASTM F2219 standard test method are illegal under the current rules of the ASA.
[0006] The Inventor is not aware of any prior art addressing the problem of deterring any portion of a ball bat from being rolled.
SUMMARY OF THE INVENTION
[0007] The present invention addresses the shortcomings of the prior art and provides, among other things, a bat which deters the modification of the bat so that the user is capable of hitting the ball further or at a pace faster than permitted within the official rules of the game.
[0008] A need exists for deterring the modification of ball bats, namely to deter rolling. The present invention discloses a bat that includes one or more supports inside of the bat oriented in such a way as to reinforce the integrity of the bat from the interior. The present invention contemplates using a retaining member to position at least one support within the bat transverse to the bat's axis to provide integrity to the bat's composition to deter rolling. Multiple retaining members and supports are preferably employed.
[0009] The primary objective of the present invention is to minimize the ability to alter the elasticity of the bat through the process of fracturing fibers within the bat, thereby creating a hot bat. The bat is characterized in that it comprises an outer shell, preferably of fiberglass, graphite, or composite materials. The ball bat is reinforced from the center using supports transverse to bat's axis. The supports of the present invention are composed of a resilient material with little or no elasticity thereby providing the maximum structural integrity to the bat. The supports are held into place using a retaining member, such as a urethane foam member, that slides into the interior of the bat. When a support is in a desired location in the bat, the retaining member, support, or both are adhered to the interior of the bat using an adhesive such as glue, urethane, or silicone.
[0010] The present invention will provide maximum structural integrity to the interior of the bat while continuing to provide a bat with sufficient elasticity for batters to adequately play the sport within the rules of the game.
[0011] More particularly, the present invention is a ball bat having a barrel with a cavity inside, a support and a retaining member. The support and retaining member are located inside the cavity, and the retaining member positions the support within the cavity.
[0012] Even more particularly, the retaining member positions the support transverse to the long axis of the bat. The retaining member may have a notch in which the support is retained.
[0013] Even more particularly, the support is composed of a lightweight resilient material, such as graphite or magnesium. The retaining member may be cylindrical or may be a non-circular geometric shape with at least three contact points and is often composed of urethane foam.
[0014] The ball bat may include one retaining member positioning one support member. The ball bat may also include two or more retaining members, each positioning one or more support members. Alternatively, the ball bat may include a single retaining member that positions two or more supports.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawings, wherein:
[0016] FIG. 1 a shows a cross section of a bat, sliced lengthwise, having 2 support and retaining member components;
[0017] FIG. 1 b shows a cross section of a bat, sliced lengthwise, having 3 support and retaining member components;
[0018] FIG. 1 c shows a cross section of a bat, sliced lengthwise, having 2 support components and 1 retaining member component;
[0019] FIG. 2 shows a second cross section of a bat, sliced along the width;
[0020] FIG. 3 shows a portion of a retaining member with a support inserted into a notch;
[0021] FIG. 4 shows a cross section of a retaining member with a support along the lines 4 - 4 shown in FIG. 5 ;
[0022] FIG. 5 shows a transverse view of a retaining member with a support;
[0023] FIG. 6 shows a cross section of a barrel, sliced lengthwise, having a support that is not in its final location;
[0024] FIG. 7 shows a cross section of a barrel, sliced along the width, having a support that is not in its final location;
[0025] FIG. 8 shows a cross section of a barrel, sliced lengthwise, having a support that is in its final location; and
[0026] FIG. 9 shows a cross section of a barrel, sliced lengthwise, having a support that is in its final location.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] Referring now to FIGS. 1-3 , the bat 10 embodied in the present invention is shown comprising a barrel 30 , a sweet spot 31 , a transition area 32 , a handle 33 , and an end knob 34 . A preferred embodiment of the present invention is bat 10 having a barrel 30 of constant outer diameter 42 of 2.25 inches (5.72 cm) and an inner diameter 43 of 1.85 inches (4.70 cm), and having a barrel wall thickness 45 of 0.2 inches (0.51 cm). The composition of the bat 10 is preferably continuous throughout, including the barrel 30 , the sweet spot 31 , the transition area 32 , the handle 33 and the end knob 34 . Alternative bat 10 constructions are known where the end knob 34 is a separate component attached to the handle 33 . Also, the barrel 30 may have a separate end cap. Even further, the bat 10 may be composed of a composite material or a metal/composite combination, as is known in the art.
[0028] The bat 10 has a sweet spot 31 that is an area at the center of percussion where the contact between bat 10 and ball results in the “best hit.” More particularly, the sweet spot 31 is where the maximum energy is transferred to the ball when struck, the ball leaves the bat 10 with the greatest speed, and the player's hands feel the least vibration from the impact. The center of the sweet spot 31 is typically five to seven inches (12.7 to 17.8 cm) down from the top of the barrel 30 and extending two inches (5.08 cm) to either side.
[0029] The novel aspect of the present invention occurs within the cavity 35 bounded by the inner diameter of the barrel. A retaining member 22 is inserted into the cavity 35 . In a preferred embodiment, the retaining member 22 is aligned with the barrel 30 and incorporates one notch 21 allowing one support 20 to be inserted into said notch 21 , positioning the support transverse to bat's 10 axis 48 . The retaining member 22 is cylindrical in shape so that it may be inserted into the barrel 30 . The retaining member 22 has an outer diameter 43 preferably equal to the inner diameter 43 of the barrel 30 so as to permit the retaining member 22 to fit snugly against the inner wall of the barrel 30 to prevent slippage. In an embodiment with the bat 10 having an inner diameter 43 of 1.85 inches (4.70 cm), the retaining member 22 will have an outer diameter 43 of 1.85 inches (4.70 cm), an inner diameter 44 of 1.6 inches (4.06 cm), and a length 46 of 1 inch (2.54 cm). Preferably one support 20 is positioned about two inches (5.08 cm) on each side of the center of the sweet spot 31 . Therefore, the supports 20 are separated by a distance of about four inches (10.16 cm), as depicted in FIG. 1 a.
[0030] As is shown in FIG. 1 b , another embodiment of the present invention the bat 110 preferably includes three supports 20 with one positioned at the center of the sweet spot 31 and one approximately two inches (5.08 cm) on either side of the center of the sweet spot 31 . The support 20 located at the sweet spot 31 being constructed such that the bat 110 cannot be rolled.
[0031] In an alternative embodiment, FIG. 1 c shows bat 210 with the retaining member 122 having a plurality of notches 21 for which multiple supports 20 may be inserted to provide structural integrity to the interior of the bat 210 . In this alternative embodiment, the retaining member 122 would be approximately 5 inches (12.7 cm) in length 146 .
[0032] The supports 20 of the present invention should be of a lightweight resilient composition to prevent a “weighting” effect on the bat 10 . Some weighted bats are improper under ASA guidelines. The supports 20 may, for example, be composed of any material suitable to prevent rolling the bat 10 , such as graphite or magnesium. In a preferred embodiment, the supports are disk-shaped.
[0033] Some embodiments of the present invention utilize the durability and structural integrity of graphite to reinforce the interior cylinder of the barrel. Graphite is a resilient material capable of resisting compression and fracturing in the rolling process. The orientation of the grain within the graphite should be structured so as to provide maximum integrity for all 360 degrees of the bat 10 such that the bat 10 cannot be rolled in any direction. The supports 20 of the present invention will preferably be constructed of 16 to 24 plies of graphite, and approximately one eighth of an inch (3.18 mm) in total thickness 47 . For the bat 10 with an inner diameter 43 of 1.85 inches (4.70 cm), these supports 20 will be disks composed of solid graphite having an outer diameter 40 of 1.75 inches (4.45 cm) and, as is explained hereafter, preferably include a center hole 23 having an inner diameter 41 of 0.625 inches (1.59 cm). However, supports 20 without a hole 23 or in shapes other than disks could be used.
[0034] The supports 20 of the present invention will preferably include a hole 23 in the center so that a liquid may be poured through the center of the supports in the bat 10 manufacturing process. Thus, in embodiments using disk-shaped supports 20 , the supports 20 of the present invention will resemble washers.
[0035] The supports 20 should be designed in such a way that they will not cause dead zones within the bat 10 . Dead zones are areas in the bat with extremely low levels of elasticity. The lower the elasticity, the less propulsion effect the bat will have on the ball. In the instance of ball bats, a dead zone is an area where the energy from the ball-to-bat contact is transferred to the bat rather than to the ball. The present invention will allow a manufacturer to determine the elasticity of the bat, such that it will be acceptable under ASA guidelines.
[0036] The supports 20 are designed to have an outer diameter 40 slightly smaller than the inner diameter 43 of the bat 10 . In one embodiment, the outer diameter 40 is 1.75 inches (4.45 cm) and the inner diameter 43 is 1.85 inches (4.70 cm). Thus, in this embodiment, a gap 56 of 0.05 inches (1.27 mm) will be present between the supports 20 and the bat 10 . This gap 56 is necessary to allow the bat 10 to “hoop bend” without the hoop bend being inhibited by the support 20 . A hoop bend is a slight temporary deformation of the bat 10 when it impacts a ball.
[0037] The retaining member 22 of the present invention must be reinforced sufficiently to prevent the force of repeated strikes of the bat 10 from knocking the supports 20 loose within the barrel 30 of the bat 10 . The notches 21 made within the retaining member 22 must be deep enough to prevent the supports 20 from coming loose when the bat 10 is used. In a preferred embodiment, the retaining member 22 is composed of urethane foam of sufficient stiffness to maintain the supports 20 in a position transverse to the axis 48 of the bat 10 .
[0038] In a first embodiment, the retaining member 22 of the present invention is inserted into the barrel 30 and when the supports 20 is at the final location, the retaining member 22 is adhered to the interior of the barrel 30 with an adhesive 24 . In this first embodiment, the retaining member 22 is cylindrical. Any means for adhesion may be used, but preferably the means will be urethane or silicone.
[0039] In a second embodiment, retaining member 222 is a non-circular geometric shape having at least three contact points 52 , as shown in FIG. 4 and FIG. 5 . In this second embodiment, the retaining member is sized so that the contact points 52 contact the interior of the barrel 30 , as shown in FIG. 7 . The retaining member 222 has a hole 50 . In this second embodiment, the means of adhesion 24 is positioned at the final location of the support 20 , as shown in FIG. 6 . In this second embodiment, the means of adhesion 24 is positioned such that the means of adhesion 24 will not contact the retaining member 222 , as shown in FIG. 7 . The retaining member 222 of the present invention is inserted into the barrel 30 until the support 20 contacts the means of adhesion 24 at the final location of the support 20 , as shown in FIG. 8 . Additional means of adhesion 54 is then added to adhere the entire perimeter of the support 20 to the interior of the barrel 30 , as shown in FIG. 9 . Any means for adhesion may be used, but preferably the means will be urethane or silicone.
[0040] The retaining member 22 of the present invention must not be resistant to the adhesive 24 . The retaining member 22 of the present invention will preferably be of a lightweight composition to prevent a “weighting” effect. In a preferred embodiment, the retaining member 22 will be of a lightweight composition capable of being adhered to the interior of the bat 10 , such as urethane foam.
[0041] The bat 10 of the present invention may be included in one-wall or multiple-wall bat technology.
[0042] The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom for modifications can be made by those skilled in the art upon reading this disclosure and may be made without departing from the spirit of the invention and scope of the appended claims.
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The present invention relates to an apparatus for playing ball sports including softball. More particularly, the present invention relates to an apparatus for deterring the modification of ball bats. The bat comprises a barrel, a sweet spot, a transition area, a handle, and an end knob. Within the barrel are found supports used to reinforce the structural integrity of the bat to deter users from crushing the bat, causing the bat to fall outside the legal classification of bats allowed by the Amateur Softball Association of America (ASA). The supports are made out of a lightweight durable composition. The supports are held in place by a retaining member. Multiple supports and retaining members may be used.
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[0001] This application claims priority under 35 U.S.C. §119(e) to U.S. provisional patent application 61/523,547, filed Aug. 15, 2011.
[0002] This invention relates to methods and apparatus of a combination of laser wave mixing technology with capillary electrophoresis diagnostic flow technologies. The combination of these technologies along with minute detection levels not yet been seen in the field.
BACKGROUND
[0003] Laser wave mixing has been described in many patents, journals and articles. Having greatest relation to embodiments of the invention described herein are Tong describing degenerate four wave mixing and apparatus therein in U.S. Pat. Nos. 5,600,444 and 6,141,094 and Patent Application 2006263777. These describe apparati and methods that in their capacities are capable of analyzing small quantities of analytes down to a detection level of attomoles. They utilize different complements of analysis systems including HPLC and HCPE and a gas phase atomizer type spectroscopy. Furthermore, the dissertation “Protein Analysis at the Single Cell Level by Nonlinear Laser Wave-Mixing Spectroscopy for High Throughput Capillary Electrophoresis Applications” from Sadri's PhD dissertation N.C. State from 2008 relates similar apparati discussed in the Tong patents that reach the levels of detection with fluorescing compounds of yoctomoles (10 −24 ). The named articles, dissertations and patents are incorporated by reference in their entirety. These references give a background into the theories, adjustments and variations upon the technology that are explanatory. Similarly, capillary electrophoresis (CE) has been explained and describe in many patents and journal articles. A current review article gives a good example of the technology as used with peptides “Peptide Separation by Capillary Electrophoresis with Ultraviolet Detection: Some Simple Approaches to Enhance Sensitivity and Resolution,” L. Noumie Suragau, Malaysian Journal of Analytical Sciences, 15:2 (2011)273-287. This reference gives a current view of CE technology with peptides as an example analyte. Some advantages of CE are: employs capillary tubing within which the electrophoretic separation occurs; adaptable to modern detector technology to give ease of use output; has great efficiencies; requires minute amounts of sample; easily automated for precise quantitative analysis and ease of use; consumes limited quantities of reagents thus making it environmentally friendly; is applicable to a wide selection of analytes.
[0004] As used in this specification and in the appended claims, the singular forms “a,” an” and “the” include plural references unless the content clearly dictates otherwise.
[0005] The use of the word “preferably” in its various forms is explanatory for ease of reading, and should not be used to read into the claims as limiting or anything more.
[0006] In describing the invention and embodiments, the following terms will be employed and are intended to be defined as indicated below. If any terms are not fully defined, then the normal usage as used in the art will fill any gaps in the understanding of the terminology.
[0007] Laser: is a device that creates a beam of light where all of the photons are in a coherent state—usually with the same frequency and phase. Among the other effects, this means that the light from a laser is often tightly focused and does not diverge much, resulting in the traditional laser beam. In free space, the beams inside and outside the cavity are usually Gaussian distributed and are highly collimated with very small divergence. The distance over which the laser beam remains collimated depends on the square of the beam diameter while divergence angle varies inversely with the beam diameter.
[0008] Collimating: is the process of making light rays parallel from a mixture of diverging light rays or beams, and therefore will spread slowly as it propagates. The word is related to “collinear” and implies light that does not disperse with distance (ideally), or that will disperse minimally (in reality). A perfectly collimated beam with no divergence cannot be created due to diffraction, but light can be approximately collimated by a number of processes, for instance by means of a collimator or collimating lens.
[0009] Diagnostic flow technology: Is a solid state technology through a series of pumps or pump like mechanisms (such as electroosmotic flow, electrophoretic flow, capillary action, siphoning, pressure, imploding gas bubbles and the like) and apparati move analytes from a sample collection area to an analysis area which comprise of multiple detectors types such as photodiode arrays (PDA), ultraviolet-visible (UV-VIS) spectrometers, charge coupled device (CCD) (such as a CCD-camera) mass spectrometer (MS), Infrared spectrometers (such as Fourier transform infrared (FT-IR)}, nuclear magnetic resonance (NMR) detectors, refractive index spectrometers (RI), fluorescence detectors, radiation photomultipliers, and the like. Flow can be achieved through liquids, fluids, gas or other means pumped or other means driven through a series of channels and mediums (such as tubing or silica gels) to move analytes from one point to another. Examples would comprise but not limited to Liquid Chromatography (LC) (which would further comprises variations such as micellar, ion exchange and the like), reverse phase high performance liquid chromatography (RP-HPLC), gas chromatography (GC), high performance capillary electrophoresis (HPCE), capillary zone electrophoresis (CZE), super critical fluid chromatography (SFC), sub-critical fluid chromatography (SubFC), inductively coupled plasma (ICP), and the like. Each technology is unique unto its own with positives and negatives propagating from each in achieving the needs of the user. For example, capillary electrophoresis has environmental positives in utilizing very little hazardous materials but has negative issues in what solvents are compatible.
[0010] Focal spot: an area or point onto which collimated light parallel to the axis of a lens is focused. This spot of light can be expanded and contracted in different shapes and geometries by some means such as a cylindrical lens.
[0011] Absorptive interaction: interaction of analytes in a flow cell chamber or capillary array chamber when the two input beams are mixed and focused in an absorbing medium. These beams form light induced gratings when analytes absorb the excitation light beam. The excited molecules in the form of interference patterns release their heat energy to surrounding solvent or matrix molecules, creating dynamic thermal gratings, and as a result, refractive index gratings. The incoming photons from the probe beam diffract off the gratings to generate the output signal beams.
[0012] Multichannel chamber: an enclosed space in which is configured to allow an absorptive interaction between multiple analytes and light beams. Multichannel flow cells and multiple capillary arrays can be situated in a multichannel chamber.
SUMMARY
[0013] The embodiments explained and described here utilize techniques to elucidate very small amounts of analyte with high sensitivity, selectivity, resolution and throughput.
[0014] The embodiments comprise of a diagnostic flow technology interconnected, configured with or linked to a single non linear optical wave mixing technique of a laser source of light absorptively interacting with an analytes either in or passing through the multichannel chamber also known as a laser sensing. Wherein, the interaction of the analyte and beam of light are sensed by photodetectors to a very small molar amount threshold.
[0015] The embodiments of the invention can be described by example. In a summary example, a device couples a low watt quadruple Nd:YAG laser beam in a unique ultraviolet (UV) wavelength of 266 nm utilizing a non linear wave mixing technique with a capillary electrophoresis diagnostic flow technology utilizing a capillary array. This example device can be used to elucidate concurrent multiple non-tagged or non-labeled native proteins that include in their sequence an amino acid picked from at least three amino acid residues of tryptophan, tyrosine, and phenylalanine down to the levels of yoctomoles (10 −24 ) and sub-yoctomoles.
[0016] Embodiments reaching this yoctomole sensitivity allows for very small injected sample quantities. These levels would have many broad spectrum uses in pharmaceutical, environmental, forensic and anti-terrorism industries. Analyzing such multiple small quantities can increase efficiencies in time and cost in analysis procedures. The embodiments' configurations allow for short optical path lengths which can allow for compact miniaturization of the equipment box. Embodiments of the invention can achieve 100% optical collection efficiencies for signals measured against a dark background.
[0017] Implementation of the embodiments comprise methods of analyzing substances through use of a diagnostic flow technology injecting a small amount of analytes into a multichannel chamber, creating multiple beams of light through the use of a non linear optical wave mixing technique, eliciting or generating a signal for each analyte, sensing the signal beams, and manipulating and storing the data. Embodiments reaching this yoctomole sensitivity allows for very small injected sample quantities.
[0018] An embodiment of the invention utilizes methods of analysis of the combination of technologies. Included in these methods is creating a single low watt laser beam also known as a light beam or light ray by some laser sensing technology. From propagation the laser beam will be guided and manipulated through a series of reflective surfaces such as minors, beam traps, beam blockers, beam choppers, beam splitters, focusing lenses, collimating lenses, and concave lenses with an interconnecting to electronic devices including, a computer to both control the front end processes of propagating and manipulating the light source and running the diagnostic flow technology to the back end process of receiving the data and processing it into useable output. Electronics included are a photodetector such as a photodiode detector and N-type Metal Oxide Semiconductor (NMOS) with a photodiode array (PDA) image sensor or detector, to receive the signal light input which could include an amplification of the signal with a photo multiplier tube, a lock in amplifier to filter out extraneous frequencies, a beam chopper controller which controls or segregates the frequency in which the output beam is settled.
[0019] As the beam is split with a ratio of 70:30 into a probe beam also known as high ratio beam and a reference pump beam also known as low ratio beam, the beams are then focused onto a target area of the capillary window in the multi channel chamber where then a cylindrical lens expands the light wave to cover all the capillaries in the multi array of capillaries. This multi channel chamber is the interaction and interconnection of the diagnostic flow technology with the laser wave mixing. In one embodiment the diagnostic flow technology is an analytical CE device. This device has a source of high voltage with microbore multi capillaries interconnected to an electrophoretic buffer solutions with platinum cathode and an electrophoretic buffer solutions with platinum anode. Other embodiments may have a mass spectrum device connected to the fluidic capillary. The sample interacts with convergent or divergent light beams moving through the target area aperture in the capillary array. After penetrating the capillary array the diffracted signal beams are collimated into a coherent light beams. Other light diffractions and rays are captured in a beam trap. This signal beams are directed to a beam splitter with the beams sent to photodetector in some embodiments could be photodiode detector and NMOS PDA. The beams are detected and the signal is translated and processed through computer applications to useable data.
BRIEF DESCRIPTION OF DRAWINGS
[0020] The objects, advantages, and features of the invention will become more apparent from the following detailed description, when read in conjunction with the accompanying drawing, in which:
[0021] FIG. 1 . is a schematic of the guided pathway of the laser light beam with the light beam interconnected to a diagnostic flow device capillary electrophoresis. Note the light beam has been given a width to show expansion and contraction of the beam through the various lenses.
[0022] FIG. 1 a. is a schematic blow up of the multichannel stage showing a side view of square capillary array. Note that the right side of the figure shows an expansion of the light beam entering the array and the left side shows collinear signal beams leaving the array (does not represent true nature of light beams)
[0023] FIG. 1 b. shows a facial flat planar view of the front of the capillary array window and the capillaries jutting out transverse (note the trapezoidal shaped light beams are not to correct angle of attack on the capillary window).
DETAILED DESCRIPTION
[0024] Referring to the embodiments in FIG. 1 , a schematic view showing an embodiment of the invention utilizing a capillary array connected to a diagnostic flow technology. The laser light source 100 emits and presents a coherent beam 110 to a beam splitter 120 . The light beam presented in FIG. 1 has a width to represent the edges of a ray of light. This allows a representation of the narrowing and expansion of the beam as it is manipulated through the guided pathway. Many sources of laser light are contemplated but lower wattage lasers give advantages to cheaper price and less robust materials in the beam manipulative devices. Preferred laser is the frequency quadrupled Nd:YAG laser emitting 266 nm radiation at a high pulse frequency. Embodiments contemplate different types of lasers. Depending on the techniques used in the cavity, such as Q-switching, mode locking or gain switching, the laser output may be continuous wave (CW) or pulsed. When the waveform is pulsed, higher peak powers are achieved. Dye lasers and vibronic solid-state lasers can generate a wide range of wavelengths that are appropriate for generating extremely short pulses of light (10 −15 s). Other types of lasers contemplated are gas such as Argon-ion, chemical, excimer, solid state, photonic crystal, semiconductor, free electron, bio, and exotic. A laser type for implementation of the embodiments contemplated is a solid state Neodynium: yttrium aluminum garnet (Nd:YAG) lasers tuned to 266 nm wavelength suitable for native protein absorption measurements. This UV laser (Model, NU-10210- 100, Teem Photonics, France) also offers low power consumption (5 mW) and a good beam quality. Embodiments of the invention can use either higher power (>1 W) or lower power lasers (<1 W). Lower power lasers allow for less damage to optical components, less cost to acquire and to use. To prevent laser damage to optical components and depending on the wavelength ranges and power, there are several optical materials commonly used comprise of borosilicate crown glasses (BK7), UV grade fused Silica, CaF 2 , MgF 2 , crystal Quartz, Pyrex and Zerodur.
[0025] At beam split, the preferable split ratio of the laser beam is 70:30 but other ratios are contemplated. Beam 130 travels to reflective surface or a mirror 150 which brings the beam to the beam chopper 170 controlled by chopper controller 180 and lock-in amplifier 190 which among other things amplifies and modulates the cycles of the light wave preferably to 200 Hz. Other cycles are contemplated as the utility demands. The modulated beam 185 travels to reflective surface or mirror 190 and redirects the beam through beam blocker 195 to visually adjust the beams towards the focusing convex lens 200 preferably 10 cm. The beam is focused onto the aperture of the target area on the capillary array on the multichannel chamber 240 . After the target area is focused upon, the beam is expanded by cylindrical lens 210 to cover all the capillaries in the array. The beam 140 travels to mirror 160 and redirects the beam through beam blocker 195 towards with similar focusing and expansion as the beam 185 with the focusing convex lens 200 and beam expansion cylindrical lens 210 . The beam 140 should orient roughly parallel with beam 185 . The spatial configuration such as distance, size and shape of the lenses allows for the beam focusing and expansion which allows for variable size focal spots and in variable areas on the X,Y,Z coordinate plane 230 a of the multi microarray of capillary tubes similar to a flow cell in other applications on the multichannel chamber 240 .
[0026] Dependent on the materials, type of laser, size of mirrors and lenses used embodiments of the invention may reach to yoctomoles level in analysis of analytes with for merely an example of analyte of native protein with an amino acid tyrosine in the sequence utilizing a laser at wavelength 266 nm.
[0027] Other analytes contemplated but not limited to are cells, biomolecules and small molecules such as labeled or unlabelled tagged and un-tagged proteins, native proteins, peptides, peptidomimetics, polysaccharides, nucleic acids, amino acids, adjuvants, celluloses, biopolymeric molecules, lipids, cell parts, organic compounds, inorganic compounds, antibodies, DNA, RNA, variations on DNA and RNA, nucleotides, drug, drug candidates, biopharmaceuticals, environmental chemicals, astral chemicals, geophysical chemicals, forensic chemicals, chiral, enantiomers, stereoisomers, optical isomers, solids, liquids and gases. At such low levels of concentration the real time analysis or efficient analysis of metabolic chemicals are contemplated.
[0028] Contemplated wavelengths of the laser beam are from the below ultraviolet (UV) range through the visible light spectrum beyond the infrared depending on the lasers capabilities and spectral characteristics of the analyte. For example, the UV spectrum for amino acid residue tyrosine, tryptophan, and phenylalanine reaches a peak of extinction coefficients between 245 nm and 280 nm. Native proteins including L and D versions of the amino acids or residues would be contemplated examples of use of the UV spectrum detection. A laser beam tuned to a unique 266 nm wavelength would be efficient in absorbing an analyte containing these residues. Similarly in another example a protein analyzed with a laser beam tuned to 210 nm would efficiently elucidate the peptide bond whose extinction coefficient reaches its maximum at 190 nm. Other embodiments contemplate UV wavelengths between 10 nm and 400 nm, visible spectrum between 380 and 800nm and infrared from 740 nm to 300000 nm. Embodiments contemplates individual UV wavelengths or spectrums of wavelengths ranging between 190 nm and 300 nm with other individual UV wavelengths and ranges contemplated such as 210 nm to 280 nm and an individual UV wavelength at 210 nm, 254 nm, 266 nm, and 280 nm.
[0029] Now turning to FIG. 1 A., the schematic view shows a blow up of the multichannel chamber 240 held on a rigid translational stage with a view directly into capillaries 238 . The beams 185 and 140 are focused then expanded and configured into beam 230 a onto the desired target area of the capillary window of the capillary array similar to a sample cell window. The window should be stabilized and kept vibration free. The photons of the beams interact with the analyte samples flowing through a multichannel capillary window similar to a flow cell, in this embodiment, the signal beams 230 b leave other side of capillary window. The figure shows example beams as collinear but it is not representative of true nature.
[0030] The expansion configured beam 230 a is shown in Figure lb a front facial planar view of the capillary window 410 of the capillary array 400 . The beam 230 a ′ and beam 230 a ″ is entering expanded to cover all the outer coating stripped capillaries 238 in the capillary window.
[0031] Analytes are flowed and separated in the capillary array by means of electroosmotic and electrophorectic force by voltage from power supply 220 applying a voltage across anode 220 a made from a proper material such as platinum to cathode 220 b made from a proper material such as platinum. Any variable amount of capillaries greater than 1 are contemplated for embodiments of the invention. The capillaries may have variable inner diameters (i.d.) and outer diameters (o.d.). The larger net o.d. of each capillary provides larger total capillary surface area per array with larger distance between each capillary probe area. The preferred i.d. is 71 um. The capillaries can be made out of any chemical combination of materials to allow for flow of analyte into the sample staging area and robust enough for any pressures the system would exert on them. The capillaries can be coated (such as polyimide) or uncoated on the outer surface as the experiment demands. The coating should allow for close proximity of the capillaries and allow for light penetration. The capillaries inner wall can be coated (such as polyacrylamide for visible range) or un-coated in the inner surfaces as the experiment demands.
[0032] In embodiments utilizing CE, capillaries should be rinsed with water before each run and filled up with a dynamic coating and sieving matrix. An example of a dynamic coating and sieving matrix is a solution comprising 50 mM TRIS borate, 2.5 mM EDTA, 0.5% methylcellulose (high viscosity), 5% Dextran and 0.1% SDS. Solutions should be transparent to applied UV wavelengths.
[0033] The capillaries may have different shape geometries for example square or round. The shape can allow among other things good bundling of the capillaries, minimization of background optical noise, less optical scattering and diffraction. The preferred shape is square configured to allow the least amount of gaps minimizing laser leakage between the capillaries. The length of capillary can vary with an effective length being the side that brings the sample analyte to the capillary window for sensing and detection. A preferable effective length is 25 cm. The number of capillaries can also be variable with the needs of the experiment and limitations of the delivery system. The variable amount of the capillaries is greater than 1 such contemplated as 5,6,7,8,9,10,11,12 and greater than 12. The bundling configuration of the capillaries can be in different 2 dimension or 3 dimension geometries that allow for the best penetration of light, less interference, optical noise, scattering and diffraction. For example, a flat stacked array of capillaries. Means of attaching of the capillaries would be uses of glues, adhesives, or other such attachment means or through the packing configuration of the capillaries in a holder that needs no attaching means. The embodiments have the capability of variable focal point or spot of the beam interacting with the capillaries and can variably be adjusted to track the amount and configuration of the capillaries.
[0034] An example to summarize for use in an embodiment utilizing CE and analyzing native unlabeled proteins is the capillaries would be un-coated on the outer surface, fused silica, utilizing a square geometry, an array amount of 10, configured in a stacked configuration and a transparent to UV coating on the inner surface.
[0035] Turning back to FIG. 1 , the coherent remnant beams 245 a, b, c, d after absorptive interaction in passing through the multichannel chamber 240 are separated into beams 245 b, c and d into beam trap 242 and beam 245 a to mirror 250 . Beam 245 a is passed through a collimating lens 260 which among other things is used to prevent too much signal divergence and to minimize optical interference between capillaries. The distance from the capillary window is important in bringing the beams to coherence and parallel without losing intensity. The beam 245 a is sent through a secondary beam blocker 265 to another reflective surface such as a minor 270 which shifts the beam into a secondary beam splitter 280 . The beam 275 is split to photodiode detector 290 as a control and beam 285 b is split to a multi photospectrometer 320 preferably a NMOS PDA to be detected, stored and analyzed among other data manipulations in the computer 310 . It is contemplated analog to digital converters would be used as needed by the application.
[0036] While the invention has been described in terms of various preferred embodiments and specific examples, the invention should be understood as not being limited by the foregoing detailed description, but as being defined by the appended claims and their equivalents.
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This invention relates to methods and apparatus of a combination of a single laser wave mixing technology with a diagnostic flow technologies with embodiments describing capillary electrophoresis. The unique combination of these technologies along with minute detection levels not yet been seen in the field.
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REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 10/810,744, filed Mar. 26, 2004, now U.S. Pat. No. 7,393,531 which is a continuation-in-part of application Ser. No. 10/762,129, filed Jan. 20, 2004, now U.S. Pat. No. 7,361,342 which is a continuation-in-part of application Ser. No. 10/743,451, filed Dec. 19, 2003, now abandoned, which is a continuation of application Ser. No. 10/348,231, filed Jan. 21, 2003, now U.S. Pat. No. 7,009,040, issued on Mar. 7, 2006, the contents of each of which are herein incorporated by reference.
FIELD OF THE INVENTION
This invention relates to the diagnosis and treatment of cancerous diseases, particularly to the mediation of cytotoxicity of tumor cells; and most particularly to the use of cancerous disease modifying antibodies (CDMAB), optionally in combination with one or more chemotherapeutic agents, as a means for initiating the cytotoxic response. The invention further relates to binding assays, which utilize the CDMAB of the instant invention.
BACKGROUND OF THE INVENTION
Melanoma-associated chondroitin sulfate proteoglycan (MCSP) was identified independently by several investigators who developed monoclonal antibodies to human metastatic melanoma cell lines. Several antibodies were found to react with a specific antigen associated with the melanoma cell surface. The independent development of these antibodies led to the multiplicity of names for the target antigen, all of which were subsequently determined to be MCSP. MCSP has therefore also been referred to as high molecular weight melanoma associated antigen (HMW-MAA), human melanoma proteoglycan (HMP), melanoma-associated proteoglycan antigen (MPG) and melanoma chondroitin sulfate proteoglycan (mel-CSPG), and has been identified as the antigen of various specific antibodies, some of which have been set out below. MCSP was also found to be over 80 percent homologous with the rat proteoglycan NG2 and is hence also referred to by that name.
MCSP is a glycoprotein-proteoglycan complex consisting of an N-linked glycoprotein of 250 kDa and a proteoglycan component >450 kDa. The core glycoprotein is present on the surface of melanoma cells, either as a free glycoprotein or modified by the addition of chondroitin sulfate. The molecular cloning of MCSP led to the identification of several structural features. There are 3 extracellular domains containing a total of 10 cysteines (5 potential disulfide bridges), 15 possible N-linked glycosylation sites, and 11 potential chondroitin sulfate attachment sites. The transmembrane segment has a single cysteine, however the functional significance of that residue has not been established. The cytoplasmic domain has 3 threonine residues that may serve as sites for phosphorylation by protein kinase C, although it has not yet been shown that MCSP is phosphorylated.
It has been shown that MCSP is expressed in the majority of melanoma cancers, and it was originally thought that it had a very limited distribution on normal cells and other tumor types. One early study that led to this conclusion used immunohistochemistry (IHC) on normal and tumor tissues fixed with formaldehyde or methanol in order to determine the distribution of MCSP using anti-MCSP antibody B5. In this study, antibody B5 was found to react with 17 out of 22 melanoma tumors tested, 2 out of 2 astrocytomas tested, and none of the 23 carcinomas tested. Out of 22 normal tissues tested, B5 was found to bind only skin keratinocytes, lung alveolar epithelium and capillary endothelium.
Another study examined the tissue distribution of MCSP as defined by anti-MCSP antibody 9.2.27 using frozen tissue sections. Again, reactivity was found in all melanoma tissues and cell lines tested, but there was no reactivity in any of the 6 various carcinoma tumors tested. Out of the 7 fetal tissues tested, reactivity was only observed in the skin and faintly in the aorta while in adult tissues; reactivity was only seen in 3 out of 13 tissues tested.
A subsequent study examined the distribution of MCSP using the anti-MCSP antibodies B5, 9.2.27, 225.28S and A0122, all of which recognize distinct epitopes of MCSP. This study was performed on frozen tissues. It was found that all of the anti-MCSP antibodies had similar staining patterns, reacting with normal and malignant tumors of neural, mesenchymal and epithelial origin, that were previously thought to be MCSP negative. Specifically, the antibody B5 reacted with various epithelial, connective, neural and muscular tissues in the 24 organs that were tested, and reacted with 28 out of 34 various tumors tested. The authors explained that the differences between their findings and previous reports were due to the use of improved and more consistent IHC techniques, noting that choice of fixative was important, presumably leading to the conclusion that an important characteristic of the MCSP antigen is its sensitivity to the processing steps involved in IHC.
A further study was carried out in order to localize MCSP at the ultrastructural level. Immunolocalization studies using electron microscopy demonstrated that MCSP was localized almost exclusively to microspikes, a microdomain of the melanoma cell surface that may play a role in cell-cell contact and cell-substratum adhesion.
The molecular cloning of MCSP in 1996 enabled northern blot analysis of MCSP expression in tumor cell lines and normal human tissues using MCSP cDNA probes. Out of 8 various tumor cell lines tested, expression of MCSP was observed only in the melanoma cell line. MCSP expression was not seen in any of the 16 normal adult and 4 normal fetal tissues tested. The discrepancies found in different studies of tissue localization of MCSP indicate that further study may be required to elucidate the actual expression patterns of this antigen or to account for the differences that have been reported.
Since proteoglycans have been known to mediate cell-cell and cell-extracellular matrix (ECM) interactions, the role of MCSP in these processes has been investigated. MCSP has been shown to stimulate α 4 β 1 -integrin mediated adhesion and spreading of melanoma cells, and it has also been proposed that signaling through the MCSP core protein induces recruitment and tyrosine phosphorylation of p130 cas which may regulate cell adhesion and motility, contributing to tumor invasion and metastasis. The combination of these results indicated that MCSP may function to enhance adhesion of melanoma cells by both activating integrins and stimulating pathways that lead to cytoskeletal rearrangement.
MCSP has also been found to associate with membrane-type 3 matrix metalloproteinase (MT3-MMP), likely through the chondroitin sulfate component of MCSP. It has been suggested that MT3-MMP expression in melanomas in vivo could promote the degradation of ECM proteins in the vicinity of the growing tumor, providing space in which the tumor can expand. Therefore, the association between MT3-MMP and MCSP may be an activation step to promote melanoma invasion.
Several in vitro assays using anti-MCSP antibodies have been carried out to examine the role of MCSP in processes linked to tumor invasion and metastasis. The role of MCSP in anchorage-independent growth was assessed using the antibody 9.2.27. Melanoma cells cultured in soft agar containing 9.2.27 showed a 67-74 percent specific decrease in their colony formation. These findings suggested that MCSP might be involved in cell-cell interaction, and contribute to anchorage-independent growth. The same authors also examined the effects of blocking MCSP with 9.2.27 in assays measuring the adhesion of M14 melanoma cells on basement membranes of bovine aorta endothelial (BAE) cells. The effect of 9.2.27 treatment was compared to treatment with a control monoclonal antibody W6/32 (directed against all class I histocompatibility antigens). M14 control cells and M14 cells pretreated with antibody were plated on basement membranes of BAE cells. A significant inhibition of 27 percent in cell adhesion was observed in 9.2.27 treated cells, whereas no significant effect was observed in W6/32 treated cells. A more striking effect of cell pretreatment with 9.2.27 was the inhibition of cell spreading which was verified at the ultrastructural level using scanning electron microscopy.
Many of the antibodies that were developed against melanoma cells and determined to specifically recognize MCSP have been tested in both in vitro and in vivo assays to determine their anti-cancer effects.
Monoclonal antibody 9.2.27 recognizes the core glycoprotein component of MCSP and was one of the first antibodies investigated for tumor suppressing properties. Bumol et al. investigated 9.2.27 and a diphtheria toxin A (DTA) conjugate of 9.2.27 for immunotherapy of melanoma tumors grown in nude mice. In vitro cytotoxicity assays were first carried out by measuring the effects of both 9.2.27 and 9.2.27-DTA conjugate on protein synthesis in M21 human melanoma cells as indicated by protein incorporation of [ 35 S]methionine. The 9.2.27-DTA conjugate significantly inhibited protein synthesis in M21 melanoma cells, though a greater effect was seen with unconjugated DTA. There was only minimal effect achieved by 9.2.27 alone. Both the 9.2.27 and 9.2.27-DTA conjugate were investigated for anti-tumor effects in human melanoma tumor-bearing nude mice. M21 tumor mince was implanted subcutaneously and allowed to establish growth for 3 days, then mice were treated at day 3 and at 3 day intervals thereafter with either 9.2.27 or 9.2.27-DTA conjugate. Tumor volumes of treated mice were compared to those of untreated control mice. At day 18 (the last day for which data was reported), 9.2.27 treated mice showed a 64 percent inhibition of tumor growth while 9.2.27-DTA conjugate treated mice showed a 52 percent inhibition of tumor growth, compared to untreated controls. In this initial study the authors concluded that 9.2.27 and 9.2.27-DTA conjugate were approximately equivalent in their effect on suppression of growth of M21 melanoma tumors in nude mice. While this initial study reports in vivo suppression of tumor growth by treatment with 9.2.27, several subsequent studies, including those by the same authors, have demonstrated that naked 9.2.27 did not exhibit any anti-tumor effects in vivo. Collectively, as outlined below, the experiments carried out to investigate the utility of using 9.2.27 to treat human tumors have demonstrated that, although cancer cells were targeted by 9.2.27, no anti-cancer activity resulted from treatment with the naked antibody.
A phase I clinical trial was carried out which was designed to give large doses of 9.2.27 in anticipation of later therapeutic studies with 9.2.27 immunoconjugates. Eight patients with malignant melanoma whose tumors reacted with 9.2.27 by flow cytometry and/or immunoperoxidase staining, received single doses of antibody intravenously, twice weekly on a dose escalating scale of 1, 10, 50, 100 and 200 mg. Although none of the patients experienced significant toxicity and 9.2.27 localized to the metastatic melanoma nodules, no clinical responses were observed.
In a later study, 9.2.27 was conjugated to the chemotherapeutic drug doxorubicin (DXR), and the conjugate was investigated for growth inhibition of melanoma in vitro and in vivo. Growth inhibition of M21 cells treated with the DXR-9.2.27 conjugate was measured using a [ 3 H]thymidine incorporation assay. The conjugate showed specific dose-dependent growth inhibition of the M21 target cells and no effect on an MCSP negative control cell line. No in vitro assays were carried out examining effects of 9.2.27 alone. To investigate the DXR-9.2.27 conjugate in vivo, M21 cells were injected subcutaneously and allowed to establish a tumor for 8-10 days. Injections were given intravenously at day 10 and at 3 day intervals thereafter for 30 days. Significant suppression of tumor growth was seen only in mice treated with the DXR-9.2.27 conjugate. Both DXR treatment alone and 9.2.27 treatment alone failed to suppress tumor growth; a mixture of 9.2.27 and DXR showed similar negative effects.
Another study was carried out investigating the effects of a 9.2.27 conjugate. Schrappe et al. conjugated the chemotherapeutic agent 4-desacetylvinblastine-3-carboxyhydrazide (DAVLBHY) to 9.2.27 and tested its effect on human gliomas. Nude mice were injected with U87MG (a human glioma cell line) cells subcutaneously and the animals were treated on days 2, 5, 7, and 9. Tumor volume was most effectively reduced by the 9.2.27-DAVLBHY conjugate. Control groups, which were treated with either PBS or 9.2.27 alone, developed fast growing tumors and there was no reduction in tumor volume in 9.2.27 treated mice compared to mice treated with PBS.
Antibody 225.28S was made against the human M21 melanoma cell line, and was initially described as reacting with a high molecular weight melanoma associated antigen. This molecule was subsequently shown to be the same molecule as MCSP. An early study tested the cytolytic ability of 225.28S, an IgG 2a , on a human melanoma cell line and compared it to another anti-MCSP antibody, clone 653.40S that was an IgG 1 . 225.28S and 653.40S were determined to recognize the same, or spatially close, antigenic determinants on MCSP. It was found that neither antibody could lyse melanoma cells in conjunction with complement in in vitro assays. Both antibodies could mediate lysis of target melanoma cells in an antibody-dependent cell-mediated (ADCC) cytotoxicity assay, with 225.28S exhibiting a higher lytic activity than 653.40S. However, lysis of melanoma cells was only obtained with a significantly higher effector/target cell ratio than had been reported by others using anti-melanoma antigen antibodies. The authors concluded that the lack of cytolytic activity of these antibodies in conjunction with human complement and the high effector/target cell ratio required for lysis to occur in ADCC suggested that the injection of monoclonal antibodies into melanoma patients was not likely to cause the destruction of tumor cells. The authors suggested that the immunotherapeutic use of these antibodies should be limited to utilizing them as carriers of radioisotope, chemotherapeutic or toxic agents.
Naked antibody 225.28S was investigated for its therapeutic potential in a phase I trial where it was delivered intravenously in 10 mg doses to 2 patients with end-stage melanoma. Although no clinically adverse or major toxic effects were noted that could be ascribed to the administration of the antibody, there was also no positive therapeutic response.
Antibody 225.28S was conjugated to purothionin, a low molecular weight polypeptide that is especially toxic to dividing cells, and was tested for its in vitro toxicity to the human melanoma cell line Colo 38. It was found that the culture of Colo 38 cells with the 225.28S-purothionin conjugate for 24 hr inhibited 3 H-thymidine uptake. In addition, the viability of Colo 38 cells was dramatically reduced in cultures incubated with the conjugate for 7 days. Although in vitro toxicity was observed, there was still a fraction of melanoma cells that survived the 225.28S-purothionin treatment. The authors suggested that the immunotherapy of malignant diseases may have to rely on cocktails of monoclonal antibodies to distinct tumor associated antigens as carriers of toxic agents, indicating that 225.8S conjugate alone would not be sufficient for treatment of cancer. The effect of 225.28S-purothionin conjugate treatment was evaluated on the growth of human melanoma in nude mice. Colo 38 cells were implanted either subcutaneously or intraperitoneally in nude mice. Treatments were made on days 1, 3 and 5 for the intraperitoneal implanted mice and on days 1, 3, 5 and 20 for the subcutaneous implanted mice. Survival was monitored for all mice. The only statistically significant prolongation of survival was observed in the intraperitoneal implanted mice that were treated with the 225.28S-purothionin conjugate. 225.28S alone, purothionin alone or a mixture of 225.28S and purothionin did not enhance survival in either the intraperitoneal or the subcutaneous implanted mice. Tumor volume was also recorded for the subcutaneous implanted mice and it was found that only the 225.28S-purothionin conjugate treatment significantly reduced tumor volume. Treatment with 225.28S alone did not result in a reduction of tumor volume.
225.28S was also conjugated to the chemotherapeutic drug methotrexate (MTX) and its effects on tumor growth were investigated in vivo. Nude mice were inoculated subcutaneously with M21 human melanoma cells and treated on days 1, 4, 7, 10 and 14. The MTX-225.28S conjugate was the only treatment that inhibited tumor growth. 225.28S alone, MTX alone or a mixture of 225.28S and MTX failed to inhibit tumor growth.
225.28S was used in a study designed to investigate the potential toxic effects in humans due to the administration of a reagent of a xenogenic nature. 85 patients with metastatic cutaneous melanoma were administered either intact 225.28S or the F(ab′) 2 fragment that were labeled with 131 I, 123 I, 111 In, or 99 Tc. The amount of injected antibody ranged from 14 to 750 μg. No clinically detectable side effects were observed in any of the patients. No clinical response was reported, though it was not necessarily anticipated as this study was designed for toxologic purposes.
225.28S was used to generate murine anti-idiotypic monoclonal antibodies including the antibody MF11-30, which bears the mirror image of MCSP. MF11-30 has been shown to induce the development of anti-MCSP antibodies in both a syngeneic and xenogeneic system. MF11-30 was tested in 2 clinical trials in escalating doses designed to test the toxicity and response in patients with advanced malignant melanoma. In both studies there were few side effects due to administration of the antibody and the therapy was well tolerated. In the second trial the average survival of 7 patients who developed anti-anti-idiotypic antibodies with a titer of at least 1:8 and displayed no marked changes in the level of serum MCSP was 55 weeks (range 16-95), which was significantly higher than the remaining 12 patients (who developed anti-antiidiotypic antibodies with a titer of 1:4 or less and displayed an increase in the serum level of MCSP) whose average survival was 19 weeks (range 8-57).
Antibody 763.74 was also generated against melanoma cells and recognizes MCSP. There have not been any reports of in vitro or in vivo anti-cancer effects of antibody 763.74, however this antibody was also used to generate murine anti-idiotypic monoclonal antibodies. One of these antibodies, MK2-23, bears the internal image of the determinant defined by the anti-MCSP antibody 763.74. In preclinical experiments, immunization with MK2-23 was shown to induce the development of anti-MCSP antibodies in both a syngeneic host (BALB/c mice) and in a xenogenic host (rabbit). The immunogenicity of MK2-23 was markedly enhanced when it was conjugated to the carrier protein keyhole limpet hemocyanin (KLH) and administered with an adjuvant. A clinical trial was carried out to characterize the humoral response induced by MK2-23 in patients with melanoma. 25 patients with stage IV melanoma were immunized on days 0, 7 and 28 with 2 mg subcutaneous injections of MK2-23 conjugated to KLH and mixed with Bacillus Calmette Guerin (BCG). Additional injections were given if the titer of anti-anti-idiotypic antibodies was low. Approximately 60 percent of the patients who were immunized with MK2-23 developed anti-MCSP antibodies, although the level and affinity of the anti-MCSP antibodies were low. It was found that survival of patients who developed anti-MCSP antibodies after immunizaiton with MK2-23 was significantly longer than those who did not. The median survival of patients who developed anti-MCSP antibodies was 52 weeks (range 19-93) while the median survival of the 9 patients without detectable anti-MCSP antibodies in their sera was 19 weeks (range 9-45). Three patients who developed anti-MCSP antibodies experienced a partial remission of their disease. Although promising results were achieved in this study, 40 percent of the patients immunized with MK2-23 did not respond with detectable anti-MCSP antibodies. As well, the 3 patients who had achieved partial remission all eventually experienced recurrence of disease. An attempt was made to increase the immunogenicity of MK2-23 by pretreatment of patients with a low dose of cyclophosphamide (CTX), which had been reported to enhance the cellular and humoral response to tumor associated antigens by selectively inactivating some sets of suppressor cells. However, no effects of pretreatment with CTX on the immunogenicity of MK2-23 were detected.
Monoclonal antibody 48.7 was developed against the human metastatic melanoma cell line M1733 and was reported to react against a molecule subsequently determined to be MCSP. 48.7 was administered in a phase I clinical trial in combination with the murine monoclonal antibody 96.5, which is directed against the transferrin-like cell surface glycoprotein p97 that is present on human melanomas. Five patients received 2 mg each of mAbs 96.5 and 48.7 on day 1, 10 mg each on day 2, and 25 mg each on days 3 through 10. Treatment was well tolerated; however there were no clinical responses to treatment and disease progression occurred in all patients. These two antibodies were investigated in a separate clinical trial where 3 patients with melanoma metastatic to the central nervous system were treated with radiolabeled Fab fragments of either one of these antibodies. Two patients received 5 mg doses of 131 I-labeled Fab fragment of 48.7 in conjunction with osmotic opening of the blood-brain barrier (BBB) in an effort to enhance entry of the antibody into tumors in the brain. The osmotic BBB modification increased the delivery of Fab to the tumor-bearing hemisphere and spinal fluid, but clear persistent localization of the antibody to the tumor was not shown. The authors hypothesized that the lack of localization may have been due to an inadequate dose of the antibody.
Melimmune was a dual preparation of two murine anti-idiotypic antibodies, Melimmune-1 (I-Mel-1) and Melimmune-2 (I-Mel-2), which mimic separate epitopes of MCSP. I-Mel-1 was a subclone of the anti-idiotypic antibody MF11-30, which was developed against the anti-MCSP antibody 225.28 (as previously discussed). I-Mel-1 was shown to induce an anti-MCSP response in rabbits. I-Mel-2 was an anti-idiotypic antibody developed against the anti-MCSP antibody MEM136, which reacts to a different epitope on MCSP than does 225.28. I-Mel-2 was also shown to induce an anti-MCSP response in rabbits. The Melimmune preparation, which contained a 1:1 composition of I-Mel-1 and I-Mel-2, was tested in a phase I trial of 21 patients with resected melanoma without evidence of metastatic disease. Detailed immune response analysis was reported for 12 of these patients enrolled in a single institution. Patients received Melimmune on 1 of 2 treatment schedules with doses that ranged from 0.2 to 4.0 mg (0.1 to 2.0 mg each of I-Mel-1 and I-Mel-2). All patients developed both anti-I-Mel-1 and anti-I-Mel-2 antibodies with the peak antibody response to I-Mel-2 greater than that to I-Mel-1 in 10 out of 12 patients. However, this study was unable to demonstrate induction of specific antibodies to MCSP since none of the patient's sera was able to inhibit either binding of radiolabeled 225.28 to MCSP expressing Mel-21 cells, or binding of radiolabeled MEM136 to Mel-21 cells. A direct cell binding assay was also used to assay for the presence of anti-MCSP antibodies in patients sera; however, there was no difference in the binding of preimmune sera compared to postimmune sera to M21 cells in a FACS based assay.
I-Mel-2 was tested in a separate clinical trial where 26 patients with metastatic melanoma were treated with 2 mg I-Mel-2 and either 100 or 250 μg of the adjuvant SAF-m delivered intramuscularly biweekly for 4 weeks and then bimonthly until disease progression. Anti-MCSP antibodies were detected in 5 of the 26 patients using an inhibition radioimmunoassay. Of the 5 patients with detectable anti-MCSP antibodies, 1 patient experienced a complete remission, 1 had stable disease and the other 3 had progressive disease. The patient with complete remission had the highest titer of anti-MCSP antibodies (1:1500).
PRIOR PATENTS
U.S. Pat. No. 5,270,202 (and its related patents: WO9216646A1, EP0576570A1) teaches an anti-idiotypic antibody, IMelpg2 (also known as “IM32”) to MEM136, an antibody directed to human melanoma-associated proteoglycan (also known as “HMW-MAA”). The IMelpg2 antibody was shown to be directed to MEM136 specifically, and suggested to be of use for the diagnosis and treatment of disease in which cells expressed the MPG epitope. Although there was an effect of IMelpg2 on tumor cell invasion, as determined by in vitro assays it was neither the most effective antibody tested, nor was there indications of in vivo anti-tumor effects despite showing an Ab3 response.
EP0380607B1 teaches anti-idiotypic antibodies to the Mab 225.28 which has specificity for an undefined epitope of HMW-MAA. These antibodies are useful as active immunotherapy for melanoma. Both MF11-30 and IMelpg1, and polyclonal anti-idiotypic antibodies to 225.28 have been reported and evaluated in animal models with MF11-30 undergoing clinical trials in melanoma patients, although there was no supporting data. MF11-30 can induce 225.28 idiotypic antibodies. The IMelpg1 cell line was derived from treating the MF11-30 cell line with BM Cycline and testing for the absence of mycoplasma contamination. Although antibodies to IMelpg1 can be induced in rabbit sera, and be shown to bind to the Colo38 melanoma cell, there was no indication of tumorcidal activity, either in vitro or in vivo.
U.S. Pat. No. 4,879,225 teaches the production of antibodies from insoluble immune complexes. In this case rat anti-idiotypic antibodies to Mab 9.2.27, an antibody directed against the HMW-MAA, were generated by immoblizing 9.2.27 on protein A-Sepharose for use as an antigen. Antibodies to melanoma cells were produced using a variety of cell or cell lysate complexes conjugated to Sepharose. Murine monoclonal antibodies that bound to melanoma cells, but not normal T-cells or B-cells were compared to 9.2.27. Those that had similar properties to 9.2.27 were selected for further characterization: NR-ML-02, NR-ML-03, NR-ML-04, NR-ML-05, NR-ML-06. Each of these antibodies were positive in a sandwich ELISA assay using 9.2.27 as the capture antibody and solublized SK MEL-28 melanoma membranes as an antigen source. Further these antibodies were characterized as recognizing melanoma tumor cells, and also reacting with smooth muscle and endothelial cells. An additional 61 anti-proteoglycan antibodies were produced with 10 recognizing the same determinant as NR-ML-02/NR-ML-04, 3 antibodies recognized the same determinant as NR-ML-03 or NR-ML-05; 45 did not recognize the same epitope as determined by the 5 antibodies. In U.S. Pat. No. 5,084,396 these antibodies were radiolabelled and compared with 9.2.27 for tumor uptake in nude mice bearing melanoma xenografts. The tumor uptake was the greatest for NR-ML-05 and NR-ML-02, then 9.2.27, and then NR-ML-02. In neither of these inventions were there indications that these antibodies produced reduction in tumor burden of cancerous disease, nor enhanced survival of mammals having cancerous disease.
U.S. Pat. No. 5,034,223 teaches a method of enhancing delivery of conjugated antibodies to tissues bearing tumor-associated antigens by pretreating with a non-conjugated blocking antibody. Antibodies to HMW-MAA, 9.2.27 and NR-ML-05, were conjugated to technicium 99 (Tc-99) and were administered in the clinical setting after prior administration of unlabelled Mab NR-2AD, an antibody with an anti-idiotype specific for only 1 patient's B-cell lymphoma. Since these studies were designed using Tc-99 as a reporter radioisotope, which does not have cytotoxic, or radioablative effects there was no evidence of anti-tumor effects although there was enhanced uptake of the anti-HMW-MAA antibodies through the use of this process.
U.S. Pat. No. 5,580,774 teaches the construction of a chimeric antibody using the antibody genes that encode Mab 9.2.27. No disclosures regarding the diagnosis or treatment of cancerous disease using the chimeric antibody were made.
U.S. Pat. Nos. 5,493,009 and 5,780,029 teaches the murine anti-idiotypic antibody MK2-23, and its conjugates, directed against an anti-HMW-MAA antibody, 763.74. MK2-23 can bind directly to 763.74 and inhibit 763.74 binding to Colo 38 melanoma cells. Further, Ab3 elicited by MK2-23 can directly bind HMW-MAA and can competitively inhibit 763.74 binding to Colo 38 melanoma cells. Active immunotherapy was carried out in a clinical trial in stage IV melanoma patients with MK2-23. In 89 percent of patient's post-immunization sera reacted with Colo 38 melanoma cells, and inhibited binding of 763.74 to Colo 38 cells suggesting induction of Ab3 antibodies. In 6 of 15 patients there was a reduction in size of metastatic lesions reported but study details were not furnished. The specificity of the antibodies in patient sera was partially characterized and it is unclear whether Ab3 antibodies, to the extent that they were present, were responsible for any of the clinical response observed, since the 763.74 antibody did not have innate anti-tumor effects. U.S. Pat. No. 5,866,124 teaches the chimeric anti-idiotypic antibody MK2-CHγ1, and its derivatives, directed against an anti-HMW-MAA antibody, 763.74, derived from MK2-23.
A number of inventions, such as U.S. Pat. Nos. 5,017,693, 5,707,603, 5,817,774, 6,248,870, 5,112,954, 6,238,667, teach conjugating compounds to antibodies directed against HMW-MAA but fail to disclose their utility in treatment of cancerous disease. Importantly, were these antibodies effective as anti-cancer therapies alone, they would not require a conjugate to impart either cytotoxic or cytostastic effects.
These patents and patent applications identify MCSP antigens and related antibodies but fail to disclose the isolated monoclonal antibody of the instant invention, or to teach or suggest the utility of the isolated monoclonal antibody of the instant invention.
SUMMARY OF THE INVENTION
The instant inventors have previously been awarded U.S. Pat. No. 6,180,357, entitled “Individualized Patient Specific Anti-Cancer Antibodies” directed to a process for selecting individually customized anti-cancer antibodies, which are useful in treating a cancerous disease. For the purpose of this document, the terms “antibody” and “monoclonal antibody” (mAb) may be used interchangeably and refer to intact immunoglobulins produced by hybridomas (e.g. murine or human), immunoconjugates and, as appropriate, immunoglobulin fragments and recombinant proteins derived from said immunoglobulins, such as chimeric and humanized immunoglobulins, F(ab′) and F(ab′) 2 fragments, single-chain antibodies, recombinant immunoglobulin variable regions (Fv)s, fusion proteins etc. It is well recognized in the art that some amino acid sequence can be varied in a polypeptide without significant effect on the structure or function of the protein. In the molecular rearrangement of antibodies, modifications in the nucleic or amino acid sequence of the backbone region can generally be tolerated. These include, but are not limited to, substitutions (preferred are conservative substitutions), deletions or additions. Furthermore, it is within the purview of this invention to conjugate standard chemotherapeutic modalities, e.g. radionuclides, with the CDMAB of the instant invention, thereby focusing the use of said chemotherapeutics. The CDMAB can also be conjugated to toxins, cytotoxic moieties, enzymes e.g. biotin conjugated enzymes, or hematogenous cells, thereby forming antibody conjugates.
This application utilizes the method for producing patient specific anti-cancer antibodies as taught in the '357 patent for isolating hybridoma cell lines which encode for cancerous disease modifying monoclonal antibodies. These antibodies can be made specifically for one tumor and thus make possible the customization of cancer therapy. Within the context of this application, anti-cancer antibodies having either cell-killing (cytotoxic) or cell-growth inhibiting (cytostatic) properties will hereafter be referred to as cytotoxic. These antibodies can be used in aid of staging and diagnosis of a cancer, and can be used to treat tumor metastases.
The prospect of individualized anti-cancer treatment will bring about a change in the way a patient is managed. A likely clinical scenario is that a tumor sample is obtained at the time of presentation, and banked. From this sample, the tumor can be typed from a panel of pre-existing cancerous disease modifying antibodies. The patient will be conventionally staged but the available antibodies can be of use in further staging the patient. The patient can be treated immediately with the existing antibodies and/or a panel of antibodies specific to the tumor can be produced either using the methods outlined herein or through the use of phage display libraries in conjunction with the screening methods herein disclosed. All the antibodies generated will be added to the library of anti-cancer antibodies since there is a possibility that other tumors can bear some of the same epitopes as the one that is being treated. The antibodies produced according to this method may be useful to treat cancerous disease in any number of patients who have cancers that bind to these antibodies.
Using substantially the process of U.S. Pat. No. 6,180,357, and as disclosed in Ser. No. 10/348,231, the mouse monoclonal antibody 11BD-2E11-2 was obtained following immunization of mice with cells from a patient's breast tumor biopsy. The 11BD-2E11-2 antigen was expressed on the cell surface of several human cell lines from different tissue origins. The breast cancer cell line MCF-7 and ovarian cancer cell line OVCAR-3 were susceptible to the cytotoxic effects of 11BD-2E11-2 in vitro.
The result of 11BD-2E11-2 cytotoxicity against MCF-7 and OVCAR-3 cells in culture was further extended by its anti-tumor activity towards these cancer cells when transplanted into mice (as disclosed in Ser. No. 10/762,129). Pre-clinical xenograft tumor models are considered valid predictors of therapeutic efficacy.
In a preventative in vivo model of human breast cancer, 11BD-2E11-2 prevented tumor growth and reduced tumor burden (as disclosed in Ser. No. 10/762,129). At day 51 (soon after last treatment), the mean tumor volume in the 11BD-2E11-2 treated group was 20 percent of the isotype control. Monitoring continued past 280 days post-treatment. 40 percent of the 11BD-2E11-2 treatment group was still alive at over 7.5 months post-implantation. Conversely, the isotype control group had 100 percent mortality after 6.5 months post-treatment. Therefore 11BD-2E11-2 enhanced survival and decreased the tumor burden compared to the control-treated groups in a well-established model of human breast cancer.
To determine if 11BD-2E11-2 was efficacious in more than one model of human breast cancer, its anti-tumor activity against MDA-MB-468 (MB-468) cells in an established model of breast cancer was determined (as disclosed in Ser. No. 10/810,744). 11BD-2E11-2 reduced tumor growth by 25 percent in comparison to the buffer control. Therefore, 11BD-2E11-2 was effective in preventing tumor growth in an established as well as a preventative breast cancer xenograft model. In addition, 11BD-2E11-2 displayed anti-tumor activity in at least two different models of breast cancer.
In addition to the beneficial effects in a model of human breast cancer, 11BD-2E11-2 treatment also had anti-tumor activity against OVCAR-3 cells in a preventative ovarian cancer model (as disclosed in Ser. No. 10/762,129). In this model, body weight was used as a surrogate measure of tumor progression. At day 80 post-implantation (16 days after the end of treatment) the mice in the treated group had 87.6 percent the mean body weight of the control group (p=0.015). Thus, 11BD-2E11-2 treatment was efficacious as it delayed tumor progression compared to the buffer control treated group in a well-established model of human ovarian cancer. The anti-tumor activities of 11BD-2E11-2, in several different cancer models, make it an attractive anti-cancer therapeutic agent.
To determine if 11BD-2E11-2 was efficacious in more than one model of human ovarian cancer, its anti-tumor activity against ES-2+SEAP cells (ES-2 ovarian cancer cells transfected with human placental secreted alkaline phosphatase (SEAP)) in an established model of ovarian cancer was determined (as disclosed in Ser. No. 10/810,744). 11BD-2E11-2 enhanced survival in a cohort of mice in the treatment group in comparison to buffer control. In addition, 1 mouse within the 11BD-2E11-2 treatment group displayed greatly reduced circulating SEAP levels after treatment. Circulating SEAP levels can be used as an indicator of tumor burden. Therefore, 11BD-2E11-2 was effective in preventing tumor growth in an established as well as a preventative ovarian cancer xenograft model. In addition, 11BD-2E11-2 displayed anti-tumor activity in two different models of human ovarian cancer.
Biochemical data indicated that the antigen for 11BD-2E11-2 is MCSP (as disclosed in Ser. No. 10/810,744) and previous immunohistochemical analysis and in vitro studies performed in other laboratories have demonstrated the expression of MCSP on melanoma cells and have indicated a role for MCSP in tumor adhesion, invasion and metastasis. Consequently, the efficacy of 11BD-2E11-2 was determined in both a preventative and established model of human melanoma. In the preventative model of melanoma, on day 55 (5 days after the end of treatment), the mean tumor volume in the 11BD-2E11-2 treated group was 58 percent of the buffer control treated group (p=0.046). In the established model, the antibody 11BD-2E11-2 suppressed tumor growth by 49 percent in comparison to the buffer control treated group after the treatment period. The result did not reach significance (p=0.1272) due to the limited number of animals in this experiment, but the trend was clear. Therefore, 11BD-2E11-2 was effective in preventing tumor growth in an established as well as a preventative melanoma cancer xenograft model. In addition, 11BD-2E11-2 displayed anti-tumor activity in two different models of human breast and ovarian cancer and in a human melanoma model.
In order to validate the 11BD-2E11-2 epitope as a drug target, the expression of 11BD-2E11-2 antigen in frozen normal human tissues was determined (as disclosed in Ser. No. 10/810,744). By IHC staining with 11BD-2E11-2, the majority of the tissues failed to express the 11BD-2E11-2 antigen, including the cells of the vital organs, such as the liver, kidney and heart. Albeit, there was staining to the smooth muscle fibers of blood vessels in almost all of the tissues. There was also epithelial staining for some of the tissues.
Localization of the 11BD-2E11-2 antigen and its prevalence within breast cancer patients is important in assessing the benefits of 11BD-2E11-2 immunotherapy to patients and designing effective clinical trials. To address 11BD-2E11-2 antigen expression in breast tumors from cancer patients, tumor tissue samples from 8 (7 additional samples were completely detached or not representative of the tumor on the microarray slide) individual breast cancer patients were screened for expression of the 11BD-2E11-2 antigen (as disclosed in Ser. No. 10/810,744). The results of the study showed that 62 percent of tissue samples positively stained for the 11BD-2E11-2 antigen. Expression of 11BD-2E11-2 within patient samples appeared specific for cancer cells as staining was restricted to malignant cells. In addition, 11BD-2E11-2 stained 0 of 3 (2 additional samples again were completely detached from the microarray slide) samples of normal tissue from breast cancer patients. When tumors were analyzed based on their stage, or degree to which the cancer advanced, results did not suggest a trend towards greater positive expression with higher tumor stage for 11BD-2E11-2. However, the result was limited by the small sample size.
Localization of the 11BD-2E11-2 antigen and its prevalence within melanoma cancer patients population was determined because the antigen for 11BD-2E11-2 is MCSP (as disclosed in Ser. No. 10/810,744) and that previous immunohistochemical analysis and in vitro studies performed in other laboratories have demonstrated the expression of MCSP on melanoma cells. This is important in assessing the benefits of 11BD-2E11-2 immunotherapy for melanoma patients and designing effective clinical trials. To address 11BD-2E11-2 antigen expression in melanoma tumors from cancer patients, tumor tissue samples from 33 individual melanoma cancer patients were assessed for expression of the 11BD-2E11-2 antigen. The results of the study showed that 67 percent of tissue samples stained positively for the 11BD-2E11-2 antigen. Expression of 11BD-2E11-2 within patient samples appeared specific for cancer cells as staining was restricted to malignant cells. In addition, 11BD-2E11-2 stained 0 of 6 available samples of normal tissue from melanoma cancer patients.
Biochemical data indicate that the antigen recognized by 11BD-2E112 is MCSP (as disclosed in Ser. No. 10/810,744). This was supported by studies showing that 11BD-2E11-2 immunoprecipitated protein was recognized by an antibody to the rat homologue of MCSP, and that anti-MCSP immunoprecipitated protein was recognized by 11BD-2E11-2. These IHO and biochemical results demonstrate that 11BD-2E11-2 bound to the MCSP antigen. Thus, the preponderance of evidence showed that 11BD-2E11-2 mediated anti-cancer effects through ligation of a unique epitope present on MCSE. Additional biochemical data, as outlined herein, also demonstrate that the antigen recognized by 11BD-2E11-2 is MCSP. These antibody epitope mapping results indicated that 11BD-2E11-2 may bind to a discontinuous epitope with two major binding sites.
In toto, this data demonstrates that the 11BD-2E11-2 antigen is a cancer associated antigen and is expressed in humans, and is a pathologically relevant cancer target. Further, this data also demonstrates the binding of the 11BD-2E11-2 antibody to human cancer tissues, and can be used appropriately for assays that can be diagnostic, predictive of therapy, or prognostic. In addition, the cell localization of this antigen is indicative of the cancer status of the cell due to the lack of expression of the antigen in most non-malignant cells, and this observation permits the use of this antigen, its gene or derivatives, its protein or its variants to be used for assays that can be diagnostic, predictive of therapy, or prognostic.
A number of distinct anti-MCSP antibodies have been developed and tested in many in vitro and in vivo systems. In pre-clinical models, with the exception of one study that was not reproduced, naked anti-MCSP antibodies have been shown to be ineffective in tumor reduction or enhancement of survival in several different melanoma models and one glioma model; other cancer types have not been studied with anti-MCSP antibodies. All trials of naked anti-MCSP antibodies in humans have failed to result in any positive clinical outcomes. Naked 11BD-2E11-2 has been shown to enhance survival and decrease tumor burden in murine models of human breast cancer. 11BD-2E11-2 has also inhibited tumor progression and enhanced survival in murine models of human ovarian cancer. Anti-MCSP antibodies have been conjugated to numerous toxic or chemotherapeutic agents, and these conjugates have demonstrated positive in vivo results when tested in murine models of melanoma. There have been no reports of anti-MCSP conjugates tested in humans, so the safety of these conjugates is not known. Delivery of monoclonal antibody alone however has been well tolerated with little, if any associated toxicity. Therefore if treatment of a cancer patient with a naked anti-MCSP antibody could result in a positive clinical outcome, it would be beneficial and an improvement upon what is currently available. Conjugation to a toxic agent is not required for 11BD-2E11-2 to exhibit anti-cancer activity; therefore the specific safety concerns associated with administration of antibody-toxin conjugate are not applicable. Many anti-MCSP antibodies have also been used to generate anti-idiotypic antibodies, which have been tested in both animals and humans. In small non-blinded trials, when the immunization of patients with anti-idiotypic antibodies resulted in a detectable anti-MCSP immune response, there was an increase in median survival of these patients compared to patients who did not develop a specific immune response. In the examples given, targeting MCSP to obtain a positive clinical response may result through the administration of anti-idiotypic antibodies. A problem with this approach is that not all patients who were immunized with the anti-idiotypic antibodies developed an anti-MCSP response. Therefore if an anti-MCSP antibody were available that could result in positive clinical outcomes upon direct administration, this would overcome the problem of relying on a patient's own immune response for producing a clinical benefit. 11BD-2E11-2 is such an antibody as it directly targets MCSP and exhibits anti-cancer effects in pre-clinical xenograft tumor models, which are considered valid predictors of therapeutic efficacy.
In all, this invention teaches the use of the 11BD-2E11-2 antigen as a target for a therapeutic agent, that when administered can reduce the tumor burden (thereby delaying disease progression) of a cancer expressing the antigen in a mammal, and can also lead to a prolonged survival of the treated mammal. This invention also teaches the use of a CDMAB (11BD-2E11-2), and its derivatives, to target its antigen to reduce the tumor burden of a cancer expressing the antigen in a mammal, and to prolong the survival of a mammal bearing tumors that express this antigen. Furthermore, this invention also teaches the use of detecting the 11BD-2E11-2 antigen in cancerous cells that can be useful for the diagnosis, prediction of therapy, and prognosis of mammals bearing tumors that express this antigen.
If a patient is refractory to the initial course of therapy or metastases develop, the process of generating specific antibodies to the tumor can be repeated for re-treatment. Furthermore, the anti-cancer antibodies can be conjugated to red blood cells obtained from that patient and re-infused for treatment of metastases. There have been few effective treatments for metastatic cancer and metastases usually portend a poor outcome resulting in death. However, metastatic cancers are usually well vascularized and the delivery of anti-cancer antibodies by red blood cells can have the effect of concentrating the antibodies at the site of the tumor. Even prior to metastases, most cancer cells are dependent on the host's blood supply for their survival and anti-cancer antibodies conjugated to red blood cells can be effective against in situ tumors as well. Alternatively, the antibodies may be conjugated to other hematogenous cells, e.g. lymphocytes, macrophages, monocytes, natural killer cells, etc.
There are five classes of antibodies and each is associated with a function that is conferred by its heavy chain. It is generally thought that cancer cell killing by naked antibodies are mediated either through antibody-dependent cell-mediated cytotoxicity (ADCC) or complement-dependent cytotoxicity (CDC). For example murine IgM and IgG2a antibodies can activate human complement by binding the C-1 component of the complement system thereby activating the classical pathway of complement activation which can lead to tumor lysis. For human antibodies, the most effective complement-activating antibodies are generally IgM and IgG1. Murine antibodies of the IgG2a and IgG3 isotype are effective at recruiting cytotoxic cells that have Fc receptors which will lead to cell killing by monocytes, macrophages, granulocytes and certain lymphocytes. Human antibodies of both the IgG1 and IgG3 isotype mediate ADCC.
Another possible mechanism of antibody-mediated cancer killing may be through the use of antibodies that function to catalyze the hydrolysis of various chemical bonds in the cell membrane and its associated glycoproteins or glycolipids, so-called catalytic antibodies.
There are two additional mechanisms of antibody-mediated cancer cell killing which are more widely accepted. The first is the use of antibodies as a vaccine to induce the body to produce an immune response against the putative antigen that resides on the cancer cell. The second is the use of antibodies to target growth receptors and interfere with their function or to down regulate that receptor so that its function is effectively lost.
The clinical utility of a cancer drug is based on the benefit of the drug under an acceptable risk profile to the patient. In cancer therapy survival has generally been the most sought after benefit, however there are a number of other well-recognized benefits in addition to prolonging life. These other benefits, where treatment does not adversely affect survival, include symptom palliation, protection against adverse events, prolongation in time to recurrence or disease-free survival, and prolongation in time to progression. These criteria are generally accepted and regulatory bodies such as the U.S. Food and Drug Administration (F.D.A.) approve drugs that produce these benefits (Hirschfeld et al. Critical Reviews in Oncology/Hematolgy 42:137-143 2002). In addition to these criteria it is well recognized that there are other endpoints that may presage these types of benefits. In part, the accelerated approval process granted by the U.S. F.D.A. acknowledges that there are surrogates that will likely predict patient benefit. As of year-end (2003), there have been sixteen drugs approved under this process, and of these, four have gone on to full approval, i.e., follow-up studies have demonstrated direct patient benefit as predicted by surrogate endpoints. One important endpoint for determining drug effects in solid tumors is the assessment of tumor burden by measuring response to treatment (Therasse et al. Journal of the National Cancer Institute 92(3):205-216 2000). The clinical criteria (RECIST criteria) for such evaluation have been promulgated by Response Evaluation Criteria in Solid Tumors Working Group, a group of international experts in cancer. Drugs with a demonstrated effect on tumor burden, as shown by objective responses according to RECIST criteria, in comparison to the appropriate control group tend to, ultimately, produce direct patient benefit. In the pre-clinical setting tumor burden is generally more straightforward to assess and document. In that pre-clinical studies can be translated to the clinical setting, drugs that produce prolonged survival in pre-clinical models have the greatest anticipated clinical utility. Analogous to producing positive responses to clinical treatment, drugs that reduce tumor burden in the pre-clinical setting may also have significant direct impact on the disease. Although prolongation of survival is the most sought after clinical outcome from cancer drug treatment, there are other benefits that have clinical utility and it is clear that tumor burden reduction, which may correlate to a delay in disease progression, extended survival or both, can also lead to direct benefits and have clinical impact (Eckhardt et al. Developmental Therapeutics: Successes and Failures of Clinical Trial Designs of Targeted Compounds; ASCO Educational Book, 39 th Annual Meeting, 2003, pages 209-219).
Accordingly, it is an objective of the invention to utilize a method for producing cancerous disease modifying antibodies from cells derived from a particular individual which are cytotoxic with respect to cancer cells while simultaneously being relatively non-toxic to non-cancerous cells, in order to isolate hybridoma cell lines and the corresponding isolated monoclonal antibodies and antigen binding fragments thereof for which said hybridoma cell lines are encoded.
It is an additional objective of the invention to teach CDMAB and antigen binding fragments thereof.
It is a further objective of the instant invention to produce CDMAB whose cytotoxicity is mediated through ADCC.
It is yet an additional objective of the instant invention to produce CDMAB whose cytotoxicity is mediated through CDC.
It is still a further objective of the instant invention to produce CDMAB whose cytotoxicity is a function of their ability to catalyze hydrolysis of cellular chemical bonds.
