description
stringlengths 2.98k
3.35M
| abstract
stringlengths 94
10.6k
| cpc
int64 0
8
|
|---|---|---|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to pressure adjuster valves, and more particularly to a pressure adjuster valve in which when chamber pressures within the two chambers are reversed, the chamber pressures may be quickly and positively caused to be equal to each other. The present invention also relates to a gas compressor utilizing the pressure adjuster valve.
2. Description of the Related Art
FIG. 6 shows a gas compressor for an automotive air conditioning system. In the same drawing, the gas compressor incorporates therein a pressure adjuster valve 50 as means for preventing the reverse phenomenon of chamber pressures between a suction chamber 11 and a back pressure chamber 23 .
That is, in case of the gas compressor shown in FIG. 6, since, upon the operation thereof, the low pressure refrigerant gas within the suction chamber 11 is compressed with in a cylinder 1 and discharged to the side of a discharge chamber 19 as high pressure refrigerant gas, comparing the suction chamber 11 and the back pressure chamber 23 , the suction chamber 11 is lower in chamber pressure than the other chamber. However, in the case where a vehicle is parked for a long period of time at a standstill state in particular under the sunshine in high summer and the like, since the refrigerant gas is soluble in the oil within an evaporator constituting the air conditioning system, the refrigerant gas contained in the oil is warmed by an external air kept at a high temperature and gasified and introduced into the suction chamber 11 side of the gas compressor and the like, under the standstill state before starting the gas compressor, the phenomenon that the chamber pressure within the suction chamber 11 is higher than the chamber pressure within the back pressure chamber 23 , i.e., the so-called reverse phenomenon would occur.
Moreover, in case of a vane rotary type gas compressor as shown in FIG. 7, the compression of refrigerant gas is performed by the volume change of a compression chamber 10 inside the cylinder 1 . Also, the pressure of refrigerant gas to be sucked into the cylinder 1 from the suction chamber 11 is applied to work on the tip ends of vanes 9 forming and partitioning the compression chamber 10 .
Accordingly, in accordance with the gas compressor with the structure shown in FIG. 6, under the standstill state before the start of the operation, the pressures of the suction chamber 11 and the back pressure chamber 23 are reversed as described above. For this reason, the vanes 9 are pressed back to vane grooves 8 of a rotor 4 by means of the pressure of refrigerant gas within the suction chamber 11 . Therefore, upon the start of the operation, the sealability of the compression chamber 10 partitioned and formed by the vanes 9 and the like is lost, and the compression function of refrigerant gas by the volume change of the compression chamber 10 is degraded, disadvantageously.
Therefore, in the gas compressor shown in FIG. 6, the discharge chamber 19 and the back pressure chamber 23 are in communication with each other through an oil feed passage composed of an oil hole 21 , clearances of bearings 5 and 6 and the like. Accordingly, the pressure adjuster valve 50 is provided between the back pressure chamber 23 and the suction chamber 11 as shown in FIG. 8 so that the reverse phenomenon of the chamber pressures between the back pressure chamber 23 and the suction chamber 11 is prevented.
In case of the pressure adjuster valve 50 shown in FIG. 8, when the chamber pressure of the suction chamber 11 is lower than the chamber pressure of the back pressure chamber 23 , a valve body 55 is pressed into a truncated conical hole 52 by means of the pressure difference between the two chambers 11 and 23 to close a communication passage 51 . On the other hand, when the chamber pressures of the two chambers 11 and 23 are reversed, the valve body 55 is released and moved away from the truncated conical hole 52 by means of the pressure difference of the two chambers 11 and 23 . Thus, the pressure of the suction chamber 11 is released to the side of the back pressure chamber 23 through the communication passage 51 and the chamber pressure of the suction chamber 11 is caused to be equal to the chamber pressure of the back pressure chamber 23 .
However, in accordance with the pressure adjuster valve 50 with the conventional structure shown in FIG. 8, a gap portion 57 between an edge portion of the truncated conical hole 52 and a surface facing the edge portion is present and the valve body 55 that has been rolled and dropped from the truncated conical hole 52 is partially engaged with this gap portion 57 . Accordingly, even if the chamber pressure of the back pressure chamber 23 is higher than the chamber pressure of the suction chamber 11 , the valve body 55 hardly would be returned in the direction toward the truncated conical hole 52 . Thus, there is a problem that a smooth opening/closing operation of the communication passage 51 could not be ensured.
In order to solve the above-described problem of the pressure adjuster valve 50 shown in FIG. 8, there has been an approach that a front portion from the truncated conical hole 52 is formed to extend in the form of a cylinder as the means for eliminating the gap portion 57 . However, in the structure according to this approach, in the case where the oil for lubricating the compressor for lubrication during the operation of the compressor is left within the communication passage 51 even after the standstill of the compressor, an oil film is formed around the valve body 55 so that the valve body 55 is kept stuck to the truncated conical hole 52 by this oil film, or even if the valve body 55 is separated away from the truncated conical hole 52 , in some cases, the communication passage 51 is closed by means of the oil film and the normal function of the pressure adjuster valve 50 is lost. For this reason, even if such a reverse phenomenon of the chamber pressure would take place, it is impossible to immediately cause the pressures to be equal, resulting in the problem of such a reverse phenomenon of the chamber pressures, i.e., the degradation in refrigerant gas compression function during the operation of the compressor.
SUMMARY OF THE INVENTION
In order to solve the above-described problems, an object of the present invention is to provide a pressure adjuster valve that may quickly cause the chamber pressures of the two chambers to be equal to each other with high reliability, when the chamber pressures of the two chambers are reversed, and to provide a gas compressor utilizing the pressure adjuster valve.
In order to achieve the above-mentioned objects, according to the present invention, there is provided a pressure adjuster valve having a communication passage for connecting two chambers, a truncated conical hole provided as a valve seat portion on the way of the communication passage, and a valve body provided to be movable within the communication passage and formed to be engageable with the truncated conical hole, characterized in that:
wherein when a chamber pressure within one of the chambers is lower than a chamber pressure of the other chamber, the valve body is depressed into the truncated conical hole by means of a pressure difference between the two chambers to thereby close the communication passage whereas the chamber pressures of the two chambers are reversed, the valve body is released and moved away from the truncated conical hole by means of the pressure difference between the two chambers upon the reversal to thereby open the communication passage;
the pressure adjuster valve comprises a broadening means for partially broadening a width of a fine gap between the valve body and the communication passage.
According to the present invention, there is provided a pressure adjuster valve having a communication passage for connecting two chambers, a truncated conical hole provided as a valve seat portion on the way of the communication passage, and a valve body provided to be movable within the communication passage and formed to be engageable with the truncated conical hole, characterized in that:
wherein when a chamber pressure within one of the chambers is lower than a chamber pressure of the other chamber, the valve body is depressed into the truncated conical hole by means of a pressure difference between the two chambers to thereby close the communication passage whereas the chamber pressures of the two chambers are reversed the valve body is released and moved away from the truncated conical hole by means of the pressure difference between the two chambers upon the reversal to thereby open the communication passage;
the pressure adjuster valve comprises a biasing means for normally biasing the valve body in a direction away from the truncated conical hole.
According to the present invention, there is provided a pressure adjuster valve having a communication passage for connecting two chambers, a truncated conical hole provided as a valve seat portion on the way of the communication passage, and a valve body provided to be movable within the communication passage and formed to be engageable with the truncated conical hole, characterized in that:
wherein when a chamber pressure within one of the chambers is lower than a chamber pressure of the other chamber, the valve body is depressed into the truncated conical hole by means of a pressure difference between the two chambers to thereby close the communication passage, whereas the chamber pressures of the two chambers are reversed, the valve body is released and moved away from the truncated conical hole by means of the pressure difference between the two chambers upon the reversal to thereby open the communication passage,
the pressure adjuster valve comprises a biasing means for normally biasing the valve body in a direction away from the truncated conical hole in addition to a broadening means for partially broadening a width of a fine gap between the valve body and the communication passage.
The pressure adjuster valve according to the present invention is characterized in that the broadening means broadens an upper portion of the overall fine gap.
The pressure adjuster valve according to the present invention is characterized in that the broadening means is a means for broadening widths at several positions of the fine gap.
The pressure adjuster valve according to the present invention is characterized in that the broadening means is composed of a groove formed in an inner wall of the communication passage along a moving direction of the valve body.
The pressure adjuster valve according to the present invention is characterized in that the broadening means is composed of a groove formed in an outer circumferential surface of the valve body.
The pressure adjuster valve according to the present invention is characterized in that the biasing force of the biasing means is greater than a bonding force of oil film for bonding the valve body to the truncated conical hole.
According to the present invention, there is provided a gas compressor comprising a cylinder disposed between a pair of side blocks, a rotor laterally rotatably supported inside of the cylinder through bearings provided on the pair of side blocks and a rotor shaft supported by the bearings, vanes provided to be projectable and retractable from an outer circumferential surface of the rotor toward an inner wall of the cylinder, a compression chamber formed and partitioned by the cylinder, the side blocks, the rotor and the vane, repeating changes in magnitude of volume in accordance with a rotation of the rotor and sucking and compressing refrigerant gas within a suction chamber to thereby discharge the medium to the side of a discharge chamber due to the volume change, a flow path of oil for pressurizing and feeding the oil to the side of a back pressure chamber in communication with bottom portions of the vanes through a bearing clearance of the side blocks from an oil sump of a bottom portion of the discharge chamber, and a pressure adjuster valve for causing both the pressures of the suction pressure and the back pressure chamber pressure of the refrigerant gas to be equal to each other when the suction pressure and the back pressure chamber pressure are reversed, characterized in that:
wherein the pressure adjuster valve comprises a communication passage for connecting the suction chamber and back pressure chamber, a truncated conical hole provided as a valve seat portion on the way of the communication passage, a valve body provided to be movable within the communication passage and formed to be engageable with the truncated conical hole, and a broadening means for partially broadening a width of a fine gap between the valve body and the communication passage;
when a chamber pressure within the suction chamber is lower than a chamber pressure of the back pressure chamber, the valve body is pressed into the truncated conical hole by means of a pressure difference between the two chambers to thereby close the communication passage, whereas the chamber pressures of the two chambers are reversed, the valve body is released and moved away from the truncated conical hole by means of the pressure difference between the two chambers upon the reversal to thereby open the communication passage.
According to the present invention, there is provided a gas compressor comprising a cylinder disposed between a pair of side blocks, a rotor laterally rotatably supported inside of the cylinder through bearings provided on the pair of side blocks and a rotor shaft supported by the bearings, vanes provided to be projectable and retractable from the outer circumferential surface of the rotor toward an inner wall of the cylinder, a compression chamber formed and partitioned by the cylinder, the side blocks, the rotor and the vane, repeating changes in magnitude of volume in accordance with a rotation of the rotor and sucking and compressing refrigerant gas within a suction chamber to thereby discharge the medium to the side of a discharge chamber due to the volume change, a flow path of oil for pressurizing and feeding the oil to the side of a back pressure chamber in communication with bottom portions of the vanes through a bearing clearance of the side blocks from an oil sump of a bottom portion of the discharge chamber, and a pressure adjuster valve for causing both the pressures of the suction pressure and the back pressure chamber pressure of the refrigerant gas to be equal to each other when the suction pressure and the back pressure chamber pressure are reversed,
wherein the pressure adjuster valve comprises a communication passage for connecting the suction chamber and back pressure chamber, a truncated conical hole provided as a valve seat portion on the way of the communication passage, a valve body provided to be movable within the communication passage and formed to be engageable with the truncated conical hole, and a biasing means for normally biasing the valve body in ad direction away from the truncated conical hole;
when a chamber pressure within the suction chamber is lower than a chamber pressure of the back pressure chamber, the valve body is pressed into the truncated conical hole by means of a pressure difference between the two chambers to thereby close the communication passage against a biasing force of the biasing means, whereas the chamber pressures of the two chambers are reversed, the valve body is released and moved away from the truncated conical hole by means of the pressure difference between the two chambers and the biasing force of the biasing means upon the reversal to thereby open the communication passage.
According to the present invention, there is provided a gas compressor comprising a cylinder disposed between a pair of side blocks, a rotor laterally rotatably supported inside of the cylinder through bearings provided on the pair of side blocks and a rotor shaft supported by the bearings, vanes provided to be projectable and retractable from the outer circumferential surface of the rotor toward an inner wall of the cylinder, a compression chamber formed and partitioned by the cylinder, the side blocks, the rotor and the vane, repeating changes in magnitude of volume in accordance with a rotation of the rotor and sucking and compressing refrigerant gas within a suction chamber to thereby discharge the medium to the side of a discharge chamber due to the volume change, a flow path of oil for pressurizing and feeding the oil to the side of a back pressure chamber in communication with bottom portions of the vanes through a bearing clearance of the side blocks from an oil sump of a bottom portion of the discharge chamber, and a pressure adjuster valve for causing both the pressures of the suction pressure and the back pressure chamber pressure of the refrigerant gas to be equal to each other when the suction pressure and the back pressure chamber pressure are reversed;
wherein the pressure adjuster valve comprises a communication passage for connecting the suction chamber and back pressure chamber, a truncated conical hole provided as a valve seat portion on the way of the communication passage, a valve body provided to be movable within the communication passage and formed to be engageable with the truncated conical hole, a broadening means for partially broadening a width of a fine gap between the valve body and the communication passage, and a biasing means for normally biasing the valve body in ad direction away from the truncated conical hole;
when a chamber pressure within the suction chamber is lower than a chamber pressure of the back pressure chamber, the valve body is pressed into the truncated conical hole by means of a pressure difference between the two chambers to thereby close the communication passage against a biasing force of the biasing means, whereas the chamber pressures of the two chambers are reversed, the valve body is released and moved away from the truncated conical hole by means of the pressure difference between the two chambers and the biasing force of the biasing means upon the reversal to thereby open the communication passage.
The gas compressor according to the present invention is characterized in that the broadening means broadens an upper portion of the overall fine gap.
The gas compressor according to the present invention is characterized in that the broadening means is a means for broadening widths at several positions of the fine gap.
The gas compressor according to the present invention is characterized in that the broadening means is composed of a groove formed in an inner wall of the communication passage along a moving direction of the valve body.
The gas compressor according to the present invention is characterized in that the broadening means is composed of a groove formed in an outer circumferential surface of the valve body.
The gas compressor according to the present invention is characterized in that the biasing force of the biasing means is greater than a bonding force of oil film for bonding the valve body to the truncated conical hole.
In the gas compressor having the broadening means according to the present invention, the continuity of the oil film around the valve body in the broadened portion of the fine gap is cut, and the operational response property of the valve body is enhanced while the sticking phenomenon of the valve body by the oil film is prevented;
In the gas compressor having the biasing means according to the present invention, the valve body is forcibly separated from the truncated conical hole by the biasing force of the biasing means. Thus, the sticking phenomenon of the valve body by the oil film is prevented and the operational response property of the valve body is enhanced.
Furthermore, in the gas compressor having both the broadening means and the biasing means according to the present invention, it is possible to positively prevent the sticking phenomenon of the valve body by the oil film by means of the oil film cutting effect by such a broadening means and the separation effect of the valve body by the biasing means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are explanatory views showing one embodiment of a primary part of the present invention, where FIG. 1A is a cross-sectional view of a pressure adjuster valve mounted on a gas compressor, and FIG. 1B is a cross-sectional view taken along the line 1 B— 1 B of FIG. 1 A.
FIGS. 2A-2B are explanatory views showing another embodiment of a primary part of the present invention, where FIG. 2A is a cross-sectional view of a pressure adjuster valve mounted on a gas compressor, and FIG. 2B is a cross-sectional view taken along the line 2 B— 2 B of FIG. 2 A.
FIGS. 3A-3B are explanatory views showing another embodiment of a primary part of the present invention, where FIG. 3A is a cross-sectional view of a pressure adjuster valve mounted on a gas compressor, and FIG. 3B is a cross-sectional view taken along the line 3 B— 3 B of FIG. 3 A.
FIGS. 4A-4B are explanatory views showing another embodiment of a primary part of the present invention, where FIG. 4A is a cross-sectional view of a pressure adjuster valve mounted on a gas compressor, and FIG. 4B is a cross-sectional view taken along the line 4 B— 4 B of FIG. 4 A.
FIGS. 5A-5B are explanatory views showing another embodiment of a primary part of the present invention, where FIG. 5A shows an opening operational condition of the pressure adjuster valve mounted on the gas compressor, and FIG. 5B shows a closing operational condition of the pressure adjuster valve.
FIG. 6 is a schematic explanatory view of a basic structure of a vane rotary type gas compressor and a pressure adjuster valve incorporated therein.
FIG. 7 is a cross-sectional view taken along the line 7 — 7 of FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Embodiments of a pressure adjuster valve and a gas compressor according to the present invention will now be described in detail with reference to FIGS. 1 to 7 .
A basic structure of the gas compressor according to this embodiment is shown in FIG. 6 in which the gas compressor has a substantially oval-shaped inner circumferential cylinder 1 , and side blocks 2 and 3 are mounted at both end faces of the cylinder 1 , respectively. A rotor 4 is disposed on the inside of the cylinder 1 thus arranged between the pair of right and left side blocks 2 and 3 . The rotor 4 is laterally supported to be rotatable through a rotor shaft 5 provided integrally with an axis thereof and bearings 6 and 7 of the two side blocks 2 and 3 for supporting this.
As shown in FIG. 7, a plurality of slit-like vane grooves 8 extending in the radial direction are formed in the rotor 4 . Vanes 9 are mounted one by one in the respective vane grooves 8 . These vanes 9 are adapted to be projectable and retractable toward an inner wall of the cylinder 1 from an outer circumferential surface of the rotor 4 , respectively.
The inside of the cylinder 1 is partitioned into a plurality of small chambers by the inner wall of the cylinder 1 , the inner surfaces of the side blocks 2 and 3 , the outer circumferential surface of the rotor 4 and both side surfaces at tip ends of the vanes 9 . These partitioned small chambers are compression chambers 10 , and by the rotation of the rotor 4 in the direction indicated by an arrow a in the drawing, it repeats the change in magnitude of volume.
When the volume change of the compression chamber 10 takes place, upon the volume increasing stage, the low pressure refrigerant gas within a suction chamber 11 formed upper flow side of the compression chamber 10 is sucked to the compression chamber 10 through suction passages 12 of the cylinder 1 or the like and suction ports 13 of the side blocks 2 and 3 . Then, when the volume of the compression chamber 10 is started to decrease, the refrigerant gas within the compression chamber 10 is started to be compressed by the volume decreasing effect. Thereafter, when the volume of the compression chamber 10 approaches the minimum level, a reed valve 15 of a cylinder discharge port 14 located in the vicinity of a short oblong diameter portion of the cylinder 1 is opened by the pressure of the compressed high pressure refrigerant gas. Thus, the high pressure refrigerant gas within the compression chamber 10 is discharged from the discharge port 14 of the cylinder to a discharge chamber 16 in the external space of the cylinder 1 and further introduced from the discharge chamber 16 to the side of a discharge chamber 19 through an oil separator 18 or the like.
Lubricant oil is contained in the form of mist in the high pressure refrigerant gas discharged into the discharge chamber 16 . The lubricant oil component contained in the high pressure refrigerant gas is separated upon passing through the oil separator 18 and is dropped and reserved in an oil sump 20 at the bottom portion of the discharge chamber 19 .
The pressure of the high pressure refrigerant gas discharged into the discharge chamber 19 works on the oil sump 20 . The oil of the oil sump 20 to which the discharge pressure Pd is thus applied passes through the oil flow path, i.e., the side blocks 2 and 3 , an oil hole 21 of the cylinder 1 , and the clearances of the bearings 6 and 7 in this order and is finally pressurized and fed to a back pressure chamber 23 in communication with the bottom portion of the vanes 9 . Note that, the back pressure chamber 23 is composed of supply grooves 22 formed in opposite surfaces of the cylinder of the side blocks 2 and 3 and the space of the bottom portions of the vanes 9 connected to the supply grooves. Then, the pressure of oil pressurized and fed to the back pressure chamber 23 works on the vane 9 as the force (back pressure) for pushing the vane 9 upwardly to the inner wall of the cylinder 1 .
In the gas compressor according to this embodiment, a pressure adjuster 50 shown in FIG. 1 is incorporated as the means for causing the suction pressure and the back pressure chamber pressure of the refrigerant gas to be equal to each other when the pressures are reversed.
The pressure adjuster valve 50 of FIG. 1 has a communication passage 51 for connecting the suction chamber 11 and the back pressure chamber 23 . A truncated conical hole 52 is provided as a valve seat portion on the way of the communication passage 51 . This truncated conical hole 52 is in communication with the suction chamber 11 side at a small diameter opening end 52 a on the apex portion of the truncated conical portion out of the two opening ends, and at the same time, a large diameter opening end 52 b on the bottom portion of the truncated conical portion is opened and formed in communication with the back pressure chamber 23 .
There are a variety of possible approaches for the method for forming the communication passage 51 . In the pressure adjuster valve 50 according to this embodiment, a casing in the form of a cylindrical body or bush 54 having a short length corresponding to about half the length of a through hole 53 is disposed in the through hole 53 for connecting the suction chamber 11 and the back pressure chamber 23 with each other. The communication passage 51 is composed of a cylindrical hollow hole 54 a of this cylindrical bush 54 and a front portion of the through hole 51 from the cylindrical bush 54 . Also, in this case, the opening end of the cylindrical bush 54 is adapted to be opened in a conical shape to form the truncated conical hole 52 .
A valve body 55 made of steel in the form of a ball is arranged within the communication passage 51 . This valve body 55 is disposed to be movable along the communication passage 51 , and at the same time formed to be engageable with the above-described truncated conical hole 52 . Note that, the valve body 55 is located on the side of the opening end 52 b having the larger diameter out of the two opening ends 52 a and 52 b of the truncated conical hole 52 and is adapted to be engageable with the hole 52 from this position.
A fine gap G that is necessary but at minimum to make it possible to move the valve body 55 is formed between the valve body 55 and the communication passage 51 . In the pressure adjuster 50 according to this embodiment, a groove 56 is formed in an inner wall of the communication passage 50 , more specifically, the inner surface of the front portion of the through hole 53 on the front side from the cylindrical bush 54 as the means for partially broadening this fine gap G. The groove 56 of this communication passage inner wall is provided in the moving direction of the valve body 55 and functions as the means for cutting the oil film to be formed around the valve body 55 .
That is, also in the gas compressor in accordance with the embodiment, if the oil for lubricating the interior of the compressor for lubrication during the operation of the compressor is left within the communication passage 51 even after the standstill of the compressor, the oil film is formed around the valve body 55 within the communication passage 51 . The means for providing the groove 56 in the inner wall of the communication passage 51 as the means for cutting the continuity of such an oil film is the pressure adjuster valve 50 according to the embodiment. In case of the pressure adjuster valve 50 according to this embodiment, the continuity of the oil film around the valve body 55 is cut so that the sealability between the valve body 55 and the communication passage 51 by this kind of oil film is considerably reduced in the forming portion of the groove 56 in the inner wall of the communication passage.
If the groove 56 of the above-described communication passage inner wall is formed at any part out of the overall portions of the fine gap G between such a valve body 55 and the communication passage 51 , it is possible to expect the cutting effect of the oil film by the groove 56 . In the pressure adjuster valve 50 according to this embodiment, such a groove 56 of the communication passage inner wall is formed in particular in an upper portion out of the overall portions of the fine gap G. This is because the loss of the effect that the oil film by the groove 56 is cut is avoided as much as possible. That is, in view of the oil distribution condition of the fine gap G as a whole, the oil is likely to be left in the lower portion of the fine gap G by the gravitational weight. Accordingly, in the case where the groove 56 in the inner wall of the communication passage is provided in the lower portion of the fine gap G, the groove 56 is likely to be filled with the oil relatively earlier, the possibility that the cutting effect of the oil film by the groove 56 is lost is high. In contrast, in the case where the groove 56 in the inner wall of the communication passage is provided in the upper portion of the fine gap G, the oil hardly would be left in the groove 56 and the cutting effect of the oil film by the groove 56 may be expected forever.
The operation of the thus constructed gas compressor in accordance with this embodiment will now be described with reference to FIGS. 1 and 6.
As shown in FIG. 6, also in the gas compressor according to this embodiment, when the operation thereof is started, the low pressure refrigerant gas within the suction chamber 11 is compressed in the cylinder 1 and discharged to the side of the discharge chamber 19 as the high pressure refrigerant gas. For this reason, comparing the chamber pressures within the suction chamber 11 and the discharge chamber 19 during the operation, the chamber pressure within the suction chamber 11 is lower. During the maintenance of such a pressure relationship, the valve body 55 of the pressure adjuster valve 50 is pressed into the truncated conical hole 52 by the pressure difference between the two chambers 11 and 19 . Thus, the communication passage 51 is brought into the closed condition. Accordingly, the pressure on the side of the back pressure chamber 23 is no longer leaked to the side of the suction chamber 11 through the communication passage 51 .
Incidentally, in the gas compressor according to this embodiment, also, in the case where a vehicle is parked for a long period of time is at a standstill state under the sunshine in high summer and the like, the same phenomenon as that of the conventional case, i.e., the phenomenon that the chamber pressure within the suction chamber 11 is higher than the chamber pressure within the discharge chamber 19 or the back pressure 23 in communication with this, i.e., the so-called reverse phenomenon would take place.
When the above-described reverse phenomenon takes place, the valve body 55 of the pressure adjuster valve 50 shown in FIG. 1 is released and moved away from the truncated conical hole 52 opens the communication passage 51 by the pressure difference between the two chamber 11 and 23 upon the reversal. Thus, the pressure of the suction chamber 11 is applied to the side of the back pressure chamber 23 through the communication passage 51 to cause the chamber pressures of the two chambers to be equal to each other.
The oil for lubricating the interior of the compressor for lubrication upon the operation of the compressor might be left within the communication passage 51 of the pressure adjuster valve 50 even after the standstill of the compressor but the phenomenon that the communication passage 51 is closed by the oil film of the left oil hardly would occur. This is because the groove 56 of the inner wall of the communication passage 51 becomes a flow path for the oil so that the oil is likely to flow out from the communication passage 51 .
In the case where the oil is left in the communication passage 51 as described above, the oil film is formed around the valve body 55 of the pressure adjuster valve 50 but the continuity of this kind of oil film is cut by the groove 56 in the inner wall of the communication passage. Thus, the operational response property of the valve body 55 is enhanced and at the same time, the sticking phenomenon of the valve body 55 by the oil film around the valve body 55 hardly would take place.
As described above, in the pressure adjuster valve 50 according to this embodiment and in the gas compressor using this, in the structure of the pressure adjuster valve 50 the broadening means of the groove 56 in the inner wall of the communication passage 51 broadens partially the fine gap G between the valve body 55 and the communication passage 51 . For this reason, the continuity of the oil film around the valve body 55 in the broadened portion of the fine gap G, i.e., the portion where the groove 56 is formed in the inner wall of the communication passage so that the operational response property of the valve body 55 is enhanced. Accordingly, when the reverse phenomenon in chamber pressures takes place in the two chambers, i.e., the discharge chamber 19 or the back pressure chamber 23 in communication with this and the suction chamber 11 , the valve body 55 sensitively responds to this so that the chamber pressures of the two chambers (the back pressure chamber 23 and the suction chamber 11 ) kept under the reverse condition may be caused to be equal to each other quickly and positively. Accordingly, the defect in the case where the compressor is restarted when the reverse phenomenon in chamber pressures takes place as described above, namely, the degradation of the compressor may effectively be prevented.
Note that, in the above-described embodiment, as shown in FIG. 1, a part of the communication passage 51 is formed of the cylindrical bush 54 . However, as shown in FIG. 2, it is possible to form almost all the communication passage 51 by a cylindrical bush 54 . Also in this case, the cylindrical bush 54 is arranged within the through hole 53 . However, the cylindrical bush 54 used here is that a large diameter 54 a - 1 is applied to the midpoint of the cylindrical hollow hole 54 a and a small diameter hole 54 a - 2 is applied to the front portion of the cylindrical hollow hole 54 a onward therefrom. Then, in this case, the truncated conical hole 52 is formed in the bottom portion of the large diameter hole 54 a - 1 . Also, the valve body 55 is provided movably within the large diameter hole 54 a - 1 . The groove 56 of the inner wall of the communication passage is formed in the inner wall of the large diameter hole 54 a - 1 .
In the case where the cylindrical bush 54 having the structure shown in FIG. 2 is used, it is possible to obtain the pressure adjuster valve 50 that operates more positively. This is because not only may the truncated conical hole 52 be formed within the cylindrical bush 54 but also the cylindrical surface for holding the valve body 55 movably is formed within the cylindrical bush 54 as the large diameter hole 54 a - 1 whereby it is possible to machine simultaneously the conical hole 52 and the large diameter hole 54 a - 1 to enhance the coaxility of the two components.
In the above-described embodiment, the single groove 56 is formed in the inner wall of the communication passage 51 as the means for partially broadening the fine gap G. However, it is possible to form a plurality of such grooves 56 radially in the inner wall of the communication passage 51 as the means for broadening the fine gap G at several positions as shown in FIG. 3 .
In the case where only one groove 56 of the inner wall of the communication passage 51 is used as shown in FIG. 1, in view of the effective exhibition of the effect for cutting the oil film by the groove 56 , it is necessary to set the groove 56 to be correctly disposed on the upper portion of the fine gap G. However, in the case where the plurality of grooves 56 of the inner wall of the communication passage 51 are provided radially as shown in FIG. 3, any one of the grooves 56 is disposed in the vicinity of the upper side portion of the fine gap G. Accordingly, it is possible to ensure the stable function without necessity to exactly control the orientation of the grooves 56 , i.e., to obtain the function of cutting the oil film.
Also, in the above-described embodiment, the valve body 55 of the steel ball shape is used. However, instead thereof, it is possible to use the valve body 55 having a shape as shown in FIG. 4 . The valve body 55 shown in the drawing has a shape provided at its tip end with a conical seal surface. In the case where the valve body 55 having such a conical seal surface is used, not only may the groove 56 as the broadening means be formed in the inner wall of the communication passage 51 but also the groove may be formed in the outer circumferential surface side of the valve body 55 as shown in the drawing. With such an arrangement, it is possible to broaden a width of the fine gap G by the groove 56 on the outer circumferential side of the valve body 55 to ensure the same effect as that described above. In addition, there is no formation of burr that is likely to occur in groove machining in the hole. It is therefore possible to dispense with the foreign matter administration of the burr or the like.
In any of the above-described embodiments, in order to prevent the bonding (sticking) phenomenon of the valve body 55 or the closing phenomenon of the communication passage 51 by the oil film, the structure for cutting the oil film around the valve body 55 by the groove 56 (broadening means) is adopted (See FIG. 1 or the like). It is however possible to use the structure as shown in, for example, FIG. 5 as the means for preventing this kind of sticking phenomenon in addition to the above-described embodiments. The difference between the pressure adjuster valve 50 shown in FIG. 5 and that shown in FIG. 1 or the like is that a coil spring 58 is provided as a biasing means within the communication passage 51 . This coil spring 58 is disposed within the communication passage 51 and the valve body 55 is normally biased in a direction away from the truncated conical hole 52 (also referred to as the direction in which the communication passage 51 is opened). Also, the biasing force of the coil spring 58 is adapted to be greater than the sticking force of the oil film for sticking the valve body 55 to the truncated conical hole 52 .
In the case of the pressure adjuster valve 50 shown in FIG. 5 provided with such a coil spring 58 , when the chamber pressure within the suction chamber 11 is lower than the chamber pressure within the back pressure chamber 23 , as shown in FIG. 5B, the valve body 55 is pressed into the truncated conical hole 52 against the biasing force of the coil spring 58 by the pressure difference between the two chambers 11 and 23 to close the communication passage 51 . When the chamber pressures of the two chambers 11 and 23 are reversed, as shown in FIG. 5A, the valve body 55 is released and moved away from the truncated conical hole 52 to close the communication passage 51 by the biasing force of the coil spring 58 and the pressure difference between the two chambers 11 and 23 upon the reversal.
Also, in case of the pressure adjuster valve 50 of FIG. 5, when the chamber pressures of the back pressure chamber 23 and the suction chamber 11 are under the equilibrium, the valve body 55 is separated from the truncated conical hole 52 overcoming the sticking force of the oil film by the biasing force of the coil spring 58 . For this reason, under such an equilibrium condition, it is possible to effectively prevent the phenomenon that the valve body 55 is stuck to the truncated conical hole 52 by the oil film. Accordingly, in the pressure adjuster valve 50 in the drawing, when the chamber pressure of the suction chamber is even slightly higher than that of the back pressure chamber 23 , the valve body 55 may sensitively respond to such a slight pressure reverse phenomenon so that the chamber pressures of the two chambers 23 and 11 may be caused to be equal immediately.
Note that, the pressure control valve according to the above-described embodiments is provided with any one of the broadening means (groove 56 ) and the biasing means (coil spring 58 ). However, it is possible to modify such a pressure adjuster valve so as to have both of the broadening means and the biasing means.
Also, in the foregoing embodiment, the coil spring 58 is used as the biasing means. However, such biasing means is not limited thereto or thereby. It is possible to adapt any elastic member having the same function as the coil spring.
The pressure adjuster valve according to the present invention may be widely applied to equipment in which when the two chambers are reversed in chamber pressure, these pressures have to be equalized to each other positively and quickly, in addition to the gas compressor according to the above-described embodiments.
According to the present invention, in view of the above-described structure of the pressure adjuster valve, the fine gap between the valve body and the communication passage is partially broadened by the broadening means. For this reason, the continuity of the oil film around the valve body is cut in the broadened portion of the fine gap and the operational response property of the valve body is enhanced. Accordingly, when the chamber pressures within the two chambers are reversed, the valve body sensitively responds to this. The reversed chamber pressures of the two chambers may be caused to be equal to each other quickly and positively.
Also, according to the present invention, in view of the structure of the pressure adjuster, the biasing means for normally biasing the valve body in a direction away from the truncated conical hole is provided. For this reason, when the chamber pressures of the two chambers are equal to each other, the valve body is forcibly separated from the truncated conical hole overcoming the sticking force of the oil film by the biasing force of the biasing means. Accordingly, the sticking phenomenon of the valve body by the oil film is prevented and the operational response property is enhanced in such an equilibrium condition.
|
A pressure adjuster valve has a body having a communication passage for connecting a first chamber in fluid communication with a second chamber and a truncated conical-shaped valve seat portion disposed at one end of the communication passage. A valve element is disposed within the communication passage for undergoing movement therein to engage the valve seat portion of the body. A biasing member normally biases the valve element in a direction away from the valve seat portion.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/294,084 filed on May 29, 2001.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
BACKGROUND OF THE INVENTION
This invention relates to a device and method for arranging bricks on a gable and, more particularly, to a device and method for positioning a guide line at each of a number of levels on a gable.
When constructing a bricked-in gable, it is often desirable to lay each course of bricks evenly across the span of the gable. In order to provide of an even course of bricks, a gable lead device or other type of level line is commonly used. Without using some type of guideline, the bricks in each course may be misaligned and uneven.
There have been various attempts to provide for a gable lead device for leveling a course of bricks when constructing a gable. An example of such a device is shown in U.S. Pat. No. 5,964,042 issued to Carper (“Carper”) on Oct. 12, 1999. This arrangement provides for a pair of clamps, a pair of L-shaped angle irons and a guideline. The angle irons are mounted on the underside of the gable so that a first portion of the iron rests flush with the underside of the gable and an extended portion that extends perpendicularly from the surface of the gable. The clamps are coupled with the angle irons by sliding the extended portion within a channel formed in each of the clamps, and then tightening a screw to secure the clamps to each of the irons. The guideline is then extended between the clamps.
Prior art guideline devices suffer from a number of drawbacks and deficiencies. For instance, it is difficult to reposition the clamps on the angle irons. In order to change the position of the clamp on the irons, a user must use one hand to adjust the screw, and use the other hand to slide the clamp into position while holding the clamp on the iron. The use of two hands to position the clamps on the irons is time consuming and inconvenient. Furthermore, the clamp can completely slide off the iron when the clamps are being re-positioned on the irons or if the screw is inadvertently loosened. This leads to further inefficiencies in positioning the guideline.
Accordingly, there remains a need for a gable lead device that may be easily and efficiently used to lay an even course of bricks when constructing a gable. The present invention fills these needs as well as various other needs.
SUMMARY OF THE INVENTION
In order to overcome the above-stated problems and limitations, and to achieve the noted objects, there is provided a gable lead device that may be easily and efficiently used to adjust the position of a guideline when laying a course of bricks to form a gable.
In general, a device having a pair of rails and a pair of guideline holders is disclosed. The rails are secured to the underside of the roof overhanging a gable. The rails define a slot within which the guideline holders are received. The guideline holders are slideable within the slot and may be releasably secured to any of a number of positions along the rails. A guideline is threaded within and releasably secured to each of the guideline holders. Preferably, by depressing a single pin, the guideline may move relative to the pin to remove slack from the line when the holders are repositioned.
Further objects, features, and advantages of the present invention over the prior art will become apparent from the detailed description of the drawings which follows, when considered with the attached figures.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The objects and features of the invention noted above are explained in more detail with reference to the preferred embodiment illustrated in the attached drawing figures, in which like reference numerals denote like elements, and in which:
FIG. 1 is a front elevation view of a bricked-in gable with the gable lead device of the present invention;
FIG. 2 is an enlarged perspective view of the gable device of the present invention;
FIG. 3 is a fragmentary perspective view of the gable device of the present invention;
FIG. 4 is a perspective view of the gable device of FIG. 3;
FIG. 5 is an exploded, perspective view of the gable device of FIG. 4; and
FIG. 6 is a front elevation view of the gable device of FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings in greater detail, the gable lead device of the present invention is shown in connection with a gable and designated generally by the numeral 10 . The invention includes a pair of rails 12 , a pair of guideline holders 14 and a guideline 16 . With reference to FIG. 4, each rail 12 include a pair of angle irons 18 and 20 . The angle irons 18 , 20 have first bars 22 , 24 , and second bars 26 , 28 angled normally from the respective first bars. The angle irons preferably have a length of about six feet. The angle irons are secured at a distance from one another to define a slot therebetween by a pair of mounting brackets 30 at either end of the angle irons. The slot is preferably has a width of about one half of an inch. As best shown in FIG. 5, each mounting bracket includes a base plate 32 and a pair of legs 34 , 36 extending normally from either side of the base plate. Near the midline of the base plate 32 between the sides of the plate from which the legs extend, a pair of apertures 38 are located. On either side of the apertures 38 , the base plate 32 is secured to the first bars 22 and 24 of angle irons 18 and 20 , respectively. Preferably, the brackets 30 are welded to the angle irons. However, the brackets may be integrally formed, attached by nut and bolt fasteners, riveted or otherwise coupled with the angle irons. The angle irons are also secured to one another near the midpoint of each iron by a U-bar 40 . Preferably, U-bar 40 is welded to the edge of the second bars 26 and 28 of either angle iron. The U-bar 40 stabilizes the rails 12 and helps maintain the width of the slot defined between the bars 22 and 24 .
As shown in FIG. 1, a gable 42 and a pair of rakes 44 are shown. The gable 42 is the triangular portion of the endwall of a building. The rakes 44 extend beyond the surface of the gable and run from the ridge 46 (or apex) of the roof and terminate at the eave 48 of the roof. Each rail 12 is secured to the overhang of the roof located between the edge of the surface of the gable 42 and one of the rakes 44 . Specifically, each rail 12 is placed at a specific distance from the gable, and is secured to the underside of the roof by placing screws (not shown) through the apertures 38 of the brackets 30 (FIGS. 3-6) and inserting the screws into the underside of the roof. As more fully set forth below, the upper ends of either rail are preferably located at the same distance from the underside of the ridge 46 .
With reference to FIG. 5, each guideline holder 14 includes a housing 50 , a bolt 52 , a spring 54 and a pin 56 . The housing 50 is preferably annular and has an inner bore 58 with a radius of one-half inch and an outer radius at the exterior of the housing of about one inch. The inner bore 58 is preferably threaded near the bottom end of the housing. When the holder is assembled as discussed below, as best shown in FIG. 2, the bottom end of the housing 50 contacts the first bars 22 and 24 . When located in proximity to the bars 22 and 24 , the housing is capable of fitting within the area defined by the U-bar 40 . The housing preferably has a textured surface to facilitate gripping of the housing when the gable
The bolt 52 is preferably a carriage bolt having a half-inch radius and a length of one and a half inches. The bolt 52 has a transverse bore 60 located proximate its terminal end and preferably having a diameter of about one-fourth of an inch. The shaft of bolt 52 is placed through the slot defined between the first bars 18 and 20 , and through the inner bore 58 of the housing 50 . The base of the shaft preferably has a base section 63 with a squared cross section that fits within the slot between the bars 22 and 24 of the rails. Above the squared section 63 , the bolt has a threaded area with threads matching those of housing 50 . When the surface of the head of the bolt 52 contacts the first bars 18 and 20 , the shaft of the bolt 52 extends beyond the end of the housing 50 so that the transverse bore 60 is cleared from the housing. The bolt 52 also has a longitudinal bore 61 extending along the entire length of the bolt.
Pin 56 is preferably a clevis pin having a shaft 62 (with a diameter of about one-fourth of an inch) and a head 64 . A number of apertures 66 are located along the length of the shaft 62 . When the bolt 52 is placed on one side of the rails and through the housing 50 as set forth above, the pin 56 may be placed through the transverse bore 60 in the bolt. The spring 54 is placed about the shaft 62 to bias the pin 56 away from the bolt 52 .
As best shown in FIG. 2, the guideline 16 is placed through the longitudinal bore 61 of the bolt 52 . Specifically, once the bolt 52 is placed within the housing 50 , and the pin 56 is placed within the transverse bore 60 of the bolt, the pin 56 is depressed in the direction of the housing 50 so that one of the apertures 66 is aligned with the longitudinal bore 61 . Preferably, when the spring is completely compressed, one of the apertures 66 comes into alignment with the longitudinal housing. By coming aligned when the spring is completely compressed, the alignment may be maintained by merely pressing on the head 64 until the head no longer moves relative to the bolt. Continuing to hold the pin 56 in this position, the guideline 16 is place through the bore 61 and the aligned aperture 66 . Once the guideline is completely threaded through the bore, as shown extended around the first bar 24 of angle iron 20 in FIG. 2, pressure may be relieved from pin 56 . The spring 54 biases the pin away from the bolt 52 . Since the guideline 16 within the bore 61 is being pulled in the direction of the inner radius of the housing 50 , the guideline is held against the housing 61 and cannot slide relative to the longitudinal bore 61 . As shown in FIGS. 1 and 2 and discussed below, the EELS guideline 16 is placed through the top of one guideline holder 14 , through the longitudinal bore 61 , around the inner bar 20 (FIG. 2 ), and across to the other guideline holder 14 .
In operation, the rails 12 are first secured to the underside of the roof at the appropriate position. Preferably, the lower end of each rail is placed at a position below the desired line of the first layer of bricks. The rails are typically placed at a constant distance of about three and a half to four and half inches from the gable so that the guideline will be in close proximity to the edges of the bricks when the bricks are place on the gable. When the rails are in the proper position, as mentioned above, screws are placed through the apertures 38 and into the underside of the roof.
Once the rails are in place, each of the guideline holders 14 are placed at a first position so that the holders 14 are at an equal vertical position relative to the ridge 46 . Specifically, with a small turn of the housing 50 relative to the bolt 52 , the space between the housing and bolt is greater than the first bars 22 and 24 , and the holders are capable of being slid to the first position. When each holder 14 is in the desired position, the housing 50 is turned relative to the bolt 52 so that the housing and bolt are frictionally secured to the rails. A number of marks are placed on the rails to determine the vertical locations of the subsequent line of bricks. Since the rails are typically painted, pencil marks are typically made to indicate the lead line of the subsequent layers of bricks.
Before placing the first row of bricks on the gable, the loose end 16 a (as shown in FIG. 2) extending through one of the place holders is pulled relative to the bolt 52 while depressing the pin 56 . The end may either be manually pulled or a weight (not shown) located on the loose end may pull the guideline taut when the pin is depressed. On the guideline is taut, as shown in FIG. 1, the line is directed directly across the gable 42 and a row of bricks may be layed. As shown in FIG. 2, since the guideline wraps about the inner iron 20 , the guideline is straight across nearly the entire width of the gable, and bricks may be placed at the appropriate orientation at the extreme edge of the gable.
Once the first row of bricks is laid, the guideline holders 14 are moved to a second position-a position preferably marked prior to placement of the first row of bricks on the gable. For instance, each layer of bricks may be placed about five and one half inches from the previous layer. Again, the guideline holders 14 are moved by unscrewing the housing 50 relative to the bolt 52 and sliding the holder 14 to the desired position, and tightening the housing to the bolt to maintain the holder at the second position. Once both guideline holders 14 are in the desired position, the pin 52 of one of the holders is depressed and the guideline drawn taut to create a reference line to lay the second layer of bricks. The process continues until the gable is completely bricked in. For larger gables, the rails 12 will be repositioned at least once on the underside of the roof on either side of the gable.
The present invention provides a method and device that allows a number of leads to be located quickly and accurately. As the guideline holders are moved from position to position, there is no risk that the holders will disengage the rails. Moreover, since only a slight turn of the housing, and a depression of the pin is required, the guideline holders may be operated by a single person, and may even be moved with only one hand. The rails allow the lineholders to be accurately positioned, and allows the straight guideline to extend from nearly one edge of the gable to another. Also, the rails may be pre-marked by the mason prior to bricking in the gable. In this respect, the mason may determine the number of course or layers needed to complete the gable prior to beginning the process. Thus, the mason can determine if adjustments must be made before reaching the final layers of the gable so that an equal and aesthetically pleasing distribution of bricks may be laid. Also, the gable may be adapted to fit any size overhang and any size of brick.
From the foregoing it will be seen that this invention is one well adapted to attain all ends and objects hereinabove set forth together with the other advantages which are obvious and which are inherent to the structure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.
For instance, the rails of the present invention have a one piece bar with a slot defined longitudinal along the bar, and the upstanding second bars of the angle irons eliminated. In another alternatively, the slot may be defined between a pair of circular rails, or rails having any of a number of cross sections. Solid blocks rather than the mounting brackets of the preferred embodiment may be used to secure the rails at either end. Additionally, a number of materials such as sheet metals, wood, and the like may be used for the rails.
Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative of applications of the principles of this invention, and not in a limiting sense.
|
A device having a pair of rails and a pair of guideline holders is provided. The rails are secured to the underside of the roof overhanging a gable. The rails define a slot within which the guideline holders are received. The guideline holders are slideable within the slot and may be releasably secured to any of a number of positions along the rails. A guideline is threaded within and releasably secured by each of the guideline holders.
| 4
|
This application claims benefit of Provisional application No. 60/109,270 filed Nov. 20, 1998.
TECHNICAL FIELD
This invention relates to computer software for managing maintenance work in an industrial facility and more particularly to integrating two software systems to optimize resource management.
BACKGROUND
It is important, particularly in large scale industrial facilities, to properly and timely coordinate workers, equipment and materials to complete repairs and to complete preventive maintenance programs. Discrepancies in the allocation of these resources can result in significant equipment downtime and increased labor costs.
Software is available which is useful for establishing job plans and work plans. One such job planning software package is known as MAXIMO®, a program developed and available from PSDI, Inc. This program assists a user in developing the actual work orders which will be issued to a crew.
Another software program available which is useful in resource planning is a job standards program used to create, maintain and manipulate standards for maintenance work, that is detailing the steps to be taken and manhours/trades needed to complete a task, allowing a user to construct new standards using information retained in a database. For example AutoMOST™, available from H.B. Maynard and Company, Inc. performs this function.
These software programs are distinct. Information used in or generated by one program is not available for use in the other program. Thus, a user typically enters information into the job planning program to prepare work orders, without access to and comparison with the job standards program.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an integration program which integrates a job planning program with a standards development program to allow a user to use such standards to build a complete job plan.
It is another object to provide an integration program which enables a user to toggle between a job planning program and a standards development program to enable the user to generate an optimum work plan.
It is yet another object to reduce data entry by allowing data entered in one program to be integrated into the databases accessible by each program.
It is yet another object to optimize resource allocation by producing job plans which integrate standards based on a logic tree coordinated with data accumulated over time, and to provide a means for updating standards based on actual time, manpower, tools and materials used to complete a task.
These and other objects of the present invention are achieved by a computer integration system for maintenance resource management comprising:
a computer;
a first software program for producing job standards based on predetermined user queries and information contained in a first database, the first software program being accessible by the computer;
a second software program for producing a job plan and work orders based on information supplied by the user, the second software program being accessible by the computer; and
an integration software program accessible by the computer, the integration software program having a switch responsive to a user command initiated from either the first or second software program to switch the user to the second or first software program respectively, and having means for supplying data from one software program to the other software program for filling predefined fields such that the user can generate a job standard in the first software program and transfer the developed job standard into a job plan saved in the second software program.
The inventive integration software package preferably utilizes the MAXIMO job planning program as the second software program, providing instructions for accessing preferably the AutoMOST program, which acts as the first software program, allowing a user to develop the specific job operation steps using the job standards program and transferring this as a complete job plan or as information for loading into the appropriate fields in the MAXIMO program. The MAXIMO program then saves the job plan or completes the job plan for use in generating work orders.
Utilizing the present invention, a user can use historical data and multi-activity analysis to identify the steps needed to complete a new job plan or use existing operation/suboperation job standards and integrate that data directly into the job plan. This substantially reduces the time needed to estimate the time, tools, material and labor needed to complete a job and optimizes resource utilization by developing a job plan based on job standards. Further, utilizing the capabilities of the job standards program increases the ability to accurately plan for manhour allocation, and material utilization, avoiding errors or omissions that can result in a poor plan that disrupts the overall manpower resource allocation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the system according to the present invention;
FIG. 2 is an illustration of a job planning display;
FIG. 3 is an illustration of a job preparation time display;
FIG. 4 is an illustration of a crew type and size determination display;
FIG. 5 is an illustration of a completed job plan; and
FIGS. 6-18 illustrate exemplary queries from a job standards program.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is an integration system that utilizes a job planning program, adds instructions for accessing a job standards program with its associated database, allows a user to use the logic tree incorporated in the job standards program to determine specific man hour, labor, material and tool requirements, prepare a job plan, transfers this information to the its corresponding fields in the job planning program and uses the job planning program to generate a final job plan and associated work orders. FIG. 1 illustrates the overall system that is accessed from a computer terminal 1 . The terminal 1 can access either the job standards program 2 or the job planning program 3 , each associated with databases 4 , 5 , an integration software program 6 allowing switching between the programs and transfer of data, and optionally access to other databases.
A key feature of the invention is the use of the job standards program logic and historical database to allow the program to propose the initial parameters for the job plan, letting the user then accept reject or modify the preliminary parameters. For this invention, “standard” means one or more operations typically required to complete a specific task, including one or more of the hours, craft, duration, materials and tools required to complete a task which are determined by the software program after user queries are answered. For example, from the database and answers to user queries, the job standards program may propose using a three man crew of select crafts to perform the work. The user may change the crew size or craft designation, because of specific conditions that may exist, with the program then updating the proposal to reflect differences, for example in duration (i.e. if a crew size of only two in the craft rather than three are available).
Using the job standards program forces the user to follow predetermined logic to develop job plans using methods based work standards during plan preparation, and thus, improves the accuracy of the manpower and resource allocations that must be made.
For this description, the term “software program” may mean either a stand alone program or a portion of a larger software program that performs the defined task. That is, the job standards program may be a component of a larger software program that performs other functions. Thus, all three programs discussed herein may be components of a single software package, which may be the preferred method for practicing the invention. Of course, other combinations are possible, as the integration software can be integral with either the job standards program or the job planning program, as well as being an independent program. Similarly, these programs need not be all resident on a single computer and can be saved on different computers accessible via intra-net, Internet, modem communication, etc.
In operation, the job planning software is modified to include a software switch that is incorporated on the job plan instructions main menu as a button.
FIG. 2 is illustration of a job plan instruction screen 8 that has a button 9 that can be activated by a user. A job plan number 10 is the link between the job planning program 3 and the job standards program 2 . The job plan number will be used to update the job planning tables in the job planning program.
When the button 9 is activated, the job standards logic tree will be executed to generate the job plan parameters. Once the job standards program is initiated, the job standards program searches for the job plan in the job planning program, and if available, will retrieve data from the job plan tables by job plan number.
Both of the programs have access to databases 4 , 5 , 7 that contain tables of information. For example, one table may contain a list of all crafts, another may contain a list of all equipment in a facility, another the number of persons available in each craft, etc. Some of these lists act as drop down menus for filling out various fields in the job plan screen, job standards screen, etc. If data was entered in the job plan fields before switch activation, then these would be transferred to the job standards program to set the initial user defined parameter.
For example, the description, operation or operation duration, if entered in the appropriate job plan fields, are retrieved and displayed in the job standards program window. If no job plan operations are found using the job plan number, then a series of questions are presented to create a new job plan specification using the logic of the job standards software program.
The job standards program, as stated above, poses questions to the user to develop the job standard. This is done by breaking down a plan into operations, and each operation broken down into various suboperations, A new file is opened for each suboperation and a title given and each step necessary to perform the suboperation is identified. Then the suboperations for each operation are grouped together, and the operations organized to complete the plan.
Each step is identified and a time value assigned, as well as a frequency. For example, if one operation were to rotate tires, one step would be to remove a tire, the frequency being four for removing all four tires.
An operation is a group of suboperations, some of which may have been created previously, combined with others that are newly created. Similarly, an existing operation can be modified to create a new operation by adding, deleting or modifying the suboperations.
Once the operations and suboperations are defined, a multi-activity analysis is performed which provide the man-hours and craft type requirements as well as other useful information, such as the control member, i.e., the worker with the most elapsed and wait time. Elapsed time is the amount of time assigned to that worker to perform the specified task and wait time is the amount of time spent waiting for other workers to complete their assigned tasks.
Allowances, for complete job planning, should include travel time, a schedule factor and daily preparation time. These will be discussed in more detail below.
In addition to labor requirements, provision is made for assigning parts needed for specific operations/suboperations such as bolts, nuts, gaskets, etc., so that material requirements are identified. Tools needed can also be identified, though this may be limited to special tools beyond those allocated to a particular craftsman. For example, if a special lift, puller or other tool must be used to perform the task, its identification should be incorporated in the operation/suboperation description.
As discussed above, the job standards program will first attempt to access information concerning the job plan from the job planning program. These may include the following specific fields as shown in Tables 1-4.
TABLE 1
Name
Size
Remarks
JOBPLAN
JPNUM
10
Unique identifier for Job Plan
DESCRIPTION
200
Job Plan description
JPDURATION
8
Job duration in hours:min
LABORCODE
8
Lead Craft
JP2
4
Support Craft #1 size
JP3
4
Support Craft #2 size
JP4
4
Support Craft #3 size
JP5
4
Job Crew Size
JP6
20
Craft #1
JP7
20
Craft #2
JP8
20
Craft #3
JOB
OPERATION
JPNUM
10
Job Plan number
JPOPERATION
4
Job Plan Operation number
DESCRIPTION
200
Job Plan description
OPDURATION
8
Operation duration in
hours:min
JO1
4
Operation reference # in
AutoMOST
JO2
8
Useful block of time in
hours:mins
JO3
8
Daily Prep in hours:mins
JO4
8
Applied Schedule Factor
TABLE 2
JOBLABOR
JPNUM
10
Job Plan number
JPOPERATION
4
Job Plan Operation number
LABORCODE
8
ID number for Craft
CRAFTQTY
4
Craft Quantity for an Operation
LABORHRS
8
Labor hours for this craft
TABLE 3
JOBMATERIAL
JPNUM
10
Job Plan number
JPOPERATION
4
Job Plan Operation number
PARTNUM
8
Part Number referring to
Inventory
PARTQTY
15
Quantity of part required
for op
PARTLOCATION
20
Location of part inventory
TABLE 4
JOBTOOL
JPNUM
10
Job Plan number
JPOPERATION
4
Job Operation number
TOOLNUM
8
Unique ID for a tool
TOOLQTY
4
Quantity of tool for operation
TOOLHRS
8
Hours:mins tool is used
JT4
20
Location
For ease in illustration, the invention will be described in relation to an example where no job plan operations are found. In such a case, the user will use the job standards program to create a job plan, thereby utilizing standards to build the job plan.
The job standards program is accessed using the button as described previously. The job standards program will automatically generate an operation number and initiate a series of questions, which will generate each operation description with the associated time, labor, tools and materials. (Various questions are illustrated in FIGS. 6-18) For example, the questions can be whether the job requires a site inspection, what is the name of the equipment being worked on, what qualifier terms can apply (i.e., “pump”, qualifier, “first sump”) what is the action required, (“repair/replace”) what specific part is involved (“impeller”), what is the frequency, is there job preparation time, is there another action required, is a test required, do you wish to change the lead craft designation?
Of course, other questions are possible such as identifying special tools required, safety steps required, such as equipment lock out which may impact setup time, etc. Typically, a database for a facility will have the specific equipment predefined so that drop down lists are available. Once a piece of equipment is selected, the question can be whether you wish to select an operation/suboperation for that equipment that was previously developed. That is, the operation for replacing the impeller could have been developed before, and if so, could be selected also from a drop down list, to utilize the existing standard specification. The job crew size, manhours/duration, etc., are calculated automatically after the job operation is defined. At that point, the user can override the specified parameters and request an updated calculation to see how the changes affect the job plan.
Once the operations/suboperations standards are created, including the parts needed, duration, craft, etc., these are available for use in creating new operations and new job plans. For example, an operation can involve disconnecting the piping to the first sump pump. This preliminary operation is stored and can be called up for use in many different repair operations.
The Job Planning Software Program
After each operation is identified and completed in the job standards program, the user is asked if the planning is complete. When the user answers yes, the details from the job standards program can be used to fill in the corresponding fields in the job planning screen. (See FIG. 5) Alternatively, the details are transferred as a complete job plan. Thus, a job plan is created using the methods based job standards program and the details loaded into the job planning software, the user obtaining a completed job plan with the job standards program generated information.
A work order is then generated. At this point, the user can apply various adjustments, for example, to change the estimated job duration to allow for actual conditions such as a schedule factor to compensate for job site conditions which would delay completion of the work. For example, based on past performance over a defined period, such as over the past 4 to 14 weeks, an average of the difference between actual hours and estimated hours is taken and applied. For example, if actual work averages 10% more time than estimated, the prior over a six week period, this can be applied to the work order. This adjustment can also take into consideration differences in performance by craft, by type of equipment, etc. depending on the to preferences of the user. Generally, after the work is completed, the work order is returned and the actual time, materials and tools used are added to the database which allows for determination of the schedule factor, as well as provide a measure of overall performance.
This schedule factor is calculated automatically and the user can be asked whether to apply the schedule factor to the duration hours and to the labor man-hours, by activating a work order update button on the job planning display or work order operations screen. Once activated, the work order operation and labor tables in the job planning program will be updated.