A still further objective of the instant invention is to produce CDMAB which are useful in a binding assay for diagnosis, prognosis, and monitoring of cancer.
Other objects and advantages of this invention will become apparent from the following description wherein, by way of illustration and example, certain embodiments of this invention are set forth.
BRIEF DESCRIPTION OF THE FIGURES
The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
FIG. 1 . Western blot of MDA-MB-231 (Lane 1) or OVCAR-3 (Lane 2) membranes probed with 11BD-2E11-2. Membrane proteins were separated under reducing conditions. Molecular weight markers are indicated on the right.
FIG. 2 . Effect of deglycosylation on the binding of 11BD-2E11-2 to MDA-MB-231 membranes. 11BD-2E11-2 binding to MDA-MB-231 membranes that were incubated in deglycosylation buffer only (Lane 1), in a combination of PNGase F, endo-o-glycosidase, sialidase, galactosidase and glucosaminodase (Lane 2), in a combination of PNGase, endo-o-glycosidase and sialidase (Lane 3), in sialidase only (Lane 4), in endo-o-glycosidase only (Lane 5), and in PNGase only (Lane 6).
FIG. 3 . SDS-PAGE (Panel A) and Western blot (Panel B) of MDA-MB-231 membrane proteins immunoprecipitated with 11BD-2E11-2. Lane 1 represents the molecular weight standard, Lane 2 the MDA-MB-231 membrane proteins, Lane 3 the 11BD-2E11-2 immunoprecipitated material and Lane 4 the isotype control immunoprecipitated material.
FIG. 4 . Western blots of proteins probed with 11BD-2E11-2 (Panel A), IgG1 isotype control (clone 107.3, Panel B), anti-rat NG2 (polyclonal, Panel C), normal rabbit IgG (Panel D), anti-MCSP (clone 9.2.27, Panel E) and IgG2a isotype control (clone G155-228, Panel F). Lane 1: 11BD-2E11-2 immunoprecipitate, Lane 2: IgG1 isotype control (clone 107.3) immunoprecipitate, Lane 3: anti-MCSP (clone 9.2.27) immunoprecipitate, Lane 4: IgG2a isotype control (clone G155-228) immunoprecipitate, Lane 5: MDA-MB-231 membranes and Lane 6: sample buffer only (negative control).
FIG. 5 . Intensity of binding (Boehringer light units) of 11BD-2E11-2-HRP to MCSP peptide array.
FIG. 6 . Representative FACS histograms of 11BD-2E11-2, isotype control or anti-EGFR directed against several cancer cell lines and non-cancer cells.
FIG. 7 . Representative micrographs showing the binding pattern obtained with 11BD-2E11-2 (A) and the isotype control antibody (B) on tissues sections of heart from a frozen normal human tissue array. There is no staining of 11BD-2E11-2 to cardiac muscle fibers. Magnification is 200×.
FIG. 8 . Representative micrographs showing the binding pattern obtained with 11BD-2E11-2 (A), anti-actin (B) and the isotype control antibody (C) on tissues sections of skeletal muscle from a frozen normal human tissue array. 11BD-2E11-2 did not stain skeletal muscle but there is staining to the smooth muscles of blood vessels (arrow). Magnification is 200×.
FIG. 9 . Representative micrograph of 11BD-2E11-2 (A) and isotype control antibody (B) binding to breast cancer tumor (infiltrating duct carcinoma). The black arrow in panel A points to tumor cells. Magnification is 200×.
FIG. 10 . Representative micrographs showing the binding pattern obtained with 11BD-2E11-2 (A), positive control anti-CD63 (NKI-C3) (B) and the negative isotype control antibody (C) on tissues sections of malignant melanoma from a frozen melanoma human tissue array. Magnification is 200×.
FIG. 11 . Representative micrographs showing the binding pattern obtained with 11BD-2E11-2 on malignant melanoma (A) and normal skin (B) tissues sections from a frozen melanoma human tissue array. There is strong staining of 11BD-2E11-2 to the malignant melanoma but not to the normal skin. Magnification is 200×.
FIG. 12 . Effect of 11BD-2E11-2 or buffer control on tumor growth in a preventative MDA-MB-468 breast cancer model. The dashed line indicates the period during which the antibody was administered. Data points represent the mean+/−SEM.
FIG. 13 . Survival of tumor-bearing mice after treatment with 11BD-2E11-2 or buffer control antibody in an established ES-2 xenograft study.
FIG. 14 . SEAP levels of tumor-bearing mice before, during and after treatment with 11BD-2E11-2 or buffer control in an established ES-2 xenograft study.
FIG. 15 . Effect of 11BD-2E11-2 or buffer control on tumor growth in a preventative A2058 melanoma cancer model. The dashed line indicates the period during which the antibody was administered. Data points represent the mean+/−SEM.
FIG. 16 . Effect of 11BD-2E11-2 or buffer control on tumor growth in an established A2058 melanoma cancer model. The dashed line indicates the period during which the antibody was administered. Data points represent the mean+/−SEM.
DETAILED DESCRIPTION OF THE INVENTION
EXAMPLE 1
Identification of Binding Proteins by Western Blotting
To identify the antigen(s) recognized by the antibody 11BD-2E11-2, cell membranes expressing this antigen were subjected to gel electrophoresis and transferred using Western blotting to membranes to determine the proteins detected by this antibody (as disclosed in Ser. No. 10/810,744).
1. Membrane Preparation
Previous work demonstrated binding by FACS of 11BD-2E11-2 to the breast cancer line MDA-MB-231 (MB-231). Previous work also demonstrated 11BD-2E11-2 efficacy against the ovarian cancer cell line OVCAR-3. Accordingly, membrane preparations from these 2 cell lines were used for antigen identification. Additional Western blotting and immunoprecipitation studies have also demonstrated a similar binding pattern of 11BD-2E11-2 to A2058 membrane preparations.
Total cell membranes were prepared from confluent cultures of MB-231 breast cancer or OVCAR-3 ovarian cells. Media was removed from cell stacks and the cells were washed with phosphate buffered saline. Cells were dissociated with dissociation buffer (Gibco-BRL, Grand Island, N.Y.) for 20 min at 37° C. on a platform shaker. Cells were collected and centrifuged at 900 g for 10 min at 4° C. After centrifugation, cell pellets were resuspended in PBS and centrifuged again at 900 g for 10 min at 4° C. to wash. Pellets were stored at −80° C. Cell pellets were resuspended in homogenization buffer containing 1 tablet per 50 mL of Complete protease inhibitor cocktail (Roche, Laval QC) at a ratio of 3 mL buffer per gram of cells. The cell suspension was subjected to homogenization using a polytron homogenizer on ice in order to lyse the cells. The cell homogenate was centrifuged at 15,000 g for 10 min at 4° C. to remove the nuclear particulate. Supernatant was harvested, divided into tubes and then centrifuged at 75,600 g for 90 min at 4° C. Supernatant was carefully removed from the tubes and each membrane pellet was resuspended in approximately 5 mL homogenization buffer. The resuspended pellets from all tubes were combined together in one tube and centrifuged at 75,600 g for 90 min at 4° C. Supernatant from the tubes was carefully removed, and the pellets were weighed. Solubilization buffer containing 1 percent Triton X-100 was added to the pellets at a ratio of 3 mL buffer per gram of membrane pellet. Membranes were solubilized by shaking on a platform shaker at 300 rpm for 1 hr on ice. The membrane solution was centrifuged at 75,600 g to pellet insoluble material. The supernatant containing the solubilized membrane proteins was carefully removed from tubes, assayed for protein content, and stored at −80° C.
2. SDS-PAGE and Western Blot
Membrane proteins were separated by SDS-polyacrylamide gel electrophoresis. 20 μg of membrane protein was mixed with SDS-PAGE sample buffer containing 100 mM DTT and was loaded onto a lane of an 8 percent SDS-PAGE gel. A sample of prestained molecular weight markers (Invitrogen, Burlington, ON) was run in a reference lane. Electrophoresis was carried out at 100 V for 10 minutes, followed by 150 V until sufficient resolution of the prestained molecular weight markers was observed. Proteins were transferred from the gel to PVDF membranes (Millipore, Billerica, Mass.) by electroblotting for 16 hr at 40 V. Transfer was assessed by noting complete transfer of the prestained markers from the gel to the membrane. Following transfer, membranes were blocked with 5 percent skim milk powder in Tris-buffered saline containing 0.5 percent Tween-20 (TBST) for 2 hr. Membranes were washed once with TBST and then incubated with 5 μg/mL 11BD-2E11-2 diluted in 3 percent skim milk powder in TBST for 2 hr. After washing 3 times with TBST, membranes were incubated with goat anti-mouse IgG (Fc) conjugated to horseradish peroxidase (HRP) from Jackson Immunologicals (West Grove Pa.). This incubation was followed by washing 3 times with TBST, followed by incubation with the HRP substrate 3,3′,5,5′-tetramethyl benzidine (TMB) (substrate kit from Vector Laboratories, Burlington ON).
In FIG. 1 , 11BD-2E11-2 clearly binds to 3 molecular weight regions of the separated MB-231 (Lane 1) and OVCAR-3 (Lane 2) membrane proteins. By comparison to the molecular weight (MW) standards, the antibody binds to proteins of MW approximately 150, 240 and 280 kDa. All further studies were done using the MB-231 membranes since stronger reactivity was seen with this cell line.
EXAMPLE 2
Determining Glycosylation of Antigens Bound by 11BD-2E11-2
In order to determine if the antigen(s) recognized by the antibody 11BD-2E11-2 were glycoproteins, MB-231 membranes were incubated with different combinations of PNGase F, endo-o-glycosidase, sialidase, galactosidase and glucosaminidase. Membranes were separated by SDS-PAGE followed by Western blotting as described with 11BD-2E11-2. FIG. 2 demonstrates the result of 11BD-2E11-2 binding to MB-231 membranes that were incubated in deglycosylation buffer only (Lane 1), in a combination of PNGase F, endo-o-glycosidase, sialidase, galactosidase and glucosaminodase (Lane 2), in a combination of PNGase, endo-o-glycosidase and sialidase (Lane 3), in sialidase only (Lane 4), in endo-o-glycosidase only (Lane 5), and in PNGase only (Lane 6). Treatment of MB-231 membranes with glycosidases does not eliminate binding of 11BD-2E11-2, however a molecular weight shift of the proteins is observed in all lanes, indicating that the antigen recognized by 11BD-2E11-2 was a glycoprotein.
EXAMPLE 3
Identification of Antigens Bound by 11BD-2E11-2
1. Immunoprecipitation
The identification of the antigen for 11BD-2E11-2 was carried out by isolating the cognate ligand through immunoprecipitation of solublized membrane gylcoproteins with the antibody. 100 μL of Protein G Dynabeads (Dynal Biotech, Lake Success N.Y.) were washed 3 times with 1 mL of 0.1 M sodium phosphate buffer pH 6.0. 100 μg of 11BD-2E11-2 in a total volume of 100 μL 0.1 M sodium phosphate buffer pH 6.0 was added to the washed beads. The mixture was incubated for 1 hr with rotational mixing. Unbound antibody was removed and the 11BD-2E11-2 coated beads were washed 3 times with 0.5 mL 0.1 M sodium phosphate pH 7.4 containing 0.1 percent Tween-20. The 11BD-2E11-2 coated beads were washed 2 times with 1 mL 0.2 M triethanolamine pH 8.2. 11BD-2E11-2 was chemically crosslinked to the beads by adding 1 mL of 0.02 M dimethylpimelimidate in 0.2 M triethanolamine pH 8.2 and incubating with rotational mixing for 30 min. The reaction was stopped by incubating the beads with 1 mL of 0.05 M Tris pH 7.5, for 15 min with rotational mixing. The 11BD-2E11-2 crosslinked beads were washed 3 times with 1 mL of 1 mM KH 2 PO 4 , 10 mM Na 2 HPO 4 , 137 mM NaCl, 2.7 mM KCl (PBS) containing 0.1 percent Tween-20. The 11BD-2E11-2 crosslinked beads were pre-eluted by incubation with 0.1 M citrate pH 3.0 for 3 min followed by 3 washes in 0.1 M PBS containing 0.1 percent Tween-20. A second set of antibody crosslinked beads were prepared in the same manner described using a mouse IgG 1 antibody (clone 107.3 from BD Biosciences, Oakville ON) to trinitrophenol, an irrelevant molecule, which was used as a negative IgG 1 isotype control.
The 11BD-2E11-2 crosslinked beads were blocked by incubating in 1 percent BSA in 0.1 M sodium phosphate pH 7.4 with rotational mixing for 30 minutes at 4° C. The beads were washed 3 times with 0.1 M sodium phosphate pH 7.4. 500 μg of total membrane preparation from MB-231 cells was incubated with the 11BD-2E11-2 crosslinked beads with rotational mixing for 2.5 hr at 4° C. The immunocomplex bound beads were washed three times with 1 mL of 1 mM KH 2 PO 4 , 10 mM Na 2 HPO 4 , 287 mM NaCl, 2.7 mM KCl containing 1 percent Triton X-100. 11BD-2E11-2 bound protein was eluted from the 11BD-2E11-2 crosslinked beads by incubation with 30 μL of 0.1 M citrate pH 3.0 for 3 min with gentle mixing. The eluted protein was brought to neutral pH by the addition of 9 μL of 1M Tris pH 9. The neutralized eluted protein was stored at −80 ° C. The 11BD-2E11-2 crosslinked beads were washed with 3 mL PBS containing 0.1 percent Tween-20. The IgG 1 isotype control (clone 107.3) crosslinked beads were incubated with MB-231 membrane proteins and processed in the same manner as the 11BD-2E11-2 beads.
Two batches of 11BD-2E11-2 immunoprecipitated protein from MB-231 membrane proteins were produced as described and combined together. The same was done for the IgG1 (clone 107.3) isotype control beads. Sixty-two percent of this immunoprecipitate mixture (corresponding to the amount of protein immunoprecipitated from 620 μg of MB-231 membrane proteins) was loaded onto a single lane of a 4-20 percent gradient SDS-PAGE gel. The same amount of material produced from the 107.3 crosslinked beads was loaded in an adjacent lane, as was 20 μg of MB-231 membrane proteins. A sample of unstained molecular weight markers (Invitrogen, Burlington ON) or pre-stained molecular weight markers were run in reference lanes. The sample was separated by electrophoresis at 100 V for 10 min, followed by 150 V for 60 minutes. Proteins were stained by incubating the gel in SYPRO Ruby™ (BioRad, Mississauga, ON). In a parallel Western blot, 18 percent of the immunoprecipitate mixture, which corresponded to the amount of protein immunoprecipitated from 180 μg of MB-231 membrane proteins, and the same amount of material produced from the IgG1 isotype control (clone 107.3) crosslinked beads, were separated by electrophoresis. Proteins were transferred from the gel to PVDF membranes (Millipore, Billerica, Mass.) by electroblotting for 16 hr at 40 V. After transfer, the membrane was blocked with 5 percent skim milk powder in TBST for 2 hr. The membrane was probed with 5 μg/mL 11BD-2E11-2 diluted in 3 percent skim milk powder in TBST for 2 hr. After washing 3 times with TBST, the membrane was incubated with goat anti-mouse IgG (Fc) conjugated HRP for 1 hr. This incubation was followed by washing 3 times with TBST, followed by incubation with the HRP substrate TMB.
FIG. 3 depicts the gel and Western blot obtained from the proteins immunoprecipitated by 11BD-2E11-2. On the gel (Panel A) Lane 1 represents the molecular weight standard and Lane 2 represents the MB-231 membrane proteins. There were two distinct bands of MW 240 and 280 kDa in the lane containing the 11BD-2E11-2 immunoprecipitated material (Lane 3) that were not present in the lane containing the 107.3 immunoprecipitated material (Lane 4). On the corresponding Western blot (Panel B), 11BD-2E11-2 reacts strongly with the 11BD-2E11-2 immunoprecipitated proteins of MW 240 and 280 kDa (Lane 3). On the Western blot 11BD-2E11-2 also reacts strongly to an additional band in the 11BD-2E11-2 immunoprecipitated protein at 150 kDa; this band was not detectable on the stained gel. The reactivity profile of 11BD-2E11-2 to 11BD-2E11-2 immunoprecipitated protein was similar to that seen in the MB-231 total membranes (Lane 2). There was no reactivity of 11BD-2E11-2 to proteins immunoprecipitated by IgG1 isotype control (clone 107.3; Lane 4), indicating that the binding of 11BD-2E11-2 to the immunoprecipitated protein was specific, and not due to the presence of contaminating proteins.
2. Mass Spectrometry
The regions of the gel corresponding to the 240 and 280 kDa protein immunoprecipitated by 11BD-2E11-2 ( FIG. 3 , Panel A, Lane 3) were cut out using sterile scalpels. These gel slices were then used for identification of proteins by mass spectrometry using MALDI/MS and LC/MS/MS.
The samples were subjected to proteolytic digestion on a PROGEST workstation using trypsin, and a portion of the resulting digest supernatant was used for MALDI/MS analysis. Spotting was performed robotically (ProMS) with ZipTips; peptides were eluted form the C18 material with matrix (α-cyano 4-hydroxy cinnamic acid) prepared in 60 percent acetonitrile, 0.2 percent TFA. MALDI/MS data was acquired on an Voyager DE-STR instrument (Applied Biosystems, Foster City Calif. and the observed m/z values were submitted to ProFound (Proteometrics software package) for peptide mass fingerprint searching. ProFound queried a locally stored copy of the NCBInr database. An additional portion of the digest supernatant was analyzed by nano LC/MS/MS on a Micromass Q-Tof2 using a 75 μm C18 column at a flow-rate of 200 nL/min. MS/MS data were searched using a local copy of MASCOT.
The proteins identified by MALDI/MS and LC/MS/MS are presented in Table 1.
TABLE 1 Proteins Identified by 11BD-2E11-2 Immunoprecipitation of MDA-MB-231 Membranes Ob- # of NCBI Sam- served Percent peptides accession ple MW Method Protein ID coverage matched # A 280 MALDI Melanoma- 13 20 gi kDa associated 4503099 chondroitin sulfate proteoglycan LC/ Melanoma 2 gi MS/ chondroitin 34148711 MS sulfate proteoglycan B 240 MALDI Melanoma 14 21 gi kDa associated 4503099 chondroitin sulfate proteoglycan
Both samples were identified as melanoma-associated chondroitin sulfate proteoglycan (MCSP).
3. Confirmation
Confirmation of the putative antigen was carried out by determining whether known anti-MCSP antibodies would react with the protein immunoprecipitated by 11BD-2E11-2 and vice versa. Immunoprecipitates were prepared in the same manner as described previously except with the addition of the mouse anti-MCSP monoclonal antibody 9.2.27 (IgG2a) (Chemicon, Temecula Calif.) and the mouse IgG2a antibody (clone G155-178 from BD Biosciences; Oakville ON) to trinitrophenol, an irrelevant molecule, which was used as a negative IgG2a isotype control. 11BD-2E11-2 immunoprecipitate, IgG1 isotype control (clone 107.3) immunoprecipitate, anti-MCSP (clone 9.2.27) immunoprecipitate, IgG2a isotype control (clone G155-228) immunoprecipitate and MB-231 membranes were separated by SDS-PAGE on six replicate 10 percent gels. Electrophoresis and Western blotting were carried out as described above. The membranes were incubated with 5 μg/mL of 11BD-2E11-2, IgG1 isotype control (clone 107.3), anti-MCSP (clone 9.2.27), IgG2a isotype control (clone G155-228), rabbit polyclonal anti-rat NG2 antibody (MCSP is the human homologue of rat NG2; Chemicon, Temecula Calif.) and normal rabbit IgG (Sigma, Saint Louis Mo.) diluted in 3 percent skim milk powder in TBST for 2.5 hr. FIG. 4 demonstrates the results of the Western blotting as described. FIG. 4 (Panel A) shows the binding of 11BD-2E11-2 to 11BD-2E11-2 immunoprecipitate (Lane 1), IgG1 isotype control (clone 107.3) immunoprecipitate (Lane 2), anti-MCSP (clone 9.2.27) immunoprecipitate (Lane 3), IgG2a isotype control (clone G155-228) immunoprecipitate (Lane 4), MB-231 membranes (Lane 5) and sample buffer only (negative control) (Lane 6). 11BD-2E11-2 recognized the same three bands of approximately 150, 240 and 280 kDa in both the MB-231 membranes and in the 11BD-2E11-2 immunoprecipitate. Only the upper 280 kDa band was recognized in the anti-MCSP (clone 9.2.27) immunoprecipitate lane. There is no reaction in either of the isotype control immunoprecipitate lanes, indicating that the reactivity of 11BD-2E11-2 to the immunoprecipitates was due to proteins being specifically bound and immunoprecipitated by both 11BD-2E11-2 and 9.2.27. In a parallel blot (Panel B) probed with IgG1 isotype control (clone 107.3), no reactivity was observed in any of the lanes, indicating that the reactivity observed in the blot probed with 11BD-2E11-2 was specific. Panel C shows the binding of rabbit polyclonal anti-rat NG2 antibody to a parallel blot. Anti-NG2 binds to two bands of approximately 150 and 240 kDa in the 11BD-2E11-2 immunoprecipitate (Lane 1) while it does not bind to proteins of this molecular weight range in any of the other lanes. In a parallel blot (Panel D), normal rabbit IgG shows faint non-specific reactivity to proteins in both the IgG2a immunoprecipitate (Lane 4) and MB-231 membranes (Lane 5). Therefore the same reactivity in these lanes on Panel C (probed with rabbit anti-NG2) should be regarded as non-specific. In a parallel blot (Panel E) anti-MCSP (clone 9.2.27) shows only very faint binding to one band in the anti-MCSP (clone 9.2.27) immunoprecipitate lane (Lane 3, indicated by arrow); this band is not seen in the MB-231 membranes (Lane 5) which indicates that 9.2.27 may have a low affinity for this antigen and only show reactivity when it is present in a concentrated form such as it is in the immunoprecipitated sample. In the final parallel blot (Panel F) probed with IgG2a isotype control (clone G155-228), no reactivity was observed in any of the lanes, indicating that the reactivity observed in the blot probed with anti-MCSP (clone 9.2.27) was specific. These results demonstrate that 11BD-2E11-2 immunoprecipitated protein was recognized by the rat homologue of MCSP, and that anti-MCSP immunoprecipitated protein was recognized by 11BD-2E11-2.
The mass spectroscopic identification combined with the confirmation using known commercial antibodies demonstrates that the antigen for 11BD-2E11-2 is MCSP. This is also consistent with the deglycosylation experiments in Example 2, as the core protein of MCSP is a glycoprotein.
EXAMPLE 4
Antibody Epitope Mapping
Antibody epitope mapping experiments were carried out in order to determine the region(s) of the MCSP molecule that were recognized by 11BD2E11-2. An overlapping peptide array based on the amino acid sequence of MCSP was synthesized and covalently bound to a cellulose membrane in a stepwise manner, resulting in a defined arrangement. Each peptide was 18 amino acids long with an overlap of 9 amino acids. The peptide array was incubated with blocking buffer for several hours. 11BD2E11-2 was conjugated to horseradish peroxidase (HRP) using a modified periodate method following the method of Wilson and Nakane. Following blocking, the peptide array was incubated with 1 μg/mL 11BD2E11-2-HRP in blocking buffer. In a separate experiment, the peptide array was incubated with a sheep anti-mouse IgG-HRP as a negative control. The peptide array was washed with TBST and incubated with a chemiluminescent substrate. The light emitted during the chemiluminescent reaction was quantified for each spot on the peptide array using a charge coupled device (CCD)-camera, resulting in a signal intensity value (Boehringer light units; BLU) for each peptide. For this experiment all signals below 7500 BLU were considered as background. The binding data for the peptide array is listed in Table 2 (SEQ ID NOS: 1257, respectively, in order of appearance)
TABLE 2
Binding of 11BD-2E11-2-HRP to MCSP
Peptide Array
Peptide
Number
Amino Acid Sequence
BLU
1
MQSGRGPPLPAPGLALAL
566
2
PAPGLALALTLTMLARLA
970
3
TLTMLARLASAASFFGEN
11290
4
SAASFFGENHLEVPVATA
494
5
HLEVPVATALTDIDLQLQ
905
6
LTDIDLQLQFSTSQPEAL
7196
7
FSTSQPEALLLLAAGPAD
937
8
LLLAAGPADHLLLQLYSG
1035
9
HLLLQLYSGRLQVRLVLG
1132
10
RLQVRLVLGQEELRLQTP
3383
11
QEELRLQTPAETLLSDSI
1148
12
AETLLSDSIPHTVVLTVV
788
13
PHTVVLTVVEGWATLSVD
1069
14
EGWATLSVDGFLNASSAV
1637
15
GFLNASSAVPGAPLEVPY
1657
16
PGAPLEVPYGLFVGGTGT
1892
17
GLFVGGTGTLGLPYLRGT
2343
18
LGLPYLRGTSRPLRGCLH
1823
19
SRPLRGCLHAATLNGRSL
2035
20
AATLNGRSLLRPLTPDVH
1672
21
LRPLTPDVHEGCAEEFSA
4678
22
EGCAEEFSASDDVALGFS
5263
23
SDDVALGFSGPHSLAAFP
564
24
GPHSLAAFPAWGTQDEGT
812
25
AWGTQDEGTLEFTLTTQS
1943
26
LEFTLTTQSRQAPLAFQA
33781
27
RQAPLAFQAGGRRGDFIY
3904
28
GGRRGDFIYVDIFEGHLR
3199
29
VDIFEGHLRAVVEKGQGT
2016
30
AVVEKGQGTVLLHNSVPV
1399
31
VLLHNSVPVADGQPHEVS
1114
32
ADGQPHEVSVHINAHRLE
1268
33
VHINAHRLEISVDQYPTH
1665
34
ISVDQYPTHTSNRGVLSY
1562
35
TSNRGVLSYLEPRGSLLL
2539
36
LEPRGSLLLGGLDAEASR
2576
37
GGLDAEASRHLQEHRLGL
1376
38
HLQEHRLGLTPEATNASL
957
39
TPEATNASLLGCMEDLSV
4354
40
LGCMEDLSVNGQRRGLRE
5881
41
NGQRRGLREALLTRNMAA
3880
42
ALLTRNMAAGCRLEEEEY
3939
43
GCRLEEEEYEDDAYGHYE
731
44
EDDAYGHYEAFSTLAPEA
1013
45
AFSTLAPEAWPAMELPEP
844
46
WPAMELPEPCVPEPGLPP
2033
47
CVPEPGLPPVFANFTQLL
7330
48
VFANFTQLLTISPLVVAE
2261
49
TISPLVVAEGGTAWLEWR
2439
50
GGTAWLEWRHVQPTLDLM
1956
51
HVQPTLDLMEAELRKSQV
2044
52
EAELRKSQVLFSVTRGAH
2944
53
LFSVTRGAHYGELELDIL
4346
54
YGELELDILGAQARKMFT
3249
55
GAQARKMFTLLDVVNRKA
4077
56
LLDVVNRKARFIHDGSED
3778
57
RFIHDGSEDTSDQLVLEV
1287
58
TSDQLVLEVSVTARVPMP
2650
59
SVTARVPMPSCLRRGQTY
1327
60
SCLRRGQTYLLPIQVNPV
1342
61
LLPIQVNPVNDPPHIIFP
25
62
NDPPHIIFPHGSLMVILE
6
63
HGSLMVILEHTQKPLGPE
564
64
HTQKPLGPEVFQAYDPDS
781
65
VFQAYDPDSACEGLTFQV
3015
66
ACEGLTFQVLGTSSGLPV
15941
67
LGTSSGLPVERRDQPGEP
2310
68
ERRDQPGEPATEFSCREL
7895
69
ATEFSCRELEAGSLVYVH
2724
70
EAGSLVYVHCGGPAQDLT
4799
71
CGGPAQDLTFRVSDGLQA
56703
72
FRVSDGLQASPPATLKVV
6138
73
SPPATLKVVAIRPAIQIH
2873
74
AIRPAIQIHRSTGLRLAQ
4406
75
RSTGLRLAQGSAMPILPA
4387
76
GSAMPILPANLSVETNAV
2024
77
NLSVETNAVGQDVSVLFR
2333
78
GQDVSVLFRVTGALQFGE
4056
79
VTGALQFGELQKHSTGGV
1554
80
LQKHSTGGVEGAEWWATQ
962
81
EGAEWWATQAFHQRDVEQ
290
82
AFHQRDVEQGRVRYLSTD
1059
83
GRVRYLSTDPQHHAYDTV
842
84
PQHHAYDTVENLALEVQV
1173
85
ENLALEVQVGQEILSNLS
3084
86
GQEILSNLSFPVTIQRAT
4928
87
FPVTIQRATVWMLRLEPL
2142
88
VWMLRLEPLHTQNTQQET
2345
89
HTQNTQQETLTTAHLEAT
2719
90
LTTAHLEATLEEAGPSPP
2513
91
LEEAGPSPPTFHYEVVQA
2380
92
TFHYEVVQAPRKGNLQLQ
4209
93
PRKGNLQLQGTRLSDGQG
8990
94
GTRLSDGQGFTQDDIQAG
3830
95
FTQDDIQAGRVTYGATAR
4641
96
RVTYGATARASEAVEDTF
1950
97
ASEAVEDTFRFRVTAPPY
1463
98
RFRVTAPPYFSPLYTFPI
870
99
FSPLYTFPIHIGGDPDAP
1092
100
HIGGDPDAPVLTNVLLVV
1043
101
VLTNVLLVVPEGGEGVLS
169
102
PEGGEGVLSADHLFVKSL
640
103
ADHLFVKSLNSASYLYEV
601
104
NSASYLYEVMERPRLGRL
2697
105
MERPRLGRLAWRGTQDKT
5728
106
AWRGTQDKTTMVTSFTNE
2771
107
TMVTSFTNEDLLRGRLVY
2243
108
DLLRGRLVYQHDDSETTE
2316
109
QHDDSETTEDDIPFVATR
3020
110
DDIPFVATRQGESSGDMA
3695
111
QGESSGDMAWEEVRGVFR
3949
112
WEEVRGVFRVAIQPVNDH
2674
113
VAIQPVNDHAPVQTISRI
4340
114
APVQTISRIFHVARGGRR
6454
115
FHVARGGRRLLTTDDVAF
5898
116
LLTTDDVAFSDADSGFAD
1615
117
SDADSGFADAQLVLTRKD
1464
118
AQLVLTRKDLLFGSIVAV
1137
119
LLFGSIVAVDEPTRPIYR
1972
120
DEPTRPIYRFTQEDLRKR
5531
121
FTQEDLRKRRVLFVHSGA
1860
122
RVLFVHSGADRGWIQLQV
465
123
DRGWIQLQVSDGQHQATA
812
124
SDGQHQATALLEVQASEP
759
125
LLEVQASEPYLRVANGSS
1502
126
YLRVANGSSLVVPQGGQG
4406
127
LVVPQGGQGTIDTAVLHL
1506
128
TIDTAVLHLDTNLDIRSG
2535
129
DTNLDIRSGDEVHYHVTA
2159
130
DEVHYHVTAGPRWGQLVR
4541
131
GPRWGQLVRAGQPATAFS
9113
132
AGQPATAFSQQDLLDGAV
3668
133
QQDLLDGAVLYSHNGSLS
3565
134
LYSHNGSLSPEDTMAFSV
3626
135
PEDTMAFSVEAGPVHTDA
2159
136
EAGPVHTDATLQVTIALE
1585
137
TLQVTIALEGPLAPLKLV
2444
138
GPLAPLKLVRHKKIYVFQ
1100
139
RHKKIYVFQGEAAEIRRD
2108
140
GEAAEIRRDQLEAAQEAV
1275
141
QLEAAQEAVPPADIVFSV
902
142
PPADIVFSVKSPPSAGYL
1224
143
KSPPSAGYLVMVSRGALA
1725
144
VMVSRGALADEPPSLDPV
949
145
DEPPSLDPVQSFSQEAVD
1189
146
QSFSQEAVDTGRVLYLHS
1447
147
TGRVLYLHSRPEAWSDAF
1661
148
RPEAWSDAFSLDVASGLG
2269
149
SLDVASGLGAPLEGVLVE
2123
150
APLEGVLVELEVLPAAIP
5144
151
LEVLPAAIPLEAQNFSVP
3152
152
LEAQNFSVPEGGSLTLAP
3277
153
EGGSLTLAPPLLRVSGPY
4455
154
PLLRVSGPYFPTLLGLSL
4311
155
FPTLLGLSLQVLEPPQHG
3545
156
QVLEPPQHGPLQKEDGPQ
1883
157
PLQKEDGPQARTLSAFSW
3132
158
ARTLSAFSWRMVEEQLIR
3149
159
RMVEEQLIRYVHDGSETL
947
160
YVHDGSETLTDSFVLMAN
1332
161
TDSFVLMANASEMDRQSH
320
162
ASEMDRQSHPVAFTVTVL
521
163
PVAFTVTVLPVNDQPPIL
884
164
PVNDQPPILTTNTGLQMW
867
165
TTNTGLQMWEGATAPIPA
1235
166
EGATAPIPAEALRSTDGD
1323
167
EALRSTDGDSGSEDLVYT
1970
168
SGSEDLVYTIEQPSNGRV
1972
169
IEQPSNGRVVLRGAPGTE
2836
170
VLRGAPGTEVRSFTQAQL
11671
171
VRSFTQAQLDGGLVLFSH
2167
172
DGGLVLFSHRGTLDGGFP
2307
173
RGTLDGGFPFRLSDGEHT
2979
174
FRLSDGEHTSPGHFFRVT
3900
175
SPGHFFRVTAQKQVLLSL
4176
176
AQKQVLLSLKGSQTLTVC
3627
177
KGSQTLTVCPGSVQPLSS
6489
178
PGSVQPLSSQTLRASSSA
3448
179
QTLRASSSAGTDPQLLLY
1159
180
GTDPQLLLYRVVRGPQLG
1266
181
RVVRGPQLGRLFHAQQDS
3735
182
RLFHAQQDSTGEALVNFT
1155
183
TGEALVNFTQAEVYAGNI
1544
184
QAEVYAGNILYEHEMPPE
889
185
LYEHEMPPEPFWEAHDTL
826
186
PFWEAHDTLELQLSSPPA
1748
187
ELQLSSPPARDVAATLAV
1713
188
RDVAATLAVAVSFEAACP
1953
189
AVSFEAACPQRPSHLWKN
2533
190
QRPSHLWKNKGLWVPEGQ
5178
191
KGLWVPEGQRARITVAAL
3891
192
RARITVAALDASNLLASV
5276
193
DASNLLASVPSPQRSEHD
2460
194
PSPQRSEHDVLFQVTQFP
2205
195
VLFQVTQFPSRGQLLVSE
2556
196
SRGQLLVSEEPLHAGQPH
1359
197
EPLHAGQPHFLQSQLAAG
1265
198
FLQSQLAAGQLVYAHGGG
1361
199
QLVYAHGGGGTQQDGFHF
1210
200
GTQQDGFHFRAHLQGPAG
3436
201
RAHLQGPAGASVAGPQTS
3587
202
ASVAGPQTSEAFAITVRD
980
203
EAFAITVRDVNERPPQPQ
1032
204
VNERPPQPQASVPLRLTR
4790
205
ASVPLRLTRGSRAPISRA
4393
206
GSRAPISRAQLSVVDPDS
2547
207
QLSVVDPDSAPGEIEYEV
1318
208
APGEIEYEVQRAPHNGFL
1561
209
QRAPHNGFLSLVGGGLGP
4879
210
SLVGGGLGPVTRFTQADV
3371
211
VTRFTQADVDSGRLAFVA
2747
212
DSGRLAFVANGSSVAGIF
5532
213
NGSSVAGIFQLSMSDGAS
3503
214
QLSMSDGASPPLPMSLAV
2245
215
PPLPMSLAVDILPSAIEV
1845
216
DILPSAIEVQLRAPLEVP
1504
217
QLRAPLEVPQALGRSSLS
5177
218
QALGRSSLSQQQLRVVSD
3060
219
QQQLRVVSDREEPEAAYR
988
220
REEPEAAYRLIQGPQYGH
762
221
LIQGPQYGHLLVGGRPTS
1334
222
LLVGGRPTSAFSQFQIDQ
2308
223
AFSQFQIDQGEVVFAFTN
2915
224
GEVVFAFTNFSSSHDHFR
3745
225
FSSSHDHFRVLALARGVN
2196
226
VLALARGVNASAVVNVTV
1991
227
ASAVVNVTVRALLHVWAG
1402
228
RALLHVWAGGPWFQGATL
1790
229
GPWPQGATLRLDPTVLDA
1447
230
RLDPTVLDAGELANRTGS
1796
231
GELANRTGSVPRFRLLEG
7317
232
VPRFRLLEGPRHGRVVRV
3761
233
PRHGRVVRVPRARTEPGG
8844
234
PRARTEPGGSQLVEQFTQ
3609
235
SQLVEQFTQQDLEDGRLG
1985
236
QDLEDGRLGLEVGRPEGR
1551
237
LEVGRPEGRAPGPAGDSL
1136
238
APGPAGDSLTLELWAQGV
993
239
TLELWAQGVPPAVASLDF
844
240
PPAVASLDFATEPYNAAR
1339
241
ATEPYNAARPYSVALLSV
786
242
PYSVALLSVPEAARTEAG
1723
243
PEAARTEAGKPESSTPTG
1417
244
KPESSTPTGEPGPMASSP
1449
245
EPGPMASSPEPAVAKGGF
1739
246
EPAVAKGGFLSFLEANMF
4457
247
LSFLEANMFSVIIPMCLV
1275
248
SVIIPMCLVLLLLALILP
1306
249
LLLLALILPLLFYLRKRN
1291
250
LLFYLRKRNKTGKHDVQV
1820
251
KTGKHDVQVLTAKPRNGL
13573
252
LTAKPRNGLAGDTETFRK
10322
253
AGDTETFRKVEPGQAIPL
4744
254
VEPGQAIPLTAVPGQGPP
3571
255
TAVPGQGPPPGGQPDPEL
1733
256
PGGQPDPELLQFCRTPNP
11325
257
LQFCRTPNPALKNGQYWV
1550
FIG. 5 represents a graphical image of the binding data. 11BD-2E11-2 bound most strongly to peptides #26, SEQ ID NO. 1 and #71, SEQ ID NO. 2. Weaker binding, which was greater than background, was recognizable on peptides #3, SEQ ID NO. 3, #66, SEQ ID NO. 4, #170, SEQ ID NO. 5, #251, SEQ ID NO. 6, #252, SEQ ID NO. 7 and #256, SEQ ID NO. 8. These results indicated that 11BD2E11-2 may bind to a discontinuous epitope with two major binding sites (peptides #26 and #71) as well as to a number of other sites.
EXAMPLE 5
As outlined in Ser. No. 10/743,451, the hybridoma cell line 11BD-2E11-2 was deposited, in accordance with the Budapest Treaty, with the American Type Culture Collection, 10801 University Blvd., Manassas, Va. 20110-2209 on Nov. 11, 2003, under Accession Number PTA-5643. In accordance with CFR 1.808, the depositors assure that all restrictions imposed on the availability to the public of the deposited materials will be irrevocably removed upon the granting of a patent.
Antibody Production:
11BD-2E11-2 monoclonal antibody was produced by culturing the hybridoma (PTA-5643) in CL-1000 flasks (BD Biosciences, Oakville, ON) with collections and reseeding occurring twice/week. The antibody was purified according to standard antibody purification procedures with Protein G Sepharose 4 Fast Flow (Amersham Biosciences, Baie d'Urfé, QC).
As previously described in Ser. No. 10/348,231, 11BD-2E11-2 was compared to a number of both positive (anti-Fas (EOS9.1, IgM, kappa, 20 micrograms/mL, eBioscience, San Diego, Calif.), anti-Her2/neu (IgG1, kappa, 10 microgram/mL, Inter Medico, Markham, ON), anti-EGFR (C225, IgG1, kappa, 5 microgram/mL, Cedarlane, Hornby, ON), Cycloheximide (100 micromolar, Sigma, Oakville, ON), NaN3 (0.1%, Sigma, Oakville, ON)) and negative (107.3 (anti-TNP, IgG1, kappa, 20 microgram/mL, BD Biosciences, Oakville, ON), G155-178 (anti-TNP, IgG2a, kappa, 20 microgram/mL, BD Biosciences, Oakville, ON), MPC-11 (antigenic specificity unknown, IgG2b, kappa, 20 microgram/mL), J606 (anti-fructosan, IgG3, kappa, 20 microgram/mL), IgG Buffer (2%)) controls in a cytotoxicity assay (Table 2). Breast cancer (MDA-MB-231 (MB-231), MDA-MB-468 (MB-468), MCF-7), colon cancer (HT-29, SW1116, 5W620), lung cancer (NCI H460), ovarian cancer (OVCAR-3 (OVCAR)), prostate cancer (PC-3), and non-cancer (CCD 27sk, Hs888 Lu) cell lines were tested (all from the ATCC, Manassas, Va.). The Live/Dead cytotoxicity assay was obtained from Molecular Probes (Eugene,OR). The assays were performed according to the manufacturer's instructions with the changes outlined below. Cells were plated before the assay at the predetermined appropriate density. After 2 days, purified antibody or controls were diluted into media, and then 100 microliters were transferred to the cell plates and incubated in a 5 percent CO 2 incubator for 5 days. The plate was then emptied by inverting and blotted dry. Room temperature DPBS containing MgCl 12 and CaCl 2 was dispensed into each well from a multi-channel squeeze bottle, tapped three times, emptied by inversion and then blotted dry. 50 microliters of the fluorescent calcein dye diluted in DPBS containing MgCl 2 and CaCl 2 was added to each well and incubated at 37° C. in a 5 percent CO 2 incubator for 30 minutes. The plates were read in a Perkin-Elmer HTS7000 fluorescence plate reader and the data was analyzed in Microsoft Excel and the results were tabulated in Table 3. The data represented an average of four experiments tested in triplicate and presented qualitatively in the following fashion: 4/4 experiments greater than threshold cytotoxicity (+++), 3/4 experiments greater than threshold cytotoxicity (++), 2/4 experiments greater than threshold cytotoxicity (+). Unmarked cells in Table 3 represent inconsistent or effects less than the threshold cytotoxicity. 11 BD-2E11-2 was specifically cytotoxic in breast and ovarian cancer cells, and did not affect normal cells. The chemical cytotoxic agents induced their expected cytotoxicity while a number of other antibodies which were included for comparison also performed as expected given the limitations of biological cell assays. In toto, it was shown that the 11BD-2E11-2 antibody has cytotoxic activity against two cancer cell types. The antibody was selective in its activity since not all cancer cell types were susceptible. Furthermore, the antibody demonstrated functional specificity since it did not produce cytotoxicity against non-cancer cell types, which is an important factor in a therapeutic situation.
TABLE 3
BREAST
COLON
LUNG
OVARY
PROSTATE
NORMAL
MB-231
MB-468
MCF-7
HT-29
SW1116
SW620
NCI H460
OVCAR
PC-3
CCD 27sk
Hs888 Lu
11BD-2E11-2
—
—
+
—
—
—
—
+
—
—
—
anti-Fas
—
—
+++
—
—
—
—
+++
+
—
+
anti-Her2
+
—
+
—
—
—
—
+
—
—
—
anti-EGFR
—
+++
+
—
+++
—
—
+
—
+
—
CHX (100 μM)
+++
+++
+++
+++
+++
+++
+++
+++
+++
+++
+++
NaN 3 (0.1%)
+++
+++
+++
+++
—
—
+++
+++
+++
—
—
IgG1
+++
+
IgG2a
+++
+
IgG2b
+++
IgG3
IgG Buffer
+
As previously described in Ser. Nos. 10/348,231 and 10/810,744, binding of 11BD-2E11-2 to the above-mentioned panel of cancer and normal cell lines plus the following additional ovarian cancer cell lines (A2780-cp, A2780-s, C-14, OV2008, Hey, OCC-1, OVCA-429 and ES-2+SEAP) was assessed by flow cytometry (FACS). Cells were prepared for FACS by initially washing the cell monolayer with DPBS (without Ca ++ and Mg ++ ). Cell dissociation buffer (INVITROGEN, Burlington, ON) was then used to dislodge the cells from their cell culture plates at 37° C. After centrifugation and collection the cells were resuspended in Dulbecco's phosphate buffered saline containing MgCl 2 , CaCl 2 and 2 or 25 percent fetal bovine serum (FBS) at 4° C. (wash media) and counted, aliquoted to appropriate cell density, spun down to pellet the cells and resuspended in staining media (DPBS containing MgCl 2 and CaCl 2 +/−2 percent FBS) containing 11BD-2E11-2 or control antibodies (isotype control or anti-EGFR) at 20 μg/mL on ice for 30 min. Prior to the addition of Alexa Fluor 488-conjugated secondary antibody the cells were washed once with wash media. The Alexa Fluor 488-conjugated antibody in staining media was then added for 20 to 30 min. The cells were then washed for the final time and resuspended in staining media containing 1 μg/mL propidium iodide or 1.5 percent paraformaldehyde. Flow cytometric acquisition of the cells was assessed by running samples on a FACScan using the CellQuest software (BD Biosciences, Oakville, ON). The forward (FSC) and side scatter (SSC) of the cells were set by adjusting the voltage and amplitude gains on the FSC and SSC detectors. The detectors for the three fluorescence channels (FL1, FL2, and FL3) were adjusted by running cells stained with purified isotype control antibody followed by Alexa Fluor 488-conjugated secondary antibody such that cells had a uniform peak with a median fluorescent intensity of approximately 1-5 units. Live cells were acquired by gating for FSC and propidium iodide exclusion (when used). For each sample, approximately 10,000 live cells were acquired for analysis and the resulted are presented in Tables 4 and 5. Tables 4 and 5 tabulated the mean fluorescence intensity fold increase above isotype control and is presented qualitatively as: less than 5 (−); 5 to 50 (+); 50 to 100 (++); above 100 (+++) and in parenthesis, the percentage of cells stained.
TABLE 4
COLON
NORMAL
BREAST
SW
SW
LUNG
OVARY
PROSTATE
CCD
CCD-
Hs
Antibody
Isotype
MB-231
MB-468
MCF-7
HT-29
1116
620
NCI H460
OVCAR
PC-3
27sk
112
888 Lu
11BD-2E11-2
IgG1, k
+
−
−
−
−
−
−
−
−
+
+
+
anti-EGFR
IgG1, k
++
++
−
+
+
−
+
+
+
+
+
+
TABLE 5
Ovarian
Antibody
Isotype
A2780-cp
A2780-s
C-14
OV2008
ES-2 + SEAP
Hey
OCC-1
OVCA-429
11BD-2E11-2
IgG1, k
+
+
−
−
+
+
+
−
anti-EGFR
IgG1, k
−
−
+
+
+
+
+
+
Representative histograms of 11BD-2E11-2 antibodies were compiled for FIG. 6 . 11BD-2E11-2 displayed specific tumor binding to the breast tumor cell line MDA-MB-231 (Table 4) and several ovarian tumor cell lines including ES-2+SEAP (Table 5). There was also binding of 11BD-2E11-2 to non-cancer cells, however that binding did not produce cytotoxicity. This was further evidence that binding was not necessarily predictive of the outcome of antibody ligation of its cognate antigen, and was a non-obvious finding. This suggested that the context of antibody ligation in different cells was determinative of cytoxicity rather than just antibody binding.
EXAMPLE 6
Normal Human Tissue Staining
IHC studies were conducted to characterize 11BD-2E11-2 antigen distribution in humans. IHC optimization studies were performed previously in order to determine the conditions for further experiments. 11BD-2E11-2 monoclonal antibody was produced and purified as stated above.
As disclosed in Ser. No. 10/810,744, binding of antibodies to 20 normal human tissues was performed using a frozen human normal organ tissue array (Clinomics, Watervliet, N.Y.). Slides were postfixed for 10 min in cold (−20° C.) acetone and then allowed to come to room temperature. Slides were rinsed in 4° C. cold phosphate buffered saline (PBS) 3 times for 2 min each followed by blocking endogenous peroxidase activity with washing in 3 percent hydrogen peroxide for 10 min. Slides were then rinsed in PBS 3 times for 5 min followed by incubation in Universal blocking solution (Dako, Toronto, Ontario) for 5 min at room temperature. 11BD-2E11-2, anti-human muscle actin (Clone HHF35, Dako, Toronto, Ontario) or isotype control antibody (directed towards Aspergillus niger glucose oxidase, an enzyme which is neither present nor inducible in mammalian tissues; Dako, Toronto, Ontario) were diluted in antibody dilution buffer (Dako, Toronto, Ontario) to its working concentration (5 μg/mL for each antibody except for anti-actin which was 2 μg/mL) and incubated overnight for 1 hr at room temperature. The slides were washed with PBS 3 times for 2 minutes each. Immunoreactivity of the primary antibodies was detected/visualized with HRP conjugated secondary antibodies as supplied (Dako Envision System, Toronto, Ontario) for 30 min at room temperature. Following this step the slides were washed with PBS 3 times for 2 min each and a color reaction developed by adding DAB (3,3′-diaminobenzidine tetrahydrachloride, Dako, Toronto, Ontario) chromogen substrate solution for immunoperoxidase staining for 10 min at room temperature. Washing the slides in tap water terminated the chromogenic reaction. Following counterstaining with Meyer's Hematoxylin (Sigma Diagnostics, Oakville, ON), the slides were dehyrdated with graded ethanols (95-100%) and cleared with xylene. Using mounting media (Dako Faramount, Toronto, Ontario) the slides were coverslipped. Slides were microscopically examined using an Axiovert 200 (Zeiss Canada, Toronto, ON) and digital images acquired and stored using Northern Eclipse Imaging Software (Mississauga, ON). Results were read, scored and interpreted by a pathologist.
Table 6 presents a summary of the results of 11BD-2E11-2 staining of an array of normal human tissues. From the table, there were 2 main categories of tissue staining. A group of tissues was completely negative. These tissues included normal thyroid, bronchus and cardiac muscle of the left ventricle ( FIG. 7 ). The second group of tissues included tissues in which staining was positive in the tissue section, but was limited to smooth muscle fibers of blood vessels and/or the epithelium ( FIG. 8 ). These results suggested that the antigen for 11BD-2E11-2 was not widely expressed on normal tissues, and that the antibody would bind only to a limited number of tissues in humans. The normal human tissue staining of 11BD-2E11-2 resembles that previously reported for an anti-MCSP antibody; B5. B5 was previously shown to bind to skin keratinocytes, lung alveolar epithelium and capillary endothelium.
TABLE 6
11BD-2E11-2 IHC on Frozen Human Normal Tissue
Data sheet
IHC Score
S. No.
Tissues
Age
Sex
11BD-2E11-2
Actin
IgG negative control
1
Bronchus
61
M
− (PD)
+++ SMF & Myoepithelium of
CD
mucus acini
2
Diaphragm
61
M
+++ SMF of blood vessels
+++ Skeletal muscle fibers &
—
+/− Skeletal muscle fibers
SMF of blood vessels
3
Pectoral muscle
61
M
+++ SMF of blood vessels
+++ Skeletal muscle fibers &
—
(Skeletal muscle)
SMF of blood vessels
4
Lung
61
M
+++ Alveolar epithelium & SMF of blood vessels
CD
− (F)
5
Aorta
61
M
++ SMF (F)
CD
—
6
Left ventricle
61
M
—
+++ SMF of blood vessels
—
(Cardiac muscle)
+ Cardiac muscle fibers
7
Esophagus
61
M
+++ SMF (PD)
CD
− (F)
8
Trachea
61
M
− (PD)
+++ SMF & myoepithelium of
—
mucus acini
9
Kidney
61
M
+++ SMF of blood vessels
+++ SMF of blood vessels
—
10
Adrenal
61
M
+++ SMF of blood vessels
+++ SMF of blood vessels
—
11
Pancreas
61
M
+++ SMF of blood vessels + Acinar epithelium
+++ SMF of blood vessels
—
12
Spleen
61
M
+++ SMF of blood vessels & Polymorphs (F)
+++ SMF of blood vessels,
Bg (polymorphs)
reticular fibers & polymorphs
(F)
13
Liver
61
M
+++ SMF of blood vessels
− (PD)
—
14
Skin
61
M
+++ SMF of blood vessels +/− Keratinocytes
+++ SMF of blood vessels
Bg (Stroma)
15
Colon
61
M
+++ SMF of blood vessels
+++ SMF
—
16
Thyroid
61
M
− (PD)
− (PD)
—
17
Prostate
61
M
++ SMF of blood vessels
CD
CD
+/− Glandular epithelium
18
Testicle
61
M
++ SMF of blood vessels
+++ stromal cells
—
19
Breast
61
M
+/− Ductal epithelium
+++ SMF of blood vessels
—
+++ SMF of blood vessels
20
Ovary
80
F
++ SMF of blood vessels & Stroma
F
CD
Abbreviations:
SMF: smooth muscle fiber,
Bg: background staining,
PD: partially detached,
F: folded,
CD: completely detached.
EXAMPLE 7
Human Breast Tumor Tissue Staining
An IHC study was undertaken to determine the cancer association of the 11BD-2E11-2 antigen with human breast cancers (disclosed in Ser. No. 10/810,744). A comparison was made for actin (positive control), and an antibody directed towards Aspergillus niger glucose oxidase, an enzyme which is neither present nor inducible in mammalian tissues (negative control). A breast cancer tissue array derived from 15 breast cancer patients and 5 samples derived from non-neoplastic breast tissue in breast cancer patients were used (Clinomics, Watervliet, N.Y.). The following information was provided for each patient: age, sex, and diagnosis. The procedure for IHC from Example 6 was followed.
Table 7 provides a binding summary of 11BD-2E11-2 antibody staining of a breast cancer tissue array. Each array contained tumor samples from 15 individual patients. Overall, 62 percent of the 8 (7 of the tissue samples were either completely detached or not representative) patients tested were positive for the 11BD-2E11-2 antigen. Also for 11BD-2E11-2, 0 out of 3 (again 2 of the tissue samples were completely detached) normal breast tissue samples from breast cancer patients were positive ( FIG. 9 ). For the 11BD-2E11-2 antigen there did not appear to be a trend to greater positive expression with higher tumor stage. However, this result was limited due to the small sample size. The 11BD-2E11-2 staining was specific for cancerous cells ( FIG. 9 ). The staining pattern, from 11BD-2E11-2, showed that in patient samples, the antibody was highly specific for malignant cells thereby making it an attractive druggable target. The breast tumor tissue staining of 11BD-2E11-2 resembles that previously reported for the anti-MCSP antibody B5. B5 was previously shown to bind to 60 percent of breast carcinoma tumor tissue.
TABLE 7
11BD-2E11-2 IHC on Frozen Human Normal and Breast Tumor Tissue
Data Sheet
IHC Score
S. NO.
Tissue
Age
Sex
Diagnosis
11BD-2E11-2
Actin
IgG negative control
1
Breast
61
F
Infiltrating Ductal Carcinoma
CD
CD
CD
2
Breast
74
F
Infiltrating Ductal Carcinoma
− (PD)
− Tumor +++ SMF of blood
—
vessels
3
Breast
60
F
Infiltrating Ductal Carcinoma
CD
PD
CD
4
Breast
69
F
Infiltrating Ductal Carcinoma
NR
NR
—
5
Breast
64
F
Infiltrating Ductal Carcinoma
CD
—
CD
6
Breast
65
F
Medullary Carcinoma
+++ (Tumor cells)
—
—
7
Breast
75
F
Infiltrating Ductal Carcinoma
+++ (Tumor cells)
CD
—
8
Breast
48
F
Infiltrating Ductal Carcinoma
++ (Tumor cells)
− Tumor ++ Stroma
—
9
Breast
87
F
Infiltrating Ductal Carcinoma
+/− (Tumor cells)
− Tumor +++− SMF of blood
CD
vessels
10
Breast
75
F
Infiltrating Ductal Carcinoma
NR (+/− SMF of
CD
—
blood vessels)
11
Breast
76
F
Infiltrating Ductal Carcinoma
—
− Tumor +++ SMF of blood
—
vessels & stroma
12
Breast
66
F
Infiltrating Ductal Carcinoma
CD
CD
—
13
Breast
58
F
Infiltrating Ductal Carcinoma
+++ (Tumor cells)
CD
CD
14
Breast
37
F
Infiltrating Ductal Carcinoma
CD
− Tumor +++ Stroma
—
15
Breast
70
F
Infiltrating Ductal Carcinoma
—
− Tumor +++ Myoepithelium
CD
& SMF of blood vessels
16
Breast
48
F
Normal
− (PD)
CD
CD
17
Breast
60
F
Normal
—
− (PD)
—
18
Breast
30
F
Normal
CD
− Tumor +++ Myoepithelium
& SMF of blood vessels
19
Breast
34
F
Normal
CD
− Tumor ++ Myoepithelium
(PD)
20
Breast
43
F
Normal
—
− Tumor + SMF of blood
vessels
Abbreviations:
SMF: smooth muscle fiber,
PD: partially detached,
F: folded,
CD: completely detached.
EXAMPLE 8
An IHC study was undertaken to determine the cancer association of the 11BD-2E11-2 antigen with human melanoma cancers. A comparison was made for an anti-CD63 antibody (NIK-C3; MEDICORP, Montreal QC); positive control), and an antibody directed towards Aspergillus niger glucose oxidase, an enzyme which is neither present nor inducible in mammalian tissues (negative control). A melanoma cancer tissue array derived from 35 melanoma cancer patients and 10 samples derived from normal skin tissue in melanoma cancer patients was used (TriStar Technology Group, LLC, Bethesda, Md.). The procedure for IHC from Example 6 was followed except for the following modifications. The color reaction developed by adding AEC (Dako, Toronto, Ontario) chromogen substrate solution for immunoperoxidase staining for 10 minutes at room temperature. Washing the slides in tap water terminated the chromogenic reaction. Following counterstaining with Meyer's Hematoxylin (Sigma Diagnostics, Oakville, ON), the slides were cleared with distilled water.
Table 8 provides a binding summary of 11BD-2E11-2 antibody staining of a melanoma cancer tissue array. Each array contained tumor samples from 35 individual patients and normal skin from 10 patients. Overall, 67 percent of the 33 (2 of the tissue samples were completely pigmented) patients tested were positive for the 11BD-2E11-2 antigen ( FIG. 10 ). In addition, 0 out of 6 (4 of the tissue samples were non representative or not available) normal skin tissue samples from melanoma cancer patients were positive ( FIG. 11 ). The 11BD-2E11-2 staining was specific for cancerous cells ( FIG. 11 ). The staining pattern, from 11BD-2E11-2, showed that in patient samples, the antibody was highly specific for malignant cells thereby making it an attractive druggable target and demonstrating the utility of 11BD-2E11-2 as a potential drug.
TABLE 8
11BD-2E11-2 IHC on Frozen Human Normal Skin and Melanoma Tumor Tissue
IHC observations
IgG negative
Coordinates
Primary/meta
Organ
11B-2E11-2
NKI-C3
control
A1a
meta
lymph node
Completely
Completely
Completely
Pigmented
Pigmented
Pigmented
A1b
meta
lymph node
—
+
—
A1c
meta
spleen
+++
+++
—
A1d
primary
skin
+
++
—
A1e
primary
esophagus
+/−
+++
—
A1f
meta
lymph node
+++
++
—
A1g
primary
skin
+
+++
—
A1h
meta
lung
++
+++
—
A1i
meta
lymph node
+/−
—
cd
A1k
meta
lymph node
++
++
—
A2a
primary
skin
Completely
Completely
Completely
Pigmented
Pigmented
Pigmented
A2b
meta
skin
—
—
—
A2c
primary
skin
+++
—
—
A2d
meta
soft tissue
+++
++
—
A2e
meta
lymph node
+++
+++
—
A2f
meta
lymph node
+++
+++
cd
A2g
primary
skin
—
+++
—
A2h
meta
lymph node
+
—
—
A2i
meta
lymph node
+++
+
—
A2k
meta
soft tissue
—
—
cd
A3a
primary
skin
+++
++
—
A3b
primary
skin
+++
+++
—
A3c
meta
lymph node
—
—
—
A3d
meta
lymph node
+
+/−
—
A3e
meta
lymph node
+/−
+++
—
A3f
meta
lymph node
+/−
++
—
A3g
meta
lymph node
—
—
—
A3h
meta
lymph node
—
—
—
A3i
meta
lymph node
—
—
—
A3k
meta
lymph node
—
—
—
A4a
meta
lymph node
—
+/−
—
A4b
meta
lymph node
+++
+++
—
A4c
primary
skin
+
+++
—
A4d
meta
soft tissue
+++
+++
—
A4e
meta
lymph node
—
++
—
A5a
normal
skin
—
—
—
A5b
normal
skin
—
—
—
A5c
normal
skin
NR
NR
NR
A5d
normal
skin
—
—
—
A5e
normal
skin
—
—
—
A5f
normal
skin
—
—
—
A5g
normal
skin
NA
NA
NA
A5h
normal
skin
—
—
—
A5i
normal
skin
NR
NR
NR
A5k
normal
skin
NR
NR
cd
Abbreviations:
meta: metastatic,
NR: section is not representative,
cd: section is completely detached,
NA: section is not available.
EXAMPLE 9
In Vivo MDA-MB-468 Established Tumor Experiment
As disclosed in Ser. No. 10/810,744 and with reference to FIG. 12 , 6 to 8 week old female SCID mice were implanted with 2 million MDA-MB-468 human breast cancer cells in 100 microlitres saline injected subcutaneously in the scruff of the neck. Tumor growth was measured with calipers every week. When the majority of the cohort reached a tumor volume of 100 mm 3 , 5-6 mice were randomized into each of 2 treatment groups. 11BD-2E11-2 or buffer control was administered intraperitoneally with 10 mg/kg/dose at a volume of 300 microliters after dilution from the stock concentration with a diluent that contained 2.7 mM KCl, 1 mM KH 2 PO 4 , 137 mM NaCl and 20 mM Na 2 HPO 4 . The antibodies were then administered 3 times per week for a total of 10 doses in the same fashion until day 66 post-implantation. Tumor growth was measured about every seventh day with calipers for the duration of the study or until individual animals reached CCAC end-points. Body weights of the animals were recorded for the duration of the study. At the end of the study all animals were euthanised according to CCAC guidelines.
At the time of randomization the mean tumor volumes and the standard deviations in each group were similar. Statistically there was no difference in body weight between the groups. This indicated that true randomization had occurred. As shown in FIG. 12 , the antibody 11BD-2E11-2 suppressed tumor growth by 25 percent in comparison to buffer control at the end of the 3-week treatment period (p=0.52). Although this was not a significant difference, a trend towards reduced tumor volume in comparison to the buffer control was observed throughout the study. Therefore, 11BD-2E11-2 has shown efficacy in an established breast cancer model.
EXAMPLE 10
In Vivo ES-2+SEAP Established Tumor Experiment
As disclosed in Ser. No. 10/810,744 and with reference to FIGS. 13 and 14 , 6 to 8 week old female athymic nude mice were intraperitoneally implanted with 10 million ES-2+SEAP human ovarian cancer cells stably transfected to express human placental secreted alkaline phosphatase (SEAP). The 10 million ovarian cancer cells were resuspended in 500 microlitres serum-free α-MEM. Tumor growth was confirmed with the sacrifice of 3 mice on day 7. Following the confirmation of tumor growth on day 7, 8 mice were randomized into each of 2 treatment groups. 11BD-2E11-2 or buffer control was administered intraperitoneally with 10 mg/kg/dose at a volume of 250 microliters after dilution from the stock concentration with a diluent that contained 2.7 mM KCl, 1 mM KH 2 PO 4 , 137 mM NaCl and 20 mM Na 2 HPO 4 . The antibodies were then administered once per day for 5 doses and then once every other day for another 5 doses for a total of 10 doses. Tumor burden was extrapolated by measuring circulating SEAP levels and assessed visually upon necropsy for the duration of the study or until individual animals reached CCAC end-points. Body weights of the animals were recorded for the duration of the study. At the end of the study all animals were euthanised according to CCAC guidelines.
At the time of randomization circulating plasma SEAP levels (indicative of tumor burden) were analyzed. There was not a significant difference in the average SEAP level between the 11BD-2E11-2 and buffer control treatment group. However, within groups there was variable tumor take-rate. As shown in FIG. 13 , the antibody 11BD-2E11-2 displayed a trend for improved survival in a cohort of the treatment group. As illustrated in FIG. 14 , one animal receiving 11BD-2E11-2 treatment had a decreased amount of circulating SEAP to nearly negligible levels. The low level of circulating SEAP continued on until approximately 60 days post-implantation.
EXAMPLE 11
In Vivo A2058 Human Melanoma Preventative Tumor Experiment
With reference to the data shown in FIG. 15 , 4 to 8 week old, female SCID mice were implanted with 0.75 million A2058 human melanoma cancer cells in 100 microliters saline injected subcutaneously in the scruff of the neck. The mice were randomly divided into 2 treatment groups of 5. On the day after implantation 20 mg/kg of 11BD-2E11-2 test antibody or buffer control was administered intraperitoneally at a volume of 300 microliters after dilution from the stock concentration with a diluent that contained 2.7 mM KCl, 1 mM KH 2 PO 4 , 137 mM NaCl and 20 mM Na 2 HPO 4 . The antibody or buffer control was then administered once per week for a period of 7 weeks in the same fashion.
Tumor growth was measured about every 7th day with calipers for up to 10 weeks or until individual animals reached the Canadian Council for Animal Care (CCAC) end-points. Body weights of the animals were recorded for the duration of the study. At the end of the study all animals were euthanised according to CCAC guidelines.
As shown in FIG. 15 , 11BD-2E11-2 treatment resulted in decreased tumor growth compared to treatment with the buffer control. On day 55 (5 days after the end of treatment), the mean tumor volume in the 11BD-2E11-2 treated group was 58 percent of the buffer control (p=0.046, unpaired t-test). Therefore, 11BD-2E11-2 displayed efficacy in the treatment of breast, ovarian and melanoma in vivo models of human cancer and reduced tumor burdens in comparison to controls in those same cancers.
EXAMPLE 12
In Vivo A2058 Human Melanoma Established Tumor Experiment
With reference to FIG. 16 , 6 to 8 week old female SCID mice were implanted with 0.5 million A2058 human melanoma cancer cells in 100 microlitres saline injected subcutaneously in the scruff of the neck. Tumor growth was measured with calipers every week. When the majority of the cohort reached a tumor volume of 100 mm 3 , 5 mice were randomized into each of 2 treatment groups. 11BD-2E11-2 or buffer control was administered intraperitoneally with 20 mg/kg/dose at a volume of 300 microliters after dilution from the stock concentration with a diluent that contained 2.7 mM KCl, 1 mM KH 2 PO 4 , 137 mM NaCl and 20 mM Na 2 HPO 4 . The antibodies were then administered 3 times per week for a total of 10 doses in the same fashion until day 44 post-implantation. Tumor growth was measured about every seventh day with calipers for the duration of the study or until individual animals reached CCAC end-points. Body weights of the animals were recorded for the duration of the study. At the end of the study all animals were euthanised according to CCAC guidelines.
At the time of randomization the mean tumor volumes and the standard deviations in each group were similar. Statistically there was no difference in body weight between the groups. This indicated that true randomization had occurred. As shown in FIG. 13 , the antibody 11BD-2E11-2 suppressed tumor growth by 49 percent in comparison to buffer control after the treatment period (p=0.1272; unpaired t-test). Although this was not a significant difference, a trend towards reduced tumor volume in comparison to the buffer control was observed throughout the study. Therefore, 11BD-2E11-2 has shown efficacy in both an established breast, ovarian and melanoma cancer model. In all, these results in which 11BD-2E11-2 produced benefits (improved survival and/or decreased tumor burden in comparison to control treatment) in mulitple models of human cancer suggest pharmacologic and pharmaceutical benefits of this antibody for cancer therapy in mammals, including man.
The preponderance of evidence shows that 11BD-2E112 mediates anticancer effects through ligation of an epitope present on MCSP. For the purpose of this invention, said epitope is defined as a “MCSP antigenic moiety” characterized by its ability to bind with a monoclonal antibody encoded by the hybridoma cell line 11BD-2E11-2, antigenic binding fragments thereof or antibody conjugates thereof. It has been shown, in Example 3, 11BD-2E11-2 antibody can be used to immunoprecipitate the cognate antigen from expressing cells such as MDA-MB-231 cells. Further it could be shown that the 11BD-2E112 antibody could be used in detection of cells and/or tissues which express a MCSP antigenic moiety which specifically binds thereto, utilizing techniques illustrated by, but not limited to FACS, cell ELISA or IHC.
Thus, it could be shown that the immunoprecipitated 11BD2E11-2 antigen can inhibit the binding of 11BD-2E11-2 to such cells or tissues using FACS, cell ELISA or IHC assays. Further, as with the 11BD-2E11-2 antibody, other anti-MCSP antibodies could be used to immunoprecipitate and isolate other forms of the MCSP antigen, and the antigen can also be used to inhibit the binding of those antibodies to the cells or tissues that express the antigen using the same types of assays.
All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification. One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. Any oligonucleotides, peptides, polypeptides, biologically related compounds, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.
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This invention relates to the diagnosis and treatment of cancerous diseases, particularly to the mediation of cytotoxicity of tumor cells; and most particularly to the use of cancerous disease modifying antibodies (CDMAB), optionally in combination with one or more chemotherapeutic agents, as a means for initiating the cytotoxic response. The invention further relates to binding assays which utilize the CDMABs of the instant invention.
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FIELD OF THE INVENTION
The present invention relates to a measuring device for refiners having refining disks that define between them refining gaps for refining material on bars arranged between the disks, the bars extending across the refining zones of the refining disks.
BACKGROUND OF THE INVENTION
In connection with the known use of relatively rotatable refining disks, the energy applied is measured in the main motor. Thus, only the total energy applied is measured. The object of the present invention is to instead measure the actual energy applied to the material to be refined, as a function of the radius of the refining disk. Using this information as a basis, the refiner can then be controlled for optimal pulp quality and minimal energy consumption. If the energy applied to the inlet zone of the refiner is too high, for instance, fiber damage may occur, and the outer refining zone will not operate under optimal conditions. Similarly, if insufficient energy is supplied to the inlet zone, the other zones will be unable to deal with the through-flow required. The operating parameters that can be varied are gap breadth, viscosity of the material to be refined, pressure difference and through-flow, to mention but a few.
The present invention has a particular application area in refiners having several independent refining gaps. In a refiner consisting of a rotor having refiner segments on both sides, and two stators, one for each side of the rotor, only the total load is obtained since the rotor is common to both refining zones. Similarly, the conically shaped peripheral zone in a conical refiner can be adjusted independently of the inner, flat zone. Hitherto it has not been practically possible to discover how much energy is applied to one zone as compared with another. Thanks to the present invention, however, refiners having one or more refining zones can be controlled more accurately since it is then known where the load has been applied.
Admittedly it is known through Swedish Patent No. B 7 601,019-8 to measure e.g. temperature or pressure on the material in the refining gap by placing sensors in that area. However, the load between bars and material is still not accessible.
SUMMARY OF THE INVENTION
In accordance with the present invention, these and other objects have now been realized by the invention of refining apparatus comprising first and second relatively rotatable refining disks defining a refining gap therebetween, the refining disks including a plurality of radial refining bars extending along at least part of the refining gap, and at least one of the plurality of refining bars comprising a sensor bar including sensing means for sensing the load exerted thereon during the refining at a plurality of points along the sensor bar.
In accordance with a preferred embodiment of the refining apparatus of the present invention, the sensing means comprises a plurality of strain gauges located at the plurality of points along the sensor bar whereby the stresses exerted on the sensor bar can be determined from the deformation of the sensor bar at the plurality of points. Preferably, the apparatus includes a plurality of these strain gauges located at at least one of the plurality of points, whereby the stresses exerted at the at least one of the plurality of points can be divided into load components acting in separate directions. In a preferred embodiment, the plurality of strain gauges are located at each of the plurality of points.
In accordance with one embodiment of the refining apparatus of the present invention, the apparatus includes a plurality of temperature gauges located proximate to each of the plurality of points along the sensor bar whereby the stresses can be compensated for thermal expansion. In a preferred embodiment, the plurality of temperature gauges includes steam pressure and velocity measurement means for measuring the pressure and velocity of steam supplied to the refining gap.
In accordance with another embodiment of the refining apparatus of the present invention, the apparatus includes control means for controlling the refining in response to the load determined by the sensing means.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described in more detail with reference to the accompanying drawings in which:
FIG. 1 is a side, elevational, radial cross-sectional view of the inner part of two refining disks in a refiner in accordance with the present invention; and
FIG. 2 is a partial, front, elevational view taken perpendicular to the bars of the refining disks shown in FIG. 1, with one sensor bar in cross section.
DETAILED DESCRIPTION
Referring to the Figures, in which like reference numerals refer to the elements thereof, FIG. 1 shows a typical refining zone. The two refining disks 1 and 2 move with a predetermined constant speed of rotation in relation to each other. The material to be refined is fed into the refining gap at the center of the refining disks, in FIG. 1 from below, and thus enters the refining zone 4. In refining zone 4, the bars 5 and 6 in the refining machinery will be subjected to a load from the material. This load is dependent on the properties of the material, the breadth of the refining gap, the through-flow, temperature, moisture content and geometry of the machinery. The energy level applied is dependent on many variables. It is well known, for instance, that at temperatures above the glass transition temperature, the energy required to break down the wood into smaller particles is much less than at temperatures somewhat below the glass transition temperature. The significance of the moisture content for the energy applied is also well known, although its mechanism is not quite clear. In general, refining pulp with a lower moisture content (high viscosity) gives higher specific energy. Similarly, the refining gaps and through-flow levels greatly influence the specific energy applied.
The parameters mentioned above, with the exception of the geometry of the machinery, an be used to control the load applied, thus producing a control system with feedback.
To this end at least one of the bars has, according to the present invention, been made in the form of a sensor bar 6. This sensor bar is provided along its length with strain gauges 7 distributed over a number of measuring points along the bar 6. FIG. 2 shows three strain gauges 7 at one measuring point. Measuring the strain at two or more points on the surface of the sensor bar enables determination of the deformation.
FIG. 2 shows a piece of wood 8 as the material to be refined, being subjected to mechanical processing between the bars 5 and 6. This operation may take several forms. The piece of wood may, for instance, be compressed, crushed or fibrillated in the refining zone. In the figure, the piece of wood 8 is crushed between the bar 5 and the sensor bar 6 when the bars move in relation to each other as indicated by the horizontal arrows. When the sensor bar 6 is loaded as indicated by the arrow 9 it will be slightly deformed. This deformation will be measured by the strain gauges 7, which are located such that the strain can be divided into load components acting in separate directions.
The stresses to which the sensor bar 6 is subjected can then be related to the strain with the aid of linear equations, provided that the liquid limit of the material has not been reached. This conversion is performed in a control device, where a computer program calculates the load applied as a function of the strain measured. The solution can be obtained analytically or numerically depending on the geometry of the sensor bar. The energy applied as a function of the radius of the refining disk is stated in kilowatt per millimeter, for instance.
Suitably, the temperature is also measured at each measuring point, in order to enable compensation of the strain measurement for thermal expansion. The temperature gauges can also be used to determine the pressure and velocity of steam supplied, as a function of the radius of the refining disk.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.
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Refining apparatus is disclosed including a pair of relatively rotatable refining disks including radial refining bars extending along at least part of the refining gap between those disks, and at least one of the refining bars comprising a sensor bar including strain gauges for sensing the load exerted thereon during refining at a number of points along the sensor bar.
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FIELD OF THE INVENTION
The present inventions relate to food racks for charcoal or gas grills. Mare particularly, the present inventions relate to food racks having reversible food support members that may be easily installed in a frame and easily removed from the frame for cleaning or to accommodate different sized food.
BACKGROUND OF THE INVENTION
Grilling, both with gas and charcoal grills, has became extremely popular. Similarly, the need for useful accessories to aid in grill cooking has also increased. In particular, there is a growing desire for specialized grilling accessories that aid in the proper preparation of various foods, such, as ribs, shishkabobs and the like.
Examples of such food racks are shown and described in U.S. Pat. No. 4,942,862 to Weber-Stephen Products LLC. Among other things, that patent discloses a universal rack suitable for cooking ribs. The rack includes a frame and generally vertically upstanding food support elements. The food support elements have free ends which are inserted into holes in the sides of the frame. Food, such as ribs, may then be placed between the food support elements. However, because the food support members have free ends that are inserted into holes in the sides of the frame, they can only be used one way. In addition they may be more difficult to install and clean.
Thus, there remains a need for food rack accessories for a grill that are easy to ship and assemble, provide flexibility for various uses and which are easy to clean.
SUMMARY OF THE INVENTION
The present inventions preserve the advantages of known food racks for grills and also provide new features and advantages.
Accordingly, it is an object of the present invention to provide a food rack or support assembly for grills that is easy to clean.
It is an additional object of the present invention to provide a food support assembly for grills that includes reversible food support members.
It is another object of the present invention to provide a food support assembly for grills that includes a frame that securely yet simply supports the food support members.
It is a further object of the present invention to provide a food support assembly for grills that may be shipped disassembled and may be easily assembled for use.
Thus, the present inventions provide a food support assembly for use on a cooking surface. The assembly includes a generally rectangular frame having two parallel side members and two parallel end members, each side member including a generally vertical leg and a generally horizontal flange, wherein each horizontal flange includes a plurality of opposing slots. A plurality of food support members, each food support member having two ends, each end including at least one loop portion adapted for insertion into the opposing slots of the side members is also provided. In addition, each end of each food support member may include two loop portions, one being a top loop portion and the other being the bottom loop portion, wherein the top and bottom loop portions are adapted for engagement by the slots of the opposing side members of the frame. As a result, the food support members are reversible and easily removed from the frame for cleaning.
The present inventions also provide a food support assembly for use on a cooking surface of a grill which includes a substantially rectangular frame having two side members and two end members, each side member including a substantially vertical leg and a substantially horizontal flange, wherein each horizontal flange includes a plurality of opposing apertures. Further included is a locking rail attached and generally parallel to each side member of the frame and positioned below the horizontal flanges, each looking rail including opposing openings substantially aligned with the plurality of opposing apertures on the horizontal flanges of the frame. A plurality of food support members, each food support member having two ends, each end having at least one loop portion, wherein the apertures on the horizontal flanges and the openings on the locking rail are adapted to receive the at least one loop portion of the food support member are also provided. The food support assembly may also include apertures in the locking rail which are hook shaped to engage the at least one loop portion of the food support member. Each of the ends of each food support member may include a first loop portion and a second loop portion so that the food support member is reversible. Moreover, the apertures on the horizontal flanges may be arcuate so that the food support members may be supported at an angular orientation when installed in the frame.
The present inventions further provide for a food support assembly for use on a grill, the assembly including a rectangular frame having two sides and two ends, each of the sides including a substantially horizontal flange, wherein each horizontal flange includes a plurality of opposing apertures. Also included are a plurality of food support members, each member having two ends and each end having at least one loop portion adapted to be received in the apertures in the horizontal flanges; and a locking rail associated with the sides of the frame and positioned below the horizontal flanges, the locking rail having openings aligned with the apertures on the horizontal flanges, the apertures adapted to receive the at least one loop portion of the food support member. A first loop portion and a second loop portion may also be included on each of the food support members so that they may be reversed for use. The locking rail may be hook-shaped and the apertures on the horizontal flanges may be arcuate in other aspects of the present inventions.
Inventor's Definition of the Terms
The terms used in the claims of this patent intended to have their broadest meaning consistent with the requirements of law. Where alternative meanings are possible, the broadest meaning is intended. All words used in the claims are intended to be used in the normal customary usage of grammar and the English language.
BRIEF DESCRIPTION OF THE DRAWINGS
The stated and unstated objects, features and advantages of the present inventions (sometimes used in the singular, but not excluding the plural) will become apparent from the following descriptions and drawings, wherein like reference numerals represent like elements in the various views, and in which:
FIG. 1 is a perspective view of a preferred embodiment of a food support assembly of the present invention;
FIG. 2 is a perspective view of a frame of the embodiment of the food support assembly of FIG. 1 ;
FIG. 3 is a front plan view of a preferred embodiment of a reversible food support member of the present invention;
FIG. 4 is a top view of a frame of an alternative embodiment of a food support assembly of the present invention having a locking rail;
FIG. 5 is a side view of the frame of the alternative embodiment of the food support assembly of FIG. 4 ;
FIG. 6 is a side view of the alternative embodiment of a food support assembly of FIG. 4 showing a plurality of reversible food support members engaged in the book-shaped cut-outs of the locking rail in a representative angular orientation in the frame; and
FIG. 7 is an end view of the alternative embodiment of the food support assembly of FIG. 6 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Set forth below is a description of what is currently believed to be the preferred embodiments or best representative examples of the inventions claimed. Future and present alternatives and modifications to the embodiments and preferred embodiments are contemplated. Any alternatives or modifications which make insubstantial changes in function, purpose, structure or result are intended to be covered by the claims of this patent.
FIGS. 1, 2 and 3 show one preferred embodiment of a food support assembly 10 of the present inventions. The food support assembly 10 includes a generally rectangular frame 20 and a plurality of food support members 40 . The preferred embodiment of food support member 40 shown in FIG. 3 is reversible and may be used with the embodiment of FIGS. 1-2 . It may also be used with the alternative embodiment of food support assembly 10 as shown in FIGS. 4-7 as hereinafter described. Preferred food support member 40 is reversible to accommodate different types of food and those of ordinary skill in the art will understand that a body portion 41 may take a variety of forms depending upon the anticipated use. It will also be understood by those of skill in the art that food support assembly 10 is placed upon the grate or cooking surface of a grill (not shown). In addition, food support assembly 10 and its various components may be made from a variety of materials. It will be further understood by those of skill in the art that frame 20 may be sized so accommodate any desired number and variety of food support members 40 and/or to fit within various sized grids.
The frame 20 of the embodiment shown in FIGS. 1-2 can best be seen by reference to FIG. 2 . Frame 20 includes two generally parallel side members 22 and two generally parallel end members 24 . Ends 24 and sides 22 are attached together using holts or rivets 21 or other well known means to form a generally rectangular frame 20 . It will be understood by those of skill in the art that frame sides 22 and/or frame ends 24 may be formed from a single piece of material or may be constructed from different pieces of material that are welded or otherwise attached together. It will also be understood that frame 20 may be square or any other shape suitable to accept food support members 40 . Ends 24 are generally L-shaped and include a lower horizontal flange 25 and an integral vertical end member 26 . A handle 2 may be provided that is attached to or integral with vertical end member 26 . Frame sides 22 preferably include a vertical leg 28 and an upper horizontal flange 29 which projects outwardly from the frame sides 22 . A lower horizontal foot portion 23 may also be provided for additional stability when the food support assembly 10 is placed on a cooking surface of a grill.
In the embodiment of frame 20 in FIG. 2 , upper horizontal flange 29 is integral with and/or formed as part of vertical leg 28 . In addition, horizontal flange 29 is preferably curvilinear. It will be understood by those of skill in the art that vertical leg 28 and horizontal flange 29 may be formed from a single sheet of material or made from separate components which are welded or otherwise attached together. In addition, the curvilinear shape of generally horizontal flange 29 is preferred, but not required. The horizontal flanges 29 of each side frame member 22 are provided with a plurality of opposing slots 30 that are aligned with each other on the opposite flanges 29 . Depending upon the configuration of food support members 40 , slots 30 may extend 31 to vertical leg 28 . The shape and size of slots 20 and any extension 31 to vertical leg 28 are adapted to releasably accommodate fond support members 40 as hereinafter described.
Preferred reversible food support member 40 may be seen by reference to FIG. 3 . Food support member 40 includes two ends 42 and an intermediate body portion 41 . Preferably, food support members 40 are formed from circular rods that are bent or deformed into the desired shape. Ends 42 are formed to preferably have two loop portions; namely, a first loop portion 43 (the top loop portion of FIG. 3 ) and a second loop portion 44 (the bottom loop of FIG. 3 ). In a preferred, embodiment body portion 41 is generally arcuate when the second loop portion 44 is on the bottom and generally U-shaped when the first loop portion 43 is on the bottom. In this manner, a user may decide which way to use reversible food support member 40 depending upon cooking needs (compare FIGS. 1 and 7 ). It is preferred, but not required, that ends 42 of food support member 40 include both the first and second loop portions 43 and 44 . Thus, it is preferred but not required that food support member 40 be reversible. In a non-reversible embodiment, only one loop portion 43 or 44 is provided. It will be understood by those of ordinary skill in the art that the loop portions 43 and 44 and the body portion 41 may take a variety of shapes and sizes. All that is required is that loop portions 43 and/or 44 are accepted by slots 30 and slots 30 (and any slot extensions 31 ) are sized and shaped to accommodate and secure either or both loop portions 43 and 44 .
As shown in FIG. 1 , slots 30 (and any necessary extensions 31 ) accept either first loop 43 and/or second loop 44 (the first loop 43 is shown engaged in FIG. 1 ). If a different configuration of body portion 41 is desired, the food support element 40 may be reversed and slots 30 (and any necessary extensions 31 ) may accept second loop ends 44 (compare FIGS. 1 and 7 ). In this manner, food support element 40 is reversible. In addition, since either loop end 43 or 44 is simply inserted into slot 30 , they may be easily removed for cleaning and both assembly and cleaning by the user are also simplified. As indicated, the size of slots 30 and the need for any extension 31 is determined by the size and shape of ends 42 and loops 43 and 44 , as will fee understood by those of skill in the art.
An alternative preferred embodiment 10 of the rack of the present inventions may be seen by reference to FIGS. 4-7 . In this embodiment the same food support element 40 used with the embodiment of FIGS. 1-2 may also be used. Alternative frame 20 also includes two generally parallel side members 22 and two generally parallel end members 24 which may be attached together with rivets 21 or other well known means. Ends 24 are generally L-shaped and include a lower horizontal flange 25 and a vertical end member 26 . A handle 21 may also be provided. Sides 22 include a generally vertical leg 28 and an upper horizontal flange 29 that projects outwardly from sides 22 . A lower horizontal foot portion 23 may also be provided. A plurality of opposing slots 30 ′ are provided on horizontal flange 29 , and slots 30 ′ may extend 31 to vertical leg 28 if necessary to accommodate the ends 42 of food support member 40 . In this alternative embodiment, slots 30 ′ are arcuate, preferably as shown in FIG. 4 . Unlike the frame 20 embodiment of FIGS. 1-2 , frame 20 of the alternative embodiment includes a locking rail 32 ( FIGS. 5, 6 and 7 ) to more securely engage first loop portion 43 or second loop portion 44 of food support member 40 .
As indicated, each side member 22 of the alternative embodiment of frame 20 includes a locking rail 32 . As shown in FIGS. 5, 6 and 7 , preferred looking rail 32 is generally L-shaped and includes a horizontal portion 33 that is attached in vertical leg 21 of side member 22 and a vertical portion 34 that rims parallel to vertical leg 28 of side member 22 . As shown in FIGS. 4, 6 and 7 , vertical portion 34 is located below generally horizontal flange 29 . Vertical portion 34 of locking nail 32 includes a plurality of hook-shaped out-outs 35 ( FIG. 5 ) having a vertical opening portion 36 that is generally aligned with arcuate slots 30 ′ of horizontal flange 29 and recess portion 37 . Hook-shaped cut-outs 35 coincide with the number of slots 30 ′.
As best shown in FIGS. 4 and 5 , arcuate slots 30 ′ are arced away from recess portion 37 of hook-shaped cut-outs 35 such that the top of the arc is in alignment with the vertical opening portion 36 . Although not required, the preferred arcuate slots 30 ′ enable the food support member 40 to be secured at a slight angle while loop portions 43 or 44 are engaged in recess portion 3 of hook-shaped cut-out 35 as shown in FIGS. 5 and 6 . In use, the desired loop portion 43 or 44 is inserted through arcuate slot 305 and into hook-shaped cut-out 35 . Because the slots 305 are arcuate, outer leg portion 45 and inner leg portion 46 of ends 42 of food support member 40 fit within the bottom of the arc such that food support member 40 may be angled once inserted through arcuate slots 30 ′. Loop portion 43 or 44 is then engaged in the recess portion 37 of book-shaped cut-out 35 . Food support member 40 is then supported in frame 20 as shown in FIGS. 6 and 7 .
It will be understood by those of skill in the art that although hook-shaped cut-outs 35 and arcuate slots 30 ′ are preferred in this embodiment, they are not required. For example, cut-outs 35 do not have to be book-shaped, but instead, simply include a vertical opening portion 36 such that loop portion 43 or 44 are accepted therein. In this manner, food support member 40 is more securely supported on frame 22 than in an embodiment without locking rail 32 or its equivalents. If required, a portion of arcuate slot 30 ′ may be extended 31 to vertical leg 28 .
The above description is not intended to limit the meaning of the words used in or the scope of the following claims that define the invention. Rather, it is contemplated that future modifications in structure, function or result will exist that are not substantial changes and that all such insubstantial changes in what is claimed are intended to be covered by the claims. Thus, while preferred embodiments of the present inventions have been illustrated and described, it will be understood that changes and modifications can be made without departing from the claimed invention. In addition, although the term “claimed invention” or “present invention” is sometimes used herein is the singular, it will be understood that there are a plurality of Inventions as described and claimed.
Various features of the present inventions are set forth in the following claims.
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A food support rack, especially for use on a grill, the food support rack including removable and reversible food support members.
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CROSS REFERENCES TO RELATED APPLICATIONS
This application is a U.S. National Phase Application under 35 USC §371 of International Application PCT/IB2006/002965 filed on 23 Oct. 2006 designating the United States, which claims priority to Italian Application No. BO2005A000643, filed Oct. 24, 2005. Priority to each of the foregoing PCT and Italian national applications is claimed herein under all applicable laws and provisions, and each of said priority applications is incorporated by reference in its entirety.
TECHNICAL FIELD
The present invention relates to methods and apparatuses for manipulation of particles in conductive or highly conductive solutions. The invention finds application principally in the implementation of biologic protocols on cells.
TECHNOLOGICAL BACKGROUND
The patent PCT/WO 00/69565 filed in the name of G. Medoro describes an apparatus and method for manipulation of particles via the use of closed dielectrophoretic-potential cages. The force used for maintaining the particles in suspension or for moving them within the microchamber dissipates, by the Joule effect, a power that is proportional to the square of the amplitude of the voltages applied and increases linearly as the electric conductivity of the suspension liquid increases, causing an uncontrolled increase in temperature within the microchamber. The individual control on the operations of manipulation may occur via programming of memory elements and circuits associated to each element of an array of electrodes integrated in one and the same substrate. Said circuits contribute to the increase in temperature by dissipating power in the substrate that is in direct contact with the suspension liquid. There follows an important limitation due to the death of the particles of biological nature present in the specimen for solutions with high electric conductivity limiting the application of said methods and apparatuses to the use of beads or non-living cells.
An example of apparatus that implements said method is represented in FIG. 1 , shown in which is the electric diagram of the circuits dedicated to each element of an array of microsites (MS) and the signals for enabling driving thereof. The manipulation of particles is obtained by means of an actuation circuit (ACT) for appropriately driving an electrode (EL), to each electrode of the array there being moreover associated a circuit (SNS) for detection of particles by means of a photodiode (FD).
The limitations of the known art are overcome by the present invention, which enables manipulation of biological particles by means of the described technique of the known art preserving the vitality and biological functions irrespective of the forces used and/or of the conductivity of the suspension liquid. In addition to the possibility of manipulation of living cells, the present invention teaches how to reduce the power consumption and how to maximize the levels of performance of said devices given the same power consumption.
SUMMARY OF THE INVENTION
The present invention relates to a method and apparatus for manipulation and/or control of the position of particles by means of fields of force of an electrical nature in electrically conductive solutions. The fields of force can be of (positive or negative) dielectrophoresis, electrophoresis, electrohydrodynamics, or electrowetting on dielectric, characterized by a set of points of stable equilibrium for the particles. Each point of equilibrium can trap one or more particles within the attraction basin. Said forces dissipate, by the Joule effect, an amount of power that increases with the square of the voltages applied and increases linearly with the conductivity of the liquid, causing in a short time lysis of the cells contained in the specimen. According to the present invention, the dissipated power can be removed through at least one of the substrates in contact with the suspension liquid in order to maintain the temperature constant or reduce it throughout the step of application of the forces in a homogeneous or selective way, that is constant or variable in time. In this connection, the system can benefit from the use of one or more integrated or external sensors for control of the temperature by means of a feedback control. Reading of the temperature can occur, according to the present invention, using the same read circuit of the optical sensor by reading the output signal of the sensor during the reset step so as to have a signal equal to the threshold voltage, which depends upon the temperature. In a second embodiment of the method, a flow constantly replaces the buffer, transporting and removing the heat by convention outside the microchamber. Forming the subject of the present invention is likewise a method for minimizing the dissipated power given the same levels of performance, dividing the forces into classes, falling within one of which classes are the forces for controlling the particles in a static way, whilst falling within a further class are the forces necessary for displacement of particles. This can occur in a practical way by increasing the number of potentials that supply the electrodes of the device or else by appropriately modulating the amplitudes of the phases applied during displacement of the cages or by means of a timed management of the amplitudes of the voltages.
Forming the subject of the present invention are likewise some practical implementations of the method through which apparatuses for manipulation of particles in conductive solutions are realized. Said apparatus requires the use of a heat pump, which can be obtained by means of a Peltier-effect device or by means of the convective transport of the heat flow absorbed by the substrate. Said convective flow uses a liquid or a gas and requires a second microchamber. Forming the subject of the present invention is likewise an apparatus that exploits the gas law for reducing the temperature by means of variation of the pressure of the gas having the function of performing convective transport or by means of a change of phase from vapour to liquid and vice versa.
DESCRIPTION OF THE INVENTION
In what follows, the term “particles” will be used to designate micrometric or nanometric entities, whether natural or artificial, such as cells, subcellular components, viruses, liposomes, niosomes, microbeads and nanobeads, or even smaller entities such as macro-molecules, proteins, DNA, RNA, etc., such as drops of unmixable liquid in the suspension medium, for example oil in water, or water in oil, or even drops of liquid in a gas (such as water in air) or droplets of gas in a liquid (such as air in water). The symbols VL or VH will moreover designate as a whole two different sets of signals, each containing the voltages in phase (Vphip) or phase opposition (Vphin) necessary for enabling actuation according to the known art.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows the circuits for actuation and optical reading associated to each element of an array of microsites.
FIG. 2 shows a cross-sectional view of a generic device, generation of the field of force associated to the generation of heat, and the working principle of heat removal through the heat-exchange surface of a substrate.
FIG. 3 shows the working principle of the method for removal of heat through a flow of solution at a controlled temperature within the microchamber.
FIG. 4 shows the principle of reduction of the dissipated power via the use of classes of electrodes.
FIG. 5 shows the sequence of the amplitudes in temporal management of the voltages aimed at reduction of the dissipated power given the same levels of performance.
FIG. 6 shows an apparatus that uses a Peltier-effect cell for removal of the heat through a substrate and a control system based upon the measurement of the temperature within the microchamber.
FIG. 7 shows the working principle of maximization of the levels of performance via modulation of the amplitude of the voltages applied to the electrodes during the transient that characterizes displacement of a particle.
FIG. 8 shows an apparatus that uses an external flow for convective transport of the heat absorbed through a substrate.
FIG. 9 shows an apparatus that maximizes the conductive and convective heat exchange between the substrate and the external flow by means of an appropriate topology of the heat-exchange surface.
FIG. 10 shows a different embodiment of the apparatus of FIG. 8 .
DETAILED DESCRIPTION
The aim of the present invention is to provide a method and an apparatus for manipulation of particles in highly conductive solutions. By “manipulation” is meant control of the position of individual particles or groups of particles or displacement in space of said particles or groups of particles.
The method is based upon the use of a non-uniform field of force (F) via which individual particles or groups of particles are attracted towards positions of stable equilibrium (CAGE). Said field of an electrical nature generates heat (Q 0 ) by the Joule effect, which typically has one or more of the following consequences:
1. damage of the cell membrane or of the organelles; 2. lysis and death of the cell; 3. uncontrolled onset of disturbance of a thermal nature such as electrohydrodynamic (EHD) or Brownian motion.
Generation of the Forces
There currently exist various methods for generation of forces for displacing particles, according to the known art, by means of arrays of electrodes (EL) provided on a substrate (SUB 1 ). Typically a lid (LID) is used, which can in turn be an electrode. The substrate (SUB 1 ) and the lid (LID) delimit, respectively from beneath and from above, a microchamber (M), within which the particles (BEAD) in suspension liquid (S) are found. In the case of DEP, the voltages applied are periodic voltages in phase (Vphip), designated by the symbol of addition (+), and in phase opposition (Vphin), designated by the symbol of subtraction (−). By “voltages in phase opposition” are meant voltages 1800 out of phase. The field generates a force, which acts on the particles, attracting them towards points of equilibrium (CAGE). In the case of negative DEP (NDEP), it is possible to provide closed cages of force, according to the known art, if the lid (LID) is a conductive electrode. In this case, the point of equilibrium (CAGE) is provided in a position corresponding to each electrode connected to Vphin (−) if the adjacent electrodes are connected to the opposite phase Vphip (+) and if the lid (LID) is connected to the phase Vphin (−). Said point of equilibrium (CAGE) is normally set at a distance in the liquid with respect to the electrodes so that the particles (BEAD) are, in the stationary state, undergoing levitation. In the case of positive DEP (PDEP), the point of equilibrium (CAGE) is normally found in a position corresponding to the surface on which the electrodes are provided, and the particles (BEAD) are, in the stationary state, in contact therewith. An example of apparatus that implements said method is represented in FIG. 1 , which shows the electric diagram of the circuits dedicated to each element of an array of microsites (MS) and the signals for enabling driving thereof. The manipulation of particles is obtained by means of an array of microsites (MS), each of which contains an actuation circuit (ACT) having the function of controlling the voltages necessary for driving appropriately an electrode (EL); moreover associated to each microsite of the array is a circuit (SNS) for detection of particles by means of a photodiode (FD) integrated in the same substrate (SUB 1 ).
For reasons of simplicity, in what follows use will be considered, purely by way of example, without, however, in no way limiting the purposes of the present invention, of closed cages of negative dielectrophoresis (NDEP) as force of actuation for describing the methods and apparatuses (for this reason it is necessary to use a lid that functions as electrode), since in highly conductive solutions the biological particles have a behaviour almost exclusively of negative dielectrophoresis. To persons with ordinary skill in the sector it is evident how it is possible to generalize the methods and apparatuses described hereinafter for use of different forces of actuation and different types of particles.
Displacement of the Cages
By controlling the phases of the voltages applied to the electrodes, it is possible by displacing the position of the points of attraction (CAGE) entraining the particles (BEAD) trapped therein. It is evident to persons skilled in the sector that the rate of displacement increases as the voltage applied increases so that it is advantageous to use high voltages, associated to which is, however, a higher power dissipation, which is frequently intolerable for the purposes of manipulation of biological organisms.
Control of the Temperature by Means of a Heat Pump
An embodiment of the method according to the present invention is shown in FIG. 2 . A microchamber (M) is enclosed between a first substrate (SUB 1 ), lying on which is an array of electrodes (EL), and a second substrate (LID). The specimen constituted by particles (BEAD) suspended in an electrically conductive liquid (S) is introduced within the microchamber. By applying appropriate electrical stimuli according to the known art, dielectrophoresis cages (CAGE) are obtained as shown in FIG. 2 . Said cages represent the point in which the lines of force (F) terminate. The presence of electric fields generates in the liquid a rise in temperature as a consequence of the generation of heat (QJ) due to the dissipation of power by the Joule effect. The method according to the present invention envisages removal of an amount of heat (Q 0 ) through one or more substrates (SUB 1 ). For this purpose, the heat (Q 0 ) is extracted using a surface of exchange (S 2 ) belonging to said substrate (SUB 1 ), but differing from the surface contacting with the liquid.
Various Conditions May Arise According to the Ratio Between Q 0 and QJ:
1. increase in temperature: during an initial time interval the heat Q 0 is equal to Q 01 and smaller than QJ, whilst for time intervals subsequent to t 1 the heat Q 0 is equal to Q 02 and substantially equal to QJ; in this case, the temperature increases during said first time interval and is stabilized to a steady-state value T 2 higher than the initial temperature T in the intervals subsequent to t 1 ;
2. constant temperature: in the case where the heat extracted Q 0 is equal instant by instant to the generated heat QJ for the entire duration of the application of the forces the mean temperature remains substantially unvaried and equal to the initial temperature T;
3. reduction in temperature: in the case where, during a first time interval, the heat Q 0 is equal to Q 01 and higher than QJ whilst, for time intervals subsequent to t 1 , the heat Q 0 is equal to Q 02 and equal to QJ, the temperature decreases during said first time interval and is stabilized to a steady-state value T 2 lower than that of the initial temperature T in the intervals subsequent to t 1 .
The possible conditions illustrated previously refer to the particular case where the power dissipation QJ is homogeneous in space. In the more general case, the power QJ can vary point by point in the microchamber, and consequently the removal of heat Q 0 can be obtained in different ways in order to achieve different results; by way of example that in no way limits the purposes of the present invention we can list two different situations:
1. Q 0 homogeneous over the entire surface S 2 ; in this case, the temperature within the microchamber will be proportional point by point to the value of QJ in a neighbourhood of the same point; 2. Q 0 equal point by point to QJ; in this case, the temperature within the microchamber will tend to become uniform.
The extraction of heat (Q 0 ) can occur in different ways according to the present invention and will be described in the next sections.
Control of the Temperature by Means of a Heat Pump and Temperature Sensor
Forming the subject of the present invention is also the use of a technique for controlling the temperature of the liquid based upon the use of a heat pump (PT), the ability of which of extracting heat (Q 0 ) is evaluated instant by instant on the basis of the information coming from one or more temperature sensors (TS) inside the microchamber, integrated within the substrate or external thereto. In this connection, a control system (C) receives and processes the information coming from the sensor (TS) and determines the operating conditions of the heat pump (PT), as shown by way of example in FIG. 6 .
Reading of the Temperature by Means of the Read Circuit of a Photodiode
Forming the subject of the present invention is likewise a method for reading the temperature by means of the read circuit of a photodiode (FD) integrated in the same substrate (SUB 1 ). According to the present invention, reading of the temperature occurs in an indirect way by reading the voltage at output from the read circuit of the photodiode during the reset step so as to detect a threshold voltage that depends upon the temperature. In this connection, in a read scheme as the one shown in FIG. 1 , it is sufficient to read the output (Voarr) by scanning the columns of each row, having addressed the row and column via ROWS (row sense) and COLS (column sense), and maintaining RESCOL active (high). Reading each element of each row is performed in this particular case in a serial way by means of a multiplexer (RMUX).
Control of the Temperature by Means of Buffer Flow
A further embodiment of the method according to the present invention is shown in FIG. 3 . In this case, the removal of heat (QJ) generated within the liquid (S) occurs by convection causing the liquid (S) itself at temperature TF to flow within the microchamber (M). The force of entrainment by viscous friction in this case must be smaller than the electric force (F) that controls the position of the particles (BEAD). The temperature within the liquid in this case is not homogeneous in space and depends upon the distance with respect to the point in which the cooling liquid (S) is introduced, as shown in FIG. 3 . The maximum temperature (TMAX) within the microchamber depends upon the heat generated (Q 0 ), the temperature (TF), and the speed of the liquid (S). The liquid (S) can be made to circulate by means of a closed circuit or else an open circuit; in the case where a closed circuit is used, said liquid (S) must be cooled before being introduced within the microchamber (M) again.
Minimization of the Power Dissipation
Forming the subject of the present invention is also a method for reducing the dissipation of power given the same levels of performance, where by “performance” is meant the rate of displacement of particles by means of the applied forces F. In this connection, it is necessary to point out that a large number of protocols of biological interest envisage non-simultaneous displacement of all the particles. In this case, two different classes of electrodes may be distinguished:
1. electrodes for control of the static position of particles that belong to a first class (SE 1 ) and are stimulated by means of a first set of signals (VL) for providing static cages (CAGE 1 ), the position (XY 11 ) of which remains unvaried; 2. electrodes for displacement of particles that belong to a second class (SE 2 ) and are stimulated by means of a second set of signals (VH) for providing dynamic cages (CAGE 2 ), the position (XY 21 ) of which is modified.
FIG. 4 shows an example of this idea. The electrodes belonging to the class (SE 2 ) are used for displacing the cages (CAGE 2 ) from the initial position (XY 21 ) to the final position (XY 22 ) typically at a distance (P) equal to the pitch between adjacent electrodes. According to the nature of the stimuli applied to the two sets of signals (SE 1 and SE 2 ), it is possible to make available various methods in order to reduce the power dissipation in the liquid given the same rate of displacement or to increase the rate of displacement given the same total power dissipation.
Use of Constant Signals
The simplest method forming the subject of the present invention is to use for the signals belonging to VH amplitudes that are greater than the ones used for the signals belonging to VL. In fact, maintaining a particle trapped in a static way in a point of stable equilibrium (CAGE 1 ) requires less power than that required for displacing it from a position (XY 21 ) of stable equilibrium (CAGE 2 ) to the adjacent one (XY 22 ), and consequently lower voltages can be used for all the static cages (CAGE 1 ). Whether the electrodes (EL) belong to one of the classes (SE 1 or SE 2 ) can be modified in time according to the type of displacement and to the cages involved in said displacement, so that cages (CAGE 1 ) that are static in a first transient can become dynamic (CAGE 2 ) in a subsequent transient, or vice versa.
Amplitude Modulation of the Potentials
A further technique forming the subject of the present invention can be described with the aid of FIG. 7 , which is a conceptual illustration of operation in a simplified case. FIG. 7 describes by way of non-limiting example the situation in which the amplitudes of the potentials belonging to VH vary in a discrete way between just two different values VH 1 and VH 2 (VH 1 different from VH 2 ) during the transient in which the particle (BEAD) initially trapped in the resting position (XY 21 ) moves towards the new destination (XY 22 ). The length and intensity of the lines of force, i.e., of the paths followed, depend upon the potentials applied, and consequently, by acting on the potentials (VH) during the transient, it is possible to modify the line of force followed by the particle and consequently the duration of the displacement. In the particular case, three different paths (TR 1 , TR 1 ′ and TR 2 ) are represented:
1. TR 1 corresponds to the voltage VH 1 and passes through the resting position XY 21 ; 2. TR 2 corresponds to the voltage VH 2 and passes through the resting position XY 21 ; 3. TR 1 ′ corresponds to the voltage VH 1 , does not pass through the resting position XY 21 , and crosses the path TR 2 in the point reached by the particle that follows the path TR 2 at the instant t 1 .
In order to reduce the total travelling time with respect to the travel path TR 1 or TR 2 , it is possible to follow a path made up of broken lines of different paths for different time intervals. For example, in the case represented in FIG. 7 we can:
1. apply the voltage VH 2 up to the instant t 1 ; the particle initially follows the path TR 2 ; 2. apply the voltage VH 1 for instants subsequent to t 1 up to t 2 ; the particle follows the path TR 1 ′.
The total time required by the particle to reach the new point of equilibrium is in this case shorter than the time required to follow entirely the path determined by application of the potential VH 1 or VH 2 for the entire duration of the transient. In the most general case, the voltage applied can vary in a discrete way between a generic number of values or continuously. It is evident to persons skilled in the art that it is possible to determine a temporal function that characterizes the evolution in time of the voltage that minimizes the travelling time. Said function can vary for different types of particles and can be determined experimentally or by means of numeric simulations.
Modulation in Time of the Potentials
A further embodiment of the method according to the present invention is shown in FIG. 5 . The signals VL and VH applied respectively to the first (SE 1 ) and second (SE 2 ) class of electrodes are made up of a succession of intervals DL in which the signal is active both for VL and for VH and intervals DH in which the signal is not active for VL but is active for VH. For VH a signal is obtained that is active throughout the transient, whilst for VL a signal is obtained that is active at intervals. Exploiting the inertia of the system constituted by the particle and the liquid that acts as low-pass filter on the dynamics, the same effect will be obtained of a signal with constant amplitude equal to the product of the amplitude of the active signal (VH) and the ratio between the duration of the interval DH and the duration of the interval DL. In this way, we can obtain the equivalent effect of low voltages for static cages (CAGE 1 ) or high voltages for dynamic cages (CAGE 2 ) by simply modifying the duration of the interval DH and/or DL. The frequency with which DH alternates with DL is determined by the property of inertia of the system. The advantage of this technique as compared to the previous ones is that it does not require the use of dedicated signals for low voltages (VL) and high voltages (VH). The source of the signal can remain the same for all the electrodes and equal to the maximum value VHMAX. Said signal is then applied to the dynamic cages (CAGE 2 ) and static cages coherently with the programming CH for the dynamic cages (CAGE 2 ) and with the programming CL for the static cages (CAGE 1 ). Associated to each electrode is a programming signal that follows the sequence designated by CL for electrodes belonging to SE 1 whilst it follows the sequence designated by CH for electrodes belonging to SE 2 . A zero value of CL or CH indicates absence of a signal on that given electrode, whilst a value of 1 indicates presence of the signal. In some cases, it may be preferable to use a period DL+DH longer than the reverse of the cut-off frequency of the inertia of the system made up of the particles and liquid. As a consequence of this, each particle belonging to EL 1 will be subjected to local oscillations around the point of equilibrium.
Apparatus for Temperature Control by Means of Peltier-effect Cells
Forming the subject of the present invention is also an apparatus for removal of the heat from the space inside the microchamber (M). By way of non-limiting example, some possible embodiments are provided based upon the use of Peltier-effect cells. FIG. 6 shows a possible embodiment in which the Peltier cell (PT) is in contact with the surface (S 2 ) of the substrate (SUB 1 ). According to the amount of heat Q 0 removed and the amount of heat QJ generated, a mean temperature may be obtained in the liquid (S) equal to, lower than, or higher than, the initial temperature (T). The apparatus requires a system (not shown in the figure) for dissipating the total heat QPT consisting of the sum of the heat removed Q 0 and the heat generated by the Peltier cell. This can be obtained with conventional techniques known to persons skilled in the art. The system can benefit from the use of one or more temperature sensors (TS) integrated in the substrate or inside the microchamber or external thereto for controlling, by means of an electronic control unit (C), the heat pump (PT) in order to maintain the temperature constant or increase or reduce the temperature. Processing of the information coming from the sensor and generation of the control signals for the heat pump (PT) can occur with conventional techniques commonly known to persons skilled in the art.
Apparatus for Temperature Control by Means of External Flow of Liquid or Gas
Forming the subject of the present invention is also an apparatus for removal of the heat from the space inside the microchamber (M) by means of forced or natural convention. By way of non-limiting example, some possible embodiments are provided based upon the use of a liquid or gas made to flow in contact with the surface S 2 of the substrate SUB 1 ( FIG. 8 ). According to the amount of heat QF removed and the amount of heat QJ generated a mean temperature may be obtained in the liquid (S) equal to, lower than, or higher than, the initial temperature (T). The amount QF of heat removed will depend upon the temperature of the liquid or gas (T 0 ), upon the flow rate, and upon the speed of the liquid or gas. Forced convection can occur for example as shown in FIG. 9 by means of a peristaltic pump (PM), which determines the direction and speed of movement of the liquid through a fluid-dynamic circuit made using tubes (TB). The liquid is drawn from a tank (SH) and traverses the microchamber (MG) flowing in contact with the surface (S 2 ) of the substrate (SUB 1 ). The heat absorbed is conveyed by the liquid, which finishes up again in the same tank (SH). Various solutions are possible based upon the use of closed or open circuits in which the heat absorbed by the liquid is dissipated in the environment through appropriate dissipaters rather than in the tank, as likewise possible are solutions in which the temperature of the cooling liquid is monitored and/or controlled. Said apparatus proves particularly useful for providing transparent devices since if a transparent substrate (SUB 1 ) and lid (LID and a transparent microchamber (MH) and cooling liquid (LH) are used, the light (LT) emitted from light source LS can traverse entirely the device for microscopy inspection based upon phase contrast for use of reversed microscopes.
Apparatus for Maximizing Convective Heat Exchange
Forming the subject of the present invention are likewise some techniques for maximizing extraction of heat by forced or natural convection.
Increase of the Exchange Surface and/or Creation of Turbulence
Convective heat exchange between one or more substrates (SUB 1 ) and the liquid (LH) can be maximized by appropriately modifying the surface S 2 . By way of non-limiting example, FIG. 10 shows a possible embodiment based upon the use of tower-like projections, which have a dual effect:
1. increasing the total exchange surface; and 2. favouring onset of turbulence in the cooling liquid (LH), thus improving the heat exchange between the substrate (SUB 1 ) and the liquid (LH).
It is evident to persons skilled in the art that different profiles for the surface S 2 are possible.
Change of Phase from Liquid to Vapour
Heat exchange between the substrate (SUB 1 ) and the cooling liquid or gas can be improved if a pressurized vapour is used so that it will condense in the proximity of the heat-exchange surface S 2 . In this case, the energy required for phase change is added to that due to the difference in temperature between S 2 and LH.
Variation of Pressure
If gas is used, heat exchange between the substrate (SUB 1 ) and the cooling liquid (LH) can be increased by reducing the pressure of the cooling gas in the proximity of the cooling microchamber (MH). In this way, the temperature of the gas drops, and the flow of heat Q 0 absorbed by the gas increases.
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The present invention relates to an apparatus and method for manipulation and/or position control of particles by means of force fields of electrical nature in electrically conductive solutions, wherein power dissipated by Joule effect, which may cause the death of biological specimens under examination, is advantageously removed. The apparatus comprises a first substrate, upon which lies an array of electrodes, the application of a set of electric voltages to the electrodes generating a force field; a second substrate at a distance from, and parallel to, the first substrate so as to delimit a microchamber within which a liquid containing the particles is inserted; and cooling means for extracting an appropriate amount of heat from the microchamber, the cooling means comprising a second microchamber made in contact with, or by means of, the first or second substrate and through which a flow of cooling liquid or gas is pumped.
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FIELD OF INVENTION
This invention related to a star and crescent structure and method thereof. More particularly it relates to a structure comprising a star which is secured to a crescent via at least one link, and method thereof
BACKGROUND OF INVENTION
Different religious, cultural and social organizations have symbols and insignias to represent them. Muslims are in the process of adopting different symbols and insignias to represent them. Thus there is a need to invent symbols and insignias for the different Muslim communities.
PURPOSES AND SUMMARY OF THE INVENTION
The invention is a novel method and a star and crescent structure.
Therefore, one purpose of this invention is to provide a star and crescent structure and method thereof.
Another purpose of this invention is to provide a structure comprising a star which is secured to a crescent via at least one link, and method thereof.
Therefore, in one aspect this invention comprises a star which is secured to a crescent via at least one link, and method thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the invention believed to be novel and the elements characteristic of the invention are set forth with particularity in the appended claims. The drawings are for illustration purposes only and are not drawn to scale. Furthermore, like numbers represent like features in the drawings. The invention itself, however, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which:
FIG. 1 illustrates a first embodiment of the invention.
FIG. 2 illustrates a first method of making a crescent and a star.
FIG. 3 illustrates a detailed method of making a star.
FIG. 4 illustrates a detailed method of making a crescent.
FIG. 5 illustrates a method of making plurality of crescents and stars.
FIG. 6 illustrates a second embodiment of the invention.
DETAILED DESCRIPTION
A star and crescent combination symbol has been invented to represent primarily the Muslims and secondarily any and all organization that would benefit from such an invention. The crescent and a star combination symbol could be used throughout the year, and especially during the holiday season.
ISNA (Islamic Society of North America) Secretary General Dr. Sayyid M. Syeed had said “This public display of the Muslim symbol alongside the symbols of Christianity and Judaism during the holiday season . . . is a much-needed recognition, especially when other major religions and their roles in the lives of Americans are being acknowledged.”
Although the crescent and star does not have any religious significance or symbolism in Islam, it will be generally accepted as a public Muslim symbol, as the crescent moon has a central function in the Muslim lunar calendar as each month starts with the sighting of the new moon.
The star can be said to represent the 5 pillars of Islam: (1) the declaration of faith; (2) the duty to pray 5 times a day; (3) giving zakat, the annual charity; (4) fasting in the month of Ramadan; and (5) performance of Hajj, the pilgrimage. The 7 points in the symbol—5 from the star and 2 from the crescent moon—may be likened to represent the 7 articles of faith for the Muslims. They are belief in (1) Allah (God), (2) Angels, (3) God's Books—the Torah, the Bible, and the Qur'an, (4) God's Messengers—Adam to Moses to Jesus to Muhammad (peace be upon them all), (5) the Day of Resurrection, (6) Destiny, and (7) Life after Death. The color white is generally recognized to symbolize peace and purity, and the color green to represent prosperity and growth.
It should be stressed that the Muslim symbol adopted in the U.S. is not meant to be an embodiment of Islam per se, and Muslims around the world may envision other designs. It should also be noted that Islam prohibits the worship of symbols or representations of any worldly structures. ISNA has also stated that any Muslim symbol has no religious significance and only represents a national Muslim identity.
FIG. 1 illustrates a first embodiment of the Muslim symbol invention 23 . On a structure 10 , a crescent 12 is secured. The crescent 12 has means to securely accommodate a linking structure 14 . One end of the linking structure 14 is securely attached to the crescent 12 , while the other end is secured to a five-point star 16 . The color of the structure 10 is preferably green, while the color of the crescent 12 and the star 16 is white. The linking structure 14 , can be of any color such as black, brown, to name a few. Preferably, a portion of the star 16 is within the inner radii of the crescent 12 .
FIG. 2 illustrates a first method of making the crescent 12 and the star 16 . On a flat structure 20 , such as, a piece of plywood, a wood panel, a metallic panel, a fiberglass panel, to name a few, preferably having a width of 36 inches and a length of 48 inches, the crescent 12 is first drawn. The five-pointed star 16 is then drawn within the area enveloped by the inner radii of the crescent 12 . After both the crescent 12 and the star 16 have been marked the crescent 12 and the star 16 can be cut out of the panel structure 20 by methods well known in the art. For the ease of illustration only one flat structure 20 has been shown but it should be understood that a plurality of flat structures 20 can be underneath. Thus, a plurality of panel would yield a plurality of crescents 12 and stars 16 when the panels 20 are cut.
FIG. 3 illustrates a detailed method of making the star 16 . From a center point C an outer radius of say 13 inches is drawn thus yielding a diameter of 26 inches for the outer circle O. An inner radius of say 5 inches is drawn from the same center point C, thus yielding a diameter of 10 inches for the inner circle I. A single point is chosen on the outer circle, say O 1 and from this single point O 1 four more points, such as, O 2 , O 3 , O 4 and O 5 , are chosen on the outer circle O such that each point O 1 , O 2 , O 3 , O 4 and O 5 are approximately 72 degrees away from the other point. A line is then drawn from each of the points on the outer circle O 1 , O 2 , O 3 , O 4 and O 5 , so that that line intersects the inner circle I at at least two different locations, thus creating points I 1 , I 2 , I 3 , I 4 and I 5 on in inner circle. A line is then drawn from each of the intersecting points on the inner circle I 1 , I 2 , I 3 , I 4 and I 5 to the closest points on the outer circle. Thus each intersecting point I 1 , I 2 , I 3 , I 4 and I 5 on the inner circle will be connected to two different points on the outer circle, and this will result in a five-pointed star 16 . The area between the inner circle I and the outer circle O that is outside of the connected lines is removed, such as, by cutting, and this will result in a stand alone five-pointed star 16 .
FIG. 4 illustrates a detailed method of making the crescent 12 . Using a panel 20 as shown in FIG. 2 , a line 41 bisecting the width is drawn. For this case, for a panel having, say a width of 36 inches and a length of say 48 inches will result in a line 41 that is at about 24 inches from the top and bottom edge. At a distance, such as, point C A a circle of say about 24 inches is drawn which would result in the outer edge of the crescent 12 . Another circle of say 21 inches is drawn from a point C B along the bisecting line 41 at a distance of say about 8 inches away from the first circle point C A along the bisecting line. The inner and outer circles meet in an arc, having ends 42 and 44 , thus creating a crescent 12 . Areas exterior to the crescent 12 are removed thus resulting in a stand-alone crescent 12 .
FIG. 5 illustrates a method of making plurality of crescents and stars. On a larger panel 50 , such as, a panel having a width of 48 inches and a length of 96 inches a plurality of stars 16 and crescents 12 can be obtained using the dimension discussed with reference to FIGS. 3 and 4 .
FIG. 6 illustrates a second embodiment of the invention. The structure 10 , having the star 16 secured to the crescent 12 with the link 14 is secured to another structure 63 . The structure 63 could be the earth, a flat panel, a base, to name a few. In order to illuminate the Muslim symbol 23 at least one illumination device 65 is provided. The illumination device 65 can be secured to a separate base or a structure or could be secured to a portion of the structure 63 . Electrical wires 60 could also be provided to provide power to the illumination device 65 . The illumination device 65 , could be selected from a group consisting of outdoor light, indoor light, flood light, halogen light, fog light, fiber optic light, to name a few.
While the present invention has been particularly described in conjunction with a specific preferred embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications and variations as falling within the true scope and spirit of the present invention.
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This invention related to a star and crescent structure and method thereof. More particularly it relates to a structure comprising a star which is secured to a crescent via at least one link, and method thereof.
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BACKGROUND OF THE INVENTION
The invention relates to a brush having a bristle carrier comprising at least two substantially parallel layers of different plastics, produced using the two-component injection molding process, and with bristles fixed to at least one of the layers.
Brushes produced in a two-component injection molding process are known in numerous different constructional forms. There are several reasons for constructing the bristle carrier from two different plastics. Thus, it can be advantageous for cost reasons alone to make a larger part of the bristle carrier from an inexpensive plastic, with the remainder being made from a higher grade, more expensive plastic, in order to obtain a cost saving. The higher grade plastic mainly fulfils strength functions, but can also fulfil special use functions. In addition, the plastic carrying the bristles can be chosen as a function of the bristle fastening mode. Fastening can take place in pre-shaped holes by punching, by injection molding of the fastening side ends in the plastic of the bristle carrier, by welding onto the bristle carrier or using other thermoplastic or mechanical processes.
From the manufacturing and also use standpoints special demands are made in the case of small brushes, particularly toothbrushes. A large number of bristles must be housed in a comparatively small surface area in order to bring about the cleaning action on the teeth and optionally a massaging action of the gums combined therewith. In addition, the large number of bristles must be housed on a bristle carrier with a small volume, because the bristle carrier must take account of the very different space conditions in the mouth of the maximum number of users. This makes necessary a narrow, flat brush head. The bristles must also have a high extraction resistance, which should be as constant as possible for all the bristles, because detached bristles not only lead to unpleasant effects in the mouth through jamming in the interdental gaps, but can also constitute a health hazard if they enter the esophagus or digestive tract.
A toothbrush head is made from two components (DE 3628722 Al) e.g. in order to wholly or partly envelop the brush head part having the necessary strength characteristics, which is made from a rigid plastic, with a softer, rubber-like material, e.g. an elastomer in order to reduce the injury risk in the mouth as a result of sharp edges and the like. In particular a layer-wise structure is known, in which the rigid plastic of the brush head is covered on its narrow sides and underside with the elastomer and the bristles are exclusively connected by welding to the elastomer layer. Through the fastening of the bristles in the elastomer layer the bristles also acquire a type of elastic mounting, which aids the sideways, elastic deflection of the bristles.
In another known construction (U.S. Pat. No. 1,770,195) the brush head of a hard material is integral with the handle and is completely surrounded by a rubber-like material provided on the bristle side with cup-shaped studs in which the bristle bundles are inserted, so as to acquire in this case again an additional springiness transversely to the bundle axis.
It is also known (U.S. Pat. No. 5,373,602) to construct the brush head in two parts, one part integral with the handle material and having a shorter construction, with the front end of the head being supplemented by a second elastomer part, which also engages over the top of the hard part and covers the latter. This is in particular intended to permit a bending of the front head part with respect to the rigid, short head part. If the handle and rear head part are made from conventional rigid plastics such as PS, PP, etc., these two different plastics cannot be adequately firmly interconnected, or this can only be achieved with considerable effort and expenditure. Conventional two-component injection molding processes are excluded, because the two plastics form no integral connection.
In another known construction (EP 310482) the brush head made from rigid plastic and in one piece with the handle is surrounded on the narrow sides and brush head end by an elastomer, whereas the bristles are exclusively fixed to the surface of the rigid part left free. This naturally leads to a deterioration of the area usable for the bristle configuration. The adhesion of the elastomer part compared with the aforementioned construction is improved in that said part engages in cap-like manner at the front end over the brush head and is fixed by a supplementary heat treatment on which EP 314482 provides no information.
It is finally known (WO 97/20484) to give a narrower construction to the hard part of the brush head in one piece with the handle in the longitudinal axis of the head and to increase the size in the vicinity of the front end to the contour dimension of the head. The narrow part forms the carrier for a type of skeleton structure with cup-shaped receptacles for the bristle bundles, said receptacles being made from the same rigid plastic. These cup-shaped receptacles are injected round with an elastomer, whilst completing the contour of the head and said elastomer may optionally surround the entire hard or rigid part. The bristles are partly fixed in the hard central part and partly in the cup-shaped receptacles of the elastomeric marginal parts. The latter are consequently able to give way in a flexible manner. In the latter construction as a result of the multiple penetration of the hard and soft components a secure connection between the two plastics can be assumed, but the structure of the brush head is extremely complicated and complicated injection moulds are required and the brush head flexibility desired in the case of toothbrushes is only obtained in the marginal areas and cannot be adapted to specific needs.
The problem of the invention, in the case of a brush, whose bristle carrier is made from different plastics, is to propose a construction which on the one hand permits an individual adaptation of flexibility to the particular requirements and on the other ensures a reliable and permanent connection between the two plastic components.
To solve this problem the invention is based on a brush having a bristle carrier comprising at least two substantially planar, parallel layers of different plastics produced in a two-component injection molding process, the bristles being fastened to at least one of the layers (DE 3628722). In a further development of this brush the problem of the invention is solved in that at least the bristle carrier layer remote from the bristles has openings, which are circumferentially closed and filled with the plastic of the other layer.
SUMMARY OF THE INVENTION
The invention firstly makes use of the clearly defined and relatively simple construction of the bristle carrier from substantially parallel layers offering for the at least two plastics large contact surfaces and correspondingly large adhesion surfaces as a consequence. In such a layer structure the use characteristics of the brush can be very precisely matched to the particular requirements without the need for complicated injection moulds for production purposes. It is in particular possible to very precisely adapt the flexibility over the entire length of the brush head or partial areas thereof to the given needs, by the selection of the plastics used, by a corresponding geometry of the layers and in particular the layer thickness with respect to the moment of inertia decisive for bendability. The circumferentially closed openings, which are provided at least in the layer remote from the bristle side are filled with the plastic of the other layer in two-component injection molding. This leads to an increase in the size of the adhesion surface and at the same time a type of tenon joint between the two layers, so as to permit an adequately firm and reliable interconnection of plastics, which are otherwise difficult to join together. In addition, the circumferentially closed openings, which lead to a weakening of the layer in which they are located, can be used for adjusting to the particular requirements the flexibility of the bristle carrier through the shape, arrangement and number of the openings.
Between the edge of the openings of one layer and the plastic of the other layer filling the same there can be a non-positive connection, which is particularly effective when the plastic of one layer, which penetrates the openings, expands during injection molding.
The non-positive connection can be supplemented or replaced by an integral connection, provided that the plastics of the at least two layers have sufficient affinity.
Both the aforementioned connection types can be supplemented or replaced by a positive connection, in that the openings have undercuts.
In the case of brushes with a flexible bristle carrier, which gives way under the forces acting on the bristles when the brush is being used, according to the invention the flexibility can be adjusted by the thickness of the layers and the choice of the plastics forming them.
Instead of or in addition thereto the flexibility of the bristle carrier can be adjusted through the number and/or the shape or size of the circumferentially closed openings in one layer.
It is particularly advantageous to have slot-like openings running transversely to the longitudinal axis of the bristle carrier and which are marginally closed. With such a construction there is mainly a non-positive and optionally also a positive connection of the two plastics in the vicinity of the opening.
Instead of this the openings in one layer can also have a wall diverging from the interface between the two layers so as to form an undercut, which leads to a positive connection. During injection molding the plastic of one layer filling the openings can, as desired, be injected on from one or other side.
The invention also provides the possibility of giving the openings in the layer remote from the bristles and forming the back of the bristle carrier a contour which, in conjunction with the differently colored plastics for the two layers, forms an information medium for the user. For example, it can be a color indicator for the type of bristles, e.g. their hardness, letters with information for the user, information in the form of ordering means or the like.
According to a preferred development, at least the layer carrying the bristles is formed from an elastomer and said layer elastically supports the bristles. In this case, the bristles are preferably anchored in the elastomer layer by welding or injection molding.
Advantageously the elastomer layer carrying the bristles is covered by a layer of a less flexible plastic through which the bristles pass. It can be a relatively thin layer, which in conjunction with the bristles welded or injection molded into the elastomer layer additionally increases the extraction resistance.
With such a three-layer structure the bristles can be located in only one or in two adjacent layers, as desired. In addition, one part of the bristles can be fastened in one layer and another part in the two adjacent layers.
The invention is described in greater detail hereinafter relative to embodiments and the attached drawings, wherein show:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 A longitudinal section through a toothbrush head in a first embodiment.
FIG. 2 A plan view of the toothbrush head of FIG. 1 .
FIG. 3 A section similar to FIG. 1 through another embodiment.
FIG. 4 A section similar to FIG. 1 through a further embodiment.
FIG. 5 a A longitudinal section through a toothbrush head in a three-layer construction.
FIG. 5 b A section corresponding to FIG. 5 a of a modified construction.
FIG. 6 A side view of a toothbrush head in a modified construction.
FIG. 7 A longitudinal section corresponding to FIG. 1 through a further embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The toothbrush shown in only detail form in the drawings has a handle 1 and a head serving as the bristle carrier 2 and on which the bristles 3 are located in the form of bundles 3 a , areas or in individual standing manner 3 b . In the embodiment shown the bristle carrier 2 comprises two substantially parallel layers 4 and 5 , whereof the layer 4 is made from a comparatively rigid plastic, whereas the layer 5 is e.g. formed from a rubber-like plastic, particularly an elastomer. The bristles 3 are fastened, e.g. by welding, injection molding or the like in said soft layer 5 .
The layer 4 , which is in one piece with the handle 1 , and the layer 5 can be produced in a single or in two successive injection moulds using so-called two-component injection molding. In order to enlarge the adhesion surface between the two layers 4 and 5 , the bristle carrier 2 has openings 6 which, as shown in FIG. 2, are circumferentially closed and e.g. have a slot-like construction which are penetrated by the plastic of the other layer 5 during injection molding. As shown in FIG. 1, the openings 6 can widen conically outwards, so that the layer 5 is firmly anchored in layer 4 .
Through the shaping, number and arrangement of the openings 6 it is possible to adjust the flexibility of the entire brush head of layer 4 and layer 5 to the given needs.
The embodiment according to FIG. 3 differs from that according to FIG. 1 only in that the interface 7 between the two layers 4 , 5 is corrugated or studded, but both layers are still substantially parallel to one another. In the area of the top of the wavy interface 7 are located the openings 6 penetrated by the plastic of layer 5 during injection molding. In the area of said top can also be embedded the bristles 3 or bristle bundles in order to ensure a maximum embedding depth. In conjunction with the plastic filling the openings a particularly high extraction resistance is obtained.
The embodiment of FIG. 4 differs from that of FIG. 1 in that the layer 5 receiving the bristles 3 has a wavy or corrugated surface. The bristles 3 combined into bundles 3 a are fastened in alignment with the openings in the area of the valleys of the wave profile or local depressions 8 , in order to obtain an adequate extraction resistance with comparatively thin layers 4 and 5 . Individual bristles 3 b are fastened in the vicinity of the wave top or in the thicker areas of the layer 5 .
In the embodiment of FIGS. 5 a and 5 b the bristle carrier 2 is constructed from three layers, namely the layer 4 , which is once again in one piece with the handle 1 and can be made from a more rigid plastic, a central layer 10 and a lower layer 11 , which can optionally be made from the same plastic as the layer 4 , whilst the central layer 10 is e.g. formed by an elastomer. The bristles 3 can either be fastened solely in the lower layer 11 , as indicated by the bundle 12 , or can extend into the central layer 10 , as indicated by the bundles 13 . It is finally possible for the bristles 3 to be inserted into the upper layer 4 , in the manner of the bristles 14 .
In the embodiment according to FIG. 5 a the upper layer 4 and lower layer 11 in each case have outwardly widening openings 6 penetrated by the plastic of the central layer 10 , whereas in the embodiment according to FIG. 5 b the central layer only has openings 15 through which penetrates the plastic of the lower layer 11 into the openings 6 of the upper layer 4 . The individual bristles 3 b can be anchored in one or more layers so as to fill the openings.
In the embodiment according to FIG. 6 the bristle carrier 2 comprises the layer 4 , which is one piece with the handle, but only extends over part of the length of the bristle carrier 2 , and the layer 5 , which engages below the layer 4 and simultaneously forms the front area 9 of the bristle carrier 2 . The layer 4 once again has the openings 6 penetrated by the plastic from the overlapping part of the layer 5 . The bristles 3 are exclusively fastened in the layer 5 in the part overlapping the layer 4 and in the part 9 forming the front end.
In the embodiment according to FIG. 7 the bristle carrier 2 once again comprises the layers 4 and 5 and in this case the layer 5 has openings 16 and the plastic of layer 4 penetrates or passes through said openings. In the resulting pin-like projections 17 are inserted the bristles 3 e.g. by punching, injection molding or fastened in some other way. In the embodiment shown the layer 4 is also provided with openings 6 penetrated by the plastic of layer 5 .
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A brush comprises a bristle carrier of at least two substantially parallel layers of different plastics produced in a two-component injection molding process and bristles fastened to at least one of the layers. The brush is characterized in that at least the bristle carrier layer remote from the bristles has openings, which are circumferentially closed and filled with the plastic of the other layer.
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This is a divisional application of Ser. No. 08/207,126, filed Mar. 8, 1994, now U.S. Pat. No. 5,426,064.
FIELD OF THE INVENTION
The present invention relates to a method of fabricating a semiconductor device in the form of a thin film such as a thin-film transistor (TFT) or a thin-film diode and, more particularly, to a method of fabricating a semiconductor device using a crystalline semiconductor material. A semiconductor device fabricated according to the invention can be formed either on an insulating substrate made of glass or the like or on a semiconductor substrate made of a single crystal of silicon or the like.
BACKGROUND OF THE INVENTION
Thin-film semiconductor devices such as thin-film transistors and thin-film diodes are classified into amorphous devices and crystalline devices, depending on the kind of silicon used. Since amorphous silicon is inferior in physical characteristics such as field mobility and conductivity to crystalline silicon, crystalline semiconductor devices are required in order to obtain excellent operating characteristics.
However, to crystallize a silicon film, a high temperature exceeding 600° C. is needed. Also, it takes a long time to crystallize the film. Where crystalline silicon devices are mass-produced in practice, several crystallizing machines are required. Consequently, huge investment in equipment results in increased costs.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method of fabricating a semiconductor device by crystallizing a silicon film below 600° C. in a substantially negligibly short time. In the present invention, a trace amount of catalytic material is added to a substantially amorphous silicon film to promote crystallization and to lower the crystallization temperature, thus shortening the crystallization time. Adequate examples of the catalytic material include metal elements such as nickel (Ni), iron (Fe), cobalt (Co), and platinum, and compounds such as silicides. In particular, a film, particles, clusters, or the like containing any one of these elements form a layer on or under an amorphous silicon film so as to be in intimate contact with this amorphous silicon film. Alternatively, any one of these elements is implanted into an amorphous silicon film by ion implantation and then the film is thermally annealed at an appropriate temperature to crystallize the film.
When the amorphous silicon film is formed by CVD, the catalytic material is added to the raw material gas. When the amorphous silicon film is formed by physical vapor deposition such as sputtering, the catalytic material is added to the target or evaporation source which forms a film. Of course, as the anneal temperature rises, the crystallization time decreases. Furthermore, as the concentrations of nickel, iron, cobalt, and platinum are increased, the crystallization temperature drops, and the crystallization time is shortened. Our research has revealed that if the concentration of at least one of these elements is in excess of 1×10 17 cm -3 , favorable results are obtained. Preferably, the concentrations of these elements are determined, using the minimum values in the film measured by SIMS (secondary ion mass spectroscopy).
Since all of the aforementioned catalytic materials are not desirable for silicon, it is desired their concentrations be made as low as possible. Our research has shown that the total concentration of these catalytic materials is preferably not in excess of 1×10 20 cm -3 . To improve the characteristics further, the surface of the silicon film which has been crystallized by thermal annealing is etched to a depth of 20 to 200 Å or to a depth of not more than 50% of the thickness of the silicon film, preferably between 1/100 and 1/5 of the thickness of the silicon film, because excessive portions of these catalytic materials tend to be deposited on the surface. The surface cleaned in this way is coated with an insulating film by a CVD method such as plasma CVD, photo-assisted CVD, or LPCVD or a physical vapor deposition method such as sputtering, the insulating film consisting mainly of silicon oxide. As a result, the clean interlace is preserved. If necessary, phosphorus or other element may be added to the insulating film. This semiconductor-insulating film structure can be directly used for a MOS structure. Where TFTs were fabricated by the method described above, leakage current (OFF current) decreased, and the sub threshold characteristics were improved.
Other objects and features of the invention will appear in the course of the description thereof, which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1(A) to 1(E) are cross-sectional views of TFTs, illustrating steps for manufacturing the TFTs according to Example 1 of the present invention;
FIG. 2 is a graph showing the characteristics of the TFTs shown in FIGS. 1(A)to 1(E); and
FIGS. 3 (A) to 3(E) are cross-sectional views of TFTs, illustrating steps for manufacturing the TFTs according to Example 2 of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
EXAMPLE 1
FIG. 1, (A)-(E), are cross-sectional views of TFTs, illustrating steps for fabricating the TFTs according to the present example. In the present example, two kinds of TFTs were fabricated. First, silicon oxide was sputtered as a base film 11 to a thickness of 2000 Å, on a substrate 10 made of Corning 7059. An amorphous silicon film 12 having a thickness of 500 to 1500 Å, e.g., 800 Å, was formed on the silicon oxide film 11 by plasma CVD. Subsequently, nickel silicide was deposited as a film 13 having a thickness of 5 to 200 Å,, e.g., 20 Å, by sputtering (FIG. 1(A)). The nickel silicide film 13 is given by the chemical formula NiSi x ;
0.4≦x≦2.5, e.g., x=2.0.
The laminate was annealed at 500° C. for four hours in a reducing ambient to crystallize the amorphous silicon film. Up to this step, the two TFTs were treated in the same way. The surface of one TFT was etched to a depth of 20 to 200 Å, e.g., 100 Å, with an etchant containing hydrofluoric acid. In this way, a clean surface 14 was exposed. The other TFT was merely cleaned with pure water and not etched (FIG. 1(B)).
Thereafter, the two TFTs underwent the same steps. The obtained silicon film was photolithographically patterned to form island regions 15. Silicon oxide was sputtered as a gate-insulating film 16 having a thickness of 1000 Å. A target consisting of silicon oxide was used in the sputtering step. In this sputtering step, the substrate temperature was 200° to 400° C., e.g., 350° C. The sputtering ambient contained oxygen and argon. The ratio of the argon to the oxygen was 0 to 0.5, e.g., less than 0.1 (FIG. 1(C)).
Subsequently, silicon containing 0.1 to 2% phosphorus was deposited to a thickness of 6000 to 8000 Å, e.g., 6000 Å by LPCVD. Preferably, the steps for forming the silicon oxide film and the silicon film are carried out in succession. The silicon film was patterned to form gate electrodes 17.
Then, phosphorus ions were implanted into the silicon region by plasma ion implantation, using the gate electrodes 17 as a mask. Phosphine (pH) was used as a dopant gas. The accelerating voltage was 60 to 90 kV, e.g., 80 kV. The dose was 1×10 15 to 8×10 15 cm -2 , e.g., 5×10 15 cm -2 . As a result, N-type doped regions 18a and 18b were formed (FIG. 1(D)).
Thereafter, the laminate was annealed at 500° C. for four hours to activate the impurities. Since the nickel atoms were diffused into the silicon film, recrystallization was promoted by the anneal, and the doped regions 18a and 18b were activated. Subsequently, an interlayer insulator 19 having a thickness of 6000 Å was formed from silicon oxide by plasma CVD. Contact holes were formed in the silicon oxide film 19. Conductive interconnects 20a and 20b were formed from a multi-layer film of titanium nitride and aluminum. Finally, the laminate was annealed at 350° C. for 30 minutes in a hydrogen ambient at 1 atm. Thus, a semiconductor circuit was completed (FIG. 1(E)).
The ID-VG characteristics of the two kinds of TFTs obtained in the present example are shown in FIG. 2. During the measurement, the source-drain voltage was 1 V. Curve a indicates the characteristic of the TFT which was derived by etching the silicon surface to a depth of 100 Å after the crystallization and then forming the silicon oxide film. Curve b indicates the characteristic of the TFT which was fabricated by forming the silicon oxide film immediately after the crystallization. It can be seen from curve a that the leakage current I OFF a when a negative voltage was applied to the gate was small, and that a steep rising characteristic (S a ) occurred when a positive voltage was applied. Furthermore, the ON/OFF ratio is given by 9 digits. In this way, this device is an ideal field-effect transistor. The device indicated by curve b acts also as a field-effect transistor. However, the leakage current I OFF b is larger than the leakage current I OFF a of the former device. The rising characteristic (S b ) occurring when a positive voltage was impressed is milder. Also, the ON/OFF ratio is given by about 6 digits. The former device has a less threshold voltage than that of the latter device. This suggests that the density of the trap levels existing in the semiconductor film of the former device is smaller. In this manner, the present invention offers TFTs having novel characteristics.
EXAMPLE 2
FIG. 3, (A)-(E), are cross-sectional views of a semiconductor device, illustrating manufacturing steps according to the present invention. Silicon oxide was sputtered as a base film 31 to a thickness of 2000 Å on a substrate 30 made of Corning 7059. Nickel was deposited as a nickel film 33 having a thickness of 5 to 200 Å, e.g., 10 Å, by electron-beam evaporation. Then, an amorphous silicon film 32 having a thickness of 500 to 1500 Å, e.g., 500Å, was deposited by plasma CVD (FIG. 3(A)).
The laminate was annealed at 480° C. for 8 hours to crystallize the amorphous silicon film 32. Then, the surface of the silicon film was lightly etched to a depth of 20 to 200 Å with a plasma of carbon tetrachloride (CCl 4 ) or carbon tetrafluoride (CF 4 ). The laminate was subsequently treated at a temperature of 350° to 480° C. for 30 minutes in an ambient containing 1 to 10% hydrogen chloride (HCl). In this way, a clean surface 34 was formed (FIG. 3(B)).
Then, this silicon film was patterned to form island silicon regions 35. A gate-insulating film 36 having a thickness of 1000 Å, was fabricated from silicon oxide by plasma CVD which used TEOS (tetraethoxysilane, Si(OC 2 H 5 ) 4 and oxygen as raw materials. Trichloroethylene (C 2 HCl 3 ) was added to the raw material gases. Before the formation of the film, oxygen was supplied into the chamber at a flow rate of 400 SCCM. A plasma was created at a substrate temperature of 300° C., at a total pressure of 5 Pa, and at an RF power of 150 W. This state was maintained for 10 minutes. Then, oxygen, TEOS, and trichloroethylene were introduced into the chamber at flow rates of 300 SCCM, 15 SCCM, and 2 SCCM, respectively. Under this condition, a silicon oxide film was formed. The substrate temperature was 300° C. The RF power was 75 W. The total pressure was 5 Pa. After the completion of the film, hydrogen was introduced into the chamber at a pressure of 100 torr. The laminate was annealed at 350° C. for 35 minutes in a hydrogen ambient.
Subsequently, aluminum containing 2% silicon was deposited as an aluminum film having a thickness of 6000 to 8000 Å, for example 6000 Å, by sputtering. Preferably, the silicon oxide film 36 and the aluminum film are formed in succession. The aluminum film was photolithographically patterned to form conductive interconnects 37a, 37b, and 37c. The interconnects 37a and 37b acted as gate electrodes. The surfaces of the aluminum interconnects were anodized to form oxide layers 39a, 39b, and 39c on the surfaces. Before the anodization, a polyimide mask 38 was selectively formed from photosensitive polyimide (Photoneece) on those portions on which contacts would later be formed. During the anodization, no anodic oxide was formed on these portions because of the presence of a mask.
The anodization was conducted in an ethylene glycol solution containing 1 to 5% tartaric acid. The thickness of the obtained oxide layer was 2000 Å. Then, phosphorus ions were implanted into the silicon region by plasma ion implantation. Phosphine (PH 3 ) was used as a dopant gas. The accelerating voltage was 60 to 90 kV, for example 80 kV. The dose was 1×10 15 to 8×10 15 cm -2 , for example 2×10 15 cm -2 . In this way, N-type doped regions 40a were formed. Only the left TFT, or an N-channel TFT, was masked with a photoresist. Boron ions were implanted into the silicon region of the right TFT, or a P-channel TFT, again by plasma ion implantation. Diborane (B 2 H 6 ) was used as a dopant gas. The accelerating voltage was 50 to 80 kV, for example 65 kV. The dose was 1×10 15 to 8×10 15 cm -2 , for example 5×10 15 cm -2 , which was larger than the dose of the phosphorus previously implanted. In this way, the P-type doped regions 40b were formed.
Then, the impurities were activated by laser annealing. A KrF excimer laser having a wavelength of 248 nm and a pulse duration of 20 nsec was used as the above-described laser. Other lasers such as an XeF excimer laser emitting a wavelength of 353 nm, an XeCl excimer laser emitting a wavelength of 308 nm, and an ArF excimer laser emitting a wavelength of 193 nm may be employed. The energy density of the laser radiation was 200 to 400 mJ/cm 2 , for example 250 mJ/cm 2 . Two to ten shots, for example 2 shots, were emitted for each one location. During the laser irradiation, the substrate can be heated to about 200° to 450° C. It is to be noted that the best energy density is varied when the substrate is heated. In the laser illumination step, the polyimide "Photoneece" mask 38 was left behind because the exposed aluminum would be damaged by laser irradiation. This mask 38 can be easily removed by exposing it to an oxygen plasma. As a result, the doped regions 40a and 40b were activated (FIG. 3(D)).
Subsequently, a silicon oxide film 41 was formed from TEOS by plasma CVD to form an interlayer insulator having a thickness of 2000 Å. Contact holes were formed in this insulator. Conductive interconnects 42a, 42b, and 42c were formed from a metal material such as a multi-layer film of titanium nitride and aluminum. The interconnects 42c connect the interconnects 37c with one 41 of the doped regions 40b of the right TFT, or a P-channel TFT. In this manner, a semiconductor circuit was completed (FIG. 3(E)).
The semiconductor circuit was completed by the steps described thus far. The characteristics of the fabricated TFTs were by no means inferior to those of TFTs fabricated by the prior art method in which crystallization is carried out by an annealing step at 600° C. We have confirmed that a shift register fabricated according to the present example operates at 11 MHz at a drain voltage of 15 V and at 16 MHz at a drain voltage of 17 V. Furthermore, a reliability test showed that the novel TFTs did not differ in reliability from the TFTs fabricated by the prior art method.
The present invention permits fabrication of TFTs having improved characteristics and improved reliability. In the present invention, as described in connection with Example 2, silicon is crystallized at a low temperature, for example below 500° C, and in a short time, for example 4 hours. In addition, the obtained characteristics and reliability are never inferior to the characteristics and reliability obtained heretofore. Obviously, the throughput is enhanced, and the cost is reduced. Where a conventional 600° C.-process is adopted, the glass substrate shrinks and warps, leading to a decrease in the production yield. The present invention enables execution of a crystallization process below 550° C., which fully solves this problem. This means that a substrate of a large area can be treated simultaneously. That is, the single substrate of a large area is sawn into numerous ICs and hence the cost of each IC can be reduced greatly. In this way, the invention is industrially advantageous.
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Method of fabricating a semiconductor device, such as a thin-film transistor, having improved characteristics and improved reliability. The method is initiated with formation of a thin amorphous silicon film on a substrate. A metallization layer containing at least one of nickel, iron, cobalt, and platinum is selectively formed on or under the amorphous silicon film so as to be in intimate contact with the silicon film, or these metal elements are added to the amorphous silicon film. The amorphous silicon film is thermally annealed to crystallize it. The surface of the obtained crystalline silicon film is etched to a depth of 20 to 200 Å, thus producing a clean surface. An insulating film is formed on the clean surface by CVD or physical vapor deposition. Gate electrodes are formed on the insulating film.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. nonprovisional patent application entitled “Electronic Swimmer Monitoring System”, Ser. No. 12/175,797, filed on Jul. 18, 2008. Said nonprovisional patent application is incorporated herein by reference.
[0002] Said application Ser. No. 12/175,797 claims priority from U.S. provisional patent application entitled “Swimmer Safety Tags”, Ser. No. 60/951,243 filed on Jul. 23, 2007. Said provisional application is incorporated herein by reference.
FIELD OF THE INVENTION
[0003] The present invention is in the field of swimmer safety.
COPYRIGHT AND TRADEMARK NOTICE
[0004] A portion of the disclosure of this patent document contains material to which a claim for copyright is made. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure as it appears in the Patent and Trademark Office patent file or records, but reserves all other copyright rights whatsoever.
[0005] The word “WAHOOO” and fish logo as shown, inter alia, as item 1116 in FIG. 11A are trademarks of Aquatic Safety Concepts LLC.
BACKGROUND
[0006] Drowning is the second leading cause of accidental death in children in the United States. Adults are present in ninety percent of those incidents, intending to monitor the children to prevent drowning, yet the children all too often drown in silence, as their instantaneous peril readily escapes notice. Adult drownings in supervised settings are sadly common for the same reason.
SUMMARY OF THE INVENTION
[0007] The Summary of the Invention is provided as a guide to understanding the invention. It does not necessarily describe the most generic embodiment of the invention or all species of the invention disclosed herein.
[0008] The systems and methods of the present invention are designed to assist supervisory personnel to monitor people to reduce the risk of dangerous submersions. The invention advances the art by providing effective and commercially economical means to automate prompt notice of supervisory personnel of a person in potential distress.
[0009] The systems and methods of the present invention comprise equipping each person to be monitored in an aquatic environment with an electronic Tag worn on the body at a position from which immersion of the nose and mouth can be inferred, together with means for timing the immersion of the Tag in water for one or more periods of time associated with possible risk of drowning, and means for communicating between the Tag and electronic monitoring equipment, including alarms, and devices for system control and communications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a view of the entrance to a pool area where swimmers place Swimmer Safety Tags on their persons.
[0011] FIG. 2 is a view of swimmers wearing Tags entering the water.
[0012] FIG. 3 is a view of swimmers being monitored by a Swim Monitor Unit.
[0013] FIG. 4 is a view of a swimmer setting off a Yellow Alert.
[0014] FIG. 5 is a view of lifeguard and Control Unit being notified of a Yellow Alert.
[0015] FIG. 6 is a view of a swimmer setting off a Red Alarm.
[0016] FIG. 7 is a view of a lifeguard responding to a Red Alarm.
[0017] FIG. 8 is a view of a lifeguard rescuing a swimmer who triggered a Red Alarm.
[0018] FIG. 9 is a view of a pool with exemplary hydrophone placement.
[0019] FIG. 10 is a view of a pool with alternative exemplary hydrophone placement.
[0020] FIGS. 11A-11D are views of an exemplary Swimmer Safety Tag (“Tag”).
[0021] FIG. 12 is an exploded perspective view of a Tag.
[0022] FIG. 12 is a top view of an alternative Tag design.
[0023] FIGS. 14A-14D are cross sectional views of an exemplary means for packaging and dispensing Tags.
[0024] FIG. 15 is a perspective view of an exemplary means for packaging Tags for retail sale.
[0025] FIG. 16 is a top view of an alternative exemplary means for packaging Tags for retail sale.
[0026] FIG. 17 illustrates a method for refurbishing Tags.
[0027] FIG. 18 illustrates a means for mounting Tags on a swimmer's head using an elastic band.
[0028] FIG. 19 illustrates a means for mounting Tags on a swimmer's head using adhesive “wings”.
[0029] FIG. 20 is an illustration of an alternative means for determining how long a swimmer's head has been below water using the blockage of radio transmissions.
[0030] FIGS. 21A-21C are illustrations of a hip mounted Tag.
[0031] FIG. 22 illustrates the functionality of a hip mounted Tag.
[0032] FIGS. 23A-23C illustrate an exemplary annunciation unit portion of a Swim Monitor Unit.
[0033] FIG. 24 illustrates means for recharging the battery of an annunciation unit and alternative means for storing a connecting cable.
[0034] FIGS. 25A-25B illustrate an exemplary hydrophone unit portion of a Swim Monitor Unit.
[0035] FIG. 26 illustrates alternative positioning of an annunciation unit.
[0036] FIG. 27 illustrates an exemplary Control Unit.
[0037] FIG. 28 illustrates means for an annunciation unit to communicate with supervisory units as well as the Control Unit.
[0038] FIG. 29 is an illustration of a neck mounted Tag.
[0039] FIG. 30 is an illustration of an ear mounted Tag.
[0040] FIG. 31 is an illustration of a neck mounted Tag.
[0041] FIG. 32 is an illustration of an alternative ear mounted Tag.
DETAILED DESCRIPTION
[0042] The following detailed description discloses various embodiments and features of the invention. These embodiments and features are meant to be exemplary and not limiting.
[0043] As used herein, the term “about” means within ±20% of a given value unless specifically indicated otherwise.
Method for Increasing the Safety of Swimmers
[0044] FIGS. 1 to 8 illustrate an exemplary method for increasing the safety of swimmers as applied to a pool area. Similar methods can be applied to open water swimming areas, such a lake or ocean.
[0045] Referring to FIG. 1 , a pool area 100 is surrounded by a perimeter fence 120 with an opening 122 therein. Swimmers, such as children 102 , or adults 108 , pass through said opening on their way to the pool area. Each swimmer is provided with a Swimmer Safety Tag 104 that is affixed to a position on his or her head. Suitable positions include the forehead 106 or behind an ear. The Tags are provided with an adhesive so that they will remain affixed even in water, but can be removed without undue force or discomfort. Hence said Tags are said to be “removably mountable”. The adhesive used in water-proof bandages is suitable.
[0046] The Tags may be stored in a locker 112 . A supervisor 110 may be present to provide assistance with putting a Tag on and/or to make sure that all persons entering the pool area are “Tagged”.
[0047] Referring to FIG. 2 , the Tags 202 are electronic devices which will determine, inter alia, how long a person's head has been underwater and hence, by implication, how long both their nose and mouth are underwater. If a person's head has been underwater longer than a predetermined safe period, such as 30 seconds, an alarm will be triggered. Different alarm levels may be set at different time periods. A “Yellow Alert” may be set in the range of 20-30 seconds. A “Red Alarm” may be set in the range of 30-45 seconds. A preferred range for Yellow Alerts is 20 to 25 seconds. This will provide adequate warning to a lifeguard to identify, rescue and administer first aid to a distressed swimmer. A 20-25 second delay to Yellow Alert may be particularly suitable for young children, such as those six years old and under. These children would be less likely swim underwater for 25 seconds as part of their normal play the way older or more skilled children can.