Travel time is another adjustment which may be made on the work order operations screen. This requires that the location field on the work order be filled in so that the program can reference a table containing travel times in the facility, for example, it may take 15 minutes to travel from a workshop to the first sump pump.
Daily preparation is another optional adjustment. This is the preparation time to start a job each day, such as time to collect tools and receive instructions from the foreman.
Various examples showing preparation of job plans and work orders according to the present invention follow.
Job Preparation Example 1
The user accesses a job planning screen in the job planning software, to prepare a job plan for replacing a broken shear pin. The user enters a job planning number and clicks onto the button to switch to the job standards program. The user then defines the first operation as follows:
Description: REPLACE BROKEN SHEAR PIN
Daily
Duration
Prep
10
REPLACE BROKEN SHEAR PIN
0.81
0.00
IN WICKET GATE
1.
Remove keeper plate
2.
Setup hydraulic jack
3.
Install jacking rod
4.
Jack out shear pin
5.
Hand ream shear pin hole
6.
Install shear pin
7.
Install keeper plate
8.
Replace detector piping
20
REPLACE SHEAR PIN
1.62
0.11
1.
Remove keeper plate
2.
Setup hydraulic jack
3.
Install jacking rod
4.
Jack out shear pin
5.
Hand ream shear pin hole
6.
Install shear pin
7.
Install keeper plate
CALCULATIONS
Formula
multi-activity analysis (MAA)Clock Time+(Sum of MAA Basic PrepTime/Crew Size)
Note: Dividing the job prep time by the crew size is simply a man-hour to duration conversion.
For Op 10 0.81 hrs+(0.00 hrs)/2 man crew=0.81 hrs
Note: The MAA for replacing a broken shear pin would not be a task performed by itself so there would not be any job prep elements assigned to the analysis.
For Op 20 1.04 hrs+(0.73 hrs+0.12 hrs+0.52 hrs)/2 man crew=1.62 hrs
Note: The shear pins in the wicket gates on either side of the gate with the broken pin are replaced as a rule of caution. The time to replace one shear pin is 0.52 hours. Therefore, the duration for the site work to replace the other two pins is 2 pins×0.52 hours/pin=1.04 hours. The logic during job plan development asks for the frequency to be applied.
After this information is developed, the user then can return to the job planning screen where either the fields are filled in from this data or saved as a complete job plan in the job planning program. The user then prepares to produce a work order as follows.
WORK ORDER CALCULATION DEFINITIONS
A. Duration after Schedule Factor—The operation duration time multiplied by the schedule factor.
Operation duration time*schedule factor
B. Daily Prep after Schedule Factor—The daily prep duration time multiplied by the schedule factor.
Daily prep duration time*schedule factor
C. Number of Days
The number of days are required to properly apply the daily prep at the operation level and the total travel time for the job. This requires two separate calculations as shown below.
C1. For Applying Daily Prep
The duration of the operation divided by the available hours in a day. The available hours in a day are adjusted to omit the round trip travel and the daily prep.
Sum of the operation duration times/(8.0−(2*one-way travel time)−B)
C2. For Applying Total Travel Time
The total duration of the job plan (sum of all operations) divided by the available hours in a day. The available hours in a day are adjusted to omit the round trip travel and the sum of the daily preps for each operation.
Sum of the operation duration times/(8.0−(2*one-way travel time)−the sum of B for all operations)
D. New Duration
The new duration is the operation duration time after application of the schedule factor plus the daily prep after application of the schedule factor multiplied by the number of days.
A+(B*C1)
E. Travel Time
The number of days multiplied by the round trip travel time.
C2*(2*travel time)
Note: The one-way travel time in C & E above is multiplied by 2 to account for a round trip travel time.
EXAMPLE WORK ORDER
Description:
REPLACE BROKEN SHEAR PIN
Assume:
Schedule Factor = 2.0 One-way travel = 0.25 hours
Daily
Duration
Prep
10
REPLACE BROKEN SHEAR PIN
1.62
0.00
IN WICKET GATE
1.
Remove keeper plate
2.
Setup hydraulic jack
3.
Install jacking rod
4.
Jack out shear pin
5.
Hand ream shear pin hole
6.
Install shear pin
7.
Install keeper plate
8.
Replace detector piping
20
REPLACE SHEAR PIN
3.46
0.22
1.
Remove keeper plate
2.
Setup hydraulic jack
3.
Install jacking rod
4.
Jack out shear pin
5.
Hand ream shear pin hole
6.
Install shear pin
7.
Install keeper plate
999
TRAVEL
0.50
Total
5.58 hrs
LABOR DISTRIBUTION
OP
CRAFT CODE
QTY
HOURS
MANHOURS
10
MECHJP
2
1.62
3.24
20
MECHJP
2
3.46
6.92
999
MECHJP
2
0.50
1.00
TOTALS
5.58
11.16
WORK ORDER CALCULATIONS
Step
Op
Description
Calculation
1.
10
Duration after Schedule Factor
0.81 hrs * 2.0 = 1.62
hrs
Daily Prep after Schedule Factor
0.00 hrs * 2.0 = 0.00
hrs
Total
1.62
hrs
2.
20
Duration after Schedule Factor
1.62 hrs * 2.0 = 3.24
hrs
Daily Prep after Schedule Factor
0.11 hrs * 2.0 = 0.22
hrs
Total
3.46
hrs
3.
For application of job prep
10
Number of days
1.62 hrs/8.0 hrs − (2 * 0.25 hrs) − 0.00
hrs
= 1.62 hrs/7.5
hrs
= 0.22
= 1.0
day
20
Number of days
3.46 hrs/8.0 hrs − (2 * 0.25 hrs) − 0.22
hrs
= 3.46 hrs/7.28
hrs
= 0.48
= 1.0
day
For application of total travel time
(1.62 hrs + 3.46 hrs)/(8.0 hrs − (2 * 0.25 hrs) − (0.00 + 0.22)
hrs
= 5.08 hrs/7.28
hrs
= 0.70
= 1.0
day
4.
10
New Duration
1.62 hrs + (1.0 day * 0.00 hrs) = 1.62
hrs
20
New Duration
3.24 hrs + (1.0 day * 0.22 hrs) = 3.46
hrs
5.
999
Travel Time
1.0 day * (2.0 * 0.25 hrs) = 0.50
hrs
Note: The bold numbers are the ones used in the work order on the previous page.
Job Preparation Example 2
The user accesses a job planning screen in the job planning software, to prepare a job plan for disassembly of a servo motor and piping. The user enters a job plan number and clicks the button for switching to the job standards program. The user then uses the logic and queries in the job standards program to identify nine operations required to complete the activity, each operation having been defined previously and being assembled to produce a new job plan. These are identified as follows.
Description: DISASSEMBLE SERVO MOTOR AND PIPING
Daily
Duration
Prep
10
DRAIN OIL IN TO SUMP
1.61
0.12
20
REMOVE GREASE LINES
0.29
0.12
30
DISCONNECT SERVO LINK ARM
2.37
0.20
40
REMOVE SERVO PIPING
1.78
0.00
50
DISCONNECT RESTORING CABLE
0.28
0.00
60
RIG CRANE
0.75
0.00
70
ATTACH RIGGING TO SERVO MOTOR
0.74
0.00
80
REMOVE DOWEL PINS AND BOLTS
0.51
0.12
90
LIFT AND MOVE SERVO TO ASSEMBLY
0.86
0.00
CALCULATIONS
Formula:
MAA Clock Time + (Sum of MAA Basic Prep Time)/Crew Size
For OP 10
1.53 hrs + (0.16 hrs)/2 man crew = 1.61 hrs
For OP 20
0.25 hrs + (0.08 hrs)/2 man crew = 0.29 hrs
For OP 30
2.24 hrs + (0.40 hrs)/3 man crew = 2.37 hrs
For OP 40
1.78 hrs + (0.00 hrs)/4 man crew = 1.78 hrs
For OP 50
0.28 hrs + (0.00 hrs)/2 man crew = 0.28 hrs
For OP 60
0.75 hrs + (0.00 hrs)/3 man crew = 0.75 hrs
For OP 70
0.69 hrs + (0.20 hrs)/4 man crew = 0.74 hrs
For OP 80
0.47 hrs + (0.08 hrs)/2 man crew = 0.51 hrs
For OP 90
0.86 hrs + (0.00 hrs)/4 man crew = 0.86 hrs
After this information is developed, the user then can return to the job planning screen where either the fields are filled in from this data or saved as a complete job plan in the job planning program. The user then prepares to produce a work order as follows.
EXAMPLE WORK ORDER
Description:
DISASSEMBLE SERVO MOTOR AND PIPING
Assume:
Schedule Factor 2.0 One-way Travel = 0.4 hrs
Daily
Duration
Prep
10
DRAIN OIL INTO SUMP
3.46
0.24
20
REMOVE GREASE LINES
0.82
0.24
30
DISCONNECT SERVO LINK ARM
5.14
0.40
40
REMOVE SERVO PIPING
3.56
0.00
50
DISCONNECT RESTORING CABLE
0.56
0.00
60
RIG CRANE
1.50
0.00
70
ATTACH RIGGING TO SERVO MOTOR
1.48
0.00
80
REMOVE DOWEL PINS AND BOLTS
1.26
0.24
90
LIFT AND MOVE SERVO TO ASSEMBLY
1.72
0.00
999
TRAVEL
3.20
WORK ORDER CALCULATIONS
Step
Op
Description
Calculation
1.
10
Duration after Schedule Factor
1.61 hrs * 2.0 = 3.22
hrs
Daily Prep after Schedule Factor
0.12 hrs * 2.0 = 0.24
hrs
Total
3.46
hrs
20
Duration after Schedule Factor
0.29 hrs * 2.0 = 0.58
hrs
Daily Prep after Schedule Factor
0.12 hrs * 2.0 = 0.24
hrs
Total
0.82
hrs
30
Duration after Schedule Factor
2.37 hrs * 2.0 = 4.74
hrs
Daily Prep after Schedule Factor
0.20 hrs * 2.0 = 0.40
hrs
Total
5.14
hrs
40
Duration after Schedule Factor
1.78 hrs * 2.0 = 3.56
hrs
Daily Prep after Schedule Factor
0.00 hrs * 2.0 = 0.00
hrs
Total
3.56
hrs
50
Duration after Schedule Factor
0.28 hrs * 2.0 = 0.56
hrs
Daily Prep after Schedule Factor
0.00 hrs * 2.0 = 0.00
hrs
Total
0.56
hrs
60
Duration after Schedule Factor
0.75 hrs * 2.0 = 1.50
hrs
Daily Prep after Schedule Factor
0.00 hrs * 2.0 = 0.00
hrs
Total
1.50
hrs
70
Duration after Schedule Factor
0.74 hrs * 2.0 = 1.48
hrs
Daily Prep after Schedule Factor
0.00 hrs * 2.0 = 0.00
hrs
Total
1.48
hrs
80
Duration after Schedule Factor
0.51 hrs * 2.0 = 1.02
hrs
Daily Prep after Schedule Factor
0.12 hrs * 2.0 = 0.24
hrs
Total
1.26
hrs
90
Duration after Schedule Factor
0.86 hrs * 2.0 = 1.72
hrs
Daily Prep after Schedule Factor
0.00 hrs * 2.0 = 0.00
hrs
Total
1.72
hrs
2.
For application of daily prep
10
Number of Days
3.22 hrs/8.0 hrs − (2 * 0.4 hrs) − 0.24
hrs
= 3.22 hrs/6.96
hrs
= 0.462
= 1.0
day
20
Number of Days
0.58 hrs/8.0 hrs − (2 * 0.4 hrs) − 0.24
hrs
= 0.58 hrs/6.96
hrs
= 0.08
= 1.0
day
30
Number of Days
4.74 hrs/8.0 hrs − (2 * 0.4 hrs) − 0.40
hrs
= 4.74 hrs/6.80
hrs
= 0.69
= 1.0
day
40
Number of Days
3.56 hrs/8.0 hrs − (2 * 0.4 hrs) − 0.00
hrs
= 3.56 hrs/7.20
hrs
= 0.49
= 1.0
day
50
Number of Days
0.56 hrs/8.0 hrs − (2 * 0.4 hrs) − 0.00
hrs
= 0.56 hrs/7.20
hrs
= 0.08
= 1.0
day
60
Number of Days
1.50 hrs/8.0 hrs − (2 * 0.4 hrs) − 0.00
hrs
= 1.50 hrs/7.20
hrs
= 0.21
= 1.0
day
70
Number of Days
1.48 hrs/8.0 hrs − (2 * 0.4 hrs) − 0.00
hrs
= 1.48hrs/7.20
hrs
= 0.21
= 1.0
day
80
Number of Days
1.02 hrs/8.0 hrs − (2 * 0.4 hrs) − 0.24
hrs
= 1.02 hrs/6.96
hrs
= 0.146
= 1.0
day
90
Number of Days
1.72 hrs/8.0 hrs − (2 * 0.4 hrs) − 0.00
hrs
= 1.72 hrs/7.20
hrs
= 0.24
= 1.0
day
3.
For application of total travel time
Sum of all operations
=
(3.22 + 0.58 + 4.74 + 3.56 + 0.56 + 1.50 + 1.48 + 1.02 + 1.72) = 18.4
hrs
Sum of all daily prep
=
(0.24 + 0.24 + 0.40 + 0.24) = 1.12
hrs
Number of Days
=
18.4 hrs/8.0 − (2 * 0.4 hrs) − 1.12
hrs
=
18.4 hrs/6.08
hrs
=
3.02
=
4.0
days
4.
New Duration
For Op 10
3.22 hrs + (1.0 day * 0.24 hrs) = 3.46
hrs
For Op 20
0.58 hrs + (1.0 day * 0.24 hrs) = 0.82
hrs
For Op 30
4.74 hrs + (1.0 day * 0.40 hrs) = 5.14
hrs
For Op 40
3.56 hrs + (1.0 day * 0.00 hrs) = 3.56
hrs
For Op 50
0.56 hrs + (1.0 day * 0.00 hrs) = 0.56
hrs
For Op 60
1.50 hrs + (1.0 day * 0.00 hrs) = 1.50
hrs
For Op 70
1.48 hrs + (1.0 day * 0.00 hrs) = 1.48
hrs
For Op 80
1.02 hrs + (1.0 day * 0.24 hrs) = 1.26
hrs
For Op 90
1.72 hrs + (1.0 day * 0.00 hrs) = 1.72
hrs
5.
Travel Time
For Op 999
Travel Time 4.0 days * (2 * 0.4 hrs) = 3.2
hrs
As described earlier, the job standards program will use the following steps to create a Job Plan:
1) Automatically generate an Operation Number for each operate step in the Job Plan. The first number will be 10. Subsequent operation numbers will be sequenced in increments of ten.
2) Select the Operation Description.
This will be done by answering all questions required by the logic tree for creating Job Plans. The responses to these questions will generate the Operation Description with the associated time and labor.
3) If there are Job Preparation time associated with the Multi Activity Analysis, MAA, the times will be displayed in a Job Preparation window for each operation step. (See FIG. 3)
The user will be asked whether to include preparation times, YES or NO. If Yes, then the time for all preparation except DAILY will be added to the operation duration. The Daily Prep will be carried over to the Job Plan as a separate entity. If No, then no preparation time will be added to the operation duration. The Daily Preparation will not be carried over to the Job Plan. After the Job Plan is stored in the job planning software database, the user can input only daily preparation in the Work Order Operations screen. The manually entered daily preparation must be reasonable and entered before the data is updated.
4) Do you want to add another Operation?
If Yes, then the user returns to Step 1 to continue using the job standards logic tree to generated additional operation descriptions.
5) Do you want to save the Job Plan?
If Yes, then a display of various crafts with crew size is presented, with a request to confirm or modify these. For example, the lead craft may be changed, with a request to modify the lead craft crew size. If the craft or crew size entered is other than what is displayed, the message “You are over-ridding values recommended by the job standards program, Do you want to continue?” will be displayed. If No, then the job standard program selections are reentered. If yes, then the user selected lead craft is used.
If any tools and materials are associated with the selected operations, the planner will be asked to include all tools and materials. These can be supplied by drop down menu, or by part or tool number. If No, then the tools and materials are not added. If yes, then the job standards selected tools and materials will be added into the job plan. Once complete, the user exits from the job standards program and returns to the job planning program by clicking on a button, where the fields in the job plan are populated with the information generated in the job standards program, or the completed job plan is transferred in its entirety.
To revise a Job Plan, the user has three actions that can be performed on an operation: add, delete, and modify. The user can add a new operation to an existing job plan by using the job standards program or by using the job planning program. The user can delete a complete operation in the Job Plan by using the job standards program, or can modify an operation in the Job Plan by using either program. To use the job standards program, the following steps may be used:
1) Display Job Plan in Job Plan Operation window.
2) Ask question: MODIFY, INSERT, or DONE
IF, MODIFY
THEN>Go to Step 3
IF, INSERT
THEN>Go to Step 8
IF, DONE
THEN>Go to Step 12
3) Select the Operation Number that the planner will modify. The Operation Number is a line entry in the Job Plan Operation screen that is associated with an operation description.
4) Ask: What is the ACTION for this operation?
>Disassemble, Modification, Assemble
>Site Inspection
>Test
Disassemble, Modification, Assemble contains the data driven logic, Site Inspection and Test are logic driven and select only specific MAA elements.
The Operation Description will be selected by answering all questions required by the logic tree for revising Job Plans. The responses to the logic tree questions will generate the Operation Description.
5) Follow steps for creating a Job Plan for qualifying the MAA selected by the job standards program.
6) If a Long Description Key exists for this operation. The planner will be asked:
Do you want to keep the LDKey for this operation?
IF, No
THEN>Delete LDKey when Job Plan is saved.
IF, Yes
THEN>Retain the current LDKey.
7) Go to Step 2.
8) Select an Operation Number.
9) Follow logic in Create a Job Plan in the job standards program.
10) Go to Step 2.
11) Do you want to save the Job Plan?
IF, Yes
THEN>Display up to 4 Crafts with crew size (See FIG. 4)
>Request to modify Lead Craft.
>Request to modify Lead Craft Crew size if Lead Craft is changed.
>If the craft or crew size entered is other than what is displayed, the message “You are over-ridding values recommended by the job standards program, Do you want to continue?” will be displayed.
If, No
THEN>Go to Modify Lead Craft
If, Yes
THEN>Continue
>If any Tools and Materials are associated with the selected operations, the planner will be asked to include all tools and materials.
If, No
THEN>Do not add Tools and Materials
If, Yes
THEN>Add Tools and Materials to the Job Plan
>Insert data into job plan tables
IF, No
THEN>Control is returned to the welcome window.
The user has the option to revise a Job Plan or EXIT.
12) The revision of a Job Plan is finished, control is returned to the job planning software.
Utilizing the present invention, optimized job plans and work orders can be generated that accurately identify manpower, material and tool requirement. With optimized planning, delays are avoided and equipment downtime minimized. For routine, emergency and preventive maintenance, specific materials and tools can be rapidly identified and made available to complete operations in a timely manner. Further, sufficient flexibility is provided in standards development to accommodate the various day to day changes that occur, allowing changes to be incorporated into the job plan so that overall planning is not disrupted. By utilizing job standards logic, the user has an effective tool for avoiding errors in job planning.
While preferred embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes or modifications can be made without varying from the scope of the invention.
|
The invention is an integration software program that enables a user to use the logic and data accessible in a job standards development program to develop a job plan which is then transferred to a job planning software program where it is finalized and used to produce work orders. Integrating these two programs results in producing job plans rapidly and assures optimum utilization of labor, materials and tools.
| 8
|
CROSS-REFERENCE TO RELATED DOCUMENTS
[0001] The present application is related to Indian Provisional Application E-106/224/2016/CHE, which was filed on Jun. 15, 2016, and which is incorporated herein in its entirety. It is also related to U.S. Provisional Patent Application 62/382,604, which was filed on Sep. 1, 2016, which is also incorporated in its entirety at least by reference. This application claims priority to both the Indian and the US provisional applications.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present invention is in the technology area of telephone conferencing, and pertains more particularly to expanding conference capability with multiple media servers.
2. Description of Related Art
[0003] Media servers with software engines to conference multiple participants in one or more conferences are well-known in the art. The media server is a computer apparatus executing software that manages multiple audio feeds from and to persons participating with telephony-enabled devices in conferences. A media server is limited partly by hardware and partly by software to a maximum number of conferees, as it is the number of persons that determines the number of audio streams that must be managed and switched. When the limit of conferees is reached, it is common practice to tie in a second media server to handle the additional load. The second media server is coupled to the firsts media server by a tie line (a trunk line). If there is one additional conferee beyond the capacity of the first media server, there is need for one tie line. A second additional conference in current art requires a second tie line.
[0004] What is needed is a method of managing the conferences and media streams so additional tie lines are not needed as conferees are added beyond the ability of the first media server.
BRIEF SUMMARY OF THE INVENTION
[0005] In one embodiment of the invention a method for managing callers into a conference system having a specific conferee limit for servers is provided, comprising, for a first caller over the conferee limit for a first conference server, the first caller electing a first conference to join, establishing a first tie line to a second conference server, and placing the first caller in a continuation of the first conference in the second conference server, the tie line dedicated to the first conference, for a subsequent caller over the conferee limit for the first conference server, the subsequent caller electing to join the first conference, placing the subsequent caller in the continuation of the first conference in the second conference server, and for a subsequent caller electing to join a conference other than the first conference, determining that there is a listener in the first conference in the first conference server, moving the listener to the continuation of the first conference in the second conference server, and accommodating the subsequent caller in the first conference server in the conference elected, preserving the single tie line.
[0006] In one embodiment f the method further comprises, for a subsequent caller electing to join a conference other than the first conference, determining that there is no listener in the first conference in the first conference server, determining that there is a conferee in the first conference in the first conference server, moving the conferee to the continuation of the first conference in the second conference, and accommodating the subsequent caller in the first conference server in the conference elected, preserving the single tie line.
[0007] In one embodiment of the invention the method further comprises, for a subsequent caller electing to join a conference other than the first conference, determining that there is no listener in the first conference in the first conference server, and determining that there is a conferee in the first conference in the first conference server, moving the conferee to the continuation of the first conference in the second conference, and accommodating the subsequent caller in the first conference server in the conference elected, preserving the single tie line, and upon determining that all conferees in the first conference have been moved to the continuation of the first conference in the second conference server, dropping the tie line between the first and the second conference servers.
[0008] Also in an embodiment, for a subsequent caller electing to join a conference other than the first conference, after the first tie line is dropped, establishing a second tie line dedicated to the conference elected by the caller, and placing the caller in a continuation of the conference elected in the second conference server. And in one embodiment, continuing to manage incoming callers by the techniques of moving listeners, and moving conferees that are in a conference for which a tie line is dedicated, such that new conference servers are added as conferee limits are reached, with a single tie line bridging conference servers.
[0009] In another aspect of the invention a system managing callers in conferences is provided, comprising a first conference server having a plurality of established conferences, and a specific limit of number of conferees total that may be accommodated in all of the plurality of conferences, and a second conference server connected to the first conference server by a first tie line dedicated to a specific one of the plurality conferences. The first tie line is established in response to a first caller over the limit of conferees in the first conference server, is dedicated to the conference the first caller elects, and wherein a conference extension for the elected conference is established in the second conference server, with the first caller as a conferee, wherein for a subsequent caller electing the same conference as the first caller, the subsequent caller is placed in the conference extension in the second conference server for which the tie line is dedicated, and wherein, for a subsequent caller electing a conference other than the conference for which the tie line is dedicated, it is determined whether there is a listener in the first conference in the first conference server, and if so, the listener is moved to the conference extension in the second conference server, and the subsequent caller is accommodated in the elected conference in the first conference server.
[0010] In one embodiment of the system, for a subsequent caller electing to join a conference other than the first conference, determining that there is no listener in the first conference in the first conference server, determining that there is a conferee in the first conference in the first conference server, moving the conferee to the continuation of the first conference in the second conference, and accommodating the subsequent caller in the first conference server in the conference elected, preserving the single tie line.
[0011] Also in one embodiment, upon determining that all conferees in the first conference have been moved to the continuation of the first conference in the second conference server, dropping the tie line between the first and the second conference servers. In one embodiment, for a subsequent caller electing to join a conference other than the first conference, after the first tie line is dropped, establishing a second tie line dedicated to the conference elected by the caller, and placing the caller in a continuation of the conference elected in the second conference server. And in one embodiment the system further comprises continuing to manage incoming callers by the techniques of moving listeners, and moving conferees that are in a conference for which a tie line is dedicated, such that new conference servers are added as conferee limits are reached, with a single tie line bridging conference servers.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0012] FIG. 1 is a diagram illustrating a single media server managing a number of conferences in current art.
[0013] FIG. 2 is a diagram illustrating a second media server coupled to a first media server in current art.
[0014] FIG. 3 is a flow chart illustrating a method in an embodiment of the invention.
[0015] FIG. 4A is a diagram of servers according to an embodiment of the invention.
[0016] FIG. 4B is another diagram illustrating a state in the method of the invention.
[0017] FIG. 4C is a diagram illustrating a further state in an embodiment of the invention.
[0018] FIG. 4D is a diagram illustrating a further state in an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] FIG. 1 is a diagram illustrating a single media server 101 , executing software 102 , and managing four conferences C 1 through C 4 , each conference having a number of conferees, a through n, in current art.
[0020] FIG. 2 illustrates a circumstance wherein media server 101 has reached its limit of conferees, and a second media server 201 has been utilized to manage an excess of conferees. In FIG. 2 there are four conferences shown as being managed by Media Server 101 , with n 1 conferees in conference 1 (C 1 ), n 2 in conference C 2 , n 3 in conference C 3 , and n 4 in conference C 4 . As described above, media server 101 is limited by a maximum number of conferees, not necessarily by the number of conferences.
[0021] As an example, Media Server 101 might be limited to 100 conferees. If n 1 +n 2 +n 3 +n 4 is equal to or less than 100, Media Server 101 is adequate to the tasks, and no second media server is needed. If additional conferees join the conferences in progress until there are a total of 100, the next person who joins one of the conferences, indicated as P 101 in FIG. 2 , will have to be accommodated in Media Server 201 for managing the audio streams. Assume that P 101 joins conference C 1 , and that puts Media Server 101 over its limit. To accomplish this enlargement of service to Media Server 201 a Tie Line T 1 is necessary to bridge conference C 1 between Media Server 101 and Media Server 201 . If yet another person P 102 joins conference C 1 that person also will be allocated to Media Server 201 , but the first Tie Line for C 1 will be adequate.
[0022] Also indicated in FIG. 2 is a circumstance wherein a third person, P 103 , has joined conference C 4 in Media Server 101 . This third person over the limit must also be allocated for media service to Media Server 201 , and in the current art a second Tie Line T 4 is now necessary, to join all of the conferees in C 4 . The skilled person will recognize that there may be more than four conferences being originally managed in Media Server 101 , and that a separate Tie Line will need to be established for every conference that is bridged between Media Servers.
[0023] FIG. 3 is a flow chart illustrating a method in an embodiment of the invention for minimizing the number of media servers and tie lines in expanded service. FIGS. 4A through 4D are schematic diagrams illustrating state of a system of the invention at different stages in the process illustrated by FIG. 3 .
[0024] Referring now to FIG. 3 , process flow is arbitrarily commenced at step 301 , under a circumstance that a first Media Server, noted as M 1 in FIG. 3 , has a plurality of conferences in progress, noted as C 1 through Cn, and under a circumstance that the number of conferees total in all of conferences C 1 through Cn, in progress, is exactly at the limit, example 100, for the capability of the first Media Server. This circumstance is illustrated by server 401 in FIG. 4 , with ongoing conferences C 1 , C 2 , C 3 and C 4 .
[0025] At step 302 a new conferee calls in to join one of the conferences. This new caller is one more than Media Server 401 can serve, designated P 101 , so will have to be accommodated in a second media server 403 . Let us assume, for illustration, that the new caller is calling for conference C 4 in Media Server 401 . Consequently, a tie line T 1 is established to Media Server 403 (M 2 ), and caller P 101 is accommodated in an extension of C 4 in M 2 , as illustrated in FIG. 4A .
[0026] In the technical field of conference bridges, servers and software for managing conferencing, a relatively large number of conferees may be engaged in conferences at any one time. It is common practice to manage conferees in different modes, one of which is a full-service mode, such that a conferee in full service mode may hear all other conferees in a particular conference, and may speak to all of the other conferees. Another mode which may be practiced is Listening mode, in which a conferee may hear one or more other conferees, or all other conferees in a conference, but cannot participate by speaking.
[0027] Now, at step 304 another caller, designated P 102 , dials in to join one of the conferences in Media Server 401 . This next caller may be asking to join the same conference C 4 as the first new caller, but it may well be a different one of the conferences in progress. If the second new caller wants to join the same conference as the first new caller, then that caller may be accommodated in M 2 , Media Server 403 , along with the first new caller, without adding a second tie line. This circumstance is also shown in FIG. 4A with both P 101 and P 102 together in an extension of whatever conference they both elected to join. There is, at this point, no need for a further tie line.
[0028] Now let us assume the second new caller, P 102 , wants to join a different conference in progress in Media server 401 than the conference elected by the first new caller P 101 , assume C 2 . In an embodiment of the invention, instead of accommodating this additional new caller P 102 in Media Server 403 , and establishing a second tie line for conference C 2 , which would then be bridged between the two media servers, in this embodiment control goes to step 305 , and it is determined whether there is a conferee in listening mode (listener) in conference C 4 , the conference for which a tie line has been established to M 2 , Media server 403 . If there is a listener in conference C 4 , that listener is moved to the C 4 extension in second Media Server 403 (M 2 ), as noted in step 306 . This frees up one position in the first media server for the new caller in conference C 2 in Media Server 401 , so there is no need to put the new caller in the second Media Server or to add a Tie Line for C 2 . This circumstance is shown in FIG. 4B , where C 4 (Listener) is now in the C 4 conference extension in Server 403 , and the second new caller P 102 is connected in C 2 in Server 401 . We have had two new callers, the second new caller in two different circumstances, and we still have but one tie line.
[0029] In the circumstance wherein a listener is moved from C 4 to Server 403 , the system in step 307 listens for a next caller, back to step 304 . This next caller is designated P 103 , wants to join one of the conferences in first Media Server 401 , and that conference elected is not C 4 , but for another conference, say C 3 . At the same time, SW 402 continues to monitor total conferees in Media Server 401 . If one or more drop out, then spaces are freed.
[0030] Considering new caller P 103 , if at step 305 there is no further listener found in the conference C 4 for which the first Tie Line has been established (NO), in step 308 , the system checks if there are conferees left in that conference, that is, is the conference still in progress with two or more conferees? If yes, then a conferee in the conference for which the Tie line has been established (our example assumes C 4 ) is moved to the second media server at step 309 . In FIG. 4C this moved conferee is designated C 4 (Moved). The control goes back to step 307 looking for a next caller. At this point, there have been three new callers, over and above the 100-conferee limit for Server 401 , and there is still need for just the one tie line to Server 403 . This process may continue, under fortuitous circumstances through a substantial number of new callers while avoiding a need for a second tie line, in embodiments of the invention.
[0031] Consider now a new caller P 104 , wanting to join a conference, say C 1 . Consider that in this circumstance there a no listeners in C 4 to move to Server 403 , and at step 308 there are no conferees left in C 4 . In previous additions of new callers, all conferees of C 4 have been moved to Server 403 , to accommodate new callers, over the threshold of 100 callers, to accommodate the new callers in Server 401 . If, at step 308 , If there are no conferees left in C 4 in the first media server, control goes to step 310 , and the Tie Line between the first and the second media servers may be dropped, as C 4 is now managed completely in the second media server. New caller 104 , having elected to join conference C 1 , is then accommodated in a continuation of C 1 in Server 403 , and a new tie line T 2 is established for the continuation of C 1 . This circumstance is illustrated by FIG. 4D . The process, of course continues, and additional callers over the Server 401 threshold of 100, will be accommodated as described above, by moving listeners and conferees out of C 1 , into Server 403 , and only one tie line is still necessary between Servers 401 and 403 .
[0032] The skilled person will understand, given the examples described, that there are many variable circumstances, and that the process may proceed according to the flow chart of FIG. 3 in a number of different ways, but that there will never be a need for more than one tie line between the original server and a second server tied in to take the progressive overload of the first server. In the second server, SW 404 , like SW 402 , enforces the operating parameters described, and a third and successive servers may be tied in, but that there will never be a need for more than a single tie line between servers.
[0033] The skilled person will realize that these novel steps may be followed to ensure that no more than one tie line need be established between any two Media Servers. The skilled person will also realize that the steps may be done perhaps in another order, and that there are alternative ways to accomplish the novel process without departing from the scope of the invention. The invention is limited only by the claims below.
|
A method for managing callers into a conference system having a specific conferee limit for servers has steps as follow: for a first caller over the limit for a first conference server, the first caller electing a first conference, establishing a first tie line to a second conference server, and placing the first caller in a continuation of the first conference in the second conference server, for a subsequent caller over the limit, electing to join the first conference, placing the subsequent caller in the continuation in the second conference server, and for a subsequent caller electing to join a conference other than the first conference, determining that there is a listener in the first conference, moving the listener to the continuation in the second conference server, and accommodating the subsequent caller in the first conference server in the conference elected, preserving the single tie line.
| 7
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a sheet feeding apparatus and an image forming apparatus having such a sheet feeding apparatus, and more particularly, it relates to a sheet feeding apparatus in which a sheet is fed out by sheet feeding means provided above the sheet for lifting and lowering movements.
[0003] 2. Related Background Art
[0004] In some of conventional image forming apparatuses such as printers, copying machines and the like, there is provided a sheet feeding apparatus in which a sheet is fed to an image forming portion by sheet feeding means such as a pick-up roller. Among such sheet feeding apparatuses, there is a sheet feeding apparatus in which the sheet feeding means is provided above the sheet for lifting and lowering movements in such a manner that, when the sheet is fed, the sheet feeding means is lowered to be urged against the sheet and, in this condition, the sheet is fed out by rotating the sheet feeding means, and, thereafter, the sheet feeding means is lifted to be separated from the sheet.
[0005] By the way, in such a sheet feeding apparatus, although means for lifting and lowering the sheet feeding means was generally comprised of a solenoid or a cam one revolution of which is controlled, recently, as the speed of the printer has been increased, it is required that the sheet feeding means be urged against the sheet at higher speed and also be separated from the sheet at higher speed after the feeding of the sheet. Further, as noise of recent printers has been reduced, it is required for avoiding usage of an actuator such as a solenoid generating great noise.
[0006] To this end, there has been proposed a sheet feeding apparatus in which, as the means for lifting and lowering the sheet feeding means, a lifting and lowering mechanism for directly lifting and lowering the sheet feeding means by using a pulse motor, for example, is provided.
[0007] [0007]FIG. 8 shows a construction of such a conventional sheet feeding apparatus using a pulse motor. In FIG. 8, the sheet feeding apparatus comprises pick-up rollers 1 a , 1 b as sheet feeding means provided for lifting and lowering movements, and rotations of the pick-up rollers around shafts 2 a , 2 b are controlled by drive sources (not shown). Further, the pick-up rollers 1 a , 1 b are rotatably held on ends of roller holders 3 a , 3 b which are held by an image forming apparatus (not shown) for rotations around shafts 4 a , 4 b.
[0008] Incidentally, there are provided roller springs 5 a , 5 b as urging means for biasing the pick-up rollers 1 a , 1 b in anti-clockwise directions (along which the rollers are urged against an upper surface of a stached sheet P) via the roller holders 3 a , 3 b so that the pick-up rollers 1 a , 1 b are urged against the sheet (not shown) with predetermined pressure by biasing the pickup rollers 1 a , 1 b in the anti-clockwise directions by means of the roller springs 5 a , 5 b.
[0009] Further, in FIG. 8, the reference numeral 6 denotes a rod as a holding member capable of moving in an up-and-down direction and adapted to hold the pick-up rollers 1 a , 1 b for lifting and lowering movements, and “M” denotes a pulse motor as a reversible motor. Rotation of the pulse motor M is transmitted to the rod 6 via a motor gear 12 , a first drive transmitting gear 11 as a first transmitting gear meshed with the motor gear 12 , a second drive transmitting gear 13 as a second transmitting gear integrally formed with the first drive transmitting gear 11 , and a rack gear 10 meshed with the second drive transmitting gear 13 and provided on one side of the rod 6 . Incidentally, the first and second drive transmitting gears 11 , 13 are rotatably held on a rotary shaft 17 .
[0010] On the other hand, guide holes 6 c extending in an up-and-down direction are formed in upper and lower portions of the rod 6 , so that, when the rotation of the pulse motor M is transmitted via the gear train comprised of the motor gear 12 , first and second drive transmitting gears 11 , 13 and rack gear 10 , the rod 6 is shifted in the up-and-down direction while being guided by pins 7 , 8 inserted in the guide holes 6 c.
[0011] Incidentally, support portions 6 a , 6 b for supporting the shafts 2 a , 2 b of the pick-up rollers 1 a , 1 b from below are protruded horizontally from lower and upper ends of the rod 6 . With this arrangement, when the rod 6 is shifted in the up-and-down direction, the pick-up rollers 1 a , 1 b are shifted in the up-and-down direction by the aid of the spring forces of the roller springs 5 a , 5 b or in opposition to the spring forces as the rod 6 is shifted.
[0012] Next, a sheet feeding operation of the sheet feeding apparatus having the above-mentioned construction will be explained.
[0013] In a waiting condition of the sheet feeding apparatus before it starts the sheet feeding operation, the rod 6 is held at a highest position or home position, so that the pick-up rollers 1 a , 1 b are positioned above the sheet. In this case, although the pulse motor M is not rotated, it is maintained in an exciting condition so that the rod 6 is held in the home position in opposition to the biasing forces of the roller springs 5 a , 5 b.
[0014] On the other hand, when sheet feeding command is emitted from a controlling device (not shown) provided in the image forming apparatus, first of all, the pulse motor M is rotated in the anti-clockwise direction, and the anti-clockwise rotation is transmitted to the rod 6 via the motor gear 12 , first and second drive transmitting gears 11 , 13 and rack gear 10 , with the result that the rod 6 is lowered. When the rod 6 is lowered in this way, the pick-up rollers 1 a , 1 b are also lowered together with the rod 6 by the biasing forces of the roller springs 5 a , 5 b , thereby urging the pick-up rollers against the sheet P.
[0015] Incidentally, even after the pick-up rollers 1 a , 1 b are urged against the sheet in this way, the rod 6 is further lowered by a predetermined distance. Here, when the rod 6 is lowered in this way, since the pick-up rollers 1 a , 1 b abut against the sheet, the support portions 6 a , 6 b of the rod 6 are separated from the shafts 2 a , 2 b of the pick-up rollers 1 a , 1 b . As a result, the pick-up rollers 1 a , 1 b are urged against the sheet P with predetermined abut pressure by the biasing forces of the roller springs 5 a , 5 b.
[0016] After the pick-up rollers 1 a , 1 b are urged against the sheet P in this way, by rotating the pick-up rollers 1 a , 1 b , the sheet P can be fed to the image forming portion (not shown).
[0017] On the other hand, when the sheet feeding operation is finished, the pulse motor M is rotated in a clockwise direction, with the result that the rod 6 is lifted and the support portions 6 a , 6 b abut against the shafts 2 a , 2 b of the pick-up rollers 1 a , 1 b from below. Further, thereafter, when the rod 6 is lifted, the pick-up rollers 1 a , 1 b are lifted together with the rod 6 in opposition to the biasing forces of the roller springs 5 a , 5 b , thereby separating the pick-up rollers from the sheet P. Thereafter, the rod 6 is returned to the home position. In this case, by bringing the pulse motor M to the exciting condition, the rod 6 is held at the home position in opposition to the biasing forces of the roller springs 5 a , 5 b.
[0018] By the way, the during such a sheet feeding operation, since the pick-up rollers 1 a , 1 b are biased so that they generally abut against the sheet P with load in the order of about 0.5 N to about 3 N, when the above-mentioned sheet feeding operation is effected, torque acting on the pulse motor M is changed as shown in FIG. 9. Incidentally, in FIG. 9, the ordinate indicates the position of the rod 6 and the abscissa indicates torque acting on the motor shaft of the pulse motor M.
[0019] As apparent from FIG. 9, when the rod 6 is in the home position, maximum torque T max acts on the pulse motor M to hold the rod 6 in the home position. Further, at the time when the pick-up rollers 1 a , 1 b are contacted with the sheet, although the torque is instantaneously decreased by an amount corresponding to the roller pressure, even in a condition HL that the rod 6 is lowered at the maximum extent, torque T min corresponding to the weight of the rod 6 itself acts on the pulse motor M.
[0020] Accordingly, in the conventional sheet feeding apparatus using such a pulse motor M, the electrical power is required even in the waiting condition, and, since the maximum torque is great, a large torque motor is required, which is very disadvantageous in consideration of the power consumption.
[0021] On the other hand, proper backlash is provided between the first drive transmitting gear 11 and the motor gear 12 . Further, as shown in FIG. 10, proper backlash B is also provided between the second drive transmitting gear 13 and the rack gear 10 of the rod 6 .
[0022] However, in the conventional sheet feeding apparatus having the lifting and lowering means including such a pulse motor M and the gear train for transmitting the rotation of the pulse motor M to the rod 6 , since the pulse motor M must quickly be started and stopped reversibly and slow-up and slow-down control is effected on demand, due to the backlash B in the gears 10 to 13 , great discordant slapping noise is generated in meshed portions in the gear train, which makes reduction of noise difficult or impossible.
SUMMARY OF THE INVENTION
[0023] The present invention is made in consideration of the above-mentioned circumstances, and an object of the present invention is to provide a sheet feeding apparatus which can reduce power consumption and noise, and an image forming apparatus having such a sheet feeding apparatus.
[0024] To achieve the above object, the present invention provides a sheet feeding apparatus comprising sheet feeding means for abutting against an upper surface of a sheet stacked and feeding out the sheet, biasing means for biasing the sheet feeding means toward the upper surface of the sheet stack, and lifting and lowering means for lifting and lowering the sheet feeding means, wherein the lifting and lowering means comprises a holding member for engaging with the sheet feeding means and shifting the sheet feeding means in an up-and-down direction by a motor, and maintaining means for regulating the holding member so as to maintain the sheet feeding means at a position where the sheet feeding means is spaced apart from the upper surface of the sheet, in opposition to a biasing force of the biasing means.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] [0025]FIG. 1 is a view showing a construction of a sheet feeding apparatus according to a first embodiment of the present invention;
[0026] [0026]FIG. 2 is an enlarged view showing main portions of the sheet feeding apparatus in a waiting condition;
[0027] [0027]FIG. 3 is an enlarged view showing a rack gear of a rod and a second drive transmitting gear in the sheet feeding apparatus;
[0028] [0028]FIG. 4 is an enlarged view showing main portions of the sheet feeding apparatus in a sheet feeding condition;
[0029] [0029]FIG. 5 is a view showing a relationship a position of the rod and torque acting on a pulse motor in the sheet feeding apparatus;
[0030] [0030]FIG. 6 is a view showing a construction of a sheet feeding apparatus according to a second embodiment of the present invention;
[0031] [0031]FIG. 7 is a view showing the sheet feeding apparatus in a waiting condition;
[0032] [0032]FIG. 8 is a view showing a construction of a conventional sheet feeding apparatus;
[0033] [0033]FIG. 9 is a view showing a relationship a position of the rod and torque acting on a pulse motor in the conventional sheet feeding apparatus; and
[0034] [0034]FIG. 10 is an enlarged view showing a rack gear of a rod and a second drive transmitting gear in the conventional sheet feeding apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] The present invention will now be explained in connection with embodiments thereof with reference to the accompanying drawings.
[0036] [0036]FIG. 1 is a view showing a construction of a sheet feeding apparatus according to a first embodiment of the present invention. Incidentally, in FIG. 1, the same elements as those shown in FIG. 8 are designated by the same reference numerals.
[0037] Pick-up rollers 1 a , 1 b as sheet feeding means are disposed above sheet supporting means such as a sheet cassette or a deck (not shown) for supporting sheets P (not shown), for lifting and lowering movements.
[0038] A rod spring 15 as biasing means constituting maintaining means (described later) has one end locked to an upper end of a rod 6 as a holding means and the other end locked to a support portion 20 provided on an image forming apparatus (not shown). The rod 6 is biased by the rod spring 15 obliquely upwardly toward a first drive transmitting gear.
[0039] In a waiting condition of the sheet feeding apparatus before a sheet feeding operation is started, a spring force of the rod spring 15 is selected so that a pulling force (tensility) of the rod spring 15 is balanced with biasing forces of roller springs 5 a , 5 b when the rod 6 is in a highest position or home position as shown in FIG. 2. Incidentally, elastic forces of the springs are selected so that resulting biasing force of the roller springs 5 a , 5 b for lowering the rod 6 becomes equal to or slightly smaller than the biasing force of the rod spring 15 or lifting the rod 6 upwardly.
[0040] By setting the spring force of the rod spring 15 in this way, the rod spring 15 acts as maintaining means for canceling the biasing forces (abutting forces) of the roller springs 5 a , 5 b acting on the rod 6 via shafts 2 a , 2 b of the pick-up rollers 1 a , 1 b , so that torque is prevented from acting on a pulse motor M via a gear train comprised of a rack gear 10 , second drive transmitting gear 13 , first drive transmitting gear 11 and motor gear 12 . As a result, in the waiting condition, it is not required that the pulse motor M be maintained in an exciting condition.
[0041] [0041]FIG. 3 is an enlarged view showing the rack gear 10 and the second drive transmitting gear 13 . As shown in FIG. 3, a guide hole 6 c provided in an upper portion of the rod 6 has a dimension greater than that of a pin 7 . Further, a shaft hole 13 a of the second drive transmitting gear 13 and a shaft hole (not shown) of the first drive transmitting gear 11 has also dimensions greater than an outer diameter of a shaft 17 .
[0042] By forming the guide hole 6 c of the rod 6 and the shaft holes 13 a of the first and second drive transmitting gears 13 , play is generated in the rod 6 and the first and second drive transmitting gears 13 . With this arrangement, during the sheet feeding operation which will be described later, by the pulling force (urging force) of the rod spring 15 acting on the rod 6 as urging means directed toward the first and second drive transmitting gears, as shown in FIG. 3, the rack gear 10 and the second drive transmitting gear 13 are brought to a non-backlash condition. Incidentally, by having arrangement in this way, although not shown, a non-backlash condition is established between the first drive transmitting gear 11 and the motor gear 12 .
[0043] Next, a sheet feeding operation of the sheet feeding apparatus having the above-mentioned construction will be explained.
[0044] In the waiting condition of the sheet feeding apparatus before it starts the sheet feeding operation, the rod 6 is held at the highest position or home position, so that the pick-up rollers 1 a , 1 b are positioned above the sheet P. When the rod 6 is in the home position, since the pulling force of the rod spring 15 is balanced with the biasing forces of the roller springs 5 a , 5 b , it is not required that the pulse motor M be maintained to the exciting condition.
[0045] On the other hand, when sheet feeding command is emitted from a controlling device (not shown) provided in the image forming apparatus, first of all, the pulse motor M is rotated in an anti-clockwise direction, and the anti-clockwise rotation is transmitted to the rod 6 via the motor gear 12 , first and second drive transmitting gears 11 , 13 and rack gear 10 , with the result that the rod 6 is lowered. When the rod 6 is lowered in this way, the pick-up rollers 1 a , 1 b are also lowered together with the rod 6 by the biasing forces of the roller springs 5 a , 5 b , thereby urging the pick-up rollers against the sheet P.
[0046] Incidentally, even after the pick-up rollers 1 a , 1 b are urged against the sheet P in this way, the rod 6 is further lowered by a predetermined distance. Here, when the rod 6 is lowered in this way, since the pick-up rollers 1 a , 1 b abut against the sheet P, support portions 6 a , 6 b of the rod 6 are separated from the shafts 2 a , 2 b of the pick-up rollers 1 a , 1 b , as shown in FIG. 4. As a result, the pick-up rollers 1 a , 1 b are urged against the sheet P with predetermined abut pressure by the biasing forces of the roller springs 5 a , 5 b.
[0047] When the rod 6 is lowered in this way, since the biasing forces of the roller springs 5 a , 5 b does not act on the rod 6 , only the spring force of the rod spring 15 acts on the rod 6 , thereby pulling the rod 6 upwardly.
[0048] In order to hold the rod 6 pulled upwardly in a position shown in FIG. 4, the pulse motor M is excited while being stopped, until the sheet feeding operation is completed. As a result, the rod 6 is held and the pick-up rollers 1 a , 1 b are urged against the sheet P positively with predetermined pressure. And, one of the upper and lower pick-up rollers 1 a , 1 b is selectively driven by a driving force from a drive source (not shown), thereby feeding out the sheet P.
[0049] After the pick-up rollers 1 a , 1 b are urged against the sheet P in this way, by rotating the pick-up rollers 1 a , 1 b , the sheet P can be fed to an image forming portion (not shown).
[0050] On the other hand, when the sheet feeding operation is finished, the pulse motor M is rotated in a clockwise direction, with the result that the rod 6 is lifted and the support portions 6 a , 6 b abut against the shafts 2 a , 2 b of the pick-up rollers 1 a , 1 b from below. Further, thereafter, when the rod 6 is lifted, the pick-up rollers 1 a , 1 b are lifted together with the rod 6 in opposition to the biasing forces of the roller springs 5 a , 5 b , thereby separating the pick-up rollers from the sheet P.
[0051] Thereafter, the rod 6 is returned to the home position again. Incidentally, in this case, since the pulling force of the rod spring 15 is balanced with the biasing forces of the roller springs 5 a , 5 b , it is not required that the pulse motor M be maintained to the exciting condition.
[0052] By the way, during the above-mentioned sheet feeding operation, as shown in FIG. 3, the rack gear 10 and the second drive transmitting gear 13 become a non-backlash condition by the pulling force of the rod spring 15 tending to pull the rod 6 toward the first and second drive transmitting gears. Further, a non-backlash condition is also established between the first drive transmitting gear 11 and the motor gear 12 .
[0053] By establishing the non-backlash conditions between the gears, slapping noise due to vibration generated every phase angle of the pulse motor M is not generated between the gears, with the result that the pick-up rollers 1 a , 1 b can be lifted and lowered silently.
[0054] [0054]FIG. 5 shows change in torque acting on the pulse motor M during the sheet feeding operation. Incidentally, in FIG. 5, the ordinate indicates a position of the rod 6 and the abscissa indicates torque acting on a motor shaft of the pulse motor M.
[0055] In this case, although a configuration of the change in torque becomes similar to the configuration shown in FIG. 9, in the illustrated embodiment, as apparent from FIG. 5, since the rod spring 15 and the roller springs 5 a , 5 b are balanced with each other when the rod 6 is in the home position, the torque becomes zero.
[0056] Further, although minimize torque Ta, is generated in a condition HL that the rod 6 is lowered at the maximum extent, an absolute value of the value thereof becomes greatly smaller than that of the torque T max explained in connection with the prior art. Further, the motor is excited only during the sheet feeding operation.
[0057] In this way, by balancing the rod spring 15 with the roller springs 5 a , 5 b when the rod 6 is in the home position, i.e., by canceling the biasing forces (abut forces) of the roller springs 5 a , 5 b acting on the rod 6 , the pulse motor M can be excited only during the sheet feeding operation. As a result, since any electric current is not required in the waiting condition, power consumption can be minimized. Further, since the torque can be reduced by pulling the rod 6 by means of the rod spring 15 , a more compact motor having lower electric current can be used, thereby minimizing the power consumption.
[0058] Next, a second embodiment of the present invention will be explained.
[0059] [0059]FIG. 6 shows a construction of a sheet feeding apparatus according to a second embodiment of the present invention. Incidentally, in FIG. 6, the same elements as those shown in FIG. 1 are designated by the same reference numerals.
[0060] In FIG. 6, the sheet feeding apparatus includes a pad 30 abutting against a side of a rod 6 opposite to a side where a rack gear 10 is formed, and a spring 31 for urging the pad 30 against the rod 6 . By using the rod 6 toward first and second drive transmitting gears by means of urging means constituted by the spring 31 and the pad 30 , backlash between the rack gear 10 and the second drive transmitting gear 13 and backlash between the first drive transmitting gear 11 and the motor gear 12 can be eliminated.
[0061] Now, maintaining means for maintaining the rod in an upper position will be described. In FIG. 6, a spherical member 32 is protruded from a distal end of the rod 6 , and an engagement portion 33 is provided in a main body of an image forming apparatus (not shown) and serves to elastically engage by the spherical member 32 of the rod 6 when the rod 6 is in the home position. Maintaining means is constituted by the spherical member 32 and the engagement portion 33 .
[0062] When the rod 6 is lifted from a lowered condition shown in FIG. 6 to the home position as shown in FIG. 7 by the rotation of the pulse motor M, as shown in FIG. 7, the engagement portion 33 is elastically engaged by the spherical member 32 , with the result that the rod 6 is held by the main body of the image forming apparatus via the engagement portion 33 . Incidentally, an engagement force (holding force) of the engagement portion 33 is set to a level which can be released by the driving force of the pulse motor M.
[0063] When the rod 6 is lifted up to the home position in this way, by engaging the spherical member 32 of the rod 6 by the engagement portion 33 , the biasing forces of the roller springs 5 a , 5 b acting on the rod 6 can be canceled. That is to say, by canceling the biasing forces (abutting forces) of the roller springs 5 a , 5 b acting on the rod 6 by means of the maintaining means comprised of the engagement portion 33 and the spherical member 32 of the rod 6 , the pulse motor M can be excited only during the sheet feeding operation. As a result, since any electric current is not required in the waiting condition, the power consumption can be minimized.
[0064] Incidentally, in the illustrated embodiment, while an example that the engagement portion 33 has a circular snap-fit configuration was explained, the present invention is not limited to such an example, but, the engagement portion may be of any type so long as it can engageably hold the rod 6 , and, for example, the engagement portion may hold the rod 6 magnetically.
|
The present invention provides a sheet feeding apparatus that has sheet feeding device for abutting against an upper surface of a sheet stacked and feeding out the sheet, biasing device for biasing the sheet feeding device toward the upper surface of the sheet, and lifting and lowering device for lifting and lowering the sheet feeding device, the lifting and lowering device including a holding member for engaging with the sheet feeding device and shifting the sheet feeding device in an up-and-down direction by a motor, and maintaining device for regulating the holding member so as to maintain the sheet feeding device at a position where the sheet feeding device is spaced apart from the upper surface of the sheet, in opposition to a biasing force of the biasing device.
| 1
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electronic computer, and more particularly to a checking mechanism in an electronic computer, having a main frame and a separable printer unit, for checking if the printer unit is correctly connected to the main frame of the electronic computer.
2. Description of the Prior Art
In a prior art electronic computer having a separable printer unit, a checking mechanism is not provided for checking if the printer unit is correctly connected to the main frame of the electronic computer and is operating correctly. Accordingly, abnormal conditions of the connection of the printer unit to the main frame of the computer such as misconnection of the printer unit or loosening of a connector by vibrations during the operation of the computer cannot be readily checked. As a result, if the computer is operated with an abnormal condition in the connection, the printing operation is carried out incorrectly.
In order to overcome the difficulty encountered with abnormal state of the connection, the connection can be checked by providing a checking mechanism at each connecting terminal to the printer unit. However, in this method, as many checking mechanisms as there are terminals to be checked for the connection are required and hence the cost is substantially increased as the number of connection terminals increases.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a checking system for the connection between an electronic computer and a printer unit connected via a plurality of signal lines. This system checks signals of the same category with a single checking mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows one embodiment of the present invention.
FIGS. 2 and 3 show timing charts for explaining the operation of the present invention, and
FIG. 4 shows another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows one embodiment of the present invention. A printer unit PT and an electronic computer main frame CUL are connected via connecting terminals CN. The printer unit PT may be a conventional line printer which comprises hammer solenoids SH 1 , SH 2 and SH 3 , a paper feed solenoid SF, drive circuits DR for the solenoids, a type drum P, a type drum drive motor M, a type drum position sensing switch SW linked to the type drum P, and a drive circuit MD for the motor M. A circuit comprising resistors R 1 , R 2 , R 3 , R 4 and r 1 detects an abnormal state of the connection of the printer PT to the main frame CUL. The electronic computer main frame CUL comprises a keyboard KB, a central processing unit CPU and a display unit DISP. A compare/detection circuit DT and resistors R 11 , R 12 , R 13 , R 14 and r 10 also detect the abnormal state of the connection.
FIGS. 2 and 3 show timing charts for explaining the operation of FIG. 1. FIG. 2 shows the timing chart where the printer unit PT and the electronic computer main frame CUL are correctly connected by the connecting terminals CN.
Referring to FIGS. 1 and 2, after the central processing unit CPU has processed in accordance with input data from the keyboard KB, it starts the print operation. The central processing unit CPU sends a drive signal SM to the type drum drive motor M to rotate it, and the type drum position sensing switch SW linked thereto is actuated to send a timing signal S s to the central processing unit CPU. The central processing unit CPU generates hammer solenoid drive signals and a paper feed solenoid drive signal in synchronism with the timing signal S s . As the hammer solenoid drive signals are generated, currents i 11 , i 12 and i 13 flow through the resistors R 11 , R 12 and R 13 , respectively, and as the paper feed solenoid drive signal is generated, a current i 14 flows through the resistor R 14 . The resistor r 10 is selected to be sufficiently smaller than the resistors R 11 , R 12 , R 13 and R 14 and the input impedance of the compare/detection circuit DT so that the mutual effects among the currents i 11 , i 12 , i 13 and i 14 can be neglected. Accordingly, the current i r10 is expressed by a sum of mutually independent currents i 11 , i 12 , i 13 and i 14 . That is, i r10 =i 11 +i 12 +i 13 +i 14 . An input voltage e c to the compare/detection circuit DT is expressed by e c =i r10 ·r 10 . The resistor r 1 is also selected to be sufficiently smaller than the resistors R 1 , R 2 , R 3 and R 4 and the input impedance of the compare/detection circuit DT so that a current i r1 flowing through the resistor r 1 is expressed by a sum of the mutually independent currents i 1 , i 2 , i 3 and i 4 flowing through the resistors R 1 , R 2 , R 3 and R 4 , respectively. That is, i r1 =i 1 +i 2 +i 3 +i 4 . An input voltage e p to the compare/detection circuit DT is expressed by e p =i r1 ·r 1 . Since the current i 1 and the current i 11 are of the same waveform, they are expressed as i 1 =k·i 11 , where k is a proportional constant between the resistor R 1 and the resistor R 11 . The currents i 2 and i 12 , i 3 and i 13 , and i 4 and i 14 are also of the same waveforms, respectively, and they are expressed as i 2 =k·i 12 , i 3 =k·i 13 and i 4 =k·i 14 , where k is the proportional constant between the resistors R 2 and R 12 , R 3 and R 13 , and R 4 and R 14 , respectively.
As a result, the current i r1 is expressed as i r1 =k·i r10 and hence the input voltage e p is expressed as e p =k·r 1 /r 10 ·e c . Accordingly, e p =K·e c , where K is a proportional constant.
Accordingly, by checking if the voltage e p is equal to K·e c with the compare/detection circuit DT, the normal state of the connection of the connecting terminals CN 0 -CN 4 can be checked. If it is normal, an output voltage Sdt of the compare/detection circuit DT is at a low level.
FIG. 3 shows the timing chart when the connection between the printer unit PT and the electronic computer main frame CUL is abnormal. Specifically, the connecting terminal CN 2 is in abnormal condition. As a result, the drive signal to the hammer solenoid SH 2 is not transmitted and the current i 2 remains at a low level. As a result, the relation of e p =K·e c is not met and the compare/detection circuit DT produces a high level output voltage Sdt at the timing of the current i 2 to inform the central progressing unit CPU of the abnormal condition of the connection between the printer unit PT and the electronic computer main frame CUL. The central processing unit CPU in turn stops the print operation and displays the abnormal condition of the connection on the display unit DISP as required. In FIG. 3, when the output voltage Sdt is high, the print operation is conducted for one print cycle (in which the motor drive signal S M changes to a high level and then to a low level) and the next print cycle is inhibited. Alternatively, the print operation can be inhibited as soon as the output voltage Sdt assumes the high level.
In FIG. 1, the connecting terminals CN 5 -CN 8 have no abnormal condition detecting circuit, but the condition of the connection of the connecting terminals CN 5 -CN 8 can be checked by monitoring the timing signal S s which is periodically sent as long as the motor drive signal S M is high. In the present embodiment, the condition of the connection of the three hammer solenoids and the one paper feed solenoid is checked by the single compare/detection circuit DT. Thus, not only signals of the same category (e.g. hammer solenoid signals) but also a signal of a different category (e.g. paper feed solenoid signal) can be checked by the single compare/detection circuit DT. Any number of terminals can be checked by the single compare/detection circuit DT, and more than one compare/detection circuit may be provided. The compare/detection circuit DT may be constructed by a resistor voltage divider circuit and a differential amplifier.
FIG. 4 shows another embodiment of the present invention in which the present invention is applied to a thermal printer head driver. The resistor r 1 is selected to be sufficiently smaller than resistors R s of heat generating elements of the thermal print head of the printer unit PT. DR denotes drive circuits for the heat generating elements. The resistor r 10 in the computer main frame CUL is selected to be sufficiently smaller than resistors R. Accordingly, as in the embodiment of FIG. 1, the input voltages e p and e c to the compare/detection circuit DT are expressed by e p =i r1 ·r 1 and e c =i r10 ·r 10 . If the connecting terminals CN are in the normal condition, the current i r1 is proportional to the current i r10 and hence e p =K·e c , where K is a proportional constant. Accordingly, by checking the relationship of e p =K·e c by the compare/detection circuit DT, the condition of the connection of the connecting terminals CN can be checked, and the print operation is stopped if an abnormal condition is detected.
|
In an electronic computer having a main frame including a keyboard and a processing unit, and a separable printer unit, a checking mechanism for checking if the printer unit is correctly connected to the main frame of the electronic computer is provided. The print operation is permitted only when the correct connection of the printer unit is detected by the checking mechanism.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATIONS
The present disclosure is a continuation Application of U.S. patent application Ser. No. 12/215,222 (now U.S. Pat. No. 8,743,939), filed on Jun. 26, 2008, which is a continuation Application of U.S. patent application Ser. No. 10/189,321 (now U.S. Pat. No. 7,409,057), filed Jul. 3, 2002. The entire disclosures of the applications referenced above are incorporated herein by reference.
FIELD
The present disclosure relates to transmitting and receiving electrical signals through a communications channel, and more particularly to a nonlinear echo compensator for a Class B transmitter line driver.
BACKGROUND
IEEE section 802.3ab, which is hereby incorporated by reference, specifies physical layer parameters for 1000 BaseT (gigabit) communications channels. The gigabit communications channel employs four twisted pairs of cable. Signals transmitted over the cable are degraded by signal attenuation, return loss, echo, and crosstalk.
Referring now to FIG. 1 , a gigabit Ethernet communications channel 10 is shown. The communications channel 10 includes two nodes 12 and 14 that transmit and receive one gigabit per second (Gbps). The node 12 includes transceivers 16 - 1 , 16 - 2 , 16 - 3 , and 16 - 4 and the node 14 includes transceivers 18 - 1 , 18 - 2 , 18 - 3 and 18 - 4 . Each transceiver transmits at 250 Mbps. The transceivers 16 and 18 are connected to opposite ends of twisted pairs 20 - 1 , 20 - 2 , 20 - 3 , and 20 - 4 . For example, the transceiver 16 - 1 is connected to one end of the twisted pair 20 - 1 . The transceiver 18 - 1 is connected to the opposite end of the twisted pair 20 - 1 . Each transceiver 16 and 18 includes a transmitter 24 , a receiver 26 , and a hybrid circuit 28 .
The transmitter 24 of the transceiver 16 - 1 generates a five level pulse amplitude modulated (PAM-5) signal that is transmitted by the transmitter 24 and the hybrid circuit 28 of the transceiver 16 - 1 onto the twisted pair 20 . The hybrid circuit 28 and the receiver 26 of the transceiver 18 - 1 receive the PAM-5 signal. The hybrid circuit 28 enables bi-directional transmission over the same twisted pairs by filtering out the transmit signal at the receiver 26 .
Attenuation refers to signal loss of the twisted pair between the transmitter of one receiver and the receiver of another transceiver and is caused by several factors including skin effect. To minimize the effect of attenuation, the lowest possible frequency range that supports the required data rate is typically used. Return loss quantifies the amount of power that is reflected due to cable impedance mismatches.
Echo occurs when signals are transmitted and received on the same twisted pair. Echo is caused by residual transmit signals and cable return loss. Crosstalk occurs due to signal coupling between twisted pairs that are in close proximity. For example, the twisted pairs used in 1000 BaseT are affected by crosstalk from adjacent twisted pairs. Near end crosstalk (NEXT) is crosstalk at the transmitter end of the twisted pair. Far-and crosstalk (FEXT) is crosstalk at the receiver end of the twisted pair. Crosstalk is preferably minimized to improve receiver symbol recovery.
Referring now to FIG. 2 , the transceiver 16 includes a transmitter line driver 50 that receives a transmitter signal 52 . The transmitter line driver 50 outputs a multi-level signal to a load such as a matched resistor 54 . A transformer 58 couples the transceiver 16 to a twisted pair 60 . A replica signal generator 64 outputs a replica of the transmitter signal 52 to a summer 66 . A received signal 68 is also input to the summer 66 .
Since the communications channel transmits and receives on the same twisted pair 60 , the replica transmitted signal is cancelled or subtracted from the received signal 68 . In addition, compensation for NEXT and echo is performed. An output of the summer 66 is input to an optional low pass filter (LPF) 70 . An output of the LPF 70 is input to an analog to digital converter (ADC) 74 . An output of the ADC 74 is input to a summer 78 . A linear echo compensation circuit 82 and NEXT compensation circuit 83 (for NEXT 12 , NEXT 13 , and NEXT 14 ) are also input to the summer 78 . A signal (TA comp ) with NEXT and linear echo compensation is output by the summer 78 . Additional details concerning the transceiver 16 can be found in “Active Resistive Summer for a Transformer Hybrid”, U.S. patent application Ser. No. 09/920,240, filed Aug. 1, 2001, and “A Method and Apparatus for Digital Near-End Echo/Near-End Crosstalk Cancellation with Adaptive Correlation”, U.S. patent application Ser. No. 09/465,228, filed Dec. 17, 1999, which are hereby incorporated by reference.
Referring now to FIG. 3 , the transmitter line driver 50 is shown further and typically includes a plurality of positive current cells 84 and negative current cells 86 . A transmitter driver control 88 selectively switches the positive and negative current cells 84 and 86 on and off to produce positive and negative signal levels. For example, the transmitter line driver for 1000 BaseT employs five symbol levels −2, −1, 0, +1, and +2, which are usually implemented as 0V, +/−0.5V and +/−1V. Future communications systems may include additional symbol levels for increased bandwidth. For example, future signal levels may include 0, +/−2, +/−4, +/−6, and +/−8 signal levels.
Referring now to FIG. 4 , a conceptual illustration of the transmitter line driver 50 is shown. The positive current cells 84 can be thought of as a plurality of individual current sources 90 - 1 , 90 - 2 , 90 - 3 , . . . , and 90 - n that are switched by switches SW P1 , SW P2 , SW P3 , . . . , and SW Pn . The negative current cells 86 can be thought of a plurality of individual current sources 92 - 1 , 92 - 2 , 92 - 3 , . . . , and 92 - m that are switched by switches SW N1 , SW N2 , SW N3 , . . . , and SW Nm . Typically, m=n. Referring now to FIG. 5 , an exemplary positive current cell 96 is shown. In FIG. 6 , an exemplary negative current cell 98 is shown. As can be appreciated, other positive and negative current cells can be utilized.
When the transmitter line driver 50 is operated in a Class A operating mode, the number of positive current cells that are turned on/off for a transition from a first signal level to a second signal level is equal to the number of negative current cells that are turned off/on. When the transmitter line driver 50 is operated in a Class B operating mode, the number of positive current cells that are turned on/off for a transition from a first signal level to a second signal level is not equal to the number of negative current cells that are turned off/on. The advantage of Class B operation is reduced power consumption as compared with Class A operation.
Referring now to FIG. 7 , Class A operation of the positive and negative current cells 84 and 86 for nine symbol levels is shown. As can be appreciated, when switching between signal level 6 and signal level −4, there are an equal number of positive and negative current cells being turned on and off. In particular, five positive current cells are being turned off and five negative current cells are being turned on.
Referring now to FIG. 8 , exemplary Class B operation of the positive and negative current cells 84 and 86 is shown. As can be appreciated, when switching between signal level 6 and signal level −4, an unequal number of positive and negative current cells are turned on and off. In particular, six positive current cells are turned off and four negative current cells are turned on. While Class B operation provides reduced power consumption, the asymmetry of Class B operation causes nonlinear echo that degrades performance.
SUMMARY
A nonlinear echo compensator according to the present invention compensates for nonlinear echo in a transceiver including a transmitter line driver with current cells that are operated in an asymmetric low power mode. A mapping circuit generates a pattern dependent driving signal. A canceling circuit communicates with the mapping circuit and compensates for nonlinear echo in a received signal based on the pattern dependent driving signal.
In other features, the mapping circuit receives a multi-level signal and maps the multi-level signal to the pattern dependent driving signal. The mapping circuit includes a symbol weighting circuit that generates a weighted signal. The symbol weighting circuit generates the weighted signal by summing a first product of a current symbol and a first weighting factor with a second product of a prior symbol and a second weighting factor. The mapping circuit includes a function generator that generates the pattern dependent driving signal based on the weighted signal and a scaling circuit that scales the pattern dependent driving signal.
In still other features, a coefficient generator generates a first compensator coefficient based on a sum of a prior compensator coefficient and a product of an error signal and a sign function of the pattern dependent driving signal. The coefficient generator generates first, second and third compensator coefficients.
In other features, the canceling circuit includes a first multiplier that has a first input that receives the pattern driving signal and a second input that receives the first compensator coefficient. The first multiplier generates a first product. A second multiplier has a first input that receives the pattern driving signal and a second input that receives the second compensator coefficient. The second multiplier generates a second product. A third multiplier has a first input that receives the pattern driving signal and a second input that receives the third compensator coefficient. The third multiplier generates a third product.
In still other features, the canceling circuit further includes a first unit delay that receives the third product of the third multiplier. A first summer has a first input that receives the second product of the second multiplier and a second input that communicates with the first unit delay. A second unit delay communicates with an output of the first summer. A second summer has a first input that communicates with the second unit delay and a second input that receives the first product of the first multiplier.
Further areas of applicability will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples are intended for purposes of illustration only and are not intended to be limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 is a functional block diagram illustrating an exemplary gigabit communications channel according to the prior art;
FIG. 2 is a functional block diagram illustrating a transceiver with a transmitter line driver and linear echo, NEXT and replica transmitter signal compensation according to the prior art;
FIG. 3 is a functional block diagram of the transmitter line driver of FIG. 2 according to the prior art;
FIG. 4 is a conceptual electrical schematic of the transmitter line driver according to the prior art;
FIG. 5 is an electrical schematic of an exemplary positive current cell in the transmitter line driver according to the prior art;
FIG. 6 is an electrical schematic of an exemplary negative current cell in the transmitter line driver according to the prior art;
FIG. 7 is a table illustrating Class A operation of the transmitter line driver according to the prior art;
FIG. 8 is a table illustrating Class B operation of the transmitter line driver according to the prior art;
FIG. 9 illustrates ideal current cell rise and fall transition characteristics;
FIG. 10 illustrates actual current cell rise and fall transition characteristics;
FIG. 11 is a functional block diagram illustrating a transceiver with a transmitter line driver and linear and nonlinear echo, NEXT and transmitter signal compensation according to the present disclosure;
FIG. 12 illustrates a nonlinear echo compensation circuit according to the present disclosure;
FIG. 13 illustrates a mapping circuit of FIG. 12 in further detail;
FIG. 14 illustrates a least means squared (LMS) circuit according to the present disclosure; and
FIG. 15 illustrates mean squared error (MSE) as a function of sample phase for a first transceiver with linear echo compensation and a second transceiver according to the present disclosure with linear and nonlinear echo compensation.
DETAILED DESCRIPTION
The following description and is in no way intended to limiting. For purposes of clarity, the same reference numerals will be used in the drawings to identify similar elements.
Referring now to FIG. 9 , rise h r and fall h f characteristics of an ideal current cell is shown. As can be appreciated, the ideal rise h r and fall h f characteristics are symmetric such that h r +h f =1. In FIG. 10 , rise h r and fall h f characteristics of typical current cells are not ideal. For some time periods, h r +h f ≠1. The nonlinear echo compensation circuit for the Class B driver according to the present disclosure compensates for nonlinear echo that is introduced as a result of this asymmetry. The transmitter line driver of the transceiver according to the present disclosure can be operated in the Class B mode with reduced power consumption and without sacrificing performance.
The sampling point of the ADC 74 is determined by the received signal and not by the transmitted signal. In some cases, the sampling point occurs when the difference between h r and 1−h f is greater than zero. The replica transmitter signal does not have nonlinear echo characteristics because the replica transmitter signal is not generated by the transmitter line driver, which is the source of the nonlinear echo.
Referring now to FIG. 11 , a transceiver 100 according to the present disclosure receives a transmitter signal 52 . The transmitter line driver 50 supplies a multi-level signal to a load such as the matched resistor 54 based on the transmitter signal 52 . The transformer 58 couples the transmitter line driver 50 to the twisted pair 60 . The replica signal generator 64 outputs a replica of the transmitter signal 52 to the summer 66 . The received signal 68 is also input to the summer 66 .
The output of the summer 66 is input to the LPF 70 . An output of the LPF is input to the ADC 74 . The output of the ADC 74 is input to the summer 78 . The linear echo compensation signal from the linear echo compensation circuit 82 and the NEXT compensation signal from the circuit 83 (canceling NEXT 12 , NEXT 13 , and NEXT 14 ) are also input to the summer 78 . A non-linear echo compensation signal from a compensator 104 according to the present disclosure is also input to the summer 78 . A signal (TA comp ) with linear and nonlinear echo compensation and NEXT compensation is output by the summer 78 .
Referring now to FIG. 12 , the nonlinear echo compensator 104 is shown to include a mapping circuit 114 and a canceller circuit 118 . A transmitted signal TA 1 (k+L) is input to a variable delay 120 that provides a delay of L clock cycles. The delayed transmitter signal is input to the linear echo compensation circuit 82 and the mapping circuit 114 . The mapping circuit 114 outputs a pattern dependent driving signal δ k to the canceller circuit 118 . The pattern dependent driving signal is input to first inputs of first, second and third multipliers 122 , 124 and 126 . Another input of the multiplier 122 receives a third compensator coefficient h 2 from unit delay 130 . As can be appreciated, unit delays can be implemented as a register or in any other suitable manner. A second input of the multiplier 124 receives a second compensator coefficient h 1 from unit delay 132 . A second input of the multiplier 126 receives a first compensator coefficient h 0 from unit delay 134 .
An output of the multiplier 122 is input to unit delay 140 . An output of the unit delay 140 is input to a first input of a summer 142 . An output of the multiplier 124 is input to a second input of the summer 142 . An output of the summer 142 is input to unit delay 146 . An output of the unit delay 146 is input to a first input of a summer 148 . An output of the multiplier 126 is input to a second input of the summer 148 . An output of the summer 148 is input to unit delay 150 . An output of the unit delay 150 is input to a summer 154 .
An output of the linear echo compensation circuit 82 is input to unit delay 158 . An output of the unit delay 158 is input to the summer 154 . Transmitter signals from other twisted pairs are input to variable delay circuits 160 , 162 and 164 . Outputs of the variable delay circuits 160 , 162 and 164 are input to NEXT compensation circuits 166 168 and 170 . Outputs of the NEXT compensation circuits 166 , 168 and 170 are summed by a summer 174 and input to the summer 154 . The transmitter signal TA 1 (k) is input to ADC 180 and output to a summer 184 . An output of the summer 154 is input to an inverting input of the summer 184 , which outputs the compensated signal (TA comp ) 186 .
Referring now to FIG. 13 , the mapping circuit 114 is illustrated in further detail. The mapping circuit 114 includes a weighting circuit 201 . The transmitter signal is input to unit delay 202 and a first input of the multiplier 204 . A second input of the multiplier 204 receives a first constant scale factor. An output of the unit delay 200 is input to a first input of a multiplier 208 . A second input of the multiplier 208 is connected to a second constant scale factor. Outputs of the multipliers 204 and 208 are input to a summer 212 . An output of the summer 212 is input to unit delay 216 , which outputs a signal b k+1 to a function generator 220 . The function generator 220 outputs the pattern dependent driving signal (before delay and scaling) as follows:
δ k+1 =|b k+1 |−|b k | if b k+1 ≧b k
δ k+1 =|b k |−|b k+1 | if b k+1 <b k
The pattern dependent driving signal that is output by the function generator 220 is input to unit delay 224 . An output of the unit delay 224 is input to a scaling circuit 228 . One exemplary scaling circuit 228 includes a multiplier 230 having a first input coupled to the unit delay 224 and a second input coupled to a constant value. The scaling circuit 228 preferably offsets the effects of the weighting circuit 201 , although other scaling may be performed. In the exemplary weighting circuit 201 , the signal TA 1 (k) is multiplied by 6 and the signal TA 1 (k−1) is multiplied by 2. The scaling circuit 228 multiplies by ⅛.
Referring now to FIG. 14 , a least mean squared (LMS) circuit 250 is illustrated. The LMS circuit 250 includes a compensator coefficient generator 254 . An error signal 255 is input to a selector switch 256 . A receiver error signal 258 is also input to the selector switch 256 . The selector switch 256 selects one of the error signals 255 or 258 . The switch 256 preferably selects the output of the compensator (the summer 78 in FIG. 11 ) as the error signal when a remote transceiver has not sent signals. Ideally, the output of the summer 78 is zero since the receiver should not detect a signal. When an incoming signal is received, the switch 256 selects the error signal at the output of the followed detector, which eliminates the effect of the incoming signal in the error signal.
An output of the selector switch 256 is input to a multiplier 260 . Another input of the multiplier 260 is coupled to a scaling factor or loop gain (μ). An output of the multiplier 260 is input to the compensator coefficient generator 254 . A sign function of the transmitted signal is input to a variable delay 264 . An output of the variable delay is input to a multiplier 266 . An output of the multiplier 260 is input to the multiplier 266 . An output of the multiplier 266 is input to a summer 270 . An output of the summer 270 is fed back through a unit delay 274 to the summer 270 . An output of the summer 270 is input to unit delay 276 . An output of the unit delay 276 provides a linear echo compensation signal (AA 0 ).
A sign function of the pattern dependent driving signal is input to a variable delay 280 of the compensator coefficient generator 254 . An output of the variable delay 280 is input to a multiplier 282 . An output of the multiplier 260 is also input to the multiplier 282 . An output of the multiplier 282 is input to a summer 284 . An output of the summer 284 is input to a limiter 286 , which limits the signal input between upper and lower limits. For example, the limiter 286 may limit the signal to +/− 1/32. An output of the limiter 286 is input to unit delay 288 and to unit delay 290 . An output of the unit delay 290 is input to the summer 284 . An output of the unit delay 288 provides the first compensator coefficient h 0 as follows:
h 0 ←h 0 +μ*e k−L *sign(δ k )
An output of the variable delay 280 is input to unit delay 300 . An output of the unit delay 300 is input to a multiplier 302 and unit delay 304 . An output of the multiplier 260 is also input to the multiplier 302 . An output of the multiplier 302 is input to a summer 306 . An output of the summer 306 is input to a limiter 308 . An output of the limiter 308 is input to unit delays 310 and 312 . An output of the unit delay 312 is input to the summer 306 . An output of the unit delay 310 provides the second compensator coefficient h 1 as follows:
h 1 ←h 1 +μ*e k−L *sign(δ k−1 )
An output of the unit delay 304 is input to a multiplier 320 . An output of the multiplier 260 is also input to the multiplier 320 . An output of the multiplier 320 is input to a summer 322 . An output of the summer 322 is input to a limiter 324 . An output of the limiter 324 is input to unit delays 326 and 328 . An output of the unit delay 328 is input to the summer 322 . An output of the unit delay 326 provides the third compensator coefficient h 2 as follows:
h 2 ←h 2 +μ*e k−L *sign(δ k−2 )
Referring now to FIG. 15 , mean squared error is shown as a function of sample phase. The mean squared error for transceivers with linear and nonlinear echo compensation according to the present disclosure is significantly lower than the mean squared error for transceivers with linear echo compensation.
Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present disclosure can be implemented in a variety of forms. Therefore, while the embodiments disclosed herein have been described in connection with particular examples thereof, other modifications will become apparent to the skilled practitioner upon a study of the drawings, the specification and the following claims.
|
A compensator generating a compensation signal to compensate for nonlinear echo in an output of a current source. The nonlinear echo is a result of transitioning the current source between an ON state and an OFF state. The compensator includes driving, weighting, function, and compensating circuits. The driving circuit receives a first signal that is based on the output of the current source. The weighting circuit is configured to generate a second signal based on weighted versions of the first signal. The function circuit, based on the second signal, (i) updates each of multiple functions, and (ii) selects a first function. The driving circuit generates a driving signal based on the first function selected by the function circuit. The compensating circuit generates the compensation signal based on the driving signal to compensate for the nonlinear echo provided by the output of the current source.
| 7
|
BACKGROUND OF THE INVENTION
Generally the composition and characteristics of coal can be described as relative amounts of moisture, volatiles, fixed carbon and ash. In describing coal the industry has standardized on data from basic tests and procedures. For example, the moisture content of coal is determined by subjecting the coal as received to heat under standard conditions with the temperature maintained slightly above the boiling point of water. This procedure results in drying of the coal and a resultant loss of weight which is readily measurable. This simple test provides a reasonably accurate measure of water entrained in the coal, although it is recognized that further heating at higher temperature could result in the expulsion of greater amounts of moisture. Likewise, the industry has standardized on tests and procedures for determining the volatile content of coal. After drying the coal to determine moisture content as described above, the dried coal is placed in a closed container where it is heated for a specific time, for example 7 minutes at an elevated temperature, for example 950° C (1742° F). Thus the volatile matter in coal can be determined by measuring the loss in weight, although it is recognized that the amount of volatile matter given up by the coal would change should the length of heating time be changed, the temperature be changed, or both. Further the standard tests may be continued by taking the residual solid material and burning it under standard conditions to a final residual or ash. Then by adding up the relative amounts of moisture, volatiles and ash expressed as percentages and subtracting the total from 100, the relative amount of fixed carbon can be computed.
The volatile matter in coal is not truly volatile in the strictest sense, but rather volatiles are a result of decomposition of the coal when subjected to heat. Volatiles extracted from coal include for the most part combustible gases, with smaller amounts of non-combustible gases. Among the combustibles are numerous hydrocarbons (including methane), hydrogen, carbon monoxide and the like. Non-combustibles generally are water vapor, carbon dioxide and the like. Further, it is quite common to find combustible gases entrained in the coal apart from the so called volatiles. Many coal deposits have large quantities of entrained combustible gases, commonly called "fire damp," the principal constituent of which is methane. In this regard it is not uncommon among coal deposits in the United States to find coal beds that contain in the order to 100 standard cubic feet of methane entrained in each ton of coal in place. Methane entrained in coal compares favorably to natural gas of petroleum origin and may be recovered, in part, from coal by the simple expedient of drilling a well from the surface of the ground into the coal deposit. While methane may be recovered from coal in this manner, rarely is it commercially attractive to do so because the methane in coal is under moderate pressure compared to methane of petroleum origin, and the resultant flow rates to the well bore are quite low, the captured gas at the surface must be compressed in order to be moved by pipeline, and the like. Methane entrained in coal cannot be removed entirely by pressure differential without introducing another fluid to displace the methane.
In the coal bearing regions of the world it is quite common to find multibedded coal deposits in which in vertical sequence and in descending order there is the overburden, then a bed of coal, then a layer of sedimentary rock, then a bed of coal, then a layer of sedimentary rock, then a bed of coal, and so on. In some cases the various beds of coals may be separated by only a short distance such as 1 to 5 feet. In other cases the beds of coal may be separated by greater distances, for example 50 to 300 feet. Generally one bed of the sequence is of particular interest because of its areal extent, the quality of the coal, its bed thickness and the like. Nearby beds may not be of commercial interest because the seam is too thin for standard mining equipment, the coal contains too much debris, and similar factors. In these cases the beds of commercial interest are produced by conventional mining methods while nearby beds of coal remain untouched because the cost of extraction exceeds the market value of recovered coal.
Looking to newer methods of producing coal and in particular to the gasification of coal in situ, economic evaluation of a multibedded coal deposit also is required before production begins. As in the case of conventional mining of coal, thickness of the coal bed is a critical consideration. Factors that are detrimental to conventional mining of coal -- increasingly thickening overburdens, high moisture contents, high ash contents, high firedamp contents, and the like -- often are advantages to production of coal in situ by gasification. Generally, coal beds that are of the proper thickness for conventional mining are also of acceptable thickness for in situ gasification. Coal beds that are too thin for conventional mining, generally also are too thin for in situ gasification. Thus thin beds of coal remain unproduced when they overlie or underlie coal beds that are being produced by methods heretofore known.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide new and improved processes for removing coal chemicals and energy values from coal in situ, with particular emphasis on coal seams considered too thin for recovery by conventional means.
It is an object of the present invention to provide new and improved processes for removing the moisture from coal as a preparation step for subsequent production processes.
Other objects of the invention will be apparent to those skilled in the art upon examination of the disclosure contained herein.
SUMMARY OF THE INVENTION
The methods taught herein may be applied to coal of any rank, but for illustrative purposes the description is directed to coals of subbituminous and lignite ranks. Typical analyses of a coal from Wyoming and a lignite from Texas are shown below on an as received basis and with moisture removed:
______________________________________ Lignite CoalAnalysis as free as freeWeight% received moisture received moisture______________________________________moisture 24.75 0 9.51 0volatile matter 33.52 44.55 32.64 36.07fixed carbon 30.34 40.31 34.09 37.67ash 11.39 15.54 23.76 26.26______________________________________
Generally the moisture and ash contents of coal are considered to be nuisances while the volatile matter and fixed carbons are considered to be useful components. Referring to the analysis table above it can be seen that removal of the moisture content from the lignite results in the removal of approximately one-fourth of the weight. On a volume basis, since water has a lower specific gravity than the fixed carbon and the ash, removal of the moisture content results in the removal of greater than one fourth of the original volume. Thus it is easy to envision that with removal of moisture from the lignite in situ, a considerable amount of porosity and permeability will be opened for the free passage of gases that can be made to migrate under the influence of differential pressure. Likewise, removal of moisture content of the coal will result in opening a considerable amount of porosity and permeability for the passage of gases.
Referring again to the analysis table above and disregarding the second nuisance, ash, it may be seen that of the useful components of lignite, more than half is composed of volatile matter, while for the coal almost half of the useful components is volatile matter. Thus it is easy to envision that once the moisture content is removed from either the lignite or the coal in situ, approximately one half of the useful components can be produced as voltatiles simply by the application of heat together with the differential pressure required to evacuate the volatiles to the surface.
The heat required to remove the moisture from coal of various ranks can be generated in one of the beds of a multibedded coal deposit by following the teachings of my copending patent application Ser. No. 531,453, filed Dec. 11, 1974, and now U.S. Pat. No. 3,952,802, which discloses methods of gasifying coal in situ. The hot exit gases generated can be diverted to another bed of coal in the multibedded deposit, thus providing the heat needed to remove moisture from the bed and the differential pressure required to remove the moisture to the surface of the ground. A continuing diversion of the hot exit gases into the second bed of coal provides heat required to release the volatile matter into the fluidized volatiles and the differential pressure to remove the volatiles to the surface of the ground for capture and commercial use.
One of the problems in gasifying coal in situ is controlling the burning of coal to a reducing environment so that the exit gases contain a reasonable amount of combustible gas. When the coal burning underground is affected by excessive oxygen such as occurs in oxygen injection bypass, the burning environment shifts from a reducing mode to an oxidizing mode and the combustible gases are substantially consumed in the fire. The exit gases then contain virtually no combustible gases and are commercially useful only for the sensible heat they carry. If the in situ gasification project is being conducted for the primary purpose of generating combustible gases and a well cannot be controlled to a reducing environment, there is little recourse but to abandon the well long before it has produced the coal reserves within its area of influence. Such premature abandonment is costly and unnecessary when reviewed in the light of the instant invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic vertical section taken through a portion of the earth illustrating the geological relationship of the coal zone that serves as a course of hot gases and another coal zone that is being produced using the method of the present invention.
FIG. 2 is a diagrammatic vertical section taken through a portion of the earth showing a typical geological setting of a multibedded coal deposit.
FIG. 3 is a diagrammatic plan view of a possible well pattern for use in practicing the method of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1 a geologic condition ideal for practicing the method of the present invention is illustrated. In the ideal situation each of the coal strata would be "dry," that is, neither of the coal strata is an aquifier but both coal strata or beds contain coal with a moisture content typical of coal at its particular point in the natural coalification process. (Coals at two different points in the coalification process are illustrated by the Texas lignite and the Wyoming coal listed in the aforementioned table). Wells 11 and 12 are drilled to the bottom of the lowermost bed of coal 13. The wells are lined with protective casings 14 which are hermetically sealed by cementing in place. Oxidizer injection lines 15 are set inside the casings 14 with the lowermost part of the injection lines 15 positioned in the coal bed 13. Gas removal exits 16 are installed in the well heads and the system is hermetically sealed. The well casings 14 are perforated at a point 17 opposite the uppermost coal bed 18 using techniques common in the petroleum industry. Initially the perforations 17 may be hermetically sealed by setting a packer (not shown) in the well in alignment with the perforations. In commercial practice a multiplicity of wells would be drilled and equipped such as illustrated by wells 11 and 12. It will be noted that wells 11 and 12 can serve as oxidizer injection wells or as gas removal wells or both.
The lower coal bed 13 is ignited and in situ gasification begins using a method such as taught in my copending patent application Ser. No. 531,453, filed Dec. 11, 1974, now U.S. Pat. No. 3,952,802, which is incorporated herein by reference. Initially the products of combustion may be removed through the annulus 19 of well 11 and through gas exit outlet 16 or as an alternate in a similar manner through well 12. After combustion is fully established in coal bed 13, for example when the exit gases reach a temperature of 2000° F, well 11 is converted into a hot gas injection well that feeds hot gases into coal bed 18. In converting well 11, the packer which may have been set to seal perforations at 17 is removed, gas exit line 16 is closed with a valve 10 and a packer 21 is set immediately above the perforations at 17 making a gas tight plug in the annulus 19. The use of a packer immediately above the perforations may not be necessary in all instances since closure of valve 10 would normally force exit gases emanating from the lowermost coal bed 13 to pass through the perforations into the uppermost coal bed 18 as desired. The packer which may have been set to seal the perforations at 17 in well 12 is removed and a packer 23 is set immediately below the perforations 17 in well 12 to provide a gas tight seal in the annulus 19 of well 12.
Preferably, oxidizer injection is terminated in well 11 by closing a valve 15a in the oxidizer injection tubing 15. Oxidizer injection continues in well 12 through oxidizer injection tubing 15 of well 12 in order to sustain in situ gasification of coal bed 13. The normal pressure of coal bed 18, for example 150 psig, is greatly exceeded by the in situ gasification pressure in coal bed 13, for example 500 psig. The pressure in the coal gasification zone of coal bed 13 may be regulated by controlling the oxidizer injection pressure in concert with controlling the pressure in exit conduits to the surface.
Initially the coal in bed 18 and its entrained fluids may be relatively cool, for example 70° F. The hot gases from the in situ gasification zone of coal bed 13, under the influence of differential pressure, proceed upward through the annulus 19 of well 11, through the perforations at 17 in well 11 and into coal bed 18. The hot gases will proceed, under the influence of differential pressure, through the porosity and permeability of coal bed 18, to a lower pressure area such as is found in the annulus 19 of well 12. As the hot exit gases migrate through coal bed 18, some of the sensible heat is released causing a portion of the moisture in coal bed 18 to evaporate and be carried as water vapor in the migrating gases. Release of heat from the hot exit gases to the coal formation in coal bed 18, raises the temperature of the coal, and when the temperature of the coal exceeds the boiling point of water, moisture content of the coal will be expelled as steam which is removed along with the migrating gases through the annulus 19 of well 12. Also when the hot exit gases first encroach into coal bed 18, entrained gases in coal bed 18, such as fire damp, are moved by displacement and differential pressure into the annulus 19 of well 12 and on to the surface. Thus the hot exit gases which may be combustible with a calorific content of, for example 90 BTU per standard cubic foot are enriched by mixing with entrained gases such as fire damp which could have a calorific content of, for example, 950 BTU per standard cubic foot.
The process is continued by diverting hot exit gases from coal bed 13 first through well 11 into coal bed 18 and then through well 12 to surface facilities. The temperature of the coal in coal bed 18 is gradually increased and at approximately 300° C (572° F) some of the volatile matter is given up in the form of gases which further serve to enrich the calorific content of the exit gases. At this temperature a considerable amount of the volatile matter can become liquid as oozing tars which will tend to sink under the influence of gravity and to migrate under the influence of differential pressure. Such movement of coal derived liquids tends to plug the permeability in the lower portion of coal bed 18, resulting in gas flow tending to be greater in the upper portion of coal bed 18. If coal bed 18 is a thin bed, for example up to 18 inchess thick, gas override generally is not a problem. If coal bed 18 is a thicker bed, for example in excess of 18 inches thick, excessive gas override may occur, resulting in poor transfer of heat from the hot exit gases to the coal in the lower portion of coal bed 18. This condition can be corrected by terminating oxidizer injection temporarily into well 12, reducing pressure in the system, injecting a thermosetting sealant material (i.e., cement) into the annulus of well 12 so that it flows into the excessively permeable upper portion of the coal bed 18, subsequently displacing the sealant from the annulus 19 of well 12 by a suitable fluid, for example water, and then allowing the sealant to set in the coal bed 18. Upon setting of the sealant, the process of pyrolysis as described above may be resumed.
When the hot exit gases from coal bed 13 contain a substantial amount of combustible gases, for example 150 BUT per standard cubic foot, and it is desired to increase the temperature of the exit gases, appropriate oxidizer injection may be resumed through the oxidizer injection tubing 15 of well 12 at an appropriate pressure, for example 510 psig. This planned oxygen bypass will cause a portion of the combustible gases to burn, raising the temperature of the exit gases flowing into annulus 19 of well 11, and thus delivering hotter gases into coal bed 18, accelerating the rate at which volatile matter in coal bed 18 is converted into fluid volatiles.
The method of the present invention is continued until substantially all of the volatile matter contained in coal bed 18 is coverted to fluid matter and captured at the surface or until the recovery of volatiles from coal bed 18 is reduced to a level which makes it no longer commercially attractive to continue the process. In some cases a substantial amount of volatile matter in the form of coal derived liquids may migrate to the annulus 19 of well 12. The likelihood of this occurring may be predicted by taking samples of the coal in coal bed 18 when wells 11 and 12 are drilled through coal bed 18. An analysis of the coal can determine the characteristics of the volatile matter and its content of tars that become flowable liquids at relatively low temperatures. When excessive liquids are anticipated, the packer set below the perforations at 17 in well 12 should be set at a lower level to form a sump below the perforations, and a liquid pumping device 30 should be set in the annulus to remove the liquids from the sump to the surface.
The gases produced in the present invention may be used completely as fuel gases, or they may be used in part as fuel gases with the remainder of the useful gases separated as coal derived chemicals in appropriate surface facilities. Likewise the liquids produced in the present invention may be separated into coal derived chemicals, or in part into coal derived chemicals and the remainder into fuel gases.
As an alternate embodiment, the process described in the present invention as it applies to coal bed 18 may be terminated when a substantial amount of moisture content is removed from coal bed 18. This is particularly desirable when coal bed 18 is a thicker bed, for example 8 feet thick, and it is planned that coal bed 18 will be gasified as the appropriately commercial process to produce the coal. In some cases it may be desirable to use the method of the present invention to remove gases entrained in the coal, for example fire damp, when the production of coal from coal bed 18 is planned for conventional underground mining techniques.
Referring to FIG. 1 only two coal beds are illustrated. Referring to FIG. 2 where a larger number of coal beds are illustrated, some of them may be quite far apart, for example 200 feet, from the nearest adjacent bed. Those skilled in the art will readily envision that coal bed 24, overlain and underlain by sedimentary rocks 28, may be produced by in situ gasification with coal bed 26 produced by the methods of the present invention. When coal bed 26 is produced to its economic limit, the perforations opposite coal bed 26 are sealed off, using techniques common in the petroleum industry, then perforations are added opposite coal bed 25 and the methods of the present invention are used to produce coal bed 25 to its economic limit. The perforations opposite coal bed 25 are sealed off and perforations are added opposite coal bed 23, then coal bed 22, and so on. Since coal bed 21, overlain by the overburden 27, is near the surface, it may be desirable to follow the method of the alternate embodiment of the present invention to drive out the fire damp and remove a substantial amount of the moisture content in preparation of coal bed 21 for conventional underground mining. In proceeding with mining coal bed 21 by conventional underground mining techniques, the mining plan, for example, could be by the room and pillar method wherein the wells used in the present invention would be contained in the pillars.
Referring to FIG. 3, a well pattern which would be useful in producing a given area is illustrated. As will be appreciated, the lowermost coal bed 18 would be gasified by injection of an oxidizer through the four spaced wells 12 which surround well 11 and the hot gases released from the gasified bed 18 would be dispensed radially through the perforations at 17 in well 11 wherefrom the gases would flow outwardly through coal bed 13 for collection in the wells 12.
Although the present invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example and that changes in details of structure may be made without departing from the spirit thereof.
|
A method of extracting energy and chemical values from coal in situ including the steps of establishing passages among two or more coal seams underground and the surface of the ground wherein one coal seam is consumed by in situ combustion with the hot exit gases diverted through a second seam of coal enroute to the surface. The second seam of coal is dewatered, then subjected to pyrolysis, with enriched exit gases captured at the surface.
| 4
|
[0001] The present application is a divisional application of U.S. patent application Ser. No. 12/341,255 filed on Dec. 22, 2008, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention provides an aligned carbon nanotube film with nano-sized particles adhered thereto and a method of preparing same. Such a film possesses a vast amount of surface area and excellent electrical conductivity along the alignment direction. This enables higher reactant flow rate and, in the case where the nanoparticles are catalysts, better contact between catalyst particles and reactants. Consequently, higher catalytic efficiency and productivity are can be obtained.
[0004] 2. Description of Related Art
[0005] A supported catalyst is composed of one or more active components deposited on a solid carrier to achieve an optimal dispersion and to prevent sintering of the active components. In order to successfully design and obtain the appropriate catalyst for a given process, several aspects should be taken into account. Because of the complexity of the preparation process, it is unlikely to design a general procedure for this type of catalyst preparation. In other words, different catalytic properties might be desirable for each particular application, because the physical and chemical properties of a catalyst can be tightly related to the preparation procedure.
[0006] The carrier of a supported catalyst should possess a high surface area upon which a highly dispersed catalyst can be formed. It is naturally desirable that the catalyst particles display a narrow particle size distribution. Impregnation, ion exchange, anchoring, grafting, and heterogenization of complexes are among the most used methods for preparing heterogeneous catalysts.
[0007] Carbon has been extensively used as a carrier for metal or alloy catalysts. It is chemically inert and usually comes as nano-sized particles. The enormous surface area it possesses makes it a very good catalyst supporting material. Furthermore, carbon is electrically conductive, ensuring its widespread use in fuel cells as a catalytic carrier.
[0008] Compared to carbon, carbon nanotubes are potentially a better catalyst carrier material because of their outstanding electrical, mechanical, and structural properties. A carbon nanotube has an exceptionally large aspect ratio, big surface area, and superior electrical conductivity along the tube direction.
[0009] As such, there exists a need for a method and process resulting in carbon nanotubes with increased catalytic efficiency.
SUMMARY OF THE INVENTION
[0010] In accordance with one embodiment of the invention, a carbon nanotube film is disclosed which includes a plurality of macroscopically aligned carbon nanotubes, and a plurality of nanoparticles which are adhered to the surfaces of the carbon nanotubes.
[0011] Pursuant to another embodiment of the invention, a method for constructing a carbon nanotube film is disclosed. This method includes multiple steps. First, a plurality of macroscopically aligned carbon nanotubes are formed on a substrate. Next, a solution including a dispersion of nanoparticles in a solvent is applied onto the carbon nanotubes. Then, the solvent is evaporated so that the nanoparticles remain and are adhered to the carbon nanotubes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 illustrates a macroscopically aligned carbon nanotube film according to an embodiment of the invention.
[0013] FIGS. 2A and 2B depict images of the carbon nanotubes of Example 1 described below.
[0014] FIGS. 3A and 3B depict images of the carbon nanotubes of Example 2 described below.
DETAILED DESCRIPTION OF EMBODIMENTS
[0015] It is to be understood that the figures and descriptions of the present invention have been simplified to illustrate elements that are relevant for a clear understanding of the present invention, while eliminating, for purposes of clarity, many other elements which are conventional in this art. Those of ordinary skill in the art will recognize that other elements are desirable for implementing the present invention. However, because such elements are well known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such elements is not provided herein.
[0016] The present invention will now be described in detail on the basis of exemplary embodiments.
[0017] A macroscopically aligned carbon nanotube film possesses a vast amount of surface area and excellent electrical conductivity along the alignment direction. In addition, the aligned film provides channels for materials such as reactants, gases, and liquids to pass through with minimal obstruction along the alignment direction, enabling higher reactant flow rate and better contact between catalyst particles and reactants. Consequently, higher catalytic efficiency and productivity are resulted.
[0018] Such a macroscopically aligned carbon nanotube film is distinguishable from a macroscopically non-aligned carbon nanotube film. FIG. 1 illustrates a macroscopically aligned carbon nanotube film. In an aligned carbon nanotube film 1 , the nanotubes are roughly all aligned, macroscopically, in the same direction. This direction is roughly perpendicular, within 10° of either direction, to the substrate 2 on which the nanotubes are grown. In other words, the angle between the length direction of the carbon nanotube film 1 and the substrate 2 is somewhere between 80° and 100°, inclusive. Such an aligned carbon nanotube film has the benefit of enabling good fluid flow in the direction of the length of the carbon nanotubes.
[0019] The above discussion of the arrangement of the carbon nanotubes relates to the macroscopic arrangement, as opposed to the microscopic arrangement. Microscopically, all carbon nanotubes appear to be jumbled. This is because, on the microscopic level, the carbon nanotubes are never perfectly aligned. However, if grown properly, the carbon nanotubes can be grown such that they are arranged to be aligned on the macroscopic level.
[0020] Such a design where the nanotubes are macroscopically aligned is different from that of a macroscopically non-aligned carbon nanotube film. In a macroscopically non-aligned film, the nanotubes are arranged at various angles and in various directions at the macroscopic level. In such a macroscopically jumbled arrangement of carbon nanotubes, the ability of fluid to travel between the nanotubes is greatly diminished from the arrangement where the carbon nanotubes are macroscopically aligned.
[0021] Due to the above listed benefits, the following embodiments use macroscopically aligned carbon nanotubes.
[0022] In one embodiment, a preformed nano-sized catalyst emulsion or microemulsion is spread in an aligned carbon nanotube film. The nano-sized catalyst solution can be an aqueous or non-aqueous solution. Examples of solvents for such solutions included isopropanol, oil and water emulsion, and hexane based solutions. What is important is that the solvent be sufficiently volatile so that the solvent can later be removed with relative ease. As such, any volatile hydrocarbon with a low boiling point may be used as a solvent in the nano-sized catalyst solution as well.
[0023] After the nano-sized catalyst solution is spread in an aligned carbon nanotube film, the volatile solvents are removed so as to allow the catalyst nanoparticles to be absorbed onto the surface of carbon nanotubes to form a carbon nanotube-supported catalyst. The catalyst/carbon nanotube combination can be used in chemical syntheses, fuel cells, chemical conversions, or purifications, depending on the composition of the catalyst particles. Examples of catalysts that can be used include oxides (e.g., metal oxides), dioxides (e.g., silicon dioxide), metals (e.g., nickel), metal alloys.
[0024] In order to disperse the nano-sized catalyst particles into the aligned carbon nanotube film, the particles should be in the form of a stable liquid dispersion. For example, the particles can be in the form of a dispersion of nano-sized catalyst particles prepared using microemulsion and/or inverse micelle methods. As another example, nano-sized powder can also be dispersed into a fluid to form a stable dispersion, which can then be used to form a carbon nanotube film-supported catalyst.
[0025] If the fluid of the nano-sized catalyst particle dispersion is hydrophilic, it can be difficult for the fluid to penetrate into the interior of the carbon nanotube film. In this case, one or more surfactants are needed to improve the wetting ability of the dispersion on the carbon nanotube surface. The best surfactants to use in such a case are neutrally charged surfactants, as such surfactants are least likely to disturb the stability of the suspension. However, anionic or cationic surfactants can also be used, so long as the chosen surfactant does not cause the nanoparticles to fall out of suspension, thereby becoming unusable.
[0026] In other words, the main criterion for selecting a surfactant is that the chosen surfactant should not cause a degradation of the stability of the dispersion of the nanoparticles. For example, if the nanoparticle being dispersed is positively charged then you can use a positively charged or neutrally charged surfactant. Similarly, if the nanoparticle being dispersed is negatively charged, then you can use a negatively charged or neutrally charged surfactant.
[0027] Conversely, for a water-in-oil inverse micellar system, the hydrophobicity of such a dispersion would allow the dispersion to readily fill in the space between the carbon nanotubes without the need to add any surfactant.
[0028] After the carbon nanotube film has completely soaked up the catalyst particle dispersion, the solvents of the dispersion are then allowed to evaporate off of the film, leaving the catalyst particles adsorbed onto the carbon nanotube surface. One way of evaporating the solvents is to air dry the carbon nanotubes. Alternatively, the solvents can be evaporated by vacuum drying the carbon nanotubes. The carbon nanotubes can also be heated in order to evaporate the solvents. However, care must be taken no to heat the nanotubes too much, as this could destroy the integrity of the carbon nanotubes.
[0029] For the embodiments described above, an upright aligned carbon nanotube film is formed contiguously across the surface of the silicon substrate with the carbon nanotubes aligned in the direction perpendicular to the substrate surface. The carbon nanotube film can be grown on a piece of silicon substrate on which 20 to 200 Å of iron is deposited. The silicon piece is then put inside a carbon nanotube growth furnace. The growth process takes place at from 400 to 900° C., more preferably from 650 to 750° C., and most preferably around 700° C. At lower temperatures, the choice of catalyst for nanotube growth becomes important. For example, catalysts such as, for example, iron, cobalt, or nickel should be used at lower temperatures of, for example, around 400° C. In addition, tungsten may also be used as a catalyst. The growth process lasts from 5 minutes to 2 hours, more preferably from 10 to 50 minutes, and even more preferably around 20 to 30 minutes, with around 25 minutes being most preferable. The growth process occurs in a flow of mixed gasses typically including 100 sccm (standard cubic centimeters per minute) of hydrogen and 690 sccm of ethylene.
[0030] Alternatively, a different recipe can be used, in which the growth process occurs in a flow of mixed gases including 400 sccm of hydrogen, 400 sccm of ethylene, and 200 sccm of argon. The resulting carbon nanotube film shows that the carbon nanotubes have a length of about 150 to 600 microns and a diameter ranging from 20 to 40 nm. Other combinations of gases which may be used include ethylene alone, ethylene and ammonia, and ethylene and water vapor. The carbon gas listed above is ethylene, however other carbon gas may be subtitled therefore (e.g., methane, acetylene, etc.), provided the carbon gas is paired with a good matching catalyst.
[0031] After the growth process has taken place, the furnace is cooled down. Then argon is blown through the furnace to remove any carbon containing gases. The end product is then a “forest” of carbon nanotubes which are macroscopically aligned in the same direction.
[0032] It should be noted that there are different ways to apply the nano catalyst particle dispersion to the aligned carbon nanotube film. For example, an appropriate amount of the dispersion can be carefully dripped or sprayed onto the carbon nanotube film. If a greater amount of catalyst particles is desired to be adhered to the carbon nanotubes, this procedure can be repeated after the previously applied dispersion has dried. It should be noted that it is important to prevent the structure of the carbon nanotubes from being destroyed during the application of the nanoparticles. Accordingly, care should be taken when spraying a dispersion onto the carbon nanotubes so as to maintain the structure of the carbon nanotubes. If the dispersion is too sprayed with too much force, a hole might be poked through the carbon nanotubes, thus making them unusable. The carbon nanotube film can also be dipped into a dispersion of nano-sized catalyst particles, subsequently allowing the solvents to evaporate. Regardless of the process, the goal of applying any nanoparticle dispersion to the carbon nanotubes is to gently apply the dispersion so that the carbon nanotubes are fully saturated with nanoparticles, while maintaining the structural integrity of the carbon nanotubes.
Example 1
Aqueous Nano-Sized Silica Dispersion
[0033] In Example 1, a few drops of an aqueous silica colloidal suspension, Snowtex-C, were added into 5 ml of deionized water to form a diluted suspension Two drops of 10% Triton X-100 were added into the mixture, and the liquid was agitated until it was thoroughly mixed. A small amount of this solution (˜0.5 ml) was carefully spread over the surface of an aligned carbon nanotube film grown on a piece of silicon wafer (about 1 cm×2 cm). The film was then dried under ambient condition. FIGS. 2A and 2B depict images of the carbon nanotubes which were taken on a Hitachi S4700 scanning electron microscope. The silica particles can clearly be seen absorbed onto the carbon nanotubes as dark areas.
Example 2
Organic-Based Nano-Sized Silica Dispersion
[0034] In Example 2, a few drops of an organic silica colloidal suspension, Snowtex IPA-ST, were added into 5 ml of isopropanol to form a diluted suspension. A small amount of this solution (˜0.5 ml) was carefully spread over the surface of an aligned carbon nanotube film grown on a piece of silicon wafer (about 1 cm×2 cm). The film was then dried under ambient conditions. FIGS. 3A and 3B depict images of the carbon nanotubes which were taken on a Hitachi S4700 scanning electron microscope. The silica particles can clearly be seen adsorbed onto the carbon nanotubes as dark areas.
[0035] While the above embodiments apply nano-sized catalyst particles to the carbon nanotubes, the invention is not limited thereto. Rather, any useful nanoparticle can be applied. For example, filtering particles can be applied so that the carbon nanotube combination can be used as a filter.
[0036] In addition, once the nanoparticles are applied to the carbon nanotubes and the solvent has evaporated, the carbon nanotubes can then be used for their intended purpose (e.g., used as a catalyst, used as a filter, used in fuel cells). For example, the carbon nanotubes can even be removed from the substrate if needed.
[0037] While this invention has been described in conjunction with the specific embodiments outlined above, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, the preferred embodiments of the invention as set forth above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the inventions as defined in the following claims.
|
A carbon nanotube film is disclosed which includes a plurality of macroscopically aligned carbon nanotubes, and a plurality of nanoparticles which are adhered to the surfaces of the carbon nanotubes. A method for constructing a carbon nanotube film is also disclosed. This method includes multiple steps. First, a plurality of macroscopically aligned carbon nanotubes are formed on a substrate. Next, a solution including a dispersion of nanoparticles in a solvent is applied onto the carbon nanotubes. Then, the solvent is evaporated so that the nanoparticles remain and are adhered to the carbon nanotubes.
| 2
|
FIELD OF THE INVENTION
[0001] The field of the invention is that of the design and manufacture of integrated circuits, e.g. of MOS type.
[0002] More specifically, the invention concerns the circuits delivering logic levels, whose voltage must remain constant even when the mains voltage varies.
BACKGROUND OF THE INVENTION
[0003] The invention concerns, in particular, the communication between two integrated circuits, e.g. via a USB connection. A USB buffer must in fact provide logic actions “1” and “0” at output, on a connection which can reach an output of 500 pF of capacitance, with a switching time of approximately 20 ns. The USB standard specifies that level “1” must have a voltage of 3V, whatever the mains voltage may be.
[0004] Normally, a USB buffer is just a power switch and is powered by a regulator delivering a constant 3V. This regulator must therefore have a very large output capacitor 15 , in order to be able to support the peaks in current, in the region of 100 mA for 20 ns. In fact, it would not be able to react in 20 ns (as illustrated in FIG. 2) without this capacitor, and the voltage would then drop greatly without the latter.
[0005] [0005]FIG. 1 illustrates such a device. It therefore comprises a regulator 11 , comprising an operational amplifier 111 , which receives a Vbgap reference voltage on its positive terminal, for example, of 1.2 V. This operational amplifier 111 is connected to a transistor 112 , this latter looping back to the negative input of the former, via a resistor 113 . This regulator therefore delivers a DC voltage of 3 V to be regulated, with the aid of the external capacitor 14 , which is directed in particular towards the buffer 12 .
[0006] This buffer comprises two transistors 121 and 122 , PMOS and NMOS respectively, which receive a command signal 123 , and deliver on a resistor 124 the invention corresponding to the desired logic level.
[0007] As mentioned above, in order to obtain a response time below 20 ns, it is necessary to provide for an external capacitor 13 , of a value of 500 pF for example. This necessitates providing for a specific output terminal on the integrated circuit, in order to connect this external capacitor 13 .
[0008] Furthermore, such a capacitor increases the cost of the assembly, as well as the space required and the complexity of assembly.
[0009] Moreover, a regulator, assuming the presence of an operational amplifier, leads to a significant crowding of the surface of the integrated circuit.
[0010] The objective of the invention is in particular to reduce these various difficulties with the state of the art.
[0011] More specifically, one objective of the invention is to produce an integrated circuit capable of delivering a predetermined output voltage representative of a logic level, whatever the mains voltage, which does not require any external component, particularly a capacitor, to support peaks in current.
[0012] Another objective of the invention is to produce such an integrated circuit, which does not require the presence of a standard USB regulator, assuming the presence of an operational amplifier.
[0013] Another objective of the invention is to produce such an integrated circuit, which allows for simplifying the design, manufacture and assembly of the integrated circuit.
[0014] In other words, one objective of the invention is to provide a simple and efficient technique which uses little of the silicon surface, to produce such an integrated circuit.
[0015] The objective of the invention is also to produce such an integrated circuit, which offers a very short rise time up to the desired voltage, e.g. in the region of 20 ns.
SUMMARY OF THE INVENTION
[0016] The invention therefore concerns an integrated circuit comprising means of delivering a predetermined output voltage representative of a logic level to at least one output, the integrated circuit comprising means of distributing a mains voltage and means of generating an internal reference voltage lower than the mains voltage.
[0017] Such a circuit comprises, in particular, means to connect the mains voltage to the output and means to limit and/or detect the voltage at the output at the value of the predetermined output voltage, taking into account the reference voltage.
[0018] In this way, it is possible to obtain an accurate output voltage, whatever the variations in the mains voltage, without an external element such as a capacitor.
[0019] Advantageously, the predetermined voltage is equal to the reference voltage.
[0020] However, in another embodiment of the invention, it is possible to generate an output voltage which is different from the reference voltage, while ensuring the same functionalities, by using for example, one or more transistors connected in series.
[0021] It is preferential that when the predetermined voltage is reached, the currents circulating in the mains voltage connection means and in the means of limiting and/or detecting the voltage are balanced.
[0022] It is preferential that the connection means comprise a first power transistor (TP 0 ).
[0023] One benefit is that the drain from the first transistor is connected to the output and its source to the mains voltage.
[0024] One benefit is that the means of limiting the voltage have at least a second transistor (TP 1 ) controlled on its gate by the reference voltage.
[0025] It is preferential that the gate of the second transistor is connected to the gate of a third transistor (TP 2 ) mounted in the diode at the reference voltage.
[0026] It is preferential that the means of limiting the voltage comprise means to block the first transistor when the predetermined voltage is reached.
[0027] It is also preferential that the blocking means comprise first and second current mirrors (TN 1 /TN 2 , TP 4 /TP 5 ) connected to each other.
[0028] One benefit is that the first current mirror delivers a blocking current when the predetermined voltage is reached at the output, and in that the second mirror transmits a copy of the blocking current to the gate of the first transistor, in such a way as to block it.
[0029] One benefit is that the gate of the first transistor is connected to a control input via a fourth transistor (TN 3 ).
[0030] Another benefit also is the size of the third transistor is smaller than those of the transistors (TP 4 , TP 5 ) of the second mirror, so that the latter imposes its level on the third transistor when it delivers the copy of the blocking current.
[0031] It is preferential that the output voltage corresponds to the logic level “1” of a USB connection.
[0032] One benefit is that the reference voltage is used to control the CMOS logic section of the integrated circuit.
[0033] One benefit is that the reference voltage and/or the predetermined voltage give a value of 3 V, the mains voltage giving a value of 5 V.
[0034] The invention also concerns an integrated circuit communication module comprising means of delivering, on at least one output, a predetermined output voltage representative of a logic level and an integrated circuit comprising means of distributing a mains voltage and means of generating an internal reference voltage lower than the mains voltage. One benefit is that this module comprises means of connecting the mains voltage to the output and means of limiting voltage at the output at the predetermined output voltage value, taking into account the reference voltage.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] Other characteristics and advantages of the invention will be shown more clearly upon reading the following description of a preferred embodiment of the invention, given as a simple but not limiting illustrative example and some attached diagrams, among which:
[0036] [0036]FIG. 1 is a diagram illustrating a regulating device according to the prior art with an external capacitor, referred to in the preamble;
[0037] [0037]FIG. 2 illustrates the voltage of the output signal, according to both the prior art and the invention;
[0038] [0038]FIG. 3 is a schematic diagram of the technique according to the invention;
[0039] [0039]FIG. 4 is a detailed example of implementing the technique according to the invention;
[0040] [0040]FIGS. 5 .a and 5 .b illustrate value curves associated with the functioning of the device in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] The general principle of the invention consists in generating the 3 V voltage in the integrated circuit, without the need for a regulator for the power section. In general, there is in fact a regulator in the circuits for the CMOS logic section, so that it always operates at a low voltage (3 V and not 5.5 V, to avoid the risk of destroying small transistors).