[0048] An alternative alarm is simply a Red Alarm that is triggered by a Tag being underwater for 25 seconds or longer.
[0049] The Tags are activated when a person's head 204 enters the water 210 . The alarm signal may be an ultrasonic signal transmitted through the water.
[0050] Referring to FIG. 3 , the pool water is monitored by one or more Swim Monitor Units (SMU) 302 . A Swim Monitor Unit comprises an annunciation unit 310 , a connector cable 320 and a hydrophone unit 330 . The annunciation unit may comprise a strobe light 312 . They hydrophone unit may be placed near the bottom of the pool.
[0051] Referring to FIG. 4 , the hydrophone unit 430 listens for ultrasonic signals from the Tags. If a swimmer's head had been below the water for more than the Yellow Alert period, for example, then that swimmer's Tag gives off the ultrasonic Yellow Alert 402 . The signal is received 404 by the hydrophone unit and is transmitted (e.g. electrically) along the connector cable to the annunciation unit and the annunciation unit takes appropriate action, such as flashing the strobe 412 .
[0052] Referring to FIG. 5 , in addition to flashing the strobe, the annunciation unit 502 may also transmit a radio signal 504 to a nearby Supervisory Control Unit 510 . The radio transmission may be at typical frequency bands allocated to alarms, such 433 MHz The Control Unit, in turn, may also take appropriate action, such as flashing its strobe 512 and activating 514 other visual or audio alarms 520 .
[0053] Alternatively or in addition, the annunciation unit may communicate 506 an alarm signal directly to a portable reception unit 540 worn by a lifeguard 530 . Communication may be via suitable portable unit communications means, such as digital signals utilizing Bluetooth® technology or Bluetooth® Version 2 technology (collectively “Bluetooth” herein). The portable reception unit may notify the life guard that there is an alert via light, noise and/or vibration 542 .
[0054] Upon activation of a Yellow Alert, a lifeguard may take appropriate action, such as to call for a “buddy check” where all swimmers grab their buddy's hand and hold it up. This way the lifeguard can quickly confirm and identify which swimmer is in distress.
[0055] Referring to FIG. 6 , if a swimmer's head is underwater for more than the Red Alarm period (e.g. 45 seconds), then the Swimmer Safety Tag may transmit 602 a Red Alarm. The hydrophone will receive the Red Alarm and the annunciation unit and other components of the system may take appropriate action, such as sounding an audio alarm or notifying local emergency medical personnel. The lifeguard, in turn, may take appropriate action, such as clearing the pool of all swimmers and searching for the swimmer in distress.
[0056] Referring to FIGS. 7 and 8 , once the swimmer in distress is located, the lifeguard 702 can retrieve the swimmer and apply appropriate first aid if needed. The life guard may also reset the alarm system to the standby state and silence the alarms.
[0057] In an alternative embodiment, the Red Alarm automatically resets after a certain period of time. 1 to 2 minutes is an appropriate period of time. The benefit of a Red Alarm automatically resetting after 1 to 2 minutes is that by that time, it is likely that a lifeguard is applying first aid to the distressed swimmer. A continuous alarm would otherwise distract the lifeguard during the administration of first aid when the lifeguard must pay particular attention to, for example, the proper administration of artificial respiration.
System for Increasing the Safety of Swimmers
[0058] It will be appreciated by a person of ordinary skill in the art of water safety, that a practical system implementing the methods describe herein must simultaneously meet a number of demanding criteria. These criteria include, but are not limited to:
Acceptably low number of “false positives”. Similar to the “Boy who Cried Wolf”, If the system constantly indicates that a swimmer is in distress when, in fact, that isn't the case, then personnel will learn to ignore the system and thus not respond appropriately when a swimmer really is in peril. Very low number of false negatives. The system must be very reliable in terms of identifying swimmers that really are in distress. Acceptable to users. The system, and in particular the Swimmer Safety Tags, must be acceptable to the users. Otherwise they will resist using them, their enjoyment will be degraded and their safety compromised. Similarly, the supervisory personnel, such as lifeguards, must find the system easy to use and understand. Cost effective. The cost of the system must be commensurate with the benefits provided, competitive with alternatives, and encourage its use. Safe to use. The system should not introduce new safety hazards that negate the overall benefit provided to the users. Similarly, the system should be environmentally compatible.
[0064] FIGS. 9 and 10 illustrate an embodiment of the present invention that has improved reliability in terms of picking up a swimmer's ultrasonic distress signal (i.e. lower false negatives). It is common for splashing, bubbles and clusters of swimmers 910 to exist from time to time in a pool. These effects can collectively block a distress signal 912 from reaching a given hydrophone 902 . With at least a second hydrophone 904 mounted in the pool, the probability of a distress signal 914 reaching at least one unit is significantly increased. Suitable positioning of four hydrophones 1002 is illustrated in FIG. 10 .
[0065] Referring back to FIG. 9 , in addition to normal duties, a lifeguard 920 may be responsible for observing all swimmers and insisting that any swimmer 930 without a Tag either get a Tag or leave the pool area. This task can be facilitated by providing Tags with a light so that they can be more easily seen.
[0066] FIGS. 11A-11D illustrate embodiments of the Tags that have improved user acceptability and reduced numbers of false positives. FIG. 11A illustrates a top perspective view of a Tag; FIG. 11B illustrates a bottom perspective view of a Tag; FIG. 11C illustrates the size scale of a Tag; and FIG. 11D illustrates the mounting of a Tag on a swimmer.
[0067] Referring to FIGS. 11A and 11C , a Tag 1100 may have a diameter 1112 in the range of 5 to 30 mm, and a thickness 1114 in the range of 1 to 10 mm. A preferred range for diameters is 10 to 20 mm. A preferred range of thicknesses is 3 to 5 mm. These dimensions give the Tag a size, shape and heft (i.e. perceived weight in the hand) comparable to that of common coins (e.g. US pennies, dimes, nickels and quarters 1130 ). An exemplary Tag, for example, would have a diameter of 20 mm, a thickness of 5 mm and a weight of 3 gm in air. The maximum suitable weight would be 10 gm in air. Thus mounting a Tag on a swimmer's head ( FIG. 11D ) would not be perceived as an undue burden. Furthermore, Tags could be effectively manipulated by persons of ordinary physical skill and dexterity. Supervisory personnel could place Tags on persons with physical handicaps.
[0068] The top surface of a Tag could be provided with a logo 1116 or other suitable indicia such as a decoration (e.g. flower) or affinity brand (e.g. sports logo). A light source, such as an LED 1118 , can be provided for easy identification as well as providing an indication that the Tag is functioning properly. The LED may blink at a frequency of no less than once every 10 seconds. This will help conserve battery life. The Tag may also be programmed to flash the LED or multiple LEDs very brightly or frequently in the event of a Yellow or Red Alarm. This will help a lifeguard identify which swimmer is in distress. The LEDs may also change color in response to a Yellow or Red Alarm.
[0069] Electrical contacts 1110 may be provided on opposite sides of a Tag to sense immersion in water. The water acts as a conductor and closes a circuit between the contacts when the Tag is immersed. An internal timer then initiates. If the Tag is removed from water, the circuit is open and the timer stops and resets.
[0070] Referring to FIG. 11B , an adhesive 1112 may be provided on the bottom of a Tag. The adhesive should be medical grade, hypo-allergenic and non-irritating. It should be able to adhere the Tag to a swimmer's head for not less than 10 hours.
[0071] A sensor 1114 may also be provided on the bottom of the Tag to confirm that the Tag is mounted on a person. The sensor may be an optical switch that opens when illuminated. Thus when the Tag is mounted on a person, the switch is dark and closed and the internal circuitry functions normally. If the Tag is removed or falls off, then the switch is illuminated and opens. The Tag may either then stop functioning, or may issue a signal indicating that it is no longer mounted on a person. If the Tag is made more dense than water, it will sink and can be retrieved by a vacuum. If a Tag is less dense than water, it will float and can be retrieved by skimming.
[0072] An alternative sensor is one that optically measures oxygen in the blood directly below the Tag. This can be used to confirm mounting on the person as well as provide an alternative measure of the distress of a person. If the oxygen is low, then the person is in distress. Similarly, the pulse can be measured and interpreted accordingly.
[0073] Another alternative sensor comprises a pair of electrical contacts 1117 on the bottom of a Tag. They are normally dry as long as the Tag is mounted on a person. If the Tag falls off in the water, however, then the contacts are connected electrically through the conductivity of the water and the Tag has an indication that it is no longer mounted on a person.
[0074] FIG. 12 illustrates an exploded perspective view of the Tag of FIGS. 11A-11D . The Tag 1200 comprises a top encapsulating layer 1210 , a battery 1220 , electronic circuitry 1230 , a piezoelectric transducer 1240 , a bottom encapsulating layer 1250 and an adhesive layer 1260 .
[0075] The top encapsulating layer may be a waterproof, two-part epoxy designed to protect electronics that are submerged in water. The Tag should be water proof to a depth of 300 meters. The epoxy may be cast over the electronics and underneath and allowed to harden. Alternatively, the top encapsulating layer may be a cover that is bonded to the bottom encapsulating layer.
[0076] Openings 1214 may be milled in the top encapsulating layer after it hardens to expose electrical contacts 1232 on the circuit board of the electronic circuitry. This would allow the circuit between the electrical contacts to close when the Tag was immersed in water and thus begin a timer. Alternatively, a conductor 1212 may pass through the top of the encapsulating layer as one contact, and one or more opening 1252 may be milled in the bottom encapsulating layer to expose the piezoelectric layer. The piezoelectric layer, therefore, acts as the second contact. The circuit between the top conductor and piezoelectric layer then is closed when the Tag is immersed in water. Four openings 1252 may be milled at four compass points to reduce the chance that a swimmer's skin blocks all of the openings to the piezoelectric contact.
[0077] Both the electrical circuit components and programming logic are chosen to give reliable performance with minimized power draw. This improves the reliability and lifetime of the Tag. The Tag may have an operating lifetime of at least 30 days, and a storage shelf-life of at least 2 years. The Tag may further comprise an activation means, such as a pull tab, which turns the Tag on.
[0078] The electrical circuit comprises a micro processor 1234 , amplifier 1238 and optional LED 1239 .
[0079] A suitable micro processor is a PIC10F220, 6 pin, 8 bit flash microcontroller by Microchip Technology Inc. Said microprocessor is more fully described in PIC10F220/22 Data Sheet, publication number DS41270A by Microchip Technology Inc, 2005. Said publication is incorporated herein by reference. Other microprocessors with similar performance, power draws, cost and size characteristics may also be suitable.
[0080] The microprocessor may be programmed to have different outputs in different states. The states and outputs are presented in Table 1.
[0000]
TABLE 1
Duty Cycle
(Duration per 1.1 or
State
Output
2.2 second cycles)
Resting
71.4 kHz square wave
15 ms
(ultrasonic)
Yellow Alert
71.4 kHz square wave
300 ms
Red Alarm
71.4 kHz square wave
700 ms
Low battery (<20%
1.2 kHz square wave
750 ms
remaining power) or
(audible)
detached Tag
[0081] The output of the microprocessor is amplified by the amplifier and then used to drive the piezoelectric layer to give the ultrasonic or audible signal. An inductor may be placed in series with the piezoelectric layer. The inductance is selected based on the effective capacitance of the piezoelectric layer to give a resonance frequency of the circuit about that of the desired ultrasonic frequency. This improves the power efficiency of the circuit.
[0082] A suitable piezoelectric layer is a CEB-20D64 piezoelectric diaphragm made by CUI Inc. The technical specifications of said diaphragm are described more fully in the CUI spec sheet for the CEB-20D64 dated Jul. 28, 2006. Said spec sheet is incorporated herein by reference. This diaphragm is disk shaped and has a suitable diameter (20 mm), material of construction (brass) and cost ($0.75 ea) for this application. It is surprising that it provides adequate ultrasonic emissions, however, given that the mechanical resonance frequency is 6.5±0.5 KHz.
[0083] The resting state is the normal default state of the system. The microprocessor is normally in a very low current “sleep” mode. Every 1.1 or 2.2 seconds (selectable by the user), it “wakes up” and determines the state that it is in. If the clock timer indicating submersion is less than the Yellow Alert level (e.g. less than 30 seconds) then it gives a 15 ms ultrasonic “ping” at 71.4 kHz. Ultrasonic frequencies in the range of 30 kHz to 100 kHz may also be used. At lower frequencies, naturally occurring ambient noise causes interferences. At higher frequencies, more expensive and different shaped (e.g. cylindrical) ultrasonic transducers must be used. 71.4 kHz was selected in this particular application since it represents an even multiple of the clock speed of the microprocessor. Thus, generating the square wave comprises counting clock cycles. It also gives a wavelength of the ultrasonic transmissions in water of about 2 cm. This wavelength is suitable in pools. Longer wavelengths, such as 10 cm, can lead to “dead spots” in the pool where the emitted ultrasonic waves destructively interfere with each other might not be heard by a hydrophone if said hydrophone were located in said dead spot.
[0084] The ping can be received by the hydrophones and might serve, for example, for counting the number of swimmers in the water in any given time. Ideally the ping should be as short as possible to minimize resting state power draw on the battery. Ping durations in the range of 5 ms to 30 ms are acceptable. The ping should have a large enough amplitude or power so that it is detectible by a hydrophone no less than 50 meters away.
[0085] If the microprocessor wakes up and determines that the submersion timer has exceeded the Yellow Alert level, then it gives a Yellow Alert signal of 300 ms at 71.4 kHz. This is immediately picked up by one or more hydrophones and a Yellow Alert is initiated. The nearest hydrophone to the signal may have an appropriate indication to assist the lifeguard in locating the distressed swimmer. The microprocessor may also simultaneously drive the piezoelectric layer to emit a loud sonic signal. This will help a lifeguard identify which swimmer is in distress.
[0086] If the microprocessor determines that the submersion timer has exceeded the Red Alarm level, then a Red Alarm signal of 700 ms is given. The hydrophones then react accordingly.
[0087] The relative and absolute length and frequency of the Yellow Alert and Red Alarm signals can be varied so long as they are readily discriminated by the hydrophones. An advantage of selecting a Red Alarm duration that is more than twice the duration of a Yellow Alert signal is that the system can discriminate between two simultaneous Yellow Alerts and a single Red Alarm. An advantage of having a pause between Red Alarm signals is that the system can discriminate between a single Red Alarm signal and multiple Red+Red or Red+Yellow signals. Multiple Red+Red or Red+Yellow signals would indicate that more than one swimmer was at risk.
[0088] An advantage of having each tag broadcast a similar signal is that the Yellow Alert or Red Alarm message will get through even if there is significant echoing within the pool.
[0089] The system can be designed to provide digital information encoded in the ultrasonic carrier wave. This has the advantage of being able to directly identify which tag is emitting a distress signal.
[0090] The low battery and/or detached Tag signal can be initiated when the battery voltage indicates that less than 20% of the battery life is remaining or when a sensor indicating that a Tag is immersed but not attached to a swimmer is indicated. The signal can be an audible 1.2 kHz signal pulsed for 750 ms per cycle. 0.5 to 2.0 kHz are also acceptable. The audible signal has the advantage of making it readily apparent to persons nearby that a Tag has a low battery or is off of a person.
[0091] A suitable battery is a CR1616 2, 3V, Lithium Coin Cell battery made by Panasonic. The technical specifications of these batteries are described more fully in the Panasonic Lithium Handbook, August 2005. Said handbook is incorporated herein by reference. The batteries are rechargeable, have a size that is suitable for this application and have a power rating of 50 milliamp hours at 3V when fully charged. A power rating of 25 to 74 milliamp-hours is suitable in this application.
[0092] The above described system has a current draw of 2 micro amps when it is in storage. That gives an estimated battery shelf life of about 3 years. The Resting state current draw is 65 micro amps. That corresponds to a 30 day life of submersions. There is enough power to give a Red Alarm for 16 hours. The low battery signal will last 8 days.
[0093] The order of the layers in FIG. 12 can be varied. The battery, for example, can be below the electronic circuit.
[0094] FIG. 13 shows a top view of an alternative Tag design 1300 for detecting submersion. The circuitry is sealed within a water tight enclosure 1306 . Electrical contacts 1304 protrude into a porous protective enclosure 1302 . When water penetrates the enclosure, the circuit is closed.
Packaging of Tags
[0095] FIGS. 14A-14D illustrate cross sections of a suitable packaging method for the Tags.
[0096] Referring to FIG. 14A , a packaging card 1410 comprises a substrate layer 1412 , and adhesive layer 1414 and a backing layer 1416 . The substrate and backing layers may be made of cardboard. The adhesive layer may be a double stick tape with hypoallergenic, waterproof bandage adhesive. A round opening 1418 is provided to receive a Tag 1400 . The Tag has rounded edges 1401 to facilitate handling. The opening may comprise a protective bumper 1420 . The Tag is pressed onto the exposed adhesive layer 1406 which, in turn, is backed by a disk 1402 . The disk is made of a material that the adhesive does not stick well to.
[0097] FIG. 14B shows how the assembly looks for shipping.
[0098] FIG. 14C shows how a Tab would be pushed out of the packaging card by an end user.
[0099] FIG. 14D shows how the backing disk would be removed leaving behind the adhesive layer 1406 .
[0100] The adhesive should stick more strongly to the Tab than it would to a person's skin so that the adhesive is removed from said person's skin when the Tab is removed.
[0101] FIG. 15 shows how a packaging card 1506 would be incorporated into a commercial retail package 1500 . Wings 1508 may be attached to the packaging card with appropriate information and indicia printed thereupon. The assembly may be folded 1504 and inserted into a sleeve 1502 .
[0102] FIG. 16 illustrates alternative packaging for a single Tag 1604 . The single Tag is packaged in a hinged container 1602 and the hinged container is mounted on a retailing card 1600 .
Refurbishing Tags
[0103] The Tags may be recycled. FIG. 17 illustrates a suitable refurbishing process. Used Tags are collected 1702 and shipped 1704 to a refurbishing facility 1706 . The Tags are cleaned, tested 1708 , recharged 1710 , and inspected 1712 . New adhesive 1715 is applied 1714 to the Tags 1713 and the Tags are packaged 1716 , crated 1718 and shipped 1720 to an end user 1722 .
Alternative Tag Technologies
[0104] FIG. 18 illustrates an alternative mounting technology for a Tag. The Tag 1802 is provides with an adjustable elastic strap 1804 . The assembly 1800 is then worn around the head of a swimmer.
[0105] FIGS. 19A to 19D illustrates an adhesive bandage type of mounting. A Tag 1900 is provided with flexible adhesive wings 1902 . The assembly is then adhered to the head of a swimmer. FIG. 19A shows a top view; FIG. 19B shows a side view; FIG. 19C shows a size comparison with a US quarter; and FIG. 19D shows the Tag mounted on a swimmer's head.
[0106] This configuration has the advantage of providing a convenient means for mounting a radio antenna 1904 on a Tag. The antenna facilitates an alternative means for determining how long a person's head has been underwater.
[0107] FIG. 20 shows a radio means for determining how long a person's head has been in water. A swimmer 2002 has a Tag mounted on his or her head. The Tag emits a constant or pulsed radio signal 2004 , along with identifying information to a control station 2006 . The control station keeps track of all Tags. When a person goes swimming and their head goes below water, the signal is blocked 2012 by water. The control station determines that a particular Tag is no longer above water and a timer 2008 is started. If the timer reaches a certain threshold, then a Yellow Alert or a Red Alarm may be signaled.
[0108] This system is advantageous at beaches where large distances can separate swimmers and where mounting and positioning of sonar based Swim Monitor Units may be difficult.
[0109] FIGS. 21A-21C illustrate a hip mounted Tag design 2100 . FIG. 21A shows a top view; FIG. 21B shows a bottom view; and FIG. 21C shows a perspective view with a size comparison to a US quarter 2110 .
[0110] This Tag is larger than the coin size sonar based Tag discussed with reference to FIG. 11C . The size may be 6 cm ( 2102 ) by 7 cm ( 2104 ). The maximum dimension may be 10 cm. The corners may be rounded 2106 to avoid snagging on clothes. The larger size facilitates the incorporation of larger indicia 2108 and strobe lights 2112 . Mounting means, such as a safety pin 2114 may be provided to removably attach the Tag to clothes and a pressure sensor 2116 may be provided.
[0111] FIG. 22 shows how a hip mounted Tag would work. The Tag 2206 is mounted on a swimmer 2202 . When the swimmer's hips are more than one meter 2204 below the surface of the water, a sensor of depth, such as a water pressure sensor, triggers a timer. If the timer runs for the duration of a Yellow Alert or a Red Alarm, the Tag sends a sonar signal to a Swim Monitor Unit. The system is functional for both tall persons and short persons 2208 .
[0112] Skipping ahead to FIG. 29 , FIG. 29 illustrates a Tag 2900 mounted on a necklace 2910 . The Tag comprises a magnetic latch or mechanical latch 2904 to allow it to be easily put on and removed. The Tag may comprise a water emersion sensor and/or a water depth sensor. The Tag may, for example be set to sound an alarm when the depth is more than 30 cm for a given period of time.
[0113] FIG. 30 illustrates a Tag 3000 that can be mounted on a swimmer's ear 3020 . The Tag comprises a sensing unit 3002 and a band 3012 . The sensing unit may comprise electrical contacts 3004 for sensing immersion in water and/or a pressure sensor for detecting immersion at depths greater than a predetermined amount, such as 30 cm. The sensing unit may also comprise LEDs 3006 .
[0114] The band 3012 may comprise a cushion 3014 as well as a means 3016 to adjust the length.
[0115] A similar Tag without the band may also be mounted in the hollow 3022 behind a swimmer's ear by using a moldable waxy mounting compound.
[0116] FIG. 31 illustrates a Tag 3100 that is in the form of a stiff but flexible open neck band. The Tag comprises a strap 3102 and pads 3104 . The electronics of the Tag can be built into the strap. Electrical contacts 3106 are built in to each end of the strap. Thus, both sides of a swimmers head must be underwater to start the submersion timer. The strap is stiff enough to hold the band onto a swimmer's head 3110 , but flexible enough to be removed by a person of ordinary strength. The Tag may further comprise one or more LEDs 3108 .
[0117] FIG. 32 illustrates a Tag 3200 that is mounted on an ear plug. The electronics 3202 are mounted on an elastomeric (e.g. silicone rubber) ear plug 3204 to form a final assembly 3206 . This is then mounted in a swimmer's ear 3210 . The ear plug may be disposable and the mounting may be mechanical by, for example, a lip (not shown) built into the plug.
Swim Monitor Unit
[0118] Referring back to FIG. 23 , a swim monitor unit comprises an annunciation unit, connector cable and hydrophone unit. FIGS. 23A , 23 B and 23 C illustrate a side, top, and bottom view of an exemplary annunciation unit 2300 . Referring to FIG. 23A , the annunciation unit comprises a strobe light 2302 for indicating alarm status, a connector cable 2304 for connecting to the submerged hydrophone, and associated electronics 2306 for amplifying and processing the ultrasonic signals received from the Tags.
[0119] Referring to FIG. 23B , the annunciation unit further comprises a removable rechargeable battery 2312 , and an LED 2314 , to indicate that it is working.
[0120] Referring to FIG. 23C , the annunciation unit further comprises mounting means 2322 , a locking cover 2324 and indicia 2326 indicating product information.
[0121] FIG. 24 illustrates other features of an annunciation unit 2400 . The rechargeable battery 2402 is removable and may be placed in a recharger 2404 to recharge. The connector cable may be stored in a retractable reel 2406 or expandable coil 2408 .
[0122] FIGS. 25A-25B illustrate an exemplary hydrophone unit. FIG. 25A shows a perspective top view of the hydrophone unit 2500 ; and FIG. 25B shows a side view of the hydrophone unit.
[0123] Referring to FIG. 25B , the hydrophone unit comprises a hydrophone 2512 for receiving ultrasonic signals from Tags; a protective cage 2514 to protect the hydrophone unit from, inter alia, swimmers hands and feet, a retractable coil 2516 for storing excess connector cable, and mounting means, such as suction cups 2518 for adhering the hydrophone unit to the wall of a pool.
[0124] Suitable hydrophone units, such as an SUR-1 Submersible Ultrasonic Receiver, may be obtained from Sonotronics Inc. of Tucson Ariz. The SUR-1 is more fully described on web page “SUR-1 Submersible Ultrasonic Receiver”, www.sonotronics.com/html/products/receivers/sur.html, last viewed Jun. 26, 2008. A copy of said web page is submitted herewith in an information disclosure statement and is incorporated herein by reference.
[0125] Suitable hydrophone units may have a bandpass of ±6 kHz of the designed ultrasonic signal of the Tags. Thus if the Tags are designed to broadcast at about 70 kHz (e.g. 71.4 kHz), then the hydrophone would have a bandpass of 64 to 76 kHz. This relatively narrow bandpass helps filter out background noise.
[0126] FIG. 26 illustrates alternative mounting configurations for an annunciation unit. The annunciation unit may be mounted horizontally 2602 on the side of the pool. This has the advantage of having the strobe light entirely out of the water. Alternatively, the annunciation unit may be mounted vertically 2602 on the wall of the pool. This has the advantage of providing strobe light to the occupants of the pool that may be underwater at the time of an alarm. Alternatively, the annunciation unit may be mounted on the deck of the pool 2606 . This has the advantage of being relatively easy to install.
Supervisory Control Unit
[0127] FIG. 27 illustrates a face view of an exemplary Supervisory Control Unit 2700 . The control unit comprises a power supply and electronics suitable for receiving signals from annunciation units and transmitting signals to alarms if necessary. The control unit further comprises a locking cover 2702 , indicator LED 2704 , strobe alarm light 2706 , informational screen 2708 and touchpad 2712 for entering data and commands. A US quarter and Tags 2720 are shown to indicate scale.
Portable Reception Units
[0128] FIG. 28 illustrates a number of alternative embodiments of portable reception units that may be worn by a lifeguard or other supervisory personnel. These include ear pieces 2826 , bracelets 2828 and necklace tokens 2832 . These designs may be both functional and have a certain aesthetic appeal.
[0129] As discussed above, the portable reception units would receive alarms 2824 from annunciation units 2812 after said alarms were received from Tags 2802 worn by swimmers. Communications may be by Bluetooth protocol.
Portable Family Systems
[0130] A completely portable embodiment is suitable for families visiting a body of water. It can consist of Tags, one or more portable battery powered SMU units, a battery powered Supervisory Control Unit and/or one or more Portable Reception Units. The Supervisory Control Unit may be configured like a briefcase or “boom box.”
Examples
Example 1
[0131] A 25 meter long by 6 meter wide indoor pool was equipped with a swim monitor unit. The pool had a shallow end 1 meter in depth, and a deep end 3 meters in depth. The swim monitor unit was mounted at the middle of the wall of the deep end. The hydrophone rested on the bottom of the pool at a depth of 3 meters. The annunciation unit rested on the edge of the wall of the pool and communicated with a Supervisory Control Unit by radio transmission. The supervisory control unit was 3 meters from the annunciation unit.
[0132] A test swimmer entered the water at the midpoint of the pool and submersed a Tag in the water. The Tag was programmed to emit an ultrasonic Yellow Alert signal at 30 seconds and an ultrasonic Red Alarm signal at 45 seconds. After the Tag had been submersed for 30 seconds, the supervisory control unit sounded a Yellow Alert. The test swimmer then removed the Tag from the water and the Yellow Alert ceased.
[0133] The test swimmer then put the Tag in the water again. At 30 seconds, the Yellow Alert sounded. At 45 seconds the Red Alarm sounded. The test swimmer removed the Tag from the water and a supervisory person reset the control unit to silence the Red Alarm.
[0134] 10 “interference swimmers” then entered the deep end of the pool, clung to the side walls of the pool and kicked the surface of the water vigorously to produce both bubbles and splashes. The interference swimmers were located between the test swimmer and the swim monitor unit. The test swimmer placed the Tag below the water, but at 30 seconds, no Yellow Alert sounded. The interference swimmers then stopped kicking and the Yellow Alert sounded.
[0135] A second swim monitor unit was then placed at the midpoint of the wall of the shallow end of the pool behind the test swimmer. The hydrophone was placed on the bottom of the pool at 1 meter depth. The annunciation unit was placed on the wall of the pool. The annunciation unit was about 28 meters from the control unit.
[0136] There were no interference swimmers between the test swimmer and the shallow end hydrophone. The interference swimmers then began kicking in the deep end and the test swimmer again placed the Tag below the surface of the water. A Yellow Alert sounded after the Tag had been submersed for 30 seconds.
Example 2
[0137] 11 swimmers were equipped with Tags placed on their heads. The Tags were 20 mm in diameter, 5 mm thick and weighed about 3.3 gm each. Some Tags were mounted directly onto swimmers' heads using a removable waterproof medical-grade adhesive. They were positioned either on a forehead or behind an ear. Other Tags were mounted on swim goggles or held onto a forehead by an elastic band. The swimmers included children, teenagers and adults of both genders. The swimmers engaged in normal water activities at their own discretion for thirty minutes. All of the Tags stayed on the swimmers. None of swimmers expressed any discomfort with the Tags or expressed a desire to remove a Tag. The only unintentional Yellow Alert that sounded was when an adult swimmer with a Tag mounted behind her ear was resting against the side of the pool with her head inclined back. She was readily identified when the Yellow Alert sounded.
CONCLUSION
[0138] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. Any of the aspects of the invention of the present invention found to offer advantages over the state of the art may be used separately or in any suitable combination to achieve some or all of the benefits of the invention disclosed herein.
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Electronic Tags are mounted on swimmers to reduce their risk of drowning by identifying when their heads are underwater for periods of time which may indicate a dangerous submersion situation, and for triggering corresponding alerts and alarms. In this method, each monitored person is equipped with a lightweight electronic Tag worn on the body that communicates with monitors that issue the alerts and alarms, including audible and visible distress signals. The monitors, in turn, communicate the alarms to receivers used by supervisory personnel, such as lifeguards or parents. The invention may be used in aquatic environments, such as public recreation facilities, pools, waterfronts, and water parks, as well as in more private settings, such as homes, apartment buildings or hotels.
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FIELD OF THE INVENTION
The present invention relates to electronic circuitry and more particularly to power shut-off circuitry and to current bias circuitry.
BACKGROUND OF THE INVENTION
Electronic paging systems incorporating portable, battery operated paging receivers use various methods for reducing the power consumption of the receivers to minimize their overall size and to extend battery life. Many of the existinq systems supply power to the receiver circuits only during intermittent and/or predetermined time periods during which data for the receiver is transmitted. The problem of limiting power consumption and extending battery life is exacerbated in miniature radio receivers incorporated in a wristwatch-pager such as that described in U.S. Pat. No. 4,713,808 to Gaskill et al. The small size and portable nature of the wristband receiver, plus the large number of circuits used compared with the number used in a conventional electronic watch, make reduced power dissipation a primary consideration in the design of the wristwatch-pager.
In the system described in the Gaskill patent the duty cycle of the radio receiver is very short, hence, in order to extend battery life it is desirable that power dissipation in the receiver circuits be virtually zero during the relatively long periods when the receiver is inactive. Further, it is desirable that the circuits involved be insensitive to decreases or fluctuations in power supply voltage caused by battery age, power on/off cycling, the resistance of interconnecting power leads, etc.
A conventional method for switching power to a circuit utilizes a switching device such as a series pass transistor; however, there are several disadvantages associated with such circuits. A series pass device, in the on state, has an associated voltage drop that subtracts from the available supply voltage. Such voltage drop is significant in low-voltage, battery operated apparatus.
Furthermore, the current must be consumed in the controlling element of a power switching device, e.g., the base current required to saturate a switching transistor is greater than the collector current divided by beta. In the case of a low-beta pnp switching device implemented in a typical bipolar integrated circuit process optimized for npn devices, the base current of the switching device can be a significant percentage of the total current, and this current is essentially wasted.
Another disadvantage of using a series switching devices is that the die area required for a switching device that carries the total chip current is significant.
A separate, off-chip switching transistor could be used to improve beta at the cost of an additional part and more board area. An npn switching device could be used to reduce the base current demand, but such a device would require a base voltage above the battery voltage for a low collector-emitter voltage V CE drop if the switching device were placed between the battery positive terminal and the load. It is noted that if a pass device were placed in the ground return path, its V CE drop could adversely affect ground-referenced signals.
The object of the present invention to provide an improved on-off switching circuit that maximizes battery life.
Another object of the present invention to eliminate the need for a series switching device and thereby eliminate the voltage drop normally associated with such a device.
Yet another object of the present invention is to provide an on-off switch for electronic circuitry which requires little or no power in the off state.
It is another object of the invention to provide an improved bias supply circuit for a system which has a short duty cycle followed by a relatively long power-off time.
Another object of the instant invention is to provide an improved microcircuit bias supply with on-off switching control that results in virtually zero current drain from the circuits during quiescent periods.
SUMMARY OF THE INVENTION
The present invention combines in a novel way an on-off switch and the current bias supply circuits for a number of functional circuits. With the present invention, a very small supply independent current source is switched by the external on-off signal. The switch which controls the small independent current source is configured so that the switch draws no current in the off state. The small independent current source in turn controls a temperature stable reference voltage source through a current mirror. The output of the reference voltage source controls a plurality of master current sources. These master current sources in turn control functional circuit current bias supplies through current mirrors. Thus when an "on" or "off" signal is received from an external source, (a) the small independent current source is switched "on" or "off" which in turn (b) switches the temperature stable reference source "on" or "off" which (c) switches the master current sources "on" or "off", which in turn (d) controls the functional circuit current bias supplies.
The major advantages of the present invention is that it draws no current in the "off" state and that it does not have a series switch with the associated voltage drop. The functional circuit current bias supply circuits are controlled from the voltage reference through current mirrors and hence they operate at a voltage which is relatively near ground potential. The entire supply voltage (except for the drop across the bias supply circuits) is available to the application circuits.
BRIEF DESCRIPTION OF THE DRAWING
While the invention is set forth with particularity in the appended claims, other objects, features, the organization and method of operation of the invention will become more apparent, and the invention will best be understood by referring to the following detailed description in conjunction with the accompanying drawing in which:
FIG. 1 is a schematic block diagram of a microcircuit bias-current supply and user circuits in accordance with the instant invention;
FIG. 2 is a schematic illustration of a microcircuit chip mounted on a watch-sized printed circuit board and incorporating the circuits of FIG. 1;
FIG. 3 is a schematic diagram of the bias-current supply circuits of FIG. 1; and
FIG. 4 shows an alternative embodiment of the remote current mirror circuit 26a of FIG. 1; and
FIG. 5 is a timing diagram of bias current shut-off in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the various views of the drawing for a more detailed description of the components, materials, construction, function, operation and other features of the instant invention by characters of reference, FIG. 1 shows a bias circuit 10 supplying bias current to a plurality of system functional circuits 12, which in the presently described embodiment of the invention comprise the bipolar integrated-circuit components of a miniature FM subcarrier receiver in a wristwatch-pager as described in the aforementioned patent to Gaskill et al. Operating voltage V CC is supplied to the bias circuit 10 and the system circuits 12 directly from a battery 14 on a bus 18; battery voltage is suitably 2.2 to 3.5 volts.
Referring to FIG. 2 in conjunction with FIG. 1, the system functional circuits 12 of FIG. 1 are shown as a plurality of functional circuit areas 20a . . . n of an integrated circuit chip 21, which can for example be mounted on a printed circuit board (PCB) 22, the bias circuit 10 being located among the circuit areas 20a . . . n to allow convenient distribution of bias currents. A functional circuit can be any circuit such as a logic gate, an amplifier or a bistable. A functional circuit area means a group of microcircuit elements that make up one or more functional circuits that perform a particular function and by design can be conveniently grouped together in a particular area of an integrated circuit die. A microcircuit element means an integrated-circuit component such as a resistor or a transistor; a microcircuit means at least one functional circuit on an integrated circuit die and formed from interconnected microcircuit elements. Such microcircuit elements could, for example, form a functional circuit area comprising an IF strip, an audio amplifier or a storage matrix. For simplicity, only representative portions of the PCB 22 and the interconnecting conductors are shown.
Transistor current sources are commonly used in analog integrated circuits as biasing elements, which results in reduced sensitivity of circuit performance to power-supply variations and to temperature. Further, current sources often utilize less die area than resistors to provide the desired bias current, particularly when the required value of bias current is small. As indicated in FIG. 1, when power is enabled in the presently described embodiment of the invention, the system circuits 12 collectively require about 15 milliamps of current. Each of the circuit areas 20a . . . n is connected internally of the area by a lead 23a . . . n to a current source 24a . . . n, one of which is illustrated symbolically in FIG. 1 as one element 24a of a current-mirror circuit 26a. Corresponding current-mirror circuits (not shown) such as the circuit 26a are provided in each of the plurality of circuit areas 20a . . . n. The current source 24a mirrors a second current source 28a of the current-mirror circuit 26a, as described in more detail below. Each of the current-mirror circuits 26a . . . n in the various circuit areas 20a . . . n is connected by a lead 30a . . . n to a corresponding current mirror circuit 32a . . . n in the bias circuit 10.
Power is applied to the system circuits by way of a power-enable control signal PWRUP1 on a lead 34 from a microprocessor (not shown) that controls system power. The PWRUP1 signal is a CMOS digital logic level, which controls a switch circuit 36 in the ground return of a supply-independent current source 38. A supply-independent current source is one in which the bias currents of the circuit are dependent on a voltage standard other than the supply voltage, for example a Zener diode or the base-emitter voltage V BE of a transistor. In the instant embodiment, the best-mode supply-independent current source is a bootstrap or self-biased current source 38, which develops a current that is made to depend directly on the output of the current source itself, thereby establishing a reference current that is relatively independent of power supply voltage. The current developed in the bootstrap current source 38 is mirrored in another current source 39, the current sources 38, 39 together forming a current-mirror circuit 40, the output of which is supplied to a band-gap reference circuit 42. The band-gap circuit 42 develops a temperature-stable reference voltage of 1.21 volts, which is distributed to a plurality of master current sources 44a . . . n in the bias circuit 10. Each of the master current sources 44a . . . n includes an on-chip current-setting resistor 46a . . . n, and is coupled to a corresponding one of the current-mirror circuits 32a . . . n.
Referring momentarily to FIG. 2, the bias circuit 10 is centrally located among the other functional circuit areas 20a . . . n, and while the band-gap voltage could be distributed to the circuits 20a . . . n, it would be susceptible to voltage drops from resistance in leads, noise, etc. However, when currents of predetermined magnitude for each of the functional microcircuit areas 20a . . . n are distributed throughout the system, the importance of voltage drops is muted. Current sources 32a . . . n have a high-impedance output, and resistance in the lines 30a . . . n does not affect the magnitude of the currents. At the various points of use throughout the device, the current is again mirrored, in each instance in one of the current mirror circuits 26a . . . n. Although the bias currents are remotely re-mirrored in the functional circuit areas, it is seen that a bias current could be supplied directly to a functional circuit locally from the bias supply 10, for example by the current source 46.
Referring to FIG. 3, a detailed schematic diagram shows the circuits of FIG. 1, which are implemented in a bipolar integrated circuit. The switch circuit 36 comprises a substrate-contact diffusion transistor 50 which has good saturation characteristics. Transistor 50 has its base connected through a 100K resistor 51 to ground, and through another 100K resistor 52 to the PWRUP1 signal input lead 34. The transistor 50, when enabled by the PWRUP1 signal, provides a ground return for the bootstrap current source circuit 38 at a node 56.
The bootstrap current source 38 comprises a first lateral pnp (LPNP) transistor 57 having its emitter connected through a 1K resistor 58 to the supply voltage V CC , a second LPNP transistor 60 and a diode-connected LPNP transistor 61, each of the latter having an emitter connected through a corresponding 2K resistor 62, 63 to the supply voltage V CC . The bases of the transistors 60, 61 are common, and the collector of transistor 60 is connected to the collector of transistor 65 and the base of transistor 57. An npn transistor 64 has its collector connected to the base-collector junction of the diode 61, and its emitter connected to the node 56. The base of transistor 64 is common with the bases of npn transistors 65, 66, and with a node 67 at the base-emitter junction of a diode-connected npn transistor 68.
The emitter of transistor 65 is connected through a 650 ohm resistor 69 to the node 56, and the emitters of the transistor 66 and the diode-connected transistor 68 are connected directly to the node 56.
A startup circuit 70 comprises a 100K resistor 72 connected in series with two diode-connected transistors 73, 74 to ground node 56, and a diode-connected transistor 76 having its emitter connected to a node 77 between the collector of transistor 57 and a 15K resistor 78, which is connected at its other end to the node 67. The collector-base junction of the diode 76 is connected to a node 79 between the resistor 72 and the diode 73.
The bootstrap current source circuit 38 has the potential of operating at two stable states, one in which there is zero current flowing in the circuit, and the other in which equal currents flow through the two branches of the circuit. The startup circuit 70 serves to avoid the zero-current state by insuring that some current always flows in the transistors of the circuit 38, and the current gain does not fall to a very low value. If the circuit 38 were near the zero-current state, the voltage at the base of transistor 65 would be at or near ground, and the voltage at the node 67 would be slightly above ground as determined by leakage currents of the circuit. The voltage at node 79 is two diode drops above ground, therefore a voltage equal to about one diode drop would appear across the resistor 78 through which a current would flow into the transistors 64-66, which in turn would cause current to flow in transistors 57, 60, 61, thereby avoiding the zero-current state. As the circuit 38 drives toward the desired stable state, the voltage drop across the resistor 78 becomes large enough to reverse bias the diode 6.
The current source 39 comprises two LPNP transistors 80, 81, having their emitters connected, respectively, through a 2K resistor 82 and a 1K resistor 83 to the supply voltage V CC . A 100K resistor 84 is connected from V CC to a node 85 between the bases of the transistors 80, 81, a third LPNP transistor 86 having its emitter connected to the node 85. The collector of transistor 86 is grounded, and its base is connected to the collector of transistor 80 at a node 87, which is connected to the collector of transistor 66 in the bootstrap current source 38. The collector of transistor 81 is connected to an output node 88. The supply-independent reference current developed in the current source 38 and flowing in the transistor 66 is mirrored in the transistor 81 and is injected into the node 88 at the input of the band-gap reference circuit 42.
The band-gap circuit develops a temperature-independent reference voltage from the supply-independent current source 39. Details of the operation of the band-gap circuit as well as other individual circuits such as the current sources and current mirror circuits disclosed herein are well known and are not described herein. See, for example, P. R. Gray and R. G. Meyer, Analysis and Design of Analog Integrated Circuits, Wiley, New York, 1984. The band-gap reference circuit 42 comprises an npn transistor 90 having its base connected to the node 88, its collector connected to the supply voltage V CC and its emitter connected to an output node 92 of the circuit 42. The node 92 is connected through a 12K resistor 93 to a node 94 connecting the base of an npn transistor 95 with the collector of an npn transistor 96. The base of transistor 96 is connected to the base-collector junction of a diode-connected transistor 97, which is connected in series with a 5K resistor 98 between the output node 92 and ground. The emitter of transistor 95 is connected to ground, and the emitter of transistor 96 is connected through a 1.48K resistor 99 to ground.
Referring to FIG. 3 in conjunction with FIG. 1, a representative one 44a of the band-gap referenced master current sources 44a . . . n and the corresponding current-mirror circuit 32a comprise an npn transistor 102 having its base connected to the output node 92 of the band-gap reference circuit 42. The emitter of the transistor 102 is connected through the current-setting resistor 46a to ground, the resistor 46a having a value of 8.4K in the instant representative circuit. The collector of transistor 102 is connected to a node 105 of the current mirror circuit 32a, which in turn is connected to the base of an LPNP resistor 106, the collector of an LPNP resistor 107 and through a 2K resistor 108 to the base of transistor 107. The emitters of the transistors 106, 107 are connected, respectively, through 1K resistors 109, 110 to the supply voltage V CC . The collector of transistor 106 is connected to an output node 112, which can for example supply 50 microamps current by way of the lead 30a to the corresponding current source 28a of current mirror circuit 26a. The current developed in the band-gap referenced master current source 44a, in this instance 50 microamps, is mirrored in the transistor 106 current source and supplied to the functional circuit group 20a (see FIG. 2) of the microcircuit chip 21 by way of the bus 30a. The bias current requirement of each of the functional circuit groups 20a . . . n is predetermined by design and the appropriate value of current provided in the design of the corresponding master current source 44a by way of the current mirror circuits 32a . . . n. The currents are individually determined in the bias supply circuit 10, which is essentially centrally located on the microcircuit chip, and derived from a supply-independent current source that is referenced to a temperature-independent voltage. The individual bias currents being distributed to the functional circuit areas throughout the chip further makes the circuits less sensitive to supply voltage variations due to line losses.
Multiple current sources 44a . . . n, which are connected to and enabled by the band-gap voltage, produce biasing currents determined by the band-gap voltage and the resistors 46a . . . n. The current-setting resistors 46a . . . n are each chosen to match the type of resistor used in the corresponding one of the functional circuit areas 20a . . . n providing nominally constant gain and voltage drops versus resistor tolerance. These biasing currents are mirrored by current mirrors 32a . . . n and distributed to the various functional circuits around the die for use as local reference currents in current mirror circuits 26a . . . n local to the individual circuits.
When the power enable control signal PWRUP1 falls low, base drive is removed from the transistor 50 of the switch circuit 36 and its collector voltage floats up to V CC , which disables the reference current source 38 and shuts off drive current to the band-gap voltage source 42. The band-gap voltage then falls to ground turning off the various master current sources 44a . . . n and current mirrors 32a . . . n, 26a . . . n, which removes bias current to the functional circuit areas 20a . . . n and shuts off the system circuits 12.
Referring to FIG. 4 in conjunction with FIG. 1, while the remote current mirror circuit 26a is shown in FIG. 1 as having two elements, viz.: the local-reference current source 28a and the current mirror element 24a, it is understood that a remote current mirror 26m can include two or more current mirror elements 24ma . . . mn, each of which mirrors the local reference current developed in the current source 28m, by developing either a true mirror of the reference current or a scaled current proportional to the reference current, the magnitude of the scaled currents being depending on the size of the current mirror 24ma . . . mn transistors relative to the size of the current source 28m transistor.
All of the system circuits 12 are connected to the supply voltage V CC , therefore leakage currents will still flow when the bias supply 10 is turned off by the switch circuit 36 as described above; if there are any significant leakage paths in any the transistors of the system circuits, which can number in the high hundreds, battery degradation could occur at a faster rate than is desirable. However, the process utilized to form the circuits of the bias supply 10 and the system circuits 20a . . . n is the oxide-isolation process, which isolates the collectors of the transistors from each other with trenches etched into the epitaxial layer, the trenches being lined with silicon dioxide and filled with polycrystalline silicon, the process yielding circuits with very low leakage current. Consequently, when the desired bias currents are shut off by disabling the PWRUP1 signal, the leakage current, from all 700 to 800 transistors in the system, is very low--on the order of nanoamps. Circuits built with conventional junction isolation processes would also benefit from this technique; however, the magnitude of the off current would not be as low.
Referring to the FIG. 5 timing diagram, it is seen that system current IV CC , from system turn-off time T to when the PWRUP1 signal is disabled, decays from 15 ma to essentially zero current, less than 100 nanoamps, within 300 microseconds. Naturally, the exact figures are circuit dependent and the invention will operate in other environments.
In summary one embodiment of the invention provides a microcircuit bias supply capable of an intermittent duty-cycle under external control. The bias supply generates circuit bias derived from a current source referenced to a voltage-reference circuit, which in turn is provided with operating current from a reference current source circuit coupled to an on/off circuit that disables the reference current source, which switches off the bias current to the microcircuits, whereby only leakage current flows during quiescent periods. The microcircuits can for example be implemented in oxide-isolated bipolar integrated circuits.
A second embodiment of the invention provides, a microcircuit bias supply capable of an intermittent duty-cycle under external control generates circuit bias mirrored from a reference current source, and supplies the bias current to a functional circuit on the chip. The current is mirrored in the functional circuit and distributed therein. A switch circuit disables the reference current source during power-off portions of the microcircuit duty cycle, which switches off the bias current to the microcircuits, whereby only leakage current flows during quiescent periods.
An important aspect of the present invention is that the functional circuit current bias supply circuits are controlled from the voltage reference through current mirrors and hence they operate at a voltage which is relatively near ground potential. The entire supply voltage (except for the drop across the bias supply circuits) is available to the application circuits. The current bias circuits are required for bias purposes regardless of what type of turn off circuitry is used, hence, the voltage drop across the bias circuit is not a penalty incurred by the use of the turn off circuit of the present invention.
While the principles of the invention have now been made clear in the foregoing illustrative embodiment, there will be immediately obvious to those skilled in the art many modifications of structure, arrangement, proportions, the elements, material and components used in the practice of the invention, and otherwise, which are particularly adapted for specific environments and operating requirements without departing from those principles. The appended claims are, therefore, intended to cover and embrace any such modifications, within the limits only of the true spirit and scope of the invention.
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A microcircuit bias-current supply in a wristwatch-pager. An FM-radio receiver in a microcircuit paging device operates intermittently with a short on-time and long off-time to reduce power consumption and preserve battery life. Ths bias-supply circuit distributes predetermined bias currents to a plurality of functional circuit areas of the microcircuit die, the bias currents being disabled during off-time of the receiver such that the current drain of the entire microcircuit is virtually zero, being in the range of nanoamps. The inefficiencies and disadvantages of a series switch to switch power on and off are eliminated by providing a plurality of switched current sources which perform the dual function of circuit biasing and current switching.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority of U.S. patent application Ser. No. 11/663,254 filed on Sep. 13, 2005 and related to European Foreign Patent Application 04022121.0 filed on Sep. 17, 2004 and U.S. Provisional Patent Application Ser. No. 61/216,126 filed on May 13, 2009, each of which are hereby incorporated by reference in their entirety.
FIELD OF ART
[0002] The present invention is related to an improved device for biomechanical stimulation of muscles.
BACKGROUND
[0003] Biomechanical stimulation was first developed in the former USSR in the 1970's by Prof. Nazarov for the field of competitive sports. Biomechanical stimulation (BMS) is a means whereby a device, such as the present device, provides an elliptical mechanical stimulation motion at controlled frequencies or speeds and at controlled amplitudes. The elliptical motion of the biomechanical stimulator is then transferred to the muscle and/or the soft tissue of the human body by the elliptical motion of the stimulation drum.
[0004] The vibration therapy provided by biomechanical stimulation positively influences the muscles, soft tissue, circulation and lymphatic system of the human body. This mechanical stimulation provides a variety of anatomical and metabolic improvements or enhancements for the human body. These improvement and enhancements include, but not limited to, the warm-up of muscle groups before an athlete competes without expending energy to warm-up these muscle groups, increasing the range of motion when muscles have atrophied, and improved recovery of muscle groups for athletes after competition. For exercising or competing athletes, BMS aids improved recovery by stimulating or stretching muscle groups, and by increasing blood circulation that aids the body's recovery by carrying away waste products such as lactic acid. Recent studies indicate that sore muscles are the result of minute muscle fiber tears, biomechanical stimulation improves the recovery of these sore muscles caused by the tiny muscle tears following exercise. Again, by increasing the blood flow and oscillating the sore muscles with the elliptical stimulation motion of the biomechanical stimulation device, the muscles are able to recover faster thus helping the athlete prepare for peak performance in the next competition.
SUMMARY
[0005] A biomechanical stimulation device is presented. The biomechanical stimulation device comprises a base that supports an arm and a drum connected to the arm. The drum is driven by a motor to provide a stimulation motion, such as an orbital stimulation motion. The drum may connect to the arm at a single attachment point. The arm 20 may be pivotally attached to the base and selectively movable to a desired position. One or more struts may support the arm to assist in positioning the arm. The strut or struts may be locked to prevent movement of the arm, or unlocked by a release button to allow selective positioning of the arm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Objects and advantages together with the operation of the invention may be better understood by reference to the following detailed description taken in connection with the following illustrations, wherein:
[0007] FIG. 1 illustrates a biomechanical stimulation device.
[0008] FIG. 2A illustrates a right view of a rotational motion drum.
[0009] FIG. 2B illustrates a left view of a rotational motion drum.
[0010] FIG. 3 illustrates a drum assembly having a single mounting attachment and slidable surface.
[0011] FIG. 4 illustrates an upper arm assembly.
[0012] FIG. 5 illustrates an underside view of a biomechanical stimulation device having an extendable strut.
[0013] FIG. 6 illustrates a cutaway view of a rotational motion drum showing the drive system.
[0014] FIG. 7 illustrates a cutaway view of a rotational motion drum of a biomechanical stimulation device showing a mounting method.
[0015] FIG. 8 illustrates the electrical and electronic components of a Lower Arm Assembly.
[0016] FIG. 9 illustrates a hand controller user interface control.
[0017] FIG. 10 illustrates a side view of an eccentric shaft.
[0018] FIG. 11 illustrates a perspective view of an eccentric shaft.
DETAILED DESCRIPTION
[0019] Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings. It is to be understood that other embodiments may be utilized and structural and functional changes may be made without departing from the respective scope of the present invention.
[0020] A device for providing biomechanical stimulation of various parts of the human anatomy is presented. The device may be used with body parts such as muscles and soft tissue for performance enhancement or rehabilitation purposes. The device enhances user interaction with the biomechanical stimulation device (“biomechanical stimulator”) by providing additional options for biomechanical stimulation therapy and improved position adjustment options.
[0021] With reference to FIG. 1 , an embodiment of a biomechanical stimulator 5 is provided. The biomechanical stimulator device 5 includes a drum 10 attached to an upper arm 20 . The drum 10 provides a biomechanical stimulation motion, such as an orbital translation motion. The drum 10 may comprise a cylindrical unit, or other shape, that contains a drive motor. The drum 10 is constrained to carry out rigid body motion, without appreciable rotation, such as by translating through a defined circular or elliptical orbit.
[0022] The upper arm 20 is pivotally attached by pivot interface bearings 55 to a pair of upright arm supports 50 that are attached to the base 40 . The position of the drum 10 may be adjusted by pivoting the arm 20 with respect to the base 40 to a desired position. For example, the upper arm 20 assembly may house a pivot release button 25 . When activated, the release button 25 may cause the arm 20 to release a clamping system of a pair of extension struts 45 . Releasing the extension struts 45 allows the drum 10 to pivot with respect to the arm supports 50 and be set at any desired position along the travel of the arm 20 . In an embodiment, the arm may travel up to 80 degrees. The 80 degrees of travel may allow the arm 20 to be positioned from a near horizontal position to a near vertical position, thus allowing for a comfortable position of the drum 10 for various body parts to be selected. The extension strut or struts 45 provide an upward force to push the drum 10 upward at a dampened velocity, thereby affording the user an easier position adjustment. The struts 45 may comprise modular locking gas springs. Once the upper arm 20 is in the desired position, the clamping system may reengage to prevent the arm 20 from moving.
[0023] In an embodiment, a locking and unlocking mechanism is configured to release all locking gas springs at once. The locking and unlocking mechanism employs a pair of serially linked slider crank linkages to control the gas springs. This arrangement provides the necessary mechanical advantage, which can be adjusted by changing the position of a single fulcrum.
[0024] The upper arm may be composed of hollow shells with thin-walled, generally C-shaped cross-sections. In an embodiment, the cross sections may be economically manufactured as aluminum castings that are joined together with fasteners to transfer shear load between the shells at their mating boundary and create dramatically higher torsional and bending stiffness in the resulting structure of the arm 20 .
[0025] An electronic housing 30 may attach to the upper arm 20 . The electronic housing 30 provides a stiffening support for the upper arm 20 . Further, the lower arm-electronic housing 30 may house electrical components and electronic controls for the biomechanical stimulator 5 . In one embodiment, the arm is composed of conductive material or a conductively coated material. An electrically conductive gasket may be disposed between the structural components of the arm 20 to create a Faraday cage and effectively shield the internal electronics from creating or being affected by electro-magnetic interference (EMI). Further, the arm 20 may include thermally conductive structural components to act as a heat sink and thus reduce the size, cost, temperature, and failure rates of the electronics in the electronic housing 30 .
[0026] The biomechanical stimulator 5 includes a drum 10 , as shown in FIGS. 2A and 2B . The drum may be configured to translate in an orbiting motion with respect to the upper arm 20 . In one embodiment, the drum 10 may comprise a cylindrically shaped body and components to facilitate motion of the drum 10 housed inside the body of the drum 10 . In general, the drum 10 may be any ergonomic shape that readily affords transfer of biomechanical stimulation to a user's body parts. The drum 10 may be manufactured from a metal, plastic, composite, or other material conventionally used for such components. The outside of the drum 10 may be coated with a layer made from a soft material such as foam rubber.
[0027] The drum 10 may be connected to the motor 70 by means of a ball bearing in such a manner that, during operation, the cylindrical basic body carries out a circular or elliptical movement about an axis that differs from the central axis of the drum cylinder and undergoes parallel displacement in the process. This movement has been described in the pending European patent applications No. 03028004.4 and No. 04000668.6, each of which are hereby incorporated by reference in their entirety.
[0028] The drum 10 thus is driven to translate in a circular or elliptical orbit. The orbit may be uniform and consistently repeated instead of random. It has been shown that biomechanical muscle stimulation can be carried out in a considerably more effective manner in this way than if it is carried out using random and therefore non-uniform movements. The elliptical or circular movements of the drum 10 provide not only a vertical force but also a tensile force that can act in an essentially parallel manner on a device or body part placed on the drum 10 . This results in considerably improved biomechanical stimulation of that part of the body which is situated on the drum.
[0029] In an embodiment, the movement of the drum may be translation in a circular orbit about an axis without appreciable rotation. As used herein, circular movement is understood as meaning a movement that differs from an ideal circular movement by no more than 5%.
[0030] A drum weldment 85 may be positioned between the inner surface of the drum 10 and drum-shaft bearings 90 . The drum-shaft bearings 90 may be configured to hold a shaft within the drum 10 . The bearings 90 may include non-contacting seals and low friction lubrication that connect the drum-shaft to the non-moving portion of the drum 10 to measurably reduce power consumption. The drum weldment 85 connects the drum 10 to a rotational drive system, further illustrated in FIG. 6 and described in further detail below. The rotational drive may consist of a motor 70 , a pulley system 75 and an eccentric drive shaft 65 positioned within the drum 10 . The eccentric drive shaft 65 is attached to an anti-rotation plate 80 and drum-shaft support bearing. The eccentric shaft 65 provides the amplitude of the elliptical stimulation motion.
[0031] The anti-rotation mechanism employs a plurality of rubber elements or sandwich mounts to appreciably limit rotation of the drum 10 , while allowing translation of the drum 10 through the prescribed orbit characteristic of biomechanical stimulation. One end of each rubber element is attached to the non-orbiting drum base while the other end is attached to the orbiting portion of the drum 10 . Other embodiments of an anti-rotation mechanism are also possible.
[0032] The drum 10 may connect to the arm 10 by way of a single attachment system. For example, the single attachment system includes a slidable mounting surface 12 of the drum 10 configured to mate with a similar slidable mounting surface 18 of the arm 20 . An alignment method may be provided to aid the docking and attachment of the drum 10 to the arm 20 . The drum alignment guides 13 direct the forks 19 of the arm 20 into the slidable mounting surface 12 of the drum 10 . An attachment bolt 14 of the drum may slide into the arm channel guide 17 of the arm 20 to provide an inner alignment. The attachment bolt 14 rests in an attachment bracket 16 of the arm, and a nut or fastener may be screwed onto the attachment bolt 14 to secure the drum 10 to the arm 20 . The drum 10 may be easily removed from the arm 20 or base by releasing the nut or fastener and disconnecting a single quick-disconnect plug. The quick-disconnect plug may be a blind-mate connector with a plurality of electrical contacts that automatically mates when the drum 10 is secured to the arm 20 or base 40 and provides electrical power and control signals to the motor. Other drums having different characteristics, such as shape, size, or eccentricity, may be interchanged with the drum 10 to increase the functionality, serviceability, and portability of the biomechanical stimulator 5 .
[0033] The biomechanical stimulator 5 may include a base 40 , as shown in FIG. 5 . The base 40 provides a leveling system to level and stabilize the biomechanical stimulator 5 on uneven floors and surfaces. The leveling system may consist of a top adjustable leveling screws 58 and leveling feet 59 .
[0034] The biomechanical stimulator 5 may be positioned to interface a body part with the drum 10 . As an example of this interface for lower leg muscles, such as a calf muscle, a user may sit in a chair with their legs draped over the drum 10 for stimulation therapy. Another example of this interface might be where the drum 10 is raised to a 45 degree elevation allowing the user to stand leaning a quadricep muscle against the drum 10 . To assist in positioning the drum 10 , the extendable strut or struts 45 provide an upward lifting force capable of lifting the arm 20 and drum 10 automatically when the pivot activation button 25 is depressed. The depression of this activation button 25 simultaneously depresses the mechanical release linkage 47 of one or more extendable struts 45 , thus allowing for pivotal adjustment of the arm 20 and drum 10 to an upward position. Alternatively, upon depression of pivot activation button 25 , the arm 20 and drum 10 can be positioned to a lower position by applying a slight added downward force to the drum 10 .
[0035] A motor 70 housed within the drum 10 generates rotational motion that is used to rotate the eccentric shaft 65 and translate the drum 10 . The rotational motion may be converted to elliptical motion for stimulation. As best illustrated in FIGS. 6 and 7 , the motor 70 is coupled to the eccentric drive shaft 65 by a pulley system 75 . The motor 70 may be an electric motor, or any other type of motor 70 or mechanical drive known in the art. The motor 70 may be a 3-phase AC motor or permanent magnet DC motor to reduce the number of conductors needed to power and control the motor 70 . The motor 70 may be ventilated to appreciably reduce operating temperature of motor 70 . The pulley system 75 includes a belt 77 that couples a first pulley wheel 78 to a second pulley wheel 79 . It will be appreciated, however, that other components, such as a gear train or a direct drive, may be used in place of the pulley system 75 . The motor 70 drives the first pulley wheel 78 to transfer torque from the motor 70 to the second pulley wheel 79 via the belt 77 . The second pulley wheel 79 is connected to the eccentric drive shaft 65 that rotates in response to rotational movement of the motor 70 .
[0036] The motor 70 may be mounted to a rotatable mounting plate 71 that is rotatably connected to the drum 10 . The mounting plate may be connected by a first bolt 72 and be rotatable about the first bolt. A second bolt 73 may be inserted to fix the motor 70 in position. The fixed position may be configured as a position where tension is applied to the belt 77 . Moreover, both bolts may be removed to extract the mounting plate 71 and the motor 70 for replacement or servicing.
[0037] The eccentric drive shaft 65 is support on the non-moving drum base 12 by two bearings 95 . The bearings may be pillow block bearing or any other type of bearings known in the art. The engagement between the bearings 95 and the eccentric drive shaft 65 may be configured to create elliptical stimulation motion of the drum 10 . The eccentric drive shaft 65 may create the amplitude of the elliptical stimulation motion. For example, the eccentric drive shaft 65 may create 2, 3, or 4 millimeters elliptical amplitude. However, it will be appreciated that the eccentric drive shaft 65 may be configured to achieve any amplitude.
[0038] As illustrated in FIGS. 10 and 11 , a pair of inner journals 66 may be positioned to support the eccentric drive shaft 65 on an axis concentric to the diameter of the drive shaft 65 . Further, a pair of outer journals 77 may be positioned parallel to, but offset from, the concentric axis by an eccentric distance. The eccentric journal radius may be smaller than the concentric journal radius by an amount at least as big as the eccentric distance. An indexing feature such as a flat 68 or keyway 69 may be configured to index rotational position of shaft during fabrication to ensure that the eccentric journals are on a common axis. Counter-balance weights may be mounted on the side of the shaft. For example, the counter balance weights may be mounted to be diametrically opposed to the direction of the eccentric distance. Further, an additional concentric axis may be configured for attaching a pulley or gear in order to transfer torque from the motor to this shaft.
[0039] The eccentric drive shaft 65 may include adjustable counter-balance masses to allow for two-plane balance of the vibration drum. The counter-balance masses minimize load on bearings and minimize vibration transmitted to the arm 20 and base 40 Further, the counter-balance masses, which can be adjusted, allow for precise balance to be maintained even if auxiliary attachments are added to the drum 10 .
[0040] In an embodiment, a non-rotating drive shaft is positioned approximately parallel to the eccentric shaft. The first end of the non-rotating shaft may be coupled to a moving portion of the drum 10 and the second end coupled to a non-moving portion of the drum base 12 by way of flexible couplings such as a universal joint, a constant velocity joint, a bellows coupling, or similar device that is rotationally stiff about the axis of the drive shaft but flexible in bending at each coupling thus allowing the moving part of the drum 10 to translate in a plane perpendicular to the axis of the eccentric shaft 65 but not rotate.
[0041] In another embodiment, the drum 10 is mounted to a non-moving base by way of bearings and two identical parallel eccentric shafts which are driven in the same direction, effectively creating a 4-bar parallelogram linkage. Both parallel eccentric shafts must be driven to prevent the linkage from inverting when the four points of the linkage are all aligned.
[0042] In an alternative embodiment, the drum is mounted to a non-moving base by way of bearings and three or more identical parallel eccentric shafts. The identical parallel eccentric shafts are positioned such that their axes are not located in a common plane. At least one of the shafts is driven. This configuration effectively creates three or more 4-bar parallelogram linkages such that at any instance at least one of the parallelogram linkages does not have all its pivot points collapsed into a line.
[0043] Motor speed may be controlled by an electrically wired or wireless hand or foot controller 100 or by a computer. The hand controller 100 may provide additional motor control signals, such as a speed control signal. It will be appreciated, however, that the motor 70 may be controlled by means other than the hand controller 100 .
[0044] The motion controller 37 , shown in FIG. 8 , may be a programmable device. For example, the motion controller 37 may retain a firmware code for operating the biomechanical stimulator 5 in a memory. A plurality of speed versus time profiles for controlling the biomechanical stimulator 5 may be pre-programmed into the memory. The lower arm 30 may house additional electrical and electronic components used to control the stimulation motion of the biomechanical stimulator 5 . A power entry module 33 may provide for the interface attachment of an AC voltage plug and line cord to a typical outlet, for powering the biomechanical stimulator 5 . This power entry module 33 further may house an on-off switch, fusing, voltage and frequency selection adjustment, an EMI-RFI filtering module, and other electrical and electronic components.
[0045] In an embodiment, the biomechanical stimulator 5 can be powered electrical power of multiple voltages typical throughout the world.
[0046] Referring to FIG. 9 , the hand controller 100 may be used to interface, control, and view operating parameters of the biomechanical stimulator 5 . The biomechanical stimulator 5 setup and current settings may be viewed by referencing the hand controller 100 displays. For example, the hand controller 100 may include display viewing areas, including a power indicator display 109 , a speed display 105 , and a runtime display 106 to provide the operating time for a stimulation therapy session. The time may be regulated by start/stop switches by either a start/stop switch 110 on the hand controller 100 or a foot start/stop switch 112 .
[0047] In an embodiment, the hand controller 100 may include a rotating knob to control the speeds of the biomechanical stimulator by way of a potentiometer or encoder. The hand controller 100 may further include a momentary switch button which starts and stops biomechanical stimulator 5 . A 6-pin connector may provide the hand controller with supply voltage for the potentiometer, and return a speed control voltage, and an on/off control signal to the motor drive. The hand controller 100 may further include a communication port to communicate with devices such as a computer, PC, laptop, touch screen or PLC.
[0048] In an embodiment, the speed and frequency adjust switches 107 may select speeds or frequency digitally from 5 Hertz to 36 Hertz. The user interface may allow a user to select any variety of pre-programmed, including on/off cycles; fixed or varying speed; fixed and varying time durations.
[0049] In use, the biomechanical stimulator 5 may be placed in a warm-up cycle to allow for 6 on-off cycles by the activating of the start/stop switch 110 or the foot control start/stop switch 112 . The stimulation speed or frequency of the drum 10 may be adjusted using the speed-frequency switches 107 . A body part may then be positioned in contact with the drum 10 . The biomechanical stimulator 5 may begins the stimulation motion of the drum 10 once the start/stop switch 110 or the foot control start/stop switch 112 is activated. The biomechanical stimulator may continue its operation for a time period, such as 30 seconds, then pause for a time period, such as 6 seconds, to allowing for repositioning of another body part in direct contact with the drum 10 before restarting. This cycle will continue until a set number of cycles, such as 6 cycles, have been completed.
[0050] The invention as described here will obviously upon the reading and understanding of this specification enlighten others to consider alterations and modifications. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalent thereof.
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A biomechanical stimulation device is presented. The biomechanical stimulation device comprises a base that supports an adjustable height arm and an easily removable drum connected to the arm. The drum is driven by a motor to provide an elliptical stimulation motion. An anti-rotation device prevents rotation, but allows orbital translation of drum. The drum may connect to the arm at a single attachment point. The arm 20 may be pivotally attached to the base and selectively movable to a desired position. A pair of struts may support the arm to assist in positioning the arm. The struts may be locked to prevent movement of the arm, or unlocked by a release button to allow selective positioning of the arm. The biomechanical stimulation device may further include a hand controller and other peripheral devices to provides a convenient interface for controlling the speed and run time of the biomechanical stimulation device.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to hoses for the transport of refrigerants and other fluids used in air conditioning systems and the like.
2. Prior Art
Hoses used in air conditioners mounted on for instance automotive vehicles are susceptible to permeation of water and/or steam, leading to frozen moisture within the air conditioner unit. To eliminate this problem, it has been proposed to use butyl-based rubber, ethylene/propylene copolymers and other such elastomeric materials for hoses as are highly impervious to water and/or steam.
Butyl-based vulcanizates such as butyl rubber (IIR) and halogenated butyl rubber (Cl-IIR, Br-IIR) are satisfactory in terms of water and/or steam impermeability (hereinafter referred to simply as moisture impermeability), but due to the presence of double bonds in the isoprene unit, they are rather poor in weather-resistance compared to an ethylene/propylene copolymer rubber. Whereas, ethylene/propylene copolymer rubber (EPM, EPDM) is highly weather-resistant due to the absence of double bonds in the main claim but is not so satisfactory in respect of moisture-impermeability compared to butyl-based rubber.
It has been proposed to use rubber compositions comprising both butyl-based rubber and ethylene/propylene copolymer rubber, the resulting vulcanizates however having no appreciable improvement particularly in respect of moisture-impermeability. Thus, there is presently known any rubber material which is truly eligible as one having adequate resistance to both moisture permeation and weather.
SUMMARY OF THE INVENTION
It is therefore a primary object of the present invention to provide a hose for use in the transport of fluids, inter alia refrigerants, which is produced from a rubber composition capable of exhibiting high resistance to weather and permeation of moisture and/or steam.
The above and other objects and features of the invention will become manifest from reading the following description taken in connection with a preferred embodiment, reference being had to the accompanying drawing.
According to the invention, there is provided a hose having at least a core tube, a reinforcing layer and a cover tube, at least said cover tube being formed from a vulcanizate of a rubber composition (C) comprising a copolymer rubber (A) having an isobutylene unit and a p-halogenated methylstyrene unit and/or a copolymer rubber (B) having an isobutylene unit, a p-halogenated methylstyrene unit and a p-methylstyrene unit.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described more fully, with reference to the accompanying drawings wherein:
FIG. 1 is a perspective view of a hose in accordance with the present invention; and
FIG. 2 is a cross-sectional view of apparatus for conducting a moisture impermeability test for sheet rubber.
DETAILED DESCRIPTION OF THE INVENTION
A rubber composition (C) according to the invention comprises a copolymer rubber (A) identified by formula (I) below and having an isobutylene unit and a p-halogenated methylstyrene unit and/or a copolymer rubber (B) identified by formula (II) and having an isobutylene unit, a p-halogenated methylstyrene unit and a p-methylstyrene unit ##STR1## wherein X is a halogen atom. ##STR2## wherein X is a halogen atom.
The above copolymer rubbers (A) and (B) can be obtained by halogenating the methyl groups in the p-methylstyrene unit of an isobutylene/p-methylstyrene copolymer rubber represented by formula (III) below. ##STR3##
The proportion of p-halogenated methylstyrene unit in copolymer rubber (A) and the proportion of the sum of p-halogenated methylstyrene unit and p-methylstyrene unit in copolymer rubber (B) are preferably in the range of 1-20 percent by weight, more preferably in the range of 1-15 percent by weight of the respective copolymers. Proportions of these units less than 1 percent by weight would mean less halogenated methyl groups, hence too little cross-linkable moieties, leading to insufficient post-vulcanization elastic modulus, whereas proportions exceeding 20 percent by weight would result in undue rise in the glass transition temperature and reduced freeze resistance of the vulcanizates.
Halogen contents in the respective copolymer rubbers (A) and (B) are preferably in the range of 0.2 to 2.2 percent by weight, more preferably in the range of 0.8 to 2.0 percent by weight. Less than 0.2 weight percent halogen contents would represent insufficient cross-linkable moieties, leading to reduced post-vulcanization elasticity, whereas greater than 2.2 percent halogen contents would result in reduced scorch time, unreacted halogen residues after vulcanization and declined thermal aging resistance of the vulcanizates.
It is preferable to use copolymer rubber (A) or (B) which contains bromine atoms in particular from amongs other halogen atoms.
Copolymer rubbers (A) and (B) are believed to undergo cross-linking reaction at their respective p-halogenated methylstyrene moieties, as represented by formula (IV), through the medium of certain vulcanizing agents hereafter described. ##STR4##
The isobutylene units in copolymer rubbers (A) and (B) contribute to enhanced moisture impermeability of the hose. Both copolymer rubbers are free of double bonds in the main chain, hence less reactive, leading to high resistance to weather, particularly to ozone and are therefore, when vulcanized, highly resistant to moisture and weather.
A copolymer rubber eligible for the purpose of the invention may be typically exemplified by a product tradenamed XP-50 of Exxon Chemical Company (a bromide of an isobutylene-para-methylstyrene copolymer) and is introduced in a literature entitled "A meeting of the Rubber Division, American Chemical Society (ACS), Washington, D.C., Oct. 9-12, 1990, ISOBUTYLENE-BASED POLYMERS IN TIRES-STATUS AND FUTURE TRENDS, by J. V. Fusco AND D. G. Young, Exxon Chemical Company".
The rubber composition (C) used in the invention is comprised chiefly of copolymer rubbers (A) and (B) but may further contain a limited amount of other suitable polymers such as butyl-based rubber, ethylene/propylene copolymer rubber and the like.
The vulcanizing agent to be used in the invention includes sulfur, quinone dioxime, modified alkylphenol resin, zinc oxide/stearate, zinc stearate, other metal stearate, zinc salts of dithiocarbamate, and thiuram/thiazole. These vulcanizing agents may be used in an amount dependent upon their peculiar characteristics.
The rubber composition (C) according to the invention may contain, if desired, suitable additives such as fillers, reinforcing agents, plasticizers, antioxidants, processing aids, pigments and the like. The rubber composition (C) may find useful application for steam hoses where high moisture resistance is required.
Referring to FIG. 1, the inventive hose 2 for use particularly in the transport of refrigerants is made up of at least a core tube 4, a reinforcing layer 6 and a cover tube 8. The cover tube in particular is formed from the rubber composition (C) and is usually about 1.0 mm-2.0 mm thick. The core tube may be formed from a vulcanizate of such a rubber composition which is vulcanizable under conditions similar to these for the rubber composition (C). The core tube is surrounded by a reinforcing layer of high strength yarns such as rayon and polyester yarns. The hose contemplated hereunder may further comprise other intermediate layers if desired. In any case, however, it is important for the purpose of the invention that the outermost layer of the covet tube is formed from a vulcanizate of the rubber composition (C). Certain preferred hose structures are disclosed in Japanese Laid-Open Patent Publication Nos. 63-125885 and 63-302036.
The inventive hose may be fabricated by any known means. For example, the core tube is formed by extension of a resin and a rubber composition onto a mandrel coated with a releasing agent and knitted thereover with suitable reinforcing yarns, followed by extrusion of the rubber composition (C). The resulting tubular body is then subjected to press vulcanization at 130°-170° C., preferably 140°-160° C., and allowed to cool, followed by withdrawal of the mandrel.
The invention will be further described by way of the following examples.
Preparation of Vulcanizates
Each of the rubber compositions shown in Table 1, 2 and 3 was kneaded and subjected to press vulcanization at 160° C. for 30 minutes until there was produced a sheet of vulcanized rubber.
Ozone-Resistance Test (Vulcanizates)
The procedure of JIS K6301 was followed. The various rubber sheets obtained as above were stretched at 60% elongation and exposed to an atmosphere of 100 pphm ozone at 50° C. Observation was made for cracks or ruptures every 24 hours over 168 hours.
Moisture Impermeability Test (Vulcanizates)
This test was made with use of an apparatus shown in FIG. 2 which comprises a stainless steel cup 10, filled halfway with water 20. A sample of each of the above rubber sheets 30 was placed over the cup 10, overlaid by a sintered metal plate 40 and secured in place by tightening bolts 50 and nuts 60. The sample 30 was disposed at an atmosphere of 80° C. and examined for loss of weight every 24 hours. Moisture permeability was determined by the equation ##EQU1## where A (cm 2 ) is an area of permeation;
T (day) is a total of hours tested;
M (mg) is a loss of weight; and
t (mm) is a thickness of each test sample.