[0042] One beneficial aspect of the invention is that this 3 V voltage thus serves as the reference to generate a logic level “1”, according to the USB standard (in the embodiment described), by taking the power directly from the 5 V supply. FIG. 3 illustrates the general principle of the invention in a simplified way.
[0043] The system of the invention therefore includes means of connecting 31 the 5 V supply at the USB output. These connection means include, notably, a PMOS transistor, which connects the 5 V supply to the USB output.
[0044] Means of limiting 32 the voltage delivered to this USB output are provided for. They are connected to this output in such a way as to absorb part of the voltage, when necessary, so that it does not exceed 3 V.
[0045] These limiting means 32 simultaneously control the blocking means 33 , comprising, for example, two current mirrors. They act on the connection means in such a way as to block the connection between the 5 V supply and the USB output.
[0046] So, it is possible to deliver a USB output at a regular 3 V voltage, without an external capacitor or an operational amplifier, or any other complex element.
[0047] Presentation of a Particular Method of Carrying Out the Invention
[0048] A particular example is now presented for implementing these techniques, with the help of FIG. 4, which shows a particular method of embodiment of the invention and FIG. 5( a and b ) which illustrates some operational values.
[0049] The transistor TP 0 (PMOS in this example, but it is of course possible to reverse the roles of the PMOS and NMOS transistors) connects the 5 V supply AL5V to the USB output. It becomes active depending on the signal it receives at its gate, controlled as explained later.
[0050] According to the invention, the transistor TP 1 (PMOS) is connected to the USB output by its drain. Its gate is connected at a VT voltage lower than the USB voltage (and with a value, for example, of approximately 2.2 V).
[0051] This VT voltage can be produced using a transistor TP 2 of the same type as TP 1 , connected to diodes with a 3 V numeric voltage (always available in the CMOS logic section of an integrated circuit). This transistor therefore generates a voltage equal to (3 V−VT). This transistor TP 1 thus has a function of instant detector of level “1” (3 V) on the USB output. In fact, as soon as the voltage at the USB output exceeds 3 V, the voltage VGS 1 of this transistor TP 1 becomes greater than VT (with a value of approximately 0.8 V) and therefore becomes active.
[0052] A current i passes through this transistor TP 1 . Due to this current i, the power transistor TP 0 can be closed, using the blocking means, which connect the USB output to the 5 V supply. It is therefore easy to limit the level “1” of the USB to 3 V.
[0053] A simple comparator comparing the USB output with the numeric 3 V voltage, to then close the power transistor TP 0 , would be too slow, and would create overshoots and would also consume much. The solution, according to the invention, uses current mirrors in the blocking means and allows for efficiently reducing this disadvantage.
[0054] It should be noted that the principle described above also works with NMOS transistors in place of the PMOS, TP 0 and TP 1 transistors.
[0055] Illustration of the Functioning of the Device in FIG. 4
[0056] When a level “1” is wanted at the USB output, the command DPLUS changes to “1” ( 51 , FIG. 5 .a ). The transistor TN 3 then opens the power transistor TP 0 , by applying a VSS voltage to its gate. The voltage at the USB output then progressively rises ( 52 , FIG. 5 .a ). When it reaches 3 V, after about 20 ns ( 53 , FIG. 5 .a ), the transistor TP 1 becomes slightly conducting, as its VGS 1 voltage has become greater than the VT voltage. The current coming from the transistor TP 0 to the transistor TP 1 is then instantly re-copied by the current mirror formed by the transistors TN 1 and TN 2 , then by the current mirror formed by the transistors TP 4 /TP 5 .
[0057] So, when a current circulates in TP 1 , there is a similar current circulating in TP 5 . This current allows for closing the transistor TP 0 , by resetting its gate voltage to 5V−VT, which leads to its closure, at least partially.
[0058] The transistor TP 5 is configured in such a way that it is able to impose its level on transistor TN 3 , the latter being a very weak transistor.
[0059] So, the system charges the USB capacity up to 3 V, and then maintains this level ( 54 , FIG. 5 .a ), by balancing the currents, in the region of a few dozen pA in the transistors TP 0 and TP 1 . All the power to charge the 500 pF of the USB thus comes directly from the mains voltage AL5V ( 55 , FIG. 5 .b ). There is therefore no need for a USB regulator or external capacitor in the solution according to the invention.
[0060] Applications
[0061] The device of the invention can be installed whenever external capacitors need to be reduced to a minimum, e.g. for USB connections. It applies particularly in the case where the integrated circuit has an internal voltage reference has the same value as the voltage to be output, via buffers.
[0062] General
[0063] In one particular embodiment of the invention, one or more other transistors are used in series with the transistor TP 2 , or even a low-power regulator (e.g. 1.2 V), so as to generate a USB output voltage (e.g. of 2 V) which is different from the reference voltage, while ensuring the same functionalities.
[0064] Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
|
The invention concerns an integrated circuit comprising means of delivering, on at least one output, a predetermined output voltage representative of a logic level, means of distributing a mains voltage and means of generating an internal voltage reference lower than the mains voltage, comprising means of connecting the mains voltage to the output and means of limiting and/or detecting the voltage at the output at the predetermined output voltage value, taking into account the reference voltage.
| 7
|
FIELD OF THE INVENTION
The disclosed invention is directed generally to front end loader vehicles with an accessory, particularly an accessory for clearing snow, manure, etc., and more particularly apparatus for protecting the vehicle and driver when the scraping edge of the accessory strikes an immovable object when the scraping edge is sliding along the ground.
BACKGROUND
Commercial snow plows, front end loaders and snow blowers have a long history of use in removing snow from streets and highways. Over the past several decades the use of snow plows on light and medium duty trucks has become commonplace. Snow plows work well for clearing snow from roadways, particularly in open places and in areas where yearly snowfall totals are such that the snow can be readily pushed off the roadway. In densely populated urban areas, where real estate is at a premium, and in areas with large annual snowfalls, there is a need to be able to lift snow over snowbanks for deposit into large piles. Alternately, the snow is often lifted into dump trucks to be hauled and deposited elsewhere, or dumped into snow melting machines. In addition, snow blowers are widely used by people in clearing snow from their yards and sidewalks.
One of the issues related to the use of these snow clearing machines is that a great amount of stress is imparted to the structural components when plowing in areas such as those prone to frost heaving where manhole covers, and other relatively fixed objects, are struck by the moving scraping edge of the machine's clearing accessory. Not only do such encounters with immovable objects greatly shorten the life of these snow clearing machines, but they are also quite jarring to the machine operator and pose an enhanced risk of injury to the machine operator as well as others in the vicinity of the machines that are in operation.
Several devices have been developed for use with snow clearing machines, particularly, snow plows, whereby either the whole plow blade, or just a portion of it, pivots back up to about 90 degrees upon encountering a fixed object in the road (see for example U.S. Pat. Nos. 6,701,646 and 5,697,172, respectively). Such devices, while effective for some of the snow plow blades, are not compatible with some other snow clearing machines. For example, due to the different geometry of a loader bucket, the bucket's longitudinal depth combined with the required rear pivotal connections for lifting and dumping prevent such a pivoting back since such pivoting generally requires a pivot point on an angle greater than 45 degrees up from the leading edge. Also, since such buckets typically have a leading edge attached to the horizontal structure of the bucket bottom, the tilting back solutions are impractical because this would require tilting the whole bucket backwards by around 180 degrees. Consequently, there is a need for a device which allows the scraping edge of snow clearing machines to ride up over fixed objects upon impacting them, which thereby reduces the wear and tear on snow clearing machines while also enhancing the safety of the machine operator and the public at large.
BRIEF SUMMARY
The disclosed invention is directed to an apparatus connecting between a clearing accessory and a vehicle. In this context, “vehicle” means a structure comprising a body, wheels, and a means for self propulsion. Examples of the type of vehicles to which the invention may be most appropriately attached include all-terrain vehicles (ATVs), farm tractors, skid loaders, and pickup trucks. It is understood that the clearing accessory may be used for snow or other accumulations, such as, for example, manure. The inventive apparatus as attached to such vehicle provides for the scraping edge of clearing accessories to rise up and pass over fixed objects, rather than tilt backwards as in the prior art.
The accessory of interest has a scraping edge and a heel, and the apparatus includes a linkage assembly attachable to the vehicle. The linkage assembly has first and second pivot axes pivotally connecting with the accessory. The first pivot axis is beneath the second pivot axis. The linkage assembly has first and second configurations: the first configuration includes the first axis located in a first position horizontally relative to the second axis, the second configuration includes the first axis located in a second position horizontally relative to the second axis. The second position is horizontally separated in a direction toward the accessory relative to the first position. When the scraping edge of the accessory strikes an immovable object, the linkage assembly moves from the first to the second configuration. When the linkage assembly is in the first configuration, the scraping edge and the heel of the accessory are both resting on ground. When the linkage assembly is in the second configuration, the heel of the accessory is on the ground and the scraping edge is elevated to allow the scraping edge to ride up and over the immovable object.
In another embodiment, the linkage assembly has a frame assembly including a pair of downwardly projecting legs which at an end attach to a bucket at a first pivot axis. A member, preferably in the form of a hydraulic cylinder attaches between the frame assembly and the bucket at a location forwardly of the downwardly projecting legs. The hydraulic cylinder is pivotally attached to the bucket to form a second pivot axis and also to the frame assembly near the top of the downwardly projecting legs at a third pivot axis. The frame assembly is further attachable to the vehicle. In one alternative embodiment, the present invention has a sensor and control mechanism for determining when the distance between the first pivot axis and the attachment to the vehicle contracts thereby signaling that the bucket has met an immovable object. When a threshold level is reached, a control mechanism causes the bucket to pivot at the first pivot axis, tilt up, and slide over the immovable object. The bucket and framework are thereby spared from bending and breaking, and the vehicle operator is less likely to be injured.
In another alternative embodiment, there are hinged joints in each of the projecting legs, and a biasing mechanism in the form of a spring or elastomeric member, or a hydraulic or pneumatic cylinder, or a flexible fluid-filled container which provide a biasing force which maintains the bucket edge along the ground. When the bucket strikes an immovable object and generates a force sufficient to overcome the biasing force, the hinged joints allow the bucket to pivot at the first and second pivot axes so that the bucket can tilt and ride over the immovable object. Once past the object, the biasing mechanism causes the hinged joint to close so that the bucket pivots back to its original scraping position.
In a further embodiment, the biasing force provided by the biasing mechanism may be adjusted directly through various mechanical, hydraulic, or pneumatic means of control so that the impact-force threshold beyond which tilting of the bucket occurs may be set by the vehicle operator. For instance, the vehicle driver may set the biasing force at one setting for plowing dirt roads, and at another level when plowing city streets having protruding manhole covers.
In yet another embodiment, lower portions of downwardly projecting legs are split into top portions and bottom portions with the bottom portion connected to the top portion through the use of guiding means and a hydraulic cylinder which can extend the overall length of the lower portion of the downwardly projecting leg so that the amount of bucket tipping is amplified by the extension.
Additionally, an adjustable threshold impact level may be set through the use of sensors incorporated into an electromechanical control circuit, or mechanically through the use of shear pins or a mechanical nipple and détente assembly. For example, when a bucket strikes an immovable object with a force sufficient to cause a nipple and détente assembly to disengage, the hinged joints allow the bucket to pivot at the first and second pivot axes so that the bucket can tilt and ride over the immovable object. The biasing mechanism then causes the hinged joint to close and the nipple and détente assembly to reset, so that the bucket pivots back to its original scrapping position.
In still another embodiment, the linkage accessory is a quadrilateral linkage having a front plate that connects to an accessory bucket and a rear plate that connects to the loader vehicle. The front plate connects to a first pair of arms at first pivot points and second pair of arms at second pivot points. The rear plate connects to the second pair of arms at third pivot points and the first pair of arms at fourth pivot points. The first pair of arms is non-parallel to the second pair of arms.
The quadrilateral linkage has an activated state and an inactivated state. In the inactivated state, the linkage is held together by a bias member, such as a spring. The linkage is activated when the scraping edge of the bucket strikes an immovable object. During this process, the elastomeric force of the spring is overcome and the linkage is compressed. The first pivot axis moves forwardly toward the bucket relative to the second pivot axis so that the bucket is tilted at its heel and the scraping edge is elevated and rides up and over the immovable object.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B illustrate schematically in side view an embodiment of the present invention, including a sensor and bucket tilt control system. FIG. 1A shows the bucket riding over a flat surface; FIG. 1B shows the bucket riding up over a fixed object which it initially struck.
FIG. 2 is a side view of another embodiment of the present invention.
FIG. 3 is an enlarged plan view of the lower bucket assembly as shown in FIG. 2 taken along auxiliary line 3 - 3 .
FIG. 4A is a sectional view of the lower bucket assembly as shown in FIG. 3 , taken along section line 4 - 4 , showing the assembly in the undeflected position.
FIG. 4B is a sectional view of the lower bucket assembly as shown in FIG. 3 , taken along section line 4 - 4 , showing the assembly in the deflected position as the bucket rides up over a fixed object.
FIG. 5A is a side view of the lower bucket assembly, which includes a nipple and détente mechanism, showing the assembly in the undeflected position.
FIG. 5B is a side view of the lower bucket assembly, which includes a nipple and détente mechanism, showing the assembly in the deflected position.
FIG. 6 is a sectional view of the lower bucket assembly of a further embodiment as shown generally in FIG. 3 , taken along section line 4 - 4 , showing the assembly in the undeflected position.
FIG. 7 is a side view of the lower bucket assembly of still another embodiment of the present invention, showing the assembly in the undeflected position.
FIG. 8 is an enlarged plan view of the lower bucket assembly as shown in FIG. 7 taken along auxiliary line 8 - 8 .
FIG. 9 is a sectional view of the lower bucket assembly as shown generally in FIG. 8 , taken along section line 9 - 9 , showing the assembly in the undeflected position.
FIG. 10A is a sectional view of the lower bucket assembly as shown in FIG. 8 , taken along section line 10 - 10 , showing the nipple and détente mechanism when the assembly is in the undeflected position.
FIG. 10B is a sectional view of the lower bucket assembly as shown in FIG. 8 , taken along section line 10 - 10 , showing the nipple and détente mechanism when the assembly is in the deflected position.
FIG. 11A is a partial side view of the lower bucket assembly of yet another embodiment as shown in FIG. 2 , showing a divided lower portion of a downwardly projecting leg, and a hydraulic cylinder (and associated hydraulic circuit) which controls its overall length, in the undeflected position.
FIG. 11B is a partial side view of the lower bucket assembly of the embodiment of FIG. 11A as shown in FIG. 2 , showing a divided lower portion of a downwardly projecting leg, and a hydraulic cylinder (and associated hydraulic circuit) which controls its overall length, in the deflected position.
FIG. 12A is a side view of a loader with a quadrilateral linkage connecting a bucket to the loader, when the quadrilateral linkage is not activated.
FIG. 12B is a side view of a loader with a quadrilateral linkage connecting a bucket to the loader, when the quadrilateral linkage is activated.
FIG. 13A is an enlarged side view of the quadrilateral linkage of FIG. 12 A, when the quadrilateral linkage is not activated.
FIG. 13B is an enlarged side view of the quadrilateral linkage of FIG. 12B , when the quadrilateral linkage is activated.
FIG. 14 is a top view of the quadrilateral linkage.
FIG. 15 is a sectional view of the quadrilateral linkage as shown in FIG. 13A , taken along section line 15 - 15 , showing the rear plate.
FIG. 16 is a sectional view of the quadrilateral linkage as shown in FIG. 13A , taken along section line 16 - 16 , showing the front plate.
FIG. 17A is a side sectional view of the quadrilateral linkage including a nipple and détente assembly, as shown in FIG. 15 , taken along section line 17 - 17 , when the quadrilateral linkage is not activated.
FIG. 17B is a side sectional view of the quadrilateral linkage including the nipple and détente assembly, when the quadrilateral linkage is activated.
DETAILED DESCRIPTION
The disclosure relates to an apparatus for attaching an accessory having a scraping edge and a heel to a vehicle and includes a linkage assembly attachable to the vehicle. The linkage assembly has first and second pivot axes pivotally connecting with the accessory. The first pivot axis is beneath the second pivot axis. The linkage assembly has first and second configurations: the first configuration includes the first axis located in a first position horizontally relative to the second axis, the second configuration includes the first axis located in a second position horizontally relative to the second axis. The second position is horizontally separated in a direction toward the accessory relative to the first position. When the scraping edge of the accessory strikes an immovable object, the linkage assembly moves from the first to the second configuration. When the linkage assembly is in the first configuration, the scraping edge and the heel of the accessory are both resting on ground. When the linkage assembly is in the second configuration, the heel of the accessory is on the ground and the scraping edge is elevated to allow the scraping edge to ride over the immovable object.
In one embodiment, the linkage assembly is mounted to a front end loader apparatus. Referring to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, and more particularly to FIGS. 1A and 1B , the front end loader apparatus in accordance with the present invention is designated generally by the numeral 10 . Designations such as front, back, top, bottom, right side and left side are to be referenced to the vehicle, particularly from the perspective of the vehicle driver. Apparatus 10 includes a frame assembly 12 attached to the vehicle (not shown). Frame assembly 12 includes a pair of downwardly projecting legs 16 which are pivotally attached at first pivot points 18 to bucket 20 . Hydraulic cylinders 22 are pivotally attached at second pivot points 24 to bucket 20 and also to frame assembly 12 near the top of downwardly projecting legs 16 at third pivot points 26 . The frame assembly 12 is pivotally attached at vehicle attachment pivot points 14 . In the first embodiment, the hydraulic cylinders 22 are part of a mechanism 28 controlled by control system 30 , which in conjunction with sensor 32 , causes the bucket 20 to tip back upon striking an immovable object 34 as shown in FIG. 1(B) . Sensor 32 senses a change in distance between first and vehicle attachment pivot points 18 and 14 or, alternatively, a change in velocity of bucket 20 or an impact deceleration of bucket 20 . That is, when bucket 20 has met immovable object 34 , sensor 32 sends a signal to control system 30 which determines if a threshold value of the parameter measured has been reached. If the threshold value has been met, control system 30 actuates a contraction of hydraulic cylinders 22 so that bucket 20 tips appropriately up at the scraping edge and rides up and over the immovable object 34 .
In another embodiment as shown in FIGS. 2-5(B) , there are two downwardly projecting legs 16 ′ which have hinged joints 36 which allow bucket 20 to tip relative to frame assembly 12 ′. Each downwardly projecting leg 16 ′ has upper and lower portions 38 , 40 separated at a break location 42 . The two upper portions 38 are rigidly connected by a first cross member 60 as shown in FIG. 3 . The two lower portions 40 are rigidly connected by a second cross member 41 . The upper portions 38 and lower portions 40 of each of the downwardly projecting legs 16 ′ are rotatably fastened together at fourth pivot point 44 . Pivot points 44 have axes lying parallel and located rearwardly of break locations 42 . A lever arm 46 is fixedly attached to the lower portion 40 of each of the downwardly projecting legs 16 ′. Alternatively, lever arm 46 could be a unitary part of the lower portion 40 of the downwardly projecting leg 16 ′. A mating leg 48 extends rearwardly from each of the upper portions 38 of downwardly projecting legs 16 ′ so that the rearward end of lever arm 46 and mating leg 48 are pivotally attached together at the fourth pivot point 44 . The lower portions 40 of the downwardly projecting legs 16 ′ are attached to bucket 20 at first pivot points 18 .
Working in conjunction with hinged joints 36 are hinged joint closing devices 50 . With respect to FIGS. 4A and 4B , a hinged joint closing device 50 includes a coil spring 52 . One end 54 of the spring 52 is attached to a forwardly extending portion 56 of lever arm 46 . The other end 58 of the spring 52 is attached to the first cross member 60 which rigidly connects the upper portions 38 of the downwardly projecting legs 16 ′. As shown in FIG. 3 , there are similar hinged joint closing devices 50 associated with each of the downwardly projecting legs 16 ′.
In use, apparatus 10 is positioned so that the bottom 62 of bucket 20 is flat on the ground so that the front edge 64 scrapes, for example, snow and ice appropriately along the ground. When front edge 64 strikes an immovable object 34 as shown in FIG. 4B , the lower portions 40 of the downwardly projecting legs 16 ′ pivot backward about the fourth pivot points 44 . As the lower portion of the downwardly projecting legs 40 pivot backward, the bucket 20 pivots about the second pivot points 24 and first pivot points 18 thereby allowing the front scraping edge 64 of the bucket 20 to lift up and over the immovable object 34 . The heel of the bucket remains on the ground. Hydraulic cylinder 22 maintains a constant length during these operations. The impact force of the immovable object 34 is counteracted by the hinged joint closing device 50 , or more particularly, springs 52 . When the impact force of the immovable object 34 overcomes the counteracting spring force, which is determined by the spring constant, as well as the length of the lever arm 46 relative to the fourth pivot points 44 , the front scraping edge 64 of the bucket 20 will lift up and over the immovable object 34 as shown in FIG. 4B . Once the immovable object 34 has been cleared, the springs 52 will pivot the lower portion 40 of the downwardly projecting legs 16 ′ about the fourth pivot points 44 so that the upper portions 38 and the lower portions 40 lie directly adjacent one another in the area of break locations 42 , thereby resetting the hinged joint closing device 50 .
In a further embodiment of apparatus 10 as shown in FIGS. 5A and 5B , a sensor in the form of a mechanical nipple/détente assembly 82 is disclosed. Nipple/détente assembly 82 includes a détente member 84 pivotally attached to both the right and left sides of the lower portion 40 of each downwardly projecting leg 16 ′ at pivot point 86 . The detent member 84 additionally provides a stop which prevents the over-rotation of the lower portion 40 of the downwardly projecting leg 16 ′. A nipple sub-assembly 88 is pivotally attached to the inside of the upper portion 38 of each downwardly projecting leg 16 ′. Nipple sub-assembly 88 includes a pair of plates 94 , on either side of détente member 84 , held together with a bolt 96 and nut 98 . A coil spring 100 is provided on bolt 96 between nut 98 and one of plates 94 . The combination of nut and bolt 98 , 96 and spring 100 provides a force adjustment for nipple/détente assembly 82 . That is, if nut 98 is tightened against spring 100 , it takes more force to separate plates 94 and allow détente member to pull away and further allow hinged joints 36 to open. Protuberance nipples 102 are provided on each of the plates 94 , while indention détentes 104 are located to receive nipples 102 when hinged joints 36 are closed. It is preferred that nipple/détente assembly 82 be a part of appropriate embodiments above.
In use, when an immovable object 34 is struck, if a force is generated above the preset threshold to which spring 100 is adjusted, détente member 84 overcomes the force of the compression spring 100 thereby releasing détente member 84 which allows lower portion 40 to rotate so that the hinge joints 36 open as depicted in FIG. 5B . Once the hinged joints 36 close, nipple/détente assembly 82 resets as in FIG. 5A .
The use of nipple/détente assembly 82 is readily tailored to snowplowing conditions, and may even provide a mechanism for locking out the bucket tilting function during activities such as excavating soil and the like for the front-end loader vehicle.
In still another embodiment as shown in FIG. 6 , springs 52 of the embodiment of FIGS. 2-5B are replaced by fluid-filled (pneumatic or hydraulic) cylinders 66 . The rest of the apparatus is as disclosed. As shown in broken lines, a fluid-filled cylinder 66 includes a piston 68 having first and second chambers 70 , 72 on either side of piston 68 . When bottom 62 of bucket 20 is sliding along the ground at a level orientation, the first chambers 70 are maintained at a greater pressure than the pressure in the second chambers 72 such that the fluid-filled cylinders 66 provide a biasing force to the end of the lever arms 46 .
When front scraping edge 64 strikes an immovable object 34 , as similarly shown in FIG. 5B , the lower portions 40 of the downwardly projecting legs 16 ′ pivot backward about the fourth pivot points 44 . As the lower portions of the downwardly projecting legs 40 pivot backward, the bucket 20 pivots about the second pivot points 24 and first pivot points 18 thereby allowing the front edge 64 of the bucket 20 to lift up and over the immovable object 34 . The first pivot points 18 move in the direction toward bucket 20 relative to the second pivot points 24 . Hydraulic cylinder 22 maintains a constant length during these operations. The impact force of the immovable object 34 is counteracted by the hinged joint closing device 50 , or more particularly fluid-filled cylinders 66 . When the impact force of the immovable object 34 overcomes the counteracting force provided by the fluid-filled cylinders, the front edge 64 of the bucket 20 will lift up and over the immovable object 34 . Once the immovable object 34 has been cleared, the fluid-filled cylinders 66 will pivot the lower portion 40 of the downwardly projecting legs 16 ′ about the pivot points 44 so that the upper portions 38 and the lower portions 40 lie directly adjacent to one another in the area of break locations 42 , thereby resetting the hinged joint closing device 50 .
In the embodiment as shown in FIGS. 7-10B , a different type of fluid-filled or elastomeric device is used. A lever arm 74 is solidly attached to the second cross member 41 ′ near its midpoint. The top end portion 76 of lever arm 74 includes a bumper member 78 comprising a volume-constrained fluid-filled bag, or an elastomeric member, which presses against a bumper coupler member 106 which is attached to a first cross member 60 ′ near its midpoint. When bucket 20 strikes an immovable object 34 causing hinged joint 36 to open, lever arm 74 presses the bumper member 78 against the bumper coupler member 106 thereby causing it to deform. This deformation stores energy in the bumper member 78 as either increased fluid pressure in the case of the volume-constrained bag, or as stored elastic energy in the case of an elastomeric member. The deformation of the bumper member 78 opposes the opening of hinged joints 36 and urges them closed. As this occurs, bucket 20 rides over immovable object 34 as discussed earlier.
In the embodiment as shown in FIGS. 11A and 11B , a lower portion of a downwardly projecting leg 40 ′ is divided into a top portion 108 and a bottom portion 110 . The top portion 108 is slidably connected to the bottom portion 110 with a bearing member 126 there between, and a hydraulic cylinder 112 is attached to the top portion 108 at top hydraulic cylinder coupling 114 , and to the bottom portion 110 at bottom hydraulic cylinder coupling 116 . The hydraulic cylinder 112 contains a hydraulic cylinder piston 118 and a hydraulic cylinder piston rod 120 . An upper cavity 122 is located in the hydraulic cylinder 112 above the piston 118 , and a lower cavity 124 exists below the piston 118 . A hydraulic circuit 150 activates the hydraulic cylinder 112 . The hydraulic circuit 150 includes a reservoir 138 , a hydraulic pump 136 , a check valve 134 , a fast-acting gas-filled accumulator 132 , and a solenoid valve 130 . A sensor 140 is connected to the solenoid 130 and determines its position. In one embodiment, the sensor 140 comprises a switch 142 , 144 , located across break location 42 .
In use, the lower portions of the downwardly projecting legs appear as in FIG. 11A . The hydraulic pump 136 supplies pressurized hydraulic fluid 146 through check valve 134 to the fast-acting gas-filled accumulator 132 . Solenoid valve 130 is in a position which supplies the hydraulic pressure from the hydraulic pump 136 and fast-acting gas-filled accumulator 132 , preferably nitrogen accumulator, to the lower cavity 124 of the hydraulic cylinder 112 which maintains the lower portion of the downwardly projecting leg 40 ′ in its shortest configuration. When an immovable object is struck by the bucket 20 , the break location 42 opens up sufficiently to cause sensor 140 to send a signal to the solenoid valve 130 , causing it to switch to the location depicted in FIG. 11B . When the solenoid valve 130 shuttles its position, hydraulic fluid 146 immediately rushes to the upper cavity 122 of the hydraulic cylinder 112 , thereby causing the hydraulic cylinder piston 118 to move downward, thus pushing the bottom portion of the lower portion of the downwardly projecting leg 110 to move away from the top portion of the lower portion of the downwardly projecting leg 108 . This extension causes the bucket 20 to tilt upwardly about the first pivot point 18 and the second pivot point 24 . Furthermore, the mechanics of elongating the lower portion of the downwardly projecting leg 40 ′ are such that the degree of upward tilting of the bucket 20 is amplified by this increased length.
The mechanism of this embodiment is preferably used as a safety device in cases where the magnitude of the collision impulse is large, e.g. where large immovable objects are struck by the bucket 20 , such as in the case when a curb is struck with the bucket 20 . The threshold of sensor 140 or switch 142 , 144 would be set so that this mechanism is activated only upon hitting an immovable object large enough or rigid enough so as to cause a large impulse to the loader and its occupant(s). After such a jarring collision, the mechanism would be reset by the operator of the vehicle, after inspecting the vehicle for damage. By amplifying the amount of rotation which bucket 20 may make in the case of extreme collisions injury to the occupant(s) and damage to the loader can be prevented.
In yet a further embodiment as shown in FIGS. 12A-17B , the linkage assembly 200 includes a quadrilateral linkage 210 and connects a clearing accessory and a vehicle. It will be appreciated that the vehicle may be ATVs, farm tractors, skid loaders, pickup trucks, or other vehicles and that the clearing accessory may clear snow, manure or other material.
The linkage assembly 200 includes a front plate 260 that connects conventionally to the bucket 220 of the loader vehicle 264 and a rear plate 212 that connects conventionally to the vehicle. With respect to the quadrilateral linkage 210 , the front plate 260 connects at braces 304 to a first pair of arms 216 at first pivot points 218 and to a second pair of arms 222 at second pivot points 224 . The rear plate 212 connects at braces 302 to the second pair of arms 222 at third pivot points 226 and the first pair of arms 216 at fourth pivot points 214 . The first pair of arms 216 is shorter than and non-parallel to the second pair of arms 222 . Pins forming the various pivot points or axes are bolts and nuts or other appropriate fasteners (not shown).
The linkage assembly 200 has an inactivated state or first configuration as shown in FIG. 13A and an activated state or second configuration as shown in 13 B. In the inactivated state, the linkage assembly 200 is urged to its designed limit by a bias member, such as a spring 252 . The linkage assembly 200 is activated when a scraping edge 266 of the bucket 220 strikes an immovable object 234 . During this process, the spring 252 is compressed and the quadrilateral linkage 210 is likewise compressed. The first pivot axis 218 moves in the direction of the bucket 220 relative to the second pivot axis 224 so that the bucket 220 is tilted at its heel 268 and the scraping edge 266 is elevated and rides up and over the immovable object 234 .
The linkage assembly 200 may also include a first stopper device 270 to prevent over compression in the activated state and a second stopper device 274 to determine the design limit of the inactivated state. Stopper device 270 is attached to a brace 302 and extends forwardly toward plate 260 and when there is a hard impact stopper device 270 contacts plate 260 and solidifies linkage assembly 200 . There could be more than one stopper device 270 . Stopper device 274 is located to contact one of the front and rear plates 260 , 212 and one of the first and second pair of arms 216 , 222 when linkage assembly 200 is in the inactivated state. Likewise, there could be more than one stopper device 274 . The linkage assembly 200 may also include a mechanical nipple and détente assembly 282 . As similarly described with respect to an earlier embodiment, the nipple and détente assembly 282 includes a détente member 284 pivotally attached to the rear plate 212 at pivot point 272 (shown attached to rear plate 212 at brace 302 ) and a nipple sub-assembly 306 pivotally attached to the front plate 260 at a pivot point 286 (shown attached to front plate 260 at brace 304 ). It will be appreciated that the nipple and détente assembly 282 can be attached anywhere between the front and rear plates 260 and 212 in any appropriate position, for example, attaching the détente member 284 to the front plates 260 and attaching the nipple sub-assembly 306 to the rear plate 212 . The nipple sub-assembly 306 includes a pair of plates 308 , on either side of détente member 284 , which are held together at one end with a bolt 296 and nut 298 . A bracket 310 is pivotally attached at the pivot point 286 and plates 308 are pivotally attached to bracket 310 at the other end of plates 308 . A coil spring 300 is provided on bolt 296 between nut 298 and one of plates 308 . The combination of nut and bolt 298 , 296 and spring 300 provides a force adjustment for nipple/détente assembly 282 . That is, if nut 298 is tightened against spring 300 , it takes more force to separate plates 308 and allow détente member to pull away and further allow the quadrilateral linkage 210 to activate. Protuberance nipples 312 are provided on each of the plates 308 , while indention détentes 314 are located to receive nipples 312 when linkage 210 is inactivated. The nipple and détente assembly 282 provides an extra retention mechanism in addition to the elastomeric force provided by the spring 252 for any impact force to overcome caused by the scraping edge striking an immovable object.
In use, the loader vehicle operator operates the hook 262 to scoop the rear plate 212 of the quadrilateral linkage 210 and then uses the front plate 260 of the linkage 210 to scoop the bucket 220 . In the inactivated state, the linkage 210 is urged to its designed limit by the spring 252 against stopper device 274 . The linkage 210 is activated when the scraping edge 266 of the bucket 220 strikes an immovable object 234 . During this process, the spring 252 is compressed and the quadrilateral linkage 210 is likewise compressed. The first pivot axis 216 moves in the direction of the bucket 220 relative to the second pivot axis 224 so that the bucket 220 is tilted at its heel 268 and the scraping edge 266 is elevated and rides up and over the immovable object 234 . In the case of a heavy impact, plate 260 may contact stopper device 270 .
In an embodiment where a nipple/détente assembly 282 appears, when an immovable object 234 is struck and a force is generated above the preset threshold force, the détente member 284 overcomes the force of the spring 300 thereby releasing détente member 284 which allows the front plate 260 to be compressed toward the rear plate 212 as depicted in FIG. 17B . Once linkage 210 is urged back to the inactivated state, the nipple and détente assembly 282 resets as in FIG. 17A .
Thus, preferred embodiments of apparatus in accordance with the present invention have been described in detail. It is understood, however, that equivalents to the disclosed invention are possible. Therefore, it is further understood that changes made, especially in matter of shape, size and arrangement to the full extent extended by the general meaning of the terms in which the appended claims are expressed, are within the principle of the invention.
|
A mounting apparatus for a bucket of a front end loader vehicle. The mounting system allows the bucket to pivot up and over fixed objects when the leading edge of the bucket strikes an immovable object for the purpose of protecting the loader assembly, vehicle, and operator.
| 4
|
BACKGROUND OF THE INVENTION
1. Object of the Invention
This invention relates to an emergency cable gripper suitable for preventing the loss of guys or cables on a guyed offshore petroleum drilling or production structure. More particularly, the invention relates to a novel apparatus employing wedges to grip the cable and hold it stopped in its protective tube. A cable clamp and stopping ram are used to automatically actuate the gripping wedges in case of an accident. The apparatus is operable under water.
2. Field of the Invention
The ever more difficult search for petroleum has led to exploration in areas previously thought by many to be incapable of producing oil at economically feasible prices. The rising price of petroleum has made acceptable the costs associated with production in Alaska and the North Sea, as well as in the near-offshore areas of North America. Petroleum exploration and production in each of these areas has created problems, both esoteric and mundane, which must be solved. This invention is concerned with the solution of a potential safety problem on an offshore structure.
One of the many structures used in offshore drilling and production is one known as the "guyed tower". Simply stated, it is a space frame construction which may stand in 1500 feet or more of water, is footed in the seabed, and has a deck above the water level. Drilling and production equipment, sleeping quarters, helicopter landing pads, etc. are positioned on the deck. It is denominated a "guyed" tower because of the guylines which hold it upright and relatively immobile. A generalized discussion of guyed towers is found in U.S. Pat. No. 3,903,705, to Beck et al. Guylines on guyed towers are often "held off" at or near the deck by clamps. A guyline, as it passes down from the deck, ideally is channelled through either a leg of the structure or a guyline protection tube (which may be oil-filled) and in either event exits the structure below the water surface through an apparatus known as a "fairlead". Fairleads have the function of directing the guyline in the direction of the anchoring means. The anchoring means exemplarily comprise a clump weight of up to 100 tons or more and is in turn connected to two anchors in series. An anchor pendant and anchor buoy often are used to indicate the position of the anchors.
The instant invention relates specifically to the solution of a safety problem on a guyed tower although the invention apparatus has a broader application to any apparatus having guy wires.
It is not difficult to appreciate the desirability of protecting the guylines from accidental loss. If the guylines are dropped from the deck's surface as the result of a fire or mishandling of the clamps, the structure could shift, bringing drilling and production operations into jeopardy, or, in a natural catastrophe such as a hurricane, topple the structure.
Several methods of gripping wire cable or rope are shown. A number of those methods are said to be suitable for emergency gripping service.
A cable locking device to be used in a passenger safety belt apparatus is disclosed in U.S. Pat. No. 3,147,527, to Gilmore. The locking device utilizes a deformable conical ferrule crimped to the cable at some desired point along the cable length. A quick but powerful jerk on the cable is needed to move the crimped ferrule and the cable into the larger end of a tapered serrated sleeve mounted, in turn, inside the mouth of a larger housing. The ferrule deforms and is squeezed in a permanent grip between the serrated sleeve and the cable. The cable gripping wedges of the instant invention are not substantially deformable, are designed to be reusable, and easily disengaged from the cable.
The invention described in U.S. Pat. No. 3,467,224, to Curtis et al, is a hydraulically operated device used for gripping an oil derrick "cat line" in an emergency. The apparatus uses two approximately wedge-shaped members which are activated either manually by a human operator on the drilling deck or automatically by a mechanism which detects a broken cable whipping to-and-fro. This apparatus does not utilize the weight of the cable to self-activate as does the device of the present invention.
Another device suitable for catching a broken wire cable is shown in U.S. Pat. No. 3,779,347, to Chevalier. The cable catcher uses a pair of wedges placed in series to squeeze the cable against a stationary braking shoe. The device allows the cable to move freely in one direction and relies on friction with the cable to prevent any movement in the other direction. In contrast, the device disclosed herein does not rely on constant contact with the cables, with the attendant probability of wear, to actuate the gripping mechanism.
A cable-anchoring mechanism described in U.S. Pat. No. 3,952,377, to Morell, utilizes a conical wedge permanently attached to a wire cable. The wedge, in turn, fits inside a fixed sleeve. The device is said to be useful as an anchor for concrete-reinforcing tendons. The wire cable must always carry the fixed conical wedge thereby limiting the motility of the wedge and causing additional stress on the wire cable.
Another cable gripping device using conical wedges is shown in U.S. Pat. No. 4,078,277. The conical wedges are split down the middle and have grooves suitable for engaging the twist of the wire cable. The two wedges contiguously fit within a cone-shaped sleeve. The wedge-sleeve assembly is inserted in a suitably sized orifice and maintained under tension. Slackening of the wire cable will cause disassembly of the clamp.
SUMMARY
The instant invention provides a simple yet sturdy and reliable device, usable underwater, which is self-actuated only when it is needed.
Only the cable itself, via a tightly attached clamp, is able to actuate the cable grippers after moving a preset distance. The device can be installed in existing structures and does not introduce any additional friction points to wear or fray the cable. The cable gripper, once actuated, is easily restored to a "ready" position by the mere installation of a set of inexpensive shear pins. It has, unlike apparatus of the prior art, no permanently deformable parts nor does it disassemble itself when the cable is slackened.
Broadly speaking, the invention comprises a set of wedges which squeezes the cable by contact with a set of inclined blocks. The wedges are actuated by a clamp attached to the cable and utilize the cable's weight to and arrest its movement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 provides a general diagram of a guyed tower and the manner in which it is deployed during use.
FIG. 2 is a schematic cross sectional representation of the invention.
FIG. 3 shows a typical placement of the invention in a guyed tower.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a typical guyed tower as it would be set up for petroleum drilling offshore. The guyed tower, having a deck for drilling, heliport, drilling equipment, etc., is set in the seabed and held upright by a number of guylines. Each of the guylines is clamped at the deck, proceeds through a fairlead below the water's surface, and attaches to a clump weight which may weigh up to 200 tons or more. The clump weights, also discussed in U.S. Pat. No. 3,093,705, supra, are often articulated devices which are longer in the direction radial to the tower than they are wide. A set of anchors to provide additional assurance of tower immobility is often placed in series with the clumpweight.
The preferred apparatus is schematically depicted in FIG. 2 as it would be used on an offshore petroleum drilling platform. Typical existing portions of the platform are the wire rope 11 used as a guyline, the guyline protection tube 13, and the fairlead 15. A guyline protection tube is a tube surrounding the guywire as it comes off the deck and extending to some distance below the water's surface. The tube is intended to protect the guyline both from corrosion in the surface splash zone and from contact with boats and floating debris. The guyline protection tube may be filled partially with a protective oil. Other offshore structure designs place the upper guyline within a leg of the guyed tower instead of within a protection tube. It is intended that any discussion of the term "guyline protection tube" with regard to this invention be understood to include the tubing or pipe used as a guyed tower leg. The generic term "guyline protection means" is intended to include guyline protection tubes, offshore structure legs, and other implements which are capable of supporting or restraining a wire cable or rope used in tension; e.g., an antenna guy wire, that will support the wedge blocks of the invention.
A cable clamp 17 is attached to the wire rope 11 at some predetermined distance above the upper surface of the gripping wedges. For purposes of illustration, the terms "upper" and "lower" are used in the text; however, the invention may be used in any position; i.e. with the wedges pointing up, down, or horizontally. The clamp 17 may be of any known design as long as it is strong enough to momentarily support the cable during the short time it takes to break the shear pins 19 supporting the gripping wedges 12, allow the gripping wedges 12 to slide down the wedge blocks 14, and thereafter grip cable 11. Although the clamp 17 may be permanently attached to the cable, e.g., by crimping, the more desirable method entails the use of a detachable clamp since cables stretch and subsea anchoring points occasionally have to be re-set.
Stopping ram 16 hangs lossely about wire cable 11 below the cable clamp 17 and above the gripping wedges 12. The ram 16 is desirably annular-shaped with an inner diameter large enough to allow free passage of the cable 11 but small enough to prevent the passage of cable clamp 17. The ram 16 may be of any convenient shape but should have a hole therethrough. The lower surface of the ram 16 is of sufficient area to meet the gripping wedges 12 and allow an effective transfer of force from cable clamp 17 to gripping wedges 12. The bottom surface of ram 16 should not be substantially smaller than the upper surface of gripping wedges 12 since twisting or rotation of the gripping wedges 12 about shear pins 19 may occur. The bottom surface of the ram 16 may be of any suitable configuration which allows the gripping wedges to slide radially inward after contact with the ram. The bottom surface may be flat, have a slight angle (sloping downward from the center of the ram), or, in certain circumstances be grooved to engage mating grooves on top of the gripping wedges. Shear pins, in general, perform their function best when encountering only shear loads. Depending upon the particular installation, some restructuring of the periphery of ram 16 need be made if the ram 16 would interfere with the operation of wedge reset means 18 or vice versa. The wedge reset means are preferably mounted in the gripping wedges 12 outside the periphery of the ram 16.
The gripping wedges 12 are attached at their widest ends to the guyline protection tube 13 by shear pins 19, which support the wedges and hold them away from wire rope 11. As will be discussed later, the shear pins alternately may be mounted at the upper ends of wedge reset means 18 and the gripping wedge 12 held loosely in position away from wire cable 11 by, e.g., spring clips, in wedge blocks 14. Although only two wedges are illustrated in FIG. 2, a larger number may be utilized. When multiple wedges are used, the width of the cable gripping surface limits use of the invention to larger size wire ropes. The upper surface of the gripping wedges may, like the lower surface of the stopping ram 16, be of any configuration allowing ready inward movement of the gripping wedges during the wire rope gripping period. The rope gripping surface of the gripping wedges has a surface configuration suitable for performing its function of holding the wire rope in place during the emergency. The particular surface configuration is not overly critical and may be rough, smooth, flat, concave or adapted to match the left- or right-handed twist of the cable. The wedge reset means 18 are attached to the upper surface of the gripping wedges, preferably outside the perimeter of the stopping ram 16. The wedge reset means 18 are, desirably, rods which extend up to the deck of the offshore drilling structure for manual manipulation by an operator. The wedge reset means are used to reset the gripping wedges after their use in an accident. The face of the gripping wedges that slopes inwardly fits in a slot or other means in wedge blocks 14. The slot is of sufficient size to smoothly direct the gripping wedges 12 onto wire rope 11.
The wedge blocks 14 are fixed to the inside of the guywire protection tube 13 and transfer the weight of the suspended cable from the gripping wedges to the guywire protection tube 13 and thence to the fairlead 15. The face of the wedge blocks toward the gripping wedges, as mentioned above, was a slot or other opening suitable for engaging the lower sloping edge of the gripping wedges. The slots may contain spring means capable of holding the gripping wedges away from the wire cable 11.
Installation and use of the invention, for instance, in a guyline protection tube is quite simple. Prior to installation of a wire rope guywire 1 in its protection tube 13, the wedge blocks 14 are attached to the inside of the protection tube, the gripping wedges 12 are placed into position within the wedge blocks, and the shear pins 19 installed through protection tube 13 to hold the gripping wedges in place. The wedge reset rods 18 are connected to the gripping wedges. The stopping ram 16 is set in place atop the gripping wedges. The wire rope 11 is then fed up through the open space between the gripping wedges 19, through the center of stopping ram 16, and then secured in normal fashion on the deck. A diver then sets the cable clamp 17 on the wire rope guyline using, e.g., a hydraulic wrench, through holes in the protection tube 13.
If the wire rope 11 is dropped or otherwise lost from the deck and during an accident begins to fall, clamp 17 descends to contact stopping ram 16 which in turn forces the gripping wedges 12 downward, breaking the shear pins 19, and inward, gripping and saving wire rope 11.
After the loose guyline is captured at the deck surface, the wire rope 11 guyline may be pulled upward. The gripping wedges 12 should readily allow upward movement of the wire rope. On occasion, it may be necessary to simultaneously pull the wedge reset rods 18 and the wire cable 11 to free the wire cable for upward movement. In any event, after the guy is re-secured in its proper position on the structure's deck, the wedge reset rods 18 are used to pull the gripping wedges back into a "ready" position. A new set of shear pins 19 is installed by a diver. The device is again ready for use.
FIG. 3 depicts an installation of the inventive device within a guyline protection tube 13 positioned above a fairlead 21. The clamp 17 can be set by a diver through hole 22. The adjacent platform leg is shown at 23 as is the water's surface 24.
The foregoing disclosure and description of the invention are only illustrative and explanatory thereof. Various changes in size, shape, materials of construction and configuration as well as in the details of the illustrated construction may be made within the scope of the appended claims without departing from the spirit of the invention.
|
An apparatus to prevent the accidental release of a wire rope used, for instance, as an underwater guy wire on a guyed tower. The apparatus has a clamp attached to the wire rope which, when the rope is released, hits a stopping ram which presses into wedge-shaped rope grippers. The wedges squeeze the rope and stop against wedge blocks which are attached to an inside portion of the guyed tower.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATION
This is a national stage of PCT/IB06/053978 filed Oct. 27, 2006 and published in English.
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to a gravity separator, primarily of the kind in which a mixture flowing from an oil well, containing water, oil, and gas is separated into discrete, vertically spaced water, oil, and gas layers in a separator vessel for subsequent extraction from the vessel by way of a water outlet, oil outlet, and gas outlet, respectively.
2. Description of the Prior Art
Gravity separators have been known for many decades and have been used within the oil industry in various embodiments of which some are quite complex, including a number of static mixers and cyclones. Examples of known types of gravity separators can be found in e.g. GB 1327991 and WO 99/25454. U.S. Pat. No. 5,080,802 discloses an air flotation separator having an eductor for drawing gas into the incoming fluid. The eductor re-circulates gas collected in the uppermost section of the vessel to the incoming fluid. The separator is provided with a coalescer riser tube positioned substantially in axial alignment with the axis of the vessel, and in order to obtain optimum coalescing high masses of gas, such as a gas to water ratio of about 30% is used. Another gas flotation separator is known from U.S. Pat. No. 5,516,434, and this separator is also provided with a coalescer riser tube with filter medium. A further separator for removing dispersed oil from an oil in water emulsion is disclosed in EP 0 793 987 where gas is dissolved in the inflowing water to form an aerated solution. This solution is introduced to the separator vessel in an assembly of closely spaced matrix plates formed of oleophilic material. The use of coalescer riser tubes with filters or of matrix plates complicates the separator and involves the risk of clogging with a resulting loss of capacity. These prior art designs also require a high degree of maintenance.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a gravity separator that performs effectively and with a relatively simple construction and suitable low gas consumption.
Thus, the invention relates to a gravity separator comprising a vessel within which a mixture containing water, oil, and gas can separate under gravity to form vertically discrete oil and water layers and a gas phase, the vessel having an inlet duct communicating with a vessel entrance for the mixture containing water, oil, and gas; an outlet for water; an outlet for oil; and an outlet for gas, wherein the inlet duct of the gravity separator comprises injector means injecting a gaseous medium in a volume in the range of 0.01-1.9 Sm 3 gaseous medium per 1 m 3 mixture into the mixture containing water, oil, and gas.
It has unexpectedly been found that injection in the inlet duct of such a small volume of gaseous medium into the mixture containing water, oil and gas is fully satisfactory to obtain the desired clean water phase by separation under gravity in the vessel. And by using such a small volume of gas medium, neither coalescer riser tubes with filters nor matrix plates need to be provided in the separator. The separator thus obtains a simple design of high reliability, continuously high capacity, and low maintenance costs. The content of impurities in the water phase leaving the separator may be as low as 40 ppm.
In a preferred embodiment a conduit supplying gaseous medium to the injector means re-circulates gas from the gravity separator to the injector means. The re-circulation of gas reduces any consumption of gaseous medium from an external source.
The conduit for recirculation can collect gas from a gas processing device downstream of the outlet for gaseous medium from the separator. However, in an embodiment preferred due to its simplicity the conduit supplying gaseous medium to the injector means is connected with the interior of the gravity separator at the upper part thereof.
In a further embodiment the conduit supplying re-circulated gas to the injector means is the sole supply of injection gas to the injector means. This provides several advantages. The gaseous medium injected through the injector means is automatically withdrawn from the volume of gas separated from the mixture in the vessel so that the separator becomes independent of external supply of gaseous medium. In connection with separators used in offshore oil/gas producing facilities this avoidance of an external supply of gas is highly advantageous. Apart from avoiding costs of maintenance and of provision of an external gas supply, space is also saved because storage tanks, piping etc. for an external gas supply can be dispensed with.
According to a suitable embodiment of the gravity separator, the injector means in the inlet duct is spaced apart from the vessel entrance with a spacing in the range of 0.05 to 2.00 m. This separation of the injector means and the entrance makes it possible to obtain a very good mix of the gaseous medium with the mixture containing water, oil and gas.
In order to further improve mixing, the gravity separator may be provided with a mixer, preferably a static mixer, in the inlet duct between the injector means and the vessel entrance.
In an embodiment of the gravity separator, suitable when only little space is available, the inlet duct extends from above down through the vessel to the vessel entrance where the mixture flows out into the vessel. In addition, the mixer may be located in a section of the inlet duct extending within the vessel so that a very compact design is obtained.
The present invention also relates to a method for separating a mixture containing water, oil, and gas, which method comprises the steps of: conducting the mixture to be separated via an inlet duct and a vessel entrance into a vessel, allowing the mixture in the vessel to separate under gravity into a water phase, an oil phase, and a gas phase; taking out the water phase via an outlet for water, taking out the oil phase via an outlet for oil, and taking out the gas phase via an outlet for gas; wherein a volume of gaseous medium in the range of 0.01-1.9 Sm 3 gaseous medium per 1 m 3 mixture is injected into the mixture flowing through the inlet duct to the vessel entrance.
This limited volume of injected gaseous medium has proven to sustain the separation process under gravity in the vessel and reduce costs for gas supplies without impairing the capacity of the separator. The water taken out of the vessel may optionally be further cleaned before it is returned to the reservoir. The oil and gas may optionally be further processed before it is shipped off.
In connection with the present invention the dimension Sm 3 is used as the volumetric unit of gaseous medium injected in relation to the volume of mixture. Sm 3 is standard cubic meters of the gaseous medium. Sm 3 is standardised within the offshore field (volume of dry gas at 15.6° C. and a pressure of 101.325 kPa).
It is possible within the limits of the present invention to inject in the range of 0.04-1.6 Sm 3 gaseous medium per 1 m 3 mixture is injected into the mixture in the inlet duct, but more preferably the volume of gaseous medium injected into the mixture in the inlet duct is limited to a volume in the range of 0.05-0.40 Sm 3 gaseous medium per 1 m 3 mixture. This volume can be withdrawn from the separator and be re-circulated to injection in the mixture in the inlet duct without any external supply of gaseous medium. The mixture flowing to the separator on the upstream side of the injector means has a sufficient content of gas to provide the separator with the necessary volume of gaseous medium. Due to injected volume of gaseous medium and the natural amount of gas phase in the mixture, the mixture flow between the injector means and the entrance to the vessel of course has an increased amount of gas phase. In a preferred method a volume of 0.05-0.15 Sm 3 gaseous medium per 1 m 3 mixture is injected into the mixture in the inlet duct, and in the most preferred method 0.08-1.2 Sm 3 gaseous medium per 1 m 3 mixture is injected into the mixture in the inlet duct.
Although the pressure in the vessel may vary and be within a wide range during operation from about 0.1 atm and upwards, it is normally preferred that the pressure in the vessel is in the range of 0.5 to 200 atm, conveniently in the range 1.0-100 atm. Adjustment of the pressure to an optimal value may improve formation of the gas phase and separation of the gas from the water and the oil.
To further improve the separation process the mixture containing water, oil, and gas is, in one embodiment, subjected to injection with one or more separation aids. Such separation aids are normally in liquid form and include flocculants, emulsifiers etc.
In a preferred embodiment of the method according to the invention the gaseous medium is re-circulated, optionally after re-extraction from the gas phase. If natural gas from the oil well is used as gaseous medium, it will normally not be necessary to re-extract it, as a part of the collected natural gas may be taken out and used as gaseous medium to be injected into the mixture containing water, oil and gas. The embodiment provides for a cost-effective method with minimum waste of resources.
BRIEF DESCRIPTION OF THE DRAWINGS
Examples of embodiments of the present invention are described in further detail in the following with reference to the highly schematic drawings, in which:
FIG. 1 illustrates a first embodiment of a gravity separator according to the present invention,
FIG. 2 illustrates a nozzle system suitable for use in the gravity separator in FIG. 1 .
FIG. 3 illustrates an alternative embodiment of a separator according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
Reference is made to FIG. 1 where a gravity separator 1 is shown with a vessel 2 with an inlet duct 3 having a vessel entrance 4 located within vessel 2 . The inflow of fluid mixture through entrance 4 spread itself freely into the vessel where gravity acts on the constituents in the mixture. The vessel 2 is further equipped with an outlet for water 5 , an outlet for oil 6 , and an outlet for gas 7 . Within vessel 2 a weir plate 8 is provided that serves to separate water phase 9 from oil phase 10 . Gas phase 11 is collected at the location in the space above the water phase 9 and the oil phase 10 .
In the inlet duct 3 of the vessel 2 is mounted an injector means 12 in form of a nozzle device for gas injection. The nozzle device is fed with a gaseous medium via line 13 . In this manner the gaseous medium is injected into the mixture containing water, oil and gas in the inlet duct 3 before the mixture enters the vessel 2 via vessel entrance 4 .
The vessel is preferably a horizontal, substantially cylindrical vessel 2 closed at both ends, preferably with curved or convex closings. Vessel 2 and attached equipment can be made from suitable metallic alloys, preferably stainless alloys. Vessel 2 is preferably assembled by welding.
The mixture containing water, oil and gas has a liquid appearance, which may be more or less viscous depending on the ratio between water and oil. The gas normally disperses in the mixture as tiny bobbles. The mixture containing water, oil and gas may contain further constituents, e.g. impurities from an oil well. The mixture may also contain solids. Possible solids in the mixture will normally leave the separator with the water phase.
In an embodiment the injector means is one or more nozzles. The nozzle may be any nozzle suitable to inject a gaseous medium into the mixture comprising water, oil and gas. Conveniently, the nozzle is capable of operating at pressures in the range of 5 to 250 atm.
Although the gravity separator may have any desired size, the vessel preferably has an internal volume in the range of 1 to 200 m 3 , such as 3 to 100 m 3 in order to optimise the input/output ratio.
In one embodiment the gravity separator comprises means to separate the water phase from the oil phase. The means are mainly physical means like weir plates and the like, which may be located at the bottom part of the vessel preventing access of the water phase to a certain zone in the vessel, but allowing oil to flow into that zone, and optionally, the outlet for oil is placed in this zone.
The internal portion of vessel 2 may also be equipped with one or more baffles and/or guide vanes to obtain a desired flow or stream in the vessel, which may improve the separation capacity of the gravity separator.
The gravity separator may comprise further means for injection of separation aids. The separation aids are mainly in liquid form, e.g. flocculants, emulsifiers, etc. Injection of such separation aids may further improve the separation under gravity. The separation aids may be injected in the inlet duct or in the vessel or in both.
The gaseous medium may be any gas suitable to facilitate the separation of water, oil and gas in the mixture. However, in an example according to the invention the gaseous medium is selected from nitrogen, hydrogen, natural gas, carbon dioxide and mixtures thereof. Natural gas is normally the gas that may be extracted from an oil well. When natural gas is chosen as the most preferable gaseous medium part, the extracted natural gas from the oil well may be recycled as the gaseous medium. In this manner, the gaseous medium may be obtained in a simple and cost-effective manner.
After the gaseous medium has been injected into the mixture, it may later be re-extracted, mainly from the gas phase, and/or re-circulated into the separation system.
According to the present invention the injector means for gas can be installed in the inlet ducts of existing gravity separation tanks, thereby modifying and improving the capacity of the existing separation tanks. Thus the benefit of the present invention can be applied on gravity separator already installed and in use, e.g. on an oil producing plant which may be located onshore or offshore.
The injector means may be one or more suitable nozzles, which may conveniently be arranged in an annular shaped device.
FIGS. 2 a and 2 b show a nozzle device 20 suitable for use in the invention. The nozzle device consists substantially of an annular flange 21 . The inner peripheral surface 22 of the flange 21 is equipped with a number of holes 23 (in this depicted embodiment eight holes 23 ). The holes 23 communicate with a channel 24 within the flange 21 (the channel 24 is shown with dotted lines in FIG. 2 b ). The channel 24 further communicates with a supply line 25 for the gaseous medium, which is fastened to the outer peripheral surface 26 of the flange 21 . The nozzle device 20 is capable of providing a good mix of the mixture and the gaseous medium in the inlet duct 3 ( FIG. 1 ).
FIG. 3 depicts an alternative embodiment of the gravity separator according to the invention. As in the embodiment of the gravity separator shown in FIG. 1 , the alternative gravity separator 31 comprises a vessel 32 . The separator 31 is also equipped with an inlet duct 33 communicating with the interior of the vessel 32 via vessel entrance 34 , an outlet for water 35 , an outlet for oil 36 and an outlet for gas 37 . A nozzle device 38 is located in the inlet duct 33 and fed with gas via a pipeline 39 from the interior of the vessel 32 . In the inlet duct 33 after the nozzle device 38 and in the vicinity of the vessel entrance 34 a static mixer 40 is arranged to ensure good mixing of the mixture entering the vessel 32 via vessel entrance 34 . In this embodiment the gaseous medium is taken directly from the gas separated in the vessel 32 and extra supply of the gaseous medium can be avoided.
As mentioned, the drawings are only schematic, and for the reasons of simplicity, means like pumps, valves, pressure-sensors, collecting vessels for oil and gas etc. have not been illustrated. The gravity separator and the method according to the present invention can be modified within the scope of the appended patent claims. Details of the various embodiments can be combined into new embodiments within the scope of the patent claims. It is e.g. possible to provide an individual separator with two or more outlets for oil and/or with two or more outlets for water and/or with two or more outlets for gaseous medium and/or with two or more inlet ducts or entrance openings. One or more of the outlets can be provided with a valve. The injector means in the inlet can be combined with a pump in the conduit for withdrawing gas from upper portion of the vessel. Such an embodiment is however less favourable because it is more complicated and not an automatic, self-regulating system which is independent from outside supplies and has no moving parts.
The invention being thus described, it will be apparent that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be recognized by one skilled in the art are intended to be included within the scope of the following claims.
|
A gravity separator includes a vessel within which a mixture containing water, oil, and gas can separate under gravity to form vertically discrete oil and water layers and a gas phase. An inlet duct communicates with a vessel entrance for the mixture containing water, oil, and gas. The inlet duct of the gravity separator includes a gas injector that injects a gaseous medium in a volume in the range of from 0.01-1.9 Sm 3 of the gaseous medium per 1 m 3 of the mixture into the mixture containing water, oil, and gas.
| 1
|
This application is a continuation of application Ser. No. 07/959,010, filed Oct. 9, 1992, now abandoned, which is a continuation-in-part of application Ser. No. 07/717,235, filed Jun. 18, 1991, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to purified and isolated antigens for the detection of bovine or swine cysticercosis and methods of synthesis of recombinant antigens using genetic engineering techniques.
2. Description of the Art
Cysticercosis is a parasitic disease of cattle and swine caused by the larval (cyst) stage of the tapeworm Taenia saginata in cattle and Taenia solium in swine. Ingestion by man of viable larvae in undercooked meat results in intestinal tapeworm infection (taeniasis). The meat of these animals contains larvae that mature, in the intestinal tract, into adults that burrow into the mucosa and at the same time attach themselves to the bowel wall with scolices which bear hooks. The mature worm then progressively develops to lengths of 3 to 6 meters (10 to 20 feet). Clinical manifestations of the intestinal infection arise from the physical mass of the worms, the trauma to the intestinal mucosa, reaction to worm metabolites, and competitive uptake of nutrition. Of particular concern is taeniasis caused by the swine tapeworm (T. solium) which has the potential to lead to human neurocysticercosis, with serious, debilitating and possibly fatal consequences. As these tapeworms pose a dramatic health risk, infected carcasses discovered during inspection at the slaughter house are condemned as a matter of public policy.
Present inspection of livestock or meat for cysticercosis infection requires dissection and visual examination of specimens, a tedious, time-consuming and labor-intensive practice. The direct meat inspection is done using organoleptic means based on prescribed procedures designed to optimize detection of lesions. These postmortem examinations for cysts are extremely insensitive. It is estimated that organoleptic inspections for metacestode cysts performed at the time of slaughter misdiagnose in excess of 25% of infected animals as falsely negative. The detection of Taenia saginata and Taenia solium, the causative agents of cysticercosis, continue to pose large economic losses and serious health concerns in a number of countries, including the United States.
As yet, serological diagnostic tests for screening livestock have not been available due to the lack of specific and sensitive antigen reagents. Previous efforts to develop specific and sensitive antigens have not met with success. Given the moderate level of host antibody responses to cestode infections and the low numbers of cysts often associated with naturally-infected animals it was necessary to develop a highly sensitive and specific test.
Antigen reagents which have been evaluated by the ELISA method for the detection of T. saginata antibodies include an adult cestode extract which is reported to have strong cross-reactivity with antibodies to Fasciola hepatica, a common trematode parasite of cattle Craig et al., Zeitschrift fur Parasitenkunde 61:287-297 (1980)!.
A de-lipidized saline extract of the larval stage of the heterologous cestode Taenia crassiceps was evaluated as an immunodiagnostic antigen and though it exhibits a high degree of specificity for T. saginata antibodies (4.3% false-positive reaction) it has an unacceptably low degree of sensitivity for antibodies in both naturally (62% false-negative reaction) and experimentally infected animals Geerts et al, Res. Vet. Sci., 30:288-293 (1981)!.
A heterologous antigenic fraction purified from Taenia hydatigena, termed ThFAS, demonstrated reliable detection of T. saginata antibodies using the enzyme linked-immunosorbent assay (ELISA) where the specific immunodiagnostic reactivity of this fraction was associated with a 10 kDa protein. See Rhoads, M. et al., J. Parasitol. 71:779-787 (1985); Kamanga-Sollo, E. et al., Proc. Am. Assoc. Vet. Parasitol. 31:31 (1986); and Rhoads, M. et al., Vet. Arch., 57(3)143-150 (1987). As ThFAS is derived from naturally-occurring sheep cestodes, limitations have been encountered in obtaining the antigen in sufficient quantities and purity for use in a viable commercial test. Obtaining the homologous antigen from T. saginata cysts presents a problem since the muscle cysts and hence the mRNA from T. saginata, is difficult to purify free of host material. Consequently, the identification of an alternative source is necessary.
Efforts to develop an assay for the diagnosis of cysticercosis in humans has also been less than completely successful. Currently, the ELISA method shows the highest accuracy of immunodiagnosis for human cysticercosis. Using either a crude extract of swine cysticerci as an antigen or a purified fraction thereof (antigen B), antibodies were detected by ELISA in sera or cerebrospinal fluid (CSF) in only 70 to 80% of the clinically diagnosed cases Diwan et al., Am. J. Trop. Med. Hyg. 31:364-369 (1982); and Espinoza et al., Cysticercosis. Present State of Knowledge and Perspectives, 163-170, Academic Press, New York (1982)!. In addition, non-specificity has been demonstrated using this method (Coker-Vann et al., Trans. Roy. Soc. Med. Hyg. 78:492-496 (1984)). However, false-positive reactions can be eliminated by combining ELISA with an immunoblotting technique Gottstein et al, Am. J. Trop. Med. Hyg. 35:308-313 (1986) and Trop Med. Parasitol. 38:299-303 (1987)!. Recently, an ELISA using any one of three purified proteins isolated from the scolex of T. solium metacestodes by monoclonal antibody-immunoaffinity chromatography was able to detect 100% of the patients with cysticercosis and showed no false-positives (Nascimento et al 1987). In all of these human cysticercosis assays, the antigenic reagent was obtained from the homologous cestode, T. solium. Furthermore, to achieve accurate and reliable assays it is necessary to use additional expensive and time-consuming techniques.
These techniques would be completely unacceptable as a screening tool for the inspection of livestock or meat. An acceptable screening method must be capable of diagnosing cysticercosis in livestock or meat with a high degree of both sensitivity and specificity while remaining cost effective. Such an immunoassay screening method requires an appropriately reactive antigen. Since availability of antigen is a major limiting factor in diagnostic test development and production, reliable sources of antigen must be secured and the antigen must be available in quantities sufficient to support field trials and large scale test implementation.
SUMMARY OF THE INVENTION
It is an object of the present invention to overcome the deficiencies in the prior art, such as indicated above.
It is another object of the present invention to isolate and purify a diagnostic antigen having specific and sensitive antigenicity for Taenia saginata and/or Taenia solium (i.e., reactivity for antibodies against T. saginata and/or T. solium). It is an additional object of the present invention to isolate and purify an antigen for use in an immunoassay for the diagnosis of bovine and swine cysticercosis without said antigen having cross-reactivity with antibodies to other common bovine and swine parasites.
In one embodiment of the invention, the antigen is immunologically distinct from other common bovine and/or swine parasites, in particular Fasciola hepatica. The antigen may be extracted from Taenia crassiceps. In a further embodiment of the invention, the antigen is a protein isolated using ultracentrifugal density flotation. In yet a further embodiment the antigen is a 70% ammonium sulfate-soluble protein and has an apparent molecular weight of 10,000 by SDS-PAGE.
It is a further object of the present invention to isolate and identify a DNA molecule having a DNA sequence coding for a homologous segment of a diagnostic antigen having specific and sensitive antigenicity for Taenia saginata and/or Taenia solium.
In one embodiment of the present invention the DNA molecule codes for a homologous segment of an antigen having the desired immunodiagnostic characteristics. In another embodiment of the present invention the DNA molecule has a specific nucleotide sequence, preferably the sequence in Table I. In yet another embodiment of the present invention the DNA molecule comprises a DNA sequence made from the mRNA isolated from Taenia crassiceps.
It is yet another object of the present invention to use genetic manipulation to obtain polynucleotides comprising a first nucleotide sequence for a diagnostic antigen in operable combination with a second nucleotide sequence.
In one embodiment of the present invention the first polynucleotide is a sequence for the isolated antigen or a homologous segment thereof, preferably for the sequence in Table I or gene TCA-2. In another embodiment of the present invention the second nucleotide codes for β-galactosidase or a fragment thereof. In a further embodiment of the present invention the second nucleotide comprises bacteriophage lambda gt 11 or the plasmids pUC18, or pIH821.
It is still another object of the present invention to use genetic manipulation to obtain a polynucleotide expression vehicle. In one embodiment the expression vehicle is a replicon, plasmid, bacteriophage, virus or hybrid thereof. In one embodiment the expression vehicle includes the operable combination of the polynucleotides, preferably the plasmid vector pTCA2.
It is a still further object of the present invention to use genetic manipulation to transform or transfect a host cell with an expression vehicle forming a cell line, preferably the cell line Y1090 and PR722.
Another object of the present invention is achieving a method of producing a purified antigen using transformed, transfected or infected host cells as a means of achieving mass production of antigens and thereby achieving an abundant and inexpensive antigen supply.
Yet another object of the present invention is achieving a purified recombinant diagnostic antigen which can be easily purified to homogeneity, in high quantitities and at relatively little expense without the need to use laboratory rodents for propagation of the diagnostic antigen.
In one embodiment of the present invention the purified recombinant diagnostic antigen is produced using the above discussed host cell line, preferably PR722. In another embodiment of the invention the purified recombinant diagnostic antigen is homologous to the purified and isolated antigen having Taenia saginata and Taenia solium antigenicity, preferably with the amino acid sequence of Table I or the antigen TCA-2 or TCA-2-MBP.
A still further object of the present invention is achieving accurate and reliable screening methods having improved efficiency of inspection procedures and reduced cost. In one embodiment of the invention the method is directed to the diagnosis of cysticercosis using the antigens of the present invention to form an immunocomplex with antibodies present in the sample to be tested and detecting the presence of the complex.
These and other objects and advantages of the instant invention will be more apparent from the following detailed description and exemplified embodiments, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a SDS-PAGE of the diagnostic antigen isolated from Taenia hydatigena. Channel one contains standards; channels two and three contain the high molecular weight components of ThFAS which elute as Peak I by HPLC: and channels four and five contain the low weight components of ThFAS which elute as Peak II by HPLC.
FIG. 2 is a Southern blot of restriction enzyme digests of T. crassiceps genomic DNA probed with TCA-2 sequence. Channel one enzyme is DRA-I; channel two is the plasmid only; channel three is Eco RI (with plasmid contaminate); channel four is blank; and channel five is Hind III.
FIG. 3 is a Northern blot of the total RNA on a formaldehyde gel. Channel one is the total RNA extracted from T. crassiceps and channel two is from T. saginata.
DETAILED DESCRIPTION OF THE INVENTION
Novel Diagnostic Antigens
The present invention provides for novel diagnostic antigens useful in the detection of bovine or swine cysticercosis. The antigens are extracted from Taenia crassiceps (TcAS) and have unexpectantly been found to react with both antibodies against Taenia saginata and Taenia solium with a high degree of sensitivity and specificity. Taenia crassiceps is a canine tapeworm that exists and can be maintained in rodents in the cyst stage (larval stage). Further, the antigen can be used to differentially diagnose bovine or swine cysticercosis due to the presence of Taenia saginata or Taenia solium from other commonly occurring parasites.
Unexpectedly, it has been found that polyclonal rabbit ThFAS antibodies cross-react with protein preparations from other parasites of the Taenia genus, including the antigen of the present invention prepared from cestode, Taenia crassiceps. The problem of obtaining pure cestode nucleic acids from T. saginata cysts, normally contaminated with bovine muscle tissue, can be circumvented using T. crassiceps metacestodes for parasite propagation within the peritoneal cavity of mice which allows isolation of protein free of integrated host tissue. However, this does not obviate the problem of using rodent models to generate parasites for antigen production.
ThFAS contains a group of high molecular weight proteins (65 to 77 kDa) and a low molecular weight protein of 10 kDa. The 10 kDa protein has been identified as the T. saginata--reactive, immunodiagnostic component. TcAS contains a related 10 kDa protein that is recognized by anti-ThFAS serum; however, the high molecular weight ThFAS-cross-reactive proteins were not present in TcAS. Conversely, rabbit anti-TcAS specifically recognized the 10 kDa proteins (appearing as a doublet) in ThFAS and TsAS (antigenic fraction prepared from Taenia saginata), as well as the homologous antigen, TcAS, but did not crossreact with any high molecular weight antigens.
The 10 kDa and 70% ammonium sulfate-soluble protein fraction from T. crassiceps (TcAS) is obtainable in the present invention. The antigen can be isolated by ultracentrifugal density flotation using either ammonium sulfate at a specific gravity of 1.231 g/ml or NACl/KBr at 1.225 g/ml, followed by gel filtration under denaturing conditions (6M guanidine-HCl, 5% 2 Me and 100° C. heat). The resulting homogenous protein has a relative (or apparent) molecular weight of 10,000 by SDS-PAGE. The antigenic fraction has shown potential as an immunodiagnostic reagent for bovine cysticercosis.
The purified antigen can be employed in a method of diagnosing cysticercosis. In particular, the antigen can be employed in an immunoassay to detect the presence of antibodies to Taenia saginata or Taenia solium in a sample. The sample can be body fluids such as blood, urine, cerebrospinal fluid, or preferably serum. The presence of these antibodies can be used to diagnose cysticercosis. Although this method can be used to make the diagnosis in humans, it is particularly useful for testing cattle or swine, either as livestock or after slaughter.
Isolation of the purified antigen allows for the genes to be cloned, the DNA sequence to be determined and the amino acid sequence determined. The antigen may then be produced using gene cloning or recombinant DNA techniques.
DNA Sequence of Novel Diagnostic Antigen
Since availability of antigen is a major limiting factor in diagnostic test development and production, reliable sources of antigen must be secured prior to field trials and large scale test implementation. Mass production of antigen by in vitro synthesis offers an attractive solution to the antigen supply once the reactive antigen has been identified.
The DNA sequence of the novel diagnostic antigen can be determined using conventional techniques such as the dideoxy chain termination method of Sanger et al., Proc. Nat. Acad. Sci. USA, 74:5463-5467 (1977) as modified by Kraft et al., Biotechniques 6:544-546 (1988).
Using these genetic engineering techniques a DNA sequence which encodes the amino acid sequence of the homologous segment of the antigen isolated from Taenia crassiceps, can be generated. The phrase "homologous segment of the antigen" means an amino acid sequence sufficiently duplicative of the antigen of the present invention to allow the possession of the unique biological property of being able to bind antibodies against Taenia saginata and/or Taenia solium.
A cDNA expression library was constructed in the bacteriophage vector lambda-gt11 using poly A mRNA purified from Taenia crassiceps metacestodes in order to identify a recombinant antigen for the diagnosis of bovine cysticercosis. The cDNA library was screened with rabbit antiserum to ThFAS, and with bovine antiserum to Taenia saginata.
Primary screening of T. crassiceps cDNA clones with rabbit anti-ThFAS serum identified at least 32 strongly reactive plaques. The positive clones were plaque purified.
One phage, designated lambda-TCA-2, lysogenized into E. coli strain Y1089, generated a β-galactosidase fusion protein with a relative molecular weight of 120 to 130 kDa and reacted specifically with cysticercosis-infected bovine sera. The clone contained a cDNA insert approximately 288 base pairs in length and reacted strongly with both antisera. The cDNA is encoded by a messenger RNA of approximately 450 bases in length.
Because of inefficient synthesis of the fusion protein, the 288 bp cDNA sequence from lambda-TCA-2 was subcloned into the plasmid pIH821 generating a 47 kDa maltose-binding fusion protein, designated TCA2-MBP. Affinity-purified TCA2-MBP reacted strongly with sera from cattle experimentally infected with T. saginata by both ELISA and Western blot analysis but did not cross-react with sera from cattle infected with Fasciola hepatica or with other common gastrointestinal parasites.
Rabbit anti-TCA2-MBP recognized the 10 kDa proteins in ThFAS, T. crassiceps and T. saginata.
Polynucleotide Molecule
On the basis of the genetic code, there exits a finite set of nucleotide sequences which can genetically code for a given amino acid sequence. All such equivalent nucleotide sequences are operable variants of the disclosed sequences, since all give rise to the same protein, having the same amino acid sequence, during the course of an in vivo transcription and translation. Consequently, all such variants are intended to be included in the scope of the present invention.
Two DNA sequences are "substantially homologous" when at least 70 to 90%, preferably 80 to 90% and most preferably 85%, of the nucleotides match over the defined length of the selected region that encodes for the antigen. Sequences which are substantially homologous can be identified in a Northern hybridization experiment under conditions defined for that particular system. Defining appropriate hybridization conditions is within the skill of the art. See, e.g., T. Maniatis et al., Molecular Cloning: A Laboratory Manual, Cold Spring Harbor Laboratory, 1982; DNA Cloning: A Practical Approach, Volumes I and II (Ed. D. N. Glover) IRL Press, Oxford, 1985.
The gene which encodes the antigen of the present invention can be derived from Taenia crassiceps. The gene encoding the antigen is obtained using standard cloning techniques (Sambrook, J. et al. Molecular Cloning: A Laboratory Manual, 2nd Edition, Cold Spring Harbor Press, Cold Spring Harbor, N.Y. (1989)). The gene is comprised of the polynucleotide DNA. Other polynucleotides can also be used to express the antigen and are intended to be within the scope of the present invention.
Thus, in a preferred embodiment, the present invention achieves polynucleotides having the sequence that encodes at least part of the antigen having the homologous segment of the antigen isolated from Taenia crassiceps.
Expression Vehicles and Transformed or Transfected Host Cells
The coding sequence can be contained in vectors which are operable as cloning vectors or expression vectors when inserted into an appropriate host. The expression vector may be for example a replicon, plasmid, bacteriophage, virus or hybrid thereof. Vectors used in practicing the invention are selected to be operable as cloning vectors or expression vectors in the selected host cell. Numerous cloning vectors are known to those skilled in the art, and selection of an appropriate cloning vector is a matter of choice. Examples of cloning vectors include bacteriophage lambda gt11, pBR 322, pUC18, and pIH821. See generally, DNA Cloning, Volumes I and II, supra, and Maniatis et al., supra. Additionally, the present invention encompasses the use of eukaryotic and other procaryotic cloning vectors. The expression vector is then inserted in host cells. A variety of vector-host combinations may be used.
The encoding DNA or expression vector of the present invention can be expressed in mammalian cells or other eukaryotic cells, such as yeast, or in prokaryotic cells, in particular bacteria. A number of approaches may be taken for evaluating optimal expression plasmids for the expression of cloned cDNAs in yeast see Glover, D. Ed., DNA Cloning, Vol. II, pp. 45-66, IRL Press (1985)!. Bacterial strains may also be utilized as hosts for the production of the antigens of the present invention, such as E. coli strains PR722 and Y1090, and other enterobacteria such as Salmonella, Serratia and Pseudomonas.
Method to Produce and Purifiy the Protein Using the Recombinant Cells
Mass production of antigen by recombinant DNA synthesis offers an attractive solution to the antigen supply problem once a reactive antigen has been identified. The recombinant antigen can be easily purified to homogeneity, in high quantities and at relatively little expense without the need to use laboratory rodents for propagation in diagnostic application.
Commercial kits are available for producing and purifying a fusion protein such as those available from New England BioLabs. The process generally comprises the following steps of inoculating broth containing glucose and ampicillin with cells containing the fusion plasmid; grow the cells; add IPTG; incubate the cells at 37° C. for 1 to 3 hours; harvest the cells by centrifugation; resuspend the cells; freeze overnight; thaw; sonicate to break open the cell; centrifuge; separate using an amylose resin; elute the fusion protein with buffer and maltose; collect fractions; pool the protein containing fractions; and concentrate.
Method of Diagnosing Bovine or Swine Cysticercosis
The development of accurate and reliable serological screening methods would be expected to result in improved efficiency of inspection procedures and reduced cost. The antigen of the present invention is useful for immunoassays which detect or quantitate the presence of Taenia saginata and/or Taenia solium in a sample, preferably serum. The immunoassay using the present invention typically comprises incubating a biological sample in the presence of an antigen of the present invention, forming an immunocomplex and detecting the complex. Various immunoassays procedures are described in Immunoassays for the 80's, Voller, A. et al., eds. University Park, 1981.
One of the ways antibodies to the antigen of the present invention can be detected is by the use of an enzyme immunoassay(EIA), or enzyme-linked immunosorbent assay (ELISA). This enzyme, when exposed to the substrate, will react and generate a chemical moiety which can be detected, for example by spectrophotometric, fluorometric or visual means. Modifications of the immunoassay include choice of solid-phase carrier surfaces, coupling or coating buffer, blocking agent, enzyme-conjugated antisera, substrate, color indicator and test configuration. Test configurations in ELISA includes use of either a double- or triple (amplified) antibody sandwich test system.
By radioactively labeling the antigen of the present invention, it is possible to use radioimmunoassay (RIA) as a method of diagnosing cysticercosis. It is also possible to use fluorescent labels, chemiluminescent labels, and bioluminescent labels.
Further, the test configuration may be a one step, two step or sandwich assay. See, for example Work, T. et al., Laboratory Techniques and Biochemistry in Molecular Biology, North Holland Publishing Company, N.Y. (1978).
In one aspect of the invention, the antigen may be added to a solid support which is capable of immobilizing particles such as the proteins of the present invention. Well-known supports or carriers include glass, polystyrene, polypropulene, polyethylene, dextran, nylon, natural and modified celluloses, polyacrylamides, and agaroses. The support material may have any possible structural configuration so long as it is capable of binding to a protein. Thus, the support configuration may be spherical, as in a bead, or cylindrical, as in the inside surface of a test tube, or the external surface of a rod. Alternatively, the surface may be flat, such as a sheet or test strip. Those skilled in the art will know many other suitable carriers for binding the antigen, or will be able to ascertain the same by the use of routine experimentation.
The binding activity of any given lot of the antigen may be determined according to well known methods. Those skilled in the art will be able to determine operative and optimal assay conditions by employing routine experimentation.
The following examples are offered to illustrate the present invention and are not intended to limit the scope of the invention.
EXAMPLE I
Isolation and Characterization of Novel Antigen from Taenia crassiceps as Well as Antigen from Taenia saginata
T. crassiceps (HYG mouse strains) were maintained in female Swiss-Webster mice. Mice were inoculated intraperitoneally with 8 to 10 metacestodes suspended in a small amount of saline. Parasites were harvested at 30 to 60 days post-infection by flushing the opened peritoneal cavity with saline. The metacestodes were washed in saline, suspended in 50 mM Tris/HCl buffer, pH 7.5 and homogenized using a Teflon on glass tissue grinder. The homogenate was centrifuged at 17000×g for 20 minutes and the supernatant treated with ammonium sulfate as described for ThFAS Rhoads, M. et al., J. Parasit., 71:774-787 (1985)!. The protein fraction was labeled TcAS.
A similarly prepared ammonium sulfate-soluble fraction from viable T. saginata metacestodes excised from the tissues of experimentally-infected calves was designated TsAS Kamanga-Sollo et al., Proc. Am. Assoc. Vet. Res. 48:1206-1210 (1987)!.
EXAMPLE II
DNA Sequencing
Taenia crassiceps were maintained in Swiss-Webster white mice by serial passage. Cysts were recovered 2-3 months after infection from the peritoneal cavity of the sacrificed mice and washed by settling through several changes of phosphate buffered saline (PBS).
Total RNA was isolated from T. crassiceps mestacestode cysts by a modification of the quanidinium isothiocyanate: cesium trifluoracetate procedure described by Okayama et al., Methods of Enzymol. Vol. 154 (1987). Approximately 100 ml of settled cysts recovered from three mice were passed through a 20 ga. needle to break the cysts open. The tissue was centrifuged 5 minutes at 3500 rpm then washed several times in phosphate buffered saline. The final pellet was suspended in 30 ml of solution containing 50 mM TRIS, pH 8.0, 100 mM sodium chloride and 50 mM EDTA and treated with 2% sodium dodecyl sulfate and 1 mg/ml proteinase K for 1 hour at 65° C. The digested tissue was extracted three times with phenol:chloroform:isoamyl alcohol (25:24:1) and the nucleic acids precipitated in 0.3M sodium acetate and 2.5 volumes of ethanol. The precipitated nucleic acids were then separated according to Okayama where the RNA was pelleted through a cesium trifluoracetate:quanidinium isothiocyanate centrifugation gradient. The RNA which pelleted at the bottom of the gradient was washed with 70% ethanol (3×1.0 ml) and redissolved in sterile TE (10 mM TRIS, pH 7.6, 1 mM EDTA). No further purification was performed.
Poly A mRNA was isolated by two successive passes of total RNA through an oligo (dT)-cellulose column essentially as described by Aviv et al., Proc. Natl. Acad. Sci. USA 69:1408-1412 (1972). The poly A mRNA was eluted from the oligo (dT) cellulose column with sterile water preheated to 65° C. and then precipitated in 0.3M sodium acetate and 2.5 volumes of ethanol. The poly A mRNA was pelleted by centrifugation, washed with 80% ethanol, centrifuged once again, dried in vacuo, and dissolved in water.
Double stranded cDNA was generated from 10 μg of purified poly A mRNA according to the method of Gubler et al., Gene 25:263-269 (1983), as modified by Watson et al., DNA Cloning, Vol. I, Ed. D. M. Glover, IRL Press, Oxford, pages 79-88 (1985) using Eco RI linkers. In brief, first strand cDNA synthesis was carried out in 55 μl by priming with oligo dT in the presence of RNAsin, the appropriate dNTPs, and Avian Myoblastosis Virus (AMV) reverse transcriptase. cDNA synthesis was stopped after 1 hour at 42° C. and the solution containing cDNA-RNA hybrid was directly treated for second strand synthesis. Second strand synthesis was carried out in 250 μl in the presence of dNTPs, RNase H and DNA polymerase I. After a 1 hour incubation at 14° C. followed by a 1 hour incubation at room temperature (22° C.), the reaction was halted and the double stranded cDNA was methylated with S-adenosyl-L-methionine by Eco RI methylase and the cDNA ends made blunt by treatment with T4 DNA polymerase in the presence of dNTP. After phenol-chloroform extraction, ethanol precipitation, centrifugation, and drying in vacuo, Eco RI linkers were ligated to the methylated cDNA termini using T4 DNA ligase and RNA ligase. The cDNA was then digested with Eco RI restriction enzyme for 1 hour at 37° C. to produce Eco RI compatible ends on the cDNA. The reaction was stopped with EDTA, phenol-chloroform extracted, ethanol precipitated, collected by centrifugation, dried in vacuo, resuspended in TE, and passed over a "NACS" column (Bethesda Research Laboratories). The cDNA was eluted in 2M NaCl in TE, ethanol precipitated, collected by centrifugation, dried in vacuo and resuspended in TE.
Ten percent of the double-stranded cDNA was ligated to 1 μg of lambda-gt11 arms containing compatible Eco RI ends using T4 DNA ligase at 14° C. for 16 hours.
The Taenia crassiceps cDNA-bacteriophage DNA was packaged into intact virus particles using a "Packagene" extract following the procedures described by the manufacture (Promega Biotech). After packaging, E. coli strain Y1090 was infected with the packaged cDNA library and plated onto Luria Broth (LB) agar plates in LB agarose containing 0.2% X-gal, 0.1 mM IPTG, and 100 μg/ml ampicillin. Using this technique, greater than 95% of the bacteriophage were observed to be recombinant (i.e., contained cDNA inserts) as judged by the percentage of white plaques of the total plaques obtained.
In order to screen the cDNA libraries, anti-sera was generated by inoculating rabbits with Taenia crassiceps, TcAS antigen or with purified ThFAS antigen. Individual rabbits were inoculated subcutaneously with one of the protein preparation emulsified in Complete Freund's adjuvant and boosted two times further at 1 week intervals. Immune sera were collected after about 4 weeks.
Calf sera was obtained from animals experimentally-infected with Taenia saginata eggs ranging from as few as 1000 eggs per animal to as high as 100,000 eggs per animal.
Aliquots of the T. crassiceps bacteriophage library were used to infect and transform (transfect) E. coli Y1090 and were plated out on LB ampicillin plates. See Young R. et al., Proc. Natl. Acad. Sci. USA 80:1194-1198 (1983) and Science 222:778-782 (1983)!. The plates containing developing phage plaques were overlaid with nitrocellulose membrane disks which had been soaked in 10 mM IPTG and were incubated at 42° C. for 3 hours to induce production of the β-galactosidase fusion protein then transferred to 37° C. The nitrocellulose disks, impregnated with the E. coli proteins containing putative recombinant fusion protein, were removed from the plates after overnight incubation at 37° C., blocked in immunowash buffer (IWB) (0.15M sodium chloride, 50 mM TRIS, pH 7.8, 0.05% Tween-20, and 5% non-fat dried milk), then screened overnight with a 1:200 dilution of serum from either a calf experimentally-infected with T. saginata eggs or with rabbit anti-ThFAS sera. Peroxidase labeled rabbit anti-bovine IgG (1.0 μg/ml) or goat anti-rabbit IgG (1.0 μg/ml) were used as second antibodies, respectively. Positive clones (antibody binding) were visualized colormetrically with 4-chloro-1-naphthol and hydrogen peroxide and approximately 32 clones were picked and rescreened as described above using rabbit anti-ThFAS infection sera.
Nineteen putative positives were picked and rescreened with rabbit antiserum to parasite antigen (diluted 1:200) followed by peroxidase-labeled goat anti-rabbit IgG. Two of these clones showed strong hybridization in all the above screenings and were designated TCA-2 and TCA-12.
Once identified and removed from the respective culture plate, positive bacteriophage TCA-2 was plaque purified by several rounds of plating, screening and isolation as described above. This procedure was repeated until 100% of the plaques from the clone produced a positive signal upon immunoscreening. The approximate mass of the β-glactosidase fusion protein is 123,000 kDa of which 7.0 kDa is attributed to protein production from the TCA-2 gene.
TCA-2 was subcloned into plasmid vectors to facilitate further characterization by DNA mapping and DNA sequencing Veira, J. et al., Gene 19:259-268 (1982) and Guan et al., Gene 67:21-30 (1987)!. See Table I for the DNA sequence of TCA-2. For subcloning procedures see generally, Maniatis et al., 1982, supra. In the cloning of TCA-2 DNA, the gene was inserted into the Eco RI restriction site of lambda-gt11. To transfer this gene into the plasmid vectors, the TCA-2 sequence in lambda-gt11 was first amplified using polymerase chain reaction (PCR) as defined in the Perkin-Elmer Cetus GENE AMP™ DNA Amplification Reagent Kit. PCR was performed using 2.5 ng of the TCA 2:lamda-gt11 hybrid DNA purified according to Maniatis et al., 1982 supra, and using the lambda DNA primers 5' GGTGGCGACGACTCCTGGAGCCCG (SEQ ID NO:3) and 5' TTGACACCAGACCAACTGGTAATG (SEQ ID NO:4). The amplified TCA-2 sequence was digested with Eco RI endonuclease and ligated to the Eco RI sites of pUC18 and pIH821 plasmid DNAs as generally described by Maniatis et al., 1982, supra. The new vectors containing the TCA-2 gene were used to transform bacterial cells JM101 and PR722, respectively according to Hanahan, J. Mol. Biol. 166:557-580 (1983). Cells containing the TCA-2 insert were assayed both by agarose gel electrophoresis relative to plasmid DNA without TCA-2 inserted and by antibody screening using rabbit anti-ThFAS antisera as described above for screening the cDNA library.
For labeling and hybridization studies, plasmid DNA was used both labeled as is or digested with Eco RI, electrophoresed on LMP agarose (FMC) and the TCA-2 insert DNA excised from the gel and purified away from the rest of the plasmid. The insert DNA was labeled with 100 μCi of 32 P-alpha dCTP (3000 μCi/mMole, New England Nuclear) by nick translation, Rigby et al. J. Mol. Biol. 113:237 (1977) using DNase I and DNA polymerase I (BRL). Labeled DNA was separated from 32 P-dCTP by spun column chromatography as described by Maniatis et al., 1982, supra. T. crassiceps DNA was purified as described by Dame, J. et al., Molecular and Biochemical Parasitology 8:263-279 (1983). The purified DNA (10 μg) was digested with either DRA I, Eco RI or Hind III restriction enzymes (BRL), electrophoresed in 0.8% agarose (FMC) and transferred to "Nytran" membrane using Southern blotting procedures (see Southern, E., J. of Molecular Biology 98:503-517 (1975)). After transfer, the DNA-blotted "Nytran" paper was linked to the membrane by using UV light then prehybridized with 0.5M NaCl, 0.05M sodium citrate, pH 7.0 (6× SSC), Denhardt's solution, and 0.2% sodium dodecyl sulfate (SDS) for 6 hours at 65° C. The blots were washed three times with 0.2× SSC, 0.1% SDS at 50° C. for 30 minutes per wash. The blots were air dried and overlaid with photographic film (Kodak XAR) to visualize the hybridization patterns.
The Southern blot restriction enzyme digests of T. crassiceps genomic DNA probed with TCA-2 sequence is shown in FIG. 2. Channel 1 enzyme is with DRA-I; channel 2 is plasmid only; channel 3 is Eco RI (with plasmid contaminated buffer); channel 4 is a blank; and channel 5 is with Hind III.
Northern blots were similarly generated using the 10 μg of total RNA isolated from T. crassiceps cysts and separated on a 1% denaturing formaldehyde gel as described by Davis, L. et al., Basic Methods in Molecular Biology, Elsevier Science Publishing Co., Inc. (1986). After separation on 1% agarose the RNA was transferred to NYTRAN and screened with insert TCA-2 cDNA as described above for Southern blot analysis. See FIG. III. Channel one contains total RNA isolated from T. crassiceps and channel two contains total RNA isolated from T. saginata.
The foregoing techniques including the sequencing described earlier indicate that the TCA-2 cDNA insert is 288 bp in length and contains sequences coding for a ribosome binding site, poly A signal sequence, poly A tail and both start and stop translation codons. Furthermore, the gene is likely to be single copy as evidenced by single bands which appeared with each restriction enzyme on the probed membranes (Southern blots).
Positive signals on probed Northern blots of RNA from T. crassiceps cysts suggest the TCA-2 is encoded by a single messenger RNA species which is approximately 450-500 bases in length.
TABLE 1__________________________________________________________________________SEQ ID NO:2__________________________________________________________________________GAATTCCATAAGGGACCTGAGGATCTGAAGAAGAAAATGATGAAGCAATTGGGTGAGGTG60MMKQGLEVCGTCGCTTCTTCAGGGAGGATCCTCTGGGCCAGAAGATTATTGACCATTTCCAAGAGACG120RRFFREDPLGQKIIDHFQETGTCTCTATCTGCAAGGCCATCAGAGAGCGGATAAGAAAACGCCTTGGAGAATACCTAAAG180VSICKAIRERIRKRLGEYLKGGTCTTGAAAATGAATAGATGTTGAGTTAAATCCACAAGGAAAAGTGATTAAATAAAAGG240GLENE-AACTCTTTCCCAGCAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAGG288__________________________________________________________________________
TCA-2 DNA sequence. Total number of bases is 288. Analysis done on the complete sequence. Done on (absolute) phase(s): 1. Using the universal genetic code.
EXAMPLE III
Expression Vehicles
The coding sequence from one ThFAS-positive clone from Example II, designated TCA-2, which also reacted specifically with cysticercosis-infected bovine sera, was subcloned into the Eco RI site of the expression plasmid pIH 821 and used to transform E. coli PR722. The plasmid was renamed pTCA2.
EXAMPLE IV
Method to Produce the Protein Using the Recombinant Cells
The plasmid-transformed PR722 cells are grown overnight in LB medium containing isopropyl-B-D-thio-galactosidase then treated with lysozyme to a final concentration of 0.5 mg/ml for 5 minutes on ice and sonicated. The lysed cells release the maltose-binding TCA-2 fusion protein into solution. As the TCA-2 gene is fused to the maltose-binding gene, induction of the production of the maltose-binding protein will produce the TCA-2 antigen as well, if the TCA-2 gene is cloned in the correct reading frame and correct orientation relative to the reading frame of the maltose-binding protein gene and the reading frame of the TCA-2 gene sequences in nature.
EXAMPLE V
Purification of Fusion Protein
The ThFAS positive clone from Example III, TCA-2 was subcloned into the Eco RI site of the expression plasmid pIH 821 and used to transform E. coli PR722. The plasmid was renamed pTCA 2. Transformed cells containing the plasmid pTCA 2 were grown at 37° C. to mid-log phase, and the maltose-binding fusion protein induced with isopropyl B-D-thiogalactopyranoside (IPTG) (0.3 mM) for 2 hours. The cells were pelleted, resuspended in lysis buffer (10 mM Tris, pH 7.2, 30 mM sodium chloride, 10 mM EDTA, 10 mM EGTA, and 0.25% Tween-20) then frozen overnight. The next day, the thawed cells were sonicated, centrifuged at 9000×g for 30 minutes and the supernatant passed over an amylose resin affinity column previously equilibrated in lysis buffer. The column was extensively washed with lysis buffer without Tween-20 and the bound fusion protein eluted in the same buffer supplemented with 10 mM maltose. Fractions containing the fusion protein were pooled and used for ELISA and Western blot analysis.
Northern blots. Total RNA from T. crassiceps metacestodes and T. saginata proglottids was electrophoresed on 1% formaldehyde gels and transferred to Nytran membranes essentially as described by Davis et al. The blots were hybridized overnight at 65° C. to pTCA-2 probe radiolabeled by nick translation then washed at 50° C. (4×20 min) in 0.1% SDS and 0.2% SSC (1× SSC is 0.15M sodium chloride, 0.015M sodium citrate, pH 7.0) and autoradiographed.
Rabbit and cattle antisera. ThFAS, TcAS and fusion protein TCA2-MBP were injected (3×200 μg protein/dose) subcutaneously at 3 week intervals into New Zealand female adult rabbits. Protein samples were emulsified prior to injection in both Freund's complete adjuvant (first injection) and Freund's incomplete adjuvant (second and third injections). Serum was collected before inoculation and one week after the final inoculation. Rabbit antiserum to maltose-binding protein (MBP) was supplied by the manufacturer (New England Biolabs).
Serum samples from cattle experimentally-infected with T. saginata (Exp-I) were obtained elsewhere at 13 to 26 weeks post-infection. Experimentally-uninfected (Exp-U) serum samples were obtained from the same animals prior to infection. Pooled sera from cattle with naturally-acquired infections of Fasciola hepatica (Fc-I) was obtained from Louisiana State University. Cattle serum from animals harboring common gastrointestinal parasites of the genera Moniezia, Ostertagia, Haemonchus, Cooperia, and Nematodirus (gp-I) was obtained from the U.S. Department of Agriculture.
Western immunoblots. Polyacrylamide gel electrophoresis and protein transfer to Immobilon PVDF membranes (Millipore) were performed essentially as described using 6 to 15% acrylamide gradient gels. After transfer, membranes were blocked for 1 hour with 0.01M PBS containing 1% bovine serum albumin. When bovine antisera was tested, 5% normal rabbit serum was included in the blocking reagent. Membranes were incubated in test antisera diluted 1/100 for at least 2 hours followed by a 1-hour incubation with 1/1000 dilutions of either goat anti-rabbit IgG or rabbit anti-bovine IgG peroxidase conjugates. Membranes were washed 5 times with PBS-0.02% Tween after each incubation then visualized with hydrogen peroxide and 4-chloro-1-naphthol substrate solution.
ELISA. One microgram of antigen (ThFAS, TcAS, TCA2-MBP, or MBP) was diluted in 0.01M sodium carbonate buffer, pH 9.6, and 100-μl aliquots were added to wells of an ELISA plate. Wells were blocked, and screened as described above. The absorbance of the peroxidase reaction (determined with 2-2-azino-di- 3-ethyl-benzothiazoline sulfonic acid and hydrogen peroxide) was measured at 405 nm.
ThFAS contains a group of high molecular weight proteins (65 to 77 kDa) and a low molecular weight protein of 10 kDa where the 10 kDa protein was identified as the T. saginata- reactive, immunodiagnostic component. TcAS contains a related 10 kDa protein that is recognized by anti-ThFAS serum; however, the high molecular weight ThFAS-cross-reactive proteins were not present in TcAS. Conversely, rabbit anti-TcAS specifically recognized the 10 kDa protein (appearing as a doublet) in ThFAS and TsAS, as well as the homologous antigen, TcAS, but did not cross-react with any high molecular weight antigens. Western blots indicated that the 10 kDa TcAS protein binds T. saginata antibodies (Exp-I) and is not recognized by Exp-U serum.
Primary screening of the T. crassiceps cDNA clones with rabbit anti-ThFAS serum identified at least 32 strongly reactive plaques. One phage, designated TCA-2, generated a β-galactosidase fusion protein with an apparent molecular weight of 120-130 kDa and reacted specifically with cysticercosis-infected bovine sera. The coding sequence, estimated to be 288 bp in length, was subcloned into the Eco RI site of the expression plasmid pIH 821 resulting in the production of a maltose-binding fusion TCA 2-MBP. When total protein from IPTG induced cells was compared to protein from uninduced pTCA-2 transformed cells, the IPTG-induced cells gave rise to an additional protein band with a molecular weight of 47 kDa. Following adsorption of the cell extract from induced cells to an amylose-resin affinity column, and washing with column buffer, a 47 kDa fusion protein was eluted in 10 μM maltose on SDS-PAGE. Rabbit anti-ThFAS did not react with proteins from uninduced cell extracts, but did react with TCA 2-MBP present in crude extracts and the affinity purified cell fraction. The 47 kDa protein was recognized by rabbit anti-MBP (maltose-binding protein).
Northern blots probed with radiolabeled pTCA-2 indicated that the TCA-2 encoding mRNA was approximately 450-500 bases in length and demonstrated hybridization of TCA-2 DNA sequence to RNA purified from adult T. saginata.
Rabbit antibodies generated against TCA2-MBP were used to identify immunologically cross-reactive 10 kDa antigens in T. crassiceps, T. hydatigena and T. saginata.
The efficacy of TCA 2-MBP to detect experimentally infected animals was assessed by both Western blot analysis and ELISA. All Exp-I sera reacted strongly with TCA2-MBP on Western blots where no reaction with Fc-I, gp-I, Exp-U sera was observed. None of the sera reacted with MBP.
ELISA. TCA2-MBP was able to detect all 10 Exp-I sera when compared to Exp-U sera. Threshold absorbance values were determined by the mean absorbance of the Exp-U plus 2 standard deviations. Fc-I and gp-I sera did not react above threshold values. MBP did not react with any of the EXP-I sera.
The foregoing description of the specific embodiments reveals the general nature of the invention and others can by applying current knowledge, readily modify and/or adapt such specific embodiments without departing from the inventive concept and therefore such adaptations and modifications should be and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for purposes of description and not of limitation.
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 4(2) INFORMATION FOR SEQ ID NO:1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 288 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: double(D) TOPOLOGY: unknown(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(vi) ORIGINAL SOURCE:(A) ORGANISM: Taenia crassiceps(B) STRAIN: HYG(D) DEVELOPMENTAL STAGE: Metacestode(ix) FEATURE:(A) NAME/KEY: CDS(B) LOCATION: 37..195(xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:GAATTCCATAAGGGACCTGAGGATCTGAAGAAGAAAATGATGAAGCAATTGGGT54MetMetLysGlnLeuGly15GAGGTGCGTCGCTTCTTCAGGGAGGATCCTCTGGGCCAGAAGATTATT102GluValArgArgPhePheArgGluAspProLeuGlyGlnLysIleIle101520GACCATTTCCAAGAGACGGTCTCTATCTGCAAGGCCATCAGAGAGCGG150AspHisPheGlnGluThrValSerIleCysLysAlaIleArgGluArg253035ATAAGAAAACGCCTTGGAGAATACCTAAAGGGTCTTGAAAATGAA195IleArgLysArgLeuGlyGluTyrLeuLysGlyLeuGluAsnGlu404550TAGATGTTGAGTTAAATCCACAAGGAAAAGTGATTAAATAAAAGGAACTCTTTCCCAGCA255AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAGG288(2) INFORMATION FOR SEQ ID NO:2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 53 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear(ii) MOLECULE TYPE: protein(xi) SEQUENCE DESCRIPTION: SEQ ID NO:2:MetMetLysGlnLeuGlyGluValArgArgPhePheArgGluAspPro151015LeuGlyGlnLysIleIleAspHisPheGlnGluThrValSerIleCys202530LysAlaIleArgGluArgIleArgLysArgLeuGlyGluTyrLeuLys354045GlyLeuGluAsnGlu50(2) INFORMATION FOR SEQ ID NO:3:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 24 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: unknown(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(vi) ORIGINAL SOURCE:(A) ORGANISM: Taenia crassiceps(B) STRAIN: HYG(D) DEVELOPMENTAL STAGE: Metacestode(xi) SEQUENCE DESCRIPTION: SEQ ID NO:3:GGTGGCGACGACTCCTGGAGCCCG24(2) INFORMATION FOR SEQ ID NO:4:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 24 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: unknown(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(vi) ORIGINAL SOURCE:(A) ORGANISM: Taenia crassiceps(B) STRAIN: HYG(D) DEVELOPMENTAL STAGE: Metacestode(xi) SEQUENCE DESCRIPTION: SEQ ID NO:4:TTGACACCAGACCAACTGGTAATG24__________________________________________________________________________
|
Antigens derived from Taenia crassiceps have been isolated which have specificity and sensitivity in their reactivity with antibodies against Taenia saginata and Taenia solium. These antigens may therefor be used in diagnostic testing for the serological screening of livestock for cysticercosis, rather than relying upon methods involving dissection and visual examination.
| 2
|
FIELD OF THE INVENTION
[0001] The present invention relates to magnet manufacturing technique field, especially to manufacturing method of rare earth magnet based on heat treatment of fine powder.
BACKGROUND OF THE INVENTION
[0002] Rare earth magnet is based on intermetallic compound R 2 T 14 B, thereinto, R is rare earth element, T is iron or transition metal element replacing iron or part of iron, B is boron; Rare earth magnet is called the king of the magnet as its excellent magnetic properties, the maximum magnetic energy product (BH)max is ten times higher than that of the ferrite magnet (Ferrite); besides, the maximum operation temperature of the rare earth magnet may reach 200° C., which has an excellent machining property, a hard quality, a stable performance, a high cost performance and a wide applicability.
[0003] There are two types of rare earth magnets depending on the manufacturing method: one is sintered magnet and the other one is bonded magnet. The sintered magnet of which has wider applications. In the conventional technique, the process of sintering the rare earth magnet is mainly performed as follows: raw material preparing→melting→ casting→ hydrogen decrepitation (HD)→jet milling (JM)→compacting under a magnetic field→sintering→heat treatment→magnetic property evaluation→oxygen content evaluation of the sintered magnet→machining→surface treatment and so on.
[0004] The development history of the sintered rare earth magnet cannot be overly summarized in a word that it is the developing of improving the content rate of the main phase and reducing the constitute of the rare earth. Recently, to improve (BH)max and coercivity, the integral anti-oxidization technique of the manufacturing method is developing continuously, so the oxygen content of the sintered magnet can be reduced to below 2500 ppm at present; however, if the oxygen content of the sintered magnet is too low, the affects of some unstable factors like micro-constituent fluctuation or infiltration of impurity during the process is amplified, so that it results in over sintering, abnormal grain growth (AGG), low coercivity, low squareness, low heat resistance property and so on.
[0005] To improve the coercivity and squareness of the magnet and solve the problem of low heat resistance, it is common to perform grain boundary diffusion with the heavy rare earth elements such as Dy, Tb, Ho and so on to the sintered Nd—Fe—B magnet, the grain boundary diffusion is generally performed after the machining process before the surface treatment process. The grain boundary diffusion method is a method of diffusing Dy, Tb and other heavy rare earth elements in the grain boundary of the sintered magnet, the method comprises the steps in accordance with 1) to 3):
[0006] 1) coating the rare earth fluoride (DyF 3 , TbF 3 ), rare earth oxide (Dy 2 O 3 , Tb 2 O 3 ) and other powder on the surface of the sintered magnet, then performing grain boundary diffusion of the elements Dy, Tb to the magnet at a temperature of 700° C.˜900° C.;
[0007] 2) coating method of rich heavy rare earth alloy powder: coating DyH 2 powder, TbH 2 powder, (Dy or Tb)—Co—No—Al metallic compound powder, then performing grain boundary diffusion of DY, Tb and other elements to the magnet at a temperature of 700° C.˜900° C.;
[0008] 3) evaporation method: using high temperature evaporation source to generate Dy, Tb and other heavy rare earth metal vapor, then performing grain boundary diffusion of DY, Tb and other elements to the magnet at a temperature of 700° C.˜900° C.
[0009] By the grain boundary diffusion method, the values of Br, (BH)max of the magnet remain unchanged essentially, the value of coercivity is increased to about 7 kOe, and the value of the heat resistance of the magnet is raised about 40° C.
[0010] The above mentioned method performs grain boundary diffusion under the temperature condition of 700° C.˜900° C., although the value of coercivity is increased, there are still some problems:
[0011] 1. the diffusion takes a long time, for example, it may take 48 hours for diffusing the heavy rare earth element to the center of a magnet with a thickness of 10 mm, however, it may not ensure 48 hours of diffusion time in mass production because it has to increase the manufacturing efficiency by shortening the diffusion time; therefore, the heavy rare earth element (Dy, Tb, Ho or other elements) may not be sufficiently diffused to the center of the magnet, and the heat resistance of the magnet may not be sufficiently improved;
[0012] 2. the magnet may react with the placement and the rule, therefore the surface of the magnet material would be scratched, and the cost of the rule consumption is high;
[0013] 3. the magnet may have a low oxygen content, consequently the oxidation may not be evenly distributed through the inside and outside of the magnet, the oxidation film may not be evenly distributed, and the magnet may easily deform (bend) after the RH diffusion.
SUMMARY OF THE INVENTION
[0014] The present invention overcomes the disadvantages of the conventional technique and provides a manufacturing method of rare earth magnet based on heat treatment of fine powder, as an oxidation film is evenly formed on the surface of the overall powder, consequently the existence status of the oxygen at the grain boundary of the magnet is changed obviously, the diffusion rate of the heavy rare earth element is accelerated and the diffusion efficiency is promoted, therefore it is capable of accomplishing the grain boundary diffusion in a short time.
[0015] The technical proposal of the present invention is that:
[0016] A manufacturing method of rare earth magnet based on heat treatment of fine powder, the rare earth magnet comprises R 2 T 14 B main phase, R is selected from at least one rare earth element including yttrium, and T is at least one transition metal element including the element Fe; the method comprising the steps of: coarsely crushing an alloy for the rare earth magnet and then jet milling to obtain a fine powder; the fine powder is then heated in vacuum or in inert gas atmosphere at a temperature of 100° C.˜1000° C. for 6 minutes to 24 hours; compacting the fine powder under a magnet field; sintering in vacuum or in inert gas atmosphere at a temperature of 950° C.˜1140° C. to obtain sintered magnet; and
[0017] machining the sintered magnet to obtain a magnet, then performing a RH grain boundary diffusion on the magnet at a temperature of 700° C.˜1020° C.
[0018] By adding the process of fine powder heat treatment, the present invention can achieve the above mentioned effects, the reason is that, with the heat treatment of the fine powder, it has the phenomena as below:
[0019] 1. tiny amounts of oxidation layer is generated on the surface of the overall powder in the vacuum condition or in the inert gas atmosphere condition under the work of the inevitable oxidizing gas, and therefore the oxidative activity of the powder is weakened in the following process;
[0020] 2. the sharp edge on the alloy powder is melted and becomes round, thus it reduces the contact area between the powder, the lubricating property of the powder is better, the lattice defect of the surface of the powder is recovered, and therefore the orientation degree of the powder and the coercivity of the magnet are improved;
[0021] 3. the scratch on the surface of the powder is removed by the hardening effect, so that it avoids the loss of sintering promotion effect due to the defect or other facts.
[0022] With above factors and combined, the property of the powder is changed drastically, as an oxidation film is evenly formed on the surface of the overall powder, consequently the existence status of the oxygen at the grain boundary of the magnet is changed obviously, the diffusion rate of the heavy rare earth element is accelerated and the diffusion efficiency is promoted, therefore it is capable of accomplishing the grain boundary diffusion in a short time.
[0023] In another preferred embodiment, the temperature of the RH grain boundary diffusion process is 1000° C.˜1020° C. In this diffusion temperature range, the diffusion rate is accelerated and the diffusion time is shortened.
[0024] In another preferred embodiment, the temperature of the fine powder heat treatment process is 300° C.˜700° C.
[0025] In another preferred embodiment, in the fine powder heat treatment process, the fine powder is vibrated or shaken. To prevent adhesion and condensation between the powder, a rotating furnace is preferably used to improve the manufacturing efficiency.
[0026] In another preferred embodiment, in vacuum condition of the fine powder heat treatment process, the pressure is configured in a range of 10 −2 Pa˜500 Pa with an oxygen content of 0.5 ppm˜2000 ppm and a dew point of −60° C.˜20° C. By a number of experiments, the present invention is capable of controlling the content of the oxidizing gas (including water and oxygen) in the gas atmosphere, so that the surface of the overall powder only generates tiny amounts of oxidation layer, the existence status of the obtained oxygen of the grain boundary of the magnet is changed obviously. And the diffusion rate of the heavy rare earth element is accelerated. In addition, as the vacuum pressure is configured as below 500 Pa, it is much lower than the standard atmospheric pressure; according to the mean free path formula, the mean free path of the oxidizing gas is inversely proportional to the pressure P, so that the oxidizing gas and the powder react more evenly, the powder disposed on the top layer, the central layer and the bottom layer can all perform oxidation reaction, thus obtaining a powder with an excellent property.
[0027] In another preferred embodiment, in inert gas atmosphere condition of the fine powder heat treatment process, the pressure is configured in a range of 10 −1 Pa˜1000 Pa with an oxygen content of 0.5 ppm˜2000 ppm and a dew point of −60° C.˜20° C. The effects are the same as mentioned in the last paragraph.
[0028] In another preferred embodiment, the alloy for the rare earth magnet is obtained by strip casting an molten alloy fluid of raw material and being cooled at a cooling rate between 10 2 ° C./s and 10 4 ° C./s.
[0029] In another preferred embodiment, the coarse crushing process is a process that the alloy for the rare earth magnet is firstly treated by hydrogen decrepitation under a hydrogen pressure between 0.01 MPa to 1 MPa for 0.5˜6 hours and then is dehydrogenated in vacuum.
[0030] In another preferred embodiment, counted in atomic percent, the component of the alloy is R e T f A g J h G i D k , R is Nd or comprising Nd and selected from at least one of the elements La, Ce, Pr, Sm, Gd, Dy, Tb, Ho, Er, Eu, Tm, Lu and Y; T is Fe or comprising Fe and selected from at least one of the elements Ru, Co and Ni; A is B or comprising B and selected from at least one of the elements C or P; J is selected from at least one of the elements Cu, Mn, Si and Cr; G is selected from at least one of the elements Al, Ga, Ag, Bi and Sn; D is selected from at least one of the elements Zr, Hf, V, Mo, W, Ti and Nb; and the subscripts are configured as:
[0031] the atomic percent at % of e is 12≦e≦16,
[0032] the atomic percent at % of g is 5≦g≦9,
[0033] the atomic percent at % of h is 0.05≦h≦1,
[0034] the atomic percent at % of i is 0.2≦≦2.0,
[0035] the atomic percent at % of k is k is 0≦k≦4,
[0036] the atomic percent at % of f is f=100−e−g−h−i−k.
[0037] Compared to the conventional technique, the present invention has advantages as follows:
[0038] 1) as an oxidation film is formed on the surface of the overall powder, the existence status of the oxygen at the grain boundary of the magnet is changed obviously, the diffusion rate of the heavy rare earth element is accelerated and the diffusion efficiency is promoted, therefore it is capable of accomplishing the grain boundary diffusion in a short time;
[0039] 2) it doesn't need to attach to the rule during the diffusion, thus avoiding defective scratches on the surface of the magnet material;
[0040] 3) with the heat treatment of the fine powder, the property of the powder is changed drastically, the magnet is machined with a desired size after being sintered and then treated with grain boundary diffusion; in the present invention, the grain boundary diffusion experiments are conducted at a temperature of 680° C.˜1050° C., a temperature of 700° C.˜1020° C. is determined as the grain boundary diffusion temperature and a temperature range of 1000° C.˜1020° C. is the most appropriate for the Dy grain boundary diffusion; therefore, it is capable of solving the time consuming problem of the conventional method for grain boundary diffusion by adopting a diffusion temperature higher than the conventional technique when the time schedule is tense;
[0041] 4) by adopting the fine powder heat treatment process of the present invention, an oxidation layer is evenly formed on the surface of the overall powder, therefore it is capable of performing mass production of non-bending magnet (non-deforming magnet);
[0042] 5) compared to the conventional technique, the powder can be sintered at a relatively temperature that is 20˜40° C. higher than before, and the phenomenon of abnormal grain growth (AGG) would not happen, so that the powder after heat treatment can be sintered in an extremely wide sintering temperature range and the manufacturing condition is expanded.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0043] The present invention will be further described with the embodiments.
Embodiment 1
[0044] Raw material preparing process: Nd, Pr, Dy, Tb and Gd with 99.5% purity, industrial Fe—B, industrial pure Fe, Co with 99.9% purity and Cu, Mn, Al, Ag, Mo and C with 99.5% purity are prepared; counted in atomic percent, and prepared in R e T f A g J h G i D k components.