The results of the above tests are shown in Table 4, from which it is seen that the inventive rubber compositions (C 1 and C 2 ) are satisfactory in respect of both ozone resistance and moisture impermeability properties, whereas control (Y 4 ) and controls (Y 1 , Y 2 and Y 3 ) are satisfactory only in respect of either, not both, of the desired properties.
Fabrication of Hoses
A polyamide resin was extended to a thickness of 0.2 mm over a mandrel measuring 11 mm in diameter. Over the resulting inner resinous tube was extruded a control rubber composition (Y 1 ) to an outside diameter of 14.5 mm. The thus extruded rubber tube was knitted thereover with a layer of polyester reinforcing yarns, followed by extrusion of each of the rubber compositions of Tables 1-3 to an outside diameter of 19.0 mm to form a cover or outermost tube. This tube was coated with lead and vulcanized in steam at 160° C. for 60 minutes. After removal of lead, the mandrel was pulled out to produce a test sample hose.
Ozone Resistance Test (Hoses)
The procedure of JIS K6330 was followed. Each sample hose was wound on a cylindrical tube having an outer diameter 6 times larger than that of the hose. It was exposed to an atmosphere of 100 pphm ozone at 50° C. and checked for cracks or rupturers after a lapse of 168 hours.
Moisture Impermeability Test (Hoses)
Each sample hose was placed in an oven at 50° C. for 5 hours, followed by introduction of a desiccant (molecular sieves 3A) in an amount equivalent to 80% volume of the hose. The oven was hermetically sealed. The hose was then exposed to an atmosphere of 95% RH and 50° C. The desiccant was examined for changes in weight, the amount of moisture absorbed being determined by conversion to mg/cm 2 /24 H.
The results of the above tests are shown in Table 5 from which it is seen that the hoses incorporating rubber compositions (C 1 and C 2 ) for the cover tubes are satisfactory in respect of both ozone resistance and moisture impermeability properties, whereas the hoses incorporating rubber compositions of control (Y 4 ) and controls (Y 1 , Y 2 and Y 3 ) are satisfactory only in respect of either, not both, of the desired properties.
TABLE 1______________________________________Rubber Compositions (C) for Hose Cover Tube C.sub.1 C.sub.2______________________________________ copolymer rubber 100.0 100.0 isobutylene (weight %) 94.0 90.5 p-methylstyrene (weight %) 5.0 7.5 bromine (weight %) 1.0 2.0 HAF carbon black *.sup.1 50.0 50.0 AC polyethylene 5.0 5.0 softening agent *.sup.2 10.0 10.0 chinese white 0.5 0.5 stearic acid 2.0 2.0 zinc stearate 1.0 1.0______________________________________
TABLE 2______________________________________Control Rubber Composition (Y) Y.sub.1 Y.sub.2 Y.sub.3______________________________________butyl rubber *.sup.3 100.0chlorinated butyl rubber *.sup.4 100.0brominated butyl rubber *.sup.5 100.0HAF carbon black *.sup.1 80.0 50.0 50.0AC polyethylene 5.0 5.0 5.0softening agent *.sup.2 10.0 10.0 10.0chinese white 3.0 5.0 3.0stearic acid 3.0 1.0 1.0brominated 8.0alkylphenol resin *.sup.6Accelerator TT *.sup.7 1.5Accelerator DM *.sup.8 1.5 1.3sulfur 0.5______________________________________
TABLE 3______________________________________Control Rubber Composition (Y) Y.sub.4______________________________________ethylene/propylene 100.0copolymer rubber (EPDM) *.sup.9FEF carbon black *.sup.10 90.0chinese white 5.0stearic acid 1.0softening agent *.sup.2 35.0sulfur 1.0Accelerator CZ *.sup.11 2.0Accelerator TT *.sup.7 0.5______________________________________ *.sup.1 Showblack N330, Showa Cabot Co., Ltd. *.sup.2 Machine Oil 22, Showa Shell Oil Co., Ltd. *.sup.3 Exxon Bytyl 268, Exxon Chemical Company *.sup.4 Chlorobutyl 1066, Exxon Chemical Company *.sup.5 Exxon Bromobutyl 2255, Exxon Chemical Company *.sup.6 Tackyroll 250I, Taoka Chemical Co., Ltd. *.sup.7 Nocceler TT, Ohuchi Shinko Kagaku Co., Ltd. tetramethylthiuram disulfide *.sup.8 Nocceler DM, Ohuchi Shinko Kagaku Co., Ltd. dibenzothiazyl sulfid *.sup.9 Mitsui EPT 4070, Chubu Carbon Co., Ltd. *.sup.10 HTC #100, Mitsubishi Petrochemical Industries Ltd. *.sup.11 Nocceler CZG, Ouchi Shinko Kagaku, Co., Ltd. Ncyclohexyl-2-benzothiazyl sulfeneamide
TABLE 4__________________________________________________________________________Test Results on Vulcanized Rubber Sheets Inventive Examples Comparative Examples 1 2 1 2 3 4__________________________________________________________________________rubber composition C.sub.1 C.sub.2 Y.sub.1 Y.sub.2 Y.sub.3 Y.sub.4 (IIR) (C1-IIR) (Br-IIR) (EPDM)ozone resistance test 168 H 168 H 24 H 24 H 24H 168H no cracks no cracks cracked cracked cracked no cracksmoisture impermeability 1.5 1.5 1.5 1.5 1.5 4.0test (mg · mm/24 H · cm.sup.2)__________________________________________________________________________
TABLE 5__________________________________________________________________________Test Results on Hoses Inventive Examples Comparative Examples 1 2 1 2 3 4__________________________________________________________________________cover tube rubber C.sub.1 C.sub.2 Y.sub.1 Y.sub.2 Y.sub.3 Y.sub.4composition (IIR) (Cl-IIR) (Br-IIR) (EPDM)ozone resistance test no cracks no cracks cracked cracked cracked no cracksmoisture impermeability 0.1 0.1 0.1 0.1 0.1 0.4test (mg/cm.sup.2 /24 H)__________________________________________________________________________
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A hose useful for handling low temperature fluids such as refrigerants is disclosed, which exhibits excellent resistance to ozone and moisture permeation. A cover or outermost tube of the hose is formed from a vulcanizate of a rubber composition comprising a first copolymer rubber having an isobutylene unit and a p-halogenated methylstyrene unit and/or a second copolymer rubber having an isobutylene unit, a p-halogenated methylstyrene unit and a p-methylstyrene unit.
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FIELD OF THE INVENTION
In the broad field of acquiring or displaying information, the need for measuring the rotational position of a shaft at rest sometimes occurs. Rapid sensing of that rotational position and conversion of the findings into an electric analog signal is important in information-gathering applications, and adjustment of shaft rotational position to a targeted, desired position is important in control-seeking applications. The invention is in the field of accomplishing these important functions with speed and precision.
DESCRIPTION OF PRIOR ART
The principal development in this field has been in the area of turning a shaft to a pre-selected angle, for steering missiles, identifying where on a circuit board to hand-load electronic components, positioning marks on products such as integrated-circuit chips, applying heat to solder tiny parts, etc. The former art had the shaft vary capacitance via an attached capacitor plate. That drifted badly, and was recently replaced by the optical feedback obtained by reflecting light from a mirror mounted on the shaft periphery, as taught in U.S. Pat. No. 5105139, a system less subject to thermal drift. Fairly large corrections were still required within the feedback electronics, however.
One object the present invention achieves is to reduce the magnitude of feedback corrections so as to reduce possible errors in them, drift errors and errors due to nonlinearity of components.
Another object is to replace discrete photoconductive sensors, the devices which in prior art detect the reflected optical beam, with the more accurate integrated diode array sensor.
Another object is to so arrange the optical circuit as to be free of almost all effects due to angles of incidence between the light beam and the component on which it impinges for either reflection or sensing. This near-freedom not only means relatively small corrections (and errors in corrections) but also confers the advantage that the optical system characteristics (such as low angle of incidence) cease to limit the range of shaft rotational angles the system will tolerate.
SUMMARY OF THE INVENTION
NOTE: As used herein, the phrase "a substantially parallel beam of electromagnetic radiation" refers not only to the output beam of a laser, but also to the small-angle cone of radiation at or near the image position in a focused beam when the object position (the radiation source) is only slightly beyond the focal length of a focusing lens (when the magnification is large).
A substantially parallel beam of electromagnetic radiation from an LED, or collimated coherent electromagnetic radiation from a laser, is set up to proceed along the axis of rotation of a shaft whose rotary position is to be closely controlled. The beam is directed toward a free end of the shaft, the free end being both converted into a mirror or bearing a mirror and finished at an angle to the shaft axis other than 90 degrees, preferably between 40 and 85 degrees and in the preferred embodiment 45 degrees. The sensitive portion of an integrated diode array is so positioned to receive the reflected electromagnetic radiation (in the preferred embodiment positioned in the plane normal to the end of the shaft axis), with the length of the sensitive portion lying at 90 degrees to the shaft, separated inches from the shaft, and tangential to a circle centered on the shaft axis. The reflected spot thus moves along the length of the sensitive portion of the integrated diode array and generates a signal related to the rotational position of the shaft. The diameter of the beam is less than the width of the sensitive portion, so the position of the center of the circular or elliptical reflected spot, whose intensity is modulated by a first electronic means to compensate for ellipticity, is an accurate measure of the rotational position of the shaft, and any error with respect to a pre-selected position may be fed back using a second electronic means to the shaft drive and corrected. This application of the invention applies to devices which require the shaft to assume a certain rotational position or a sequence of desired positions (shaft angles with respect to whatever zero position was selected; i.e., the shortest line from the shaft axis to any point on the sensitive area of the integrated diode array).
When an application of the invention requires measurement of the rotational position to which the shaft is driven by external means, the comparison and feedback elements are omitted from the second electronic means and the position data, amplified or not, is supplied to external measuring instruments. The first electronic means is used as noted above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of the invention, together with a schematic representation of the electronic means to be used when the application is positioning.
FIG. 2 is a perspective view of the invention itself, differing from FIG. 1 in that typical mounting structure is shown and an alternate angle on the shaft end is shown.
FIG. 3 is a sketch to be used in discussing choice of shaft-end angle, taken basically from the light source position, except that the integrated diode array is rotated 90° into the plane of the paper and construction lines to clarify the discussion are shown.
DETAILED DESCRIPTION
FIG. 1 shows the invention as it would be used in the most physically complex application--that of establishing a desired shaft angle or rotational position of the shaft at rest. The preferred embodiment of using a mirror (Item 4) angle of 45 degrees is illustrated. Item 1 is the hardware which produces a substantially parallel beam of electromagnetic radiation, shown as a filament close to the focal point of a lens. In FIG. 2, Item 1 remains the hardware but is shown as a laser which produces a beam not only collimated but also coherent. Either will produce a substantially parallel beam of electromagnetic radiation. Item 1 must have a power supply (not shown) capable of being modulated so as to vary the intensity of the substantially parallel beam of electromagnetic radiation under the control of a first electronic means (Item 8). Since the integrated diode array outputs are somewhat affected by the intensity of light in the reflected beam, and since an off-normal circular spot becomes elliptical and hence of lower local intensity, the correction made by Item 8 is necessary for the apparatus to be as error-free as possible. By keeping the sum of the two outputs from Item 5, X and X 1 (the distances of the spot from fixed end points), constant, Item 8 converts their difference into a highly accurate measurement of the motion of the reflected light spot from an initial position. The initial position may be set by the user at any point in the sector of interest, by means external to the invention.
Item 2 is the shaft drive, a special-purpose electric motor in the preferred embodiment. Item 8 is the shaft, and Item 4 the reflective surface or mirror fashioned on or attached to the free end of shaft Item 3. Item 4 intersects the shaft axis at an angle other than 90 degrees, 45 degrees being the preferred embodiment. FIG. 1 shows Item 4's angle to be 45 degrees; FIG. 2 shows it roughly 70 degrees.
Item 9 standoffs and Item 10 hardware mounting plate shown in FIG. 2 simply depict a typical mounting arrangement. Item 7 is a second electronic means used for the primary application of this apparatus, to establish the rotary position of shaft 3 at a desired shaft angle. As is shown in FIG. 1, Item 7 performs in sequence amplification of the integrated diode array Item 5's two output signals, subtraction, amplification of the difference, comparison with a signal corresponding to the desired shaft rotary position, feedback of any error to shaft drive 2 to correct the actual shaft rotary position to that desired. (The discussion assumes the initial position is in the center of the integrated diode array Item 5.)
A brief description of an integrated diode array commercially available currently is a small packaged integrated circuit having a sensitive area about 3/4 inch long by 1/16 wide on one face, capable of distinguishing between 40,000 positions along its length when a position is illuminated by a beam of microscopic cross section and used with beams up to 1/16 inch cross section.
The geometric relations of shaft axis, integrated diode array sensitive area placement and its effect on the two analog voltage signal outputs (one output indicating distance of the illuminated spot from one end of the sensitive area and the other voltage output likewise proportional to the distance of the illuminated spot from the other end of the sensitive area) follows straightforward solid geometry. Were the integrated diode array sensitive surface curved to be a constant distance from the shaft axis, whether the illuminated spot was at the center or at an end, the outputs would be proportional to angle directly. However, since the sensitive surface is flat in all commercially available integrated diode arrays, the closest approach of it to the shaft axis represents a point of tangency to the cone traced by the reflected beam if the mirror angle is greater than 45 degrees. The sensitive area is normally (in the preferred embodiment) centered on this point when the shaft is at "zero" rotational position, hence spot positions not at the center of the sensitive area correspond not to angular displacement from "zero" but to the tangent of angular displacement. Obviously the "zero" rotational position need not be at the center of the sensitive area; if the application calls for control only clockwise from "zero" greater displacement angles can be measured or established when the "zero" point, the point of tangency, is preset at one end of the sensitive area. Such a change, obvious to one skilled in the art, is deemed within the scope of this invention.
FIG. 3 is a mathematical construction to aid in understanding off-square conditions when the light from mirror 4 strikes flat sensitive area 6. The lines across Item 4 are both lines showing the locus of maximum slope of Item 4; the vertical one corresponding to the situation in FIG. 2 when the reflected beam is at an arbitrary angle to the incident beam (twice the angle between mirror 4 and the axis of shaft 3). Integrated diode array 5 is mounted tilted by the same arbitrary angle with respect to the surface of hardware mounting plate 10, so the substantially parallel electromagnetic beam--taken to be cylindrical--illuminates a circular spot on sensitive area 6. If sensitive area 6 were a flat plate, the lower set of the two curved lines in FIG. 3 would trace a cone with its apex at the point where shaft 3 axis intersects mirror 4. Since sensitive area 6 is not curved but flat and lies tangent to the swept-out cone, its ends are farther from the apex, farther down the cone, and have therefore a greater radius as shown in FIG. 3 by the pair of shorter curved lines. The spot illuminated is no longer a circle but an ellipse; a geometric construction too small to analyze from FIG. 3 but lying between the pair of short curved lines. The size of the ellipse may be calculated from an angle of incidence calculated by solid geometry, adding two angles at right angles to each other to obtain the angle across the diagonal. One of the angles is displacement of the spot along the length of sensitive area 6, the other is represented by the distance between the pairs of lines. The drawing does not show these angles at a right angle to each other because, to be geometrically correct it would show the sensitive area 6 as a line (and instead of pairs of sweep lines; the sweep lines would be singular). In any case this calculation need only be done to design the mounting properly; in operation regardless of spot size as long as the output signal total is rendered equal to itself (held constant) regardless of spot position, by altering the electromagnetic beam's intensity the apparatus will give spot distance along the sensitive area accurately. It is true that a spot width less than the width of sensitive area 6 will allow a small amount of transverse motion to occur due to the second angle discussed above. This transverse motion calculates to be 0.019 inches per inch between Items 4 and 6 when the angle of Item 4 is 70 degrees. There is also an effect on the angle of incidence (making the ellipse axis tilt) which amounts to less than 0.1 degree (out of 7 degrees or so). These factors will not affect the performance of individual diodes in the array, nor the performance of the apparatus as described and claimed. Simple reasoning from FIG. 3's teaching reveals that a wide sector of interest, which requires close spacing between Items 4 and 6, elongates the ellipse even for a 45 degree tile of mirror 4, but this is fully compensated for by Item 8.
For completeness, it should be mentioned that the two outputs of integrated diode array 5 in FIG. 1 are X and X 1 and are referred to a ground lead brought out of Item 5 which is not shown in the figure. Position detector means (not shown) would merely sense, amplify, and display either one of the two outputs, and eliminate the commanded signal, its comparator, and the feedback from second electronic means 7 shown in FIG. 1, retaining first electronic means 8.
The integrated diode array Item 5 is known commercially as a position sensing detector. The sensitive area consists of a stack of photoconductive diodes, a tiny resistor being associated with each diode and the diodes being long and narrow. The array is thus like a ladder containing only rungs, no foot spaces. When a diode is adequately illuminated at any point along its length, it conducts current through its resistor (which, being on the upright element of the ladder, is in series with all the resistors associated with non-conducting diodes to the foot and top of the "upright." Current flowing to ground through those diodes which are conducting comes partially from the "X" end of the array and partially from the "X 1 " end, through as many tiny resistors as there are diodes between the illuminated spot and the end of the array, thus providing a signal affected by position.
When the illuminated spot is elliptical due to geometry rather than circular, a broader set of diodes become photoconductive. For reasons unclear to the inventor, experience shows that reducing the intensity of the substantially parallel beam will decrease the total current conducted by the set of photoconductive diodes to that which would be conducted were the beam perpendicular and the spot circular about the same center as the ellipse. This phenomenon may be due to differing intensities within the cross section of the beam or to some other cause, but it is reliable and enables second electronic means Item 8 to render the total signal X +X 1 constant without exceeding current carrying limitations on integrated diode array Item 5.
It is noted that the description given earlier and that given above pertains to currently available commercial products, the preferred embodiment. In the claims the term is intended to include arrays of photoconductive diodes operating on the same principles, for example non-flat arrays or arrays with wider sensitive areas, since in terms of the present invention, as long as modulation of the beam intensity helps positioning accuracy detailed construction of the array is not germane to this invention.
The invention having been described in its preferred embodiment, it is clear that modifications are within the capacity of those skilled in the art without exercise of the inventive faculty.
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Apparatus for using an integrated diode array, also called a position sensing detector, which indicates the position of a spot of electromagnetic radiation along a sensitive strip, to measure angular rotation of a stationary shaft from a zero point. A beam of infrared or laser radiation is reflected from a mirror set at an angle other than 90 degrees to the shaft axis, located on a free end of the shaft. The reflected beam falls on the integrated diode array, its position being proportional to the tangent of the angle from the zero point (preferably the center of the sensitive area). The sum of analog voltage signals from both ends of the sensitive area is held constant by second electronic means through feedback monitoring of the radiation source power (beam intensity). In a shaft-angle controlling embodiment, the difference of the two analog voltage signal outputs is adjusted to be equal to a predetermined voltage corresponding to the desired angle using a first electronic means feeding back to whatever rotates the shaft.
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FIELD OF THE INVENTION
[0001] The present invention relates to the field of insulated walls for building, more particularly, to insulated load bearing walls and the construction thereof.
BACKGROUND OF THE INVENTION
[0002] The field of wall structure elements has provided many building solutions in the form of various sandwiched wall structures. The main parameters to consider in the construction of such a wall are: 1) load capacity, 2) insulation, 3) thickness, 4) cost, and 5) complexity to build. For example U.S. Pat. No. 4,998,394 provides such a wall structure which claims to provide solutions for the above-mentioned parameters. However, the load capacity of the wall disclosed in said patent is insufficient for the construction of high rise building. Furthermore, the need for additional insulation layers, creates a relatively thick wall. U.S. Pat. No. 5,845,445 describes an insulated concrete from which also has insufficient load bearing capacity and relatively poor insulating capabilities. There are many types of such wall structures; however all have at least one insufficiency with respect to the parameters mentioned above.
[0003] In 1914 in Sweden the foamed concrete was invented by adding aluminum powder to cement, lime, water, and silica sand, which caused the mixture to expand dramatically. The Swedes allowed this “foamed” concrete to harden in a mold, and then they cured it in a pressurized steam chamber-an autoclave to create autoclaved aerated concrete (AAC, also called autoclaved cellular concrete—ACC). At a density of roughly one-fifth that of conventional concrete and a compressive strength of about one-tenth, AAC is used in load-bearing walls only in low-rise buildings. The material is also fairly friable and must be protected from weather with siding or coating. On the positive side, it insulates much better than concrete and has very good sound absorbing characteristics.
[0004] Accordingly, there is a long felt need for a wall structure with improved load bearing capability, good insulation properties, minimal thickness, low cost and simple to assemble.
[0005] It is therefore an objective of the present invention to provide a wall structure which provides the above-mentioned properties.
[0006] It is yet a further objective of the present invention to provide a method for constructing such a wall.
[0007] Other objectives of the invention shall become apparent as the description proceeds.
SUMMARY OF THE INVENTION
[0008] The present invention provides a structural wall section having a sandwich like structure comprising an external vertical panel and an internal vertical panel spaced apart in parallel relationship, further comprising of a vertical insulating layer wherein between said panels there is a space, “core” comprising
a vertical layer of concrete wherein said concrete layer contains vertical steel reinforcements, a support structure for the internal panel, and a rigid spacer wherein said spacer is positioned horizontally between the external panel and the support structure of the internal panel, wherein the outer surface of the external panel is covered with a coating layer.
[0012] Optionally, the wall comprises horizontal tie elements which secure the outer coating of the external panel to the core.
[0013] Further optionally, the wall structure comprises strips which connect between sections of the wall and pegs which reinforce the wall structure to the ceiling and/or floor. Further provided by the present invention, is a method for forming a wall structure comprising of the following steps, which may be carried out in various sequences wherein the casting of the concrete must always be the final step.
a) positioning the external panel, b) constructing and positioning the support structure on which the internal panel is supported, wherein said structure is constructed at a given distance and parallel to the external panel such that there is a hollow space between the external panel and the internal panel, c) vertically positioning a steel reinforcement in the hollow space between the external panel and support structure of said internal panel, d) installing the rigid spacers, e) covering the outside surface of the external panel with a coating layer, f) positioning a vertical insulation layer within the core g) mounting the internal panel on the support structure, h) casting concrete into the hollow space between the external panel and internal Panel.
[0022] Optionally, wherein horizontal tie elements are employed for securing the coating layer to the core, said tie elements are installed in the process of applying said coating.
BRIEF DESCRIPTIONS OF THE DRAWING
[0023] FIG. 1 is a cross sectional view of the wall structure.
[0024] FIG. 2 is a sectional view of the wall structure.
[0025] FIG. 3 is a top plan view of a corner of the wall structure.
[0026] FIG. 4 is a sectional view of the wall structure.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0027] The following description is illustrative of embodiments of the invention. The following description is not to be construed as limiting, it being understood that the skilled person may carry out many obvious variations to the invention.
[0028] The present invention provides a load bearing wall structure which is constructed in a layered manner wherein insulating and reinforcing elements are sandwiched between an external coated panel and an internal panel.
[0029] In accordance with a particular embodiment of the invention, with reference to FIGS. 1 to 4 , there is provided a wall structure comprising;
[0030] An outside coating layer ( 1 ). Said layer protects the external panel ( 2 ) from mechanical damage and may further provide insulation against permeation of water and humidity. The primary functions of the outside surface are decorative, protection and insulation. Any material which may impart said functions is suitable for use as the outside coating layer. Non-limiting examples of suitable coating materials include stone, marble, mortar, wood, aluminum, glass, porcelain and ceramics.
[0031] The external panel ( 2 ) can be constructed of various types of materials which are suitable for bearing the coating layer and functioning as a concrete forming panel. Non-limiting examples of suitable materials for the external panel include gypsum board, rock sheet, wood panels and the like. According to a preferred embodiment of the invention, the external panel is constructed of building blocks. Non-limiting examples of suitable blocks include concrete and AAC, e.g. Ytong® building blocks. More preferablyan AAC block. Thus, providing improved thermal and sound insulation. The external panel ( 2 ) may be constructed of blocks of various sizes depending on the technical requirements of the structure.
[0032] According to an embodiment of the invention wherein the external panel is not constructed of blocks, there may be a need to insert a vertical layer of insulating material within the core. Non-limiting examples of suitable insulating materials include polymeric materials such as foaming polystyrene.
[0033] The internal panel ( 3 ) is supported on a support structure ( 4 ). Non-limiting examples of suitable materials for said internal panel include rock sheet, gypsum board, wood panel and polymeric materials. The support structure ( 4 ) and internal panel ( 3 ) are positioned parallel to the external panel ( 2 ) and at a distance such that a hollow space is formed between the internal panel ( 3 ) and external panel ( 2 ) into which the concrete is cast ( 8 ). The distance between the internal panel ( 3 ) and external panel ( 2 ) is adjusted according to the structural requirements. The support structure ( 4 ) is preferably constructed of horizontal and vertical beams. Non-limiting examples of suitable materials for said support structure include steel, aluminum or wood, preferably steel.
[0034] The steel reinforcement ( 5 ) can be of various forms suitable for providing structural strength to the wall structure. Preferably, the steel reinforcement ( 5 ) is a network of steel rods interweaved. Said network is positioned at a fixed distance, parallel to the external panel ( 2 ) and within the hollow space in the core of the wall. The fixed distance between the steel reinforcement ( 5 ) and the external panel ( 2 ) is maintained by rigid spacers ( 6 ), which are positioned horizontally between said external panel ( 2 ) and the steel reinforcement ( 5 ). The length of the spacers ( 6 ) is adjusted to the required distance between the external panel ( 2 ) and steel reinforcement ( 5 ). Said spacer ( 6 ) can be made of metal, wood, plastic or any suitable material for this purpose. According to yet a further embodiment of the invention the steel reinforcement may be in the form of steel beams positioned vertically within the core and optionally connected by other steel connectors.
[0035] According to a further embodiment of the invention, the tie elements ( 7 ) which are preferably made of steel, are connected at one end to the outside coating layer ( 1 ) and at the other end to the internal panel ( 3 ) and/or support structure ( 4 ). The function of said tie elements ( 7 ) are to secure the outside coating layer ( 1 ) to the core of the wall structure.
[0036] Various types of concrete ( 8 ) may be used for casting into the hollow space, as may be appreciated by the skilled artisan. Preferably, the characteristics of the concrete are such that it is free flowing, self leveling, rapid hardening with negligible retardation, improved anti-segregation properties and excellent workability. Such concrete is also known in the art as Self Compacting Concrete (SCC). Said properties are important for ensuring that the concrete when cast, flows freely to fill all of the hollow space such that there are no voids where the concrete did not settle in. Furthermore, said properties are important for providing a wall structure of the required technical features, e.g. strength.
[0037] According to a further preferred embodiment of the invention, the wall structure may be constructed to include an opening e.g., window or door, by creating the required size opening in the external panel, support structure and internal panel and then building a frame on the internal perimeter of the opening. Thus, when the concrete is cast to the hollow space it will not seep through the opening. Said frame may further function as door post or mounting frame on which the door or window is mounted.
[0038] According to a specific embodiment of the invention, with reference to FIG. 2 , the wall structure further comprises a strip ( 9 ) which connects between sections of the external panel. Said strip ( 9 ) provides reinforcement to the wall structure and provides improved insulation. Said strip ( 9 ) is preferably of rigid material. Non-limiting examples of suitable materials for the strip are cement board, gypsum board and the like.
[0039] According to yet a further embodiment of the invention with reference to FIG. 4 , the wall structure comprises a peg ( 10 ) which reinforces the floor and/or ceiling of the building to the wall. Said peg ( 10 ) is embedded in the ceiling/floor and connects to the wall structure. The peg ( 10 ) may connect to any part of the wall structure, e.g. to the concrete ( 8 ) or preferably into the external panel ( 2 ). The peg ( 10 ) may be of any suitable material, e.g. steel, wood, preferably steel.
[0040] Optionally, the wall structure further comprises insulating material ( FIG. 4 ;( 11 ),( 14 )) in the seam between the ceiling/floor and the wall structure. Thus, providing improved insulation. Non-limiting examples of insulating materials are polystyrene and polyurethane.
[0041] The side of the ceiling/floor which faces the outer side of the structure may be coated with an external coating ( FIG. 4 ;( 12 )).
[0042] According to an optional embodiment of the invention, the seam between the ceiling and the internal panel of the wall structure is hidden by a decorative molding ( 13 ). The seam between the floor and the wall structure is hidden by the floor sub-base ( 15 ) on which the flooring finish ( 16 ) is mounted.
[0043] The overall thickness of the complete wall structure is dependent upon the dimensions of the elements of the wall and the distances between them, all of which may be adjusted to the functional and structural requirements. The thickness of the wall structure is preferably between 10 cm to 50 cm. As may be appreciated by the skilled artisan, at certain wall thicknesses reinforcements may be required.
[0044] In accordance with a particular aspect of the invention, with reference to FIGS. 1-4 , there is provided a method for constructing wall structures comprising of the following steps;
a) positioning the external panel ( 1 ), b) constructing and positioning the support structure ( 4 ) on which the internal panel ( 3 ) is supported, wherein said structure is constructed at a given distance and parallel to the external panel ( 2 ) such that there is a hollow space ( 8 ) between the external panel ( 2 ) and the internal panel ( 3 ), c) vertically positioning a steel reinforcement ( 5 ) in the hollow space between the external panel ( 2 ) and support structure ( 4 ) of said internal panel, d) installing the rigid spacers ( 6 ), e) covering the outside surface of the external panel ( 2 ) with a coating layer ( 1 ), f) mounting the internal panel ( 3 ) on the support structure, g) casting concrete into the hollow space ( 8 ) between the external panel ( 2 ) and internal Panel ( 3 ).
[0052] Optionally, wherein horizontal tie elements ( 7 ) are employed for securing the coating layer ( 1 ) to the core, said tie elements ( 7 ) are installed in the process of applying said coating.
[0053] According to a preferred embodiment of the invention the external panel ( 2 ) is constructed of building blocks, preferably of AAC blocks. Thus, the function of the vertical insulation layer is imparted onto the AAC blocks which display improved insulating properties. Accordingly, the need for a separate insulating layer is obviated. According to the present embodiment the external panel provides all three functions of a concrete forming panel, bearing the outer coating layer and insulation.
[0054] Optionally, wiring, plumbing and other building elements may be installed in the wall before the final installation of the internal panel ( 3 ) and the casting of the concrete ( 8 ).
[0055] Optionally, upon completing the casting of the concrete and subsequent drying thereof, the inside surface of the internal panel ( 3 ) is coated with a coating such as paint, wall paper or any suitable finish.
[0056] According to a specific embodiment of the method of the present invention, with reference to FIG. 2 , a strip ( 9 ) which connects between sections of the external panel is inserted into the external panel ( 2 ) in a longitudel orientation, hence, providing insulation and rigidness to the seams of the wall structure. The strip ( 9 ) is installed by making a cut along the outer profile of the external panel of the wall sections, which are to be connected, and then sliding the strip into the cut. Non-limiting examples of suitable materials for the strip are cement board, gypsum board and the like.
[0057] According to yet a further embodiment of the method of the present invention with reference to FIG. 4 , the wall structure is reinforced to the floor and/or ceiling of the building by a peg ( 10 ) which is embedded in the ceiling/floor and connects to the wall structure. The peg ( 10 ) may be inserted such that it connects to any part of the wall structure, e.g. to the concrete ( 8 ) or preferably into the external panel ( 2 ). The peg ( 10 ) may be of any suitable material, e.g. steel, wood, preferably steel.
[0058] Optionally, insulating material ( FIG. 4 ; ( 11 ), ( 14 ) may be applied to the seams between the ceiling/floor and the wall structure. Thus, providing improved insulation. Non-limiting examples of insulating materials are polystyrene and polyurethane.
[0059] While the steps of the present method have been described in a particular order, it is within the scope of the present invention to alter the order of the construction steps. Further more, certain steps may be carried but at various locations, and not necessarily at the construction site. For example the coating layer of the external panel may be applied prior to transferring the external panel to the construction site.
[0060] The present wall structure and method for the construction thereof are advantageous in that they provide a wall with load bearing capability, improved insulation and at a relatively minimal wall thickness. The use of AAC blocks of improved insulation compared to conventional concrete blocks obviates the need for further insulation layers in the wall, hence maintaining minimal wall thickness. Furthermore, the incorporation of the reinforcement in the concrete core imparts load bearing capabilities to the wall, thus rendering the wall suitable for the construction of high rise building as well. The use of gypsum board for the inside surface provides for easier and faster finishing and further obviates the need for plastering the walls as in conventional building. The present wall structure and method of construction facilitate the incorporation of pre-fabricated building elements into the construction process. The flexibility in the construction steps provides a building process which is faster than conventional methods and has less rate determining steps which may impede the process.
[0061] While embodiments of the invention have been described by way of illustration, it will be apparent that the invention may be carried out with many modifications, variations and adaptations, without departing from its spirit or exceeding the scope of the claims.
[0062] It should be understood that some modification, alteration and substitution is anticipated and expected from those skilled in the art without departing from the teachings of the invention. Accordingly, it is appropriate that the following claims be construed broadly and in a manner consistent with the scope and spirit of the invention.
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A structural wall section having a sandwich like structure, which includes an external vertical panel and an internal vertical panel spaced apart in a parallel relationship, further including of a vertical insulating layer. Between the panels there is a space, “core” which includes a vertical layer of concrete, the layer of concrete contains vertical steel reinforcements, a support structure for the internal panel, and a rigid spacer wherein said spacer is positioned horizontally between the external panel and the support structure of the internal panel. The outer surface of the external panel is covered with a coating layer.
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[0001] This Application claims priority to Taiwan Patent Application No. 092103685 filed on Feb. 21, 2003.
FIELD OF INVENTION
[0002] The present invention relates to a data driver for an active matrix organic light emitting display (AMOLED), which is configured to convert digital voltage signals into analog current signals to drive pixels in the display to emit light.
BACKGROUND OF THE INVENTION
[0003] Pixels in an AMOLED are driven by analog current signals; however, the signals that control the pixels to emit light are digital voltage signals. Therefore, each AMOLED needs a data driver (or source driver) to convert digital control voltage signals into analog current signals.
[0004] [0004]FIG. 1 illustrates a data driver 1 of the prior art. As it shows, the data driver 1 includes a first shift register 101 , a data register 103 , a voltage latch 105 , a converter 107 , a current latch 109 , a current source 111 , and a second shift register 113 . The converter 107 is configured to receive the digital voltage signals 110 , which will later drive pixels to emit light, from the voltage latch 105 , and to convert the digital voltage signals 110 into analog current signals 112 based on the reference currents provided by the current source 111 . The second shift register 113 is configured to switch on or off each cell in the current latch 109 in order to store the analog current signals 112 sent by the converter 107 . After a proper period of time, an enabling signal 108 enables the current latch 109 so that all the analog current signals 114 , identical to the analog current signals 112 , are able to reach all pixels of the AMOLED to present a transient frame.
[0005] The framework of the converter 107 is basically a current mirror. FIG. 2 illustrates one kind of current mirror of the prior art. With reference to FIG. 2, a reference current I s , generated by the current source 111 shown in FIG. 1, mirrors I p1 , I p2 , I p3 , etc. through a transistor MP 1 . It is noted that the values of the mirrored currents, e.g. I p1 , I p2 , I p3 , etc., are associated with the characteristics, i.e. aspect ratio, threshold voltage, and mobility, of MP 2 , MP 3 , MP 4 , etc. Once any deviation from the theoretical characteristics of the transistors is induced during fabricating, the practical values of the mirrored current I p1 , I p2 , I p3 etc. will bring error as well. The error, even if it is tiny, might still influence the gray level that an analog current signal actually sets in due to the narrow band of each gray level and, therefore, pixels might emit unexpected illumination.
SUMMARY OF THE INVENTION
[0006] The present invention discloses a data driver for an active matrix organic light emitting display (AMOLED), which converts digital voltage signals into analog current signals in order to drive all pixels in the display to emit light.
[0007] The data driver includes a first shift register, a data register, a data latch, a second shift register, and N converters. The first shift register is configured to provide an N-bit first control signal. The data register is configured to store N M-bit digital voltage signals by switching on the cells in it in turn in response to the first control signal, and to send the N digital voltage signals to the data latch. The data latch is configured to receive the N digital voltage signals and respectively transmit them to the N converters in response to an enabling signal. The second shift register is configured to provide an (M+1)-bit second control signal to control the procedure of converting the digital voltage signals into analog current signals.
[0008] Each converter of the data driver of the present invention is a digital-voltage-to-analog-current converter with M units regarded as current sources. Each current source (or each unit) includes two control signals to enable or disable the transistors within so as to control the generation timing of mirrored currents. The current source can overcome the drawbacks of the prior art and, therefore, the mirrored current does not deviate even if the characteristics of the transistors within have been changed during fabricating.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] [0009]FIG. 1 illustrates a data driver of the prior art.
[0010] [0010]FIG. 2 is the exemplary circuitry of a current mirror of the prior art.
[0011] [0011]FIG. 3 illustrates the data driver of the present invention.
[0012] [0012]FIG. 4 illustrates the converter of the present invention.
[0013] [0013]FIG. 5 is the circuitry of a current mirror of the present invention.
DETAILED DESCRIPTION
[0014] With reference to FIG. 3, the data driver 2 disclosed by the present invention includes a first shift register 201 , a data register 203 , a data latch 205 , a second shift register 207 , and N converters 209 . The first shift register 201 is configured to receive a data shift signal 202 and provide an N-bit first control signal 204 . The first control signal 204 is transmitted to the data register 203 to switch on the cells in the data register 203 so that N M-bit digital voltage signals 206 are stored in turn. The digital voltage signals 206 are the signals that need to be converted into analog current signals 218 , which are then respectively transmitted through data lines to drive pixels and make pixels emit light. After receiving and storing all of the digital voltage signals 206 , the data register 203 will send these signals 206 to the data latch 205 . The data latch 205 is switched on by an enabling signal 210 at a particular timing so that the digital voltage signals 208 , identical to the digital voltage signals 206 , are able to be transmitted to N converters 209 respectively. The second shift register 207 is configured to provide an (M+1)-bit second control signal 216 in response to a signal 214 to activate the procedure of converting digital voltage signals 212 , identical to the digital voltage signals 208 , to analog current signals 218 in N converters 209 . The converters 209 are digital-voltage-to-analog-current converters with the same function that the current latch 109 shown in FIG. 1 has. Each of the converters 209 is capable of seizing the converted analog current signals 218 and does not release them to pixels until all of the digital voltage signals 212 have been converted.
[0015] To specify one preferred embodiment of the converters 209 of the present invention, each digital voltage signal is assumed to be a 6-bit signal. As shown in FIG. 4, each of the N converters 209 , responsive to a 6-bit input, is required to have 6 first devices 301 and 6 second devices 303 . Each first device 301 , responsive to one of the preceding 6 bits SW 0 ˜SW 5 of the second control signal 216 , is configured to generate one of the 6 first mirrored currents I m0 ˜I m5 respectively, and to transmit it to the corresponding second device 303 . Each second device 303 , responsive to both a last bit SW 6 of the second control signal 216 and one of the 6 first mirrored currents I m0 ˜I m5 , is configured to generate one of the 6 second mirrored currents I 10 ˜I 15 . Finally, the specific digital voltage signal 212 is converted into an analog current signal 218 when all of the 6 second mirrored currents I 10 ˜I 15 are added together.
[0016] Take the unit 3 shown in FIG. 4 as an example, the first device 301 converts the reference current I ref1 provided by the current source 211 into a first mirrored current I m1 after receiving the second bit SW 1 of the second control signal 216 . The second device 303 then converts the first mirrored current I m1 into a second mirrored current I 11 , according to the value of the second bit D 1 of the specific digital voltage signal 206 while receiving the last bit SW 6 of the second control signal 216 .
[0017] The current source 211 of the embodiment has at least 6 outputs so that it provides 6 different reference currents I ref0 ˜I ref5 for the 6 first devices 301 to respectively generate the 6 first mirrored currents I m0 ˜I m5 . The value of each 6 referent currents I ref0 ˜I ref5 is 2 times larger than that of each preceding one. If I ref0 =2 μA, for example, then I ref1 =4 μA, I ref2 =8 μA, I ref3 =16 μA, I ref4 =32 μA, and I ref5 =64 μA. Assuming that one of the digital voltage signals is (D 5 D 4 D 3 D 2 D 1 D 0 )=(101001), the corresponding analog current signal I TOTAL generated by the converter 209 , as shown in FIG. 4, will equal IM 0 +I m3 +I m5 =I ref0 +I ref3 +I ref5 =82 μA.
[0018] [0018]FIG. 5 illustrates the circuitry of the unit 3 shown in FIG. 4. The converter 209 can provide a high level voltage source VDD and a low level voltage source VSS externally or internally. The first device 301 includes a first transistor M 1 , a second transistor M 2 , a third transistor M 3 , and a first capacitor C 1 . The first transistor M 1 and the second transistor M 2 are n-channel TFTs, and the third transistor M 3 is a p-channel TFT. All of the transistors M 1 , M 2 , and M 3 include a source, a drain, and a gate respectively. Since there is no difference between the source and the drain of a TFT, both are renamed as a first terminal and a second terminal in the following description to avoid misunderstanding. The first capacitor C 1 includes a first end 1 st and a second end 2 nd. The interconnections within the first device 301 include: the gate G of the first transistor M 1 is configured to input the second bit SW 1 of the second control signal 216 , the second terminal 2 nd of the first transistor M 1 is connected to the second output I ref1 of the current source 211 , the first terminal 1 st of the first transistor M 1 is respectively connected to the first terminal 1 st of the second transistor M 2 and the second terminal 2 nd of the third transistor M 3 , the gate G of the second transistor M 2 is connected to the gate G of the first transistor M 1 , the second terminal 2 nd of the second transistor M 2 is respectively connected to the gate G of the third transistor M 3 and the second end 2 nd of the first capacitor C 1 , and the first end 1 st of the first capacitor C 1 is respectively connected to the first terminal 1 st of the third transistor M 3 and the high level voltage source VDD.
[0019] The second device 303 includes a fourth transistor M 4 , a fifth transistor M 5 , a sixth transistor M 6 , a seventh transistor M 7 , and a second capacitor C 2 . The transistors M 4 ˜M 7 are all n-channel TFTs having a first terminal 1 st, a second terminal 2 nd, and a gate G. The second capacitor C 2 includes a first end 1 st and a second end 2 nd. The interconnections within the second device 303 include: the gate G of the fourth transistor M 4 is configured to input the last bit SW 6 of the second control signal 216 , the second terminal 2 nd of the fourth transistor M 4 is connected to the second terminal 2 nd of the third transistor M 3 of the first device 301 , the first terminal 1 st of the fourth transistor M 4 is respectively connected to the first terminal 1 st of the fifth transistor M 5 and the second terminal 2 nd of the sixth transistor M 6 , the gate G of the fifth transistor M 5 is connected to the gate G of the fourth transistor M 4 , the second terminal 2 nd of the fifth transistor M 5 is respectively connected to the gate G of the sixth transistor M 6 and the second end 2 nd of the second capacitor C 2 , the first end 1 st of the second capacitor C 2 is respectively connected to the first terminal 1 st of the sixth transistor M 6 and the low level voltage source VSS, the first terminal 1 st of the seventh transistor M 7 is connected to the second terminal 2 nd of the sixth transistor M 6 , and the gate G of the seventh transistor M 7 is configured to input the second bit D 1 of the 6-bit digital voltage signal 212 .
[0020] The second bit SW 1 of the second control signal 216 is used to enable or disable the first transistor M 1 and the second transistor M 2 . When SW 1 is high, the first transistor M 1 and the second transistor M 2 are enabled so that the second reference current I ref1 provided by the current source 211 is able to flow through the first transistor M 1 and the third transistor M 3 and hence charge the first capacitor C 1 . In other words, the second reference current I ref1 is converted into a corresponding first voltage stored in the first capacitor C 1 . After the first capacitor C 1 is fully charged, SW 1 will switch to a low level so that the first transistor M 1 and the second transistor M 2 are disabled and, therefore, the first voltage is saved in the first capacitor C 1 .
[0021] The last bit SW 6 of the second control signal 216 is used herein to enable or disable the fourth transistor M 4 and the fifth transistor M 5 . When SW 6 is high, the fourth transistor M 4 and the fifth transistor M 5 are enabled so that the first voltage stored in the first capacitor C 1 is able to convert into a second voltage stored in the second capacitor C 2 . After the second capacitor C 2 is fully charged, SW 6 switches to a low level to disable the fourth transistor M 4 and the fifth transistor M 5 and, therefore, the second voltage is saved in the second capacitor C 2 . If the second bit D 1 of the digital voltage signal 212 transmitted to the converter 209 shown in FIG. 4 is high, the second voltage will be converted into the second mirrored current I 11 flowing through the sixth transistor M 6 and the seventh transistor M 7 . Otherwise, the transistor M 7 will be off and the second mirrored current I 11 will not appear.
[0022] The equation showing the relation of the current and the potential difference between the gate and the source of a field effect transistor (FET) in a saturation region is
i D = 1 2 μ C OX W L ( v GS - V t ) 2
[0023] According to this equation, when the first capacitor C 1 is in charging mode, the second reference current I ref1 can be converted into a corresponding V GS stored in the first capacitor C 1 regardless of the practical aspect ratio, threshold voltage, or mobility of the third transistor M 3 . When SW 6 is high, the V GS stored in the first capacitor C 1 is converted into the first mirrored current I m1 to charge the second capacitor C 2 through the transistors M 3 , M 4 , and M 6 . Because the V GS still biases on the third transistor M 3 , the value of the second mirrored current I 11 is substantially equal to that of the first mirrored current I m1 , i.e. equal to the reference current I ref1 .
[0024] Based on the aforementioned function of the unit 3 , one can appreciate that the unit 3 is a current mirror. In this current mirror, SW 1 is regarded as a first control signal for enabling or disabling the first transistor M 1 and the second transistor M 2 ; SW 1 also assures that the reference current I ref1 be converted into the first voltage stored in the first capacitor C 1 . Moreover, SW 6 is regarded as a second control signal for enabling or disabling the fourth transistor M 4 and the fifth transistor M 5 ; SW 6 assures that the first voltage be converted into the corresponding second voltage stored in the second capacitor C 2 . The second mirrored current I 11 is then generated in reference to the second voltage, i.e. in reference to the reference current I ref1 . The framework of the current mirror of the present invention has an advantage of generating a steady mirrored current without respect to the characteristics of the transistors within.
[0025] The frameworks and functions of other units shown in FIG. 4 are identical to those of the unit 3 . As FIG. 4 shows, the second terminals of all the seventh transistors M 7 of the second device 303 are respectively connected to a common node n 1 . A sum I TOTAL of all the currents flowing through the common node n 1 is one of the analog current signals 218 , which drives one pixel in an AMOLED to emit light. There are N converters 209 provided by the present invention to drive N pixels in an AMOLED to emit light simultaneously.
[0026] As set forth above, the data driver of the present invention is capable of converting digital voltage control signals for controlling pixels to emit light into analog current signals that can drive OLEDs directly. Moreover, the data driver of the present invention is capable of generating steady analog current signals even if the characteristics of the transistors within deviate from theoretical values during fabricating.
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A data driver for driving pixels in an active matrix organic LED (AMOLED) is provided. The data driver includes a plurality of converters configured to convert to analog current signals from digital voltage signals in order to drive the pixels to emit light. Each converter has a plurality of current mirror devices configured to generate mirrored current signals by inputting two control signals. Meanwhile, the mirrored current signals can maintain their preciseness even if deviation of the characteristics of the transistors implanted within the current mirror devices occurs during fabricating.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims priority to U.S. Provisional Application No. 60/630,184, filed Nov. 22, 2004.
BACKGROUND OF THE INVENTION
This invention relates to vitamin D compounds, and more particularly to 2α-methyl-19-nor-(20S)-1α-hydroxy-bishomopregnacalciferol and its pharmaceutical uses.
The natural hormone, 1α,25-dihydroxyvitamin D 3 and its analog in ergosterol series, i.e. 1α,25-dihydroxyvitamin D 2 are known to be highly potent regulators of calcium homeostasis in animals and humans, and their activity in cellular differentiation has also been established, Ostrem et al., Proc. Natl. Acad. Sci. USA, 84, 2610 (1987). Many structural analogs of these metabolites have been prepared and tested, including 1α-hydroxyvitamin D 3 , 1α-hydroxyvitamin D 2 , various side chain homologated vitamins and fluorinated analogs. Some of these compounds exhibit an interesting separation of activities in cell differentiation and calcium regulation. This difference in activity may be useful in the treatment of a variety of diseases such as renal osteodystrophy, vitamin D-resistant rickets, osteoporosis, psoriasis, and certain malignancies.
Another class of vitamin D analogs, i.e. the so called 19-nor-vitamin D compounds, is characterized by the replacement of the A-ring exocyclic methylene group (carbon 19), typical of the vitamin D system, by two hydrogen atoms. Biological testing of such 19-nor-analogs (e.g., 1α,25-dihydroxy-19-nor-vitamin D 3 ) revealed a selective activity profile with high potency in inducing cellular differentiation, and very low calcium mobilizing activity. Thus, these compounds are potentially useful as therapeutic agents for the treatment of malignancies, or the treatment of various skin disorders. Two different methods of synthesis of such 19-nor-vitamin D analogs have been described (Perlman et al., Tetrahedron Lett. 31, 1823 (1990); Perlman et al., Tetrahedron Lett. 32, 7663 (1991), and DeLuca et al., U.S. Pat. No. 5,086,191).
In U.S. Pat. No. 4,666,634, 2β-hydroxy and alkoxy (e.g., ED-71) analogs of 1α,25-dihydroxyvitamin D 3 have been described and examined by Chugai group as potential drugs for osteoporosis and as antitumor agents. See also Okano et al., Biochem. Biophys. Res. Commun. 163, 1444 (1989). Other 2-substituted (with hydroxyalkyl, e.g., ED-120, and fluoroalkyl groups) A-ring analogs of 1α,25-dihydroxyvitamin D 3 have also been prepared and tested (Miyamoto et al., Chem. Pharm. Bull. 41, 1111 (1993); Nishii et al., Osteoporosis Int. Suppl. 1, 190 (1993); Posner et al., J. Org. Chem. 59, 7855 (1994), and J. Org. Chem. 60, 4617 (1995)).
2-substituted analogs of 1α,25-dihydroxy-19-nor-vitamin D 3 have also been synthesized, i.e. compounds substituted at 2-position with hydroxy or alkoxy groups (DeLuca et al., U.S. Pat. No. 5,536,713), with 2-alkyl groups (DeLuca et al U.S. Pat. No. 5,945,410), and with 2-alkylidene groups (DeLuca et al U.S. Pat. No. 5,843,928), which exhibit interesting and selective activity profiles. All these studies indicate that binding sites in vitamin D receptors can accommodate different substituents at C-2 in the synthesized vitamin D analogs.
In a continuing effort to explore the 19-nor class of pharmacologically important vitamin D compounds, analogs which are characterized by the presence of a methylene substituent at carbon 2 (C-2), a hydroxyl group at carbon 1 (C-1), and a shortened side chain attached to carbon 20 (C-20) have also been synthesized and tested. 1α-hydroxy-2-methylene-19-nor-pregnacalciferol is described in U.S. Pat. No. 6,566,352 while 1α-hydroxy-2-methylene-19-nor-homopregnacalciferol is described in U.S. Pat. No. 6,579,861 and 1α-hydroxy-2-methylene-19-nor-bishomopregnacalciferol is described in U.S. Pat. No. 6,627,622. All three of these compounds have relatively high binding activity to vitamin D receptors and relatively high cell differentiation activity, but little if any calcemic activity as compared to 1α,25-dihydroxyvitamin D 3 . Their biological activities make these compounds excellent candidates for a variety of pharmaceutical uses, as set forth in the '352, '861 and '622 patents.
SUMMARY OF THE INVENTION
The present invention is directed toward 2α-methyl-19-nor-(20S)-vitamin D analogs, and more specifically toward 2α-methyl-19-nor-(20S)-1α-hydroxy-bishomopregnacalciferol, their biological activity, and various pharmaceutical uses for these compounds. These new 1α-hydroxylated vitamin D compounds not known heretofore are the 19-nor-vitamin D analogs having a methyl group at the 2-position, and sec-butyl substituent at the 17-position (C-17).
Structurally these 2α-methyl-19-nor-(20S)-vitamin D analogs are characterized by the general formula I shown below:
where X 1 and X 2 , which may be the same or different, are each selected from hydrogen or a hydroxy-protecting group. The preferred analog is 2α-methyl-19-nor-(20S)-1α-hydroxy-bishomopregnacalciferol which has the following formula Ia:
The above compounds I, particularly Ia, exhibit a desired, and highly advantageous, pattern of biological activity. These compounds are characterized by relatively high binding to vitamin D receptors, but very low intestinal calcium transport activity, as compared to that of 1α,25-dihydroxyvitamin D 3 , and have very low ability to mobilize calcium from bone, as compared to 1α,25-dihydroxyvitamin D 3 . Hence, these compounds can be characterized as having little, if any, calcemic activity. It is undesirable to raise serum calcium to supraphysiologic levels when suppressing the preproparathyroid hormone gene (Darwish & DeLuca, Arch. Biochem. Biophys. 365, 123-130, 1999) and parathyroid gland proliferation. These analogs having little or no calcemic activity while very active on differentiation are expected to be useful as a therapy for suppression of secondary hyperparathyroidism of renal osteodystrophy.
The compounds I, particularly Ia, of the invention have also been discovered to be especially suited for treatment and prophylaxis of human disorders which are characterized by an imbalance in the immune system, e.g. in autoimmune diseases, including multiple sclerosis, lupus, diabetes mellitus, host versus graft rejection, and rejection of organ transplants; and additionally for the treatment of inflammatory diseases, such as rheumatoid arthritis, asthma, and inflammatory bowel diseases such as celiac disease, ulcerative colitis and Crohn's disease. Acne, alopecia and hypertension are other conditions which may be treated with the compounds of the invention.
The above compounds I, and particularly Ia, are also characterized by relatively high cell differentiation activity. Thus, these compounds also provide a therapeutic agent for the treatment of psoriasis, or as an anti-cancer agent, especially against leukemia, colon cancer, breast cancer, skin cancer and prostate cancer. In addition, due to their relatively high cell differentiation activity, these compounds provide a therapeutic agent for the treatment of various skin conditions including wrinkles, lack of adequate dermal hydration, i.e. dry skin, lack of adequate skin firmness, i.e. slack skin, and insufficient sebum secretion. Use of these compounds thus not only results in moisturizing of skin but also improves the barrier function of skin.
The compounds of the invention of formula I, and particularly formula Ia, are also useful in preventing or treating obesity, inhibiting adipocyte differentiation, inhibiting SCD-1 gene transcription, and/or reducing body fat in animal subjects. Therefore, in some embodiments, a method of preventing or treating obesity, inhibiting adipocyte differentiation, inhibiting SCD-1 gene transcription, and/or reducing body fat in an animal subject includes administering to the animal subject, an effective amount of one or more of the compounds or a pharmaceutical composition that includes one or more of the compounds of formula I. Administration of one or more of the compounds or the pharmaceutical compositions to the subject inhibits adipocyte differentiation, inhibits gene transcription, and/or reduces body fat in the animal subject.
One or more of the compounds may be present in a composition to treat the above-noted diseases and disorders in an amount from about 0.01 μg/gm to about 1000 μg/gm of the composition, preferably from about 0.1 μg/gm to about 500 μg/gm of the composition, and may be administered topically, transdermally, orally, rectally, nasally, sublingually or parenterally in dosages of from about 0.01 μg/day to about 1000 μg/day, preferably from about 0.1 μg/day to about 500 μg/day.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-5 illustrate various biological activities of 2α-methyl-19-nor-(20S)-1α-hydroxy-bishomopregnacalciferol, hereinafter referred to as “2α-methylbisP,” as compared to the native hormone 1α,25-dihydroxyvitamin D 3 , hereinafter “1,25(OH) 2 D 3 .”
FIG. 1 is a graph illustrating the relative activity of 2α-methylbisP and 1,25(OH) 2 D 3 to compete for binding with [ 3 H]-1,25-(OH) 2 -D 3 to the full-length recombinant rat vitamin D receptor;
FIG. 2 is a graph illustrating the percent HL-60 cell differentiation as a function of the concentration of 2α-methylbisP and 1,25(OH) 2 D 3 ;
FIG. 3 is a graph illustrating the in vitro transcription activity of 1,25(OH) 2 D 3 as compared to 2α-methylbisP;
FIG. 4 is a bar graph illustrating the bone calcium mobilization activity of 1,25(OH) 2 D 3 as compared to 2α-methylbisP; and
FIG. 5 is a bar graph illustrating the intestinal calcium transport activity of 1,25(OH) 2 D 3 as compared to 2α-methylbisP.
DETAILED DESCRIPTION OF THE INVENTION
2α-methyl-19-nor-(20S)-1α-hydroxy-bishomopregnacalciferol (referred to herein as 2α-methylbisP) a 19-nor vitamin D analog which is characterized by the presence of a methyl substituent at the carbon 2 (C-2), and sec-butyl substituent at the carbon 17 (C-17), was synthesized and tested. Such vitamin D analog seemed an interesting target because the relatively small methyl group at the C-2 position should not interfere with binding to the vitamin D receptor. Structurally, this 19-nor analog is characterized by the general formula Ia previously illustrated herein, and its pro-drug (in protected hydroxy form) is characterized by general formula I previously illustrated herein.
The preparation of 2α-methyl-19-nor-(20 S)-1α-hydroxy-bishomopregnacalciferol analogs having the structure I can be accomplished by a common general method, i.e. the selective homogeneous catalytic hydrogenation of the exomethylene unit at carbon 2 in the 2-methylene-19-nor-1α-hydroxy-bishomopregnacalciferol compounds of the general formula II performed efficiently in the presence of tris(triphenylphosphine)rhodium(I) chloride [Wilkinson's catalyst, (Ph 3 P) 3 RhCl]. Such reduction conditions allowed to reduce only C(2)=CH 2 unit leaving C(5)-C(8) butadiene moiety unaffected. The isolated material is an epimeric mixture (ca. 1:1) of 2-methyl-19-nor-vitamins I and III differing in configuration at C-2. The mixture can be used without separation or, if desired, the individual 2α-(formula I) and 2β-(formula III) isomers can be separated by an efficient HPLC system
In the structures I, II and III, substituents X 1 and X 2 represent the groups defined above.
2-methylene-19-nor-bishomopregnacalciferol analogs of the general structure II are known, or can be prepared by known methods.
The overall process of the synthesis of compounds I, II and III is illustrated and described more completely in U.S. Pat. No. 5,843,928 entitled “2-Alkylidene-19-Nor-Vitamin D Compounds” the specification of which is specifically incorporated herein by reference.
As used in the description and in the claims, the term “hydroxy-protecting group” signifies any group commonly used for the temporary protection of hydroxy functions, such as for example, alkoxycarbonyl, acyl, alkylsilyl or alkylarylsilyl groups (hereinafter referred to simply as “silyl” groups), and alkoxyalkyl groups. Alkoxycarbonyl protecting groups are alkyl-O—CO—groupings such as methoxycarbonyl, ethoxycarbonyl, propoxycarbonyl, isopropoxycarbonyl, butoxycarbonyl, isobutoxycarbonyl, tert-butoxycarbonyl, benzyloxycarbonyl or allyloxycarbonyl. The term “acyl” signifies an alkanoyl group of 1 to 6 carbons, in all of its isomeric forms, or a carboxyalkanoyl group of 1 to 6 carbons, such as an oxalyl, malonyl, succinyl, glutaryl group, or an aromatic acyl group such as benzoyl, or a halo, nitro or alkyl substituted benzoyl group. The word “alkyl” as used in the description or the claims, denotes a straight-chain or branched alkyl radical of 1 to 10 carbons, in all its isomeric forms. Alkoxyalkyl protecting groups are groupings such as methoxymethyl, ethoxymethyl, methoxyethoxymethyl, or tetrahydrofuranyl and tetrahydropyranyl. Preferred silyl-protecting groups are trimethylsilyl, triethylsilyl, t-butyldimethylsilyl, dibutylmethylsilyl, diphenylmethylsilyl, phenyldimethylsilyl, diphenyl-t-butylsilyl and analogous alkylated silyl radicals. The term “aryl” specifies a phenyl-, or an alkyl-, nitro- or halo-substituted phenyl group.
A “protected hydroxy” group is a hydroxy group derivatised or protected by any of the above groups commonly used for the temporary or permanent protection of hydroxy functions, e.g. the silyl, alkoxyalkyl, acyl or alkoxycarbonyl groups, as previously defined. The terms “hydroxyalkyl”, “deuteroalkyl” and “fluoroalkyl” refer to an alkyl radical substituted by one or more hydroxy, deuterium or fluoro groups respectively.
More specifically, reference should be made to the following illustrative example and description as well as to Scheme 1 herein for a detailed illustration of the preparation of compound 2α-methylbisP.
In this example specific products identified by Arabic numerals (1, 2, 3) refer to the specific structures so identified in the Scheme I.
EXAMPLE
Chemistry. Ultraviolet (UV) absorption spectra were recorded with a Hitachi Model 60-100 UV-vis spectrometer in the solvent noted. 1 H nuclear magnetic resonance (NMR) spectra were recorded at 500 MHz with a Bruker AM-500 FT spectrometer in deuteriochloroform. Chemical shifts (δ) are reported downfield from internal Me 4 Si (δ 0.00). Mass spectra were recorded at 70 eV on a Kratos DS-50 TC instrument equipped with a Kratos MS-55 data system. Samples were introduced into the ion source maintained at 120-250° C. via a direct insertion probe. High-performance liquid chromatography (HPLC) was performed on a Waters Associates liquid chromatograph equipped with a Model 6000A solvent delivery system, a Model 6 UK Universal injector, a Model 486 tunable absorbance detector, and a differential R 401 refractometer.
Example 1
Hydrogenation of 2-methylene-19-nor-(20S)-1α-hydroxy-bis-homo-pregnacalciferol (1). Tris(triphenylphosphine)rhodium (I) chloride (29.0 mg, 31.3 μmol) was added to dry benzene (30 mL) presaturated with hydrogen (for 20 min). The mixture was stirred at room temperature until a homogeneous solution was formed (ca. 50 min). A solution of vitamin 1 (10 mg, 29.0 μmol) in dry benzene (4 mL) was then added and the reaction was allowed to proceed under a continuous stream of hydrogen for 3.5 h. Benzene was removed under vacuum, the residue was redissolved in hexane/ethyl acetate (7:3) and applied on Waters silica Sep-Pak (Vac 20 cc). Less polar impurities were eluted with the same solvent system (30 mL), and a mixture of 2-methyl vitamins was eluted with hexane/ethyl acetate (65:35, 10 mL) and hexane/ethyl acetate (6:4, 20 mL). The combined fractions were evaporated to give crude products (ca. 11 mg) which were further purified by HPLC (10 mm×25 cm Zorbax-Sil column, 4 mL/min) using hexane/2-propanol (90:10) solvent system. The mixture (ca. 1:1) of both 2α-and 2β-methyl-19-norvitamins 2 and 3 (6.85 mg, 69%) gave a single peak at R v 28 mL (the starting 2-methylene compound 1 was eluted at R v 26 mL in the same system). Separation of both epimers was achieved by reversed-phase HPLC (6.2 mm×25 cm Zorbax-ODS column, 2 mL/min) using methanol/water (90:10) solvent system. 2β-Methyl vitamin 3 (2.99 mg, 30%) was collected at R v 24 mL and its 2α-epimer 2 (3.46 mg, 34%) at R v 28 mL (the starting 2-methylene compound 1 was eluted at R v 27 mL in the same system).
2: UV (in EtOH)λ max 242.0, 250.0, 260.0 nm; 1 H NMR (CDCl 3 ) δ 0.531 (3H, s, 18-H 3 ), 0.827 (3H, d, J˜5.5 Hz, 21-H 3 ), 0.834 (3H, t, J=7.2 Hz, 23-H 3 ), 1.134 (3H, d, J=6.9 Hz, 2α-CH 3 ), 2.13 (1H, ˜t, J˜11 Hz, 4β-H), 2.22 (1H, br d, J˜13 Hz, 10β-H), 2.60 (1H, dd, J=12.7, 4.2 Hz, 4α-H), 2.80 (2H, m, 9β- and 10α-H), 3.61 (1H, m, w/2=25 Hz, 3α-H), 3.96 (1H, m, w/2=12 Hz, 1β-H), 5.82 and 6.37 (1H and 1H, each d, J=11.2 Hz, 7- and 6-H); MS m/z (relative intensity) 346 (M + , 100), 317 (16), 289 (39), 253 (18), 229 (35), 191 (56), 135 (59), 91 (64); exact mass calcd for C 23 H 38 O 2 346.2872, found 346.2857.
Biological Activity of 2α-METHYL-19-NOR-(20S)-1α-HYDROXY-BISHOMOPREGNACALCIFEROL
The introduction of a methyl group to the 2-position, and the elimination of carbons 24, 25, 26 and 27 in the side chain of 1α-hydroxy-19-nor-vitamin D 3 had little binding to the full length recombinant rat vitamin D receptor, as compared to 1α,25-dihydroxyvitamin D 3 . The compound 2α-methylbisP bound slightly less to the receptor as compared to the standard 1,25-(OH) 2 D 3 ( FIG. 1 ). It might be expected from these results that compound 2α-methylbisP would have equivalent biological activity. Surprisingly, however, compound 2α-methylbisP is a highly selective analog with unique biological activity.
FIG. 5 shows that 2α-methylbisP has very little activity as compared to that of 1,25-dihydroxyvitamin D 3 (1,25(OH) 2 D 3 ), the natural hormone, in stimulating intestinal calcium transport.
FIG. 4 demonstrates that 2α-methylbisP has very little bone calcium mobilization activity, as compared to 1,25(OH) 2 D 3 .
FIGS. 4 and 5 thus illustrate that 2α-methylbisP may be characterized as having little, if any, calcemic activity.
FIG. 2 illustrates that 2α-methylbisP is almost as potent as 1,25(OH) 2 D 3 on HL-60 cell differentiation, making it an excellent candidate for the treatment of psoriasis and cancer, especially against leukemia, colon cancer, breast cancer, skin cancer and prostate cancer. In addition, due to its relatively high cell differentiation activity, this compound provides a therapeutic agent for the treatment of various skin conditions including wrinkles, lack of adequate dermal hydration, i.e. dry skin, lack of adequate skin firmness, i.e. slack skin, and insufficient sebum secretion. Use of this compound thus not only results in moisturizing of skin but also improves the barrier function of skin.
FIG. 3 illustrates that the compound 2α-methylbisP has about the same transcriptional activity as 1α,25-dihydroxyvitamin D 3 in bone cells. This result, together with the cell differentiation activity of FIG. 2 , suggests that 2α-methylbisP will be very effective in psoriasis because it has direct cellular activity in causing cell differentiation, gene transcription, and in suppressing cell growth. These data also indicate that 2α-methylbisP may have significant activity as an anti-cancer agent, especially against leukemia, colon cancer, breast cancer, skin cancer and prostate cancer.
The strong activity of 2α-methylbisP on HL-60 differentiation suggests it will be active in suppressing growth of parathyroid glands and in the suppression of the preproparathyroid gene.
EXPERIMENTAL METHODS
Vitamin D Receptor Binding
Test Material
Protein Source
Full-length recombinant rat receptor was expressed in E. coli BL21 (DE3) Codon Plus RIL cells and purified to homogeneity using two different column chromatography systems. The first system was a nickel affinity resin that utilizes the C-terminal histidine tag on this protein. The protein that was eluted from this resin was further purified using ion exchange chromatography (S-Sepharose Fast Flow). Aliquots of the purified protein were quick frozen in liquid nitrogen and stored at −80° C. until use. For use in binding assays, the protein was diluted in TEDK 50 (50 mM Tris, 1.5 mM EDTA, pH7.4, 5 mM DTT, 150 mM KCl) with 0.1% Chaps detergent. The receptor protein and ligand concentration were optimized such that no more than 20% of the added radiolabeled ligand was bound to the receptor.
Study Drugs
Unlabeled ligands were dissolved in ethanol and the concentrations determined using UV spectrophotometry (1,25(OH) 2 D 3 : molar extinction coefficient=18,200 and λ max =265 nm; Analogs: molar extinction coefficient=42,000 and λ max =252 nm). Radiolabeled ligand (3H-1,25(OH) 2 D 3 , ˜159 Ci/mmole) was added in ethanol at a final concentration of 1 nM.
Assay Conditions
Radiolabeled and unlabeled ligands were added to 100 mcl of the diluted protein at a final ethanol concentration of ≦10%, mixed and incubated overnight on ice to reach binding equilibrium. The following day, 100 mcl of hydroxylapatite slurry (50%) was added to each tube and mixed at 10-minute intervals for 30 minutes. The hydroxylapaptite was collected by centrifugation and then washed three times with Tris-EDTA buffer (50 mM Tris, 1.5 mM EDTA, pH 7.4) containing 0.5% Titron X-100. After the final wash, the pellets were transferred to scintillation vials containing 4 ml of Biosafe II scintillation cocktail, mixed and placed in a scintillation counter. Total binding was determined from the tubes containing only radiolabeled ligand.
HL-60 Differentiation
Test Material
Study Drugs
The study drugs were dissolved in ethanol and the concentrations determined using UV spectrophotometry. Serial dilutions were prepared so that a range of drug concentrations could be tested without changing the final concentration of ethanol (≦0.2%) present in the cell cultures.
Cells
Human promyelocytic leukemia (HL60) cells were grown in RPMI-1640 medium containing 10% fetal bovine serum. The cells were incubated at 37° C. in the presence of 5% CO 2 .
Assay Conditions
HL60 cells were plated at 1.2×10 5 cells/ml. Eighteen hours after plating, cells in duplicate were treated with drug. Four days later, the cells were harvested and a nitro blue tetrazolium reduction assay was performed (Collins et al., 1979; J. Exp. Med. 149:969-974). The percentage of differentiated cells was determined by counting a total of 200 cells and recording the number that contained intracellular black-blue formazan deposits. Verification of differentiation to monocytic cells was determined by measuring phagocytic activity (data not shown).
In vitro Transcription Assay
Transcription activity was measured in ROS 17/2.8 (bone) cells that were stably transfected with a 24-hydroxylase (24 Ohase) gene promoter upstream of a luciferase reporter gene (Arbour et al., 1998). Cells were given a range of doses. Sixteen hours after dosing the cells were harvested and luciferase activities were measured using a luminometer.
RLU=relative luciferase units.
Intestinal Calcium Transport and Bone Calcium Mobilization
Male, weanling Sprague-Dawley rats were placed on Diet 11 (0.47% Ca) diet +AEK for one week followed by Diet 11 (0.02% Ca)+AEK for 3 weeks. The rats were then switched to a diet containing 0.47% Ca for one week followed by two weeks on a diet containing 0.02% Ca. Dose administration began during the last week on 0.02% calcium diet. Four consecutive ip doses were given approximately 24 hours apart. Twenty-four hours after the last dose, blood was collected from the severed neck and the concentration of serum calcium determined as a measure of bone calcium mobilization. The first 10 cm of the intestine was also collected for intestinal calcium transport analysis using the everted gut sac method.
INTERPRETATION OF DATA
VDR binding, HL60 cell differentiation, and transcription activity. 2α-methylbisP (K i =1.6×10 −9 M) is slightly less active than the natural hormone 1α,25-dihydroxyvitamin D 3 (K i =1.8×10 −10 M) in its ability to compete with [ 3 H]-1,25(OH) 2 D 3 for binding to the full-length recombinant rat vitamin D receptor ( FIG. 1 ). There is also little difference between 2α-methylbisP (EC 50 =3.7×10 −8 M) in its ability (efficacy or potency) to promote HL60 differentiation as compared to 1α,25-dihydroxyvitamin D 3 (EC 50 =3.6×10 −9 M) (See FIG. 2 ). Also, compound 2α-methylbisP (EC 50 =4.4×10 −9 M) has similar transcriptional activity in bone cells as 1α25-dihydroxyvitamin D 3 (EC 50 =2.9×10 −10 M) (See FIG. 3 ). These results suggest that 2α-methylbisP will be very effective in psoriasis because it has direct cellular activity in causing cell differentiation, gene transcription, and in suppressing cell growth. These data also indicate that 2α-methylbisP will have significant activity as an anti-cancer agent, especially against leukemia, colon cancer, breast cancer, skin cancer and prostate cancer, as well as against skin conditions such as dry skin (lack of dermal hydration), undue skin slackness (insufficient skin firmness), insufficient sebum secretion and wrinkles. It would also be expected to be very active in suppressing secondary hyperparathyroidism.
Calcium mobilization from bone and intestinal calcium absorption in vitamin D-deficient animals. Using vitamin D-deficient rats on a low calcium diet (0.02%), the activities of 2α-methylbisP and 1,25(OH) 2 D 3 in intestine and bone were tested. As expected, the native hormone (1,25(OH) 2 D 3 ) increased serum calcium levels at all dosages ( FIG. 4 ). FIG. 4 shows that 2α-methylbisP has little, if any, activity in mobilizing calcium from bone. Administration of 2α-methylbisP at 87 pmol/day for 4 consecutive days did not result in mobilization of bone calcium, and increasing the amount of 2α-methylbisP to 260 pmol/day and then to 780 pmol/day and finally to 7020 pmol/day was also without any substantial effect.
Intestinal calcium transport was evaluated in the same groups of animals using the everted gut sac method ( FIG. 5 ). These results show that the compound 2α-methylbisP does not promote intestinal calcium transport when administered at 87 pmol/day, 260 pmol/day or 780 pmol/day, whereas 1,25(OH) 2 D 3 promotes a significant increase at the 260 pmol/day dose. It was only when 2340 pmol/day of 2α-methylbisP was administered that significant intestinal calcium transport activity was recorded, an almost 10-fold increase in dosage over the 260 pmol/day dose. Thus, it may be concluded that 2α-methylbisP is essentially devoid of intestinal calcium transport activity at the recommended lower doses.
These results illustrate that 2α-methylbisP is an excellent candidate for numerous human therapies as described herein, and that it may be particularly useful in a number of circumstances such as suppression of secondary hyperparathyroidism of renal osteodystrophy, autoimmune diseases, cancer, and psoriasis. 2α-methylbisP is an excellent candidate for treating psoriasis because: (1) it has significant VDR binding, transcription activity and cellular differentiation activity; (2) it is devoid of hypercalcemic liability unlike 1,25(OH) 2 D 3 ; and (3) it is easily synthesized. Since 2α-methylbisP has significant binding activity to the vitamin D receptor, but has little ability to raise blood serum calcium, it may also be particularly useful for the treatment of secondary hyperparathyroidism of renal osteodystrophy.
These data also indicate that the compound 2α-methylbisP of the invention may be especially suited for treatment and prophylaxis of human disorders which are characterized by an imbalance in the immune system, e.g. in autoimmune diseases, including multiple sclerosis, lupus, diabetes mellitus, host versus graft rejection, and rejection of organ transplants; and additionally for the treatment of inflammatory diseases, such as rheumatoid arthritis, asthma, and inflammatory bowel diseases such as celiac disease, ulcerative colitis and Crohn's disease. Acne, alopecia and hypertension are other conditions which may be treated with the compound 2α-methylbisP of the invention.
The compounds of the invention of formula I, and particularly formula Ia, are also useful in preventing or treating obesity, inhibiting adipocyte differentiation, inhibiting SCD-1 gene transcription, and/or reducing body fat in animal subjects. Therefore, in some embodiments, a method of preventing or treating obesity, inhibiting adipocyte differentiation, inhibiting SCD-1 gene transcription, and/or reducing body fat in an animal subject includes administering to the animal subject, an effective amount of one or more of the compounds or a pharmaceutical composition that includes one or more of the compounds of formula I. Administration of the compound or the pharmaceutical compositions to the subject inhibits adipocyte differentiation, inhibits gene transcription, and/or reduces body fat in the animal subject. The animal may be a human, a domestic animal such as a dog or a cat, or an agricultural animal, especially those that provide meat for human consumption, such as fowl like chickens, turkeys, pheasant or quail, as well as bovine, ovine, caprine, or porcine animals.
For prevention and/or treatment purposes, the compounds of this invention defined by formula I may be formulated for pharmaceutical applications as a solution in innocuous solvents, or as an emulsion, suspension or dispersion in suitable solvents or carriers, or as pills, tablets or capsules, together with solid carriers, according to conventional methods known in the art. Any such formulations may also contain other pharmaceutically-acceptable and non-toxic excipients such as stabilizers, anti-oxidants, binders, coloring agents or emulsifying or taste-modifying agents.
The compounds of formula I and particularly 2α-methylbisP, may be administered orally, topically, parenterally, rectally, nasally, sublingually or transdermally. The compound is advantageously administered by injection or by intravenous infusion or suitable sterile solutions, or in the form of liquid or solid doses via the alimentary canal, or in the form of creams, ointments, patches, or similar vehicles suitable for transdermal applications. A dose of from 0.01 μg to 1000 μg per day of the compounds I, particularly 2α-methylbisP, preferably from about 0.1 μg to about 500 μg per day, is appropriate for prevention and/or treatment purposes, such dose being adjusted according to the disease to be treated, its severity and the response of the subject as is well understood in the art. Since the compound exhibits specificity of action, each may be suitably administered alone, or together with graded doses of another active vitamin D compound—e.g. 1α-hydroxyvitamin D 2 or D 3 , or 1α25-dihydroxyvitamin D 3 —in situations where different degrees of bone mineral mobilization and calcium transport stimulation is found to be advantageous.
Compositions for use in the above-mentioned treatments comprise an effective amount of the compounds I, particularly 2α-methylbisP, as defined by the above formula I and Ia as the active ingredient, and a suitable carrier. An effective amount of such compound for use in accordance with this invention is from about 0.01 μg to about 1000 μg per gm of composition, preferably from about 0.1 μg to about 500 μg per gram of composition, and may be administered topically, transdermally, orally or parenterally in dosages of from about 0.01 μg/day to about 1000 μg/day, and preferably from about 0.1 μg/day to about 500 μg/day.
The compounds I, particularly 2α-methylbisP, may be formulated as creams, lotions, ointments, topical patches, pills, capsules or tablets, suppositories, aerosols, or in liquid form as solutions, emulsions, dispersions, or suspensions in pharmaceutically innocuous and acceptable solvent or oils, and such preparations may contain in addition other pharmaceutically innocuous or beneficial components, such as stabilizers, antioxidants, emulsifiers, coloring agents, binders or taste-modifying agents.
The compounds I, particularly 2α-methylbisP, may be advantageously administered in amounts sufficient to effect the differentiation of promyelocytes to normal macrophages. Dosages as described above are suitable, it being understood that the amounts given are to be adjusted in accordance with the severity of the disease, and the condition and response of the subject as is well understood in the art.
The formulations of the present invention comprise an active ingredient in association with a pharmaceutically acceptable carrier therefore and optionally other therapeutic ingredients. The carrier must be “acceptable” in the sense of being compatible with the other ingredients of the formulations and not deleterious to the recipient thereof.
Formulations of the present invention suitable for oral administration may be in the form of discrete units as capsules, sachets, tablets or lozenges, each containing a predetermined amount of the active ingredient; in the form of a powder or granules; in the form of a solution or a suspension in an aqueous liquid or non-aqueous liquid; or in the form of an oil-in-water emulsion or a water-in-oil emulsion.
Formulations for rectal administration may be in the form of a suppository incorporating the active ingredient and carrier such as cocoa butter, or in the form of an enema.
Formulations suitable for parenteral administration conveniently comprise a sterile oily or aqueous preparation of the active ingredient which is preferably isotonic with the blood of the recipient.
Formulations suitable for topical administration include liquid or semi-liquid preparations such as liniments, lotions, applicants, oil-in-water or water-in-oil emulsions such as creams, ointments or pastes; or solutions or suspensions such as drops; or as sprays.
For nasal administration, inhalation of powder, self-propelling or spray formulations, dispensed with a spray can, a nebulizer or an atomizer can be used. The formulations, when dispensed, preferably have a particle size in the range of 10 to 100 μ.
The formulations may conveniently be presented in dosage unit form and may be prepared by any of the methods well known in the art of pharmacy. By the term “dosage unit” is meant a unitary, i.e. a single dose which is capable of being administered to a patient as a physically and chemically stable unit dose comprising either the active ingredient as such or a mixture of it with solid or liquid pharmaceutical diluents or carriers.
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This invention discloses 2α-methyl-19-nor-(20S)-vitamin D analogs, and specifically 2α-methyl-19-nor-(20S)-1α-hydroxy-bishomopregnacalciferol and pharmaceutical uses therefor. This compound exhibits pronounced activity in arresting the proliferation of undifferentiated cells and inducing their differentiation to the monocyte thus evidencing use as an anti-cancer agent and for the treatment of skin diseases such as psoriasis as well as skin conditions such as wrinkles, slack skin, dry skin and insufficient sebum secretion. This compound also has little, if any, calcemic activity and therefore may be used to treat autoimmune disorders or inflammatory diseases in humans as well as renal osteodystrophy. This compound may also be used for the treatment or prevention of obesity.
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The invention relates to a crystalline (1α,2β,4β,5α,7β)-7-[(hydroxydi-2-thienylacetyl)oxy]-9,9-dimethyl-3-oxa-9-azoniatricyclo[3.3.1.0 2,4 ]nonane-bromide in anhydrous form, processes for preparing it and its use for preparing a pharmaceutical composition, particularly for preparing a pharmaceutical composition with an anticholinergic activity.
BACKGROUND OF THE INVENTION
The compound (1α,2β,4β,5α,7β)-7-[(hydroxydi-2-thienylacetyl)oxy]-9,9-dimethyl-3-oxa-9-azoniatricyclo[3.3.1.0 2,4 ]nonane-bromide, is known from European Patent Application EP 418 716 A1 and has the following chemical structure:
The compound has valuable pharmacological properties and is known by the name tiotropium bromide (BA679BR). Tiotropium bromide is a highly effective anticholinergic and can therefore provide therapeutic benefit in the treatment of asthma or COPD (chronic obstructive pulmonary disease).
Tiotropium bromide is preferably administered by inhalation. Suitable inhalable powders packed into appropriate capsules (inhalettes) and administered by suitable powder inhalers may be used. Alternatively, it may be administered by the use of suitable inhalable aerosols. These also include powdered inhalable aerosols which contain, for example, HFA134a, HFA227 or mixtures thereof as propellant gas.
The correct manufacture of the abovementioned compositions which are suitable for use for the administration of a pharmaceutically active substance by inhalation is based on various parameters which are connected with the nature of the active substance itself. In pharmaceutical compositions which are used like tiotropium bromide in the form of inhalable powders or inhalable aerosols, the crystalline active substance is used in ground (micronised) form for preparing the formulation. Since the pharmaceutical quality of a pharmaceutical formulation requires that the active substance should always have the same crystalline modification, the stability and properties of the crystalline active substance are subject to stringent requirements from this point of view as well. It is particularly desirable that the active substance should be prepared in the form of a uniform and clearly defined crystalline modification. It is also particularly desirable that the active substance be prepared in a crystalline form which does not tend to form polymorphs.
Apart from the requirements indicated above, it should be generally borne in mind that any change to the solid state of a pharmaceutical composition which is capable of improving its physical and chemical stability gives a significant advantage over less stable forms of the same medicament.
The aim of the invention is thus to provide a new, stable crystalline form of the compound tiotropium bromide which meets the stringent requirements imposed on pharmaceutically active substances as mentioned above.
DETAILED DESCRIPTION OF THE INVENTION
It has been found that, depending on the choice of conditions which can be used when purifying the crude product obtained after industrial manufacture, tiotropium bromide occurs in various crystalline modifications.
It has been found that these different modifications can be deliberately produced by selecting the solvents used for the crystallisation as well as by a suitable choice of the process conditions used in the crystallisation process.
Surprisingly, it has been found that, starting from the monohydrate of tiotropium bromide, which can be obtained in crystalline form by choosing specific reaction conditions, it is possible to obtain an anhydrous crystalline modification of tiotropium bromide which meets the stringent requirements mentioned above and thus solves the problem on which the present invention is based. Accordingly the present invention relates to this crystalline anhydrous tiotropium bromide. Any reference to tiotropium bromide anhydrate within the scope of the present invention is to be regarded as a reference to the crystalline tiotropium bromide according to the invention in anhydrous form.
According to another aspect, the present invention relates to a process for preparing the crystalline form of anhydrous tiotropium bromide. This preparation process is characterised in that tiotropium bromide, which has been obtained for example by the method disclosed in EP 418 716 A1, is taken up in water, the mixture obtained is heated and finally the hydrate of tiotropium bromide is crystallised while cooling slowly. Anhydrous crystalline tiotropium bromide can then be obtained from the resulting crystalline tiotropium bromide monohydrate by drying.
The present invention further relates to crystalline anhydrous tiotropium bromide which may be obtained by the above method.
One aspect of the present invention relates to a process for preparing crystalline anhydrous tiotropium bromide starting from crystalline tiotropium bromide monohydrate which is described in more detail hereinafter.
In order to prepare the crystalline monohydrate, tiotropium bromide, which has been obtained for example according to the method disclosed in EP 418 716 A1, has to be taken up in water and heated, then purified with activated charcoal and, after removal of the activated charcoal, the tiotropium bromide monohydrate has to be crystallised out slowly while cooling gently. The anhydrous form is obtained from these crystals by careful heating to more than 50° C., preferably 60-100° C., more particularly to 70-100° C. under reduced pressure, preferably under a high vacuum, over a period of from 15 minutes to 24 hours, preferably 20 minutes to 12 hours.
The method described below is preferably used according to the invention. In a suitably dimensioned reaction vessel the solvent is mixed with tiotropium bromide, which has been obtained for example according to the method disclosed in EP 418 716 A1. 0.4 to 1.5 kg, preferably 0.6 to 1 kg, most preferably about 0.8 kg of water are used as solvent per mole of tiotropium bromide used. The mixture obtained is heated with stirring, preferably to more than 50° C., most preferably to more than 60° C. The maximum temperature which can be selected will be determined by the boiling point of the solvent used, i.e. water. Preferably the mixture is heated to a range from 80-90° C. Activated charcoal, dry or moistened with water, is added to this solution. 10 to 50 g, more preferably 15 to 35 g, most preferably about 25 g of activated charcoal are put in per mole of tiotropium bromide used. If desired, the activated charcoal is suspended in water before being added to the solution containing the tiotropium bromide. 70 to 200 g, preferably 100 to 160 g, most preferably about 135 g water are used to suspend the activated charcoal, per mole of tiotropium bromide used. If the activated charcoal is suspended in water prior to being added to the solution containing the tiotropium bromide, it is advisable to rinse with the same amount of water.
After the activated charcoal has been added, stirring is continued at constant temperature for between 5 and 60 minutes, preferably between 10 and 30 minutes, most preferably about 15 minutes, and the mixture obtained is filtered to remove the activated charcoal. The filter is then rinsed with water. 140 to 400 g, preferably 200 to 320 g, most preferably about 270 g of water are used for this, per mole of tiotropium bromide used.
The filtrate is then slowly cooled, preferably to a temperature of 20-25° C. The cooling is preferably carried out at a cooling rate of 1 to 10° C. per 10 to 30 minutes, preferably 2 to 8° C. per 10 to 30 minutes, more preferably 3 to 5° C. per 10 to 20 minutes, most preferably 3 to 5° C. roughly per 20 minutes. If desired, the cooling to 20 to 25° C. may be followed by further cooling to below 20° C., most preferably to 10 to 15° C.
Once the filtrate has cooled, it is stirred for between 20 minutes and 3 hours, preferably between 40 minutes and 2 hours, most preferably about one hour, to complete the crystallisation.
The crystals formed are finally isolated by filtering or suction filtering the solvent. If it proves necessary to subject the crystals obtained to another washing step, it is advisable to use water or acetone as the washing solvent. 0.1 to 1.0 1, preferably 0.2 to 0.5 1, most preferably about 0.3 1 solvent are used, per mole of tiotropium bromide, to wash the tiotropium bromide monohydrate crystals obtained. If desired the washing step may be repeated.
The product obtained is dried in vacuo or using circulating hot air until a water content of 2.5-4.0% is obtained.
The anhydrous form is obtained from the resulting crystalline tiotropium bromide monohydrate by careful drying at more than 50° C., preferably at 60-100° C., most preferably at 70-100° C., under reduced pressure, preferably in a high vacuum over a period of 15 minutes to 24 hours, preferably 20 minutes to 12 hours, most preferably 30 minutes to 6 hours. The term “reduced pressure” most preferably refers to a pressure of up to 5×10 −2 bar, preferably 1×10 −2 bar, most preferably 5×10 −3 bar.
Most preferably, the abovementioned dehydration to form the anhydrate is carried out at about 1×10 −3 bar or less.
Alternatively to the drying step at elevated temperature under reduced pressure described above, the anhydrous form may also be prepared by storing the crystalline tiotropium bromide monohydrate over a drying agent, preferably over dried silica gel at ambient temperature for a period of 12 to 96 hours, preferably 18 to 72 hours, most preferably at least 24 hours. The anhydrous form thus obtained should be stored more or less dry, depending on the particle size, to preserve its anhydrous state. In the case of coarse crystals of anhydrous tiotropium bromide, which may be prepared for example as described above, storage at <75% r.h. (relative humidity) is sufficient to maintain the anhydrous state. In the micronised state, i.e. where the material has a much larger surface area, water may even be absorbed at lower humidity levels. In order to maintain the anhydrous form in the micronised state, it is therefore advisable to store the anhydrous form of tiotropium bromide over dried silica gel until it is further processed to form the desired inhalable powder containing suitable excipients (e.g. lactose) in addition to tiotropium bromide.
One aspect of the present invention relates to crystalline anhydrous tiotropium bromide which can be obtained using the method described above. The invention further relates to the use of crystalline tiotropium bromide monohydrate for preparing crystalline tiotropium bromide in anhydrous form.
Characterisation of Crystalline Tiotropium Bromide Monohydrate
The tiotropium bromide monohydrate obtainable using the method described above and used as a starting material for preparing the anhydrous crystalline tiotropium bromide according to the invention was investigated by DSC (Differential Scanning Calorimetry). The DSC diagram shows two characteristic signals. The first, relatively broad, endothermic signal between 50-120° C. can be attributed to the dehydration of the tiotropium bromide monohydrate into the anhydrous form. The second, relatively sharp, endothermic peak at 230±5° C. can be put down to the melting of the substance with decomposition. This data was obtained using a Mettler DSC 821 and evaluated using the Mettler STAR software package. The data was recorded at a heating rate of 10 K/min.
Since the substance melts with decomposition (=incongruent melting process), the melting point observed depends to a great extent on the heating rate. At lower heating rates, the melting/decomposition process is observed at significantly lower temperatures, e.g. at 220±5° C. at a heating rate of 3 K/min. It is also possible that the melting peak may be split. The split is all the more apparent the lower the heating rate in the DSC experiment.
The tiotropium bromide monohydrate obtained by the method described above and used as a starting material for preparing the anhydrous crystalline tiotropium bromide according to the invention was characterised by IR spectroscopy. The data was obtained using a Nicolet FTIR spectrometer and evaluated with the Nicolet OMNIC software package, version 3.1. The measurement was carried out with 2.5 μmol of tiotropium bromide monohydrate in 300 mg of KBr. Table 1 shows some of the essential bands of the IR spectrum.
TABLE 1
Attribution of specific bands
Wave number (cm −1 )
Attribution
Type of oscillation
3570, 3410
O—H
elongated oscillation
3105
Aryl C—H
elongated oscillation
1730
C═O
elongated oscillation
1260
Epoxide C—O
elongated oscillation
1035
Ester C—OC
elongated oscillation
720
Thiophene
cyclic oscillation
The tiotropium bromide monohydrate obtained by the method described above and used as a starting material for preparing the anhydrous crystalline tiotropium bromide according to the invention was characterised by X-ray structural analysis. The measurements of X-ray diffraction intensity were carried out on an AFC7R-4-circuit diffractometer (Rigaku) using monochromatic copper K α radiation. The structural resolution and refinement of the crystal structure were obtained by direct methods (SHELXS86 Program) and FMLQ-refinement (TeXsan Program). Experimental details of the crystalline structure, structural resolution and refinement are collected in Table 2.
TABLE 2
Experimental data on the analysis of the crystalline structure of tiotropium
bromide monohydrate.
A.
Crystal data
Empirical formula
[C 19 H 22 NO 4 S 2 ] Br · H 2 0
Weight of formula
472.43 + 18.00
colour and shape of crystals
colourless, prismatic
dimensions of crystals
0.2 × 0.3 × 0.3 mm
crystal system
monoclinic
lattice type
primitive
space group
P 2 1 /n
lattice constants
a = 18.0774 Å,
b = 11.9711 Å
c = 9.9321 Å
β = 102.691°
V = 2096.96 Å 3
formula units per elementary cell
4
B.
Measurements of intensity
Diffractometer
Rigaku AFC7R
X-ray generator
Rigaku RU200
wavelength =
1.54178 (monochromatic copper
K α -radiation)
current, voltage
50 kV, 100 mA
take-off angle
6
crystal assembly
steam-saturated capillary
crystal-detector gap
235 mm
detector opening
3.0 mm vertical and horizontal
temperature
18
determining the lattice constants
25 reflexes (50.8 <2 <56.2 )
Scan Type
−2
2 max
120
measured
5193
independent reflexes
3281 (R int = 0.051)
corrections
Lorentz polarisation
Absorption
(Transmission factors 0.56-1.00)
crystal decay 10.47% decay
C.
Refinement
Reflections (I > 3 I)
1978
Variable
254
ratio of reflections/parameters
7.8
R-values: R, Rw
0.062, 0.066
The X-ray structural analysis carried out showed that crystalline tiotropium bromide monohydrate has a simple monoclinic cell with the following dimensions:
a=18.0774 Å, b=11.9711 Å, c=9.9321 Å, β=102.691°, V=2096.96 Å 3 .
The atomic coordinates described in Table 3 were determined by the above X-ray structural analysis:
TABLE 3
Coordinates
Atom
x
y
z
u (eq)
Br(1)
0.63938(7)
0.0490(1)
0.2651(1)
0.0696(4)
S(1)
0.2807(2)
0.8774(3)
0.1219(3)
0.086(1)
S(2)
0.4555(3)
0.6370(4)
0.4214(5)
0.141(2)
O(1)
0.2185(4)
0.7372(6)
0.4365(8)
0.079(3)
O(2)
0.3162(4)
0.6363(8)
0.5349(9)
0.106(3)
O(3)
0.3188(4)
0.9012(5)
0.4097(6)
0.058(2)
O(4)
0.0416(4)
0.9429(6)
0.3390(8)
0.085(3)
O(5)
0.8185(5)
0.0004(8)
0.2629(9)
0.106(3)
N(1)
0.0111(4)
0.7607(6)
0.4752(7)
0.052(2)
C(1)
0.2895(5)
0.7107(9)
0.4632(9)
0.048(3)
C(2)
0.3330(5)
0.7876(8)
0.3826(8)
0.048(3)
C(3)
0.3004(5)
0.7672(8)
0.2296(8)
0.046(3)
C(4)
0.4173(5)
0.7650(8)
0.4148(8)
0.052(3)
C(5)
0.1635(5)
0.6746(9)
0.497(1)
0.062(3)
C(6)
0.1435(5)
0.7488(9)
0.6085(9)
0.057(3)
C(7)
0.0989(6)
0.6415(8)
0.378(1)
0.059(3)
C(8)
0.0382(5)
0.7325(9)
0.3439(9)
0.056(3)
C(9)
0.0761(6)
0.840(1)
0.315(1)
0.064(3)
C(10)
0.1014(6)
0.8974(8)
0.443(1)
0.060(3)
C(11)
0.0785(5)
0.8286(8)
0.5540(9)
0.053(3)
C(12)
−0.0632(6)
0.826(1)
0.444(1)
0.086(4)
C(13)
−0.0063(6)
0.6595(9)
0.554(1)
0.062(3)
C(14)
0.4747(4)
0.8652(9)
0.430(1)
0.030(2)
C(15)
0.2839(5)
0.6644(9)
0.1629(9)
0.055(3)
C(16)
0.528(2)
0.818(2)
0.445(2)
0.22(1)
C(17)
0.5445(5)
0.702(2)
0.441(1)
0.144(6)
C(18)
0.2552(6)
0.684(1)
0.019(1)
0.079(4)
C(19)
0.2507(6)
0.792(1)
−0.016(1)
0.080(4)
H(1)
−0.0767
0.8453
0.5286
0.102
H(2)
−0.0572
0.8919
0.3949
0.102
H(3)
−0.1021
0.7810
0.3906
0.102
H(4)
−0.0210
0.6826
0.6359
0.073
H(5)
−0.0463
0.6178
0.4982
0.073
H(6)
0.0377
0.6134
0.5781
0.073
H(7)
0.1300
0.7026
0.6770
0.069
H(8)
0.1873
0.7915
0.6490
0.069
H(9)
0.1190
0.6284
0.2985
0.069
H(10)
0.0762
0.5750
0.4016
0.069
H(11)
0.1873
0.6082
0.5393
0.073
H(12)
−0.0025
0.7116
0.2699
0.066
H(13)
0.1084
0.8383
0.2506
0.075
H(14)
0.1498
0.9329
0.4626
0.071
H(15)
0.0658
0.8734
0.6250
0.063
H(16)
0.2906
0.5927
0.2065
0.065
H(17)
0.2406
0.6258
−0.0469
0.094
H(18)
0.2328
0.8191
−0.1075
0.097
H(19)
0.4649
0.9443
0.4254
0.037
H(20)
0.5729
0.8656
0.4660
0.268
H(21)
0.5930
0.6651
0.4477
0.165
H(22)
0.8192
−0.0610
0.1619
0.084
H(23)
0.7603
0.0105
0.2412
0.084
x, y, z: fractional coordinates;
U(eq) mean quadratic amplitude of atomic movement in the crystal
Characterisation of Crystalline, Anhydrous Tiotropium Bromide
As described hereinbefore, the crystalline anhydrous tiotropium bromide according to the invention may be obtained from crystalline tiotropium bromide monohydrate. The crystalline structure of anhydrous tiotropium bromide was determined from high-resolution X-ray powder data (synchrotron radiation) using a real space approach with a so-called simulated annealing process. A final Rietveld analysis was carried out to refine the structural parameters. Table 4 contains the experimental data obtained for crystalline, anhydrous tiotropium bromide.
TABLE 4
Experimental data relating to the crystalline structural
analysis of tiotropium bromide (anhydrous)
formula
C 19 H 22 NO 4 S 2 Br
temperature [° C.]
25
molecular weight [g/mol]
472.4
space group
P2 1 /c
a [Å]
10.4336(2)
b [Å]
11.3297(3)
c [Å]
17.6332(4)
β [°]
105.158(2)
V [Å 3 ]
2011.89(8)
Z
4
calculated density [g cm −3 ]
1.56
2Θ (range) [°]
2.0-20
interval [°2Θ]
0.003
counting time/step [sec]
3
wavelength [Å]
0.7000
Accordingly, the present invention relates to crystalline anhydrous tiotropium bromide, which is characterised by the elementary cells
α=10.4336(2) Å,
b=11.3297(3) Å,
c=17.6332(4) Å and
α=90°,
β=105.158(2)° and
γ=90° (cell volume=2011.89(8) Å 3 ).
The crystalline structure of the anhydrous form of tiotropium bromide can be described as a layered structure. The bromide ions are located between the layers of tiotropium.
In order to clarify the structure of crystalline anhydrous tiotropium bromide a high-resolution X-ray powder diagram was taken at ambient temperature at the National Synchrotron Source (Brookhaven National Laboratory, USA) at measuring station X3B1 (λ=0.700 Å). For this experiment a sample of crystalline tiotropium bromide monohydrate was placed in a quartz glass capillary 0.7 mm in diameter. The water was eliminated by heating to 80° C. in an oven under reduced pressure.
The structural resolution was obtained by a so-called simulated annealing process. The DASH program package produced by Cambridge Crystallographic Data Center (CCDC, Cambridge, United Kingdom) was used for this.
Table 5 shows the atomic coordinates obtained for crystalline anhydrous tiotropium bromide.
TABLE 5
Coordinates
Atom
x
y
z
U iso
S1
1.0951(8)
0.3648(8)
0.8189(5)
0.075(9)
S1
0.9143(9)
0.1374(8)
0.9856(5)
0.075(9)
O
0.6852(13)
0.2339(6)
0.7369(6)
0.075(9)
O1
0.7389(15)
0.0898(9)
0.8234(6)
0.075(9)
O2
0.8211(10)
0.3897(17)
0.8277(7)
0.075(9)
O3
0.4975(17)
0.4816(9)
0.6011(7)
0.075(9)
N
0.4025(10)
0.2781(8)
0.5511(5)
0.075(9)
C
0.7509(8)
0.1885(6)
0.8038(5)
0.075(9)
C1
0.8593(7)
0.2788(5)
0.8495(4)
0.075(9)
C2
0.9924(9)
0.2533(6)
0.8225(6)
0.075(9)
C3
0.8884(9)
0.2664(7)
0.9382(4)
0.075(9)
C4
0.5848(12)
0.1596(8)
0.6753(8)
0.075(9)
C5
0.4544(13)
0.1929(14)
0.6809(8)
0.075(9)
C6
0.6156(13)
0.1810(13)
0.5973(9)
0.075(9)
C7
0.5493(11)
0.2881(11)
0.5578(6)
0.075(9)
C8
0.5869(12)
0.3832(11)
0.6092(7)
0.075(9)
C9
0.4947(13)
0.3902(10)
0.6575(6)
0.075(9)
C10
0.4004(10)
0.2998(11)
0.6332(6)
0.075(9)
C11
0.3220(13)
0.3670(13)
0.4935(6)
0.075(9)
C12
0.3450(19)
0.1643(26)
0.5211(11)
0.075(9)
C13
0.9184(16)
0.3808(9)
0.9920(6)
0.075(9)
C14
1.0313(16)
0.1552(15)
0.8011(15)
0.075(9)
C15
0.9515(17)
0.3374(10)
0.0501(6)
0.075(9)
C16
0.9756(18)
0.2190(11)
1.0742(5)
0.075(9)
C17
1.1483(22)
0.1762(18)
0.7718(24)
0.075(9)
C18
1.1860(16)
0.2800(15)
0.7768(19)
0.075(9)
BR
0.4597(4)
0.8200(15)
0.61902(25)
0.042(9)
In the above Table the “U iso ” values denote the isotropic temperature factors. For example, in single-crystal X-ray structural analysis this corresponds to the u(eq) values.
Table 6 shows the reflexes (h,k,l indices) of the powder diagram obtained for crystalline ahydrous tiotropium bromide.
TABLE 6
Experimental data relating to the crystalline structural analysis
of anhydrous tiotropium bromide
No.
h
k
l
2Θ obs.
2Θ calc.
2Θ obs. − 2Θ calc
1
1
0
0
8.762
8.769
−0.007
2
0
1
1
9.368
9.369
−0.001
3
−1
0
2
11.730
11.725
0.005
4
0
1
2
12.997
13.004
−0.007
5
−1
1
2
14.085
14.094
−0.009
6
1
0
2
15.271
15.275
−0.004
7
0
0
3
15.620
15.616
0.004
8
0
2
1
16.475
16.475
0.0
9
1
1
2
17.165
17.170
−0.005
10
2
0
0
17.588
17.591
−0.003
11
−1
2
1
18.009
18.035
−0.026
12
1
2
1
19.336
19.328
0.008
13
−2
1
2
19.596
19.600
−0.004
14
−1
0
4
20.417
20.422
−0.005
15
0
0
4
20.865
20.872
−0.007
16
2
1
1
21.150
21.145
0.005
17
−2
1
3
21.759
21.754
0.005
18
0
2
3
22.167
22.160
0.007
19
−1
2
3
22.289
22.288
0.001
20
2
0
2
22.735
22.724
0.011
21
−2
2
1
23.163
23.159
0.004
22
−2
0
4
23.567
23.575
−0.008
23
2
1
2
24.081
24.058
0.023
24
1
0
4
24.746
24.739
0.007
25
−1
3
1
25.220
25.221
−0.001
26
1
2
3
25.359
25.365
−0.006
27
0
3
2
25.790
25.783
0.007
28
1
1
4
25.978
25.975
0.003
29
0
2
4
26.183
26.179
0.004
30
−1
3
2
26.383
26.365
0.018
31
−1
1
5
26.555
26.541
0.014
32
−3
1
2
27.024
27.021
0.003
33
3
1
0
27.688
27.680
0.008
34
−3
1
3
28.221
28.215
0.006
35
3
0
1
28.377
28.376
0.001
36
−3
0
4
29.246
29.243
0.003
37
3
1
1
29.459
29.471
−0.012
38
−1
2
5
29.906
29.900
0.006
39
−3
2
1
30.171
30.165
0.006
40
0
2
5
30.626
30.626
0.0
41
1
1
5
30.871
30.856
0.015
42
0
0
6
31.504
31.532
−0.028
43
2
1
4
31.826
31.847
−0.021
44
−2
1
6
32.888
32.888
0.0
45
1
4
1
33.605
33.615
−0.010
46
3
0
3
34.379
34.377
0.002
47
1
0
6
35.021
35.018
0.003
48
−4
1
1
35.513
35.503
0.01
49
1
1
6
35.934
35.930
0.004
50
−1
1
7
36.544
36.543
0.001
51
−4
1
4
37.257
37.255
0.002
52
−4
2
2
37.933
37.952
−0.019
53
4
1
1
38.258
38.264
−0.006
According to another aspect, the present invention relates to the use of crystalline anhydrous tiotropium bromide as a medicament in the light of the pharmaceutical efficacy of the anhydrous form according to the invention. To prepare a medicament which can be inhaled, particularly an inhalable powder, which contains the anhydrous, crystalline tiotropium bromide described by the present invention, methods known from the prior art may be used. In this respect, reference is made, for example, to the teaching of DE-A-179 22 07. Accordingly a further aspect of the present invention relates to inhalable powders characterised in that they contain anhydrous, crystalline tiotropium bromide.
Because of the potency of tiotropium bromide, the powders for inhalation mentioned above preferably contain, in addition to the active substance, the following physiologically acceptable excipients. The following physiologically acceptable excipients may be used, for example: monosaccharides (e.g. glucose or arabinose), disaccharides (e.g. lactose, sucrose, maltose), oligo- and polysaccharides (e.g. dextrane), polyalcohols (e.g. sorbitol, mannitol, xylitol), salts (e.g. sodium chloride, calcium carbonate) or mixtures of these excipients with one another. Preferably, mono- or disaccharides are used, while the use of lactose or glucose is preferred, particularly, but not exclusively, in the form of their hydrates. For the purposes of the invention, lactose is the particularly preferred excipient, while lactose monohydrate is most particularly preferred.
Within the scope of the inhalable powders according to the invention the excipients which are characterised in that they contain anhydrous crystalline tiotropium bromide have a maximum average particle size of up to 250 μm, preferably between 10 and 150 μm, most preferably between 15 and 80 μm. It may sometimes seem appropriate to add finer excipient fractions with an average particle size of 1 to 9 μm to the excipients mentioned above. These finer excipients are also selected from the group of possible excipients listed hereinbefore.
Preferred inhalable powders containing the tiotropium bromide anhydrate according to the invention are characterised in that the excipient consists of a mixture of coarser excipient with an average particle size of from 17 to 50 μm, more preferably 20 to 30 μm, and finer excipient with an average particle size of 2 to 8 μm, more preferably 3 to 7 μm. The term average particle size here denotes the 50% value from the volume distribution measured with a laser diffractometer by the dry dispersion method. Inhalable powders wherein the proportion of finer excipient in the total quantity of excipient is 3 to 15%, more preferably 5 to 10%, are preferred.
One possible method of preparing these inhalable powders which are preferred according to the invention is discussed in more detail hereinafter.
After the starting materials have been weighed out, first the excipient mixture is prepared from the defined fractions of the coarser excipient and finer excipient. Then the inhalable powders according to the invention are prepared from the excipient mixture and the active substance. If the inhalable powder is to be administered by means of inhalettes in suitable inhalers, the preparation of the inhalable powders is followed by the production of the capsules containing the powder.
The inhalable powders according to the invention are prepared by mixing the coarser excipient fractions with the finer excipient fractions and subsequently mixing the resulting excipient mixtures with the active substance.
In order to prepare the excipient mixture the coarser and finer excipient fractions are placed in a suitable mixing container. The two components are preferably added through a screening granulator with a mesh size of 0.1 to 2 mm, most preferably 0.3 to 1 mm, even more preferably 0.3 to 0.6 mm. Preferably the coarser excipient is put in first and then the finer excipient fraction is added to the mixing container. In this mixing process the two components are preferably added batchwise, with half the coarser excipient being put in first followed by finer and coarser excipient added alternately. It is particularly preferable when preparing the excipient mixture to screen the two components in alternate layers. Preferably this screening of the two components takes place in 15 to 45, more preferably in 20 to 40 alternate layers. The mixing of the two excipients may take place while the two components are being added. However, it is preferably not done until the layers of ingredients have been added.
After the preparation of the excipient mixture, this and the active substance are placed in a suitable mixing container. The active substance used has an average particle size of 0.5 to 10 μm, preferably 1 to 6 μm, more preferably 2 to 5 μm. The two components are preferably added through a screening granulator with a mesh size of 0.1 to 2 mm, most preferably 0.3 to 1 mm, even more preferably 0.3 to 0.6 mm. Preferably the excipient mixture is put in first and then the active substance is added to the mixing container. It is particularly preferable when preparing the excipient mixture to screen the two components in alternate layers. Preferably this screening of the two components takes place in 25 to 65, more preferably in 30 to 60 alternate layers. The mixing of the excipient mixture with the active substance may take place while the two components are being added. However, it is preferably not done until the layers of ingredients have been added.
The powder mixture thus obtained may optionally be passed through a screening granulator once again or several times more and then subjected to another mixing operation each time.
The inhalable powders obtained by the above method preferably contain about 0.001 to 2% tiotropium bromide in admixture with a physiologically acceptable excipient. Preferred are inhalable powders which contain 0.04 to 0.8% of tiotropium bromide in admixture with a physiologically acceptable excipient, characterised in that the excipient consists of a mixture of coarser excipient with an average particle size of 15 to 80 μm and finer excipient with an average particle size of 1 to 9 μm, the proportion of finer excipient in the total quantity of excipient being 1 to 20%.
According to the invention, inhalable powders which contain 0.08 to 0.64%, more preferably 0.16 to 0.4% tiotropium bromide, are preferred.
If anhydrous crystalline tiotropium bromide is included in the inhalable powders mentioned above, these powder mixtures preferably contain 0.0012-2.41% of tiotropium bromide anhydrate. Also preferred are inhalable powders which contain between 0.048 and 0.96% of tiotropium bromide anhydrate. Of particular interest according to the invention are inhalable powders which contain 0.096 to 0.77%, more preferably 0.19 to 0.48% tiotropium bromide anhydrate.
The percentages mentioned within the scope of the present invention are always percent by weight.
An alternative, equally preferred embodiment for preparing inhalable powders containing tiotropium bromide anhydrate may also be prepared from inhalable powders formulated on the basis of the crystalline tiotropium bromide monohydrate. These contain between 0.0012 and 2.5%, preferably 0.05 to 1%, preferably 0.1 to 0.8%, more preferably 0.2 to 0.5% crystalline tiotropium bromide monohydrate and may preferably be obtained analogously to the process described hereinbefore. These inhalable powders containing crystalline tiotropium bromide monohydrate may be dried in order to prepare inhalable powders containing the tiotropium bromide anhydrate according to the invention, either before being packed into the inhalation capsules or, preferably, after being packed into the corresponding inhalation capsules, at more than 60° C., preferably at 65-100° C., more preferably at 70-100° C., under reduced pressure, preferably under a high vacuum, over a period of 15 minutes to 24 hours, preferably 20 minutes to 12 hours, more preferably 30 minutes to 6 hours. The term reduced pressure particularly denotes a pressure of up to 5×10 −2 bar, preferably 1×10 −2 bar, more preferably 5×10 −3 bar.
Most preferably, the dehydration mentioned above to form the anhydrate is carried out at about 1×10 −3 bar or less.
In view of the anticholinergic effects of tiotropium bromide a further aspect of the present invention relates to the use of crystalline anhydrous tiotropium bromide for preparing a pharmaceutical composition for treating diseases in which the use of an anticholinergic agent may have a therapeutic benefit. It is preferably used for preparing a pharmaceutical composition for treating asthma or COPD.
The following example of synthesis serves to illustrate a method of preparing anhydrous crystalline tiotropium bromide carried out by way of example. It is to be regarded only as a possible method described by way of example, without restricting the invention to its contents.
EXAMPLE OF SYNTHESIS
A) Preparation of Crystalline Tiotropium Bromide Monohydrate:
In a suitable reaction vessel 15.0 kg of tiotropium bromide are added to 25.7 kg of water. The mixture is heated to 80-90° C. and stirred at constant temperature until a clear solution is formed. Activated charcoal (0.8 kg), moistened with water, is suspended in 4.4 kg of water, this mixture is added to the solution containing the tiotropium bromide and rinsed with 4.3 kg of water. The mixture thus obtained is stirred for at least 15 min at 80-90° C. and then filtered through a heated filter into an apparatus which has been preheated to an outer temperature of 70° C. The filter is rinsed with 8.6 kg of water. The contents of the apparatus are cooled to a temperature of 20-25° C. at a rate of 3-5° C. per 20 minutes. The apparatus is further cooled to 10-15° C. using cold water, and the crystallisation is completed by stirring for at least one hour. The crystals are isolated using a suction filter drier, the crystal slurry isolated is washed with 9 l of cold water (10-15° C.) and cold acetone (10-15° C.). The crystals obtained are dried at 25° C. for 2 hours in a nitrogen current.
Yield: 13.4 kg of tiotropium bromide monohydrate (86% of theory)
B) Preparation of Crystalline Anhydrous Tiotropium Bromide:
The anhydrous form is produced from the crystalline tiotropium bromide monohydrate obtained as described above by careful drying at 80-100° C. under reduced pressure, preferably under a high vacuum (at about 1×10 −3 bar or less) over a period of at least 30 minutes. Alternatively to the drying step at 80-100° C. in vacuo the anhydrous form may also be prepared by storing over dried silica gel at ambient temperature for a period of at least 24 hours.
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The invention relates to crystalline anhydrous (1α,2β,4β,5α,7β)-7-[(hydroxydi-2-thienylacetyl)oxy]-9,9-dimethyl-3-oxa-9-azoniatricyclo[3.3.1.02 2,4 ]nonane-bromide, processes for preparing it and its use for preparing a pharmaceutical composition, particularly for preparing a pharmaceutical composition with an anticholinergic activity.
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BACKGROUND OF INVENTION
[0001] The present invention provides a method for reducing noise in a non-contact gauge measurement system utilizing structured light. In particular, the present invention provides a method to facilitate inspection of prismatic objects having uncoated surfaces, such as turbine or compressor blades, using a combination of object orientation and polarized light in an optical three-dimensional structured light gauge measurement system.
[0002] Traditionally, gauge measurement of a manufactured object having a complex three dimensional surface such as an airfoil (e.g. compressor blade) is a tedious and time consuming process. Airfoils, including forged blades such as those used on aircraft engines, electrical power generators, and the like, are inspected for deformations which may include, but are not limited to, skew, twist, scaling, and translation. More specifically, airfoils are inspected for deformation parameters such as platform orientation, contour cross-section, bow and twist along a stacking axis, thickness, and chord length at given cross-sections.
[0003] One method of obtaining dense and accurate digital data representing these parameters for an individual airfoil is through use of a coordinate measuring machine (commonly known as a “CMM”). CMM's translate and rotate a sensor probe into contact with the surface of an object undergoing testing to sample the position of various points on the object's surface. Before a sensor probe may be brought into contact with an object, the object must be secured in a known physical position and orientation, such that a set of known reference points may be established. For airfoil measurement, six physical contact points are utilized, defining a “six point nest”. This set of six data points establish the position and orientation of the airfoil in its physical holder and enable the contact points to be translated to any other coordinate system. CMM's provide high quality (i.e. highly accurate) measurements of the sample points. However, the time to scan an airfoil is relatively slow as the process of positioning the airfoil in the six point nest is time-consuming, and the sensor probe must be continually repositioned to obtain data. Once the high quality surface points are collected, software processes these points into deviations from values generated in a computer assisted drawing (CAD) model of the object and analyzes the deviations in terms of process-based shape deformations. Current CMM processing software, however, is also relatively slow.
[0004] An alternate method of obtaining measurements representing deformation parameters of an object employs full-field non-contact range sensors. Non-contact full-field sensors can quickly scan the external surfaces of opaque objects, using laser or white light, significantly faster than CMMs. Examples of non-contact sensors include sensors that project laser line gratings onto the surface of an object and process detected images thereof using stereo triangulation; and those based on single laser line scan plus rotation of the object. Additional non-contact sensors are based on phase-shifted moir é patterns and white light. While these sensors are capable of scanning the part quickly and obtaining large quantities of data, the level of accuracy is affected by undesirable reflections of the scan light from shiny or prismatic surfaces on the object.
[0005] To compensate for these undesired reflections, shiny or prismatic surfaces on the object are traditionally coated with a diffusing material such as a paint or powder to non-contact gauge measurement. This additional step adds uncertainty to the measurement, and increases measurement time which is highly undesirable. Accordingly, there is a need for eliminating or reducing the effect of undesired reflections from shiny or prismatic object surfaces in a non-contact measurement system in a manner which does not require application of diffuse coatings to surfaces of the object being tested.
SUMMARY OF INVENTION
[0006] Briefly stated, the present invention provides a method for the inspection of shiny metal prismatic objects having uncoated prismatic surfaces, such as compressor blades, using polarized light in an optical three-dimensional structured light measurement system.
[0007] In one embodiment of the present invention, a structured light measurement system projects a structured light pattern onto the surface of an object, parallel to a plane bisecting one or more prismatic features of the object. An imaging system receives the structured light pattern reflected from the surface of the object and analyzes the deformation of the reflected light pattern to calculate the surface features of the object. The projected light is polarized at a known polarization angle, and the reflected light is polarized to a related angle, such that light reflected directly and indirectly from the planar surfaces of the object is separated by the imaging system. Using multiple images of the object obtained with polarized light, difference images and region masks can be generated to reduce or eliminate undesired reflections and noise from the resulting images of the object.
[0008] The foregoing and other objects, features, and advantages of the invention as well as presently preferred embodiments thereof will become more apparent from the reading of the following description in connection with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0009] In the accompanying drawings which form part of the specification:
[0010] [0010]FIG. 1 is a block diagram of an apparatus for effecting the method of the present invention for measuring surface features of an object under test;
[0011] [0011]FIG. 2 is a side sectional view of an object under test, illustrating single-bounce and double-bounce light paths;
[0012] [0012]FIG. 3 is a top view of an object under test, illustrating changes in reflected light polarization for light following the paths shown in FIG. 2.
[0013] Corresponding reference numerals indicate corresponding parts throughout the several figures of the drawings.
DETAILED DESCRIPTION
[0014] The following detailed description illustrates the invention by way of example and not by way of limitation. The description clearly enables one skilled in the art to make and use the invention, describes several embodiments, adaptations, variations, alternatives, and uses of the invention, including what is presently believed to be the best mode of carrying out the invention.
[0015] [0015]FIG. 1 is a block diagram of an apparatus 10 for measuring surface features of a manufactured object 12 , according to one embodiment of the present invention. Apparatus 10 is adapted to inspect and determine surfaces of the object. These surfaces may include features such as tilts, bends, twists, or warps when compared to a reference model or other ideal representations of the object.
[0016] In one embodiment of the invention, object 12 comprises a blade, e.g., a compressor blade of an aircraft engine, having an airfoil 14 extending from a platform 16 , and having an axis 18 . While the following description is directed to inspecting blades, one skilled in the art will appreciate that the apparatus and the method of the present invention may be utilized to improve structured light imaging for any object having similar characteristics.
[0017] An object 12 to be inspected is positioned within the sensing range of an imaging system 20 , preferably a full field, non-contact, laser line grating range sensor mounted on a translation stage. The imaging system comprises a structured light emitter 22 and one or more imaging sensors 24 configured to receive structured light reflected from object 12 . One or more computers 25 are utilized to process images received from the sensors 24 , and a monitor 27 may be utilized to display information to an operator.
[0018] Full field, non-contact range sensors suitable for use as imaging systems 20 are currently readily available from commercial sources. For example, the model 4DI sensors sold by Integrated Automation Systems may be employed with the present invention. The 4DI sensors utilize the projection of a laser line grating onto the surface on an object 12 , and the stereo triangulation of the projected lines by one or more imaging detectors. Other suitable sensors employ single laser line scans with rotation of the object, or phase-shifted Moir é and white light.
[0019] To improve the performance of the full-field, non-contact range sensors on objects 12 having shiny or prismatic surfaces, the object is positioned in a preferred orientation relative to the source of structured light. As seen in FIG. 2, the angle α of orientation is selected so as to present a view to the imaging sensors 24 in which a plane β defined by light emitter 22 and imaging sensors 24 approximately bisect one or more prismatic features on the surface of the object 12 . For example, if the object 12 comprises a compressor blade, airfoil 14 and platform 16 define a prismatic feature of the blade, as a portion of light projected onto the airfoil may reflect onto platform 16 , thus producing a double reflection back towards the imaging system 20 .
[0020] To reduce and identify reflections of the projected light from prismatic features of object 12 , the structured light projected onto the surface of the object from light emitter 22 is polarized with a polarizing filter 26 oriented at a known angle θ relative to a the plane β defined by light emitter 22 and imaging system 20 . A second polarizing filter 28 is placed between imaging sensors 24 and object 12 and oriented to block any light reflected back through two surface reflections. Now, any light reflecting off two facets of the prismatic surfaces of the object is reduced in intensity or completely blocked from the imaging sensors.
[0021] The imaging sensors 24 obtain an image of the structured light. projected onto a surface of object 12 . This image is composed of an array of pixels, with each pixel representing the intensity of received light at that particular point in the image. If some portions of the image are either over or under saturated, i.e. the intensity levels exceed a maximum observable level or does not reach a minimum threshold level, additional images of the object can be taken with the structured light projected at different levels of intensity and/or with different polarization angles so to provide additional data in the usual manner.
[0022] Only directly reflected light from a surface of object 12 can be readily interpreted in a structured light imaging system 20 . A directly reflected light path is indicated as SB in FIG. 2. Light which has reflected off of a prismatic surface on the object, as indicated by light path DB in FIG. 2,(i.e. “double-bounce light”), produces light patterns observed by the imaging sensors 24 , but at erroneous orientations. This can lead to an incorrect interpretation of the surface features of object 12 .
[0023] As shown in FIG. 3, the polarization of any light which has bounced off of two or more surfaces of object 12 is changed so as to be different from directly reflected light. By selecting polarization angle θ for the light illuminating the surface of object 12 , and subsequent filtering of the light as seen by the imaging sensors 24 , single bounce and double bounce light is effectively separated.
[0024] Reflected light which has bounced off of two prismatic surfaces of object 12 is enhanced by positioning the second polarization filter 28 in front of imaging sensor 24 so to be 90° out of phase with the first polarization filter 26 which is placed in front of the structured light emitters 22 . Other orientations of the second polarization filter 28 can provide additional information on the angle and number of bounces through which light received by the imaging sensor 24 has passed.
[0025] By taking multiple images of the structured light projected on a surface of object 12 , and using different polarizations angles of second polarization filter 28 , reflections from single bounce light, double bounced light, or other variations, are readily identified and selectively extracted from the image using conventional image processing techniques.
[0026] Suitable image processing methods include subtraction or difference imaging between two images, masking of certain areas of an image, as well as correlations of image information. For example, it is known that if two or more images of an object are obtained, and are correlated such that they have common reference points or are from the same position and orientation, digital processing techniques permit one image to be “subtracted” from the other, so to obtaining a resulting difference image. This resulting difference image includes only information on those regions in the field of view which have changed between the first and second images.
[0027] Alternatively, with prior knowledge of the shape or configuration of the object undergoing measurement, or two or more images, specific regions in an image known to contain erroneous or irrelevant information may be digitally masked or blocked from further processing. For example, using subtraction techniques, regions of an image containing background can be identified in a difference image, and then utilized to mask out background regions in subsequent or current or subsequent images.
[0028] Similarly, using known information or multiple images, an image of an object undergoing measurement may be correlated or registered to a stored reference image, facilitating identification of differences between the object and an ideal model or representation of the object.
[0029] In this manner, even if the second polarizing lens 28 does not completely block unwanted light reflections from imaging sensor 24 , the effects of the these reflections can be analyzed within the image and incorrect information sorted from correct information for use in the surface inspection of the object.
[0030] In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results are 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 shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
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A method for filtering undesired light reflections in a structured light measurement system during the inspection of shiny metal prismatic objects having uncoated prismatic surfaces, such as turbine blades, using polarized light.
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BACKGROUND OF THE INVENTION
The invention concerns a wide-angle hinge with crossing articulated arms, the ends of which, on one side, are articulated with hinge parts attachable to a portion of the body and to a furniture part swinging horizontally and the other ends of which are linked by means of transversal swinging arms to the hinge portions at a distance from the articulations of the hinge arms, where the hinge arms are connected to each other in an articulated manner between their articulations.
Wide-angle hinges of this type are known in various methods of embodiment and have been described, for example, in DE 33 12 496 C2, U.S. Pat. No. 1,269,403, U.S. Pat. No. 2,137,751, EP 0 763 642 A1, IT 83 427 A/78 and U.S. Pat. No. 3,673,635.
SUMMARY OF THE INVENTION
The known hinges appear unattractive in the open position and frequently project inward, so that they narrow the clear space inside the body to the side of which they are nailed.
The object of the invention is to create a sunken wide-angle hinge of the type described at the beginning that does not significantly reduce the clear space inside the body while being sturdy in construction and having an attractive appearance in the open position.
Pursuant to the invention, this object is solved in that the articulated arms consist of U-shaped profiled levers, the lateral sides of which, articulated at the hinge portions and projecting beyond these connecting webs, are offset from each other such that they lie on the inside and outside, that the U-shaped profiled transversal swinging arms are articulated to the levers with the same offset and that, in the open position, the hinge pins of both levers lie in approximately a cylindrical shell, the axis of which lies on the outside of the hinge portions.
The levers and transversal swinging arms of the wide-angle hinge pursuant to the invention, in the open position, form practically an arc-shaped carrier, the height of which essentially does not exceed the width of the lateral side of the lever and transversal swinging arm. In this manner, the contiguous lateral sides of the lever and transversal swinging arm do not appear unattractive in the open position, since they provide a uniform arc-shaped appearance and they take up only a small space so that the open cross-section of the portion of the body to which the hinges are attached is not significantly reduced.
The lateral sides of the lever and/or transversal swinging arm are expediently bent at right angles such that they lie close together in their extended open position.
Pursuant to a preferred method of embodiment, provision is made so that the lateral sides of the lever are connected together only in their end regions and the lateral sides of the transversal swinging arms are essentially connected down to the coupling region by means of web plates such that the web plates of all levers and transversal swinging arms adjoin each other in the open position. In this method of embodiment, the web parts of the lever and transversal swinging arms form a practically complete cover surface in the open position of the hinge so that the levers and transversal swinging arms offer a closed, nice appearance.
In another method of embodiment, provision is made so that the bearing pins for the lateral sides of the levers and transversal swinging arms pass through the side walls of each portion of the hinge consisting of a hinge cup, in longitudinal slots, and are supported in a frame that is carried on a plate in a longitudinally-displaceable manner, which plate, in turn, is carried in the hinge cup in a diagonally-displaceable manner, while positioning devices, e.g., cams, are provided for said displacement in a diagonal and longitudinal direction. The method of embodiment of the wide-angle hinge thus permits simple adjustment of the furniture part in three common directions of adjustment.
Pursuant to another method of embodiment, provision is made so that the hinge portion nailed to a portion of the body consists of a U-shaped profiled hinge arm and the hinge portion that can be swung in a horizontal direction is made of a flat block with a level underside. In this method of embodiment, the hinge arm is in the form of the usual hinge arm in transversal swinging arm hinges that is attached to a portion of the body by means of a plate facilitating displacement. The hinge portion that can be swung horizontally can, for example, be attached to a glass door, and this, for example, by a simple glued connection.
Pursuant to another method of embodiment, a closing device is provided that consists of a bent leaf spring, the one end of which is supported on pegs between the lateral sides of a lever, that are located between the articulation connecting the levers and the coupling of the lever, and the other end of which impinges on a pin that is contained in the longitudinal slots of the lateral side of the same lever, that is located between the articulation connecting the levers and the coupling of the transversal swinging arm, and that the pin is adjacent to a closing curve with the desired closing characteristics that surround the drilled holes of the articulation of the lateral side of the transversal swinging arm connected therewith in an articulated manner.
BRIEF DESCRIPTION OF THE DRAWINGS
Methods of embodiment of the invention are explained in greater detail below based on the drawing in which:
FIG. 1 is a perspective view of the first method of embodiment of the wide-angle hinge pursuant to the invention, in its open position,
FIG. 2 is a perspective representation of one of the two identical levers of the wide-angle hinge pursuant to FIG. 1,
FIG. 3 is a perspective view of one of the two identical transversal swing arms of the wide-angle hinge pursuant to FIG. 1,
FIG. 4 is a perspective view of one of the two hinge parts of the wide-angle hinge pursuant to FIG. 1, without the lever and transversal swinging arm coupled thereto,
FIG. 5 is a cross-section through the hinge portion pursuant to FIG. 4,
FIG. 6 is a side view of the wide-angle hinge pursuant to FIG. 1 in its closed position,
FIG. 7 is a side view of the wide-angle hinge pursuant to FIG. 1 in its open position,
FIG. 8 is a perspective view of a second method of embodiment of the wide-angle hinge pursuant to the invention in its open position,
FIG. 9 is a perspective view of the hinge arm of the wide-angle hinge pursuant to FIG. 8,
FIGS. 10 and 13 are perspective views of the two transversal swinging arms of the wide-angle hinge pursuant to FIG. 8,
FIGS. 11 and 12 are perspective views of the lever of the wide-angle hinge pursuant to FIG. 8,
FIG. 14 is a perspective view of the movable hinge portion of the wide-angle hinge pursuant to FIG. 8,
FIGS. 15 and 16 are side views of the wide-angle hinge pursuant to FIG. 8 in its closed and open position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first method of embodiment of the wide-angle hinge pursuant to the invention is described based on FIGS. 1 through 7.
The wide-angle hinge consists of two common hinge cups 1,1', provided with attachment flanges that are nailed, in the usual manner, into countersinks in one wall of a portion of the body and a door or shutter coupled thereto. Wall 4 of the portion of the body and door 5 are shown by dotted lines in FIG. 6. Levers 2, 2' and transversal swinging arms 3, 3' are lodged in an articulated fashion on hinge bolts 6, 7, and 6', 7', parallel to each other, of hinge cups 1, 1'. Levers 2, 2', are connected together in an articulated fashion, crossing each other, by means of hinge bolt 8. Transversal swinging arms 3, 3' are connected with levers 2, 2' in an articulated fashion, by means of hinge bolts 9, 9'.
Levers 2, 2' and transversal swinging arms 3, 3' are formed identically, as can be seen from FIGS. 2 and 3, so that the wide-angle hinge is constructed symmetrically, where, however, the lever and transversal swinging arm are not symmetrical to their longitudinal axis.
Levers 2, 2' have a U-shaped profile, while its lateral sides 10, 11 are connected to each other only in the area of their outer ends, by means of web plate 12. The lateral sides are easily bent around a diagonal axis, as can be seen from FIGS. 2 and 6. Lateral side 10 is formed flat in a plane at right angles to web plate 12, while lateral side 11 is provided, in its end region lodged in the hinge cup, with wide right-angle bend 13, and is provided, in an end region connected in an articulated manner with transversal swinging arms 3, 3', with another wide right-angle bend 13'. Web plate 12 connects the lateral sides in the area between articulation axes 8 and 9, 9'.
Transversal swinging arms 3, 3' also have a U-shaped profile, where web plate 14 covers the area between the ends of the lateral sides with the bores of the bearings for the bearing journals. Lateral sides 15, 16 of transversal swinging arms 3, 3' are provided with a right angle bend, so that they lie close next to the lateral sides of levers 2, 2' in the extended position of the levers and transversal swinging arms in the open position, as seen in FIG. 1.
The arrangement of hinge bolts 6, 6', 8 and 9, 9' of levers 2, 2' is selected, as can be seen from FIG. 7, in such manner that they lie on imaginary cylindrical shell 18, shown by the dashed line in FIG. 7, the axis of curvature of which is on the outside of the hinge cups and/or wall body 4 and door 5 carrying them.
Web plates 12, 14 of the levers and transversal swinging arms are arranged in relation to each other in such manner that they form an essentially continuous cover surface in the open position of the hinge, as can been seen from FIG. 1.
Web plates 12 have tongues 19, directed toward each other and offset to one another, that are adjacent to each other in the open position of the hinge in the manner shown in FIG. 1.
Hinge bolts 6, 7 for the levers and transversal swinging arms are supported in frame 20, which is carried on intermediate plate 21 in the direction of double arrow 22, in a longitudinally-displaceable manner. The ends of hinge bolts 6, 7 pass through the side walls of hinge cup 1, 1' in longitudinal slots 23, 24. Intermediate plate 21 is carried such that it is displaceable diagonally relative to hinge cup 1, 1' in the direction of double arrow 25. To displace fixed bracket 29 and intermediate plate 21, eccentric bolts 26, 27 are provided, bolt 27 of which is held such that it can rotate but not shift axially in the floor of hinge cup 1, 1', and bolt 26 is held such that it can rotate but not shift axially on intermediate plate 21. Philips heads are provided to rotate the eccentric bolts.
The second method of embodiment of the wide-angle hinge pursuant to the invention is now described based on FIGS. 8 through 16. In contrast to the wide-angle hinge pursuant to FIGS. 1 through 7, this one is not formed symmetrically. The hinge portion nailed to the body part consists of U-shaped, profiled hinge arm 30, that can be nailed in known manner to body wall 32 by means of plate 31, serving to adjust it. Movable hinge portion 33 consists of a flat, right-angle block with a level underside, that can be attached, for example, to glass door 34 by means of glue.
At a front, reduced-width extension 40 of hinge arm 30, clean-cut lateral sides 35, 36 of lever 37 are supported on hinge bolts 39. Clean-cut lateral sides 42, 43 of other lever 41, to be seen in FIG. 11, are supported on hinge bolt 44 of hinge part 33.
Transversal swinging arm 45 in FIG. 13 is supported on hinge bolt 46 of hinge portion 33. The crossing lateral sides of levers 37, 41 are connected together by means of hinge bolt 47.
Lateral sides 35, 36 of lever 37 are overlapped by lateral sides 48, 49 of transversal swinging arm 38, as can be seen in FIG. 8. Lateral sides 42, 43 of lever 41 are bent outward at right angles, as can be seen in FIG. 11, so that they can overlap the lateral side of transversal swinging arm 45 in the manner shown in FIG. 8.
Levers 37 and 41 as well as transversal swinging arms 38 and 45 are provided with web plates connecting the lateral sides such that in the open position of the hinge seen in FIG. 8, they lie adjacent to each other and form an essentially flat cover surface.
The arrangement of hinge bolts 39, 44, 47 of the levers and of hinge bolts 50, 51, that connect the transversal swinging arm with the levers, is selected, in turn, such that they lie on imaginary cylindrical shell 52, indicated by dotted lines, the axis of which is on the outside of hinge parts 30, 33.
The wide-angle hinge can be provided with a closing mechanism that consists of C-shaped bent leaf spring 55, indicated by the dashed line in FIG. 15. The end of this leaf spring is supported on pegs 56, which are arranged on the inside of lateral sides 35, 36 of lever 37. The other end of the leaf spring is supported on pin 57 that is carried in a displaceable manner in longitudinal slots 58 of lateral sides 35, 36. Spring-loaded pin 57 is supported on a curve, corresponding to the desired opening characteristics, formed at the ends of the lateral sides of transversal swinging arm 45 and that borders hinge bolts 51. Leaf spring 55 borders hinge bolts 47 connecting levers 37 and 41 in the manner shown in FIG. 15.
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The invention is directed to a wide-angle hinge having articulated arms in the form of U-shaped profiled levers, the lateral sides of which are offset from one another and with U-shaped profiled transverse swinging arms being articulated to the levers with the same offset. In an open position, hinge pins of both levers lie in an approximately cylindrical shell, the axis of which lies on the outer side of the hinge portions.
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FIELD OF THE INVENTION
This invention relates to a method for neutralizing and removing metals and sulfate from acid mine drainage and other acidic metal sulfate solutions.
DESCRIPTION OF PRIOR ART
A number of investigators have studied the use of sulfate-reducing bacteria (SRB) for treatment of acid mine drainage. The findings of some of those studies are presented below.
Tuttle et al, in Applied Microbiology, Vol. 17, pp. 297-302 (1969), described the potential utility of microbial sulfate reduction as an acid mine drainage water pollution abatement procedure. Batch testing of cultures grown in acid mine drainage (pH 3.6) and wood dust at various temperatures indicated that more sulfate was reduced at 37 C. than at 25 C. or 50 C. Enrichment of wood dust-acid water cultures with sodium lactate resulted in a pH increase from 3.6 to 7.0 in a 10-day period.
King et al, Journal of Water Pollution Control Federation, Vol. 46, pp. 2301-2315 (1974), described the use of sulfate-reducing bacteria in accelerating the rate of acid strip mine lake recovery. They indicated that the key to the process is the accrual of enough organic material at the bottom of the lake to allow generation of suitably reduced conditions for sulfate-reducing bacteria to grow. They noted significant differences in both acidity (2,660 mg/l vs 0 mg/l) and specific conductance (6,400 micromho/cm vs 230 micromho/cm) in lakes that were attributed to the process.
Ilyaletdinov and Loginova reported the findings of batch testing of the use of sulfate-reducing bacteria for removal of copper from the effluent of the Balkhash Mining and Metallurgical Combine in Microbiology, Vol. 46, pp. 92-95 (1977). They were able to reduce copper concentrations of 0.08 mg/l in setting pond effluent (with a sulfate concentration of 1,200 mg/l and lactate as a carbon source) to 0.02 mg/l within a few weeks. Batch testing of treatment of effluent from the secondary settling pond with chopped reed and ammonium sulfate additions showed that 1.0 mg/l concentrations of copper could be reduced to zero in 10 days.
The concept was also tested in continuous culture in a six-section reactor with a residence time of 10 days. The bottom of the reactor was covered with mud to provide a habitat for the bacteria. At 25 C., the reactor was able to reduce an initial concentration of copper of 1.26 mg/l to zero.
In 1977 and again in 1978, Yagisawa et al presented the results of continuous recovery of metals from a solution prepared by bacterial leaching of copper sulfide ore. See Noboro and Yagisawa in Metallurgical Applications of Bacterial Leaching and Related Microbiological Phenomena, pp. 321-344, New York: Academic Press (1978) and Yagisawa et al, Journal of the Mining and Metallurgical Institute of Japan, Vol. 93, p. 447 (1977). Batch culture of sulfate-reducing bacteria in the leaching solution was impossible because of the low pH and high concentration of metals in the solution.
The specific growth rate and the rate of removal of metals were found to be strongly influenced by the pH of the culture. The optimum pH for metal removal and the optimum pH for growth was 6. In continuous culture at 30 C. and pH 6, the maximum rate of metals removal occurred at 40 percent of the metal concentration of the original solution. The original solution contained 270.0 mg/l copper, 102.5 mg/l zinc and 135.0 mg/l iron. Sodium lactate and yeast extract were added to the culture. A black precipatate was produced that contained 19.96 percent copper, 6.13 percent zinc and 10.95 percent iron.
Olson and McFeters, Microbial Sulfur Cycle Activity at a Western Coal Strip Mine, Bozeman, MT: Montana University Joint Water Resources Center (1978), described microbial sulfur cycle activity. The sediments of the mine settling pond supported a large and active population of sulfate-reducing bacteria, producing up to 10.5 mg hydrogen sulfide per liter of sediment per day. Metal bound sulfides were found to comprise, at times, over 0.2 percent of the dry weight of pond sediments, leading the investigators to suggest that sulfate-reducing bacteria were precipitating heavy metals in the pond.
Cork and Cusanovich reported the findings of batch studies of biological conversion of sulfate in solvent extraction raffinates, a waste product of hydrometallurgical copper ore processing, to elemental sulfur. For reference see Murr et al (eds.), Metallurgical Applications of Bacterial Leaching and Related Microbiological Phenomena, pp. 207-222, New York: Academic (1978). Desulfovibrio desulfuricans was used for sulfate-reduction and either of the photosynthetic bacteria Chlorobium thiosulfatophilum or Chromatium vinosum was used for conversion to elemental sulfur. The organisms were cultured separately and a purge system using an inert carrier gas was used to transfer hydrogen sulfide gas from one culture to the other. Lactic acid and yeast extract were used as the carbon source for sulfate reduction. With Chlorobium, an overall process conversion rate of 55 percent was achieved.
Cork and Cusanovich presented the results of pilot scale batch and continuous culture studies of the two-stage conversion process they introduced in 1978. Reference may be made to Developments in Industrial Microbiology, Vol. 20, pp. 591-602 (1979). The tests were carried out at an optimum temperature of 30 C. and an optimum pH of 7.0. At an initial sulfate concentration of 13,400 mg/l, a conversion rate of 91 percent was achieved using lactic acid as the carbon source for sulfate reduction. Utilization of Chlorobium biomass as an alternate carbon source was investigated, but only 10 percent of the required carbon could be supplied in that manner. The investigators suggested using other carbon sources such as raw sewage.
Uphaus et al described another version of purged microbial mutualism using Desulfobacter postgatei, a sulfur-reducing bacterium capable of using acetate as it sole preformed carbon source. For reference see Developments in Industrial Microbiology, Vol. 24, pp. 435-442 (1983). This substrate is more economical than lactate and the products of its metabolism include carbon dioxide and hydrogen sulfide which can serve as feed gas for the growth of photosynthetic green sulfur bacteria. Rigid compressed panels of fiberglass taken from commercial ceiling panels were used as a solid support matrix for the cells of the sulfate-reducing bacteria. Addition of concentrated, cell-free Chlorobium culture supernatant to the immobilized Desulfobacter culture increased sulfate reduction rates by 3 to 4 times.
Grim et al described the findings of batch and continuous culture studies of sulfate reduction by an acetate-utilizing strain Desulfobacter postgatei. For reference see Developments in in Microbiology, Vol. 25, pp. 709-716 (1984). Growth was optimized by constant pH control, slow nitrogen purge to prevent inhibition by the sulfide ion, and immobilization of cells in a continuously stirred tank reactor. A ferric sulfate precipitate adhered to the wall of the reactor apparently allowing cell numbers to increase and facilitating increased sulfate reduction.
The acid-formation phase of anaerobic digestion has been thoroughly reviewed. See for example, Toerien and Jaffingh, Water Research, Vol. 3, pp. 385-416 and Zehnder, in Mitchell (ed.). Water Pollution Microbiology, New York: John Wiley and Sons (1978). Its outcome is the conversion of complex organic matter into saturated fatty (volatile) acids, carbon dioxide and ammonia. The volatile acids have been found to be acetic, propionic and butyric acids with lesser amounts of formic, lactic and valeric acids. For reference see Toerien and Jaffingh in the above-noted publication. Acetic acid is the most plentiful followed by propionic acid. Acid phase anaerobic digestion has been successfully accomplished on a laboratory scale by many investigators. Examples include the following references: Ghosh et al, Journal of the Water Pollution Control Federation, Vol. 47(1), pp. 30-45; Heijmem, Biological Industrial Waste-Water Treatment Minimizing Biomass Production and Maximizing Biomass Concentration, Delft, Holland: Delft University Press (1984); Pohland and Ghosh, in Proceedings of Biotechnology and Bioengineering Symposium, Vol. 2, pp. 85-106 (1971); and Pohland and Ghosh, Environmental Letters, Vol. 1(4), pp. 255-266 (1971), Marcel Dekker, Inc. The maximum specific growth rate, μ max of acidifying bacteria is about 0.3 to 0.5 hr -1 . See Heijmem referenced in this paragraph.
The methane-production phase of anaerobic digestion has been accomplished in conventional chemostats, in fluidized bed reactors and in packed bed reactors. Reference is made to Ghosh et al, Journal of the Water Pollution Control Federation, Vol. 47(1), pp. 30-45 and Heijmem, Biological Industrial Waste-Water Treatment Minimizing Biomass Production and Maximizing Biomass Concentration, Delft, Holland: Delft University Press (1984). Several workers have noted that when acetic, propionic and butyric acids are subjected to methane-phase anaerobic digestion, only acetic and butyric acids are metabolized. Propionic acid is only degraded when acetic acid concentrations have reached low levels. Examples of this literature include Cappenberg, Microbial Ecology, Vol. 2, pp. 60-72; Heijmem, as cited above, and Pohland and Ghosh, Environmental Letters, Vol. 1(4), pp. 255-266 (1971), Marcel Dekker, Inc.
When anaerobic digestion is divided into two phases kinetically, two populations of bacteria occur in the methane production phase. The first group are acetogenic bacteria which convert propionic and butyric acids into acetate and hydrogen. The μ max of this population is about 0.01 hr -1 . The second group is a methanogenic population which converts acetate or hydrogen and carbon dioxide into methane. The μ max of this population is about 0.05 hr -1 with hydrogen plus carbon dioxide as substrate and 0.01 hr -1 to 0.03 hr -1 with acetate as substrate. The biomass yield of both groups is very low.
OBJECTIVES OF THE INVENTION
It is an object of the invention to provide a method for microbial removal of heavy metals, acidity and sulfate from acidic metal sulfate solutions such as acid mine drainage. It is a further object of the invention to provide a method of treatment of acid mine drainage without the need for input of preformed chemicals, such as electron donors, and without the need for input of energy. It is also an object of the invention to economically recover sulfur from wastewaters containing dissolved sulfate.
SUMMARY OF THE INVENTION
The objects of this invention are provided by a process that relies on kinetic control to ensure incomplete oxidation of electron donors during sulfate reduction with conversion of acetate to methane in a subsequent step in the process.
The proposed process will allow treatment and acid mine drainage and, in fact, any acid wastewater containing excessive concentrations of metals and sulfates, more effectively and at lower cost than with conventional treatment methods. It has been estimated that 10,000 miles of streams and 29,000 surface acres of impoundments are seriously affected by mine drainage. About 40 percent of this drainage comes from active mines; the remainder from abandoned surface mines (25 percent) and shaft and drift mines (75 percent). Reference may be made to Goldhaber and Kaplan in Goldberg (ed.), The Sea, Vol. 5, New York: John Wiley and Sons (1974).
The free mineral acid loads associated with coal mine drainage alone in the United States exceed 5,300 tons per day. Reference is made to Zobell, Ecology of Sulfate-Reducing Bacteria, Pennsylvania Oil Production Association, Vol. 22, pp. 12-29 (1958). Neutralization of this acidity would consume over 1,100,000 tons of lime per year. Manufacture of this amount of lime would consume about 5 trillion BTU per year. The proposed process could eliminate this requirement.
Neutralization of acidity with lime does not reduce dissolved sulfate levels. Lime addition to such waters usually results in oversaturation of the water with calcium sulfate (gypsum). Subsequent gypsum precipitation typically causes scaling in downstream treatment units and cementation of gravels in natural stream beds lowering their habitat value. With the proposed invention, this problem would not occur.
Anaerobic digestion of an amount of wastewater treatment sludge sufficient to provide electrons for reduction of 500 mg/l of sulfate in 0.5 million gallons per day (mgd) of acid mine drainage would also provide sufficient methane to heat the mine drainage to 37 degrees C.
BRIEF DESRIPTION OF THE DRAWINGS
FIG. 1 presents a highly schematic block diagram illustrating a first representative embodiment of the invention, said embodiment comprising the steps of biological sulfate reduction and methane phase anaerobic digestion.
FIG. 2 presents a highly schematic block diagram illustrating a second representative embodiment of the invention, said embodiment comprising the additional step of acid phase anaerobic digestion.
FIG. 3 presents a highly schematic block diagram illustrating a third representative embodiment of the invention in which biological sulfate reduction is conducted as a batch operation.
DETAILED DESCRIPTION OF THE INVENTION
Reference is now made to FIG. 1 which is a highly schematic block diagram illustrating a representative embodiment of the invention, the dotted lines representing possible variations in the process. Substrate 1 is the input to the process, and, under certain conditions, may be the only chemical input to the process. Substrate 1 contains dissolved sulfate ions and at least one dissolved electron donor with a molecular weight greater than that of acetic acid. Examples of such electron donors include propionic acid, propionate ion, butyric acid, butyrate ion, lactic acid and lactate ion. These substances are termed electron donors because it is their purpose to serve as such during the biological reduction of sulfate to sulfide. Acetic acid or acetate ion may or may not be present in the substrate. The molar concentration of electron donors with molecular weights greater than that of acetic acid are such that the cumulative number of moles is greater than that required for incomplete oxidation of the electron donor and essentially complete microbial reduction of the sulfate present in substrate 1. Examples of stoichiometric requirements for electron donors are available in the literature. Reference may be made to Pfennig and Widdel, in Biology of Inorganic Nitrogen and Sulfur, Bothe and Trebst (eds.), pp. 169-177, New York: Springer-Verlag (1981).
Examples are given below:
______________________________________ Moles of sulfate required perElectron donor mole of electron donor______________________________________Propionate 0.75Butyrate 0.50Valerate 1.0Lactate 0.50______________________________________
The electron donors are provided in excess to ensure that they are not exhausted prior to essentially complete removal of sulfate. The situation also ensures that utilization of one of the products of incomplete oxidation of the electron donors, acetate, is not required for sulfate reduction. If substrate 1 contains sufficient acid to neutralize the basic (caustic) product(s) of microbial sulfate reduction, e.g., bicarbonate, then addition of acid to the sulfate reducing (first) reactor 2 is not required. In this case, substrate 1 is added to first reactor 2 at the rate needed to maintain the pH in the range 6.0 to 8.0. Otherwise, an acid 3 such as sulfuric acid or hydrochloric acid is added to the first reactor 2 to maintain the pH in the correct range. First reactor 2 is maintained at a temperature in the range 20 degrees C. to 40 degrees C.
First reactor 2 may be innoculated with sulfate-reducing bacteria (SRB) but innoculation would not normally be necessary because of their ubiquitous nature. The concentration of SRB maintained in first reactor 2 is such that the mean cell residence time is less than that required for complete oxidation of the electron donor(s) by SRB at the selected pH and temperature. Under conditions of suspended growth, if cell recycle 4 is not practiced, the relationship between the flow rate of substrate into first reactor 2 and the mean cell residence time is as follows:
MCRT=V/Q
where
MCRT=mean cell residence time
Q=volumetric flow rate
V=volume of reactor
Thus, either the flow rate into first reactor 2 or the volume of first reactor 2 is adjusted to meet the above criterion. If 100 percent efficient cell recycle 4 is practiced, the mean cell residence time is as follows:
MCRT=V/F.sub.w
where F w =volumetric flow rate of removal of reactor contents containing cells (waste sludge removal rate)
In a reactor operated at a given mean cell residence time, microorganisms reproducing (doubling) at a rate such that their mean cell residence time is greater than approximately the reactor residence time (TD=V/Q) will be washed out of the reactor. Such microorganisms will not be present at sufficient concentrations sufficient to effectively utilize substrate delivered to the reactor. Actually, Monod growth kinetics predicts that washout, the loss of all cells of a particular organism, will occur for dilution rates, D=Q/V, greater than the maximum dilution rate D max , in which
D max =μ max S o /(K s +S o )
D max =maximum dilution rate (Q/V), hr -1
μ max =maximum organism specific growth rate, that is, the maximum growth rate achievable by a particular organism when the concentration of limiting nutrient in the reactor is much greater than K s and the concentrations of all other essential nutrients are unchanged, hr -1
S o =limiting nutrient concentration in substrate (feed), mg/1
K s =value of limiting nutrient concentration at which the specific growth rate is half its maximum value, mg/1
Because S o is always much greater than K s in the systems disclosed herein, D max may be assumed to be approximately equal to μ max .
Various researchers have found that SRB grow more slowly when they utilize acetate as a substrate than when they utilize higher molecular weight electron donors. For example, F. Widdel and N. Pfenning found that pure cultures of Desulfotomaculum acetoxidans grew faster on butyrate than on acetate (15 hr doubling time instead of 30 hr). This reference is found in Bothe and Trebst (eds.), Biology of Inorganic Nitrogen and Sulfur, pp. 169-177, New York: Springer-Verlag, (1981). Similarly, Widdel et al found that pure culture of Desulfonema limicola and Desulfonema magnum grew faster on propionate, butyrate or valerate than on acetate. Reference may be made to Archives of Microbiology, Vol. 134, pp. 286-294 (1983). Volume one of Bergey's Manual of Systematic Bacteriology (1984), reported that species that carry out complete oxidation of propionate, such as Desulfococcus multivorans and Desulfosarcina variasilis, grow more slowly than does Desulfobulbus propionicus which oxidized propionate incompletely to acetate. Furthermore, Traore et al have shown that SRB grow more rapidly on substrates from which they derive more energy. See for reference Journal of Bacteriology, Vol. 145(1), pp. 191-199. Thauer et al have shown that SRB derive more energy from incomplete oxidation of electron donors other than acetate than they do from complete oxidation of those electron donors. Refer to Bacteriological Review, Vol. 41, pp. 100-180 (1977). Furthermore, SRB derive more energy from complete oxidation of electron donors other than acetate than they do from complete oxidation of acetate. Examples are as follows:
______________________________________ Free energy changeElectron per each two electronsdonor Product transferred, ΔG°' ,______________________________________ kJAcetate Carbon dioxide -11.83Propionate Carbon dioxide -12.10Butyrate Carbon dioxide -12.24Propionate Acetate + CO.sub.2 -12.63Butyrate Acetate -13.92Formate Carbon dioxide -36.68Lactate Acetate + CO.sub.2 -40.08______________________________________ where ΔG°' = free energy change at pH 7.
From the above, it is apparent that operation of first reactor at mean cell residence time less than that required for oxidation of acetic acid by SRB at any selected pH and temperature will cause oxidation of the other electron donors in substrate 1.
As an example, Middleton and Lawrence, Journal WPCF, pp. 1659-1670 (1977) found that at a temperature of 31 degrees C., a mixed culture of SRB could grow at a maximum specific growth rate, μ max , of 0.022 hr -1 where μ=Q/V in a chemostat without cell recycle. Thus, under these conditions, operation of first reactor 2 at a mean cell residence time less than about 1/μ max =45 hr would ensure that oxidation of any electron donor present in the substrate with a molecular weight greater than that of acetic acid would occur. Middleton and Lawrence also found that the μ max of SRB using acetate as the electron donor for sulfate reduction at an unreported pH varied with temperature as follows:
______________________________________TemperatureDegrees C. μ.sub.max, hr.sup.-1______________________________________20 0.01425 0.01931 0.022______________________________________
Because one of the products of microbial sulfate reduction, dissolved sulfide, inhibits the growth of SRB, removal of this substance is necessary to ensure rapid growth. If sufficiently high concentrations of dissolved metal(s) are present in (or are added to) substrate 1, dissolved sulfide will be removed by precipitation as metal sulfide. See for example, Cork and Cusanovich, Developments in Industrial Microbiology, Vol. 20, pp. 591-602 (1979). If insufficient metals are present, excess sulfide may be removed at pHs near and above 7 (neutral) by purging the reactor with a gas other than oxygen, such as nitrogen. See for example, Cork and Konan, Developments in Industrial Microbiology, Vol. 26, pp. 41-52 (1985).