[0045] The contents of the elements are shown in TABLE 1:
[0000]
TABLE 1
proportioning of each element
R
T
A
J
G
D
Nd
Pr
Dy
Tb
Gd
Fe
Co
C
B
Cu
Mn
Al
Ag
Mo
7
3
1
1
1
remain-
1
0.05
7
0.2
0.2
0.2
0.1
1
der
[0046] Preparing 500 Kg raw material by weighing in accordance with TABLE 1.
[0047] Melting process: the 500 Kg raw material is put into an aluminum oxide made crucible, an intermediate frequency vacuum induction melting furnace is used to melt the raw material in 1 Pa vacuum below 1650° C.
[0048] Casting process: After the process of vacuum melting, Ar gas is filled to the melting furnace so that the Ar pressure would reach 80000 Pa, then the material is casted as a strip with an average thickness of 0.3 mm by strip casting method.
[0049] Hydrogen decrepitation process (coarse crushing process): the strip of 0.3 mm average thickness is put into a stainless steel container of a rotating hydrogen decrepitation furnace with an inner diameter of φ1200 mm, the container is then pumped to be vacuum and the vacuum level is below 10 Pa, then hydrogen of 99.999% purity is filled into the container, the hydrogen pressure would reach 0.12 MPa, the container rotates for 2 hours at a rotating rate of 1 rpm to absorb hydrogen, after that, the container is pumped for 2 hours at 600° C. to dehydrogenate, then the container rotates and gets cooled at a rotating rate of 30 rpm simultaneously, the cooled coarse powder is then taken out.
[0050] Fine crushing process: a jet milling device is used to finely crush the coarse powder to obtain a fine powder with an average particle size of 4.2 nm.
[0051] Fine powder heat treatment process: the fine powder is divided into 8 equal parts, each part is respectively put into a stainless steel container of a rotating hydrogen decrepitation furnace with an inner diameter of φ1200 mm, the container is then pumped to be vacuum and obtain a vacuum level of 10 −1 Pa with an oxygen content of 1˜1000 ppm, and a dew point of 0˜10° C., then the stainless steel container is put to an externally heating oven for heat treatment.
[0052] The heating temperature and heat treatment time of each part of fine powder are shown in TABLE 2, the stainless steel container rotates at a rotating rate of 10 rpm when heated.
[0053] After the heat treatment of the fine powder, the container is taken out of the externally heating oven, the container is then externally water cooled at a rotating rate of 20 rpm for 3 hours.
[0054] Compacting process under a magnetic field: no organic additive such as forming aid and lubricant is added into the fine powder after heat treatment, a transversed type magnetic field molder is used, the powder is compacted in once to form a cube with sides of 40 mm in an orientation field of 2.1 T and under a compacting pressure of 0.2 ton/cm 2 , then the once-forming cube is demagnetized in a 0.2 T magnetic field.
[0055] The once-forming compact (green compact) is sealed so as not to expose to air, the compact is secondary compacted by a secondary compact machine (isostatic pressing compacting machine) under a pressure of 1.0 ton/cm 2 .
[0056] Sintering process: each of the green compact is moved to the sintering furnace, firstly sintering in a vacuum of 10 −3 Pa and respectively maintained for 2 hours at 200° C. and for 2 hours at 600° C., then in Ar gas atmosphere of 0.01 MPa, sintering for 2 hours at 1080° C., after that filling Ar gas into the sintering furnace so that the Ar pressure would reach 0.1 MPa, then cooling it to room temperature.
[0057] Heat treatment process: the sintered magnet is heated for 1 hour at 600° C. in the atmosphere of high purity Ar gas, then cooling it to room temperature and taking it out.
[0058] Magnetic property evaluation process: the sintered magnet is tested by NIM-10000H type nondestructive testing system for BH large rare earth permanent magnet from China Jiliang University.
[0059] Oxygen content of sintered magnet evaluation process: the oxygen content of the sintered magnet is measured by EMGA-620W type oxygen and nitrogen analyzer from HORIBA company of Japan.
[0000]
TABLE 2
The magnetic property and oxygen content evaluation of the embodiments
and the comparing samples in different heating temperature and heating time.
Oxygen
content of
the
Heating
sintered
temperature
Heating
Br
SQ
(BH)max
magnet
No.
(° C.)
time (hr)
(kGs)
Hcj (k0e)
(%)
(MG0e)
(ppm)
0
Comparing
None heat treatment of
10.1
11.4
82
21.4
2580
sample
the fine powder
1
Comparing
80
30
10.2
11.6
82.3
22.8
1589
sample
2
Embodiment
100
24
12
35.1
98.2
31.2
562
3
Embodiment
300
6
12.3
35.4
99.1
35.3
375
4
Embodiment
500
4
12.3
36.7
99.1
35.2
369
5
Embodiment
700
1
12.3
37.8
99.2
35.2
383
6
Embodiment
1000
0.3
11.8
34.5
98.5
33.2
582
7
Comparing
1020
0.5
10.6
27.6
84.2
23.2
1587
sample
8
Comparing
1050
12
10.2
24.3
78.6
16.5
2598
sample
[0060] As can be seen from TABLE 2, with the heat treatment of the fine powder, a very thin oxidation film is formed on the surface of the overall powder evenly, so that the lubricity is well among the powder, and the orientation degree of the powder is improved, so that it can obtain higher values of Br and (BH)max; furthermore, the phenomenon of abnormal grain growth would not happen when sintering, so that it can obtain a finer organization, and the value of coercivity Hcj is increased drastically; in addition, by the heat treatment of the fine powder, the sharp portion on the surface of the powder is melted and becomes round, so the counter magnetic field coefficient at the partial portion is increased, it can also obtain a higher value of coercivity. Moreover, during the processes from compacting to sintering, the powder with even oxidation film on the surface is weakened in activity, so that during those processes, even the powder is contacted with the air, drastic oxidation would not happen; on the contrary, the fine powder without heat treatment has a strong activity and is easily oxidized, during the processes from compacting to sintering, even contacted with a little amount of air, drastic oxidation would happen, leading to a higher oxygen content of the sintered magnet.
[0061] It has to be noted that, if the heating temperature of the fine powder exceeds 1000° C., the oxidation film on the surface of the fine powder particle may be easily diffused into the inner of the particle, consequently it would be like no oxidation film, therefore the adhesion power between the powder gets stronger, in this case, the values of Br and (BH)max would be extremely adverse, the phenomenon of abnormal grain growth (AGG) would easily happen when sintering, and the value of coercivity Hcj would be reduced.
[0062] In the past, in the low oxygen content process, as the adhesive power among the magnet powder is strong, and the orientation degree of the magnet powder is not too high, so that it also has problems of low values of Br and (BH)max; moreover, as the surface activity among the magnet powder is strong, the grains are easily welded when sintering, therefore the phenomenon of abnormal grain growth happens, and the value of coercivity is reduced rapidly. The above mentioned problems are solved by adopting the proposal of the present invention.
Embodiment 2
[0063] Raw material preparing process: Nd, Y with 99.9% purity, industrial Fe—B, industrial pure Fe—P, industrial Fe—Cr, industrial pure Fe, Ni, si with 99.9% purity, and Sn, W with 99.5% purity are prepared.
[0064] Counted in atomic percent, and prepared in R e T f A g J h G i D k components.
[0065] The contents of the elements are shown in TABLE 3:
[0000]
TABLE 3
proportioning of each element
R
T
A
J
G
D
Nd
Y
Fe
Ni
B
P
Cr
Si
Sn
W
12.7
0.1
remainder
0.1
5.9
0.05
0.2
0.1
0.3
0.01
[0066] Preparing 500 Kg raw material by weighing in accordance with TABLE 3.
[0067] Melting process: the 500 Kg raw material is put into an aluminum oxide made crucible, an intermediate frequency vacuum induction melting furnace is used to melt the raw material in 10 −2 Pa vacuum below 1600° C.
[0068] Casting process: After the process of vacuum melting, Ar gas is filled to the melting furnace so that the Ar pressure would reach 50000 Pa after vacuum melting, then the material is casted as a strip with an average thickness of 2 mm on a water-cooling casting disk.
[0069] Hydrogen decrepitation process: the strip is put into the stainless steel container of a rotating hydrogen decrepitation furnace with an inner diameter of φ1200 mm, the container is then pumped to be vacuum and the vacuum level is below 10 Pa, then hydrogen of 99.999% purity is filled into the container, the hydrogen pressure would reach 0.12 MPa, the container rotates for 2 hours at a rotating rate of 1 rpm to absorb hydrogen, after that, the container is pumped for 2 hours at 600° C. to dehydrogenate, then the container rotates and gets cooled at a rotating rate of 30 rpm, the cooled coarse powder is then taken out.
[0070] Fine crushing process: a jet milling device is used to finely crush the coarse powder to obtain a fine powder with an average particle size of 6.8 nm, then the powder is divided into 6 equal parts.
[0071] Fine powder treatment process: 4 parts of the fine powder are respectively put into the stainless steel container of a rotating hydrogen decrepitation furnace with an inner diameter of φ1200 mm, the container is then pumped to be vacuum to obtain a vacuum level of 10 −2 Pa with an oxygen content of 0.5˜50 ppm, and a dew point of 10˜20° C., then the stainless steel container is put to an externally heating oven for heat treatment; the heating temperature is 600° C., the heating time is 2 hours, and the container is heated at a rotating rate of 1 rpm.
[0072] After the heat treatment of the fine powder, the container is taken out of the externally heating oven, the container is then externally water cooled at a rotating rate 20 rpm for 3 hours.
[0073] Compacting process under a magnetic field: no organic additive is added into the 4 parts of fine powder with the process of fine powder heat treatment and the rest 2 parts of fine powder without the process of fine powder heat treatment, and the transversed type magnetic field molder is respectively used for the two types of the fine powder; the two types of powder are respectively compacted in once to form a cube with sides of 40 mm in an orientation field of 2 T and under a compacting pressure of 0.20 ton/cm 2 , then the once-forming cube is demagnetized in a 0.2 T magnetic field. The once-forming compact (green compact) is sealed so as not to expose to air, then the compact is secondary compacted by a secondary compacting machine (isostatic pressing compacting machine) under a pressure of 1.2 ton/cm 2 .
[0074] Sintering process: each of the green compact is moved to the sintering furnace to sinter, firstly sintering in a vacuum of 10 −3 Pa and respectively maintained for 2 hours at 300° C. and for 2 hours at 500° C., then sintering for 6 hours at 1050° C., after that filling Ar gas into the sintering furnace so that the Ar pressure would reach 0.1 MPa, then cooling it to room temperature.
[0075] Heat treatment process: the sintered magnet is heated for 1 hour at 550° C. in the atmosphere of high purity Ar gas, then cooling it to room temperature and taking it out.
[0076] Machining process: the sintered magnet compacted by the 2 parts of fine powder without fine powder heat treatment is machined to be a magnet with 415 mm diameter and 5 mm thickness, the 5 mm direction (along the direction of thickness) is the orientation direction of the magnetic field; thereinto, one sintered magnet is served as no grain boundary diffusion treatment and is tested its magnetic property (comparing sample 1), the other magnet is treated by Method A in TABLE 4 for grain boundary diffusion treatment after washed and surface cleaning (comparing sample 2).
[0077] The 4 parts of sintered magnet compacted by fine powder with fine powder heat treatment is machined to be a magnet with φ15 mm and 5 mm thickness, the 5 mm direction (the direction along the thickness) is the orientation direction of the magnetic field; one magnet of which is served as no grain boundary diffusion treatment and is directly tested its magnetic property (comparing sample 3).
[0078] Grain boundary diffusion process: the other 3 parts of sintered magnet compacted by fine powder with heat treatment are respectively treated by Methods A, B, and C in TABLE 4 for grain boundary diffusion treatment after washed and surface cleaning.
[0000]
TABLE 4
grain boundary diffusion method
Grain boundary diffusion type
Detailed process
A
Dy oxide powder, Tb
Dy oxide and Tb fluoride are prepared in proportion of
fluoride powder coating
3:1 to make raw material to fully spray and coat on the
diffusion method
magnet, the coated magnet is then dried, then in high
purity of Ar gas atmosphere, the magnet is treated with
heat and diffusion treatment at 850° C. for 12 hours.
B
(Dy, Tb)—Ni—Co—Al serial
The Dy 30 Tb 30 Ni 5 Co 25 Al 10 alloy is finely crushed as fine
alloy fine powder coating
powder with an average grain particle size 15 μm to
diffusion method
fully spray and coat on the magnet, the coated magnet is
then dried, then in high purity of Ar gas atmosphere, the
magnet is treated with heat and diffusion treatment at
950° C. for 12 hours.
C
Dy metal vapor diffusion
In Ar gas atmosphere, the Dy metal plate, Mo screen
method
and magnet are put into a vacuum heating furnace for
vapor treatment at 1010° C. for 6 hours.
[0079] Magnetic property evaluation process: the sintered magnet is tested by NIM-10000H type nondestructive testing system for BH large rare earth permanent magnet from China Jiliang University.
[0080] Oxygen content of sintered magnet evaluation process: the oxygen content of the sintered magnet is measured by EMGA-620W type oxygen and nitrogen analyzer from HORIBA company of Japan.
[0081] The magnetic property and oxygen content evaluation of the embodiments and the comparing samples with the fine powder heat treatment and the grain boundary diffusion treatment are shown in TABLE 5.
[0000]
TABLE 5
The magnetic property and oxygen content evaluation of the
embodiments and the comparing samples
Oxygen
Heat
content of
treatment
the
of
Grain
sintered
the fine
boundary
Br
SQ
(BH)max
magnet
No.
powder
diffusion
(kGs)
Hcj (k0e)
(%)
(MG0e)
(ppm)
0
Comparing
no
no
13.1
6.5
76.5
23.1
2687
sample 1
1
Comparing
no
A
13.2
13.2
86.6
32.5
2785
sample 2
2
Comparing
yes
no
15.4
9.5
86.7
46.4
421
sample 3
3
Embodiment
yes
A
15.5
22.3
98.4
56.5
278
4
Embodiment
yes
B
15.6
22.4
99.2
56.8
276
5
Embodiment
yes
C
15.6
24.2
99.1
57.2
289
[0082] As can be seen from TABLE 5, the sintered magnet sintered by the fine powder with fine powder heat treatment has an obvious change in the existence state of the oxygen in the grain boundary, the diffusion rate of the elements Dy, Tb is accelerated and the diffusion efficiency is promoted, so that the grain boundary diffusion can be finished in a short time, the effect of the grain boundary diffusion is obvious and the coercivity is improved significantly.
Embodiment 3
[0083] Raw material preparing process: La, Ge, Nd, Tb, and Ho with 99.5% purity, industrial Fe—B, industrial pure Fe, Ru with 99.99% purity and P, Si, Cr, Ga, Sn, Zr with 99.5% purity are prepared; counted in atomic percent, and prepared in R e T f A g J h G i D k components.
[0084] The contents of the elements are shown as follows:
[0085] R component, La is 0.1, Ce is 0.1, Nd is 12, Tb is 0.2, and Ho is 0.2;
[0086] T component, Fe is the remainder, and Ru is 1;
[0087] A component, P is 0.05, and B is 7;
[0088] J component, Si is 0.2, and Cr is 0.2;
[0089] G component, Ga is 0.2, and Sn is 0.1; and
[0090] D component, Zr is 0.5.
[0091] Preparing 500 Kg raw material by weighing in accordance with above contents of elements.
[0092] Melting process: the 500 Kg raw material is put into an aluminum oxide made crucible, an intermediate frequency vacuum induction melting furnace is used to melt the raw material in 1 Pa vacuum below 1650° C.
[0093] Casting process: Ar gas is filled to the melting furnace so that the Ar pressure would reach 80000 Pa after vacuum melting, then the material is casted as a strip with an average thickness of 0.15 mm by strip casting method (SC).
[0094] Hydrogen decrepitation process: the strip is put into a stainless steel container of a rotating hydrogen decrepitation furnace with an inner diameter of φ1200 mm, the container is then pumped to be vacuum and the vacuum level is below 10 Pa, then hydrogen of 99.999% purity is filled into the container, the hydrogen pressure would reach 0.12 MPa, the container rotates for 2 hours at a rotating rate of 1 rpm to absorb hydrogen, after that, the container is pumped for 2 hours at 600° C. to dehydrogenate, then the container rotates and gets cooled at a rotating rate of 30 rpm simultaneously, the cooled coarse powder is then taken out.
[0095] Fine crushing process: a jet milling device is used to finely crush the coarse powder to obtain a fine powder with an average particle size of 5 nm.
[0096] Fine powder heat treatment process: the fine powder is divided into 6 equal parts, each part is respectively put into the stainless steel container of a rotating hydrogen decrepitation furnace with an inner diameter of φ1200 mm, the container is then pumped to be vacuum and the vacuum level is below 10 Pa, then Ar gas with 99.9999% purity is filled into the container to obtain a pressure of 500 Pa, the oxygen content is controlled as 1800˜2000 ppm, and the dew point is −60˜50° C., then the stainless steel container is put into an externally heating oven for heat treatment, the stainless steel container rotates at a rotating rate of 5 rpm when heated.
[0097] The heating temperature and heat treatment time of each part of fine powder are shown in TABLE 6.
[0098] After the process of fine powder heat treatment, the container is taken out of the externally heating oven, the container is then externally water cooled at a rotating rate of 20 rpm for 3 hours.
[0099] Compacting process under a magnetic field: no organic additive is added into the fine powder with the process of fine powder heat treatment, a transversed type magnetic field molder is directly used, the powder is compacted in once to form a cube with sides of 40 mm in an orientation field of 1.8 T and under a compacting pressure of 1.2 ton/cm 2 , then the once-forming cube is demagnetized in a 0.2 T magnetic field. The once-forming compact (green compact) is sealed so as not to expose to air, and then the green compact is delivered to a sintering furnace.
[0100] Sintering process: each of the green compact is moved to the sintering furnace to sinter, in a vacuum of 10 −3 Pa and respectively maintained for 2 hours at 200° C. and for 2 hours at 600° C., then in Ar gas atmosphere of 0.02 MPa, sintering for 2 hours at 1080° C., after that filling Ar gas into the sintering furnace so that the Ar pressure would reach 0.1 MPa, then cooling it to room temperature.
[0101] Heat treatment process: the sintered magnet is heated for 1 hour at 600° C. in the atmosphere of high purity Ar gas, then cooling it to room temperature and taking it out.
[0102] Magnetic property evaluation process: the sintered magnet is tested by NIM-10000H type nondestructive testing system for BH large rare earth permanent magnet from China Jiliang University, and an average value is calculated.
[0103] Oxygen content of sintered magnet evaluation process: the oxygen content of the sintered magnet is measured by EMGA-620W type oxygen and nitrogen analyzer from HORIBA company of Japan.
[0104] The magnetic property and oxygen content evaluation of the embodiments and the comparing samples in same heating temperature and different heating time with the process of fine powder heat treatment are shown in TABLE 6.
[0000]
TABLE 6
The magnetic property and oxygen content evaluation of the
embodiments and the comparing samples
Oxygen
content of
Heating
the sintered
temperature
Heating
Br
Hcj
(BH)max
magnet
No.
(° C.)
time (hr)
(kGs)
(k0e)
SQ (%)
(MG0e)
(ppm)
0
Comparing
700
0.05
13.8
9.8
81.2
45.3
2980
sample
1
Embodiment
700
0.1
15.1
13.3
97.8
54.3
565
2
Embodiment
700
1
15.2
13.6
98.2
54.8
354
3
Embodiment
700
4
15.3
14.2
99.1
55.2
375
4
Embodiment
700
12
15.4
14.1
99.2
56
395
5
Embodiment
700
24
15.3
13.5
99.1
55.3
573
6
Comparing
700
48
14.9
11.7
94.8
52.7
980
sample
[0105] As can be seen from TABLE 6, at a temperature of 700° C., if the time of the fine powder heat treatment is less than 0.1 hour, the effect of the heat treatment of the fine powder is not sufficient, resulting in that it would be like no oxidation film, the adhesive power among the powder gets stronger, in this case, the values of Br, (BH)max would be extremely adverse, the phenomenon of abnormal grain growth would easily happen when sintering, and the value of coercivity Hcj would be reduced.
[0106] At the same time, at a temperature of 700° C., when the time of the fine powder heat treatment exceeds 24 hours, the oxidation film on the surface of the fine powder particle would be absorbed and diffused into the particle, it would be like no oxidation film, consequently the oxygen content increases, in this case, the values of Br and (BH)max would be reduced, the phenomenon of abnormal grain growth would easily happen when sintering, and the value of coercivity Hcj would be reduced.
Embodiment 4
[0107] Raw material preparing process: Lu, Er, Nd, Tm, and Y with 99.5% purity, industrial Fe—B, industrial pure Fe, Co with 99.99% purity and C, Cu, Mn, Ga, Bi, Ti with 99.5% purity are prepared, counted in atomic percent, and prepared in R e T f A g J h G i D k components.
[0108] The contents of the elements are shown as follows:
[0109] R component, Lu is 0.2, Er is 0.2, Nd is 13.5, Tm is 0.1, and Y is 0.1;
[0110] T component, Fe is the remainder, and Co is 1;
[0111] A component, C is 0.05, and B is 7;
[0112] J component, Cu is 0.2, and Mn is 0.2;
[0113] G component, Ga is 0.2, and Bi is 0.1; and
[0114] D component, Ti is 1.
[0115] Preparing 500 Kg raw material by weighing in accordance with above contents of elements.
[0116] Melting process: the 500 Kg raw material is put into an aluminum oxide made crucible, an intermediate frequency vacuum induction melting furnace is used to melt the raw material in 0.1 Pa vacuum below 1550° C.
[0117] Casting process: Ar gas is filled to the melting furnace so that the Ar pressure would reach 40000 Pa after the process of vacuum melting, then the material is casted as a strip with an average thickness of 0.6 mm by strip casting method (SC).
[0118] Hydrogen decrepitation process: the strip is put into a stainless steel container of a rotating hydrogen decrepitation furnace with an inner diameter of φ1200 mm, the container is then pumped to be vacuum and the vacuum level is below 10 Pa, then hydrogen of 99.999% purity is filled into the container, the hydrogen pressure would reach 0.12 MPa, the container rotates for 6 hours at a rotating rate of 2 rpm to absorb hydrogen, after that, the container is pumped for 3 hours at 600° C. to dehydrogenate, then the container rotates and gets cooled at a rotating rate of 10 rpm simultaneously, the cooled coarse powder is then taken out.
[0119] Fine crushing process: a jet milling device is used to finely crush the coarse powder to obtain a fine powder with an average particle size of 2 nm.
[0120] The fine powder after jet milling is divided into 2 equal parts.
[0121] Fine powder heat treatment process: one part of the fine powder is put into the stainless steel container with an inner diameter of φ1200 mm, the container is then pumped to be vacuum below 1 Pa, then Ar gas with 99.9999% purity is filled into the container and the pressure reaches 1000 Pa, the oxygen content is controlled as 800˜1000 ppm, and the dew point is −50˜−40° C., then the stainless steel container is put into an externally heating oven to heat, the heating temperature is 600° C., the heating time is 2 hours. The stainless steel container rotates at a rotating rate of 5 rpm when heated.
[0122] After the heat treatment, the container is taken out of the externally heating oven, the container is then externally water cooled at a rotating rate of 5 rpm for 5 hours.
[0123] Compacting process under a magnetic field: no organic additive is added into the fine powder with the process of fine powder heat treatment, a transversed type magnetic field molder is directly used, the powder is compacted in once to form a cube with sides of 40 mm in an orientation field of 1.8 T and under a compacting pressure of 1.2 ton/cm 2 , then the once-forming cube is demagnetized in a 0.2 T magnetic field. The once-forming compact (green compact) is sealed so as not to expose to air, and then the green compact is delivered to a sintering furnace.
[0124] Sintering process: each of the green compact is moved to the sintering furnace to sinter, in a vacuum of 10 −3 Pa and respectively maintained for 2 hours at 200° C. and for 2 hours at 600° C., then in Ar gas atmosphere of 0.02 MPa, sintering at 925° C.′ 1150° C., after that filling Ar gas into the sintering furnace so that the Ar pressure would reach 0.1 MPa, then cooling it to room temperature.
[0125] Heat treatment process: the sintered magnet is heated for 1 hour at 600° C. in the atmosphere of high purity Ar gas, then cooling it to room temperature and taking it out.
[0126] The other part of the fine powder is not treated with the process of fine powder heat treatment, and served as a comparing sample, which is sequentially treated with the above mentioned compacting process, sintering process and heating process except the process of fine powder heat treatment under the same treatment condition.
[0127] Magnetic property evaluation process: the sintered magnet is tested by NIM-10000H type nondestructive testing system for BH large rare earth permanent magnet from China Jiliang University, and an average value is calculated.
[0128] Oxygen content of sintered magnet evaluation process: the oxygen content of the sintered magnet is measured by EMGA-620W type oxygen and nitrogen analyzer from HORIBA company of Japan.
[0129] The magnetic property and oxygen content evaluation of the embodiments and the comparing samples with or without the process of fine powder heat treatment in different sintering temperature are shown in TABLE 7. No. 1˜11 are the sintered magnet without the process of fine powder heat treatment, No. 12˜22 are the sintered magnet with the process of fine powder heat treatment.
[0000]
TABLE 7
The magnetic property and oxygen content evaluation of the embodiments
and the comparing samples
Oxygen
Fine
content of
powder
Sintering
the sintered
heat
temperature
Density
Br
Hcj
SQ
(BH)max
magnet
No.
treatment
(° C.)
(g/cc)
(kGs)
(k0e)
(%)
(MG0e)
(ppm)
1
Comparing
no
925
6.98
12.8
12.8
76.5
25.6
2840
sample
2
Comparing
no
950
7.21
13.4
12.3
93.2
39.8
2940
sample
3
Comparing
no
975
7.32
13.6
12.1
95.6
43.2
2850
sample
4
Comparing
no
1000
7.38
13.9
11.9
96.3
44.5
2840
sample
5
Comparing
no
1025
7.53
14.1
11.5
96.4
44.7
2840
sample
6
Comparing
no
1050
7.54
14.2
11.2
96.3
45.9
2870
sample
7
Comparing
no
1075
7.56
14.2
10.9
96.4
47.1
2780
sample
8
Comparing
no
1100
7.57
14.3
10.2
96.2
47.2
2790
sample
9
Comparing
no
1125
7.55
14.1
9.2
92.3
46.7
2830
sample
10
Comparing
no
1140
7.51
13.8
8.5
87.4
39.8
2840
sample
11
Comparing
no
1150
7.48
13.6
7.6
82.3
37.6
2980
sample
12
Comparing
yes
925
7.23
13.8
9.8
81.2
45.3
982
sample
13
Embodiment
yes
950
7.47
14.4
13.8
97.8
50.1
354
14
Embodiment
yes
975
7.49
14.4
13.6
98.2
50.2
341
15
Embodiment
yes
1000
7.51
14.5
13.5
98.3
50.4
340
16
Embodiment
yes
1025
7.54
14.5
13.4
98.4
50.4
342
17
Embodiment
yes
1050
7.56
14.6
13.4
98.5
50.6
345
18
Embodiment
yes
1075
7.59
14.6
13.4
98.6
50.8
343
19
Embodiment
yes
1100
7.61
14.7
13.4
98.9
50.8
346
20
Embodiment
yes
1125
7.64
14.7
13.4
99
51.1
347
21
Embodiment
yes
1140
7.65
14.8
13.4
99.1
51.2
349
22
Comparing
yes
1150
7.32
13.4
12.2
76.5
38.4
768
sample
[0130] As can be seen from TABLE 7, with heat treatment of the fine powder, it can expand the sintering temperature range to obtain a magnet with an excellent property. The reason is that, it avoids oxidation, so that the compacts can be sintered at a low sintering temperature, on the other hand, when sintering at a high temperature, the phenomenon of abnormal grain growth would not happen, thus it can obtain a magnet with an excellent property whether at the low sintering temperature or at the high sintering temperature.
Embodiment 5
[0131] Raw material preparing process: Lu, Er, Nd, Tm, and Y with 99.5% purity, industrial Fe—B, industrial pure Fe, Co with 99.99% purity and C, Cu, Mn, Ga, Bi, Ti with 99.5% purity are prepared, counted in atomic percent, and prepared in R e T f A g J h G i D k components.
[0132] The contents of the elements are shown as follows:
[0133] R component, Lu is 0.2, Nd is 13.5, Tm is 0.1, and Y is 0.1;
[0134] T component, Fe is the remainder, and Co is 1;
[0135] A component, C is 0.05, and B is 7;
[0136] J component, Cu is 0.2, and Mn is 0.2;
[0137] G component, Ga is 0.2, and Bi is 0.1; and
[0138] D component, Ti is 1.
[0139] Preparing 500 Kg raw material by weighing in accordance with above contents of elements.
[0140] Melting process: the 500 Kg raw material is put into an aluminum oxide made crucible, an intermediate frequency vacuum induction melting furnace is used to melt the raw material in 0.1 Pa vacuum below 1550° C.
[0141] Casting process: After the process of vacuum melting, Ar gas is filled to the melting furnace so that the Ar pressure would reach 40000 Pa after vacuum melting, then the material is casted as a strip with an average thickness of 0.6 mm by strip casting method (SC).
[0142] Hydrogen decrepitation process: the alloy is put into the stainless steel container of a rotating hydrogen decrepitation furnace with an inner diameter of φ1200 mm, the container is then pumped to be vacuum and the vacuum level is below 10 Pa, then hydrogen of 99.999% purity is filled into the container, the hydrogen pressure would reach 0.12 MPa, the container rotates for 6 hours at a rotating rate of 2 rpm to absorb hydrogen, after that, the container is pumped for 3 hours at 600° C. to dehydrogenate, then the container rotates and gets cooled at a rotating rate of 10 rpm simultaneously, the cooled coarse powder is then taken out.
[0143] Fine crushing process: a jet milling device is used to finely crush the coarse powder to obtain a fine powder with an average particle size of 2 nm.
[0144] Fine powder heat treatment process: the fine powder is put into a stainless steel container with an inner diameter of φ1200 mm, the container is then pumped to be vacuum obtain a pressure of below 1 Pa, then Ar gas with 99.9999% purity is filled into the container to obtain a pressure of 900 Pa, the oxygen content is controlled as 800˜1000 ppm, and the dew point −50˜−40° C., then the stainless steel container is put to an externally heating oven for heat treatment, the heating temperature is 600° C., the heating time is 2 hours. The stainless steel container rotates at a rotating rate of 5 rpm when heated.
[0145] After the heat treatment of the fine powder, the container is taken out of the externally heating oven, the container is then externally water cooled at a rotating rate of 5 rpm for 5 hours.
[0146] Compacting under a magnetic field process: no organic additive is added into the fine powder with the process of fine powder heat treatment, a transversed type magnetic field molder is directly used, the powder is compacted in once to form a cube with sides of 40 mm in an orientation field of 1.8 T and under a compacting pressure of 1.2 ton/cm 2 , then the once-forming cube is demagnetized in a 0.2 T magnetic field. The once-forming compact (green compact) is sealed so as not to expose to air, and then the green compact is delivered to a sintering furnace.
[0147] Sintering process: each of the green compact is moved to the sintering furnace to sinter, firstly sintering in a vacuum of 10 −3 Pa and respectively maintained for 2 hours at 200° C. and for 2 hours at 600° C., then in Ar gas atmosphere of 0.02 MPa, sintering at 980° C., after that filling Ar gas into the sintering furnace so that the Ar pressure would reach 0.1 MPa, then cooling it to room temperature.
[0148] Heat treatment process: the sintered magnet is heated for 1 hour at 600° C. in the atmosphere of high purity Ar gas, then cooling it to room temperature and taking it out.
[0149] Machining and RH diffusion processes: After the heat treatment process, the sintered magnet is machined as a magnet with a diameter of 15 mm and a thickness of 5 mm, the 5 mm direction (along the direction of thickness) is the orientation direction of the magnetic field. The machined magnet is washed and surface cleaned. A raw material with the Dy oxide and Tb fluoride is prepared in proportion of 3:1, fully sprayed and coated on the magnet, then the coated magnet is dried. In high purity of Ar gas atmosphere, the heat and diffusion process is performed at 680˜1050° C. for 12 hours.
[0150] Magnetic property evaluation process: the sintered magnet is tested by NIM-10000H type nondestructive testing system for BH large rare earth permanent magnet from China Jiliang University, and an average value is calculated.
[0151] Oxygen content of sintered magnet evaluation process: the oxygen content of the sintered magnet is measured by EMGA-620W type oxygen and nitrogen analyzer from HORIBA company of Japan.
[0152] The magnetic property and oxygen content evaluation of the embodiments and the comparing samples at different sintering temperatures after heat treatment are shown in TABLE 8.
[0000]
TABLE 8
The magnetic property and oxygen content evaluation of the
embodiments and the comparing samples
Oxygen
content of
Diffusion
Diffusion
the sintered
temperature
time
Density
Br
Hcj
SQ
(BH)max
magnet
No.
(° C.)
(hr)
(g/cc)
(kGs)
(k0e)
(%)
(MG0e)
(ppm)
1
Comparing
680
8
7.49
13.5
11.3
81.1
43.2
972
sample
2
Embodiment
700
8
7.50
14.0
19.8
98.2
46.6
954
3
Embodiment
750
8
7.52
14.2
20.8
98.6
47.2
941
4
Embodiment
800
6
7.52
14.2
21.3
98.3
46.8
940
5
Embodiment
850
6
7.51
14.4
22.1
99.4
47.6
942
6
Embodiment
900
4
7.51
14.2
22.5
99.5
46.6
945
7
Embodiment
950
4
7.52
14.2
23.0
99.6
46.2
943
8
Embodiment
1000
2
7.51
14.2
24.4
99.7
46.2
946
9
Embodiment
1020
2
7.52
14.2
24.4
99.3
46.1
947
10
Comparing
1040
2
7.50
14.2
23.1
99.1
46.1
949
sample
11
Comparing
1050
2
7.49
13.4
18.7
79.8
42.8
968
sample
[0153] As can be seen from TABLE 8, as an oxidation layer is formed on the surface of the overall powder, the existence status of the oxygen at the grain boundary of the magnet is changed obviously, the diffusion rate of the heavy rare earth element is accelerated and the diffusion efficient is promoted; therefore it is capable of subverting the common sense and accomplishing the grain boundary diffusion in a short time.
[0154] With the heat treatment of the fine powder, the property of the powder is changed drastically, the magnet is machined with a desired size after being sintered, and then treated with grain boundary diffusion; in the present invention, the grain boundary diffusion experiments are conducted at temperature of 680° C.˜1050° C., the temperature of 700° C.˜1020° C. is set as the grain boundary diffusion temperature and the temperature range of 1000° C.˜1020° C. is the most appropriate for the Dy grain boundary diffusion temperature.
[0155] Common sense says that it generally takes more than 10 hours for the grain boundary diffusion of a magnet with a thickness of 5 mm in a temperature range of 800° C.˜950° C. so as to obtain an improving effect of coercivity; raising the diffusion temperature is benefit to shorten the diffusion time, but it may leads to the problems of deformation, surface molten and AGG, and the diffusion is simultaneously performed in the grain boundary phase and the main phase, resulting in losing of magnet property. In contrast, the diffusion to the magnet of the present invention is performed in a temperature range of 1000° C.˜1200° C. and only needs 2 hours, which is capable of obtaining an improving coercivity effect and shortening the production cycle without arising the above mentioned problems.
[0156] Although the present invention has been described with reference to the preferred embodiments thereof for carrying out the patent for invention, it is apparent to those skilled in the art that a variety of modifications and changes may be made without departing from the scope of the patent for invention which is intended to be defined by the appended claims.
|
A manufacturing method of rare earth magnet based on heat treatment of fine powder includes the following: an alloy for the rare earth magnet is firstly coarsely crushed and then finely crushed by jet milling to obtain a fine powder; the fine powder is heated in vacuum or in inert gas atmosphere at a temperature of 100° C.˜1000° C. for 6 minutes to 24 hours; then the fine powder is compacted under a magnet field and is sintered in vacuum or in inert gas atmosphere at a temperature of 950° C.˜1140° C. to obtain a sintered magnet; and machining the sintered magnet to obtain a magnet; then the magnet performs a RH grain boundary diffusion at a temperature of 700° C.˜1020° C. An oxidation film forms on the surface of all of the powder.
| 1
|
This application claims the benefit of U.S. Provisional Application No. 60/874,701 filed Dec. 14, 2006, which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to the field of computer software, particularly online dating and social networking sites.
BACKGROUND OF THE INVENTION
The birth of the internet has revolutionized all manner of human communications. One form of human interaction that has adapted successfully to the internet is dating. Numerous websites have sprung up to support the interest in online dating services. Relationships are frequently forged in online chats and on message boards. Meeting potential mates over the internet offers the advantage of convenience and selection. Yet many of the problems that make it difficult to meet a romantic partner in traditional settings remain in online dating services.
One major obstacle to identifying potential romantic partners is fear of rejection. In a traditional setting or in an online dating service, one person has to make the first move. That person is opening themselves up to rejection by the party to whom advances are made. On an introduced a new “wink” option on its website. The “wink” allows members to indicate interest in another member without sending a personal message. Because interaction between the parties is limited, rejection is less of an issue. Nevertheless, this innovation does not solve the problem. “Wink”ing is still a unilateral advance and cannot determine a mutual interest.
Other websites have been created in an attempt to solve this problem. Sites such as secretadmirer.com, ecrush.com, and crushdate.com offer a service whereby members can determine whether their love interests share an attraction for them. After signing up, the member inputs the email addresses of his romantic interests. These people receive emails from the site informing them that someone is interested in them and asking them to become site members themselves. When they sign up, the new members enter the email addresses of their romantic interests. Whenever two people list each other as romantic interests, the site sends an email to both parties letting them know of the mutual attraction.
These websites do not effectively deal with the problem of shyness and fear of rejection. Users must take affirmative action and sign up at the site and the people they email must do so as well. More than likely the people who receive emails will believe they are spam and simply delete them. The member who caused the emails to be sent will never know whether those people are not interested in him or whether they simply deleted the email. Furthermore, it requires a person to know the email address of the person they are interested in. The method is also unlikely to result in matches between people with moderate interest in each other. People will not go to the effort of finding and entering the email address of everyone they are even somewhat attracted to. At most, they will enter the addresses of those they have a very strong interest in.
Another attempt at solving this problem can be found in Sutcliffe et al (U.S. Pat. No. 6,249,282). In Sutcliffe, a user enters a number of characteristic and criteria data describing his or herself and the kind of people he or she is interested in dating, respectively, into a common database. The Sutcliffe program then searches through the database to find users whose characteristic data satisfy the user's criteria data and whose criteria data is satisfied by the user's characteristic data. When it finds a match, the program notifies the user and provides contact information for the matches.
A similar method is used with a paging device in Shapira (U.S. Pat. No. 5,086,394). In Shapira, personal data such as traits and interests are entered into a device at a central location. The device searches for matching entries satisfying geographic and time constraints and pages users when a match is found. Fraccaroli (U.S. Pat. No. 6,549,768) does essentially the same thing but for cell phone users.
Sutcliffe, Shapiro, and Fraccaroli are imperfect solutions. They really only automate to some extent the process of finding potential romantic partners who are compatible. One user still must approach the other, and may still be rejected. Any set of data input is insufficient to encompass the many poorly understood factors that go into a mutual attraction or lack thereof. Additionally, the members are still strangers and cannot rely on the information provided by the other party. Many shy people will still be unwilling to join such a site or service.
Another attempt at resolving this difficulty is Sudai et al (U.S. Pat. No. 5,950,200). The Sudai method is much like that of the secretadmirer.com type of websites. Users input the identities of persons who they are attracted to or who share mutual interests. The inputs are stored in a database and searched repeatedly for matches, that is, for two people who feel the same way about each other. When a match is found, both users will be notified unless both agree that one of the parties should initiate (they have input this preference previously), in which case that party is informed before the other. This system suffers from the major flaw that both users must be members of this service. Like the secretadmirer.com websites, it will also result in few matches between people with only moderate attraction for one another because it requires each user to manually enter the names of people they are interested in.
Another obstacle that online dating sites do not resolve is the limited amount of information available about a potential date. Because the members are generally strangers, they have no way to verify the truthfulness of the other party's statements about themselves. This is an enormous problem in online dating. Many members are married but pass themselves off as single or portray themselves in a much more desirable light than is warranted. When the members meet in real life, they may be very disappointed by what they see, or may not learn of the other party's deception until well into the relationship, leading to heartbreak and pain. Members may even be subjected to physical violence when they meet for the first time.
One way to deal with this obstacle is to meet people that you already know or who know people who you also know. You then have a basis for determining the truthfulness of those peoples' representations of themselves. One efficient way of finding and communicating with people who share contacts with you is through a social networking site such as Friendster (Friendster.com, U.S. Pat. Nos. 7,069,308 and 7,117,254 B2). These sites allow you to know and view information about the friends and other contacts of your friends and contacts.
The sites thus provide users with an efficient means of identifying people they may have an interest in and whose information they can verify. However, no system exists for the full exploitation of the social network phenomenon for facilitating the meeting of people with a mutual interest. These sites do not have a process by which members can indicate an interest in other members and be automatically contacted when the interest is mutual.
Lists of contacts are also often stored in “buddy lists” (See U.S. Pat. No. 6,366,962) in online messaging software or in cell phones. Although Fraccaroli uses cell phones to notify users of matches, it does not take advantage of the contact lists in users' cell phones.
Needs exist for improved methods of facilitating contact between mutually interested parties.
SUMMARY OF THE INVENTION
The present invention is software that enables users of communication technologies such as cell phones, instant messaging, and social networking engines to date romantically people on their contact lists without the risk of rejection.
The invention will preferably be integrated (or done via a separate website with “friends” imported into an account) with a social networking website such as Friendster, MySpace, or Facebook, an instant messaging software such as AOL Instant Messenger or MSN Messenger, and/or a cell phone. If a separate website is used, alone or in combination with the integrated software, that website can collect and compile a user's contacts from each of these technologies, allowing the user to set ratings and software options and preferences from a central location. The users will rate their friends, buddies, or contacts on a scale of 1-10, or not interested, possibly interested, or very interested or some other such rating scheme. The ratings will be blind and neither user will expressly know the ratings their friends give them.
Once each user rates a counterpart a certain level, say “interested” or 6+ then they will both get notified. In a preferred embodiment of the invention, the notification is effected by an email stating that there may be a match with that friend. The notification may also take the form of an instant message, cell phone text message, or other similar communication, and may be effected by a different means for each party. Ads may be sold in the notification suggesting possible date locations or events to go to. The notification also will provide context-specific relationship advice. This advice may vary depending on the relative ratings of each party for one another, and could include suggestions of how best to contact and establish a baseline relationship with the other user.
In another embodiment, users have the ability to set a preference for one party to initiate. If both parties agree, only the initiating party will be contacted when a match occurs. The other party will be notified some time later.
In an alternative embodiment, the invention, at the user's option, may suggest other users the first user might be interested in who the first user does not know based on comparison of the first user's ratings with other users'. In another embodiment, users may “matchmake,” suggesting potential matches to other users they know.
The present invention may also be used outside of a dating context, for example in forming business or any other type of relationships. The rating system is simply modified to reflect the changed type of interest.
In a new method of facilitating contact between mutually interested entities, a graphical interface is provided for a user to rate its level of interest in one or more respects in at least one other user from a pre-existing list of contacts, the user's ratings are not displayed to other users, and a pair of users is notified when each user's rating for the other has exceeded a threshold level. The graphical interface provided may be a modification of an existing graphical interface of a social networking site, instant messaging software, cell phone, or PDA. The existing graphical interface may be an existing graphical interface of two or more social networking sites, instant messaging software, or cell phones, in which case lists of contacts from each are combined so that a user can rate contacts from at least two of the two or more social networking sites, instant messaging software, cell phones, or PDAs from a single graphical interface. User settings or preferences may be set and adjusted for all the modified graphical interfaces from a central location. User settings or preferences may be set and adjusted for all the modified graphical interfaces from any one of the modified graphical interfaces.
In one embodiment, the pre-existing list of contacts is from a social networking site, instant messaging software, cell phone, or PDA, and the graphical interface is provided on a separate website. The pair of users further may be notified by sending an email, instant message, or cell phone text message. A graphical interface may be provided to allow the user to set the way in which it is notified. When the pair of users is notified, the pair of users may be sent suggestions for date or meeting locations, events to go to, general relationship or dating advice, or context-specific relationship advice. The suggestions or advice may include advertisements. The context-specific advice may vary depending on the relative ratings of each of the pair of users for the other. The context-specific advice may include suggestions of how to best contact and establish a baseline relationship with the other of the pair of users.
A graphical interface may be provided for users to set a preference for one party to initiate and the notification of the pair of users may be modified based on the preference of the pair of users. The notification may be modified by notifying one user of the pair before the other when both prefer one party to initiate. At least one user of the pair may be notified of the preference for one party to initiate of the other.
Other users that a first user may be interested in may be suggested to a first user based on a comparison of the first user's ratings with other users'. The other users suggested may not be on the first user's pre-existing list of contacts. The other users suggested may be users rated highly by users other than the first user who rate the users on the first user's pre-existing list of contacts similarly to the first user. The suggesting may be done only when the user has opted to receive such suggestions.
A graphical interface may be provided to allow the user to match-make by suggesting potential matches to other users they know. The user may be allowed to choose not to receive suggested potential matches. The user may be allowed to choose whether to receive suggested potential matches depending on characteristics of the suggested potential match. One member of a suggested potential match may be notified if the other party has opted not to receive the suggested potential match. An option may be provided for the other party to allow the notifying one party of a suggested potential match to include informing the one party of the reason the other party has opted not to receive the suggested potential match.
In one embodiment, one of the one or more respects is a non-romantic respect. The graphical interface for a user to rate its level of interest in one or more respects in at least one other user may be provided in part by providing different access points and contact lists for the user to rate its level of interest in romantic and non-romantic respects. A single access point and contact list may be used for rating interest in romantic and non-romantic respects.
A graphical interface may be provided that allows a user to import contacts from an instant messaging software, social networking site, PDA, or cell phone, and a comprehensive list of contacts for the user to rate may be displayed.
When the graphical interface provided is a modification of an existing graphical interface of a social networking site, instant messaging software, cell phone, or PDA, a graphical interface may be provided that allows the user to invite contacts who are not yet users of the social networking site, instant messaging software, cell phone, or PDA with the modified graphical interface to join the social networking site, instant messaging software, cell phone, or PDA with the modified graphical interface. Rating information may be stored on a social networking site or in an instant messaging software or instant messaging software server. If the graphical interface provided is a modification of an existing graphical interface of a cell phone or PDA, the rating information may be stored on an online server.
As part of the notification of a pair of users when each user's rating for the other has exceeded a threshold level, each contact the user has rated above the threshold level may be checked to see if that contact has also rated the user above that threshold level whenever a user rates a new contact or changes an existing rating. To notify the pair of users, a single notification may be sent as soon as the pair's ratings exceed the threshold level, and another notification may not be sent unless the ratings change such that one of the pair's ratings does not exceed the threshold level, and subsequently the pair's ratings change again such that each rating exceeds the threshold level. An indicator may be provided to indicate for the user each contact on a pre-existing list of contacts for which that contact's rating of the user and the user's rating of that contact each exceed the threshold level.
A graphical interface may be provided that allows the user to set a number of preferences regarding how contact lists and ratings are displayed and accessed. In the embodiment where the existing graphical interface may be an existing graphical interface of two or more social networking sites, instant messaging software, or cell phones, a single graphical interface outside of the social networking sites, instant messaging software, cell phones, or PDAs with modified graphical interfaces may be provided that the user can use to rate contacts from at least two of the two or more social networking sites, instant messaging software, cell phones, or PDAs. The single graphical interface outside of the social networking sites, instant messaging software, cell phones, or PDAs with modified graphical interfaces may be a downloadable program or website. In that case, a central database of contact, rating, and preference information may be maintained with the downloadable program or website.
The graphical interface may be provided, the user's ratings not displayed to other users, and a pair of users notified using an existing website and software infrastructure, making additional storage or servers or maintenance of a separate website are not necessary. A graphical interface may be provided allowing the threshold level to be modified by the user. The threshold level may be allowed to be modified upwards but not downwards. A graphical interface may be provided allowing a desired threshold level to be set by the user and setting the threshold level to the highest desired threshold level of the pair of users.
An option may be provided to the user to receive relationship advice when the user rates another user highly but the other user does not rate the user above the threshold level, when the user rates another user more highly than the other user rates the user and the other user does rate the user above the threshold level, or whenever a pair of users including the user is notified. The user may be informed when another user who the user has rated does not have a rating for the user. An option may be provided to the user to allow another user to be informed when the user does not have a rating for the other user, and otherwise the other user is not informed.
The pre-existing list of contacts may be read, the list displayed, whether a new contact was added to the contact list is checked, if so a graphical notice provided for the user to rate the new contact, the list sorted according to rating, the sorted list displayed, the list scanned for ratings exceeding the threshold level, and whether contacts rated above the threshold level have rated the user above the threshold level is checked.
When the invention is integrated into a networking site, instant messaging software, or cell phone or PDA, the method makes use of the existing software of the networking site, instant messaging software, or cell phone or PDA. The method is implemented by programs using the existing software infrastructure, thus minimizing the programming expertise required for implementation and making the integration a relatively simple task. For example, Facebook has a public software platform for application development. The Appendix contains the source code for a simple example implementation of the method as a Facebook application making use of that software.
In any integration, implementation of the method typically requires new graphics for allowing the user to rate and view ratings for its contacts and procedures for storing and checking the rating information. Procedures for sending notifications and storing contact lists are typically existing features of whatever the method is being integrated into and can be easily adapted to the purpose of this method.
These and further and other objects and features of the invention are apparent in the disclosure, which includes the above and ongoing written specification, with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing the operation of one embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a diagram showing the operation of one embodiment of the invention. A user first initiates the program 1 and is prompted to enter his login information 3 . The program automatically reads the user's friends/contact list(s) 5 and displays it 7 . The program then checks to see if any new friends have been added to the list since the last time the program was run 9 . If no friends have been added 10 , the user can check and update the list for status or ranking changes 11 . The program offers an option 13 to instant message, text message, or email other contacts not subscribed to a social networking group or to this program to join before the user terminates the program 15 .
If a friend/contact has been added 16 , the user can then rank or classify the new friends 17 . The contact list is then sorted according to user preference 19 and the modified list is now displayed 21 . The list is then scanned for mutual interest above a specified level 23 . If no mutual interest is found 25 , an email is sent to the more interested party giving advice on how to entice less interested parties to date 27 . If a mutual interest is found 29 , the program sends a notification of the match to the users 31 . The user can then check and update the list for status or ranking changes 11 and the program offers an option 13 to instant message, text message, or email other contacts not subscribed to a social networking group or to this program to join before the user terminates the program 15 .
In a preferred embodiment, the present invention is a program integrated into one or more social networking sites, instant messaging software, or cell phone/PDA software. Because of this, the user does not have to download or sign up for anything. Once the integration is complete and initiated every user of the site or software will immediately have the option of using the present invention.
When a user loads or logs into the site or software, they will find the display has changed slightly. Next to the name of each contact in their “friends list” or “buddy list” will be an icon the user can click on in order to rate or characterize that contact by the user's level of interest in that contact as a romantic partner.
Because social networking sites, instant messaging software, and cell phones are so popular and because the program will be displayed prominently, high levels of participation are expected. This aspect is critical. In order for any matching system based on mutual attraction to be effective in locating dates, many people who know each other must participate.
There will also be an option within the site or software for the user to import additional contacts from any other instant messaging software or social networking sites in which the user participates, or from the user's cell phone. The user can then view a comprehensive list of all of these contacts and rate them and set options for the program from this central location within the user's social networking site, instant messaging software, or cell phone. If the user is a member of more than one site or software into which the program is integrated, the user will be exposed to the program whenever the user uses either site or software. The user will be able to manage his contact list and program options from each point. An option within the program allows the user to invite contacts who are not yet a member of an integrated site or software to join.
Whenever a user rates or characterizes a new contact or changes an existing rating, the program checks each contact that the user has rated above a certain threshold interest level to see if that contact has also rated the user above that threshold level. Rating information is stored by the site or messaging software just like other information about the user, e.g. name, location, etc. However, rating information is not visible to other people who access the user's page on the social networking site or “profile” on a messaging site. Only someone who is logged in as the user can view the user's ratings. If the user is accessing the program from a cell phone, the ratings are stored not on the cell phone, but on a server online. This allows the program to compare the users' ratings for matches even when their phones are off or otherwise inaccessible.
Because the program checks for matches whenever a user makes a new rating or modifies an old one, a match will always be detected as soon as it occurs. The program then notifies the users that a match has occurred. This notification will be sent by email, instant message, or cell phone text message, according to the preference set by each user. The notification will inform each user that a match has occurred, but will not reveal the other user's actual rating. The notification will also contain advertisements suggesting date locations and events.
After a match has been initially detected and the parties notified, the program will not send another notification for the same match unless the match lapses (one user lowers their rating of the other below the threshold level) and then is reestablished. Optionally, an indicator, such as an icon of some kind, may be displayed on the list beside each user for which a match presently exists. The indicator helps to prevent a situation in which neither user received or viewed the notification for some reason and therefore is unaware that a match has occurred.
Within the program interface in the social networking site or software, there will be many preferences that can be set by the user. These preferences allow the user to customize how the contact lists and ratings are displayed and accessed, how notifications will be received, etc.
The user will also be able to access the user's combined contact list and ratings from outside any of the sites or software the program is integrated into. The user can instead access the program through a downloadable program or a website that is just for the program itself. In this way, users will be able to access the program even when logging into an integrated site or software is undesirable, for example for privacy reasons, or when an integrated site of software is experiencing technical difficulties. This aspect of the program also allows it to be used by people who are not members of the integrated sites or software, who may download or sign up for the program directly instead.
This downloadable program or website maintains a central database of the contact, rating, and preferences information. Having a centralized database of the information makes it easier to use with more than one site or software. Every time the user makes a change to the information from an integrated site or software, those changes are uploaded to the central database. Each site or software can check its data against the centralized database each time it loads, automatically making changes to its data that the user initiated from a different access point (site or software).
In an alternative embodiment, the program functions without the use of a centralized database and access point. In this way, the program entirely piggybacks on existing site and software infrastructure. Additional storage and servers are not necessary, nor is maintenance of a separate website.
In another embodiment, the user has the option of modifying the threshold interest level above which matches are detected. The user may modify this level upwards, but not downwards. This prevents users from being flooded with notifications regarding low interest contacts.
In an alternative embodiment, the user has the option of setting an “initiation” preference. Some people believe that, for an inter-gender relationship, the male should always initiate contact. Users will therefore have the option of setting a preference for male initiation or female initiation. In one embodiment, the user who is preferred to initiate will receive notification some time period before the other user, allowing the first user to initiate contact. If the users have conflicting preferences, they are sent simultaneous notifications. In another embodiment, both users receive notification at the same time regardless, but are simply informed of the other user's preference in the notification.
In another embodiment, the invention dispenses dating advice under some circumstances. This feature is an option that the user can set a preference for or against. In one embodiment, dating advice is given within the notification whenever a user has rated the match higher than the match has rated the user. This advice may include ways to initiate contact, when to ask for a date, etc. In another embodiment, general dating advice and first date tips are given in every notification. In a third embodiment, advice is given when a user rates a contact highly and a match is not found. This advice may be given by email, instant message, or cell phone text message. This advice helps the user to create an interest in the user by the contact.
In an alternative embodiment, users are informed when a contact they have rated does not have a rating for them at all. This feature allows users to distinguish between a contact who is not interested in the user and a contact who simply does not use the rating system. In another embodiment, a user may set as a preference whether other users are informed when the user has not rated them at all.
In an alternative embodiment, the program is capable of suggesting possible romantic interests who are not in a user's contact list. The program compares a user's ranking of contacts with the rankings of other users of those same contacts. When a high correlation is found between the contacts indicated as high interest by the first user and by another user, contacts of that other user who are rated by the other user as high interest, but who are not on the first user's contact list, will be recommended to the first user as a person of potential interest. This recommendation can be made by email, instant message, or text message. In one embodiment, this feature is an option that can be turned on or off as one of the user's preferences.
In another embodiment, users can play matchmaker. One user can suggest two other users the first user knows as a possible match. The program will then send those users a notification as with a normal match, except that the notification will inform them that this match is based not on mutually indicated attraction, but on the suggestion of the matchmaking user. Users may opt out of this feature. Users may elect never to receive match notifications originating from matchmakers or may limit the receipt of such notifications based on characteristics of the proposed match. For example, users might elect not to receive notifications when the other user they are matched up with is not Jewish, is under a certain height, etc. This “filtering” option is limited only by the amount of user data stored by the site or software the program uses.
When one user does not receive a matchmaking notification and the other user does, that user will be informed that the other user elected not to receive the matchmaking notification, but will not give the reason why. The receiving user will not know whether the other user's filtering requirements were not met, or whether that user simply does not wish to receive matchmaking notifications at all. Alternatively, the user may elect to have the reason sent to the other user when a matchmaking notification is not received due to the user's preferences.
In an alternative embodiment, the program is used for non-romantic relationships, such as friendships or business associations. In one embodiment, the use of the program for non-romantic relationships is entirely separate from its use for romantic relationships, involving different access points and contact lists. In another embodiment, the program uses one access point and contact list for both romantic and non-romantic interests. Each contact simply has one rating for romantic interest and one or more for non-romantic interest, such as business interest or friendship interest. In either embodiment, this use of the program functions in the same way as the use of the program for romantic relationships, except that the rating is of a different kind of interest and the ads and type of advice that is given, if any, are adapted to the appropriate relationship.
While the invention has been described with reference to specific embodiments, modifications and variations of the invention may be constructed without departing from the scope of the invention.
|
An improved method of facilitating contact between mutually interested people takes advantage of existing contact lists such as those on social networking sites, instant messaging programs, or cell phones. A program is integrated into one or more of those technologies, allowing the user to characterize each contact on the basis of the user's level of interest in that contact as a date. The program keeps these rankings secret until two users indicate an interest in each other that surpasses a certain threshold. The users are then notified of the mutual interest. Ads and dating advice are sent along with the notification.
| 7
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/306,765 filed on Feb. 22, 2010, and incorporates said provisional application by reference into this document as if fully set out at this point.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of recreational boating and, more particularly, to hull designs that are intended to reduce the drag of a boat in the water when the boat is in motion.