High dissolved sulfide concentrations also inhibit the growth of methanogenic (methane-producing) bacteria (MB). However, Heijmem found that dissolved sulfide concentrations up to 160 mg/l have been found not to inhibit the growth of MB. This research was described by Heijmem in Biological Industrial Waste-water Treatment Minimizing Biomass Production and Maximizing Biomass Concentration, Delft, Holland: Delft University Press (1984).
Sulfide removed from first reactor 2 may be biologically converted to relatively pure elemental sulfur 91 in third reactor 90. This is accomplished by innoculating third reactor 90 with a green sulfur bacteria such as Chlorobium limicola f. sp or Chlorobium thiosulfatophilum, exposing the reactor to a source of light such as sunlight 92. Detail of this step of the process may be obtained by reference to Uphouse et al, Developments in Industrial Microbiology, 24, pp. 435-442 (1983).
Liquid effluent 7 is delivered to second reactor 8. The liquid effluent 7 of a first reactor 2 operated as indicated above contains a relatively high concentration of acetate and relatively low concentrations of sulfate, sulfide, and higher molecular weight electron donors. If first reactor 2 is operated at a pH between 6.8 and 7.4, then no chemical additions are required to operate second reactor 8 in that pH range. If this is not the case, then acid or base 9 is added to second reactor 8 to cause the reactor to operate within a pH range of about 6.8 to 7.4.
Second reactor 8 is operated at a temperature between 20 degrees to 65 degrees C. it is also operated at a mean cell residence time greater than that required for utilization of acetic acid by MB at the selected pH and temperature. Under conditions of suspended growth, this is achieved as was noted above recognizing that the μ max of this MB population is about 0.01 hr -1 . If the MB are grown in biofilms (e.g., in a fluidized bed reactor), then the theoretical mean MB cell residence time is infinite. Colonization of MB in the biofilm may be encouraged by maintaining the hydraulic residence time of the second reactor 8 at less than 100 hours.
Gaseous methane 10 generated in second reactor 8 is removed from the reactor. Methane 10 may be burned in methane combustion unit 11 and energy 12 used to heat substrate 1, first reactor 2, and second reactor 8. Alternatively, methane combustion unit 11 may be an engine generator, in which case energy 12 may be produced in the forms of electricity and waste heat. The electricity may be used to power electrical equipment associated with first reactor 1 and second reactor 8 such as pumps and mixers. The waste heat may be used to heat substrate 1, first reactor 2 and second reactor 8 as noted above.
Effluent 13 is removed from second reactor 8. It may undergo aerobic post treatment 14 prior to release to the environment.
Reference is now made to FIG. 2 which is a highly schematic block diagram illustrating a second alternative representative embodiment of the invention, which is the best mode, the dotted lines representing possible variations in the process. With this embodiment, biomass 20 is subjected to acid phase anaerobic digestion (acidogenesis) in digester 21. Biomass 20 may be an easily degraded substance such as municipal wastewater treatment sludge or a milk-processing waste stream such as whey. Biomass 20 may also be a substance requiring pretreatment by acid or caustic hydrolisis prior to anaerobic digestion. Several embodiments of acid phase anaerobic digestion and pretreatment schemes are described in U.S. Pat. No. 4,022,665. Other embodiments of acid phase anaerobic digestion that incorporate hydrogen management techniques are described by Harper and Pohland, Biotechnology and Bioengineering, Vol. 28, pp. 585-602 (1986).
The effluent 22 from the acidogenesis process may undergo degasification 23 to facilitate subsequent solids separation 24. Degasification 23 may be accomplished by vacuum degasification. Solids separation 24 may be accomplished by settling, by centrifugation, or by vacuum or pressure filtration. The gas 25 removed during degasification 23 could be routed to a methane combustion process 30.
The semisolid portion 26 of the output of solids separation 24 may undergo further processing prior to utilization as a soil amendment or disposal or it may be used or disposed of directly. If the semisolid portion 26 is further processed by anaerobic digestion, the gas produced may also be routed to methane combustion process 30.
Referring to the process train on the right side of FIG. 2, acid mine drainage 40 may undergo cementation 41 prior to subsequent processing. Cementation should be used to reduce copper concentrations in acid mine drainage 40, if said copper concentrations exceed about 100 mg/l. Cementation is an oxidation-reduction reaction accomplished by passing an acidic solution containing dissolved copper through finely divided waste iron 42. During the process, iron is dissolved and copper 43 is removed from the solution as a precipitate.
Acid mine drainage 40 may also be pretreated in metals precipitation reactor 44. In this reactor, acid mine drainage is mixed with excess hydrogen sulfide gas 51 evolved in sulfate reduction reactor 50. The reaction of metals in the acid mine drainage 40 with the gas 51 produces metal sulfides 45.
Acid mine drainage 40 and the liquid portion 27 of the output of solids separation 24 are delivered to sulfate reduction reactor 50. Sulfate reduction reactor 50 is operated in a manner similar to that described for second reactor 8 in the previous embodiment of the invention. Cell recycle 51 and/or degasification 52 may be practiced.
The effluent 53 from the sulfate reduction reactor 50 undergoes subsequent solids separation 54. One or more of the solids separation processes mentioned earlier may be used. The semisolid portion 55 of the output of solids separation 54 is removed and will consist primarily of metal sulfides with some biomass.
The liquid portion 56 of the output of solids separation 54 is delivered to methane production reactor 60. Methane production reactor 60 is operated in a manner similar to that described for second reactor 8 in the previous embodiment of the invention. Cell recycle 61, degasification 62 and/or solids separation may be practiced. Post treatment 64 by aerobic treatment may also be practiced prior to discharge or reuse.
Reference is now made to FIG. 3 which is a highly schematic block diagram illustrating a third alternative representative embodiment of the invention, the dotted lines representing possible variations in the process. With this embodiment, substrate 100 is discharged to substrate storage tank 101 to equalize the flow rate through the process. When valve 102 is opened, and valve 105 is closed, substrate 100 flows into batch sulfate reduction tank 103. The reactor is innoculated with sulfate-reducing bacteria innoculum 104. For highest efficiency, innoculum 104 should be conditioned by growing the bacteria in a medium rich in the highest molecular weight electron donor present in significant quantities in substrate 100. The contents of batch sulfate reduction tank 103 are heated to a temperature of about 35 degrees C. to accelerate the rate of biological action. If substrate 100 contains insufficient acid or buffering capacity to maintain a pH in the range 6.0 to 8.0, acid 106 may be added during the biological sulfate reduction process to maintain the pH in that range. Sulfide 108 is removed from the reactor to prevent the buildup of sulfide concentrations that are toxic to sulfate-reducing bacteria.
The concentrations of electron donors are measured at regular intervals during the process using a conventional technology such as gas chromotography. The sulfate-reducing bacteria present in batch biological sulfate reduction tank 103 will oxidize the electron donors in the order from the electron donor providing the bacteria with the most energy to the electron donor providing the least. All electron donors with a higher molecular weight than acetate will be oxidized before acetate is oxidized with a short time lag between the consumption of each electron donor. With two electron donors in substrate 100, this phenomena is termed diauxic growth; with three electron donors, it is termed triauxic growth. Before the bacteria begin to oxidize the acetate in substrate 100, valve 105 is opened and the effluent 107 is discharged to biological methane production tank 110. Methane 111 produced is removed from methane production tank 110. The effluent 115 from biological methane production tank 110 may undergo post treatment 120 prior to discharge or reuse.
Substrate storage tank 101 may be reduced in size by providing a second sulfate reduction train with components indicated by 200 level numbers on FIG. 3. These components would be used during emptying of biological sulfate reduction tank 103.
WORKING EXAMPLE
Design criteria for a working example of the invention are presented in the following Table I.
TABLE I______________________________________Process/Criteria Value______________________________________AcidogenesisVolatile solids 1.67loading, grams/liter · hourDilution rate, per hour 0.042Temperature, degrees C. 35Products, grams/hourAcetic acid 79Propionic acid 113Butyric acid 84DegasificationVacuum, meters of mercury 0.5Solids separationMass loading rate, kilograms/ 4.9hour · square meterSulfate reductionSulfate loading, grams/liter · hour 45Dilution rate, per hour 0.031Temperature, degree C. 35pH, units 7.0DegasificationVacuum, meters of mercury 0.5Solids separationSurface loading rate, kilograms/ 4.9hour · square meterBiofilm methanogenesisMedia specific surface, square 100meters per cubic meterDilution rate, per hour 0.67Temperature, degrees C. 35pH, units 7DegasificationVacuum, meters of mercury 0.5Solids separationsurface loading rate, kilograms/ 4.9hour · square meter______________________________________
The invention is not to be construed as limited to the particular forms disclosed herein, since these are to be regarded as illustrative rather than restrictive. For example, those skilled in the art will realize that in a multiple substrate environment in which diauxic, triauxic or similar growth phenomena are possible, kinetic control (variation of dilution rate) can be used to determine the relative rate of consumption of each substrate present in the feed. Moreover, as indicated by Kompala et al in Biotechnology and Bioengineering, Vo. 26, pp. 1272-1281 (1984), incremental increases in dilution rate cause incremental decreases in the rate of consumption of less preferred substrates. Thus, a kinetically controlled reactor need not be operated only at a dilution rate that causes complete consumption of one substrate, e.g., lactate, and no consumption of another substrate, e.g., acetate. Rather, kinetic control can be used to vary, for example, the rate or percentage of acetate consumption while lactate is completely consumed. Thus, it is the intention of this patent to cover all changes and modifications of the examples of the invention herein chosen for the purposes of the disclosure, which do not constitute departures from the spirit of, and scope of the invention.
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This invention comprises the steps of (1) acid phase anaerobic digestion of biomass to produce volatile acids and a stabilized sludge, (2) use of the volatile acids as the carbon source and electron donor for biological sulfate reduction for removal of acidity, metals and sulfate from acid mine drainage, and to produce acetate, (3) use of the acetate solution as feed for methane phase anaerobic digestion to produce methane and to reduce the organic content of the effluent of the process, (4) and use of the methane to satisfy the energy requirements of the process. Key to the process is the use of kinetic control (i.e., a relatively short mean cell residence time) to ensure partial oxidation of higher molecular weight volatile acids (e.g., propionic, butyric, valeric) and production of acetate during the sulfate reduction step. In this way, the higher molecular weight volatile acids produced during acid phase anaerobic digestion can be used both as electron donors for sulfate reduction (during which they are converted to acetate) and as substrates for the subsequent methane production step.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to provisional application 60/651,284, filed Feb. 9, 2005.
FIELD OF THE INVENTION
This invention relates in general to subsea wellhead equipment and in particular to a metal-to-metal seal for a bridging hanger or tieback connection.
BACKGROUND OF THE INVENTION
A subsea well assembly includes a wellhead housing that is secured to large diameter conductor pipe extending to a first depth in the well. After drilling to a second depth, a string of casing is lowered into the well and suspended in the wellhead housing by a casing hanger. A packoff seals between an outer diameter portion of the casing hanger and the bore of the wellhead housing. Some wells have two or more strings of casing, each supported by a casing hanger in the wellhead housing.
In one type of completion, a string of production tubing is lowered into the last string of casing. A tubing hanger lands and seals in the upper casing hanger. The well is produced through the tubing. Prior to running the tubing, the operator will test the upper casing hanger packoff. On rare occasions, the packoff may be unable to pass the pressure test, possibly due to damage on the interior wall of the wellhead housing. If so, one remedy is to install an emergency or bridging hanger in the wellhead housing. The bridging hanger does not support a string of casing, but has an interior profile that is normally the same as the profile in the upper casing hanger. The operator lands and seals the lower portion of the bridging hanger to the casing hanger. The operator installs a packoff between the upper exterior portion of the bridging hanger and the wellhead housing above the casing hanger. The operator then runs the tubing and lands and seals the tubing hanger in the bridging hanger.
In the prior art, the inner seal between the bridging hanger and the casing hanger is normally elastomeric. As the bridging hanger enters the casing hanger, the elastomeric seal deforms to cause the sealing engagement. Metal-to-metal outer seals or packoffs have been used for years because they can withstand higher pressures than elastomeric seals and also do not deteriorate under harsh environments as readily. Metal-to-metal tubing hanger seals are also employed in many wells. A metal-to-metal seal, however, typically requires much more force to set than simply the weight of the running string. Various running tools have been developed to apply the high forces needed. Developing a running tool to set a metal-to-metal inner seal would require an additional trip down the riser with another running tool to set the metal-to-metal outer seal. In offshore wells, particularly in deep water, it is very expensive to run an additional trip.
SUMMARY OF THE INVENTION
In this invention, a metal-to-metal inner seal is attached to the lower exterior portion of the bridging hanger. The bridging hanger is lowered on a running tool into the wellhead housing and inserted into the casing hanger. The inner seal is set between the interior of the casing hanger and the lower exterior portion of the bridging hanger in response to the weight of the running string. Preferably, the inner seal has a deflectable locking portion to lock the inner seal in the pre-load caused by the weight of the running string. The weight causes the locking portion to defect outward into engagement with a profile in the casing hanger.
In one embodiment, while the running tool is still inserted into the wellhead housing, the running tool is actuated to set a metal-to-metal outer seal between the upper exterior portion of the bridging hanger and the wellhead housing. The bridging hanger may be used in place of the casing hanger to support a string of tubing. If so, the tubing hanger lands in and seals to the interior of the bridging hanger
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical sectional view of a subsea wellhead assembly having a bridging hanger with a metal-to-metal seal in accordance with this invention.
FIG. 2 is an enlarged sectional view of the wellhead assembly of FIG. 1 , showing the bridging hanger being run in prior to energizing the metal-to-metal seal.
FIG. 3 is a further enlarged view of a portion of the bridging hanger of FIG. 2 , showing the metal-to-metal seal prior to being energized.
FIG. 4 is a view similar to FIG. 3 , but showing the seal in the energized position.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , the subsea wellhead assembly in this embodiment includes an outer or low pressure wellhead housing 11 . A string of conductor pipe 13 is attached to the lower end of low pressure wellhead housing 11 and extends into a first section of the well. A high pressure or outer wellhead housing 15 lands in low pressure wellhead housing 11 . High pressure wellhead housing 15 is secured to a string of casing 17 that extends through conductor pipe 11 to a greater depth in the well. High pressure wellhead housing 15 has an exterior grooved profile 19 for engagement by a drilling riser assembly that extends to a surface vessel.
After drilling the well through high pressure wellhead housing 15 to a greater depth, a next section of casing 23 is run on a casing hanger 21 . Casing hanger 21 lands in high pressure wellhead housing 15 . A packoff or casing hanger seal 25 seals the annulus around casing hanger 21 to high pressure wellhead 15 . Some wells may have only one casing hanger such as casing hanger 21 . In this example, an additional casing hanger 27 is shown, casing hanger 27 being attached to a string of production casings 29 that extends to a final depth in the well. A casing hanger seal 31 seals between the outer diameter of the upper casing hanger 27 and the bore of wellhead housing 15 .
A bridging hanger 33 is shown landed on production casing hanger 27 . Bridging hanger 33 would be employed in the event that upper casing hanger seal 31 could not be installed or if it leaked. Bridging hanger 33 has an interior or bore substantially identical to bore 39 of production casing hanger 27 in this example. Bridging hanger 33 has a structure similar to casing hanger 27 , except there is no provision for securing casing to its lower end. A casing hanger outer seal 35 , which may be identical to casing hanger seals 25 and 31 , seals the annulus around bridging hanger 33 to wellhead housing 15 . Bridging hanger 33 has an interior grooved profile 37 that is engaged by a conventional casing hanger running tool 38 , illustrated in FIG. 2 by dotted lines. Running tool 38 carries outer seal 35 , and after bridging hanger 33 lands, moves outer seal 35 downward and sets it. Bridging hanger 33 may subsequently support a conventional tubing hanger 40 , shown by dotted lines in FIG. 1 . Tubing hanger 40 has a seal 42 that sealingly engages a sealing surface in bridging hanger 33 below profile 37 .
Referring to FIG. 3 , bridging hanger 33 is shown being lowered into bore 39 of production casing hanger 27 , but running tool 38 ( FIG. 2 ) is not shown for clarity. Bridging hanger 33 has a retainer ring 41 on its lower end that is secured by threads 43 . Preferably, retainer ring 41 has a backup elastomeric seal 45 that seals against a portion of production casing hanger bore 39 . Retainer ring 41 also has an inner seal 47 that seals to an exterior portion of bridging hanger 33 above threads 43 . The body of bridging hanger 33 has a guide portion 49 on its outer diameter that is cylindrical and has an outer diameter less than the outer diameter of retainer ring 41 . A seal surface 51 is formed on the outer diameter of the body of bridging hanger 33 above guide portion 49 . Seal surface 51 is finished to a desired metal-to-metal surface finish, such as 32 RMS. Seal surface 51 has an outer diameter that is slightly greater than the outer diameter of guide portion 49 , but less than the outer diameter of retainer ring 41 . A transition shoulder 53 is located between seal surface 51 and guide portion 49 .
A bridging hanger seal ring 55 is carried on the outer diameter of bridging hanger 33 above retainer ring 41 . Seal ring 55 has a metal seal 57 on its lower end. In this embodiment, metal seal 57 comprises a welded inlay of a conventional type of material suitable for forming metal-to-metal seals. For example, the inlay may be a nickel-base alloy. Metal seal 57 has a cylindrical surface on its inner diameter and a downward facing tapered surface on its outer diameter. The tapered surface mates with a tapered seal surface 58 formed in bore 39 of production casing hanger 27 . Seal surface 58 is prepared for metal-to-metal sealing, having a finish substantially the same as seal surface 51 on bridging hanger 33 . In this embodiment, tapered seal surface 58 is formed at taper angle, such as 20 degrees, that is considerably larger than a locking taper, which is typically about 7½ degrees. Seal surface 51 on the exterior portion of bridging hanger 33 is cylindrical in this example.
Seal ring 55 has a plurality of vertical slots (not shown) spaced circumferentially apart from each other, defining a collet section with collet fingers 59 . The slots extend through the upper end of seal ring 55 , thus collet fingers 59 are not connected to each other at their upper ends. The individual fingers 59 with free upper ends enable the upper portion of seal ring 55 to plastically deflect outwardly from a cylindrical configuration to a conical configuration, as shown in FIG. 4 . In the running-in position shown in FIG. 3 , fingers 59 are located around seal surface 51 of the body of bridging hanger 33 . Seal ring 55 may be made of any suitable metal, such as Inconel 718.
A drive or cam ring 61 is secured to bridging hanger 33 above seal ring 55 . Drive ring 61 has an upper end that abuts a downward facing shoulder 65 on the outer diameter of bridging hanger 33 . Preferably, a plurality of fasteners 63 may be used to secure ring 61 and prevent it from sliding downward. Fasteners 63 insert into oversized holes 64 in bridging hanger 33 in the preferred embodiment. Thermal changes that cause axial cyclic deflections will not be transferred through fasteners 63 due to a clearance provided between fasteners 63 and holes 64 . Up and down movement between casing hanger 27 and bridging hanger 33 will not loosen drive ring 61 .
An upper backup seal 67 is optionally located above drive ring 61 . Upper backup seal 67 is positioned to engage an upper portion of bore 39 of production casing hanger 27 . Production casing hanger 27 has a grooved profile 69 formed in an upper portion of bore 39 above the cylindrical portion that normally is prepared for sealing engagement with tubing hanger seal 42 ( FIG. 1 ). Profile 69 may take a variety of shapes and is typically used for engagement with running tool 38 ( FIG. 2 ) to run casing hanger 27 . Also, profile 69 may be used for securing a lock member of a tieback assembly (not shown) when tubing hanger 40 ( FIG. 1 ) is not utilized. Profile 69 has a downward and inward facing conical reaction shoulder 71 at its upper edge or end. Tapered seal surface 58 defines the lower edge of profile 69 .
Collet fingers 59 of seal ring 55 have mating conical upper ends 72 that engages shoulder 71 when deflected outward as shown in FIG. 4 . Drive ring 61 has an outer tapered surface 73 that engages the inner diameter of fingers 59 of seal ring 55 to cause collet fingers 59 to deflect outward when drive ring 61 moves downward relative to seal ring 55 . The amount of taper is selected to provide a locking taper to resist upward movement of drive ring 61 relative to seal ring 55 once engaged.
In operation, the operator connects running tool 38 ( FIG. 2 ) to bridging hanger 33 and lowers it through a drilling riser into high pressure wellhead housing 15 . Initially, retainer ring 41 will slide into bore 39 of production casing hanger 27 , as shown in FIG. 3 . Metal seal 57 of seal ring 55 will land on tapered seal surface 58 in bore 39 of production casing hanger 27 . At this point, the inner diameter of seal ring 55 at collet fingers 59 remains cylindrical.
Then, continued weight is applied to bridging hanger 33 from the running string, causing bridging hanger 33 to move downward. As shown in FIG. 4 , metal seal 57 remains in the same axial position while the body of bridging hanger 33 moves downward. Bridging hanger seal surface 51 slides into contact with the inner diameter of metal seal 57 . Drive ring 61 slides between the inner surfaces of collet fingers 59 and the outer diameter of bridging hanger 33 . Tapered surface 73 of drive ring 61 pushes collet fingers 59 outward. Drive ring 61 and collet fingers 59 lock at taper 73 . Tapered upper ends 72 of fingers 59 slide into engagement with reaction shoulder 71 and lock at this point, also. The locking engagement of fingers 59 pre-loads seal ring 57 at seal surface 58 . Any axial motion thereafter must be transmitted through collet fingers 59 .
Metal-to-metal sealing engagement occurs on both sides of metal seal 57 . Elastomeric seals 45 , 47 and 67 provide a secondary backup. The sealing engagement is prevented from movement because of the engagement of tapered upper ends 72 of fingers 59 with reaction shoulder 71 . Subsequently and on the same trip, running tool 38 ( FIG. 2 ) conventionally installs bridging hanger seal 35 ( FIG. 1 ), sealing the annulus around bridging hanger 33 .
If the operator wishes to retrieve bridging hanger 33 , he reengages running tool 38 with profile 37 ( FIG. 1 ) and pulls upward. This causes drive ring 61 to move above seal ring 55 as shown in FIG. 3 . The upper end of retainer ring 41 pushes upward on metal seal 57 , causing upper ends 72 of fingers 59 to slide out of engagement with reaction shoulder 71 for retrieval.
After the installation shown in FIG. 1 , bridging hanger 33 can serve in place of production hanger 27 for receiving tubing hanger 40 ( FIG. 1 ). Alternately, bridging hanger 33 could receive an isolation sleeve, which forms part of a tubing hanger assembly. The tubing hanger could thus be supported in a tubing spool (not shown) mounted on high pressure wellhead housing 15 . Further, bridging hanger 33 could receive an isolation tube suspended from a Christmas tree of a type where the tubing hanger is located within the tree. In that instance, the isolation tube would be considered to be part of the tubing hanger assembly.
Alternately, bridging hanger 33 could form the lower end of a tieback connector (not shown), which stabs and locks into production casing hanger 27 and is located at the lower end of a string of conduit extending to the surface. If bridging hanger 33 is part of a tieback connector, it typically would not need an outer annulus seal such as seal 35 . The conduit extending upward from such a tieback connector would extend to a surface vessel for receiving a production tree.
The invention has significant advantages. The bridging hanger utilizes a metal-to-metal inner seal, while is longer lasting than elastomeric seals and better able to withstand high pressures. The inner and outer seals are run on the same trip. A special purpose running tool for the inner seal is not required.
While the invention has been shown in only one of its forms, it should be apparent to those skilled in the art that it is not so limited but is susceptible to various changes without departing from the scope of the invention.
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A method of completing a well having a casing hanger set in a subsea wellhead housing includes attaching a running tool to a tubular bridging hanger. A metal-to-metal inner seal is attached to a lower exterior portion of the bridging hanger and a metal-to-metal outer seal is located on an upper exterior portion of the bridging hanger. The assembly is lowered into the well and the lower exterior portion of the bridging hanger is inserted into the casing hanger. The inner seal is wedged between the casing hanger and the bridging hanger in response to weight of the running string. The running tool is actuated to set the outer seal between the upper exterior portion of the bridging hanger and the wellhead housing. Then, a tubing hanger is landed and sealed in the interior of the bridging hanger.
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FIELD OF THE INVENTION
The invention concerns a locking means for an opening in the wall of a self-service device, in particular for a dispensing or deposit gate of an automatic teller machine. The invention also concerns a self-locking latch and actuator means for pivoting a movable component to one of two positions, in particular for actuating a locking means of a self-service device.
BACKGROUND OF THE INVENTION
A problem with self-service devices, such as cash terminals and automatic teller machines, is that they are not only installed in the lobby of, say, banks, but that they may also be installed in a place which is unprotected from the weather. In such a case, the device is exposed to extreme climatic conditions, such as rain, snow, cold and strong sunshine. Mechanical assemblies that must withstand such extremes both statically and kinematically are the locking means which releases or covers the dispensing gate and the locking means for the gate through which notes, cheques and the like are deposited.
Such units must be rain water repellent; must not freeze up; and must function even when the locking means becomes blocked by the formation of ice or as a result of vandalism. Existing cash terminals use locking means which do not meet the preceding requirements satisfactorily.
One prior art design comprises, for instance, a slotted cylinder which is supported on a plate provided with a slot. In the open position, currency is fed from the outside through a slot in the outer wall and an aligned slot in the cylinder. Water may enter through top and bottom joints between the cylinder and the outer wall. If a slot of relatively small size is used, serious problems may occur in high temperature ranges. A further disadvantage of this kind of seal is that the mechanism freezes up rapidly in the winter. Another serious disadvantage is that the mechanism may be blocked or jammed by inserted objects.
Another prior art design includes a plate, behind which a slide is arranged which, through the action of a gear and pinion, is shifted by a motor to close or release an opening in the plate. In this case the bottom joint between the slide and the outer plate is liable to cause problems, since it is here that water may enter or ice form. Even if the ice is smashed as the flap is opened by a suitably strong motor, fresh ice frequently forms when the flap is open, preventing it from closing reliably. The functioning of this design may be disrupted by objects jammed between the plate and slide as a result of vandalism.
It is an object of the present invention to design a locking means for an automatic teller machine such that the preceding problems are eliminated, and to substantially avoid and preclude the adverse effects produced by water, the formation of ice and jammed objects.
SUMMARY OF THE INVENTION
A locking means is disclosed whose design, over a wide range of installed positions, repels rain water and substantially avoids the formation of ice. Any ice which is formed, is broken up through the operation of the locking means. Furthermore, jammed objects do not prevent the opening of the locking means.
An aspect of the invention is a closure locking means for the opening of a self-service device, in particular an automatic teller machine, which includes a locking flap, the outside of which is indented. The locking flap, pivotable about an axis, is positioned behind a projecting upper wall panel and in front of a recessed wall panel. A gap is created when the locking flap is pivoted, and as the flap is opened, the width of the gap increases, so that any ice formed is broken up or jammed objects are released. A self-locking latch and actuator means for the locking flap uses an actuating lever which is pivotable about axis. The actuating lever includes a shaped guide slot, which is engaged by the actuator means. In a first part of the guide slot, no displacement work is performed by the actuator means, whereas in a second part, which is positioned at an angle to the first part, displacement work is performed to move the lever and locking flap.
DESCRIPTION OF THE DRAWINGS
A preferred manner for carrying out the invention is described in detail below with reference to drawings which illustrate a specific embodiment, in which
FIG. 1 is a schematic isometric, partly sectional view of the locking means according to the present invention.
FIG. 2 is a schematic isometric, partly sectional view of the locking flap designed according to the invention.
FIG. 3 is a schematic sectional view of the locking means in two of its possible installation positions.
FIG. 4 is a schematic partly sectional side view of a self-locking latch and actuator means in accordance with the present invention.
FIG. 5 shows the arrangement of FIG. 4 but in an intermediate position of the drive arm in which the opening is still closed but already unlatched;
FIG. 6 shows the arrangement of FIG. 4 but in a further intermediate position in which half the opening of the locking means is opened;
FIG. 7 shows the arrangement of FIG. 4 but in the unlatched and completely opened position, and
FIG. 8 is a schematic rear top view of the arrangement of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
The essential components of the locking means of the invention are described in detail below with reference to FIGS. 1 to 3.
FIG. 1 is a schematic isometric, partly sectional view of a locking means 1 according to the present invention. Locking means 1 includes an opening 2, a top front wall panel 3, a lower recessed wall panel 4 and two side elements 5 and 6 linking panels 3 and 4. The lower wall panel 4 tilts inward and is most recessed immediately adjacent to top front wall panel 3. A locking flap 7, mounted on two levers 8, is pivotable about an axis 9 extending parallel to wall panels 3 and 4. To open locking flap 7, it is pivoted upwards by a predetermined angular amount in the direction of arrow 10. It is closed by being pivoted downwards about axis 9 in the direction of arrow 11.
Locking flap 7 is arranged in such a manner that when opening 2 is blocked, it is positioned partly behind upper front wall panel 3 (see in particular the encircled region 12) and partly in front of the lower recessed wall panel 4 (see the encircled region 13). In upper region 14, facing the outside, and in lower region 15 also facing the outside, locking flap 7 is substantially cylindrically shaped. Between regions 14 and 15, the outer surface of locking flap 7 is provided with a substantially planar recess or indentation 16. The transition between cylindrical region 14 and recess or indentation 16 is designed as a step 17.
To match the pivotal range of locking flap 7, inner face 19 of upper protruding wall panel 3 is inclined towards the top and the inside, with a gap 18 being formed between locking flap 7 and inner face 19. As a result, a nose-shaped projection is formed in the region of lower edge 20 of the upper front wall panel above the transition between the cylindrical region 14 and substantially planar recess 16 with its step 17. When the locking flap 7 is opened by being pivoted upwards in the direction of arrow 10, the width of gap 18 between the outer elements of the locking flap 7 and inner face 19 of upper front wall panel 3 increases continually. The great advantage of this is that any ice formed in gap 18 is broken up and that jammed objects are not pulled farther inside the gap but are released, to be removed as the width of the gap increases.
As may be seen from FIG. 1 and the sectional arrangement of FIG. 3, lower edge 20, forming a nose-shaped projection above outer top region 14 of locking flap 7, and lower region 15 of locking flap 7, protruding over recessed wall panel 4, effectively repel any ingress of water.
To reliably seal locking flap 7 and outer surface 21 of the lower recessed wall panel, the shape of inner surface 22 of the lower portion of locking flap 7 is matched to outer surface 21 of wall panel 4, which extends downwards towards the outside. The structure is such that the bottom-most edge 23 is bound to come to rest against outer surface 21, so that reliable sealing is ensured in the extreme inclined position of about 25°, as shown in the left bottom position in FIG. 3.
FIG. 2 is a schematic isometric, partly sectional view of locking flap 7 without wall panels 3 and 4 and side elements 5 and 6. It may be seen that substantially planar recess or indentation 16 is positioned in the region of opening 2 (FIG. 1). To prevent any ingress of water in the regions below the side elements 5 and 6, locking flap 7 is provided with cylindrically shaped side elements 24 and 25 in those regions. Vertical grooves 26 and 27, respectively, are provided on the outboard sides of elements 24 and 25. By means of these grooves, any water entering via the cylindrical side elements 24 and 25 is discharged downwards. Such water is also discharged by small channels 28 (FIG. 1) provided in the side elements. As may be seen from FIG. 3, the side elements, in particular the inner portion of side elements 5 and 6 (see element 6, shown in FIG. 3 on the right), are substantially cylindrically shaped, thus mating with and sealing to cylindrically shaped elements 25 and 24, respectively, of locking flap 7.
With regard to FIG. 3, it has been mentioned that the wall-mount position is shown on the right. In that position, the face of locking means 1 is perpendicularly arranged, however it may be tilted to up to 25° from horizontal line 30, giving a functional range F. This second position is shown on the left in FIG. 3. In the illustrated example, the slope of outer surface 21 of lower recessed wall panel 4 is such that any fluid, such as rain water, is still reliably discharged.
The lower built-in position of FIG. 3 illustrates a further essential advantage of the locking means. If, for example, wind drives water from right to left, that position would be the most susceptible to leakage. As lower edge 23 of locking flap 7 rests against outer surface 21 of lower recessed wall panel 4 (not shown in the drawing), the lower region is reliably sealed. In addition, step 17 prevents any wind-driven water from entering the upper region of gap 18. It is clearly shown that when locking flap 7 is pivoted in the direction of arrow 10, gap 18 increases between inner face 19 of upper front wall panel 3 and locking flap 7.
As a result, any ice formed in gap 18 is broken up and jammed objects are automatically released.
A self-locking latch and actuator means 31 for pivoting a component to one of two positions will now be described with reference to FIGS. 4 to 8. The component to be pivoted is locking flap 7 of locking means 1 (shown in greater detail in FIGS. 1 to 3).
The actuator used to pivot component 7 is a reversible geared electromotor 32. A drive arm 34 is arranged on driven shaft 33 of motor 32. A pin 35 is fixed to the end of drive arm 34. When arm 34 is actuated, pin 35 moves along an arc 36. Pin 35 is fitted into a slot 37 provided in an actuating lever 38. Actuating lever 38 is pivotable about an axis 9. One side of lever 38 is engaged by the actuator through pin 35 in slot 37 and its other side is attached to pivotable component 7. Guide slot 37 is divided into two parts, 39 and 40. The first part 39 is designed such that its centerline lies substantially on arc 36 described by the movement pin 35. The advantage of this is that in the starting phase of motor 32, pin 35 is allowed to accelerate to the beginning of second part 40 of guide slot 37 while performing no displacement work on actuating lever 38.
Second part 40 of guide slot 37 is arranged relative to first part 39 at such an angle that pin-35 applies displacement force to the sides 41 and 42 of the second part 40 of guide slot 37 in a direction which is substantially perpendicular to pivotal radius 43.
Pivotal radius 43 represents a connecting line extending through pivot axis 9 of actuating arm 38 and substantially through the center of the locking flap 7 fixed thereto. The angle between first part 39 and second part 40 of guide slot 37 is chosen such that when actuating arm 38 is pivoted about its axis 9, the direction of force action is retained, i.e., it is substantially perpendicular to the pivotal radius 43. This force direction is retained until the displacement end position is reached. At the driving end of actuating lever 38, a component 44 is arranged which actuates a sensor 45 or 46 at its respective movement limits. The position of actuating lever 38 and pin 35 in guide slot 37, (FIG. 4), is the latched position. In this position, the opening between the wall panels 3 and 4 is closed by locking flap 7. If, for example, a force is applied to locking flap 7 in a direction from lower wall panel 4 to upper wall panel 3, the force action of the actuating lever 38 on pin 35 and its arm 34 is such that actuating lever 38 is prevented from moving.
FIG. 5 shows the same arrangement as FIG. 4, with actuator pin 35 assuming another position on arc 36 as a result of the pivotal motion of drive arm 34 of motor 32. This position is shown at the very point where parts 39 and 40 of guide slot 37 coincide. Pin 35 rests against side 41 of guide slot 37. As shown in FIG. 5, locking flap 7 is not yet removed from lower recessed wall panel 4. This means, that the opening, although still being closed is unlatched at this stage.
As drive arm 34 with its pin 35 is moved further along arc 36 in the direction of arrow 47, actuating arm 38 is pivoted.
FIG. 6 shows the same arrangement as FIGS. 4 and 5, but with the movable components assuming another position. Compared with FIGS. 4 and 5 and the sequence shown therein (from the latched to the unlatched position), FIG. 6 depicts pin 35 halfway along second part 40 of guide slot 37. For this purpose, pin 35, by being actuated by motor 32 and pivoting drive arm 34 in the direction of arrow 47, slides along arc 36 on side 41 of second part 40 of guide slot 37. In response, actuating lever 38 with its part 44, (for actuating the sensors), assumes a position roughly halfway between sensors 45 and 46. Subsequently, locking flap 7 is removed from lower wall panel 4, releasing half of the opening provided therein.
The arrangement of FIGS. 4, 5 and 6 is again shown in FIG. 7, but in an end position opposite to that of FIG. 4. Compared with FIG. 6, motor 32 has moved pin 35 with its drive arm 34 further along arc 36 in the direction of arrow 47. As a result, pin 35 resides in the second part of guide slot 37 and has moved to the end of that part, with drive arm 34 coming to rest against stop 52. Stop 52 may be made of a flexible material, so that the end position is reached smoothly. The end position is detected by part 44 of actuating lever 38 and associated sensor 46. In that position, actuating lever 38, by being pivoted about axis 9, moves locking flap 7 to a position where it is at a maximum distance from recessed wall panel 4. As a result, an opening is formed between the inner face 22 of the lower portion of locking flap 7 and lower edge 20 of upper front wall panel 3 on the one hand and top edge 49 of lower recessed wall panel 4 on the other. Inner face 48 of lower wall panel 4 is inclined, and locking flap 7 is provided with a face 50 on its inside. These two faces 48 and 50 form a chute through which items to be released, such as bank notes or statements of account, are reliably passed to the outside.
The operation of the locking means from the latched and/or closed position to the unlatched and fully opened position has been described above in the order of FIGS. 4 to 7 and with reference to the movement of drive arm 34 in the direction of arrow 47. During that phase, pin 35, by force transfer, acts on side 41 of part 40 of guide slot 37. When motor 32 is started, this sequence may be reversed, so that pin 35, from the position shown in FIG. 7 acts on side 42 of part 40 of guide slot 37, pivoting the actuating lever 38 in a direction causing the locking flap to be moved downwards in a closing direction about pivotal axis 9. This movement continues until pin 35 has been restored to the position shown in FIG. 5, in which the opening is already closed but not yet latched. By pivoting pin 35 from the position of FIG. 5 to the position of FIG. 4, the locking means is again latched.
To ensure that the end positions are reliably reached, electromotor 32 is controlled such that its current, once it has reached an end position, is switched off only after a certain increase in current has been detected. This occurs whenever pin 35 encounters resistance at the end of part 39 or 40 of guide slot 37, such as when drive arm 34 comes to rest against flexible stops such as those designated as 52 in FIG. 7. Sensors 45 and 46, which are used to detect the respective end position may be, for example, photosensors.
The arrangement shown in FIGS. 4 to 7 is inclined relative to the horizontal. This inclination substantially corresponds to an ergonometrically satisfactory built-in position of about 30° to 35° to the horizontal. As a result, any items fed through the opening to the outside or placed therein for removal can be readily removed.
FIG. 8 is a schematic rear top view of the arrangement shown in FIGS. 4 to 7. A carrier arm 53 is fixed to side element 5 which, as shown in particular in FIG. 1, links upper front wall panel 3 with lower recessed wall panel 4. Motor 32, whose shaft 33 moves drive arm 34 with pin 35 is fixed to carrier arm 53. Pin 35 is guided in guide slot 37 (not shown in FIG. 8). In response to the movement of pin 35 in the guide slot of actuating lever 38, the latter along with the attached locking flap is pivoted about axis 9. In addition to other components, not shown, sensor 45 is fixed to carrier arm 53. Component 44, arranged on the actuating lever 38, actuates sensor 45 in the respective end position. Carrier arm 53 is also provided with a stop 52 against which drive arm 34 rests in the full open position.
As can thus be seen locking means 1 enables water to be reliably repelled in different built-in positions. The formation of ice is either substantially avoided or any ice which is formed despite the indicated precautions, does not interfere with the operation of the locking means. This applies also to items that become jammed as a result of vandalism. The invention operates such that any jammed items are released as the width of the opening increases and they generally do not prevent the locking means from being opened. Needless to say, the power of the motor used for this purpose and the force at which an item is introduced into the flap are significant. The self-locking latch and actuator means has a simple design and may be used to particular advantage for the locking means according to the invention.
It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devices by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.
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A closure locking means for the opening of a self-service device, in particular an automatic teller machine includes a locking flap, the outside of which is indented. The locking flap, pivotable about an axis, is positioned behind a projecting upper wall panel and in front of a recessed wall panel. A gap is created when the locking flap is pivoted, and as the flap opens the width of the gap increases, so that any ice formed is broken up or jammed objects are released. A self-locking latch and actuator means for the locking flap uses an actuating lever which is pivotable about an axis. The actuating lever includes a shaped guide slot which is engaged by the actuator means. In a first part of the guide slot, no displacement work is performed by the actuator means, whereas in a second part, which is positioned at an angle to the first part, displacement work is performed to move the lever and locking flap.
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This application claims the benefit from the priority of Taiwan Patent Application No. 095146115 filed on Dec. 8, 2006, the disclosures of which are incorporated by reference herein in their entirety.
CROSS-REFERENCES TO RELATED APPLICATIONS
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a fluid delivering system and a fluid delivering kit. In particular, the invention relates to a fluid delivering system and kit which are adapted to deliver small quantities of fluid. The present invention is especially adapted for micro-equipments, such as fuel cells, for providing raw materials during operation.
2. Descriptions of the Related Art
In the chemical industry, fluids are frequently transported. In general, mechanical compression pumps, which have devices with reciprocating, diaphragm pressing, centrifuging or eccentrically rotating, are used as a source of pressure for transporting fluids. The pumps are usually disposed on the upstream end of the tube for elevating the pressure at the upstream end of the tube. The fluid is then delivered to the other end (downstream) of the tube which is at lower pressure. Unfortunately, this kind of system is bulky, noisy and high in energy consumption due to the use of the mechanical compressor pump for raising the pressure and converting electric energy into mechanical energy. Moreover, those pressure pumps always require sealing structures to prevent leakage. Thus, it turns into an issue for using the pumps to provide stable and quantitative delivery of small volume of liquid.
With technique improvements, various application devices have been gradually miniaturized. As a result, fluids need to be delivered in smaller quantities. For example, only a small quantity of methanol or methanol-water is needed for a reaction in a small fuel cell to generate electricity. In this situation, the delivery capability of the conventional mechanical pumps is far beyond the requirements, which is not suitable for delivering fluid in small quantity instead. Furthermore, when high technology products are designed with a lighter weight and slimmer size, the conventional mechanical pumps are too bulky for these products. In addition, conventional mechanical pumps are often fluctuated in volume delivering and energy consuming. Thus, a simple, quiet and low in energy consuming pump which is suitable for delivering small amount of fluids are needed in this field.
Recently, fluid delivering technologies have utilized the capillary action of the fluid to counteract the force of gravity on the fluid. However, the strength of the capillary action is still tied to gravity, surface tension, temperature of the fluid, fluid nature and the transporting environment. Moreover, when the pressure resistance downstream is higher, such as 0.5 to 1 atmospheric pressure or more, the capillary action is insufficient to drive the fluid.
As a result, the development of pumps for overcoming the abovementioned disadvantages of the conventional mechanical pumps in delivering small quantities of fluid becomes a serious challenge. The present invention provides a simple and economical manner to achieve the objective of transporting micro-fluids in a slim device.
SUMMARY OF THE INVENTION
The primary objective of this invention is to provide a fluid delivering system and a fluid delivering kit by using the vapor pressure of fluid as the source of the driving pressure. Vapor pressure is formed by applying a heat source to the system, so that a small quantity of fluids can be delivered.
Another objective of this invention is to provide a fluid delivering system and a fluid delivering kit without any moving component, and hence to achieve a silent delivery mechanism. An auxiliary liquid can be adequately added if necessary to boost up the vapor pressure to overcome potential back pressure resistance in the downstream or to allow a higher pressure operation in the downstream process. The auxiliary liquid is immiscible with the fluid to be delivered (FTBD). Preferably, the auxiliary liquid possesses a boiling point lower than that of the FTBD. Alternatively, the auxiliary liquid and the FTBD can form an azeotrope. Thus, when the heat source is provided, sufficient vapor pressure at a constant magnitude can be generated in the system to overcome the pressure resistance downstream in the tube and to provide constant pressure differential for delivering the fluid stably and steadily.
In comparison with the conventional mechanical pumps, the fluid delivering system and kit of the present invention are portable, slim, stable, quiet and low in energy consumption.
To achieve the abovementioned objectives, a fluid delivering system comprising a container, a heat source, and a delivery tube is provided. The container has a discharging aperture and a containing space for the FTBD, which is in a liquid state at room temperature. The heat source provides an elevated vapor pressure in the containing space by heating the FTBD. The delivery tube includes two ends in which one end connects to the containing space and the other end opens to the outside of the container. Thus, the FTBD partially vaporized in the container by the heat source forms the elevated vapor pressure which drives the FTBD out of the fluid delivering system through the delivery tube.
The present invention further discloses a fluid delivering kit, which comprises a container, a delivery tube and an auxiliary liquid. The auxiliary liquid is immiscible with the FTBD. The auxiliary liquid also possesses a boiling point lower than that of the FTBD or can form an azeotrope with the FTBD to generate the desired vapor pressure at a lower temperature. The auxiliary liquid can be at least partially vaporized in the containing space to form a stable upstream vapor pressure to drive the FTBD.
The detailed technology and preferred embodiments implemented for the subject invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a schematic view illustrating a preferred embodiment of the present invention;
FIG. 1B is a diagram showing the stable fluid delivery in a preferred embodiment of the present invention;
FIG. 2 is a schematic view illustrating another preferred embodiment of the present invention; and
FIG. 3 is a schematic view illustrating a hydrogen-oxygen fuel cell using the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the present invention is shown in FIG. 1A . The fluid delivering system 10 mainly comprises a container 11 , a heat source 13 and a delivery tube 15 . The container 11 has a discharging aperture 111 and a containing space. Preferably, the container 11 is pressure-resistant and corresponds to the operating conditions, such as operation temperature and the various fluids involved. The containing space is used to contain the fluid to be delivered (FTBD) 20 which is going to be delivered. The FTBD 20 is in a liquid state at room temperature. The delivery tube 15 is disposed through the discharging aperture 111 . When the fluid delivering system 10 is in operation, the container 11 is substantially sealed, with the exception of the delivery tube 15 which has a pathway leading out of the system. A portion of the FTBD 20 can be delivered out of the fluid delivering system 10 through the delivery tube 15 .
Specifically, the delivery tube 15 has a first end 151 and a second end 153 opposite to the first end 151 . The first end 151 opens into the bottom of the containing space of the container 11 . The FTBD 20 is guided from the first end 151 (the inlet end) through the delivery tube 15 to the second end 153 (the outlet end). Thus, a pathway is provided for the FTBD 20 to be stably discharged under pressure.
The heat source 13 is used to raise the temperature of the fluid, including the delivered FTBD 20 , in the container 11 for vaporizing the fluid and providing an elevated vapor pressure in the containing space. The vapor pressure can stably drive the FTBD 20 through the both the delivery tube 15 and discharging aperture 111 and out of the fluid delivering system 10 . It is noted that the temperature of the fluid does not to be continuously raised. The heat source only has to maintain the vapor pressure as the source of the driving pressure in the containing space.
In this embodiment, the manner of controlling the flowing speed of fluid delivery not only comprises temperature adjustments, but also uses a control element 17 , such as valves, which is disposed on the delivery tube 15 . The control element 17 is used to adjust the flowing speed of the FTBD 20 into the delivery tube 15 , such as controlling the flowing availability and the flow rate. For example, the control element 17 can be a metering valve, such as a needle valve. When the temperature is raised to a setting temperature, the control element 17 is then actuated to adjust the flow rate. Alternatively, a tubing with a small opening, such as a capillary tube with suitable length, can be used as the delivery tube for simultaneously controlling the flow rate. When the capillary tube is adopted, the control element 17 can be an ON-OFF simple valve.
During the operation, the FTBD 20 is partially vaporized, and a portion of the FTBD 20 in the liquid state is discharged out of the system. Therefore, there are less FTBD 20 in the container 11 . For operation convenience in the system 10 , the FTBD 20 should be supplied into the container 11 . Thus, a filling aperture 113 should be disposed on the container 11 . Furthermore, because the fluid delivering system 10 should be substantially sealed during the operation, a cover 115 is disposed to seal the filling aperture 113 if necessary. For example, the container 11 can communicate with a reservoir (not shown in the figures), which is filled with the fluid, through the filling aperture 113 . Accordingly, the fluid in the reservoir can be fed into the container 11 by using a simple and cheap pump or with the use of gravitation force from being disposed at a higher place. The reservoir can also be detached from the container 11 when the supplement is accomplished, or be replaced with a fresh one with full volume of the fluid, thus to facilitate supplying the FTBD 20 into the container 11 . In this way, the size and cost of the container 11 can be reduced. Since the delivery tube 15 and the filling aperture 113 with the cover 115 are independently disposed on the container 11 as shown in FIG. 1A , the delivery tube 15 can alternatively be disposed on the cover 115 for providing similar benefits. Those skilled in the art should understand without further descriptions.
The heat source 13 that is directly or indirectly providing heat to the system can vary. The heat source 13 as shown in FIG. 1A directly heats the FTBD 20 whereas the heat source 13 as shown in FIG. 2 indirectly heats the FTBD 20 . For example, the heat source 13 can use the surplus heat generated from the adjacent heat generating element. More specifically, as indicated by the arrows shown in FIG. 2 , in an indirect heating manner, the heat source 13 heats the container 11 so as to vaporize the FTBD 20 to generate a vapor pressure in the container 11 . The heat source 13 can be a high-temperature gas, or even a fluid delivering system 10 disposed in the environment with high temperatures for raising the temperature of the FTBD 20 . Thus, the surplus heat or water with high temperature generated from various electric appliances, vehicles or factories, for example, can be reused. Alternatively, the heat source 13 can be selected from a group consisting of thermocouple wires, heating bands, electric heaters, hot baths, hot gases, and combinations thereof, wherein hot gases include the exhausted gases generated during the operation of equipments or the gases generated from chemical reactions. Those skilled in the art can substitute the heat source 13 using any conventional technique that is not limited herein. Thus, the FTBD 20 in the container 11 can be partially vaporized to provide the needed vapor pressure.
In actuality, the heat needed for elevating the vapor pressure is not that much due to the small fluid delivering system 10 . For example, heat from an electric apparatus, chemical reactions or combustion can be used to heat the fluid delivering system 10 of the present invention. The FTBD 20 can be, but is not limited to, water, methanol and/or ethanol. The FTBD 20 can also be gasoline or diesel fuel.
The delivering system of the present invention can be utilized to stably deliver a fluid. A container, having a delivery pipe with a metering valve and containing 100 ml methanol, was disposed in hot baths for being gradually heated, wherein the container was equipped with a thermal couple and a pressure meter for recording the temperature of the methanol and pressure inside the container. The capacity of the container was 160 ml. Referring to FIG. 1B , the curve line presents the temperature of the methanol and the bars presents the flow rate of the discharged methanol. As shown in FIG. 1B , methanol started to be discharged as its temperature was raised above 65° C. When the temperature of methanol was gradually raised, the vapor pressure inside the container was also elevated. With the adjustment of the metering valve, methanol was delivered by the above described fluid delivering system at a rate of approximately 0.5 c.c./min stably and steadily.
Another preferred embodiment of the present invention is shown in FIG. 2 . In addition, the auxiliary liquid 30 , which is immiscible with the FTBD 20 , can be added into the containing space. It is preferred for the auxiliary liquid 30 to possess a boiling point lower than that of the FTBD 20 . When the heat source 13 is applied, the temperatures of the FTBD 20 and the auxiliary liquid 30 are raised. Because the auxiliary liquid 30 possesses a lower boiling point, it will be vaporized prior to the FTBD 20 and will elevate the auxiliary vapor pressure in the containing space for delivering the FTBD 20 . The auxiliary liquid 30 can boost up the vapor pressure to overcome potential back pressure resistance in the downstream or to allow a higher pressure operation in the downstream process. In choosing the auxiliary liquid 30 , the liquid should either have lower boiling point and be immiscible with the FTBD 20 or, preferably, have a gravity smaller than that of the FTBD 20 to float above the FTBD 20 without being delivered along with it. If the gravity of auxiliary liquid 30 is larger than that of the FTBD 20 , the inlet end of the delivery tube 15 should be disposed slightly above the bottom of the container 11 . Another preferred option for the auxiliary liquid 30 can be one that forms an azeotrope with the FTBD 20 . Because the azeotrope has a boiling point lower than that of the FTBD 20 and the auxiliary liquid 30 , it will facilitate the formation of vapor pressure in the container 11 for delivering the FTBD 20 .
For example, in one situation, an auxiliary liquid 30 with high volatility such as pentane, cyclopentane, hexane, and/or cyclohexane can be adopted, while the FTBD 20 is methanol and/or ethanol. In another situation, an auxiliary liquid such as methanol, isopropanol, and/or dichloromethane can be adopted, while the FTBD 20 is gasoline or diesel fuel. Since the gravity of dichloromethane is larger, the first end 151 of the delivery tube 15 should not be touching the bottom of the container 11 so as to prevent the auxiliary liquid 30 from being discharged out of the system. The following examples illustrate the FTBD 20 and the auxiliary liquid 30 forming an azeotrope:
the fluid to
azeotropic
be delivered (FTBD)
the auxiliary liquid
temperature (° C.)
water (H 2 O)
pentane (C 5 H 12 )
34.6
methanol (CH 3 OH)
pentane (C 5 H 12 )
30.9
methanol (CH 3 OH)
cyclopentane (C 5 H 10 )
38.8
methanol (CH 3 OH)
hexane (C 6 H 14 )
50.6
methanol (CH 3 OH)
cyclohexane (C 6 H 12 )
54.2
For example, when the FTBD 20 is methanol and the auxiliary liquid 30 is pentamethylene, the azeotropic temperature can be lowered to 38.8° C. Similarly, when the FTBD 20 is methanol and the auxiliary liquid 30 is pentane, the azeotropic temperature can be lowered to 30.9° C. By using the aforesaid azeotropic temperatures that are close to room temperature and are more applicable by applying a general heating manner, the practice threshold can be effectively lowered.
In actuality, due to the slim fluid delivering system 10 of the present invention, only a few of the auxiliary liquid 30 is needed in the containing space of the container 11 . In comparison with the quantity of the FTBD 20 in the container 11 , the quantity of the added auxiliary liquid 30 is relatively low and does not effect the concentration of the FTBD 20 substantially. For example, assume that a fluid delivering system 10 has a container 11 with a 1 liter containing space, the FTBD 20 is methanol, the auxiliary liquid 30 is pentane (C 5 H 12 ), and the azeotrope is vaporized to generate a pressure of 2 atmA in the container 11 . The azeotrope vapor should approximately be 0.08 mole to fill the containing space at the boiling temperature of the azeotrope (i.e. 30.9° C.) according to the ideal gas equation (PV=nRT). Because methanol is 14.5% of the azeotrope and pentane is 85.5% of the azeotrope, i.e. 0.0684 moles, only about 5 grams of pentane is enough. Furthermore, the vaporized methanol is much less than the total methanol in the container 11 , and thus, the contents of the FTBD 20 are not affected when it is mixed. If the containing space is 1 liter and with the consideration that the vapor pressure needs to be higher than 2 absolute atmospheres for delivering the FTBD and a portion of unvaporized auxiliary liquid 30 is inevitably discharged out of the system, the added pentane should approximately be 5 to 10 grams. With respect to a system with the containing space filled with FTBD, pentane is only a very small percentage of the discharged fluid. Furthermore, the formed azeotrope will contain less than 0.37 grams of methanol. In other words, most of the initially added methanol will be no longer remaining in the system.
Other implements derived from the present invention should be part of the general concept of the present invention. For example, another preferred embodiment of the present invention disclosed herein is a fluid delivering kit. The fluid delivering kit comprises the container 11 , the delivery tube 15 and the auxiliary liquid 30 described hereinbefore. Upon assembling the parts, the kit can be used to deliver fluids. When the user starts to operate this fluid delivering kit, the auxiliary liquid 30 can be added into the containing space before, simultaneously, or after the FTBD 20 is added into the containing space. After the auxiliary liquid 30 is at least partially vaporized by heating, the auxiliary vapor pressure can be formed in the containing space for providing at least a partial driving pressure to deliver the FTBD.
Similarly, the fluid delivering kit disclosed in this embodiment can also comprise the abovementioned control element 17 , filling aperture 113 and cover 115 which are not further described herein.
For verifying the effects of the present invention, a simple experiment was performed as follows. A pot made of stainless steel with an outer diameter of 60 mm, and a height of 75 mm was filled with 120 milliliter of water and was be disposed in a sink as a hot bath. The pot was also disposed with a pressure gauge, a thermometer, and a 1/16 inch capillary outlet for measuring fluid delivery.
First, the system was heated from room temperature. The measured temperature, pressure and flowing variation was shown in Table 1. As the result, when the temperature was at 88° C., the pressure was at 1.7 atmA. At the same time, the fluid flow rate from the pot was about 0.32 grams per minute.
Moreover, another similar experiment was conducted. This time, the pot was filled with 120 milliliter of water, with 1 milliliter of pentane as the auxiliary liquid. Similarly, the system was heated from room temperature with being measured in temperature, pressure and flowing variation. As a result, when the water temperature was 46° C., the vapor pressure was 1.7 atmA. The fluid flowing rate from the pot was about 0.33 grams per minute. Likewise, when the water temperature was at 70 degrees centigrade, the vapor pressure was 2.5 atmA and the fluid flowing rate was about 0.79 grams per minute. In all cases, a micro-delivery needs not a very high temperature, and the delivering efficiency can be enhanced with the addition of little amount of adequate auxiliary liquid.
TABLE 1
water (120 c.c.)
water (120 c.c.) + pentane (1 cc)
temperature
pressure
flow rate
temperature
pressure
flow rate
(° C.)
(atmA)
(g/min)
(° C.)
(atmA)
(g/min)
40
1.0
—
29
1.1
—
55
1.1
—
33
1.3
—
61
1.2
—
36
1.5
—
68
1.3
—
46
1.7
0.33
72
1.4
—
50
1.9
—
75
1.5
—
56
2.1
0.60
83
1.6
—
63
2.3
—
88
1.7
0.32
70
2.5
0.79
According to the abovementioned fluid delivering system, kit and method for enhancing the fluid delivery, either the vapor pressure elevated by the fluid itself or a vapor pressure generated from an auxiliary liquid added thereto can drive the FTBD after the fluid is heated. The present invention is especially suitable for deliver fluids in micro-quantities. The present invention can deliver a micro-quantity of FTBD with the use of heat available from the environment and without the need of an additional pump. The product of the present invention is portable, slim, consumes little energy and is suitable for many applications in liquid delivery.
FIG. 3 shows the structure of a hydrogen generator of a hydrogen fuel cell applying the present invention for delivering methanol-water to generate hydrogen. In FIG. 3 , a methanol container a 1 , a methanol-water container a 2 , and a reaction zone a 3 are illustrated. The methanol container a 1 further comprises a methanol filling assembly (including a filling aperture and a cover), while the methanol-water container a 2 further comprises a methanol-water filling assembly (including a filling aperture and a cover). A methanol-water delivering tube a 22 is disposed to connect the methanol-water container a 2 and the reaction zone a 3 . A needle valve a 23 is further disposed on the methanol-water delivering tube a 22 .
In this embodiment, air can be introduced into the methanol container a 1 through the air inlet a 12 by a micro-compressor or a blower (not shown in the figures). Subsequently, methanol is carried into the oxidation catalyst a 31 to perform an oxidation-combustion reaction. The heat generated from the reaction can not only raise the temperature of the reaction zone a 3 but also raise the temperature of the methanol-water container a 2 . Thus, vapor pressure is elevated in the methanol-water container a 2 to deliver the methanol-water from the methanol-water container a 2 to the reaction zone a 3 through the methanol-water delivering tube a 22 and the needle valve a 23 . The methanol-water then performs a steam reforming reaction in the reaction zone a 3 , and generates hydrogen for the fuel cell. When the hydrogen fuel cell is applied to electric products, such as laptops, the abovementioned micro-compressor or the blower can use the existing facilities in the electric products. Thus, a small quantity of methanol-water can be stably delivered without additional pumps.
The performing results of the assembly shown in FIG. 3 are illustrated as below. For portability, the system was designed in a size of only 1000 cubic centimeters, i.e., of the same volume as a cube with 10 cm edges. Heat generated from the methanol oxidation-combustion raised the temperature of the reaction zone a 3 from room temperature to 260 degrees centigrade in approximate 5 minutes, and raised the temperature of methanol-water container a 2 as well. When the temperature of the reaction zone a 3 reached the reaction temperature, the needle valve a 23 was adjusted to control the flow rate of the methanol-water to the reaction zone a 3 for generating hydrogen.
1. Temperature raising period in the reaction zone: 5 minutes (to 280° C.);
2. Methanol-water consumption: 0.36 gram/minute;
3. Methanol consumption in initial: 0.05 gram/minute;
4. Initial temperature of the methanol-water container: 47° C.;
5. Operating temperature and pressure of the methanol-water container: 62° C., 7 psig;
6. Water/methanol (mole ratio) in the methanol-water container=1.2
7. Yield of hydrogen: 30 liter/hour
8. Product combination in the reaction zone: as shown in Table 2.
TABLE 2
reforming products
methanol-water
composition (%)
temperature (° C.)
converting ratio (%)
H 2
CO
CO 2
280
100%
75.17
0.89
23.94
290
100%
73.99
1.43
24.59
The above disclosure is related to the detailed technical contents and inventive features of the present invention. People skilled in this field may proceed with a variety of modifications and replacements based on the disclosures and suggestions of the invention as described without departing from the characteristics thereof. Nevertheless, although such modifications and replacements are not fully disclosed in the above descriptions, they have substantially been covered in the following claims as appended.
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A portable fluid delivering system is provided. The system comprises a container, a heat source, a flow rate regulating device and a delivery tube. The container has a containing space for a fluid to be delivered, in a liquid state at room temperature. The heat source provides an elevated vapor pressure in the containing space over the fluid to be delivered, whereby the fluid to be delivered is driven at a desirable rate along the delivery tube.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 09/844,232, filed Apr. 27, 2001 now U.S. Pat. No. 6,915,006, which is a continuation-in-part of application Ser. No. 09/351,892, filed Jul. 13, 1999 now U.S. Pat. No. 6,862,365, which is a continuation-in-part of application Ser. No. 09/008,243, filed Jan. 16, 1998, now issued as U.S. Pat. No. 6,072,898. The application Ser. No. 09/844,232, application Ser. No. 09/351,892, and U.S. Pat. No. 6,072,898 are incorporated by reference herein, in their entireties, for all purposes.
NOTICE REGARDING COPYRIGHT
A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
This invention relates to a method and apparatus for three dimensional inspection and, more particularly, a method and apparatus for three dimensional inspection of solder balls on ball grid arrays and solder bumps on wafer and die, and to a calibration method.
BACKGROUND OF THE INVENTION
Prior art three dimensional inspection systems have involved laser range finding technology, moire interferometry, structured light patterns or two cameras. The laser range finding method directs a focused laser beam onto the Ball Grid Array, BGA, and detects the reflected beam with a sensor. Elements of the BGA are determined in the X, Y and Z dimensions utilizing a triangulation method. This method requires a large number of measurement samples to determine the dimensions of the BGA resulting in longer inspection times. This method also suffers from specular reflections from the smooth surfaces of the solder balls resulting in erroneous data.
Moire interferometry utilizes the interference of light waves generated by a diffraction grating to produce a pattern of dark contours on the surface of the BGA. These contours are of known distance in the Z dimension from the diffraction grating. By counting the number of contours from one point on the BGA to another point on the BGA, the distance in the Z dimension between the two points can be determined. This method suffers from the problem of low contrast contour lines resulting in missed counting of the number of contours and resulting in erroneous data. This method also suffers from the contour lines merging at surfaces with steep slopes, such as the sides of the balls on the BGA, resulting in an incorrect count of the number of contours and resulting in erroneous data.
Structured light systems project precise bands of light onto the part to be inspected. The deviation of the light band from a straight line is proportional to the distance from a reference surface. The light bands are moved across the part, or alternately the part is moved with respect to the light bands, and successive images are acquired. The maximum deviation of the light band indicates the maximum height of a ball. This method suffers from specular reflections due to the highly focused nature of the light bands resulting in erroneous data. This method further suffers from increased inspection times due to the number of images required.
Two camera systems utilize one camera to view the BGA device in the normal direction to determine X and Y dimensions and the second camera to view the far edges of the balls from an angle. The two images are combined to determine the apparent height of each ball in the Z dimension utilizing a triangulation method. This method suffers from the need for a higher angle of view of the ball from the second camera resulting in looking at a point significantly below the top of the ball for BGA's having fine pitch. This method also suffers from limited depth of focus for the second camera limiting the size of BGA's that can be inspected. This system can only inspect BGA's and not other device types such as gullwing and J lead devices.
The prior art does not provide two separate and opposite side views permitting larger BGA's to be inspected or nonlinear optics to enhance the separation between adjacent ball images in the side perspective view.
It is therefore a motivation of the invention to improve the accuracy of the measurements, the speed of the measurements, the ability to measure all sizes and pitches of BGA's and to measure other devices including gullwing and J lead parts in a single system.
SUMMARY OF THE INVENTION
The invention provides an apparatus for three dimensional inspection of an electronic part, wherein the apparatus is calibrated using a precision pattern mask with dot patterns deposited on a calibration transparent reticle, the apparatus for three dimensional inspection of an electronic part comprising a camera and an illuminator for imaging the electronic part, the camera being positioned to obtain a first view of the electronic part, a means for light reflection positioned to reflect a different view of the electronic part into the camera, wherein the camera provides an image of the electronic part having differing views of the electronic part, and a means for image processing the image of the electronic part that applies calculations on the differing views of the image to calculate a three dimensional position of at least one portion of the electronic part.
The invention further comprises a ring light. The means for light reflection could further comprise a mirror, a prism, or a curved mirror. The electronic part may be a ball grid array, balls on a wafer, or balls on a die.
The means for imaging provides the image to a frame grabber board. The frame grabber board provides an image data output to a processor to perform a three dimensional inspection of the part.
The apparatus may further comprise a nonlinear optical element to magnify the second image in one dimension. In the apparatus a maximum depth of focus of a side perspective view allows for a fixed focus system to inspect larger electronic parts, with one perspective view imaging one portion of the electronic part and a second perspective view imaging a second portion of the electronic part. Also, in the apparatus a maximum depth of focus of a side perspective view includes an area of the electronic part including a center row of balls. Furthermore, all of the balls on the electronic part may be in focus resulting in two perspective views for each ball.
The invention comprises a means for inspecting gullwing and J lead devices.
The invention further provides a method for three dimensional inspection of a lead on a part, the method comprising the steps of using a camera to receive an image of the lead, transmitting the image of the lead to a frame grabber, providing fixed optical elements to obtain a side perspective view of the lead, transmitting the side perspective view of the lead to the frame grabber, operating a processor to send a command to the frame grabber to acquire images of pixel values from the camera, and processing the pixel values with the processor to calculate a three dimensional position of the lead. State values may be determined from the part itself.
The lead may be a curved surface lead, a ball, a ball grid array, a formed wire, a stamped metal form or similar object that can be imaged from two separate directions.
The processor processes the pixel values to find a rotation, an X placement value and a Y placement value of the part relative to world X and Y coordinates by finding points on four sides of the part.
The invention further provides the steps of using a part definition file that contains measurement values for an ideal part, calculating an expected position for each lead of the part for a bottom view using the measurement values from the part definition file and the X placement value and Y placement value.
The invention further provides the step of using a search procedure on the image data to locate the lead.
The invention further provides the step of determining a lead center location and a lead diameter in pixels and storing the lead center location and lead diameter in memory.
The invention further provides the step of calculating an expected position of a center of each lead in both side perspective views in the image using a known position of each side view from calibration.
The invention further provides the step of using a subpixel edge detection method to locate a reference point on each lead.
The invention further provides the step of converting the pixel values into world locations by using pixel values and parameters determined during calibration wherein the world locations represent physical locations of the lead with respect to world coordinates defined during calibration.
The invention further provides for the calculation of a Z height of each lead in world coordinates in pixel values by combining a location of a center of a lead from a bottom view with a reference point of the same lead from a side perspective view.
The invention further provides the step of converting the world values to part values using the rotation, the X placement value and the Y placement value to define part coordinates for the ideal part where the part values represent physical dimensions of the lead including lead diameter, lead center location in X part and Y part coordinates and lead height in Z world coordinates.
The invention further provides the step of comparing ideal values defined in the part file to calculate deviation values that represent a deviation of the center of the lead from its ideal location. The deviation values may include lead diameter in several orientations with respect to the X placement value and Y placement value, lead center in the X direction, Y direction and radial direction, lead pitch in the X direction and Y direction and missing and deformed leads, further comprising the step of calculating the Z dimension of the lead with respect to the seating plane based on the Z world data.
The invention further provides the step of comparing the deviation values to predetermined tolerance values with respect to an ideal part as defined in the part definition file to provide a lead inspection result.
Electronic components are produced according to manufacturing methods that provide for three dimensional inspection of the electronic components.
BRIEF DESCRIPTION OF THE DRAWINGS
To illustrate this invention, preferred embodiments will be described herein with reference to the accompanying drawings.
FIG. 1A shows the apparatus of the invention for system calibration.
FIGS. 1 B 1 , 1 B 2 , and 1 B 3 show an example calibration pattern and example images of the calibration pattern acquired by the system.
FIG. 2A shows a flow chart of a method of the invention used for calibration of the bottom view.
FIG. 2B shows a flow chart of a method of the invention used for determining the state values, and the X and Y world coordinates, of the bottom view of the system.
FIG. 2C shows a flow chart of a method of the invention used for calibration of the side perspective views.
FIG. 2D shows a flow chart of a method of the invention used for determining the state values of the side perspective views of the system.
FIG. 2E shows the relationship of a side perspective angle to the ratio of the perspective dimensions to the non-perspective dimensions.
FIGS. 2 F 1 and 2 F 2 show a bottom view and a side perspective view of precision dots used in the method for determining a side perspective view angle.
FIG. 3A shows the apparatus of the invention for part inspection.
FIGS. 3 B 1 , 3 B 2 , and 3 B 3 show example images of a part acquired by the system.
FIG. 4 shows a method of the invention for the three dimensional inspection of balls on a ball grid array.
FIGS. 5A and 5B together show a flow chart of the three dimensional inspection method of the invention.
FIGS. 6A and 6B show an example ball of a ball grid array and associated geometry used in a method of the invention for determining the Z position of the ball.
FIG. 7A shows one example of an image used in the grayscale blob method of the invention.
FIG. 7B shows one example of an image used with the method of the invention to perform a subpixel measurement of the ball reference point.
FIG. 8A shows a side perspective image of the calibration pattern magnified in one dimension.
FIG. 8B shows a side perspective image of the balls on a BGA, magnified in one dimension.
FIG. 9 shows an apparatus for presenting a BGA for inspection.
FIGS. 10A and 10B show an example ball of a ball grid array with associated geometry as used with a method of the invention for determining the Z position of a ball using two side perspective views.
FIG. 11A shows the apparatus of the invention for system calibration, utilizing a single side perspective view.
FIGS. 11 B 1 , 11 B 2 , and 11 B 3 show an example calibration pattern and example images of a calibration pattern acquired by the system, utilizing a single side perspective view, of the invention.
FIG. 12A shows the apparatus of the invention for ball inspection utilizing a single side perspective view.
FIGS. 12 B 1 , 12 B 2 , and 12 B 3 show an example ball grid array and example images of the ball grid array for three dimensional inspection, utilizing a single side perspective view.
FIG. 13 shows the apparatus of the invention for the three dimensional inspection of ball grid array devices, gullwing devices and J lead devices.
FIG. 14 shows the apparatus of the invention for the three dimensional inspection of parts utilizing three cameras.
FIG. 15 shows the apparatus of the invention configured with a calibration reticle 1020 for use during calibration of the state values of the system.
FIGS. 16A and 16B show an example calibration pattern and example images of the calibration pattern acquired by the single camera system.
FIG. 17 shows the apparatus of the invention configured with a part 1040 to be inspected by the system.
FIGS. 18A and 18B show a part and example images of a part acquired by the system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In one embodiment of the invention, the method and apparatus disclosed herein is a method and apparatus for calibrating the system by placing a pattern of calibration dots of known spacing and size on the bottom plane of a calibration reticle. From the precision dots the missing state values of the system are determined allowing for three dimensional inspection of balls on ball grid array devices, BGA devices or balls on wafers or balls on die. In one embodiment of the invention the system may also inspect gullwing and J lead devices as well as ball grid arrays.
Refer now to FIG. 1A which shows the apparatus of the invention configured with a calibration reticle for use during calibration of the state values of the system. The apparatus obtains what is known as a bottom image 50 of the calibration reticle 20 . To take the bottom image 50 the apparatus includes a camera 10 with a lens 11 and calibration reticle 20 with a calibration pattern 22 on the bottom surface. The calibration pattern 22 on the reticle 20 comprises precision dots 24 . The camera 10 is located below the central part of the calibration reticle 20 to receive an image 50 described in conjunction with FIGS. 1 B 1 , 1 B 2 , and 1 B 3 . In one embodiment the camera 10 comprises an image sensor. The image sensor may be a charged coupled device array. The camera 10 is connected to a frame grabber board 12 to receive the image 50 . The frame grabber board 12 provides an image data output to a processor 13 to perform a two dimensional calibration as described in conjunction with FIG. 2A . The processor 13 may store an image in memory 14 . The apparatus of the invention obtains an image of a pair of side perspective views and includes using a camera 15 with a lens 16 and a calibration reticle 20 . The camera 15 is located to receive an image 60 , comprising a pair of side perspective views, described in conjunction with FIGS. 1 B 1 , 1 B 2 , and 1 B 3 . Fixed optical elements 30 , 32 and 38 provide a first side perspective view and fixed optical elements 34 , 36 , 38 for a second side perspective view. The fixed optical elements 30 , 32 , 34 , 36 and 38 may be mirrors or prisms. As will be appreciated by those skilled in the art additional optical elements may be incorporated. The camera 15 is connected to a frame grabber board 17 to receive the image 60 . The frame grabber board 17 provides an image data output to a processor 13 to perform a two dimensional inspection as described in conjunction with FIG. 2B . The processor 13 may store an image in memory 14 . In one embodiment of the invention, the apparatus may contain a nonlinear optical element 39 to magnify the side perspective image 60 in one dimension as shown in FIG. 8A . In another embodiment of the invention optical element 38 may be a nonlinear element. The nonlinear optical elements 38 and 39 may be a curved mirror or a lens.
FIGS. 1 B 1 , 1 B 2 , and 1 B 3 show an example image 50 from camera 10 and an example image 60 from camera 15 acquired by the system. The image 50 , a bottom view of dot pattern 22 , shows dots 52 acquired by camera 10 . The dot pattern contains precision dots 24 of known dimensions and spacing. The precision dots 24 are located on the bottom surface of the calibration reticle 20 . The image 60 shows two side perspective views of the dot pattern 22 . A first side perspective view in image 60 contains images 62 of dots 24 and is obtained by the reflection of the image of the calibration reticle dot pattern 22 off of fixed optical elements 30 , 32 and 38 into camera 15 . A second side perspective view in image 60 contains images 66 of dots 24 and is obtained by the reflection of the image of the calibration reticle dot pattern 22 off of fixed optical elements 34 , 36 and 38 into camera 15 .
Optical element 36 is positioned to adjust the optical path length of a second side perspective view to equal the optical path length of a first side perspective view. Those skilled in the art will realize that any number of perspective views can be utilized by the invention. In one embodiment of the invention, the maximum depth of focus of a side perspective view includes an area of the reticle including the center row of dots. This allows for a fixed focus system to inspect larger parts, with one perspective view imaging half of the part and the second perspective view imaging the other half of the part.
FIG. 2A shows a flow diagram for the calibration of the bottom view of the system. The method starts in step 101 by providing a transparent reticle 20 having a bottom surface containing a dot pattern 22 , comprising precision dots 24 of known dimensions and spacing. The method in step 102 provides a camera 10 located beneath the transparent reticle 20 to receive an image 50 . In step 103 the processor 13 sends a command to a frame grabber 12 to acquire an image 50 , comprising pixel values from the camera 10 . The method then proceeds to step 104 and processes the pixel values with a processor 13 .
FIG. 2B shows a flow diagram for determining the state values of the bottom view of the system. In step 111 the method begins by finding the dots 52 in image 50 , corresponding to the calibration dots 24 . The processor finds a dimension and position for each dot visible in image 50 in subpixel values using well known grayscale methods and stores these values in memory 14 . By comparing these results to known values stored in memory, the processor calculates the missing state values for the bottom calibration in steps 112 and 113 . In step 112 the processor 13 calculates the optical distortion of lens 11 and the camera roll angle with respect to the dot pattern 22 . Step 113 calculates the pixel width and pixel height by comparing the subpixel data of dots 52 with the known dimensions of the precision dot pattern 22 . The pixel aspect ratio is determined from the pixel width and pixel height. In step 114 the processor defines the X and Y world coordinates and the Z=0 plane from the image 50 of the precision dot pattern 22 . The processor then stores these results in memory. These results provide conversion factors for use during analysis to convert pixel values to world values.
FIG. 2C shows a flow diagram for the calibration of the side perspective views of the system. The method starts in step 121 by providing a transparent reticle 20 having a bottom surface containing a dot pattern 22 , comprising precision dots 24 of known dimensions and spacing. The method in step 122 provides fixed optical elements 30 , 32 , 34 , 36 and 38 to reflect two perspective images of the precision dot pattern 22 into camera 15 . The method in step 123 provides a camera 15 located to receive an image 60 . In step 124 the processor 13 sends a command to a frame grabber 12 to acquire an image 60 , comprising pixel values from the camera 15 . The method then proceeds to step 125 and processes the pixel values with a processor 13 .
FIG. 2D shows a flow diagram for determining the state values of the side perspective views of the system. In step 131 the method begins by finding dots 62 in image 60 , corresponding to the calibration dots 24 . The processor finds a dimension and position for each dot visible, comprising the group of dots 62 , in image 60 for a first side perspective view in subpixel values and stores these values in memory 14 . By comparing these results to known values stored in memory, the processor calculates the missing state values for a side perspective view, comprising the group of dots 62 , in steps 132 and 133 . In step 132 the processor 13 calculates the optical distortion of lens 16 and the camera roll angle with respect to the dot pattern 22 . In step 133 the processor 13 calculates the pixel width and pixel height by comparing the subpixel data of dots 62 with the known dimensions of the precision dots 24 . The pixel aspect ratio is determined from the pixel width and pixel height. In step 134 the processor defines the X and Y world coordinates and the Z=0 plane from the dots 62 in image 60 of the dot pattern 22 . The processor then stores these results in memory. These results provide conversion factors for use during analysis to convert pixel values to world values. In step 135 the method of the invention computes the side view angle. In step 136 the method is repeated for a second side perspective view using the dots 66 in image 60 .
FIG. 2E shows the relationship of a side perspective angle to the ratio of the perspective dimension to the non-perspective dimension. Ray 171 , 172 , and 173 defining point 181 is parallel to ray 174 , 175 and 176 defining point 182 . Point 181 and point 182 lie on a plane 170 parallel to a plane 180 . The intersection of ray 175 and ray 176 define point 186 . The intersection of ray 176 and ray 172 define point 184 . The intersection of ray 173 and ray 172 define point 187 . The intersection of ray 174 and ray 172 define point 183 . The reflecting plane 179 intersecting plane 180 at an angle D is defined by ray 172 and ray 175 and the law of reflectance. Ray 172 and ray 175 intersect plane 170 at an angle 177 . Referring to FIG. 2E it can be shown:
tan θ= C/D B C /sin A=L /sin A Therefore: C=L cos θ= D S /L=D S /C C=D S /cos θ
Substituting:
tan θ=( D S /cos θ)/ D B =D S /D B cos θ (tan θ)(cos θ)= D S /D B =sin θ θ=arcsin( D S /D B )
FIGS. 2 F 1 and 2 F 2 show a bottom view and a side perspective view of precision dots used in the method for determining a side perspective view angle 177 as shown in FIG. 2E of the system. A bottom view image 200 comprising precision dots 201 , 202 and 203 of known spacing and dimensions from the calibration method described earlier can be used to provide a reference for determination of a side perspective view angle 177 . The value D H and D B are known from the bottom view calibration. A side perspective view image 210 comprising precision dots 211 , 212 and 213 , corresponding to bottom view dots 201 , 202 and 203 respectively, of known spacing and dimensions D s and D h from the calibration method described earlier, can be used to determine the side view perspective angle. The ratio of (D h /D H ) from the bottom image 200 and the side perspective image 210 can be used in the bottom view to calibrate DB in the same units as the side perspective view as follows:
D Bcal =D B ( D h /D H )
Substituting into the equation for the side perspective view angle 177 described earlier yields:
θ=arcsin( D S /D B )=arcsin( D S /D Bcal )
θ=arcsin( D S D H /D B D h )
FIG. 3A shows the apparatus of the invention for a three dimensional inspection of the balls of a ball grid array. The apparatus of the invention includes a part 70 to be inspected. The apparatus further includes a camera 10 with a lens 11 , located below the central area of part 70 , to receive a bottom image 80 , described in conjunction with FIGS. 3 B 1 , 3 B 2 , AND 3 B 3 , of part 70 . The camera 10 is connected to a frame grabber board 12 to receive the image 80 . The frame grabber board 12 provides an image data output to a processor 13 to perform a two dimensional inspection as described in conjunction with FIG. 3A . The processor 13 may store an image in memory 14 . The apparatus of the invention obtains an image of a pair of side perspective views with a camera 15 and a lens 16 . The camera 15 is located to receive an image 90 , comprising a pair of side perspective views, described in conjunction with FIGS. 3 B 1 , 3 B 2 , and 3 B 3 and utilizing fixed optical elements 30 , 32 and 38 for a first side perspective view and fixed optical elements 34 , 36 and 38 for a second side perspective view. In one embodiment of the invention, the apparatus may contain a nonlinear optical element 39 to magnify the side perspective image 60 in one dimension as shown in FIG. 8B . In another embodiment of the invention optical element 38 may be the nonlinear element. The fixed optical elements 30 , 32 , 34 , 36 and 38 may be mirrors or prisms. As will be appreciated by those skilled in the art additional optical elements may be incorporated without deviating from the spirit and scope of the invention. The camera 15 is connected to a frame grabber board 17 to receive the image 90 . The frame grabber board 17 provides an image data output to a processor 13 to calculate the Z position of the balls, described in conjunction with FIG. 32 . The processor 13 may store an image in memory 14 .
FIGS. 3 B 1 , 3 B 2 , and 3 B 3 show an example image 80 from camera 10 and an example image 90 from camera 15 acquired by the system. The image 80 shows the bottom view of the balls located on the bottom surface of a part 70 . The image 90 shows two side view perspectives of the balls located on part 70 . A first side perspective view in image 90 contains images of balls 91 and is obtained by the reflection of the image of the part 70 off of fixed optical elements 30 , 32 and 38 into camera 15 . A second side perspective view in image 90 contains images of balls 92 and is obtained by the reflection of the image of the part 70 off of fixed optical elements 34 , 36 and 38 into camera 15 . Optical element 36 is positioned to adjust the optical path length of a second side perspective view to equal the optical path length of a first side perspective view. In one embodiment of the invention, the maximum depth of focus of a side perspective view just includes an area of the part including the center row of balls. This allows for a fixed focus system to inspect larger parts, with one perspective view imaging at least half of the part and the second perspective view imaging at least the other half of the part. Those skilled in the art will realize that any number of perspective views can be utilized by the invention. In another embodiment of the invention, all of the balls are in focus from both side perspective views resulting in two perspective views for each ball. This permits two Z calculations for each ball as shown in conjunction with FIGS. 10A and 10B .
FIG. 4 shows a flow diagram for the three dimensional inspection of balls on a ball grid array. The method starts in step 141 by providing a part 70 having balls 71 facing down. The method in step 142 provides a camera 10 located beneath the part 70 to receive an image 80 . In step 143 a frame grabber 12 is provided to receive the image 80 from camera 10 . In step 144 , fixed optical elements are provided for obtaining two side perspective views of the part 70 . A first optical path is provided by optical elements 30 , 32 and 38 . A second optical path is provided by optical elements 34 , 36 and 38 . A second camera 15 receives an image 90 of two side perspective views in step 145 . In step 146 a second frame grabber board 17 is provided to receive the image 90 from camera 15 . A processor 13 sends a command to frame grabbers 12 and 17 to acquire images 80 and 90 comprising pixel values from cameras 10 and 15 . The method then proceeds to step 147 and processes the pixel values with a processor 13 to obtain three dimensional data about part 70 .
The invention contemplates the inspection of parts that have ball shaped leads whether or not packaged as a ball grid array. The invention also contemplates inspection of leads that present a generally curvilinear profile to an image sensor.
FIGS. 5A and 5B together show a flow chart of the three dimensional inspection method of the invention. The process begins in step 151 by waiting for an inspection signal. When the signal changes state, the system initiates the inspection. The processor 13 sends a command to frame grabber boards 12 and 17 to acquire images 80 and 90 respectively of part 70 having balls 71 . In step 152 , camera 10 captures an image 80 comprising pixel values and camera 15 captures an image 90 comprising pixel values and the processor stores the images in memory 14 . The images comprise information from both a bottom view and two side perspective views as shown in FIGS. 3 B 1 , 3 B 2 , AND 3 B 3 . In step 153 , the inspection system sends a signal to a part handler shown in FIG. 9 to allow the part handler to move the part out of the inspection area and allows the next part to be moved into the inspection area. The handler may proceed with part placement while the inspection system processes the stored image data.
The inspection system processes the pixel values of the stored image 80 in step 154 to find a rotation, and X placement and Y placement of the part relative to the world X and Y coordinates. The processor determines these placement values finding points on four sides of the body of the part. In step 155 , the processor employs a part definition file that contains values for an ideal part.
By using the measurement values from the part definition file and the placement values determined in step 154 , the processor calculates an expected position for each ball of the part for the bottom view contained in image 80 . The processor employs a search procedure on the image data to locate the balls 81 in image 80 . The processor then determines each ball's center location and diameter in pixel values using grayscale blob techniques as described in FIG. 7A . The results are stored in memory 14 .
The processor proceeds in step 156 to calculate an expected position of the center of each ball in both side perspective views in image 90 using the known position of each s side view from calibration. The processor employs a subpixel edge detection method described in FIG. 72 to locate a reference point on each ball in step 157 . The results are stored in memory 14 .
Now refer to FIG. 5B . In step 158 the processor converts the stored pixel values from steps 154 and 157 into world locations by using pixel values and parameters determined during calibration. The world locations represent physical locations of the balls with respect to the world coordinates defined during calibration.
In step 159 the Z height of each ball is calculated in world coordinates in pixel values. The method proceeds by combining the location of the center of a ball from the bottom view 80 with the reference point of the same ball from a side perspective view in image 90 as described in FIGS. 6A and 6B . The processor then converts the world values to part values using the calculated part rotation, and X placement and Y placement in step 160 to define part coordinates for the ideal part. The part values represent physical dimensions of the balls such as ball diameter, ball center location in X part and Y part coordinates and ball height in Z world coordinates.
In step 161 these part values are compared to the ideal values defined in the part file to calculate the deviation of each ball center from its ideal location. In one example embodiment of the invention the deviation values may include ball diameter in several orientations with respect to the X and Y part coordinates, ball center in the X direction, Y direction and radial direction, ball pitch in the X direction and Y direction and missing and deformed balls. The Z world data can be used to define a seating plane, using well known mathematical formulas, from which the Z dimension of the balls with respect to the seating plane can be calculated. Those skilled in the art will recognize that there are several possible definitions for seating planes from the data that may be used without deviating from the spirit and scope of the invention.
In step 162 the results of step 161 are compared to predetermined thresholds with respect to the ideal part as defined in the part file to provide an electronic ball inspection result. In one embodiment the predetermined tolerance values include pass tolerance values and fail tolerance values from industry standards. If the measurement values are less than or equal to the pass tolerance values, the processor assigns a pass result for the part. If the measurement values exceed the fail tolerance values, the processor assigns a fail result for the part. If the measurement values are greater than the pass tolerance values, but less than or not equal to the fail tolerance values, the processor designates the part to be reworked. The processor reports the inspection result for the part in step 163 , completing part inspection. The process then returns to step 151 to await the next inspection signal.
FIGS. 6A and 6B show an example ball of a ball grid array and associated geometry used in a method of the invention for determining the Z position of the ball. The method determines the Z position of a ball with respect to the world coordinates defined during calibration. Using parameters determined from the calibration procedure as shown in FIGS. 2B and 2D to define a world coordinate system for the bottom view and the two side perspective views, comprising world coordinate plane 250 with world coordinate origin 251 and world coordinate axis X 252 , Y 253 and Z 254 shown in FIG. 6A , and a pair of images 80 and 90 as shown in FIGS. 3 B 1 , 3 B 2 , AND 3 B 3 , the processor computes a three dimensional location.
Now refer to FIG. 6A . The processor locates a point 258 on the world plane 250 determined by a bottom view ray 255 passing through the center 257 of a ball 71 on a part 70 . The processor locates a side perspective view point 260 on the world plane 250 determined by a side perspective view ray 256 intersecting a ball reference point 259 on ball 71 and intersecting the bottom view ray 255 at a virtual point 261 . Ray 256 intersects the world plane 250 at an angle 262 determined by the reflection of ray 256 off of the back surface 263 of prism 30 . The value of angle 262 was determined during the calibration procedure.
Now refer to FIG. 6B . The distance L.sub. 1 is calculated by the processor as the difference between world point 258 , defined by the intersection of ray 255 with the Z=0 world plane 250 , and world point 260 , defined by the intersection of ray 256 and the Z=0 world plane 250 . The value Z is defined as the distance between world point 261 and 258 and is related to L 1 as follows:
tan θ1= Z/L 1
Z can be computed by processor 13 since the angle 262 is known from calibration. The offset E 265 is the difference between the virtual point 261 defined by the intersection of ray 255 and ray 256 and the crown of ball 71 at point 264 , defined by the intersection of ray 255 with the crown of ball 71 , and can be calculated from the knowledge of the angle 262 and the ideal dimensions of the ball 71 . The final value of Z for ball 71 is:
Z Final =Z−E
FIG. 7A shows one example of an image used in the grayscale blob method of the invention. The image processing method finds the location and dimensions of a ball 71 from a bottom image 80 . From the expected position of a ball 71 , a region of interest in image 80 is defined as (X 1 , Y 1 ) by (X 2 ,Y 2 ). The width and height of the region of interest are large enough to allow for positioning tolerances of part 70 for inspection. Due to the design of the lighting for the bottom view, the spherical shape of balls 71 of part 70 present a donut shaped image where the region 281 , including the perimeter of the ball 71 , comprises camera pixels of higher grayscale values and where the central region 282 comprises camera pixels of lower grayscale values. The remainder 283 of the region of interest 280 comprises camera pixels of lower grayscale values.
In one embodiment of the invention the processor 13 implements image processing functions written in the C programming language.
The C language function “FindBlobCenter”, as described below, is called to find the approximate center of the ball 71 by finding the average position of pixels that are greater than a known threshold value. Using the coordinates of the approximate center of the ball 71 , the region 282 of lower grayscale pixel values can be converted to higher grayscale values by calling the C language function “FillBallCenter”, as described below. The exact center of the ball 71 can be found by calling the C language function “FindBallCenter” which also returns an X world and Y world coordinate. The diameter of the ball 71 can be calculated by the C language function, “Radius=sqrt(Area/3.14)”. The area used in the diameter calculation comprises the sum of pixels in region 281 and 282 .
FIG. 7B shows one example of an image used with the method of the invention to perform a subpixel measurement of the ball reference point. The method of the invention finds a reference point on a ball 71 in an image 90 of a side perspective view as shown in FIGS. 3 B 1 , 3 B 2 , AND 3 B 3 . From the expected position of a ball 71 , a region of interest 290 in image 80 is defined as (X 3 , Y 3 ) by (X 4 ,Y 4 ). The width and height of the region of interest are large enough to allow for positioning tolerances of part 70 for inspection. Due to the design of the lighting for a side perspective view, the spherical shape of balls 71 of part 70 present a crescent shaped image 291 comprising camera pixels of higher grayscale values and where the remainder 293 of the region of interest 290 comprises camera pixels of lower grayscale values.
The C language function “FindBlobCenter” is called to compute the approximate center of the crescent image 291 by finding the average position of pixels that are greater than a known threshold value. Using the coordinates of the approximate center of the crescent image 291 , the C language function “FindCrescentTop” is called to determine the camera pixel, or seed pixel 292 representing the highest edge on the top of the crescent. The camera pixel coordinates of the seed pixel are used as the coordinates of a region of interest for determining the subpixel location of the side perspective ball reference point.
One example of grayscale blob analysis and reference point determination implemented in the C language is presented as follows:
——————————————————————————————
////////////////////////////////////////////////////////////
//
// FindBlobCenter - finds the X,Y center of the pixels that have a greater
than THRESHOLD in the region (x1,y1) to (x2,y2)
////////////////////////////////////////////////////////////
//
long FindBlobCenter(int x1,int y1,int x2,int y2, double* pX,double* pY)
{
int x,y;
long Found = 0;
long SumX = 0;
long SumY = 0;
for (x=x1;x<=x2;x++)
{
for (y=y1;y<=y2;y++)
{
if (Pixel [x] [y] > THRESHOLD)
{
SumX += X;
SumY += y;
Found ++;
}
}
}
if (Found > 0)
{
*pX = (double)SumX / (double)Found;
*pY = (double)SumY / (double)Found;
}
return Found;
}
////////////////////////////////////////////////////////////
//
// FillBallCenter - fills the center of the BGA “donut”
////////////////////////////////////////////////////////////
//
void FillBallCenter(double CenterX,double CenterY,double Diameter)
{
int x,y;
int x1 = (int) (CenterX − Diameter / 4.0);
int x2 = (int) (CenterX + Diameter / 4.0);
int y1 = (int) (CenterY − Diameter / 4.0);
int y2 = (int) (CenterY + Diameter / 4.0);
for (x=x1;x<=x2;x++)
{
for (y=y1;y<=y2;y++)
{
Pixel [x] [y] = 255;
}
}
}
////////////////////////////////////////////////////////////
//
// FindBallCenter - finds the X,Y center of the a BGA ball
//
using the grayscale values
////////////////////////////////////////////////////////////
//
long FindBallCenter(int x1,int y1,int x2,int y2, double* pX,double* pY,
double* pRadius)
{
int x,y;
long Found = 0;
long Total = 0;
long SumX = 0;
long SumY = 0;
for (x=x1;x<=x2;++)
{
for (y=y1;y<=y2;y++)
{
if (Pixel [x] [y] > THRESHOLD)
{
SumX += x*Pixel [x] [y];
SumY += y*Pixel [x] [y];
Total += Pixel [x] [y];
Found ++;
}
}
}
if (Found > 0)
{
*pX
= (double)SumX / (double)Total;
*pY
= (double)SumY / (double)Total;
*pRadius
= sqrt((double)Found / 3.14159279);
}
return Found;
}
////////////////////////////////////////////////////////////
//
// FindCresentTop - finds the X,Y top position of a BGA cresent
////////////////////////////////////////////////////////////
//
void FindCresentTop(int CenterX,int CenterY,int Diameter, int* pX,
int* pY)
{
int x,y,Edge,Max,TopX,TopY;
int x1 = CenterX − Diameter / 2;
int x2 = CenterX + Diameter / 2;
int y1 = CenterY − Diameter / 2;
int y2 = CenterY;
*pY = 9999;
for (x=x1;x<=x2;x++)
{
Max = −9999;
for (y=y1;y<=y2;y++)
{
Edge = Pixel [x] [y] − Pixel [x] [y−1];
if (Edge > Max)
{
Max = Edge;
TopY = y;
TopX = x;
}
}
if (TopY < *pY)
{
*pX = TopX;
*pY = TopY;
}
}
(c) 1997 Scanner Technologies Inc.
FIG. 8A shows a side perspective image of the calibration pattern magnified in one dimension. FIG. 8A shows a side perspective image 300 of a reticle calibration pattern where the space 303 between dot 301 and dot 302 is magnified, increasing the number of lower value grayscale pixels when compared to a non magnified image.
FIG. 8B shows a side perspective image of the balls on a BGA, magnified in one dimension. In FIG. 8B a side perspective image 310 of two views are shown where the space 313 between ball image 311 and ball image 312 is magnified, increasing the number of lower value grayscale pixels when compared to a non magnified image. The increased number of lower grayscale value pixels allows for the successful application of the subpixel algorithm.
In another embodiment of the invention, the method and apparatus disclosed herein is a method and apparatus for calibrating the system by placing a pattern of calibration dots of known spacing and dimensions on the bottom plane of a calibration reticle and for providing for two side perspective views of each ball for the three dimensional inspection of parts. From the precision dots the missing state values of the system are determined allowing for three dimensional inspection of balls on BGA devices or balls on wafers or balls on die.
FIG. 9 shows an example apparatus for presenting a BGA to the system for inspection. An overhead light reflective diffuser 5 includes a vacuum cup assembly 6 . The vacuum cup assembly may attach to a BGA part 70 having balls 71 and suspend the BGA part 70 below the overhead light reflective diffuser 5 .
FIGS. 10A and 10B show an example ball on a ball grid array and associated geometry for use with the method of the invention for determining the Z position of a ball with respect to the world coordinates defined during calibration, using two perspective views for each ball. Using parameters determined from the calibration procedure as shown in FIGS. 2B and 2D to define a world coordinate system for the bottom view and the two side perspective views, comprising world coordinate plane 700 with world coordinate origin 701 and world coordinate axis X 702 , Y 703 and Z 704 shown in FIG. 10A and FIG. 10B , and a pair of images 80 and 90 as shown in FIGS. 3 B 1 , 3 B 2 , AND 3 B 3 , the processor computes a three dimensional location.
Now refer to FIG. 10A . The processor locates a point 709 on the world plane 700 determined by a bottom view ray 705 passing through the center 708 of a ball 717 . The processor locates a first side perspective view point 711 on the world plane 700 determined by a side view ray 706 intersecting a ball reference point 710 on ball 717 and intersecting the bottom view ray 705 at a virtual point 714 . Ray 706 intersects the world plane 700 at an angle 715 determined by the reflection of ray 706 off of the back surface of prism 30 . The value of angle 715 was determined during the calibration procedure. The processor locates a second side perspective view point 713 on the world plane 700 determined by a side view ray 707 intersecting a ball reference point 712 on ball 717 and intersecting the bottom view ray 705 at a virtual point 718 . Ray 707 intersects the world plane 700 at an angle 716 determined by the reflection of ray 707 off of the back surface of prism 34 . The value of angle 716 was determined during the calibration procedure.
Now refer to FIG. 10B . The distance L 1 is calculated by the processor as the distance between world point 709 and world point 711 . The distance L 2 is calculated by the processor as the distance between world point 713 and world point 709 . The value Z 1 is defined as the distance between world point 714 and 709 and is related to L 1 as follows:
tan θ 1 =Z 1 /L 1
Z 1 =L 1 tan θ 1
The value Z 2 is defined as the distance between world point 718 and 709 and is related to L 2 as follows:
tan θ 2 =Z 2 /L 2
Z 2 =L 2 tan θ 2
The average of Z 1 and Z 2 are calculated and used as the value for Z of the ball. This method is more repeatable and accurate than methods that use only one perspective view per ball.
In still another embodiment of the invention, the method and apparatus disclosed herein is a method and apparatus for calibrating the system by placing a pattern of calibration dots of known spacing and dimensions on the bottom plane of a calibration reticle and for providing a single side perspective view for the three dimensional inspection of parts. From the precision dots the missing state values of the system are determined allowing for three dimensional inspection of balls on BGA devices or balls on wafers or balls on die.
FIG. 11A shows the apparatus of the invention for system calibration, utilizing a single side perspective view. The method and apparatus for calibration of the bottom view is identical to the method and apparatus described earlier in FIGS. 2A and 2B for the two side perspective views method. The apparatus for an image of a side perspective view includes a camera 15 with a lens 18 and a calibration reticle 20 . The camera 15 is located to receive an image 64 of a side perspective view comprising dots 65 , described in conjunction with FIGS. 11 B 1 , 11 B 2 , AND 11 B 3 , and utilizing fixed optical elements 40 and 42 . The fixed optical element 40 may be a mirror or prism. The fixed optical element 42 is a nonlinear element that magnifies the image in one direction. In another embodiment fixed optical element 40 may be this nonlinear element. As will be appreciated by those skilled in the art additional optical elements may be incorporated. The camera 15 is connected to a frame grabber board 17 to receive the image 64 . The frame grabber board 17 provides an image data output to a processor 13 to perform a two dimensional inspection as described in conjunction with FIG. 2B . The processor 13 may store an image in memory 14 .
FIGS. 11 B 1 , 11 B 2 , and 11 B 3 show an example calibration pattern and example images of a calibration pattern acquired by the system, utilizing a single side perspective view, of the invention. FIGS. 11 B 1 , 11 B 2 , and 11 B 3 show an example image 50 from camera 10 and an example image 64 from camera 15 acquired by the system. The image 50 showing dots 52 acquired by camera 10 includes a bottom view of the dot pattern 22 , containing precision dots 24 of known dimensions and spacing, located on the bottom surface of the calibration reticle 20 . The image 64 shows a side perspective view of the dot pattern 22 , containing precision dots 24 of known dimensions and spacing, located on the bottom surface of the calibration reticle 20 . A side perspective view in image 64 contains images of dots 65 and is obtained by the reflection of the image of the calibration reticle dot pattern 22 off of fixed optical element 40 , passing through nonlinear element 42 and into camera 15 .
The side perspective calibration is identical to the method shown in FIG. 2C except the fixed optical elements may have different properties.
The determination of the state values for the side perspective view is identical to the method shown in FIG. 2D except the fixed optical elements may be different and there is only one side perspective view. The principles and relationships shown in FIG. 2E , FIG. 2 F 1 , and FIG. 2 F 2 apply.
In still another embodiment employing a single side perspective view, the invention does not include the nonlinear element 42 .
FIG. 12A shows the apparatus of the invention for ball inspection utilizing a single side perspective view. The apparatus of the invention includes a part 70 to be inspected. The apparatus further includes a camera 10 with a lens 11 , located below the central area of part 70 , to receive a bottom image 80 , described in conjunction with FIGS. 12 B 1 , 12 B 2 , and 12 B 3 , of part 70 . The camera 10 is connected to a frame grabber board 12 to receive the image 80 . The frame grabber board 12 provides an image data output to a processor 13 to perform a two dimensional inspection as described in conjunction with FIGS. 12 B 1 , 12 B 2 , and 12 B 3 . The processor 13 may store an image in memory 14 . The apparatus for an image of a single side perspective view includes a camera 15 with a lens 18 . The camera 15 is located to receive an image 94 , comprising a single side perspective view, described in conjunction with FIGS. 12 B 1 , 12 B 2 , and 12 B 3 and utilizing fixed optical element 40 and nonlinear, fixed optical element 42 , to magnify the side perspective view in one dimension. In another embodiment of the invention optical element 40 may be the nonlinear element. The fixed optical element 40 may be a mirror or prism. As will be appreciated by those skilled in the art additional optical elements may be incorporated. The camera 15 is connected to a frame grabber board 17 to receive the image 94 . The frame grabber board 17 provides an image data output to a processor 13 to calculate the Z position of the balls, described in conjunction with FIGS. 12 B 1 , 12 B 2 , and 12 B 3 . The processor 13 may store an image in memory 14 .
FIGS. 12 B 1 , 12 B 2 , and 12 B 3 show an example ball grid array and example images of the ball grid array for three dimensional inspection, utilizing a single side perspective view. FIGS. 12 B 1 , 12 B 2 , and 12 B 3 show an example image 80 from camera 10 and an example image 94 from camera 15 acquired by the system. The image 80 shows the bottom view of the balls 71 located on the bottom surface of a part 70 . The image 94 shows a side perspective view of the balls 71 located on part 70 . The side perspective view in image 94 contains images of balls 95 and is obtained by the reflection of the image of the part 70 off of fixed optical element 40 and passing through the nonlinear fixed element 42 into camera 15 .
In an alternate embodiment of the invention, the system can be used to inspect other types of electronic parts in three dimensions, such as gullwing and J lead devices. By utilizing only one camera and adding an additional set of prisms on the reticle 400 these other devices may be inspected. The advantage of being able to inspect different devices with the same system includes savings in cost, and floor space in the factory. Additionally this design allows more flexibility in production planning and resource management.
FIG. 13 shows the apparatus of the invention for the three dimensional inspection of ball grid array devices, gullwing devices and J lead devices. The apparatus described in FIG. 13 allows the inspection of BGA, gullwing and J lead devices all on the same system. The apparatus includes a part 402 to be inspected located over the central area of a transparent reticle 400 with prisms 401 glued to the top surface to receive side perspective views of part 402 . A gullwing and J lead inspection device 21 may be integrated into the ball grid array inspection device. One example embodiment of such a gullwing and J lead inspection device is the “UltraVim” scanner from Scanner Technologies of Minnetonka, Minn. The apparatus further includes a camera 10 A with a lens 11 A, located below the central area of part 402 and reticle 400 to receive a bottom view and side perspective views of part 402 . The camera 10 A is connected to a frame grabber board 12 A to receive an image. The frame grabber board 12 A provides an image data output to a processor 13 A to perform a three dimensional inspection of part 402 . The processor 13 A may store an image in memory 14 A. These components comprise the hardware of the gullwing and J lead inspection device 21 and are shared by the ball grid array inspection device as described herein.
The UltraVim is described in U.S. patent application Ser. No. 08/850,473 entitled THREE DIMENSIONAL INSPECTION SYSTEM by Beaty et al., filed May 5, 1997 which is incorporated in its entirely by reference thereto.
Refer now to FIG. 14 . In still another embodiment of the invention, the system may use three cameras to image directly the bottom view and two side perspective views as shown in FIG. 14 . FIG. 14 shows the apparatus of the invention for a three dimensional inspection of the balls of a BGA. The apparatus of the invention includes a part 70 , with balls 71 to be inspected. The apparatus further includes a camera 10 with a lens 11 , located below the central area of part 70 , to receive a bottom image 80 , described in conjunction with FIGS. 12 B 1 , 12 B 2 , and 12 B 3 , of part 70 . The camera 10 is connected to a frame grabber board 12 to receive the image 80 . The frame grabber board 12 provides an image data output to a processor 13 to perform a two dimensional inspection as described in conjunction with FIGS. 12 B 1 , 12 B 2 , and 12 B 3 . The processor 13 may store an image in memory 14 . The apparatus for an image of a first side perspective view includes a camera 15 with a lens 19 . The camera 15 is located to receive an image 94 , comprising a single side perspective view, described in conjunction with FIGS. 12 B 1 , 12 B 2 , and 12 B 3 and utilizing fixed optical element 38 , to magnify the side perspective view in one dimension. The camera 15 is connected to a frame grabber board 17 to receive the image 94 . The frame grabber board 17 provides an image data output to a processor 13 to calculate the Z position of the balls, described in conjunction with FIGS. 12 B 1 , 12 B 2 , and 12 B 3 . The processor 13 may store an image in memory 14 . The apparatus for an image of a second side perspective view includes a camera 15 with a lens 19 . The camera 15 is located to receive an image similar to 94 , comprising a single side perspective view, described in conjunction with FIGS. 12 B 1 , 12 B 2 , and 12 B 3 and utilizing fixed optical element 38 , to magnify the side perspective view in one dimension. The camera 15 is connected to a frame grabber board 17 to receive the image similar to 94 . The frame grabber board 17 provides an image data output to a processor 13 to calculate the Z position of the balls, described in conjunction with FIGS. 12 B 1 , 12 B 2 , and 12 B 3 . The processor 13 may store an image in memory 14 . In another embodiment, the nonlinear fixed optical element 38 may be missing. In still another embodiment of the invention, only one side perspective view may be utilized.
In another embodiment of the invention, the method and apparatus disclosed herein is a method and apparatus using a single camera for calibrating the system by placing a pattern of calibration dots of known spacing and size on the bottom plane of a calibration reticle. From the precision dots the missing state values of the system are determined allowing for three dimensional inspection of balls on ball grid array devices, BGA devices or balls on wafers or balls on die.
Refer now to FIG. 15 which shows one example of the apparatus of the invention configured with a calibration reticle 1020 for use during calibration of the state values of the system. Calibration reticle 1020 is positioned to be viewed by camera 1008 . Camera 1008 further comprises a lens 1006 . Camera 1008 receives a composite image of the calibration reticle 1020 , one portion of the image, through mirror 1002 and an additional portion directly. A frame grabber 1010 receives image information from the camera 1008 and provides processor 1012 with image information of the calibration reticle 1020 . The image information and other inspection information may be stored in memory 1014 . The apparatus obtains an image 1024 showing a bottom view 1026 containing an image 1031 of a precision dot 1030 and a side view 1028 containing an image 1032 of precision dot 1030 of the calibration reticle 1020 shown in FIG. 16A . This image 1024 is shown in FIG. 16B . To take the image 1024 , the apparatus includes a means of illumination 1017 , an overhead light diffuser 1015 , the camera 1008 , with lens 1006 , and calibration reticle 1020 with a calibration pattern 1022 on the bottom surface of the calibration reticle 1020 . A separate optical element 1002 is positioned below the calibration reticle 1020 to provide an additional perspective or side view 1028 containing an image of precision dot 1032 of the calibration reticle 1020 .
In one embodiment of the invention, the optical element 1002 may comprise a prism. In another embodiment of the invention, the optical element 1002 may comprise a mirror. As will be appreciated by one skilled in the art, the invention will work with any number of side views. The calibration pattern 1021 on the reticle 1020 comprises precision dots 1022 . The camera 1008 is located below the central part of the calibration reticle 1020 to receive an image 1024 described in conjunction with FIGS. 16A and 16B . In one embodiment of the invention, the camera 1008 comprises an image sensor. The image sensor may be a charged coupled device array. The camera 1008 is connected to a frame grabber board 1010 to receive the image 1024 . The frame grabber board 1010 provides an image data output to a processor 1012 to perform a three dimensional calibration as described in conjunction with FIG. 16B . The principles and relationships shown in FIGS. 2E and 2F apply. The processor 1012 may store an image in memory 1014 .
Now refer to FIGS. 16A and 16B which show a calibration reticle 1020 having precision dots 1022 . FIG. 16B shows a composite image 1024 of the calibration reticle 1020 . The bottom view 1026 shows precision dot 1030 with a first perspective view 1031 and a side view 1028 shows precision dot 1030 with a second perspective view 1032 . The system processor processes the composite image 1024 according to the system of equations described herein with the bottom view 1026 and side view 1028 providing information for the solution of the system of equations. The principles and relationships shown in FIG. 2E , FIG. 2 F 1 , and FIG. 2 F 2 apply.
In another embodiment of the invention, the method and apparatus disclosed herein is a method and apparatus using a single camera for a three dimensional inspection of balls on ball grid array devices, BGA/CSP devices or balls on wafers or balls on die.
Refer now to FIG. 17 which shows the apparatus of the invention configured with a part 1040 to be inspected by the system. The apparatus obtains an image 1044 showing a bottom view 1046 containing an image of a ball 1050 and a side view 1048 containing an image of a ball 1052 of the part 1040 . To take the image 1044 , the apparatus includes a means of illumination 1017 which may be a ring light, camera 1008 with a first optical element, lens 1006 , and a part 1040 with a ball 1042 on the bottom surface. In one embodiment of the invention, the means of illumination 1017 lights the bottom surface of the part 1040 to allow imaging the perimeter of the part 1040 . In another embodiment of the invention, overhead diffuser 1015 provides illumination for imaging of the perimeter of the part 1040 .
In one example, the means for illumination may comprise reflected light, the lens 1006 may comprise a plurality of lens elements, a pin hole lens or a telecentric lens, and the processor 1012 may comprise a personal computer. Those skilled in the art will understand that the output of the sensor may be transmitted directly to memory without the use of a frame grabber.
A separate second optical element 1002 is positioned below the bottom plane of part 1040 to provide an additional perspective or side view 1048 of the part 1040 containing an image of the ball 1052 of the part 1040 . In one embodiment of the invention, the optical element 1002 may comprise a prism. In another embodiment of the invention, the optical element 1002 may comprise a mirror. As will be appreciated by one skilled in the art, the invention will work with any number of side views. The camera 1008 is located below the central part of the part 1040 to receive an image 1044 described in conjunction with FIGS. 18A and 18B . In one embodiment of the invention, the camera 1008 comprises an image sensor. The image sensor may be a charged coupled device array or a complementary metal oxide semiconductor device array. The camera 1008 is connected to a frame grabber board 1010 to receive the image 1044 . The frame grabber board 1010 provides an image data output to a processor 1012 to perform a three dimensional inspection of the part 1040 as described in conjunction with FIGS. 18A and 18B . The principles and relationships shown in FIG. 6A and FIG. 6B apply. The processor 1012 may store an image in memory 1014 .
Now refer to FIGS. 18A and 18B which shows a ball grid array 1040 having balls 1042 . FIG. 18B shows a composite image 1044 of the ball grid array 1040 . The bottom view 1046 shows ball 1050 with a first perspective view 1051 and a side view 1048 shows ball 1050 with crescent shape 1052 with a second perspective view. The system processor processes the composite image 1044 according to the system of equations described herein with the bottom view 1046 and side view 1048 providing information for the solution of the system of equations. The principles and relationships shown in FIG. 6A and FIG. 6B apply.
The invention has been described herein in considerable detail in order to comply with the Patent Statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by specifically different equipment and devices, and that various modifications, both as to the equipment details and operating procedures, can be accomplished without departing from the scope of the invention itself.
|
A calibration and part inspection method for the inspection of ball grid array, BGA, devices. One or more cameras image a precision pattern mask with dot patterns deposited on a transparent reticle. The precision pattern mask is used for calibration of the system. A light source and overhead light reflective diffuser provide illumination. A camera images the reticle precision pattern mask from directly below. An additional mirror or prism located below the bottom plane of the reticle reflects the reticle pattern mask from a side view, through prisms or reflective surfaces, into the camera. By imaging more than one dot pattern the missing state values of the system can be resolved using a trigonometric solution. The reticle with the pattern mask is removed after calibration and the BGA to be inspected is placed with the balls facing downward, in such a manner as to be imaged by a single camera, or optionally, via additional cameras. The scene of the part can thus be triangulated and the dimensions of the BGA are determined.
| 7
|
The present invention relates to processes for producing concrete.
FIELD OF THE INVENTION
Concretes are widely used in construction. They should meet a number of requirements: thus, they should have high mechanical strength and adequately low deformation characteristics: shrinkage and creep. These properties are due to the presence of a large-size aggregate in their composition, i.e. crushed stone, gravel which act as a matrix and a fine aggregate-large-size sand with gradation factor (Gf) above 1.
In certain countries there are substantially unlimited resources of fine barkhan sands with Gf below 1, but scarce stock of large-size crushed stone, gravel and large-size sands as aggregates for concrete.
The countries carrying out construction works in the areas of barkhan sand location have to use rather expensive crushed stone, gravel and large-size sands shipped from more distant regions.
For such countries the solution of the problem of concrete production with the use of fine barkhan sands as aggregates is very urgent.
BACKGROUND OF THE INVENTION
A process for producing concrete is known in the art using, as an aggregate, fine barkhan sands (cf. O. A. Gershberg "Technology of Concrete and Reinforced-Concrete Articles", Moscow, Strojizdat Publishing House, 1971). This process contemplates production of concrete by mixing cement, barkhan sand and water in specified proportions.
The process is rather simple, but concrete produced thereby feature a low mechanical strength due to a high specific surface area of the sand.
Another process is known in the art for the production of concrete, wherein sand is first screened to fractions and then enriched with fractions having larger particle size. Thereafter sand is mixed with cement and water (cf. Yu. M. Bazehenov "Methods for determination of composition of concrete of different kinds", Moscow, Strojizdat Publishing House, 1975). This process has a limited application, since it contemplates the use of sands having only large-size fractions. Furthermore, concrete produced by this process has a high bulk mass and an insufficient mechanical strength.
A process for producing a light-weight concrete, is known in the art wherein a large-size aggregate: crushed stone, gravel is first prepared. To this end, burnt and dump rocks are crushed and intermixed with a plastic clay and coal at the following proportions of the components, percent by weight:
dump rock: 8 to 25
burnt rock: 50 to 72
plastic clay: 12 to 27
coal: 3 to 9
The thus-prepared charge is granulated, roasted, crushed and screened. Thereafter, the resulting material is mixed with cement and water (cf. I. A. Ivanov "Technology of light-weight concretes with artificial porous aggregates", Moscow, Strojizdat Publishing House, 1974).
The use is also known of loess in the charge compositions for the manufacture of a coarse aggregate-crushed stone, gravel having, for example, the following composition, percent by weight:
loess: 90 to 94
ground apatite: 3 to 7
liquid fuel: 3
(cf. I. I. Moroz "Technology of Building Ceramics", Kiev, Visha Schkola Publishing House, 1972).
However thus-produced concretes have insufficient mechanical strength, since the charge employed for the production of a coarse aggregate has a great amount of dump and burnt rocks and loess.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a process for producing concrete which makes it possible to produce a light-weight durable concrete meeting the requirements imposed on concretes produced with the use of cheap and readily available raw material--barkhan sands.
This and other objects of the present invention are accomplished by a process for the production of concrete which comprises mixing barkhan sand with a fuel selected from the group consisting of a liquid fuel and a solid fuel, and a plastic binder selected from the group consisting of clay, loess, loam and surfactants possessing liquifying and water-consumption reducing properties at the following proportions of the components, percent by weight:
barkhan sand: 95 to 30
fuel: 3 to 20
plastic binder: 2 to 60;
the thus-prepared charge is granulated, the granules are calcined at a temperature within the range of from 1,000° to 1,600° C.; the calcined material is crushed; the crushed material is mixed with cement and water using cement in an amount within the range of from 10 to 100% by weight of the calcined material and water--in an amount of from 10 to 60% by weight of the mixture of the calcined material and cement.
As the liquid fuel, use can be made of diesel fuel, mazout, coal-tar, lignite, peat and shale resins as well as rosin.
Diesel fuel comprises a fuel for diesel engines, mazout is the residue resulting from petroleum refining; coal-tar resin can be produced from coking of coal; lignite resin--as a result of semi-coking or gasification of lignite; peat resin--from low-temperature coking or gasification of peat; shale resin--from low-temperature coking or gasification of shales; rosin--as a result of dry distillation of wood.
The above-mentioned substances employed as a fuel can be used both separately or in any possible combination with each other.
As the solid fuel, use can be made of coal, lignite, anthracite, semi-anthracite, coke.
As has been mentioned hereinbefore, the plastic binder can be clays, loess, loams and surface-active substances possessing liquifying properties and reducing water consumption. As such surfactants, use can be made of:
naphtha soap--sodium soaps of water-insoluble organic acids recovered from wastes obtained from wastes of alkali purification of kerosene, gasoline and solaroil distillates of petroleum;
acidol--petroleum acids recovered from alkali wastes obtained from purification of oil and solaroil distillates;
resin neutralized air-occluding produced from abietic resin by treatment thereof with caustic soda:
methylhydrosiloxane polymers of the general formula: ##STR1## wherein n=15 to 20
water-alcohol solutions of sodium ethylsiliconate of the general formula: ##STR2## wherein m=1-2,
water-alcohol solutions of sodium methylsiliconate of the general formula: ##STR3## wherein p=1-2;
sulphite-alcohol slops and sulphite-yeast mash--by-products obtained from processing of sulphate-pulp liquors into ethanol and yeast consisting mainly of calcium salts of lignosulphonic acids.
The above-mentioned methylhydrosiloxane polymer comprises a colourless or light-yellow hydrophobizing liquid; water-alcohol solutions of sodium ethylsiliconate and sodium methylsiliconate are also hydrophobizing liquids from yellow to light-brown colour.
The above-mentioned substances employed as a plastic binder can be used both individually and in various combinations with one another.
The plastic binder clay, loess, loam, above-mentioned surface-active substances in the amounts falling within the range specified above provides for the opportunity of granulation of the mixture of sand and fuel. Increasing the amount of the plastic binder above the upper limit fails to improve physico-mechanical characteristics of crude granules.
Introduction of the plastic binder in an amount below the above-mentioned lower limit does not provide for granulation of the materials. Barkhan sand in the amounts within the range specified hereinabove together with the plastic binder contributes to a better sintering of the charge and production of a durable calcined material.
The fuel introduced in the bove-specified proportions ensures the possibility of sintering of the charge.
The use of the fuel above the upper limit specified hereinabove affects physico-mechanical characteristics of the resulting concrete.
In the amounts below the lower limit the fuel does not provide for the possibility of the production of a light-weight concrete.
The process according to the present invention makes it possible to efficiently employ fine desert sands--barkhan sands in the manufacture of concretes. This process also makes it possible to improve physico-mechanical characteristics of barkhan sand as an aggregate for concrete. In particular, there is provided the opportunity of a drastic improvement of the particle size distribution in barkhan sand and thus obtaining a fractionated material with a particle size of fractions of up to 40 mm and above with a volume bulk mass of from 400 to 1,200 kg/m 3 and mechanical strength of up to 50 kgf/cm 2 which is superior to that of known light-weight aggregates.
The process according to the present invention results in the manufacture, from fine barkhan sands, of light-weight durable concretes with a wide range of variation of their volume mass and mechanical strength of up to 500 kgf/cm 2 and above without over-consumption of cement.
In the manufacture of light-weight concretes the necessity of shipment of large-size or coarse aggregates to the regions having vast resources of barkhan sands; is eliminated savings are also provided due to minimized cost of hardly-available argillaceous rocks.
DETAILED DESCRIPTION OF THE INVENTION
The process for producing concrete according to the present invention is simple and can be performed in the following manner.
In a mixer there are intermixed barkhan sand, a fuel and a plastic binder. The prepared charge is granulated on a plate-type granulator. The granulated material is sintered in an agglomeration machine. After cooling the sintered material is crushed, fractionated, mixed with cement, water and articles are moulded therefrom.
For a better understanding of the present invention the following specific examples are given hereinbelow by way of illustration.
EXAMPLE 1
A charge is prepared from the following components, percent by weight:
barkhan sand: 50
coal: 20
clay: 30.
The resulting charge is granulated, calcined in an agglomeration machine at the temperature of 1,250° C. The calcined material is crushed and screened. The resulting calcined material has the following physico-mechanical characteristics: Volume bulk mass of the fraction with the particle size (mm):
20-40: 400 to 550 kg/m 3
10-20: 400 to 600 kg/m 3
5-10: 500 to 700 kg/m 3
1.25-5: 600 to 800 kg/m 3
below 1.25: 700 to 1,000 kg/m 3 .
Compression strength, kgf/cm 2 : 28 to 38
Frost-resistance, mass loss, %: 0.4
Silicate decomposition, %: 0.6.
The calcined material is intermixed with cement taken in the amount of 34% by mass of the calcined material. To the resulting mixture there is added water in the amount of 17% by weight of the mixture of the calcined material and cement.
The resulting concrete has the following physico-mechanical characteristics:
compression strength after 28-days' hardening under normal temperature-moisture conditions (t=20° C.±2, H=95%), kgf/cm 2 : 270
volume mass, kg/m 3 : 1,400.
EXAMPLE 2
A charge is prepared from the following components, percent by weight:
barkhan sand: 60
coal: 7
mazout: 3
clay: 20
loess: 10.
The resulting charge is granulated, calcined in an agglomeration machine at the temperature of 1,300° C. The calcined material is crushed and screened. The resulting calcined material has the following physico-mechanical properties:
Volume bulk mass of fractions with the particle size (mm):
20-40: 450 to 550 kg/m 3
10-20: 500 to 600 kg/m 3
5-10: 550 to 700 kg/m 3
1.25-5: 600 to 800 kg/m 3
below 1.25: 800 to 1,000 kg/m 3 ;
Compression strength, kgf/cm 2 : 28 to 38
Frost-resistance, mass loss, %: 0.4
Silicate decomposition, %: 0.6.
The calcined material is mixed with cement in the amount of 10% by weight of the calcined material. To the resulting mixture water is added in the amount of 10% by mass of the mixture of the calcined material and cement.
The resulting concrete has the following physico-mechanical characteristics:
compression strength after 28-days' hardening under normal temperature-humidity conditions, kgf/cm 2 : 150
volume mass, kg/m 3 : 1,900.
EXAMPLE 3
A charge is prepared which has the following composition, percent by weight:
barkhan sand: 30
lignite: 10
loam: 60.
The thus-prepared charge is granulated, calcined in an agglomeration machine at the temperature of 1,000° C. The calcined material is crushed and screened. The resulting calcined material has the following physico-mechanical properties:
Volume bulk mass of fractions with the particle size (mm):
20-40: 450 to 550 kg/m 3
10-20: 0.500 to 600 kg/m 3
5-10: 550 to 700 kg/m 3
1.25-5: 600 to 800 kg/m 3
below 1.25: 800 to 1,000 kg/m 3
Compression strength, kgf/cm 2 : 14 to 22
Frost-resistance, mass loss, %: 0.9
Silicate decomposition, %: 0.8.
The calcined material is mixed with cement taken in the amount of 100% by mass of the calcined material. To the resulting mixture water is added in the amount of 60% by mass of the mixture of the calcined material and cement.
The resulting concrete has the following physico-mechanical characteristics:
compression strength after 28-days' hardening under normal conditions of temperature and moisture, kgf/cm 2 : 50
volume mass, kg/m 3 : 900.
EXAMPLE 4
A charge is prepared which has the following composition, percent by weight:
barkhan sand: 43
coke: 7
loess: 50.
The resulting charge is granulated, calcined in an agglomeration machine at the temperature of 1,600° C. The calcined material is crushed and screened. The resulting calcined material has the following physico-mechanical characteristics:
Volume bulk mass of fractions with the particle size (mm):
20-40: 600 to 650 kg/m 3
10-20: 650 to 700 kg/m 3
5-10: 700 to 750 kg/m 3
1.25-5: 750 to 800 kg/m 3
below 1.25: 900 to 1,000 kg/m 3 .
Compression strength, kgf/cm 2 : 30 to 46
Frost-resistance, mass loss, %: 0.5
Silicate decomposition, %: 0.8.
The calcined material is mixed with cement in the amount of 40% by mass of the calcined material. To the resulting blend water is added in the amount of 17% by mass of the mixture of the calcined material and cement.
The final concrete has the following physico-mechanical characteristics:
compression strength after 28-days' hardening under normal conditions of temperature and humidity, kgf/cm 2 : 330
volume mass, kg/m 3 : 1,600.
EXAMPLE 5
A charge is prepared which has the following composition, percent by weight:
barkhan sand: 95
diesel fuel: 3
acidol: 2.
The resulting charge is granulated, calcined in an agglomeration machine at the temperature of 1,400° C. The calcined material is crushed and screened. The resulting calcined material has the following physico-mechanical properties:
Volume bulk mass of fractions with the particle size (mm):
20-40: 650 to 700 kg/m 3
10-20: 700 to 750 kg/m 3
5-10: 750 to 800 kg/m 3
1.25-5: 800 to 950 kg/m 3
below 1.25: 1,000 to 1,100 kg/m 3
Compression strength, kgf/cm 2 : 35 to 47
Frost-resistance, mass loss, %: 0.4
Silicate decomposition, %: 0.6.
The calcined material is mixed with cement in the amount of 39% by mass of the calcined material. To the resulting mixture water is added in the amount of 16% by mass of the mixture of the calcined material and cement.
The final concrete has the following physico-mechanical characteristics:
compression strength after 28-days' hardening under normal conditions of temperature and humidity, kgf/cm 2 : 380
volume mass, kg/m 3 : 1,800.
EXAMPLE 6
A charge is prepared which has the following composition, percent by weight:
barkhan sand: 58
mazout: 5
loess: 35
acidol: 2.
The resulting charge is granulated, calcined in an agglomeration machine at the temperature of 1,400° C. The calcined material is crushed and screened. The resulting calcined material has the following physico-mechanical properties:
Volume bulk mass of fractions with the particle size (mm):
20-40: 650 to 700 kg/m 3
10-20: 700 to 750 kg/m 3
5-10: 750 to 800 kg/m 3
1.25-5: 800 to 950 kg/m 3
below 1.25: 1,000 to 1,100 kg/m 3 ;
Compression strength, kgf/cm 2 : 40 to 48
Frost-resistance, mass loss, %: 0.4
Silicate decomposition, %: 0.6.
The calcined material is mised with cement in the amount of 38% by mass of the calcined material. To the resulting blend water is added in the amount of 19% by mass of the total of the calcined material and cement.
The resulting concrete has the following physico-mechanical characteristics:
compression strength under normal conditions of temperature and humidity after 28-days' hardening, kgf/cm 2 : 405
volume mass, kg/m 3 : 1,700
EXAMPLE 7
A charge is prepared which has the following composition, percent by weight:
barkham sand: 78
coal: 20
surfactant--sulphite-yeast mash: 2.
The resulting charge is granulated, calcined in an agglomeration machine at the temperature of 1,300° C. The calcined material is crushed and screened. The resulting calcined material has the following physico-mechanical properties:
Volume bulk mass of fractions with the particle size, mm:
20-40: 450 to 550 kg/m 3
10-20: 500 to 600 kg/m 3
5-10: 550 to 700 kg/m 3
1.25-5: 600 to 800 kg/m 3
below 1.25: 800 to 1,000 kg/m 3
Compression strength, kgf/cm 2 : 28 to 38
Frost-resistance, mass loss, %: 0.6
Silicate decomposition, %: 0.7.
The calcined material is mixed with cement in the amount of 38% by mass of the calcined material. To the resulting mixture water is added in the amount of 18% by mass of the total of the calcined material and cement.
The final concrete has the following physico-mechanical characteristics:
compression strength after 28-days' hardening under normal temperature and humidity conditions, kgf/cm 2 : 310
Volume mass, kg/m 3 : 1,400
EXAMPLE 8
A charge is prepared which has the following composition, percent by weight:
barkhan sand: 78
coal: 18
methylhydrosiloxane polymer of the general formula: ##STR4## wherein n=15: 4.
The resulting charge is granulated, calcined in an agglomeration machine at the temperature of 1,300° C. The calcined material has the following physico-mechanical properties:
Volume bulk mass of fractions with the particle size (mm):
20-40: 450 to 550 kg/m 3
10-20: 500 to 600 kg/m 3
5-10: 550 to 700 kg/m 3
1.25-5: 600 to 800 kg/m 3
below 1.25: 800 to 1,000 kg/m 3
Compression strength, kgf/cm 2 : 30 to 39
Frost-resistance, mass loss, %: 0.6
Silicate decomposition, %: 0.7.
The use of a methylhydrosiloxane polymer of the general formula: ##STR5## wherein n=20 has given a similar result.
The calcined material is mixed with cement in the amount of 38% by mass of the calcined material. To the resulting mixture water is added in the amount of 18% by the total of the calcined material and cement.
The final concrete has the following physico-mechanical characteristics:
compression strength after 28-days' hardening under normal temperature and humidity conditions, kgf/cm 2 : 315
volume mass, kg/m 3 : 1,400.
EXAMPLE 9
A charge is prepared which has the following composition, percent by weight:
barkhan sand: 79
anthracite: 16
water-alcohol solution of sodium ethylsiliconate of the general formula: ##STR6## wherein m=1: 5.
The prepared charge is granulated, calcined in an agglomeration machine at the temperature of 1,300° C. The calcined material is crushed and screened. The resulting calcined material has the following physico-mechanical properties:
Volume bulk mass of fractions, particle size (mm):
20-40: 500 to 550 kg/m 3
10-20: 550 to 600 kg/m 3
5-10: 600 to 700 kg/m 3
1.25-5: 700 to 800 kg/m 3
below 1.25: 800 to 1,000 kg/m 3
Compression strength, kgf/cm 2 : 30 to 38
Frost-resistance, mass loss, %: 0.6
Silicate decomposition, %: 0.7.
The use of a water-alcohol solution of sodium ethylsiliconate of the general formula: ##STR7## wherein m=2 has given a similar result.
The calcined material is mixed with cement in the amount of 37% by mass of the calcined material. To the resulting mixture water is added in the amount of 18% by mass of the total of the calcined material and cement.
The final concrete has the following physico-mechanical characteristics:
compression strength after 28-days' hardening under normal temperature and humidity conditions, kgf/cm 2 : 320
volume mass, kg/m 3 : 1,450.
EXAMPLE 10
A charge is prepared which has the following composition, percent by weight:
barkhan sand: 77
semi-anthracite: 17
water-alcohol solution of sodium methylsiliconate of the general formula: ##STR8## wherein p=1: 6.
The resulting charge is granulated, calcined in an agglomeration machine at the temperature of 1,300° C. The calcined material is crushed and screened. The resulting calcined material has the following physico-mechanical properties:
Volume bulk mass of fractions with the particle size (mm):
20-40: 500 to 550 kg/m 3
10-20: 550 to 600 kg/m 3
5 to 10: 600 to 700 kg/m 3
1.25-5: 700 to 800 kg/m 3
below 1.25: 800 to 1,000 kg/m 3
Compression strength, kgf/cm 2 : 30 to 38
Frost-resistance-mass loss, %: 0.7
Silicate decomposition, %: 0.7.
The use of a water-alcohol solution of sodium methylsiliconate of the formula: ##STR9## wherein p=2 has given a similar result.
The calcined material is mixed with cement in the amount of 47% by mass of the calcined material. To the resulting mixture water is added in the amount of 22% by mass of the total of the calcined material and cement.
The final concrete has the following physico-mechanical characteristics:
compression strength after 28-days' hardening under normal temperature and humidity conditions, kgf/cm 2 : 415
volume mass, kg/m 3 : 1,800
EXAMPLE 11
A charge is prepared which has the following composition, percent by weight:
barkhan sand: 87
coal-tar resin: 6
sulphite-alcohol slops: 7.
The resulting charge is granulated, calcined in an agglomeration machine at the temperature of 1,300° C. The calcined material is crushed and screened. The resulting calcined material has the following physico-mechanical characteristics:
Volume bulk mass of fractions with the particle size (mm):
20-40: 500 to 550 kg/m 3
10-20: 550 to 600 kg/m 3
5-10: 650 to 700 kg/m 3
1.25-5: 750 to 800 kg/m 3
below 1.25: 900 to 1,100 kg/m 3
Compression strength, kgf/cm 2 : 35 to 45
Frost-resistance, mass loss, %: 0.5
Silicate decomposition, %: 0.7.
The calcined material is mixed with cement in the amount of 38% by mass of the calcined material. To the resulting mixture water is added in the amount of 18% by weight of the total of the calcined material and cement.
The final concrete has the following physico-mechanical characteristics:
compression strength after 28-days' hardening under normal temperature and humidity conditions, kgf/cm 2 : 320
volume mass, kg/m 3 : 1,500
EXAMPLE 12
A charge is prepared which has the following composition, percent by weight:
barkhan sand: 86
lignite resin: 7
naphtha soap: 7.
The resulting charge is granulated, calcined in an agglomeration machine at the temperature of 1,300° C. The calcined material is crushed and screened.
The resulting calcined material has the following physico-mechanical characteristics:
Volume bulk means of fractions with the particle size (mm):
20-40: 500 to 550 kg/m 3
10-20: 550 to 600 kg/m 3
5-10: 650 to 700 kg/m 3
1.25-5: 750 to 800 kg/m 3
below 1.25: 900 to 1,100 kg/m 3
Compression strength, kgf/cm 2 : 35 to 45
Frost-resistance, mass loss, %: 0.5
Silicate decomposition, %: 0.7.
The calcined material is mixed with cement in the amount of 48% by mass of the calcined material. To the resulting mixture water is added in the amount of 18% by mass of the total of the calcined material and cement.
The final concrete has the following physico-mechanical characteristics:
compression strength after 28 days' hardening under normal temperature and humidity conditions, kgf/cm 2 : 520
volume mass, kg/m 3 : 1,900.
EXAMPLE 13
A charge is prepared which has the following composition, percent by weight:
barkhan sand: 90
peat resin: 5
acidol: 5.
The resulting charge is granulated, calcined in an agglomeration machine at the temperature of 1,300° C. The calcined material is crushed and screened.
The resulting calcined material has the following physico-mechanical characteristics:
Volume bulk mass of fractions with the particle size (mm):
20-40: 500 to 550 kg/m 3
10-20: 550 to 600 kg/m 3
5-10: 600 to 700 kg/m 3
1.25-5: 750 to 800 kg/m 3
below 1.25: 900 to 1,100 kg/m 3
Compression strength, kgf/cm 2 : 35 to 45
Frost-resistance, mass loss, %: 0.5
Silicate decomposition, %: 0.7.
The calcined material is mixed with cement in the amount of 38% by mass of the calcined material. To the resulting mixture water is added in the amount of 18% by mass of the total of the calcined material and cement.
The final concrete has the following physico-mechanical characteristics:
compression strength under normal temperature and humidity after 28-days' hardening, kfg/cm 2 : 320
Volume mass, kg/m 3 : 1,500.
EXAMPLE 14
A charge is prepared which has the following composition, percent by mass:
barkhan sand: 76
shale resin: 18
resin, neutralized and air-occluding prepared from abietic resin by treatment thereof with caustic soda: 6.
The resulting charge is granulated, calcined in an agglomeration machine at the temperature of 1,300° C. The calcined material is crushed and screened. The resulting calcined material has the following physico-mechanical properties:
Volume bulk mass of fractions with the particle size (mm):
20-40: 500 to 550 kg/m 3
10-20: 550 to 600 kg/m 3
5-10: 600 to 700 kg/m 3
1.25-5: 750 to 800 kg/m 3
below 1.25: 900 to 1,100 kg/m 3
Compression strength,kgf/cm 2 : 38 to 50
Frost-resistance, mass loss,%: 0.5
Silicate decomposition, %: 0.7.
The calcined material is mixed with cement in the amount of 38% by mass of the calcined material. To the resulting mixture water is added in the amount of 18% by mass of the total of the calcined material and cement.
The final concrete has the following physico-mechanical characteristics:
Compression strength after 28-days' hardening under normal temperature and humidity conditions, kgf/cm 2 : 310
volume mass, kg/m 3 : 1,500
EXAMPLE 15
A charge is prepared which has the following composition, percent by mass:
barkhan sand: 85
rosin: 8
water-alcohol solution of sodium methylsiliconate of the formula: ##STR10## wherein p=2: 7.
The resulting charge is granulated, calcined in an agglomeration machine at the temperature of 1,300° C. The calcined material is crushed and screened.
The resulting calcined material has the following physico-mechanical characteristics:
volume bulk mass of fractions with the particle size (mm):
20-40: 500 to 550 kg/m 3
10-20: 550 to 600 kg/m 3
5-10: 600 to 700 kg/m 3
1.25-5: 750 to 800 kg/m 3
below 1.25: 900 to 1,200 kg/m 3
Compression strength, kgf/cm 2 : 38 to 45
Frost-resistance, mass loss, %: 0.6
Silicate decomposition, %: 0.5.
The calcined material is mixed with cement in the amount of 38% by mass of the calcined material. To the resulting mixture water is added in the amount of 18% by mass of the total of the calcined material and cement.
The resulting concrete has the following physico-mechanical characteristics:
compression strength after 28-days' hardening under normal temperature and humidity conditions, kgf/cm 2 : 300
volume mass, kg/m 3 : 1,550.
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A process for producing concrete comprising mixing barkhan sand with a fuel selected from the group consisting of a liquid fuel and a solid fuel, and a plastic binder selected from the group consisting of clay, loess, loam and a surfactant liquifying the charge composition and reducing its water consumption, the component being present in the following proportions, percent by weight:
barkhan sand: 95 to 30
fuel: 3 to 20
plastic binder: 2 to 60
The resulting charge is granulated, the granules are calcined at a temperature ranging from 1,000° to 1,600° C. The calcined material is crushed. The crushed material is mixed with cement and water, cement being used in an amount of from 10 to 100% by mass of the calcined material and water--in an amount of from 10 to 60% by mass of the total of the calcined material and cement.
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BACKGROUND OF THE INVENTION
The present invention relates to a process for the manufacture of a protecting and immobilising element of the mattress-like type, and to a mattress-like element so obtained, and in particular to a process for the manufacture of a protecting and immobilising mattress for underwater pipes.
It is known from the document U.S. Pat. No. 4,477,206, belonging to the same applicant, to use parallelepipedal flexible protecting elements for immobilising and protecting underwater pipes. Those elements comprise a flexible outer covering which covers a gabion produced from metal material and filled with a mixture composed of bitumen, sand and stones or pebbles. The protecting elements, once manufactured, are to be lowered into water, at the location of the pipes to be protected, by means of handling machines, such as cranes, mechanical arms and the like.
In order to facilitate such positioning, processes are known for the manufacture of mattress-like protecting elements comprising support elements which, in use, facilitate the handling thereof. Document EP0881334, in the name of Giuseppe Sarti & C., illustrates a process for the manufacture of a mattress-like flexible component comprising the stages of covering the chamber of a mould with a cover, positioning inside the chamber a reinforcement of wire netting lying in a plane parallel with the base of the chamber, introducing into the chamber a filling material, which is premixed at high temperature and is composed of an aggregate having dimensions such as to pass through the meshes of the netting until the reinforcement is incorporated, and covering the filling material with the cover.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a process for the manufacture of protecting elements of the mattress-like type in a rapid, efficient and economical manner which thus permits a high degree of saving in terms of installation costs and time.
A further object of the present invention is to optimise the stages of the process for the manufacture of a protecting element of the mattress-like type which is easy to handle and is adaptable to different conditions of use.
In order to achieve the objects indicated above, the present invention relates to a process for the manufacture of protecting elements of the mattress-like type, comprising the stages of providing containing means; providing a layer of flexible material and arranging it inside the containing means, with the peripheral edges of the flexible layer protruding from the containing means; arranging anchoring means and a first netting structure inside the containing means, the netting structure being in direct contact with the flexible layer and the anchoring means passing through the netting structure at predetermined positions; filling the containing means with a filling material comprising solid and/or fluid elements; superposing a second netting structure on the filling material, and superposing, at least partially, the peripheral edges of the flexible layer in such a manner as to produce a closed cover from which the ends of the anchoring means protrude.
One of the main advantages of the present invention is that it provides a process for the manufacture of protecting elements of the mattress-like type, which, by reducing the number of stages necessary compared with the known processes, is rapid and efficient and, at the same time, preserves unchanged all of the characteristics of solidity and flexibility present in the protecting and immobilising elements of known type.
A further advantage of the present invention resides in the use of a filling material which comprises solid elements which are readily available even in situ, and the form and dimensions of which are not limited, as long as the characteristics of resilience of the mattress-like element can be maintained.
Another advantage of the present invention consists in the particular and innovative form of the anchoring means which facilitate the homogeneous distribution of the filling material inside the mould, preventing impurities, discontinuity and residual cavities, and increasing the resilient characteristics of the mattress-like element.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages will become clear from the following description of a preferred embodiment, with reference to the appended drawings, which are given purely by way of non-limiting example and in which:
FIGS. 1 to 7 are perspective views illustrating the stages of a process for the manufacture of a mattress-like protecting element according to one embodiment of the present invention;
FIGS. 8 to 10 are perspective views of different embodiments of an anchoring means;
FIG. 11 is a sectional view of the mattress-like protecting element during stage e) of the process according to the present invention;
FIG. 12 is a perspective view of stage d) of the process according to the present invention in which different embodiments of the anchoring means are illustrated; and
FIGS. 13 to 20 are perspective views illustrating the stages of a further process for the manufacture of a mattress-like protecting element according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, in order to manufacture a protecting element that is in mattress-like form, containing means, for example, although this is not to constitute a limitation, a preferably parallelepipedal mould 2 which has a rectangular base and which is generally produced from a rigid heat-resistant material are first of all provided. A layer of fabric 3 is positioned inside the mould 2 , the fabric 3 being constituted, for example, by a so-called “non-woven fabric” which therefore covers the inner portion of the mould. The surface extent of the fabric 3 is larger than the inner surface of the mould 2 so that peripheral edges 4 of the fabric 3 protrude from the mould.
Anchoring means 5 are then arranged at the location of predetermined positions 12 , indicated by broken lines in FIGS. 1 and 2, on the central portion of the fabric 3 contained in the mould 2 . FIG. 8 shows an embodiment, purely by way of non-limiting example, of an anchoring means 5 comprising a plate 9 to which a hollow cylindrical element 10 is secured in a direction perpendicular to the surface of the plate 9 . Two openings 13 , which are particularly suitable for the insertion and connection of a pin element 14 , are formed in the surface of the hollow cylinder 10 in diametrically opposite positions. The anchoring means 5 also comprise a strap 11 , for example of fibres or the like, which is secured to the pin 14 and is accommodated inside the cylinder 10 in such a manner that it is concealed and protected during the process of manufacturing the mattress-like element.
Naturally, the anchoring means 5 can be produced in various different forms, as long as the objects and advantages of the present invention are achieved. For example, in another embodiment, illustrated in FIG. 9, the anchoring means 5 comprise an “omega”-shaped bar 19 , the upper end 31 of which is accommodated inside a portion of a hollow cylindrical element 15 . Two foot elements 16 are secured to the outer surface of the cylindrical element 15 and rest, together with the lower ends of the bar 19 , in direct contact with the surface of the fabric and maintain the cylindrical portion 15 at a height which almost corresponds to the height of the lateral walls of the mould 2 . An eye-like element 17 is engaged with the upper end 31 of the bar 19 and is selectively retractable into the cylindrical element 15 . In use, during the stages of manufacturing the protecting element, the eye 17 is kept inside the cylindrical element 15 so that it does not interfere with the other elements, while, in the stage of handling the protecting element, the eye 17 is removed from the cylindrical element 15 to enable it to be fastened to fastening means, such as, for example, hooks, ropes, spring catches and the like (not illustrated) In a further embodiment, illustrated in FIG. 10, in order to increase the stability of the anchoring means 5 , the lower ends of the bar 19 are connected to a plate-like element 18 .
When that preparation stage has been completed, a netting structure 6 is arranged in the mould 2 in such a manner that it is in direct contact with the fabric 3 . The structure 6 is produced from double-twist wire netting having hexagonal meshes. In one embodiment of the present invention, the base comprises a panel of wire netting, the hexagonal meshes of which are preferably oriented in such a manner that the portions at the location of which the various wires are twisted with one another extend in the longitudinal direction of the structure 6 . The longitudinal lateral walls are constituted by panels of wire netting, likewise having hexagonal meshes, in which the portions at the location of which the various wires are twisted with one another preferably always extend in directions perpendicular to the longitudinal direction of the structure 6 . That characteristic is intended to promote the flexibility of the protecting element when it is superposed on a tubular pipe to be protected and immobilised, although it is not to be regarded as limiting.
Finally, the hexagonal meshes of the wire netting of the base of the structure 6 are of a size such as to permit the complete passage of the cylindrical element 10 of the anchoring means 5 , and thus to enable the netting structure 6 to adhere to the fabric 3 , so that, as illustrated in FIG. 11, the plate 9 is compressed between the fabric 3 and the base of the netting structure 6 .
According to the process of the present invention, the mould 2 is then filled with a filling material 7 of known type, comprising, for example, a hot mixture of crushed stones and/or pebbles, mastic based on sand and bitumen, or any other type of mixture comprising solid and/or fluid elements which ensures a semi-plastic consistency down to low temperatures. Naturally, the solid elements may be inserted in the mould 2 before the mastic is poured in, without preliminary crushing operations, thus reducing manufacturing costs, as long as the resilient characteristics of the mattress-like protecting element are ensured at the end of the process.
The ratio between the amount of solid material and the amount of mastic poured in is advantageously to be such that the mastic occupies from 30 to 40% of the volume of the mould. To achieve that result, it is possible, for example, to use a mastic based on sand “filler” and bitumen, the composition of which is such as to ensure good flexibility under the conditions of use.
The filling material 7 is poured into the mould 2 until its level reaches approximately the height of the lateral walls of the mould 2 , but leaving the upper ends of the cylindrical elements 10 emerging at least partially and avoiding the formation of residual cavities by spreading and levelling operations.
Before the filling material 7 reaches its setting point, the mould 2 is covered with a further netting structure 8 in order to ensure continuity of form and material with the first netting structure 6 , and to constitute a carrying structure for the mattress-like element. Given the chemical and physical characteristics of the filling material, once cooled, it will constitute a natural securing element between the two netting structures 6 and 8 . Of course, the further netting structure 8 also is preferably produced from double-twist wire netting having hexagonal meshes of a size such as to permit the passage of the cylindrical element 10 of the anchoring means 5 .
Finally, the peripheral edges 4 of the layer of fabric 3 , which have remained outside the mould 2 during the first stages of the process, are lifted and secured to one another in such a manner as to close the entire layer of fabric 3 on itself and to produce the mattress-like protecting element.
The peripheral edges 4 are to permit, by means of openings which are predefined or formed during the manufacture of the mattress-like element, the emergence of the upper ends of the cylinders 10 of the anchoring means 5 , in order to render accessible the straps 11 contained inside them.
In order to facilitate the moving and handling of the mattress-like protecting element, the straps 11 can be removed from the cylinder 10 and thus provide anchoring and fastening points for handling means (not illustrated). The vertical stresses caused by the lifting forces will be distributed by the anchoring means 5 onto the plates 9 which, being positioned beneath the netting structure 6 in direct contact with the layer of fabric 3 , will in turn distribute the stresses over the entire extent of the mattress-like protecting element.
In another embodiment, the structure of the mattress-like protecting element may be further reinforced by means of steel cables, or stranded wire, anchored to the upper corners of the netting structure 6 , or preferably superposed on the other netting structure 8 .
According to a further process for the manufacture of a protecting element of the mattress-like type according to a further embodiment of the present invention, as illustrated in FIGS. 13 to 20 , containing means, for example, although this is not to constitute a limitation, a preferably parallelepipedal mould 20 which has a rectangular base and which is generally produced from a rigid heat-resistant material are first of all provided. A layer of fabric 21 is positioned inside the mould 20 , the fabric being constituted, for example, by a so-called “non-woven fabric”, which therefore covers the inner portion of the mould. The surface extent of the fabric 21 is larger than the inner surface of the mould 20 so that peripheral edges 22 of the fabric 21 protrude from the mould.
A netting structure 23 is then arranged inside the mould 20 in such a manner that it is in direct contact with the fabric 21 . The structure 23 is produced from double-twist wire netting having hexagonal meshes. In one embodiment of the present invention, the base comprises a panel of wire netting, the hexagonal meshes of which are preferably oriented in such a manner that the portions at the location of which the various wires are twisted with one another extend in the longitudinal direction of the netting structure 23 . That characteristic is intended to promote the flexibility of the protecting element when it is superposed on a tubular pipe to be protected and immobilised, although it is not to be regarded as limiting.
The longitudinal surface extent of the netting structure 23 is larger than the inner surface of the mould 20 , so that the peripheral edges 24 of the netting structure 23 are bent in accordance with a line 25 and protrude from the mould 2 .
Anchoring means are then arranged at the location of the bending lines 25 on the inner surface of the netting structure 23 contained inside the mould 20 . FIG. 15 illustrates an embodiment, purely by way of non-limiting example, of an anchoring means comprising a rod 26 to which a plurality of straps 27 , for example of fibres or the like, are secured. Naturally, the anchoring means may be produced in various different forms, as long as the objects and advantages of the present invention are achieved.
Finally, the hexagonal meshes of the peripheral edges 24 of the wire netting of the netting structure 23 are of a size such as to permit the complete passage of the straps 27 , as illustrated in FIG. 15 .
According to this process, the mould 20 is then filled with a filling material 7 of known type, comprising, for example, a hot mixture of crushed stones and/or pebbles, mastic based on sand and/or bitumen, or any other type of mixture comprising solid and/or fluid elements which ensures a semi-plastic consistency down to low temperatures. Naturally, the solid elements may be inserted in the mould 20 before the mastic is poured in, without preliminary crushing operations, thus reducing the manufacturing costs, as long as the resilient characteristics of the mattress-like protecting element are ensured at the end of the process.
The ratio between the amount of solid material and the amount of mastic poured in is advantageously to be such that the mastic occupies from 30 to 40% of the volume of the mould. To achieve that result, it is possible to use, for example, a mastic based on sand “filler” and bitumen, the composition of which is such as to ensure good flexibility under the conditions of use.
The filling material 7 is poured into the mould 20 until its level reaches approximately the height of the lateral walls of the mould 20 , avoiding the formation of residual cavities by spreading and levelling operations.
Before the filling material 7 reaches its setting point, the peripheral edges 24 of the netting structure 23 , which have remained outside the mould 20 during the first stages of the process, are bent towards the upper surface of the filling material 7 which, in turn, is covered by a further netting structure 8 , in order to ensure continuity of form and material with the first netting structure 23 , and to constitute a carrying structure for the mattress-like element. Given the chemical and physical characteristics of the filling material, once cooled, it will constitute a natural securing element between the two netting structures 23 and 8 and the peripheral edges 24 . Naturally, the further netting structure 8 also is preferably produced from double-twist wire netting having hexagonal meshes.
In a further, alternative, embodiment of the present invention, the peripheral edges 24 of the netting structure 23 are bent towards the base of the netting structure 23 before starting the stage of filling the mould 20 , thus ensuring that the anchoring means have greater stability inside the netting structure 23 .
Finally, the peripheral edges 22 of the layer of fabric 21 , which have remained outside the mould 20 during the first stages of the process, are lifted and secured to one another in such a manner as to close the entire layer of fabric 21 on itself and to produce the mattress-like protecting element.
The peripheral edges 22 are to permit, by means of openings which are predefined or produced during the manufacture of the mattress-like element, the emergence of the straps 27 in order to render them accessible to any handling means (not illustrated) and thus to facilitate the moving and handling of the mattress-like protecting element.
Naturally, the principle of the invention remaining the same, the forms of embodiment and details of manufacture may be varied widely with respect to those defined in the claims which follow, without thereby departing from the scope of the present invention.
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A process for the manufacture of a protecting and immobilizing element of the mattress-like type consists in providing containing means ( 2, 20 ) and a layer of flexible material ( 3, 21 ) inside them, with the peripheral edges ( 4, 22 ) of the flexible layer ( 3, 21 ) protruding from the containing means ( 2, 20 ). Anchoring means ( 5 ) and a first netting structure ( 6, 23 ) are also arranged inside the containing means ( 2, 20 ) so that the netting structure ( 6, 23 ) is in direct contact with the flexible layer ( 3, 21 ) and the anchoring means ( 5 ) pass through the netting structure at predetermined positions ( 12, 25 ). The containing means ( 2, 20 ) are then filled with a filling material ( 7 ) comprising solid and/or fluid elements, and a second netting structure ( 8 ) is superposed on the filling material. Finally, by superposing, at least partially, the peripheral edges ( 4, 22 ) of the flexible layer ( 3, 21 ), a closed cover is produced from which the ends ( 11, 27 ) of the anchoring means ( 5 ) protrude.
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