BACKGROUND OF THE INVENTION
[0003] It is well known that the shape of the hull of the boat can have a huge impact on the boat's stability and performance. One familiar modification to the generally streamlined shape of boat hulls is the stepped hull design. In short, a stepped hull is one that contains an abrupt step-like discontinuity in its surface. Typically, leading edge of the bottom surface of the “step” is conventionally flat or streamlined to match the remainder of the hull. The step then terminates on its aft face with a vertical wall that steps upward toward the bottom of the boat. The step would resemble a stair step down if the boat were turned upside down. Providing a boat hull with steps is generally believed to increase the efficiency of boat's movement through the water by pulling air underneath the boat, thereby reducing drag of the water against the hull when the boat is in motion.
[0004] Conventional hull steps are understood to operate by pulling air in behind the step from both sides of the hull. The force with which air is pulled underneath the boat is dependent on the speed of the boat and the size of the cavity behind the step leading to free air. Some steps are pointed forwards to get help from the dynamic pressure.
[0005] There are two conventional approaches to forming a stepped hull: solid steps and so-called ventilated steps. Solid-type steps are completely solid abrupt changes in the curvature of the hull surface, whereas ventilated steps are hollow and are open to the rear of the boat, but are closed on the sides.
[0006] Because conventional solid steps have a limited flow area with which to draw air under the boat, they may require a significant velocity to be efficient. Thus, this sort of step is mostly used for high speed racing boats to increase speed by reducing drag forces.
[0007] The lack of efficiency in pulling air under the boat has prompted the development of technology that utilizes forced air to increase the amount of air behind the steps. Typically, the air supply is increased through the use of an air pump that releases air proximate to the rearward face of the steps. However, force-air methods are expensive to implement and require a source of energy for the pump (e.g., electricity). Thus, solid steps—whether augmented with a force air supply or not—have not proven to be practical for common (e.g., low velocity) use. However, if the supply of air behind the step could be made more efficient in a natural and inexpensive way, the steps could be more widely used to save propulsion energy and reduce transportation time.
[0008] Heretofore, as is well known in the boating arts, there has been a need for a hull design that improves the efficiency of the traditional stepped hull. Accordingly, it should now be recognized, as was recognized by the present inventor, that there exists, and has existed for some time, a very real need for a stepped hull design that would address and solve the above-described problems.
[0009] Before proceeding to a description of the present invention, however, it should be noted and remembered that the description of the invention which follows, together with the accompanying drawings, should not be construed as limiting the invention to the examples (or preferred embodiments) shown and described. This is so because those skilled in the art to which the invention pertains will be able to devise other forms of the invention within the ambit of the appended claims.
SUMMARY OF THE INVENTION
[0010] According to a preferred aspect of the instant invention, there is provided a stepped boat hull that is an improvement over the state-of-the-art stepped hull. More particularly, in contrast to prior art designs, the instant steps are specifically constructed to have an internal void that is in hydraulic communication with an opening/air passage on the side of a step that is closest to the surface of the water. The step will additionally utilize a rearward facing opening that is similarly in fluid communication with the internal void. This feature tends to introduce more air under the boat, thereby reducing water drag and improving its overall performance.
[0011] Another embodiment utilizes a stepped double hull configuration that conducts air that is captured by an air intake proximate to the prow of the ship. In the preferred arrangement, the air will pass between the double hulls (in some cases via one or more air conduits that are provided for that purpose) to the steps where the air is expelled.
[0012] The foregoing has outlined in broad terms the more important features of the invention disclosed herein, so that the detailed description that follows may be more clearly understood, and so that the contribution of the instant inventors to the art may be better appreciated. The instant invention is not limited in its application to the details of the construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. Rather the invention is capable of other embodiments and of being practiced and carried out in various other ways not specifically enumerated herein. Additionally, the disclosure that follows is intended to apply to all alternatives, modifications and equivalents as may be included within the spirit and the scope of the invention as defined by the appended claims. Further, it should be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting, unless the specification specifically so limits the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:
[0014] FIG. 1 contains a schematic representation of a longitudinal cross section of a boat that includes one or more steps of the instant invention on hull.
[0015] FIG. 2 depicts a magnified view of the rear portion of the boat cross section of FIG. 1 .
[0016] FIG. 3 depicts a cross sectional view of the embodiment of FIG. 2 .
[0017] FIG. 4 an illustration of a preferred embodiment that makes clearer the nature and configuration of the side openings of a preferred embodiment of the instant invention.
[0018] FIG. 5 contains another preferred embodiment which is double hulled, with at least a portion of the space that separates the two hulls being used to transport air from the front of the boat to the portion of its hull that is under water.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Referring now to the drawings, wherein the reference numerals indicate the same parts throughout the several views, there is provided herein a system for improving the performance of a boat via a modification to its hull shape. In the preferred embodiment, and as is discussed below, the instant invention will utilize a plurality of hollow steps that are positioned on or incorporated into the hull, with the steps having at least one opening on the side nearest the surface of the water and being opened toward the rear of the boat.
[0020] Turning first to FIGS. 1 and 4 , in a preferred embodiment the underside of the boat 105 will have a plurality of notches or steps 100 which might be made integral to the boat 105 hull during its manufacture or added onto it after the fact. As can be seen in this figure, each step 100 will be substantially hollow and have a side aperture 120 which is preferably located on the side of the step 100 remote from the centerline of the boat. Said another way, the side aperture 120 will, in most cases, be the side of the step 100 that is nearest to the surface of the water 110 . Note that this feature is critical to the operation of the instant invention.
[0021] Additionally, each step 100 will preferably be oriented transversely to the centerline of the boat, wherein “transverse” should be broadly understood to mean that the rearward face of the step 100 generally extends away from the centerline of the boat, as opposed to the more restrictive “orthogonal” meaning for transverse that is occasionally seen in other contexts.
[0022] In some embodiments, the steps 100 will be angled to create a chevron-type pattern on the underside of the boat. Further, each step 100 will have a downward facing (i.e., when the boat is in an upright position) lower face 150 that is preferably impermeable to the flow of water and, in the preferred embodiment, substantially flat or shaped to create a streamlined lower surface. Of course, it is not inconceivable that the lower face 150 might have one or holes therethrough, but preferably that surface would be solid.
[0023] Additionally, the step 100 will be at least partially defined by a lower surface of the hull of the ship 105 or by a separate upper face (e.g., wall 310 in FIG. 3 ), depending on whether the step 100 is added onto an existing hull or made to be integral to a hull during the boat's construction. Those of ordinary skill in the art will recognize how a step 100 such as that taught herein could be added to an existing hull or formed along with it.
[0024] FIG. 2 contains a magnified view of the embodiment of FIG. 1 . As is made clearer in this figure, the rearward facing portion of each step 100 will preferably be open to the water via aperture 120 . Although it is preferable that a single aperture 120 that occupies the entire side of the step 100 be utilized, in some preferred embodiments less than the entire side of the step 100 might be used and/or multiple openings might be placed in the side of the step 100 . For example, a plurality of smaller openings of different shapes (e.g., round, square, rectangular, triangular, etc.) might be used instead. However, generally speaking it is believed to be preferable that the side of the step 100 be as open as possible to facilitate the flow of air into and through the step 100 .
[0025] Turning next to FIG. 3 , this figure contains a cross sectional view of the embodiment of FIG. 2 which illustrates that the rear (aft-facing face) of each step 100 will preferably be largely open to the water. That being said, in some preferred embodiments instead of the single large aperture 130 a plurality of smaller apertures might be utilized. In some instances, one or more internal reinforcing partitions 135 might be utilized for purposes of, for example, strengthening the step. In any case, it is preferred that the opening(s) provided on the rearward face of the step 100 be as large as possible to encourage the flow of water therethrough. Further, in the preferred embodiment the internal partitions 135 (if any) will also have openings therein to allow free flow of water and air bubbles from the outermost/air gathering aperture to the innermost step which is located nearer the centerline of the boat. In the preferred embodiment, each of the steps will be in fluid communication with the other through the one or more openings in each internal partition 135 , thereby making it possible for air bubbles to move transversely between adjacent steps.
[0026] In practice, as the boat 105 moves forward through the water 110 , air will tend to enter the into the aperture 120 defined by the step 100 that is situated furthest from the centerline of the boat when the boat is in motion. This will tend to create a cushion of air bubbles that are pushed by the force of the water through the rearward opening 130 of each step. The air bubbles will tend to reduce the friction between the boat lower surface and the water, thereby reducing drag and decreasing the amount of power that is required to move the boat. The mechanism by which air bubbles reduce friction is well known to those of ordinary skill in the art.
[0027] Preferably the steps will be positioned near the prow of the boat but exact placement of the steps 100 that provide optimal advantage may need to be determined on a trial and error basis. As has been suggested previously, in a preferred embodiment, each step 100 will be open at the side and at the rear (see, e.g., FIG. 4 ), thereby creating an aperture 120 within. It is especially important for purposes of the instant invention that the sides of the steps 100 nearest the waterline be open to the water. Further, any steps not adjacent to the waterline will preferably have one or more openings in their sidewalls to allow movement of water and air between adjacent steps. This concept is discussed more fully below.
[0028] It should be further noted that in some preferred embodiments the steps 100 will be configured to allow air and water to move from steps on one side of the boat to steps on the other. By way of explanation, consider the walls 325 between two adjacent steps in FIG. 3 . In some preferred configurations, the adjoining walls 325 (which, of course, might actually be formed from a single piece of wood or other material) would have one or more openings therein to make it possible to have air move across the centerline of the boat in some circumstances. For example, this might be especially desirable when the instant invention is utilized with sail boats that have keels, where it might be desirable to pull in air from the up side of the boat when it is leaning.
[0029] Turning next to a technical discussion of the features of the instant invention, it should be remembered that the ventilated steps 100 of the instant invention are hollow rather than solid and contain an opening on their rearward (stern facing) surface. In some embodiments, the steps will also have an internal opening in their leading edge as well that places them in fluid communication with the step or steps that are closer to the bow of the boat. By way of explanation, consider the walls 125 between two adjacent steps 100 in FIG. 2 . Those of ordinary skill in the art will readily understand how a passage way might be created between these two steps 100 .
[0030] A key objective of the instant invention is to increase the area through which air can flow into the step and under the hull. In addition to flowing in from the side of the boat behind the steps, in another preferred arrangement air will be able to also flow in through the step itself and out through the open rear part of the step. The suction that the water creates when flowing across the steps provides the energy needed to pull the air in underneath the boat.
[0031] According to some preferred embodiments, existing boats can be retrofitted with steps of the sort taught herein. Instead of distinct hollow steps, the hull could also be made as a double hull with the two hulls being separated a uniform distance apart all along the boat. Thus, in this variation the invention would appear to be a traditional boat hull with an extra layer of hull material arranged at a certain fairly constant distance away from the inner hull. There will preferably be an opening between the two hulls all along length of the boat (e.g., the side portion of each step) that lets air in from the sides of the boat into the space between the hulls. The bottom hull closest to the water (or closest to the bottom of the body of water when the boat is in an upright orientation) will preferably have holes in it behind each step, the holes being designed to provide additional suction force to pull air out of that step and through the hull toward the aperture on the rearward portion of the step. In some preferred embodiments, these holes could also be arranged in a corrugated fashion that is integral to the steps. These stepped openings/slots could either be small or large and could be arranged in any number of ways along the hull. The two arrangements can also be combined.
[0032] According to still another preferred embodiment, there is provided a double hull boat configuration that utilizes air that is drawn from the front of the boat and conveyed to the portion of the hull that is under the water, thereby introducing air bubbles to the underside of the boat and reducing drag on the hull. FIG. 5 contains an illustration of a preferred double hull boat configuration 800 in cross section. As is indicated in this figure, this embodiment may not utilize distinct steps but instead might utilize a matrix of air discharge orifices 810 situated on the outer hull 815 . One or more air intakes 820 will preferably be provided on the front of the boat proximate to the prow, although it is certainly possible that the air intake could be located, say, amidships, with air ducts conveying the air from its intake point to the underside of the boat where the air can be released within the steps 100 to replace or augment the air that originates from air intake 820 . Further, and in some preferred embodiments, the air intake 820 will wrap around both sides of the boat 800 and might extend its entire length or some part thereof. Additionally, in some embodiments there will be multiple small air intakes 820 that are situated at various locations near the prow of the boat 800 and/or along its sides. All that is important is that one or more of the air intakes 820 be above the waterline when the boat 800 is in motion.
[0033] Note that in some preferred arrangements, the double hull configuration 800 might have a hull with many small steps (or even corrugations) rather than the larger steps that were preferred in the previous embodiments. The inner 805 and outer 815 hulls will preferably be separated by a near constant amount throughout, although the amount of separation that is best for a particular vessel may need to be determined on a trial and error basis and may or may not utilize a constant separation distance. In FIG. 5 , one or more spacers 830 have been illustrated as an example of how the hulls might be kept apart. Preferably, the separators 800 will be designed so as to not impede the flow of air between the hulls either laterally or horizontally so that air can move the length of the boat 800 and from side to side if the boat is tilted while it is maneuvered. As is illustrated, the spacers 830 might be chosen to allow air to flow through them. Those of ordinary skill in the art will be able to readily devise alternative means for keeping the two hulls separated such that air is free to flow in between.
[0034] In some preferred embodiments, the passively gathered air from air intake 820 will be passed between the hulls to one or more of the steps 100 that are made to be in hydraulic communication therewith. This additional air (i.e., in addition to what is picked up through the open sides of the steps 100 at the water line) will then be released through the steps as is indicated generally in FIG. 6 . This might further be augmented by, for example, routing all or a portion of the engine exhaust via exhaust conduits to the steps 100 . Additionally, and preferably in some circumstances, the outer hull 815 might be corrugated and/or slotted with a multiplicity of openings therein to assist in the passage of air therethrough. Finally, in some preferred embodiment one or more air conduits will be used to conduct air from the air intake 820 to the steps 100 where it will be released into the water.
Technical Discussion: CFD Modeling
[0035] Preliminary computational fluid dynamics (“CFD”) modeling results have been obtained calculated for the instant invention. A comparison was made between the performance of the hollow ventilated step technology of the instant invention with that of solid steps which represent known technology.
[0036] The boat hull that was used in the simulations was modeled after a Norwegian 18 ft. mahogany runabout that has been modified to include the new hollow ventilated step technology. A propulsion force of 5000 N was applied and the boat was assumed to have a weight of 1000 kg with a center of gravity located 2 m from the bottom rear point of the boat. In this simulation, the first two steps and the last step are taken to be traditional solid steps that have been used in some race boat designs. However, in this example steps #3 and 4 (counting from the front of the boat) are of the new and more efficient hollow inventive design.
[0037] It should be noted that it is the part of the hull located behind a step that benefits most from the air pulled in under the hull by the step. Thus, for the simulation boat, only the hull behind step 3 will have full benefit from the new and hollow steps, while the hull behind step one would benefit from air pulled in behind the old solid steps.
[0038] Based on the results of this simulation, air is most efficiently pulled in through and behind the new hollow steps (behind step 3) while almost no air is pulled in behind the solid steps at the velocities investigated in this study, i.e., at velocities less than about 13 m/s or approximately less than 26 knots. In fact it can be shown that traditional steps do not work well at these speeds while the hollow steps of the instant invention supply the entire downstream hull with air at velocities above 10 m/s or 20 knots. This comports with the conventional wisdom that solid steps are most useful at high speeds. Thus, it can be seen that the instant invention would be especially useful for relatively slow moving boats such as, for example, sailboats.
[0039] Thus, the present invention is well adapted to carry out the objects and attain the end and advantages mentioned above as well as those inherent therein. While the inventive device has been described and illustrated herein by reference to certain preferred embodiments in relation to the drawings attached thereto, various changes and further modifications, apart from those shown above or suggested therein, may be made therein by those of ordinary skill in the art, without departing from the spirit of the inventive concept the scope of which is to be determined by the following claims
|
According to a preferred aspect of the instant invention, there is provided a boat hull that is an improvement over the state-of-the-art stepped hull. More particularly, in contrast to prior art designs, the instant steps are specifically constructed to have an opening/air passage situated on the side of each step. The air passage will be preferably placed on the side of the step closest to the surface of the water or farthest away from the keel of the boar. This feature tends to introduce more air under the boat, thereby reducing water drag on the hull and improving its overall performance.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a radio selective call receiver, and more particularly to a radio selective call receiver in which a call count and fee are informed.
2. Description of the Related Art
In recent years, a charging system of the radio selective call receiver is reconsidered. That is, a conventional system is adopted in which a user of the radio selective call receiver pays a predetermined charge and a call originating person to the radio selective call receiver pays a telephone charge for every call. However, a new call count dependent on the charging system will be adopted in the future, in which an additional fee is imposed on the user of the radio selective call receiver in accordance with the reception call count, i.e., the number of reception calls.
By the way, although the additional fee is imposed on the user of the radio selective call receiver in accordance with the call count as mentioned above, the user does not generally count the reception calls one by one. Also, it is difficult to perform such a counting operation. Thus, the user cannot estimate how much additional fee is charged. Therefore, there is a problem in that there is a case that a large amount of additional fee is charged which the user does not expect. Especially, it is a serious problem for the user who receives tens of calls a day.
In Japanese Laid Open Patent Application Disclosure (JP-A-Showa 60-169245), a radio selective call receiver system is disclosed in which same information is provided to all radio selective call receivers having a same group number. However, in this system, even if the information is unnecessary to a user, the radio selective call receiver of the user receives the information, resulting in the charge of an additional fee.
SUMMARY OF THE INVENTION
The present invention is accomplished in view of the circumstances described above. Accordingly, an object of the present invention is to provide a radio selective call receiver, in which it is possible to estimate an additional fee when a new call count dependent charging system is adopted, and a method used in the same.
In order to achieve an aspect of the present invention, a radio selective call receiver includes a receiving unit for receiving a call, a memory unit storing a fee table for relation a fee and a call count, and a control unit for counting the calls received by the receiving unit to produce the call count, for referring to the fee table based on the call count to determine the fee, and for storing the call count and the fee in the memory unit.
The radio selective call receiver The further includes an input unit for inputting an instruction, and a display unit. In this case, the control unit may read the call count from the monthly table of the memory unit to display on the display unit in response to the instruction. Also, the control unit may read the fee from the memory unit to display on the display unit in response to the instruction.
The control unit may count time, store the call count and the fee in the monthly table, and reset the call count and the fee when a month changes.
Alternatively, the control unit may count time, and reset the call count and the fee when a month changes. In this case, the control unit may read the call count from the memory unit to display on the display unit in response to the instruction. Also, the control unit may read the fee from the memory unit to display on the display unit in response to the instruction. Instead, the control unit may read the call count and the fee from the memory unit to display on the display unit in response to the instruction.
When the memory unit stores a monthly table for storing the fee and the call count for every month, the control unit stores the call count and the fee in an area of the monthly table corresponding to a present month each time a call is received. Alternatively, when the memory unit further stores a monthly table for storing the fee and the call count for every month, the control unit stores the fee and the call count in an area of the month table corresponding to a present month.
In order to achieve another aspect of the present invention, a method of informing at least one of a call and a fee in a radio selective call receiver includes the steps of:
receiving a call;
counting the calls received to produce the call count;
referring to a fee table in a memory unit based on the call count to determine the fee, a fee table storing a relation a fee and a call count; and
storing the call count and the fee in the memory unit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating the structure of a radio selective call receiver according to a first embodiment of the present invention;
FIG. 2 is a diagram illustrating a new charging system;
FIGS. 3A and 3B are flow charts illustrating the operation of the radio selective call receiver according to the first embodiment of the present invention;
FIGS. 4A to 4C are diagrams illustrating display examples on a display section used in the radio selective call receiver according to the first embodiment of the present invention;
FIG. 5 is a block diagram illustrating the structure of the radio selective call receiver according to a second embodiment of the present invention;
FIGS. 6A and 6B are flow charts illustrating the operation of the radio selective call receiver according to the second embodiment of the present invention; and
FIG. 7 is a diagram illustrating a display example on a display section used in the radio 5 selective call receiver according to the second embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Next, a radio selective call receiver of the present invention will be described with reference to the accompanying drawings.
FIG. 1 is a block diagram illustrating the structure of the radio selective call receiver according to the first embodiment of the present invention. Referring to FIG. 1, the radio selective call receiver in the first embodiment is composed of an antenna 1, a radio frequency section 2, a waveform shaping circuit 3, a control unit 4, a ROM 5, a RAM 16 as a memory section, a display section driver 10, a display section 11, amplifying circuits 6 and 8, a speaker 7, an LED 9, an input unit 14, an oscillating unit 13, and a battery 12. The control unit is composed of a counting section 15, a referring section 17, a timer section 18, and a reset control section 19. The ROM 5 stores a fee table 5-1 to be described later. The RAM 16 as the memory section stores a call count data 16-1, and a fee data 16-2.
The fee table 5-1 shows a new call count dependent charging system in which an additional fee is determined based on the monthly call count. In FIG. 2, a data plot A indicates an example of how additional fees may be calculated and a data plot B indicates another example of how additional fees may be calculated. In data plot A, the additional fee is increased for every 50 calls. On the other hand, in data plot B, additional fee is constant until the monthly call count reaches 200 calls. The additional fee is increased for every 50 calls, when the call count exceeds 200.
Referring to FIG. 1 again, the radio selective call receiver operates in response to a clock signal from the oscillator 13 based on the power from the battery 12. A wireless signal is received by the antenna 1 and then is amplified by a radio frequency section 2 for demodulation. The demodulated signal is converted into a signal having the waveform which the control unit 4 can read, by the waveform shaping circuit 3.
The control unit 4 controls each unit or section of this radio selective call receiver. When a call of the wireless signal is received by the antenna 1, the wireless unit 2, and the waveform shaping circuit 3, the control unit 4 compares a call number of the wireless signal and an identification number stored in the ROM 5. When the call number and the identification number are both coincident with each other, the control unit 4 drives the speaker 7 and the LED 9 through the amplifying circuits 6 and 8 to inform the call reception to the user with sound and light. Also, when a reception message is contained in the radio reception signal from the waveform shaping circuit 3, the control unit 4 drives the display section 11 through the display unit driver 10 to display the reception message on the display section 11.
When recognizing that the call is present, the control unit 4 sends a signal to the counting section 15 such that the counting section 15 performs the call counting operation. The counting section 15 of the control unit 4 counts up the content of the call count data in the call count area 16-1 of the memory section 16. The referring section 17 of the control unit 4 refers to the fee table 5-1 which has been previously stored in the ROM 5 based on the call count data in response to the counting operation to determine an additional fee.
When the user operates the input unit 14 to confirm the call count or the additional fee, the control unit 4 reads the call count data from the call count area 16-1 of the memory section 16 and the fee data from the fee data area 16-2 thereof. The read data is displayed on the display section 11 through the display section driver 10.
Also, the timer section 18 of the control unit 4 counts time to output time information which indicates a present time. When detecting the change in month based on this time information, the reset control unit 19 resets or clears the call count data 16-1 and the fee data 16-2 in the memory unit 16.
Next, the operation of the radio selective call receiver in the first embodiment will be described. FIGS. 3A and 3B are flow charts illustrating the operation of the radio selective call receiver in the first embodiment.
Referring to FIG. 3A, when the radio selective call receiver is called in the wait state (steps 101, 102 and 106), the control unit 4 performs an informing operation in which the speaker 7 and the LED 9 are driven by the amplifying circuits 6 and 8 such that the reception of a call is informed to the user (step 107). Further, the control unit 4 informs the counting unit 15 that the call is received. The counting unit 15 counts up the call count data C 16-1 in the memory section 16 (steps 108 and 109).
Next, the referring section 17 refers to the fee table 5-1 of the ROM based on the call count data C to determine the additional fee (step 110). Then, the additional fee data corresponding to the call count C is stored in the memory unit 16 (step 112).
Next, in the wait state (step 101), when the user operates the input unit 14 to confirm the call count and/or the additional fee, a confirmation mode is set to confirm the call count and/or the additional fee (steps 102, 106 and 115). Further, the user performs the selection of the object of the confirmation, i.e., the selection of the additional fee or the call count, or both (step 116 and 119).
When the user selects the confirmation of the call count, the control unit 4 reads the call count data 16-1 from the memory section 16 (step 117) to display the call count data 16-1 on the display section 11, as shown in FIG. 4A (step 118). When the user selects the confirmation of the additional fee, the control unit 4 reads the additional fee data 16-2 from the memory section 16 (step 120) to display the additional fee data 16-2 on the display section 11, as shown in FIG. 4B (step 118). When both of the call count data 16-1 and the additional fee data 16-2 are selected, the control unit 4 reads the call count data 16-1 and the additional fee data 16-2 from the memory section 16 (step 127) to display the additional fee data 16-2 on the display section 11, as shown in FIG. 4C (step 118). Thereby, the user can confirm the call count and/or the additional fee.
By the way, a call count dependent charging system is applied to the call count of one month. For this reason, the call counting operation is performed on the basis of a one-month unit in the present invention. That is, when the month changes, for example, from August to September, a control signal is sent out from the timer section 18 to the reset control section 19 (steps 101, 102 and 103). The reset control section 19 sends out a reset signal to the counting section 15 and the memory section 16 (step 104) to reset the counting section 15 and the memory section 16 (step 105).
Next, the radio selective call receiver according to the second embodiment of the present invention will be described.
The radio selective call receiver in the second embodiment has the structure similar to the first embodiment and operates in a similar manner to the first embodiment. Therefore, only the difference between the first embodiment and the second embodiment will be described.
In the second embodiment, the memory section 16 stores a monthly table 16-3 for storing the call count and the additional fee for every month of a predetermined number of months, in addition to the call count data 16-1 and the addition fee data 16-2.
In the operation, after the determination of whether the call count data or the additional fee data is confirmed is performed (step 115), it is determined whether the call count data or the additional fee data for the present month is to be confirmed (step 130). If the answer is affirmative, the step 116 is executed as in the first embodiment. If the answer is negative, a step 134 is executed. In the step 134, the control unit 4 reads the monthly table 16-3 from the memory section 16 to drive the display section driver 10 such that the monthly table 163 is displayed as shown in FIG. 7 (step 118).
Also, when the month changes (step 102), the control unit 4 writes the call count data 161 and the additional fee data 16-2 in an area of the monthly table 16-3 corresponding to the previous month.
It should be noted that the counting section 15 may update the call count of the monthly table 16-3 corresponding to the present month. In this case, the field for the call count 16-1 can be omitted. Also, the referring section 17 may write the additional fee of the monthly table 16-3 corresponding to the present month determined by referring to the fee table 5-1 based on the call count. In this case, the field for the additional fee 16-2 can be omitted. In addition, when the month changes, it becomes unnecessary for the control unit 4 to write the call count and the additional fee in the monthly table 16-3.
Further, in the second embodiment, the call count and the additional fee of the monthly table 16-3 are displayed as shown in FIG. 7. However, only the call count or only the additional fee of the monthly table 16-3 may be displayed, as in the first embodiment.
In addition, in the first and second embodiment, the referring section 17 refers to the fee table 5-1 when the call is reception and the call count data 16-1 is counted up. However, the referring section 17 may refer to the fee table 5-1 only when the display of the additional fee is requested by the user.
As described above, according to the radio selective call receiver of the present invention, since the calls are counted, the user can estimate an amount of additional fee determined in accordance with the call count. Also, there is no case that the user pays an unexpected amount of money in the payment of the additional fee. That is, because the user can prompt a call originating person to pay attention to restrict calls when the additional fee gets too large, it is possible to restrain the call count. As a result, an increase of an amount of money to be paid can be prevented. Also, as a result of the restraint of the call count, congestion of traffic is restrained and the situation in which the connection to the radio selective call receiver becomes impossible can be avoided.
|
A radio selective call receiver includes a receiving unit which receives a call, a memory unit which stores a fee table and a call count, and a control unit which counts a number of received calls to produce the call count and which refers to the fee table to determine a fee based on the call count. The call count and fee are stores in a memory unit of the receiver in a manner suitable for recall on a display.
| 7
|
BACKGROUND OF THE INVENTION
[0001] This invention relates to an apparatus and method for production of high purity argon. More specifically, this invention relates to an apparatus and method for improving argon recovery from air using a cryogenic rectification column in combination with a pressure swing adsorber.
[0002] A crude argon stream containing about 0.2-15% by volume oxygen and about 1% by volume nitrogen may be recovered in the operation of a cryogenic air separation plant that produces oxygen and/or nitrogen. One of the methods generally employed to further purify the crude argon stream, is the so-called deoxo method, whereby oxygen in the crude argon stream is reacted with excess hydrogen. This process is energy intensive, since the gas stream is heated to a high reaction temperature and later cooled to cryogenic temperatures to remove the excess hydrogen and residual nitrogen. In addition, this process may not be practical in those parts of the world where hydrogen availability is limited. Another method, based on cryogenic distillation only, requires the use of a large or superstaged argon column due to the small difference in the relative volatility between argon and oxygen. Additional methods include the use of solid electrolyte membrane(s), two or more adsorption beds in a vacuum pressure swing adsorption (VPSA) process, getter/deoxo system, and temperature swing adsorption (TSA).
[0003] The cryogenic rectification of air to produce oxygen, nitrogen and/or argon is well-known. Typically, a three stage cryogenic process is used, wherein feed air is separated into nitrogen and oxygen in a double column system that uses nitrogen top vapor from a higher pressure column to reboil oxygen-rich bottom liquid in a lower pressure column, and argon-containing fluid from the lower pressure column is passed into a crude argon column for the production of argon product. For example, U.S. Pat. No. 5,440,884 by Bonequist and Lockett, disclosed a three stage cryogenic rectification system, employing a double column system with an associated crude argon column, to produce high purity (>99.999%) argon. In order to produce high purity argon, a large or superstaged argon column was used. According to U.S. Pat. No. 5,440,884, the large crude argon column is preferably divided into two separate argon columns, and a stripping column is used upstream of the double main column to suppress the thermodynamic irreversibility of the crude argon column top condenser and the lower pressure column.
[0004] U.S. Pat. No. 4,477,265 to Kumar et al., discloses the adsorption of oxygen and nitrogen from an argon-rich feed taken from the rectification column of a cryogenic air separation plant. According to this patent, argon of high purity is separated and recovered from a crude argon stream containing minor amounts of oxygen and nitrogen, by selective adsorption of these contaminants in a series of adsorption columns (beds). In an embodiment, the system utilizes two separate adsorbent columns in series wherein the first column contains a nitrogen equilibrium selective adsorbent (e.g. zeolite) that is used for nitrogen removal, and the second bed containing an oxygen rate selective adsorbent (e.g. carbon molecular sieve) used for oxygen removal. Further purification of the recovered argon may be carried out by catalytic hydrogenation of residual oxygen therein.
[0005] U.S. Pat. No. 6,527,831 to Baksh et al., discloses a vacuum pressure swing adsorption system for purifying argon from a crude argon feed stream utilizing two adsorption beds and continuously promotes the crude argon feed stream to the bed during the process with simultaneous equalization of pressure in the two beds in top-to-top end and bottom-to-bottom end equalizations in each bed following purging of each bed.
[0006] U.S. Pat. No. 6,351,971 to Nguyen et al., discloses a process and system for producing a high purity argon product with high argon recovery from an air feed stream utilizing a low ratio argon column, a high ratio argon column and a vacuum pressure swing adsorption unit in combination with a cryogenic air separation plant.
[0007] Other patents related to argon production include U.S. Pat. No. 5,730,003 to Nguyen et al., U.S. Pat. No. 5,557,951 to Prasad et al., U.S. Pat. No. 5,601,634 to Jain et al., U.S. Pat. No. 5,159,816 to Kovak et al., U.S. Pat. No. 4,239,509 to Bligh et al.
BRIEF SUMMARY OF THE INVENTION
[0008] As can be observed from the art, it would be desirable to provide a system and process for producing product argon with 99.999 mole percent argon with less than 1 ppm oxygen and less than 1 ppm nitrogen. Improvements in the refining of crude argon in a cryogenic air separation system have long been sought. Economic factors, along with more stringent purity specification for argon, increase the need for improved processing to more completely eliminate both oxygen and nitrogen from the argon product.
[0009] While argon purity is important, it would also be desirable to recover a greater portion of the argon from cryogenic distillation of air.
[0010] It would be desirable to maintain stability of the cryogenic distillation column. It has heretofore been unrecognized that some of the downstream purifying methods may impact the stability of the cryogenic distillation column.
[0011] For example, with reference to FIG. 1 , argon production may be increased as the argon feed stream 180 from the low pressure column (not shown) to the crude argon column 150 is increased. Feed stream 180 may only be increased to the point where the stream does not contain significant amounts of nitrogen. Nitrogen in feed stream 180 is detrimental to the operation of the crude argon column 150 since nitrogen will accumulate as a vapor in condenser 170 . If nitrogen vapor is allowed to accumulate in condenser 170 , condenser 170 will cease to function properly, and liquid held up in column 150 may flow back into the low pressure column; so-called “column dumping.” On column dumping, oxygen product is contaminated and the column will typically be shut down.
[0012] The flow rate of feed stream 180 is selected to provide a balance between argon production and column dumping. To avoid column dumping, the flow rate of feed stream 180 is conventionally kept well below this threshold.
[0013] The flow rate of feed stream 180 may be pushed closer to the threshold without column dumping, as long as fluctuations in the system are minimized. For improved argon production, downstream processing, such as argon purification, should provide minimal fluctuations to the system.
[0014] For example, any streams returning to the crude argon column 150 , such as stream 190 , should be steady in order to minimize fluctuations in column 150 . Any variation in stream 190 will affect feed stream 180 . This is because condenser 170 acts to draw a fixed amount of vapor into column 150 as it turns vapor into liquid. Therefore, variability in stream 190 will cause variability in feed stream 180 .
[0015] The present invention is intended to provide the above-mentioned benefits while overcoming disadvantages of the prior art.
[0016] In an embodiment, the present invention is a method for producing argon product comprising withdrawing an argon-containing fluid from a cryogenic distillation column, increasing the pressure of at least a portion of the argon-containing fluid in a means for increasing pressure thereby forming a compressed argon-containing fluid, introducing at least a portion of the compressed argon-containing fluid into a first end portion of a first pressure swing adsorption vessel, withdrawing a first argon-rich gas from a second end portion of the first pressure swing adsorption vessel. After terminating the introduction of the compressed argon-containing fluid into the first pressure swing adsorption vessel, the method according this embodiment further comprises withdrawing a depressurization gas from at least one of the first end portion and a middle portion of the first pressure swing adsorption vessel thereby reducing the pressure in the first pressure swing adsorption vessel to a final depressurization pressure, regulating the flow of at least a portion of the depressurization gas by passing the at least a portion of the depressurization gas to a means for moderating flow thereby forming a regulated depressurization gas, and introducing at least a portion of the regulated depressurization gas into at least one of the cryogenic distillation column and the means for increasing pressure.
[0017] For at least 90% or 95% of the cycle time, the at least a portion of the regulated depressurization gas may have a molar flow rate within 50% and 400%, or within 66% and 200%, of the time-averaged molar flow rate of the at least a portion of the regulated depressurization gas. The final depressurization pressure may be 0 psig to 20 psig.
[0018] The argon-containing fluid may comprise greater than 50 volume % argon. The first argon-rich gas may comprise greater than 90 volume % argon. The first argon-rich gas may comprise less than 0.001 volume % oxygen.
[0019] The method according to the invention may comprise one or more of the following characteristics, taken alone or in any possible technical combinations.
[0020] The means for moderating flow in the present invention may comprise a gas capacitance means and a downstream flow restriction. The gas capacitance means may have a volume that is 0.5 to 20 times the volume of the first pressure swing adsorption vessel.
[0021] The compressed argon-containing fluid may comprise oxygen, and the method may further comprise kinetically adsorbing the oxygen in the first pressure swing adsorption vessel using carbon molecular sieve.
[0022] The inventive method may further comprise withdrawing a first equalization gas from the middle portion of the first pressure swing adsorption vessel, introducing at least a portion of the first equalization gas into a first end portion of a second pressure swing adsorption vessel, withdrawing a second equalization gas from the second end portion of the first pressure swing adsorption vessel, and introducing at least a portion of the second equalization gas into a second end portion of the second pressure swing adsorption vessel.
[0023] The inventive method may further comprise introducing a second argon-rich gas from at least one of the second pressure swing adsorption vessel and a third pressure swing adsorption vessel into the second end portion of the first pressure swing adsorption vessel during at least a portion of the step of withdrawing the depressurization gas.
[0024] The inventive method may further comprise filtering at least a portion of the depressurization gas. The inventive method may further comprise filtering at least a portion of the regulated depressurization gas.
[0025] The inventive method may further comprise introducing at least a portion of the first argon-rich gas into another cryogenic distillation column. The inventive method may further comprise introducing at least a portion of the first argon-rich gas into a purifier vessel containing a getter.
[0026] In an embodiment the present invention is an apparatus for producing argon product comprising a distillation column having an inlet and an outlet, the outlet for withdrawing an argon-containing fluid, a means for increasing pressure of the argon-containing fluid having an inlet and an outlet, the inlet in fluid communication with the distillation column outlet, a first pressure swing adsorption vessel having a first end portion, a middle portion, and a second end portion, the first end portion in selective fluid communication with the outlet of the means for increasing pressure, and a second pressure swing adsorption vessel having a first end portion, a middle portion, and a second end portion, the first end portion of the second pressure swing adsorption vessel in selective fluid communication with the outlet of the means for increasing pressure. The apparatus of the present invention further comprises a means for moderating flow having an inlet and an outlet, the inlet of the means for moderating flow in selective fluid communication with the first end portion of the first pressure swing adsorption vessel and in selective fluid communication with the first end portion of the second pressure swing adsorption vessel, the outlet of the means for moderating flow in fluid communication with at least one of the inlet of the distillation column and the inlet of the means for increasing pressure.
[0027] The means for moderating flow may comprise a gas capacitance means and a downstream flow restriction. The downstream flow restriction may comprise at least one flow control valve. The gas capacitance means may have a volume 0.5 to 20 times greater than the volume of the first pressure swing adsorption vessel.
[0028] The apparatus according to the invention may comprise one or more of the following characteristics, taken alone or in any possible technical combinations.
[0029] The first pressure swing adsorption vessel and the second pressure swing adsorption vessel may contain carbon molecular sieve.
[0030] The middle portion of the first pressure swing adsorption vessel may be in selective fluid communication with the first end portion of the second pressure swing adsorption vessel and the second end portion of the first pressure swing adsorption vessel may be in selective fluid communication with the second end portion of the second pressure swing adsorption vessel.
[0031] The apparatus according to the present invention may comprise a particulate filter having an inlet and an outlet, the inlet of the particulate filter in fluid communication with the outlet of the means for moderating flow, the outlet in fluid communication with the inlet of the distillation column.
[0032] The apparatus according to the present invention may comprise another distillation column having an inlet and an outlet, the inlet of the other distillation column in selective fluid communication with the second end of the first pressure swing adsorption vessel and in selective fluid communication with the second end of the second pressure swing adsorption vessel.
[0033] The apparatus according to the present invention may comprise a purifier vessel containing a getter. The purifier vessel may be in selective fluid communication with the outlet of the pressure swing adsorption vessel. The outlet of the purifier outlet may be in fluid communication with the inlet of the other distillation column.
BRIEF DESCRIPTION OF THE DRAWING
[0034] FIG. 1 shows a schematic of an apparatus according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The production of argon from a cryogenic air separation plant is known. Conventionally, the cryogenic air separation plant will have high and low pressure distillation columns and a crude argon column as described in U.S. Pat. No. 5,313,800 to Howard et al. In some cases the crude argon column may be incorporated within the low pressure column in a divided wall configuration as described in U.S. Pat. No. 6,240,744.
[0036] As used herein, the term “column” means a distillation or fractionation column or zone, i.e. a contacting column or zone, wherein liquid and vapor phases are countercurrently contacted to effect separation of a fluid mixture, as for example, by contacting of the vapor and liquid phases on a series of vertically spaced trays or plates mounted within the column and/or on packing elements such as structured or random packing. For a further discussion of distillation columns, see the Chemical Engineer's Handbook, fifth edition, edited by R. H. Perry and C. H. Chilton, McGraw-Hill Book Company, New York, Section 13, The Continuous Distillation Process. The term, double column, is used to mean a higher pressure column having its upper portion in heat exchange relation with the lower portion of a lower pressure column.
[0037] Embodiments of the invention are shown with reference to FIG. 1 , which illustrates an apparatus 1 for carrying out process steps of the invention. Equipment relating to cryogenic distillation may be constructed by means known in the art. Equipment relating to pressure swing adsorption may be constructed by means known in the art. Operating conditions known in the art, except as specifically noted, may be used for carrying out this invention.
[0038] An argon feed stream 180 from the low pressure column (not shown) is introduced to the crude argon column 150 . The crude argon column may have multiple packed or trayed sections 152 and 154 . Liquid 181 may be removed from the bottom of crude argon column 150 and introduced back to the low pressure column. A gas stream 156 , which may comprise greater than 50 volume % argon, is withdrawn near the top of the column and at least partially condensed in condenser 170 . Condenser 170 may be integrated within the crude argon column 150 or may be a separate vessel. A portion of the at least partially condensed stream 172 may be introduced back into crude argon column 150 as stream 174 , whilst another portion 176 may be passed through an optional heat exchanger 60 and to a means for increasing pressure 50 thereby forming a compressed argon-containing fluid. The means for increasing pressure may be a compressor, blower, or other device known in the art, or an evaporator that increases pressure via liquid to gas expansion. The compressed argon-containing fluid may be passed to an optional surge vessel 40 .
[0039] The compressed argon-containing fluid is passed to a pressure swing adsorption (PSA) system. The compressed argon-containing fluid may have a temperature between −20° C. and 50° C. and have a pressure between 30 psig and 130 psig. The pressure swing adsorption system comprises at least two pressure swing adsorption vessels 10 and 20 , each containing one or more layers of adsorbents. One of the layers may comprise carbon molecular sieve (CMS). Carbon molecular sieve adsorbents operate based on a kinetic selectivity for oxygen compared to argon. The oxygen diffuses into the adsorbent faster than argon, allowing the argon to be purified. Adsorbents based on kinetic selectivity are distinct from adsorbents that operate on equilibrium (or thermodynamic) selectivity. Adsorbents that operate on equilibrium selectivity have a higher affinity for one component relative to other components in a gas mixture at equilibrium. In addition to a CMS adsorbent, the pressure swing adsorption vessel may contain a zeolite, either as a separate layer or mixed with the CMS, that has a thermodynamic selectivity for nitrogen relative to argon. The pressure swing adsorption system may operate by various cycle steps known in the art, especially the steps used in nitrogen PSA systems.
[0040] In a phase of the PSA cycle, compressed argon-containing fluid is introduced into a first end portion of pressure swing adsorption vessel 10 via open valve 12 . While this compressed argon-containing fluid is being introduced, argon-rich gas, which may comprise greater than 90 volume % argon and less than 0.001 volume % oxygen, is withdrawn from a second end portion of the pressure swing adsorption vessel 10 . Argon-rich gas may pass through product valve 15 and valve 38 . At least a portion of the argon-rich gas may be passed through optional surge vessel 52 , optional purifier 54 , optional heat exchanger 60 , optional distillation column 120 , and then to an argon product storage vessel 100 .
[0041] Optional purifier 54 may be any purifier known in the art for removing trace impurities, for example a getter-based purifier and/or a deoxo unit. Possible getter materials include transition metals, for example, copper, nickel, cobalt, iron, and manganese. U.S. Pat. No. 4,983,194 to Hopkins et al., discloses a getter system in combination with crude argon purification. Deoxo units remove oxygen by reacting hydrogen with oxygen impurities over a noble metal catalyst such as platinum, palladium and/or a transition metal catalyst such as nickel to form water which is removed in a dryer. U.S. Pat. No. 6,123,909 discloses a deoxo unit in combination with argon purification.
[0042] In at least one embodiment of the invention, optional distillation column 120 removes additional nitrogen before introducing the stream to the argon product storage vessel 100 . Liquid nitrogen from another part of the cryogenic distillation process may be introduced via conduit 164 to the condenser section of distillation column 120 . The condenser may be integrated within distillation column 120 or may be a separate vessel. A stream containing increased amounts of nitrogen may be rejected from the top of column 120 via conduit 124 and a stream with purified argon exits through conduit 128 .
[0043] Argon product may be withdrawn from argon product storage vessel 100 , as needed, via conduit 102 . Boiloff from argon product storage vessel 100 may be passed to optional distillation column 120 via conduit 104 .
[0044] As part of another phase of the PSA cycle, the introduction of the compressed argon-containing fluid into the pressure swing adsorption vessel 10 is terminated by closing valve 12 .
[0045] As part of another phase of the PSA cycle, a depressurization gas is withdrawn from pressure swing adsorption vessel 10 via valve 11 and/or optional valve 14 , thereby reducing the pressure in pressure swing adsorption vessel 10 to a final depressurization pressure. The final depressurization pressure in the pressure swing adsorption vessel 10 may be 0 psig to 20 psig.
[0046] During at least part of the step of withdrawing depressurization gas, argon-rich gas may be introduced via metering valve 17 into the second end portion of pressure swing adsorption vessel 10 . Argon-rich gas may be provided from pressure swing adsorption vessel 20 , optional surge vessel 52 , or another pressure swing adsorption vessel in the case of more than two adsorption vessels.
[0047] In at least one embodiment of the invention, at least a portion of the depressurization gas is passed to a means for moderating flow, shown schematically as a flow control valve 32 . Means for moderating flow may comprise at least one of a flow control valve, a gas capacitance means in combination with a downstream flow restriction, and a pressure control valve where the downstream pressure is controlled.
[0048] A flow control valve is defined herein as a device which can produce variable resistance to flow. The resistance of this device is varied in order to achieve a desired range of flow rates.
[0049] A flow restriction downstream of the gas capacitance means may be any type of valve, an orifice or the like.
[0050] A downstream pressure control valve is defined herein as a device which can produce variable resistance to flow. The resistance of this device is varied in order to achieve a desired range of pressures downstream of the pressure control valve.
[0051] In an embodiment of the invention, at least a portion of the depressurization gas is passed to a flow control valve 32 , thereby regulating the flow of the depressurization gas and at least a portion of the regulated depressurization gas is introduced to a location upstream of the means for increasing pressure 50 .
[0052] In another embodiment of the invention, at least a portion of the depressurization gas is passed to an optional gas capacitance means 30 and then to a flow control valve 32 , thereby regulating the flow of the depressurization gas. At least a portion of the regulated depressurization gas is introduced to a location upstream of the means for increasing pressure 50 . The optional gas capacitance means 30 may be a surge vessel and/or a volume of conduit. The optional gas capacitance means 30 may have a volume 0.5 to 20 times greater, or 2 to 10 times greater, than the volume of the pressure swing adsorption vessel 10 .
[0053] In another embodiment of the invention, at least a portion of the depressurization gas is optionally passed through a filter (not shown) before being introduced to the means for increasing pressure 50 .
[0054] In another embodiment of the invention, at least a portion of the depressurization gas is optionally passed to gas capacitance means 30 and subsequently flow control valve 34 , thereby regulating the flow of the depressurization gas. The regulated depressurization gas may be optionally passed to optional filter 42 and heat exchanger 60 and then introduced into crude argon column 150 . Optional filter 42 removes any particulates that may be in the stream from the adsorption vessels 10 and 20 . The regulated depressurization gas may be introduced to one or more locations in crude argon column 150 as shown in FIG. 1 .
[0055] In another embodiment of the invention, during a portion of the process cycle, at least a portion of the depressurization gas is passed to gas capacitance means 30 and at least of portion of the depressurization gas bypasses gas capacitance means 30 through valve 31 . During this portion of the cycle, valve 35 is closed and valves 32 and/or 34 may be used to control the flow rate of the depressurization gas. During a subsequent portion of the process cycle, valve 33 is closes to prevent additional gas from entering gas capacitance means 30 . Valves 32 and/or 34 continue to control the flow until a later portion of the cycle when flow control valve 35 opens to allow gas to exit gas capacitance means 30 . This embodiment may provide a reduced bed pressure in the PSA.
[0056] According to an embodiment of the invention, to facilitate stability of the distillation process, the regulated depressurization gas, i.e. regulated by one or more of flow control valves 32 and 34 , has a molar flow rate within 50% and 400% of the time-averaged molar flow rate of the regulated depressurization gas for at least 90% of the cycle time of the PSA cycle. Here the molar flow rate is defined as the molar flow rate immediately downstream of the means for moderating flow. The pressure swing adsorption vessels are subjected to repeated process operations, such as pressurization and depressurization, in a cyclical manner. The period of time required to complete one such cycle is referred to as the cycle time. In another embodiment of the invention, for at least 95% of the cycle time, the regulated depressurization gas has a molar flow rate within 66% and 200% of the time-averaged molar flow rate of the regulated depressurization gas. In another embodiment of the invention, for at least 95% of the cycle time, the regulated depressurization gas has a molar flow rate within 80% and 120% of the time-averaged molar flow rate of the regulated depressurization gas.
[0057] In an embodiment of the invention, the process comprises an equalization step. Equalization gas may be withdrawn from a middle portion of the pressure swing adsorption vessel 10 , passed through valve 14 and check valve 23 , and introduced into a first end portion of pressure swing adsorption vessel 20 . Equalization gas may also be withdrawn from the second end portion of the pressure swing adsorption vessel 10 , passed through valves 16 and 26 , and introduced into a second end portion of pressure swing adsorption vessel 20 .
[0058] As is typical of adsorption systems, at least one vessel is in a production phase while at least one other is in a regeneration phase, thereby allowing continuous production of product gas.
[0059] Therefore, in another phase of the PSA cycle, compressed argon-containing fluid is introduced into a first end portion of pressure swing adsorption vessel 20 via open valve 22 . While this compressed argon-containing fluid is being introduced, argon-rich gas is withdrawn from the second end portion of the pressure swing adsorption vessel 20 . Argon-rich gas may pass through product valve 25 and valve 38 . At least a portion of the argon-rich gas may be passed through optional surge vessel 52 , optional purifier 54 , optional heat exchanger 60 , optional distillation column 120 , and then to an argon product storage vessel 100 . Argon product may be withdrawn, as needed, via conduit 102 .
[0060] As part of another phase of the PSA cycle, the introduction of the compressed argon-containing fluid into the pressure swing adsorption vessel 20 is terminated by closing valve 22 .
[0061] As part of another phase of the PSA cycle, a depressurization gas is withdrawn from pressure swing adsorption vessel 20 via valve 21 and/or optional valve 24 , thereby reducing the pressure in pressure swing adsorption vessel 20 to a final depressurization pressure. The final depressurization pressure in the pressure swing adsorption vessel 20 may be 0 psig to 20 psig.
[0062] During at least a portion of the step of withdrawing depressurization gas, argon-rich gas may be introduced via metering valve 17 into the second end portion of pressure swing adsorption vessel 20 . Argon-rich gas may be provided from pressure swing adsorption vessel 10 , optional surge vessel 52 , or another pressure swing adsorption vessel in the case of more than two adsorption vessels.
[0063] The depressurization gas exiting adsorption vessel 20 may flow through means for moderating flow and optional filter 42 in the same manner as the depressurization gas which exited adsorption vessel 10 .
[0064] In an embodiment of the invention which comprises an equalization step, equalization gas may be withdrawn from a middle portion of the pressure swing adsorption vessel 20 , passed through valve 24 and check valve 13 , and introduced into a first end portion of pressure swing adsorption vessel 10 . Equalization gas may also be withdrawn from the second end portion of the pressure swing adsorption vessel 20 , passed through valve 16 and valve 26 , and introduced into a second end portion of pressure swing adsorption vessel 10 .
EXAMPLE
[0065] As discussed above, there is a threshold flow rate of the feed stream from the low pressure column where, above this threshold flow rate, detrimental quantities of nitrogen are passed to the argon column. In practice, the system may be operated close to this threshold flow rate as long as the flows throughout the system are steady. To study the effect, a cryogenic distillation column system was modeled by a dynamic simulation computer program. The system comprised a low pressure column and an attached crude argon column.
[0066] In Case 1, representing operation using a means for moderating flow with perfect flow control, the recycle flow to the crude argon column (stream 190 in FIG. 1 ) was maintained at a steady rate, R. In Case 2, representing operation using a means for moderating flow with moderate flow control, the recycle flow to the crude argon column was maintained at 66% of R for most of the period and 200% of R only briefly, but still having a time-averaged rate of R. In Case 3, representing operation under the natural behavior of uncontrolled recycle flow with no means for moderating flow, the recycle flow to the crude argon column was maintained at 70% of R for most of the period, briefly at 200% of R, and briefly at zero flow, but still having a time-averaged rate of R.
[0067] In Case 1, the system may operate at or near the threshold flow rate thereby providing the theoretical maximum argon recovery. For this case, the initial composition of nitrogen in stream 180 was 1.5 ppm. Because there is no disturbance, the dynamic simulation calculation shows that the composition of nitrogen in stream 180 was 1.5 ppm. In Case 2, for an initial concentration of 1.5 ppm of nitrogen, the dynamic simulation calculation shows that the composition of nitrogen in stream 180 grows to over 300 ppm nitrogen. To correct the situation the initial concentration of nitrogen needs to be reduced to 0.15 ppm. To achieve this for Case 2, the flow rate to the crude argon column was decreased.
[0068] Similarly, for Case 3 the dynamic simulation calculation shows that the initial concentration of nitrogen needs to be reduced to 0.005 ppm to prevent the nitrogen concentration from growing to unacceptable levels. To achieve this for Case 3, the flow rate to the crude argon column was decreased again.
[0069] To summarize, the dynamic simulation demonstrates that the concentration of nitrogen in stream 180 has to be reduced by 1 to 2 orders of magnitude, depending on the degree of flow variability.
[0070] Steady state simulations based on the limitation of reducing the concentration of argon by 1 order of magnitude for Case 2, and 2 orders of magnitude for Case 3 demonstrate the impact on power consumption of the entire facility. These simulations show that the system would need to process about 0.4% to 1.5% more feed air for Case 2 relative to Case 1. The variability in the feed air flow penalty is related to the initial stage count in the distillation section in the low pressure column above the point where the crude argon column feed is withdrawn. The system consumes more power to process more feed air. The power penalty for Case 2 relative to Case 1 is calculated to be 0.3% to 1.5%.
[0071] Similarly, in Case 3, the system would need to process about 1.0% to 5.9% more feed air to make up the lost argon production for Case 3 relative to Case 1. The power penalty for Case 3 relative to Case 1 is calculated to be 1% to 5.9%.
[0072] The results of the two sets of simulations show that regulating the flow of the depressurization gas by a means for moderating flow improves the process efficiency relative to processes without the means for moderating flow. As the means for moderating flow provides less flow variability, the process efficiency may be improved.
[0073] The present invention has been set forth with regard to several preferred embodiments. However, the scope of the present invention should be ascertained from the claims that follow.
|
A method and apparatus for producing high purity argon by combined cryogenic distillation and adsorption technologies is disclosed. Crude argon from a distillation column or a so-called argon column is passed to a system of adsorption vessels for further purification. Depressurization gas from adsorption is introduced back, in a controlled manner, to the distillation column and/or a compressor or other means for increasing pressure. Particulate filtration and getter purification may optionally be used.
| 5
|
FIELD OF THE INVENTION
[0001] This invention relates generally to coal mining, and more particularly to a process for applying rock dust to a mine wall for the purpose of suppressing mine fires and preventing explosions.
BACKGROUND OF THE INVENTION
[0002] In coal mining, it has been common practice to apply limestone in the form of a dust to the walls of a mine, thereby causing the limestone to adhere to the walls. The process, known as “rock dusting,” has two effects. First, because the limestone dust covers exposed surfaces of unmined coal, it prevents mine fires from being propagated along those exposed surfaces. Second, if methane, coal dust, or a mixture of methane and coal dust, ignite in a mine causing an explosion, the rock dust adhering to the mine wall will become airborne, and suppress the propagation of fire resulting from the explosion.
[0003] The United States Mine Safety and Health Administration has established standards for rock dusting, which include a requirement that all exposed surfaces of a mine be covered with rock dust at least 80% of the content of which is non-combustible. Existing methods for applying rock dust include application of rock dust to a mine wall. Recently, mines have begun using chemical foam to achieve improved adhesion of the rock dust to mine surfaces. One method of using foam in rock dust application is to apply a dry mixture of rock dust and a foaming agent to a mine wall. Another method is to apply a mixture of foam and rock dust to a mine wall. In the last-mentioned method, the foam is formed, mixed with rock dust in a mixing vessel, and pumped through a conduit to the point of application. A system for utilizing foam to enhance the adhesion of rock dust to a mine wall is described in U.S. Pat. No. 6,726,849, granted Apr. 27, 2004.
[0004] One of the difficulties encountered in rock dusting of mines is that when the rock dust comes into contact with water, it tends to agglomerate, and lose its ability to inhibit coal dust explosions and to suppress mine fires. The fineness of the limestone dust also contributes to cohesion of the dust particles.
[0005] The problem of agglomeration of limestone dust particles has been recognized, and has been addressed by measures to impart hydrophobic properties to the limestone dust. To this end, there is now available for use in mine dusting, as well as in various other applications such as in polymer fillers, a limestone powder treated to make it hydrophobic in order to reduces its agglomeration potential. One successful method of treatment is to coat the limestone particles with stearic acid. Coating with stearic acid can be carried out by immersing the limestone dust in a solution of stearic acid and then drying the material. Alternatively, the limestone particles can be coated by exposing them to a stearic acid vapor. Other approaches, including coating the limestone particles with a silicone preparation to impart hydrophobic properties to the particles, have been used to avoid agglomeration.
[0006] The commercially available treated limestone dust, which is typically composed of at least approximately 95% calcium carbonate (CaCO 3 ), a small amount (typically less than 2%) of silica (SiO 2 ), and from about 0.5% to 1.0% stearic acid, CH 3 (CH 7 ) 16 COOH. This commercially available treated limestone, and other treated limestone products, are relatively expensive, and there is a need for a less expensive and efficient way to avoid agglomeration of rock dust used in mining applications.
SUMMARY OF THE INVENTION
[0007] The invention is a method and apparatus, different from those previously used. One difference, which allows a number of advantages to be realized, is that in the method according to the invention, rock dust and foam are combined at the point of application to the mine wall.
[0008] In accordance with one aspect of the invention, an apparatus for applying rock dust to a mine wall comprises first and second conduits. Means are provided for entraining rock dust in air in the first conduit, and means are provided for mixing a foamable liquid and air to produce a flowable foam, and for delivering the flowable foam through the second conduit. Means are also provided for combining rock dust and air taken from the first conduit with flowable foam taken from the second conduit. A nozzle connected to the combining means is provided for applying a mixture of air, rock dust and foam from the combining means to a mine wall.
[0009] In a preferred embodiment, the apparatus comprises the following interrelated elements. A vessel for temporarily containing rock dust is connected to receive rock dust from a supply thereof. A first source of compressed air is connected to the vessel, and a first conduit connected to the vessel is provided for carrying air, along with rock dust entrained therein, from the vessel. A first control means is provided for regulating the concentration of rock dust in the air carried by the first conduit. The apparatus also includes a mixing block for mixing a foamable liquid and air to produce a flowable foam. A pump, connected to a supply of foamable liquid and to the mixing block delivers the foamable liquid to the mixing block. A second source of compressed air is connected to the mixing block to supply air to the mixing block. A second control means is provided for independently controlling the rates at which foamable liquid and air are supplied to the mixing block. A second conduit is provided for carrying flowable foam from the mixing block to a Y-joint. The Y-joint has a first inlet connected to the first conduit for receiving rock dust and air, and a second inlet connected to the second conduit for receiving flowable foam. A mixture of air, rock dust and foam is delivered through an outlet of the Y-joint to a nozzle used to apply the mixture of air, rock dust and foam to a mine wall.
[0010] Various kinds of pumps can be used to deliver the foamable liquid to the mixing block. For example, the pump can be an air-driven pump connected to be driven by air from the second source of compressed air.
[0011] In another aspect, the invention is a method of applying rock dust to a mine wall. In accordance with the method rock dust is entrained in air in a first conduit. A foamable liquid and air are mixed to produce a flowable foam, which is delivered through a second conduit. The combination of rock dust and air from the first conduit and the flowable foam from said second conduit are combined in a Y-joint having an outlet. A mixture of rock dust, air and foam are thereby caused to flow through the outlet and applied through a nozzle to a mine wall.
[0012] The method and apparatus in accordance with the invention can utilize existing rock dust application equipment. The method and apparatus can also avoid the time-consuming and difficult process of mixing of foam and rock dust in a mixing vessel and delivery of the mixture over long distances from the mixing tank to a mine wall. The method and apparatus are also superior to alternatives in which a dry composition of rock dust and foaming agent are applied to a wet mine.
[0013] Another aspect of the invention is a process for applying rock dust to a mine wall comprising mixing finely ground limestone powder with a foam containing a composition consisting of one or more saturated fatty acids to produce a resulting mixture of foam and limestone powder, and applying the resulting mixture to the wall of a coal mine. The concentration of the fatty acid composition in the foam, and the amount of foam mixed with the limestone powder, are preferably such that the ratio of grams of the composition consisting of one or more fatty acids to each kilogram of limestone powder in the mixture is in the range from approximately 1.74 to 3.48. This range is inclusive of the ratios 1.74 to 3.48.
[0014] Although the fatty acid composition can come into contact with the limestone at any stage of the process, preferably the limestone powder and foam containing the fatty acid composition are combined by causing the limestone powder and foam to flow through separate conduits to a combiner from which the resulting mixture is caused to flow through a nozzle for application to the wall of a coal mine.
[0015] Stearic acid is preferred as the fatty acid composition because it is inexpensive and readily available. However, good results can be achieved using related compositions such as palmitic acid or arachidic acid. Comparable results can also achieved with other related saturated fatty acids, and of course combinations of two or more different saturate fatty acids can be utilized.
[0016] Further advantages of the invention will be apparent from the following description when read in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a schematic diagram of an apparatus in accordance with the invention;
[0018] FIG. 2 is a more detailed schematic diagram of the dry rock dust entrainment apparatus which constitutes a component of the apparatus of FIG. 1 ;
[0019] FIG. 3 is a more detailed schematic diagram of the foam/air mixing device which constitutes a component of the apparatus of FIG. 1 ;
[0020] FIG. 4 is a detailed schematic diagram of the Y-joint and nozzle structure for application of a foam and rock dust mixture to a mine surface; and
[0021] FIG. 5 is a graph depicting the results of flotation tests on limestone particles treated with varying quantities of foam containing stearic acid.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] In the apparatus shown in FIG. 1 , compressed air is supplied through a first line 10 and through a second line 12 . The compressed air can be supplied by a single compressor or by plural compressors. For the purpose of this description, line 10 and line 12 will be referred to respectively as “first and second” sources of compressed air even if they both derive air from the same compressor.
[0023] The first source is connected to a rock dust system 14 , which is a known apparatus designed to draw rock dust from a supply, entrain the rock dust in air, and deliver the air-entrained rock dust through a long, flexible, conduit to an applicant site within a mine, where the rock dust is sprayed onto a mine wall.
[0024] Details of the rock dust system 14 are shown in FIG. 2 . The system comprises an enclosed vessel 16 in the form of a horizontally elongated, enclosed, cylindrical, tank, which can be pressurized. A quantity of rock dust 18 is brought into the tank through a hatch (not shown) from a supply, usually above-ground. For compliance with U.S. Department of Labor regulation 30 C.F.R. §75.2, the rock dust used in the tank should consist of “pulverized limestone, dolomite, gypsum, anhydrite, shale, adobe or other inert material, preferably light colored, 100 percent of which will pass through a sieve having 20 meshes per linear inch, the particles of which when wetted and dried will not cohere to form a cake which will not be dispersed into separate particles by a light blast of air, and which does not contain more than 5 percent combustible matter or more than a total of 4 percent free and combined silica (SiO 2 ), or, where the Secretary finds that such silica concentrations are not available, which does not contain more than 5% percent of free and combined silica.”
[0025] The supply of rock dust 18 in tank 16 rests on a diffuser 20 , typically a layer of cloth, below which an air chamber 22 is formed. The air chamber 22 receives air from air line 10 . In an embodiment having two or more air chambers in side-by-side relationship, a diverting valve 24 can be used to divide the air flow so that each of the air chambers receives an adequate supply of air.
[0026] The air passes up through the diffuser (or through plural diffusers if more than one diffuser are provided), into the rock dust 18 , causing the rock dust to take the form of a fluidized bed, from which rock dust can be drawn through a dip pipe 26 , which extends into the fluidized bed to a location a short distance above the diffuser. The dip pipe leads to modulating valve 28 located outside the tank. Through a conduit 30 , the modulating valve receives compressed air derived from the space 32 inside the tank above the fluidized bed. In the modulating valve 28 , the rock dust flowing through the dip tube 26 is entrained in the air from conduit 30 , and the mixture of air and rock dust is carried away from the modulating valve through a first conduit 32 , also shown in FIG. 1 .
[0027] The modulating valve includes a flexible diaphragm 34 , forming a part of the wall of a mixing chamber 36 , through which air flows from conduit 30 past the outlet of dip pipe 26 . A stem 38 that extends through and moves with diaphragm 34 has a poppet 40 at one end, arranged to regulate flow of air and rock dust from dip pipe 26 into the mixing chamber 36 . The stem also extends through a wall 42 and is connected to an operating diaphragm 44 that separates the space between wall 42 and a cover 46 into two control chambers 48 and 50 . A spring 52 urges the operating diaphragm in the direction to close the poppet 40 .
[0028] A valve 54 in conduit 30 is controllable to restrict the flow of air through the conduit. On the upstream side of the valve 54 , the conduit 30 is connected through a tube 56 to control chamber 50 , and on the downstream side, the conduit is connected through a tube 58 to control chamber 48 .
[0029] The restriction of air flow by valve 54 causes a pressure drop which in turn creates a pressure differential across the operating diaphragm 44 in the modulating valve, thereby allowing the amount of dust delivered through conduit 32 to be controlled. When the aperture of valve 54 is reduced, the pressure differential across the operating diaphragm 44 cause the poppet 40 to move in the opening direction, increasing the rate of flow of dust and air from dip tube 26 into the mixing chamber 36 . At the same time, the reduction of the aperture of valve 54 reduces the flow of air into the mixing chamber through conduit 30 . The result is that the rate of flow of rock dust exiting through conduit 32 increases while the air flows through conduit 32 at a relatively steady rate. Thus, the valve 54 can be used to control the concentration of rock dust delivered through conduit 32 .
[0030] Referring again to FIG. 1 , the air in line 12 is split into two flow paths, one passing through a ball valve 60 to an air motor 62 , which operates a high pressure hydraulic pump 68 , arranged to deliver a foamable liquid from a supply line 70 to a line 72 , which leads to a mixing block 74 . Exhaust air from the air motor 62 passes to the atmosphere through line 76 . A pressure gauge 78 is provided for monitoring the pressure of foamable liquid delivered to the mixing block through line 72 . Valve 60 can be used to control the flow of foamable liquid though line 72 .
[0031] The other path into which air from line 12 is split comprises line 80 , another ball valve 82 , and a check valve 84 , the outlet of which is connected to deliver air to the mixing block 74 . Valve 82 can control the air to the mixing block. A pressure gauge 86 is provided to monitor the air pressure in the air path leading to the mixing block.
[0032] As shown in FIG. 3 , the mixing block 74 comprises a metal block having internal passages. Compressed air delivered through check valve 84 ( FIG. 1 ) enters the block though an opening 88 and diluted foam concentrate, delivered as a liquid by pump 68 through line 72 , enters the block through opening 90 . The diluted foam concentrate flows through passage 92 and restriction 94 into a mixing chamber 96 having an outlet 98 . Compressed air flows through passage 100 and into the mixing chamber 96 through a restricted passage 102 , which meets the side of mixing chamber 96 so that the flow of compressed air into mixing chamber 96 is perpendicular to the direction of flow of the liquid foam concentrate. Turbulence in the mixing chamber produces the foam that is delivered through outlet 98 . The mixing block regulates the flow of diluted foam concentrate and compressed air to maintain proper proportions.
[0033] Referring again to FIG. 1 , the outlet of the mixing block is connected through a conduit 104 to a Y-joint 106 , in which foam in conduit 104 and rock dust entrained in air in conduit 32 are mixed.
[0034] As shown in FIG. 4 , the Y-joint 106 comprises a coupling 108 for connection to rock dust conduit 32 , and a side inlet 110 for connection to the foam conduit 104 . The side inlet 110 delivers the foam into an elongated interior chamber 112 aligned with the coupling 108 . The foam and rock dust are mixed in chamber 112 , and the mixture is delivered through a discharge nozzle 114 at the end of chamber 112 remote from coupling 108 .
[0035] All or parts of the rock dust conduit 32 and the foam conduit 104 can be flexible, allowing an operator to aim the nozzle for application of a foam and rock dust mixture to a mine surface.
[0036] The foamable liquid delivered to pump 68 through line 70 ( FIG. 1 ) can be prepared by dilution of a foam concentrate with water. A suitable foam concentrate is composed of an anionic surfactant and a carboxylic acid salt, described in U.S. Pat. No. 4,874,641, granted Oct. 17, 1989, the disclosure of which is here incorporated by reference. The foam exhibits a high degree of stiffness and longevity, making it especially suitable for application along with rock dust to a mine surface. Optionally, a quantity of a thickener such as hydroxypropylmethylcellulose to the foam concentrate can be added to increase foam stability and increase foam volume.
[0037] An example of a suitable foam concentrate described in U.S. Pat. No. 4,874,641 is one composed of 4% by weight sodium α-olefin sulfonate (100% active basis), 3.6% by weight stearic acid (100% active basis), 0.71% by weight potassium hydroxide, and 91.69% by weight, water. Any of the compositions described in U.S. Pat. No. 4,874,641, as well as many other known foaming compositions, can be used. The foam concentrate can be diluted with water to a ratio as high as approximately 10:1.
[0038] Another foam concentrate that can be used is one composed of 4% by weight sodium α-olefin sulfonate (100% active basis), 5% by weight stearic acid (100% active basis), 0.71% by weight potassium hydroxide, and 90.29% by weight, water. This concentrate can be utilized effectively at dilution ratios (water to concentrate) up to about 10:1. Significantly lower dilution ratios can be used, but reducing the dilution ratio below 7:1 has little if any beneficial effect, and can increase operating costs unnecessarily.
[0039] As mentioned above, the function of the mixing block is to maintain proper proportions of the diluted foam concentrate and compressed air. In the case of a diluted foam concentrate having the composition described above, a desirable proportion is from 2.75 to 3 cubic feet of compressed air (at approximately 100 psi) for each gallon of liquid. The apertures of the restrictions in the mixing block are chosen accordingly. The sizes of the apertures, of course, also affect the rate of foam delivery.
[0040] In the operation of the apparatus of FIG. 1 , foam generated in the mixing block is carried to the point of application to a mine surface by conduit 104 while rock dust entrained in air is carried to the point of application by conduit 32 . The foam, rock dust, and air are combined in the Y-joint 106 , and sprayed onto the mine surface by nozzle 114 . The Y-joint/nozzle assembly can be hand-held, or moved by robotic machinery.
[0041] The concentration of rock dust in air in conduit 32 is controlled by valve 54 ( FIG. 2 ) and regulated by the operation of the modulating valve 28 .
[0042] The proportion of foam to rock dust can vary considerably, and will depend to a large extent on the personal preference of the individual who carries the nozzle and applies the foam/rock dust mixture to a mine wall. In general, if the mixture contains too much rock dust, excessive amounts of fugitive rock dust can become airborne. On the other hand, if excessive amounts of foam are used, there is not only waste of foam producing chemical, but the amount of rock dust may be insufficient to achieve the desired fire-suppressing effect.
[0043] A number of foam/rock dust compositions were produced using a foam concentrate containing 5% stearic acid, diluted with 8 parts of water to 1 part concentrate. The wet weight of the foam/rock dust composition varied from 21.78 to 69.5 Lb/ft 3 . The water content (by weight) and the air content (by volume) of the several compositions are shown in the following table. The increasing weight of the samples corresponds to increased rock dust content, the rock dust by itself having a density of 90 Lb/ft 3 .
[0000]
TABLE
Sample
Lb/ft 3 (wet)
% water
% air
1
21.78
37.35
84.74
2
31.18
22.88
73.28
3
33.29
15.8
68.86
4
35.07
25.27
70.88
5
35.29
21.7
69.3
6
40.84
19.48
63.46
7
42.9
18.69
61.25
8
54.28
13.38
47.76
9
54.39
11.99
46.82
10
55.72
11.98
45.51
11
57.15
12.13
44.2
12
61.05
11.19
39.76
13
69.5
9.58
30.18
[0044] Samples 2-10 yielded satisfactory results, and sample 5, having a wet weight of 35.29 Lb/ft 3 was considered to produce the best results. Sample 1 contained too much water and samples 11-13 had too high a rock dust to water ratio. It was observed that a higher air content produced a lighter, and more readily dispersed, mixture. For that reason, an air content of at least approximately 40% by volume is preferred.
[0045] The apparatus and method of the invention produce results in common with prior methods that utilize foams in combination with rock dust. For example, fugitive dust is significantly reduced, and the foamed rock dust encapsulates coal dust particles. The invention, however, has additional advantages. As mentioned above, conventional rock dust application equipment, e.g., the apparatus shown in FIG. 2 , can be utilized in the practice of the invention, so that high volumes of rock dust/foam mixture can be applied to mine surfaces easily, rapidly, and efficiently. Since mixing of the rock dust and foam takes place immediately upstream of the application nozzle, it is unnecessary to carry out the mixing of foam and rock dust as a batch process utilizing a mixing vessel. The method and apparatus can provide for delivery of the rock dust and foam to the vicinity of the application nozzle through flexible hoses over relatively long distances, so that movement of the foam generating and rock dust entrainment equipment can be minimized. Still another advantage of the invention lies in its ability to allow the operator to make adjustments of the foam/rock dust composition and density rapidly, and while at the application site in a mine, in order to meet existing conditions.
[0046] Further experiment were carried out to determine the effectiveness of the stearic acid component of the foam in imparting hydrophobic properties to limestone particles. In these experiments, limestone dust samples were prepared by obtaining commercially available pre-screened limestone, sized specifically for mine wall application. The dust particles were then mixed with a diluted foam concentrate corresponding closely to one of the foam concentrates described above, namely, the one composed of approximately 4% by weight sodium α-olefin sulfonate (100% active basis), approximately 5% by weight stearic acid (100% active basis), approximately 0.71% by weight potassium hydroxide, and the remainder water. The coated dust particles were then dried in an oven at 200° F. and then screened to yield dust particles in a size range from 200 to 100 US mesh.
[0047] Weighed samples of the dried and screened coated dust particles were then subjected to a flotation test by sprinkling the material onto the surface of a quantity of water, and the amount that fell to the bottom was dried and weighed.
[0048] In an exemplary experiment, the foam concentrate was diluted 7:1 with water and mixed with a quantity of limestone particles as set forth in the following table:
[0000] Sample 1 2 3 4 5 6 7 8 lb rock dust/ 20 25 30 38.4 all 35 15 10.0 gal mix rock gal mix/ .05 .04 .033 .026 0 .029 .067 0.10 lb rock dust wt % stearic 0.26 0.21 0.17 0.13 0 0.15 0.34 0.52 g stearic/ 2.62 2.09 1.74 1.37 0 1.50 3.48 5.24 kg rock dust
The graph in FIG. 5 shows the percentage of each sample that remained on the surface of the water on a dry weight basis. From the graph it can be seen that four of the samples exhibited a flotation ratio of 93% or higher, and were evaluated as having satisfactory hydrophobic properties.
[0049] The satisfactory samples were derived from a mixture in which the calculated weight % of stearic acid in the diluted foam concentrate was in the range from approximately 0.17 to 0.34. Outside this range, the percentage of particles that remained afloat after a short time fell off rapidly. Accordingly, based on the exemplary test described above and similar tests, it was determined that the useful range for the ratio of grams of stearic acid to a kilogram of limestone particles in the mixture of foam and limestone particles was in the range of approximately 1.74 to 3.48.
[0050] Similar results can be achieved using saturated fatty acids closely related to stearic acid, such as palmitic acid, CH 3 (CH 2 ) 14 COOH, and arachidic acid CH 3 (CH 2 ) 18 COOH in a foam composition. Moreover, hydrophobic properties can be imparted to limestone dust by treating them with other saturate fatty acids in the same family, such as caprylic acid CH 3 (CH 2 ) 14 COOH, capric acid CH 3 (CH 2 ) 8 COOH, lauric acid CH 3 (CH 2 ) 10 COOH, myristic acid CH 3 (CH 2 ) 12 COOH, behenic acid CH 3 (CH 2 ) 20 COOH, lignoceric acid CH 3 (CH 2 ) 22 COOH, and serotic acid CH 3 (CH 2 ) 24 COOH. Stearic acid is preferred, however, primarily because it is inexpensive and readily available.
|
Rock dust is applied to a coal mine wall for mine fire suppression in combination with a chemical foam containing a saturated fatty acid, preferably stearic acid, which imparts hydrophobic properties to the rock dust particles, avoiding agglomeration. The rock dust and foam containing a saturated fatty acid are combined by causing the rock dust and foam to flow through separate conduits to a combiner from which the resulting mixture is caused to flow through a nozzle for application to the mine wall.
| 4
|
FIELD OF THE INVENTION
This application relates to heating apparatus for railway switch assemblies.
BACKGROUND OF THE INVENTION
It is common in the railway industry in cold climates to use a heating system to control snow and ice build-ups at the switches to ensure that the switches throw properly. It is also common that a switch heater system for this purpose comprises a furnace placed adjacent the switch and duct work for moving the heated air from the furnace to the desired locations along the rails or the switch assembly.
Many of the conventional switch heaters currently in use comprise duct work running from the furnace between a pair of ties and under a near rail to a position between the rails. The heated air is then fed up along the top of the ties parallel to the rails to cover the required distance along the switch rails.
The conventional switch heaters thus described are prone to several significant problems. The energy demand required to successfully melt the ice and snow is extremely high. However, the duct work currently used is typically of simple steel manufacture and consequently, there is tremendous energy lost through the walls of the duct work.
The placement of the duct work between the rails also contributes to significant problems in the switch assembly. It is known to be highly desirable to keep the road bed beneath the switching area in as good condition as possible so as to reduce the impact of the switching process on the wheels of the train, thereby reducing the risk of breakage or derailments. Since the conventional switch heaters heat not only the rails in the area of the switch but also the road bed lying beneath the duct work, a softening effect, commonly referred to as soft-track, occurs on the road bed which can result in significant depressions in the switching area. Also, since the ballast between the ties in the area of the switch must be continually re-tamped with the use of tamping machines, the duct work that is located in that space between the ties must be removed and replaced each time, a task of considerable effort, time and cost.
The area around the switch assembly is prone to a great deal of vibration and movement resulting from the passing of trains. A resulting problem is that the duct work leading from the furnace is often susceptible to undue wear and metal fatigue requiting the duct work to be frequently replaced.
Thus, many of the existing conventional switch heaters produce undesired results which may in some cases severely diminish their advantages and significantly increase the costs of maintaining the switch assembly in proper working condition. Reference is made for example to U.S. Pat. No. 4,081,161 of Upright, issued Mar. 28, 1978 (currently owned by the present applicant); U.S. Pat. No. 3,536,909 of Czyl, issued Oct. 27, 1970; U.S. Pat. No. 2,704,517 of De Garcia (Mengod), issued Mar. 22, 1955; and U.S. Pat. No. 1,802,875 of Conley, issued Apr. 28, 1931.
SUMMARY OF THE INVENTION
In one aspect of the invention there is provided an apparatus for use in the heating of a railway switch assembly. The apparatus comprises a hollow structural member adapted to replace a track supporting member (such as a conventional railway tie) and adapted to be connected to a source of heated air. There is also provided discharge means for distributing the heated air from the hollow structural member to at least one desired location on the assembly.
In a preferred embodiment of the invention, the hollow structural member is insulated.
In another preferred embodiment of the invention, there is provided an insulation assembly between the hollow structural member and the rails.
In yet another preferred embodiment, the source of heated air and the hollow structural member are connected by a flexible connection which permits axial and rotational between the source of heated air and the hollow structural member.
In still another preferred embodiment, the discharge means comprises at least one of a point nozzle or a distribution duct running parallel to and between a pair of rails.
The railway switch heater apparatus of the present invention thus provides a means of heating the switch assembly and the rails. The construction of the hollow structural member is adapted to replace a conventional railway tie and direct heated air from a source to desired points along the switch assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other advantages of the invention will become apparent upon reading the following detailed description and upon referring to the drawings in which:
FIG. 1 is a perspective view of the invention in use with a railway switch assembly.
FIG. 2 is an exploded view of the invention having a single hollow structural member.
FIG. 3 is an exploded view of the invention having a pair of hollow structural members.
FIG. 4 is a cross-sectional view of the hollow structural member taken along the line A--A of FIG. 2.
FIG. 5 is a cross-sectional view of the insulating assembly taken along line B--B of FIG. 2.
FIG. 6 is a plan view, partly in cross-section, of a preferred embodiment of the flexible connection.
While the invention will be described in conjunction with illustrated embodiments, it will be understood that it is not intended to limit the invention to such embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, similar features in the drawings have been given similar reference numerals.
Turning to the drawings, FIG. 1 illustrates a switch heating assembly 2 for use in heating rails 10 mounted on ties 12. The assembly comprises a housing 14 generally containing a propane or natural gas fired furnace 16 (not shown) with supply duct 18. The supply duct 18 is connected to at least one hollow structural member 20 adapted to replace a conventional tie 12 and having discharge nozzle 22 (discussed in more detail below) or an upstanding discharge elbow duct 24 connected to a distribution duct 26 to discharge heated air from the housing 14 to desired points along the assembly 2.
FIG. 2 shows an exploded view of the switch heating apparatus of the present invention having a single hollow structural member 20. The member 20 is constructed to replace a conventional railway tie 12 and thus support rails 10. The member 20 is connected to a supply duct 18 of a source of heated air 16 (not shown), commonly a propane or natural gas fired furnace. The member is provided with discharge means for transferring the heated air from the source 16 to the rails 10, namely a standard point nozzle 22 and/or an upstanding discharge elbow duct 24 connected to a discharge duct 26 extending parallel to the rails 10.
FIG. 3 shows an exploded view of a preferred embodiment of the heating apparatus having a pair of hollow structural members 20, and a Y-shaped duct 28 connecting the members 20 to the supply duct 18.
The members 20 are preferably thermally insulated along their length. As most clearly illustrated in FIG. 4, the member 20 comprises an outer shell 30, an insulating liner 32 of suitable insulation material, such as Roxul™, and an inner liner 34 of stainless steel.
With reference to FIG. 5, in a preferred embodiment of the invention, the member 20 is electrically and thermally insulated from the rails 10 by a first insulating pad 36, of approximately 1/4 inch thickness and constructed of material such as silicone or neoprene, mounted on the member 20; a steel pad 38 of approximately 3/4 inch thickness, having a pair of rail shoulders 40 welded thereon; and a second insulating pad 42, of approximately 1/4 inch thickness and made of material such as polyurethane. The steel pad 38 is insulated from the member 20 by the first insulating pad 36 and from the rails 10 by the second insulating pad 42. The steel pad may be tapered at 43 to account for banking, or curvature (not shown) in the rails 10. The rail 10 is thus secured to the member 20 by securing the rail clip 44 to the rail 10 and the rail shoulder 40 mounted on the steel pad 38; and by securing the steel pad 38 to the member 20 by the rail clip 45, secured to the shoulder 47, mounted on the member 20. The steel pad 38 is further insulated from the rails 10 by use of rail clip insulator 46, mounted between the rail clips 44 and the rail 10 and between the rail clips 45 and the steel pad 38.
In one embodiment of the invention, as best illustrated in FIGS. 2 and 3, there is provided in the first insulating pad 36, an aperture 48 concentric with an aperture 50 in the member 20, an aperture 52 in the steel pad 38, a nozzle adapter 54 and the inlet portion 56 of nozzle 22. Provided between the steel pad 38 and the nozzle adapter 54 is an adapter insulator 58 to further prevent heat or energy loss from the member 20.
In another embodiment of the invention, the elbow 24 connecting the member 20 to the distribution duct 26 is mounted to the member 20 by means of an adapter plate 60 having downwardly turned flanges 62. The member 20 is provided with an aperture 64 through which heated air may pass. In use, that aperture 64 is placed in mating relation with an aperture 66 on an adapter plate insulator 68, constructed from material such as silicone or neoprene to insulate the adapter plate 60 from the member 20, and an aperture 70 on the adapter plate 60. The heated air may passes from the member 20, through the described apertures to the inlet portion 74 of elbow 24. The heated air is then passed to the outlet portion 76 of the elbow 24 which, in use, is in mating relation with the inlet aperture 78 of the distribution duct 26. The heated air may then be distributed along various points of the assembly 2 by means of a plurality of selectively opened apertures 80 at points along the distribution duct 26. These apertures may be selectively opened during the installation of the apparatus to direct heated air to points along the rails 10 as required by the application. The distribution duct 26 is sealed at opposing end 82.
In a preferred embodiment of the invention, there is a flexible connection, shown generally at 84 connecting the member 20 to the supply duct 18. As illustrated in FIG. 3, this flexible connection may be in the form of a flexible duct 86, constructed of silicone. There is further provided a covering member 88, preferably constructed of galvanised steel, positioned relative to the flexible duct 86 so as to protect it from being damaged by rocks and similar debris displaced by a passing train.
In a most preferred embodiment of the invention, the flexible connection is in the form of a gasket assembly 90, as best illustrated in FIG. 6, which permits rotative and axial movement about the end of the member 20 occasioned by the vibration of a passing train. The gasket assembly 90 comprises a first 92 and second 94 overlapping duct member in slidable and telescoping relation to each other and a flexible gasket 96 mounted respectively between the outer extremities 98 and 100 of the first 92 and second 94 overlapping duct members and the outer extremity 102 of the adjacent member 20 or supply duct 18. The overlapping duct members 92 and 94 are typically constructed of stainless or galvanized steel and the flexible gasket 96 is preferably constructed of silicone.
The outer extremities 98 and 100 of the first 92 and second 94 overlapping duct members respectively and the outer extremity 102 of the adjacent member 20 or supply duct 18 are provided with flanges 104 extending normally from the first 92 and second 94 overlapping duct members and the outer extremity 102 of the adjacent member 20 or supply duct 18 for engagement into the recesses 106 provided in the flexible gasket 96. Positioned around the flexible gasket 96, there is provided a coveting member 108, preferably constructed of stainless steel, having a cross member 110 extending across said gasket and a pair of inwardly turned flanges 112 extending over at least a portion of the exposed lateral surfaces 114 of the gasket 96.
The gasket 96 is comprised of a first portion 116, a second portion 118 and a third portion 120. The first 116 and second 118 portions and the second 118 and third 120 portions are separated by the recesses 106 respectively. Each of the first 116, second 118, and third 120 portions of the gasket 96 is provided with a longitudinal cavity 122, 124, and 126 respectively. The cavities provide stiffness to the gasket 96 while permitting the requisite axial and rotative flexibility of the gasket 96 about the respective abutting member ends. The second portion 118 extends longitudinally between the abutting member ends to fill the gap between the ends when in place within the heating apparatus thus providing a flexible seal between the adjacent member 20 and duct.
As seen in FIG. 2, in an embodiment of the invention, there may be provided an extension duct 128 connecting the member 20 and the supply duct 18, or the flexible connection 84 and the supply duct 18. There is further provided at least one insulating gasket 130 positioned between the abutting end 132 of the extension duct 128 and of the abutting end 134 of the supply duct 18 or, the abutting end 136 of the flexible connection 84 (when the supply duct 18 is not used). A similar gasket may be positioned between abutting ends of any two extension ducts 128 when used.
As demonstrated above, the member 20 is adapted to replace a conventional tie 12, rather than being positioned between a pair of ties 12 as is common in the prior art. This configuration and the insulation of the member 20 along its length thus help prevent the problem of soft-tracking and the need for re-tamping which are prevalent in conventional railway switch heaters while delivering improved control of snow and ice to required points along the switch assembly.
Thus, it is apparent that there has been provided in accordance with the invention an apparatus for use in a railway switch assembly that fury satisfies the objects, aims and advantages set forth above. While the invention has been described in conjunction with example embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and broad scope of the invention.
|
There is provided a new and useful apparatus for use in a railway switch heating assembly. The apparatus includes a hollow structural member adapted to replace a conventional railway tie and adapted to be connected to a source of heated air, and a mechanism for discharging the heated air from the hollow member to desired locations along the assembly.
| 4
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the servicing of underground watering systems, and more particularly concerns a hand tool for the removal and replacement of sprinkler head components of underground systems for lawn watering.
2. Description of the Prior Art
Underground watering systems are commonly utilized for accurately and controllably spraying water onto grass lawns. Such systems are comprised of plastic supply pipes arranged as a substantially horizontal network installed about one to two feet below the lawn. At strategic intervals and locations, riser pipes are vertically emergent from the supply pipes, and terminate in male threaded extremities.
A sprinkler head is attached to the upper extremity of each riser pipe. The sprinkler head is comprised of a cylindrical housing, generally of plastic construction, having a centered bottom female threaded collar aperture adapted to screw onto the threaded upper extremity of the riser pipe. A removable spring-actuated internal cartridge is seated within the cylindrical housing, and is secured therein by external threading on the upper extremity of the housing. The upper extremity of said cartridge has a circular rim having peripheral apertures for the radial distribution of water. Said rim is operationally positioned at an elevation adjacent the root line of the grass.
In the course of foot and/or vehicle traffic upon the lawn, and mowing maintenance, sprinkler heads become damaged, and often require replacement. U.S. Pat. No. 4,788,894 to Mitschele discloses a hand tool for removing sprinkler heads from underground watering systems. Mitschele's tool is comprised of a hollow encasement dimensioned to embrace the entire length of the sprinkler head while also engulfing surrounding soil. The encasement containing the sprinkler head is then twisted, causing the engulfed soil to compressively grip the housing member of the sprinkler head. Further twisting causes the sprinkler head to unthreadably detach from the underlying riser pipe to permit upward removal. Such action leaves an empty hole in the ground.
Although the Mitschele tool may perform properly with permissive soil texture and moisture, removal of the compressed soil from the encasement is difficult. Even more difficult is the return of the removed soil to the hole to facilitate proper seating of a replacement sprinkler head while preventing soil from entering the open upper extremity of the riser pipe. Also, Mitschele makes no provision for accurately aligning a replacement sprinkler head for threadable engagement with the upper extremity of the riser pipe.
Accordingly, it is an object of the present invention to provide a tool for the removal and replacement of a sprinkler head component of an underground watering system.
It is another object of this invention to provide a tool as in the foregoing object which can be hand-manipulated.
It is a further object of the present invention to provide a tool of the aforesaid nature which does not require removal of surrounding soil to achieve removal of a sprinkler head.
It is an additional object of this invention to provide a tool of the aforesaid nature having means for aligning a replacement sprinkler head for proper threaded installation upon an underlying riser pipe.
It is a still further object of the present invention to provide a tool of the aforesaid nature adaptable to use with sprinkler heads of various diameter.
It is yet another object of this invention to provide a tool of the aforesaid nature which is easily maintainable, durably constructed and amenable to low cost manufacture.
These objects and other objects and advantages of the invention will be apparent from the following description.
SUMMARY OF THE INVENTION
The above and other beneficial objects and advantages are accomplished in accordance with the present invention by a hand manipulatable tool for removing and replacing the sprinkler head of an underground watering system, said sprinkler head having an uppermost circular top rim, said tool comprising:
1) a metal pipe component extending on a straight center axis between large and small open gripping extremities, and having at least one pair of diametrically opposed apertures, each gripping extremity having an outwardly flared portion adapted to engage variously sized circular top rims of sprinkler heads, said engagement being sufficiently strong to permit rotation and lifting of said sprinkler head, and 2) a straight handle rod adapted to penetrate said apertures to facilitate rotation of said pipe about said axis and lifting of said tool with an engaged sprinkler head.
BRIEF DESCRIPTION OF THE DRAWING
For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawing forming a part of this specification and in which similar numerals of reference indicate corresponding parts in all the figures of the drawing:
FIG. 1 is a side view of an embodiment of the tool of the present invention shown in operative association with a sprinkler head of an underground watering system.
FIG. 2 is an enlarged vertical sectional view of the embodiment of FIG. 1 .
FIG. 3 is an enlarged bottom view of the embodiment of FIG. 2 .
FIG. 4 is an enlarged vertical sectional side view of the large gripping extremity of the embodiment of FIG. 2 .
FIG. 5 is a sectional side view illustrating a secondary mode of function of the tool of the present invention.
FIG. 6 is an exploded side view of the sprinkler head of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1-5 , an embodiment of the sprinkler head removing tool 10 of this invention is shown comprised of a metal pipe component 11 of monolithic construction extending upon a straight center axis 12 between large and small open gripping extremities 13 and 14 , respectively. At least one pair of diametrically opposed apertures 15 slidably accommodate a straight rod handle 16 .
In the illustrated embodiment, pipe 11 has an overall length between 27 and 32 inches, and an inside diameter of about 2″ inches. Rod handle 16 has a diameter of about ½″ and a length of 12 to 14 inches. Both the large and small gripping extremities have outwardly flared, substantially conically shaped portions 17 and 22 respectively, terminating in circular perimeter edges 41 and 42 , respectively. Such flared structure is the result of high force insertion of a substantially conical shaping mandrel into the extremities of pipe 11 , causing controlled expansion of said perimeter edges. The interior surface 46 of each flared portion preferably contains gripping features capable of frictionally securing the circular plastic upper rim 24 of a typical sprinkler head 25 .
The present invention is based in part upon the discovery that effective gripping features can be in the form of discontinuities in the otherwise symmetrical circular cross section of the flared portions. Preferred discontinuities are in the form of axially elongated intrusions 45 integral with the interior surface 46 of the flared portions and projecting inwardly toward said axis by an amount equal to about 1%-2% of said inside circular diameter. At least two such intrusions are preferred in spaced apart relationship. In a particularly preferred embodiment, a first intrusion, having a width of about 5% of the circumference of the circular cross section of the flared portion, is spaced apart by about 3% of said circumference from a second intrusion having a shape and dimensions comparable to said first intrusion. In preferred embodiments, the number and spacing of said intrusions is such as to occupy about 90° of the periphery of the flared portion. Said intrusions are produced by axially elongated flattened regions in a conically shaped mandrel which is forced into each extremity of pipe 11 for the purpose of producing said flared portions.
The conically shaped portion 17 of large gripping extremity 13 extends axially about 3.7 inches. Its associated circular perimeter edge 41 has an inside diameter of about 2⅜ inches, thereby defining a convergence angle A of about 5° relative to axis 12 . Small gripping extremity 14 extends between circular perimeter edge 42 , having an inside diameter of about 2⅛ inches, and an annular crimp depression 21 having been formed in a compression swage reduction operation. The distance of separation between edge 42 and depression 21 is about 3.7 inches, and defines a convergence angle A of about 6°. The overall effect of the two gripping extremities is to enable the handling of sprinkler heads whose circular rim diameters 24 range from 1¾″ and 2⅜″. The different convergence angles, which may range between 4° and 7°, provide versatility of gripping effectiveness. It has further been found that the gripping effectiveness is better when the tool is fabricated of iron rather than plastic.
In operation, as shown in FIG. 1 , the tool of the present invention is vertically placed upon the circular rim 24 of sprinkler head 25 confined within hole 26 in the soil 27 . Said circular rim is generally positioned at the root level of the lawn grass 28 . A female threaded collar 29 centered within the bottom of said sprinkler head threadably engages the male threaded upper extremity 30 of riser pipe 31 emergent from supply line 32 . With downward force, the gripping extremity secures the circular rim 24 , and permits unthreading and lifting motions to remove the sprinkler head from hole 26 without disturbing the contour of the hole.
A replacement sprinkler head can generally be installed simply by inserting it into the hole and twisting. However, in many instances there may be difficulties in precisely aligning the female threaded collar 29 on the bottom of the sprinkler head with the male threaded upper extremity 30 of the riser pipe. In such instances, a typical sprinkler head, constructed as shown in FIG. 6 , is dismantled by unthreading and removing the center cartridge 34 from housing component 35 . Then, as shown in FIG. 5 , rod handle 16 , removed from pipe 11 , is inserted downwardly through said housing component and into riser pipe 31 . Such action achieves the necessary alignment and securement of the involved threaded members. It also prevents entrance of dirt into the riser pipe. The rod handle is then removed and center cartridge 34 is re-threaded onto housing component 35 . The aligned and intact sprinkler head is then twisted using the tool of this invention to complete the installation.
While particular examples of the present invention have been shown and described, it is apparent that changes and modifications may be made therein without departing from the invention in its broadest aspects. The aim of the appended claims, therefore, is to cover all such changes and modifications as fall within the true spirit and scope of the invention.
|
A hand manipulatable tool for removing and replacing sprinkler heads threadably connected to an underground watering system employs a straight metal pipe component having outwardly flared portions at both extremities adapted to grip the sprinkler heads. A straight handle rod interactive with the pipe component facilitates unscrewing and lifting of the gripped sprinkler head.
| 8
|
FIELD OF THE INVENTION
[0001] This invention relates to the transdermal delivery of therapeutic or diagnostic substances using apparatus or devices to assist in the delivery, including iontophoresis, sonophoresis, syringes and needles and micro-needle devices. In particular, this invention describes the enhanced delivery profiles for drug substances when these agents are formulated to include a vasomodulatory chemical agent with the intent to induce either a vasodilatory or vasoconstrictive response in the area of tissue that has been exposed to the drug application (e.g., injection site).
BACKGROUND OF THE INVENTION
[0002] Administration of drug substances through the skin for systemic circulation of the drug or for a localized delivery has been practiced for years through the use of syringes and needles. However, the physical act of introducing a needle into the skin has certain obvious negative reactions including pain and discomfort as well as potential negative side effects to the localized tissue as a result for the trauma of physical disruption due to the relatively large needle penetrating the skin.
[0003] Other devices have been developed that also promote the efficiency of transdermal drug delivery, including sonophoresis and iontophoresis. These methods have certain advantages over the syringe and needle method by not breaking the skin, however there are also disadvantages inherent to these technologies, including some skin irritation associated with the adhesives and the tissue disruption due to the energies involved with the delivery. In addition, there are limitations to these technologies related to the speed of drug administration and the associated need to remain attached to an external apparatus during the administration.
[0004] The stratum corneum layer of the skin has been identified as the rate-limiting barrier to successful transdermal drug delivery. The technologies listed above addressed this barrier through the energy-assisted movement of drug molecules across this barrier. Others have included the use of different vasoactive chemicals to assist in the optimized delivery of drug molecules, either for localized or systemic delivery (U.S. Pat. No. 5,302,172). The inclusion of vasodilator substances in transdermal delivery vehicle has been described as being useful for enhanced efficiencies in transdermal drug delivery (U.S. Pat. Nos. 5,460,821; 5,645,854; 5,853,751; and 6,635,274).
[0005] There are however limits to the abilities of some of these systems, either with or without the use of vasoactive chemicals to achieve successful transdermal drug delivery as a result of the significant barrier presented by the stratum corneum. These drug molecules include those molecules that are larger in physical size and those with significant ionic charges and those with complex quaternary structure.
SUMMARY OF THE INVENTION
[0006] The invention identifies methods to be employed for improving the efficiency of transdermal drug delivery using vasoactive chemicals in the delivery vehicle or in concert with the delivery vehicle. In particular, improvements in delivery efficiency are focused on the inclusion and use of vasoactive chemicals with the devices designed to assist in the passage across the stratum corneum. These devices may include but are not limited to the syringes and needles and microneedle devices with size gauges 30 and larger with smaller needle diameters. This may include any device which uses a physical device used to penetrate the stratum corneum and/or other layers of the skin, then the simultaneous or subsequent or pre-treatment of the injected area with a pharmaceutical formulation containing the active drug molecule and also a vasoactive chemical substance. The vasoactive chemical may be introduced into the injected area, either before, or simultaneous to or following the introduction of the active drug molecule.
[0007] The methods described in this invention include compositions of drugs and vasoactive chemical substances in forms that are typical associated with pharmaceutically acceptable formulations sufficient to achieve the desired level of optimized vasodilation or vasoconstriction and also sufficient to achieve the desired pharmacologic delivery of the active drug molecule.
[0008] This invention describes the methods necessary for the inclusion of vasoactive chemicals as part of a transdermal drug delivery formulation in concert with any physical skin or stratum corneum penetration device, including but not limited to needles and micro-needles and their associated devices.
[0009] The efficiency and the breadth of application of use and result for the prior art has been increased by the present invention to include a broader range of drugs and agents that can be delivered transdermally. These classes of drugs and agents include macromolecular compounds and agents, or other drug molecules whose chemical characteristics were previously precluded from being incorporated into the prior art formulation or configuration for the purpose of transdermal drug delivery. More specifically, the present invention combines functional elements of the transdermal drug delivery system that can perform in more than one functional capacity to achieve the results of delivering a drug or therapeutic or diagnostic agent through the skin and into the bodily fluids. Establishing multi-functioning molecules as part of the delivery system introduces a great degree of flexibility in the system. The molecular size of the delivery complex can be reduced and the chemical characteristics of the delivery complex can be altered. The corresponding reduction in size of the delivery complex permits the consideration of introducing an active drug molecule or agent with a larger molecular weight. This expansion in molecular weight of the active drug molecule may extend to macromolecules (e.g., proteins and peptide fragments). The advantages of the present invention over the prior art have implications for the delivery of active drugs and agents such as large organic molecules including peptides and proteins (e.g., insulin, erythropoietin, interferon, growth hormones). In addition, there are advantages to the incorporation of a vasodilatory substance into the dermal or subcutaneous layer of skin in combination with the active drug molecule, with an improved bioavailability index and also with respect to the speed with which the drug may be introduced into the bloodstream. The addition of a chemical vasodilator could significantly enhance both the efficiency and also enhance the kinetics of the drug uptake.
DETAILED DESCRIPTION OF THE INVENTION
[0010] The invention describes the incorporation of a vasoactive chemical substance in the therapeutic or diagnostic drug formulation that is being delivered transdermally with the assistance of a device, such as, but not limited to, a needle and syringe or a microneedle-type device. The application of drugs and drug substances to the skin, with the desired target of either the localized tissue in and adjacent to the skin or the blood stream for systemic circulation is the goal of this application and invention.
[0011] Subcutaneous injections with a standard needle are effective in terms of achieving bioavailability of virtually all drug molecules, regardless of physical size or shape. However, there are disadvantages to this method, including pain, discomfort, infections, and inadvertent bleeding. Despite the limitations of this standard and accepted process, there are advantages such as the avoidance of the stratum corneum layer of the skin, which serves as a primary barrier to the transdermal entry of any substance into the body. As a result, there is a level of consistency with this method that is desired and accepted, the primary issue is the pain and inconvenience of using a syringe and needle.
[0012] Microneedles have been developed for the delivery of drug substances, serving to cross the stratum corneum layer of skin, without penetrating deep into the subcutaneous layer. This method also serves advantages with the reduction in discomfort or pain with the injections and also offers the advantage of safety with little concern over cross use or secondary use of the device for purposes other than the original intent. A limitation of this microneedle device and variants of the device is that the low efficiency of delivery of some drugs into the body following deposition of the drug substance into the epidermal and upper dermal layer, for either systemic or localized tissue delivery.
[0013] This invention uniquely incorporates the advances made in the microneedle technology and have coupled it with the advances made in device-free transdermal drug delivery technology, for use in the technology of subcutaneous or dermal drug delivery, to elevated the efficiency of the microneedle-assisted process to the level for effective clinical use.
[0014] In particular, the use of microneedles offers several focused advantages in the therapeutic or diagnostic fields when the objective is to deliver large molecular weight substances, such as, but not limited to proteins, peptides, DNA, or RNA. These molecules are not good candidates for transdermal delivery because of their inability to cross the stratum corneum as they are large and typically water soluble molecules. Both characteristics make them in opposition to the chemistry and the physical compatibility with the stratum corneum of the skin.
[0015] There have been several examples of these molecule classes being delivered through injection means into the skin and tissue surrounding the skin as a method to introduce them into the body. In many instances, this has been acceptable however, the protocol requires a number of injections, as in the case of vaccinations or even for some gene therapy indications. However, in many instances for the treatment of medical conditions and diseases, the need for introducing drug molecules, including proteins and peptides, into the body is required several times each day, which in turn requires the patient or the physician to inject the drug into the subcutaneous layer of the skin, with all of the associated pain and discomfort, such as in the example of insulin-dependent diabetes.
[0016] The incorporation of vasoactive substances into the drug formulation has been demonstrated to improve delivery efficiency as either systemic or localized tissue distribution. Injection of microneedle-assisted drugs has avoided many of the negative aspects of standard needle injections but in many cases lacks the efficiency of delivery. This invention describes the method to be used for the incorporation of vasoactive chemical substances into a drug formulation to be delivered into the epidermis, below the stratum corneum, with the purpose and intent to enhance the deliver of the drug substances deposited in that tissue.
[0017] The introduction of vasoactive chemicals into a pharmaceutical formulation delivered into the skin tissue, either with the drug substance in the same formulation or separately in advance or subsequent to the injection of the drug substance enhances the delivery of the drug into the blood stream and also deeper into the skin tissue.
[0018] The formulation containing the vasoactive chemicals will also contain passive penetration enhancing chemicals, which may be chosen from the class of lipids and lipid-like or lipid-derived molecules, including liposomes and lipid based emulsion and lipid associated hydro-gels. In addition, there may be other chemical agents designed to disrupt or disorganize the architecture of the skin tissue and to promote the penetration of drug substances through the skin.
[0019] There are different formats to the use this invention for the delivery of different drugs, depending on the pharmacology profiles desired for that drug and also depending on the interactions of the drug with the other component parts of the delivery enhancement formulation. In one instance, where the drug is stable in the presence of the vasodilator chemical and also in the presence of the other component parts of the formulation, then this may be prepared as a single formulation. The combined drug, vasodilator, penetration enhancing agents, and other formulating chemicals may be prepared in the reservoir of a microneedle device in advance of the application and then administered by applying the microneedle to the skin and injecting the drug.
[0020] In contrast, there may be other drug molecules, whose chemistry indicates that it may not be stable for a practical period of time for standard drug formulations, either at room temperature or at a lowered storage temperature when prepared in the presence of the vasodilator(s) or the other component chemicals of the delivery formulation. In this example, then the drug molecule is prepared in a standard solution, which has been demonstrated to maintain the integrity of the drug molecule, and this is inserted into the reservoir of a microneedle device alone. The drug delivery enhancing formulation, containing the vasodilator, penetration enhancer chemicals and other supporting chemicals for the formulation, is prepared as described and introduced into a separate reservoir for a microneedle device. The administration of the drug molecule takes place by first introducing the drug molecule into the skin with the device, followed by the application of the drug delivery enhancing formulation using the separate microneedle device to the same area of skin. The sequence of which formulation to deliver first is determined empirically through experimentation. Alternatively, a novel device composed of microneedles and two separate reservoirs for the two formulations could be applied simultaneously with a single application, through the same microneedles, using partition construction of the device separating the formulations from each other and also from the microneedle portion of the device until the time of application.
[0021] In a similar but different application of this technology, the formulations containing vasodilators and penetration enhancing chemicals could be incorporated into devices using iontophoresis and sonophoresis. In these examples, the pharmacokinetic and pharmacodynamic profiles of the drug determine the concentrations used for the enhancing chemicals, such as vasodilators and also penetration enhancers, to ensure that the effect of either the electrical current or the sound waves was enhanced by the presence of the vasodilator enhancing formulation.
[0022] The active drug molecule may be included in the same formulation constructed for the delivery of the vasoactive chemical substance, however depending upon several factors, including the possible chemical or micro-environmental lability and stability of the drug substance, the drug substance may be prepared in physiological saline or other formulated chemical vehicle that would be compatible with the subsequent injection into the body using either a needle and syringe and/or with a microneedle device or other device constructed to physically penetrate the stratum corneum and/or other layers of the skin tissue with the purpose of depositing drug substance into the live skin tissue.
[0023] Vasoactive drug substances to be included in the chemical formulation may include, but are not limited to: amrinone, L-arginine, bamethan sulphate, bencyclane fumarate, benfurodil hemisuccinate, benzyl nicotinate, buflomedil hydrochloride, buphenine hydrochloride, butalamine hydrochloride, cetiedil citrate, ciclonicate, cinepazide maleate, cyclandelate, di-isopropylammonium dichloroacetate, ethyl nicotinate, hepronicate, hexyl nicotinate, ifenprodil tartrate, inositol nicotinate, isoxsuprine hydrochloride, kallidinogenase, methyl nicotinate, naftidrofuryl oxalate, nicametate citrate, niceritrol, nicoboxil, nicofuranose, nicotinyl alcohol, nicotinyl alcohol tartrate, nitric oxide, nonivamide, oxpentifylline, papaverine, papaveroline, pentifylline, peroxynitrite, pinacidil, pipratecol, propentofyltine, raubasine, suloctidil, teasuprine, thymoxamine hydrochloride, tocopherol nicotinate, tolazoline, xanthinol nicotinate, diazoxide, hydralazine, minoxidil, and sodium nitroprusside. Centrally acting agents include clonidine, quanaberz, and methyl dopa. Alpha-adrenoceptor blocking agents include indoramin, phenoxybenzamine, phentolamine, and prazosin. Adrenergic neuron blocking agents include bedmidine, debrisoquine, and guanethidine. ACE inhibitors include benazepril, captopril, cilazapril, enalapril, fosinopril, lisinopril, perindopril, quinapril, and ramipril. Ganglion-blocking agents include pentolinium and trimetaphan. Calcium channel blockers include amlodipine, diltiazem, felodipine, isradipine, nicardipine, nifedipine, nimodipine, and verapamil. Prostaglandins including: prostacyclin, thrombuxane A2, leukotrienes, PGA, PGA1, PGA2, PGE1, PGE2, PGD, PGG, and PGH. Angiotensin II analogs include saralasin. Other vasodilators include nitroglycerin, labetalol, thrazide, isosorbide dinitrate, pentaerythritol tetranitrate, digitalis, hydralazine, diazoxide, and sodium nitroprusside. This element may serve exclusively as the vasodilation agent or it may also, in addition, serve another function to the delivery complex such as penetration, as the active drug agent, or binding of the delivery complex. One or more vasodilators or chemically modified vasodilators can be used in the delivery complex at any one time for one formulation for the purpose of transdermally delivering an active drug molecule or agent. Typically the concentration of vasodilator to be introduced in the formulation will range between about 0.0005% and about 5%, with the more specific concentration being determined empirically with the desired vasodilator.
[0024] Penetration enhancers that may be used as part of the drug delivery vehicle and/or as part of the vasoactive component of the delivery process may include by example only but are not limited to: individual fatty acids or phospholipids or plant extract oils or a plant extract oil/alcohol mix. Suitable fatty acids include by example but are not limited to: linoleic acids, linolenic acids, oleic acids, stearic acids, and myristic acids. Phospholipids include by example but are not limited to: phosphatidylcholine, phosphatidylethanolamine, and phosphatidylserine. Plant extract oils include peanut oil, hemp, barrag, olive oil, sunflower oil, soybean oil, monoi oil and macadamia oil, with olive oil being preferred. Suitable alcohols for the plant extract oil/alcohol mix include ethyl alcohol, isopropyl alcohol, methyl alcohol and witch hazel. Olive oil mixed with isopropyl alcohol is a preferred vegetable oil/alcohol mix. Eucalyptol is a further suitable example of a vegetable oil/alcohol mix. Suitable ratios of vegetable oil: alcohols range from about 5:1 to about 1:10, preferably 1:2. Suitable amounts of plant extract oil or plant extract oil/alcohol mix in the delivery complex range from about 1% to about 66% by weight, more preferably from about 10% to about 33.3% by weight. This component may serve exclusively as the penetrating agent or it may also, in addition, serve another function to the delivery complex such as vasodilation, as the active drug agent, or binding of the delivery complex. One or more penetrating agents or chemically modified penetrating agents may be used in varying quantities or ratios with respect to the other component parts in the drug delivery complex at any one time. The penetrating agent molecule may also serve in any of the other critical functions for the delivery system, including that of active drug molecule, vasodilator, and/or binding agent.
[0025] The third element of the delivery complex is the active ingredient. The term “active ingredient” is used herein to indicate any material or composition desired to be delivered transdermally, especially therapeutic drugs and diagnostic agents and especially drug substances that are physically large and difficult to transdermally deliver without the aid of a device. Examples of active ingredients that can be used in accordance with the present invention include but are not limited to: insulin, growth hormone, erythropoietin, interferons, peptide fragments, RNA, DNA and DNA fragments, albumin, keratin, collagens, plasmids, therapeutic proteins, antibodies, Fab fragments of antibodies, Fc portions of antibodies, tolazoline, L-arginine, tocopherol nicotinate, methyl nicotinate, hexyl nicotinate, papaverine, sodium nitroprusside, acetylcholine, lidocaine, tetracine, benzocaine, thiabendazole, hydrocortisone, steroids, hormones, and antisense molecules.
[0026] The transdermal delivery formulation may optionally include a fourth primary component in the form of a polymer or a chemical stabilizer molecule. This substance is designed to be compatible with the composition of the remainder of the chemicals in the formulation and will also simultaneously be bio-labile and degrade once the material is in the skin or it may remain on the skin surface as an occlusive barrier. Examples of suitable polymers include but are not limited to: carbopol, pemulen, hydroxyethylcellulose, u-care polymer, and water-soluble gums (e.g., agar, arabic, carob, CMC, carrageenans, ghatti, guar, karaya, kadaya, locust bean, tragacanth, and xanthan gums). The binding agent should be used in an amount ranging from about 1% to about 20% by weight, most preferably 1-2%. The polymer may serve exclusively as the binding agent or it may also, in addition, serve another function to the delivery complex such as vasodilation, penetration, or as the active drug agent of the delivery complex.
EXAMPLE 1
[0027] Oleic acid (5%), gamma linolenic acid (5%), cholesterol (1%), menthol (5%), Lipomulse 165 (2%) and cetyl alcohol (2%) are mixed at 40C for 30 minutes and blended to homogeneous. A separate vessel containing Pemulen (1%) and (10%) propylene glycol is mixed to homogeneity and then added to the first vessel to form an emulsion. A third mixture of tolazoline (1%), papaverine (0.5%) is added in (5%) propylene glycol and (56.5%) deionized water. The mixture is then blended to homogeneity for approximate 20 minutes at room temperature. 100 μg of recombinant human growth hormone is dissolved in (1%) physiologic saline. The growth hormone is added to the main delivery vehicle formulation, blended to homogeneity. A 1 g aliquot is inserted into a reservoir in a 1 cc 29 gauge syringe needle device and injected into the subcutaneous tissue for delivery.
EXAMPLE 2
[0028] Oleic acid (5%), gamma linolenic acid (5%), cholesterol (1%), menthol (5%), Lipomulse 165 (2%) and cetyl alcohol (2%) are mixed at 40C for 30 minutes and blended to homogeneous. A separate vessel containing Pemulen (1%) and (10%) propylene glycol is mixed to homogeneity and then added to the first vessel to form an emulsion. A third mixture of tolazoline (1%), papaverine (0.5%) is added in (5%) propylene glycol and (56.5%) deionized water. The mixture is then blended to homogeneity for approximate 20 minutes at room temperature. 100 μg of recombinant human growth hormone is dissolved in (1%) physiologic saline. The growth hormone is added to the main delivery vehicle formulation, blended to homogeneity. A 1 g aliquot is inserted into a reservoir in a microneedle device, designed to deliver a precise amount of material. The device is placed in contact with the skin and the composite mixture of drug and vasoactive drug delivery formulation vehicle are simultaneously administered.
EXAMPLE 3
[0029] Oleic acid (5%), gamma linolenic acid (5%), cholesterol (1%), menthol (5%), Lipomulse 165 (2%) and cetyl alcohol (2%) are mixed at 40C for 30 minutes and blended to homogeneous. A separate vessel containing Pemulen (1%) and (10%) propylene glycol is mixed to homogeneity and then added to the first vessel to form an emulsion. A third mixture of tolazoline (1%), papaverine (0.5%) is added in (5%) propylene glycol and (56.5%) deionized water. The mixture is then blended to homogeneity for approximate 20 minutes at room temperature. A separate preparation of the active drug molecule (e.g., 0.1% human insulin), dissolved in (1%) physiologic saline is added to the drug delivery formulation in a separate and discrete reservoir in the delivery device. This pharmaceutical formulation (0.1-2 g of each drug delivery vehicle) is applied to a reservoir in a microneedle device, designed to deliver a precise amount of material. The device is placed in contact with the skin and both reservoirs are added to the skin tissue through the action of the device simultaneously.
EXAMPLE 4
[0030] Oleic acid (15%), gamma linolenic acid (5%), cholesterol (2%), menthol (10%), lipomulse 165 (2%) and cetyl alcohol (2%) are mixed at elevated temperatures and blended to homogeneity. A separate vessel containing hydroxyethylcellulose (2%) and propylene glycol is added to the first vessel to form an emulsion. A third mixture of tolazoline (0.1%), papaverine (0.2%), and tocopherol nicotinate (0.5%) is added in propylene glycol and water. The mixture is then blended to homogeneity for approximate 20 minutes at room temperature. A separate preparation of the active drug molecule (e.g., 0.1% human recombinant insulin), dissolved in physiologic saline is added to the drug delivery formulation in a separate and discrete reservoir in the delivery device. This pharmaceutical formulation (0.1-2 g of each drug delivery vehicle) is applied to a reservoir in a microneedle device, designed to deliver a precise amount of material. The device is placed in contact with the skin and the contents of reservoir containing the vasoactive substances are added to the skin tissue. After a 10-minute period, the contents of the reservoir containing the insulin are added to the same location of the skin tissue.
EXAMPLE 5
[0031] Oleic acid (15%), gamma linolenic acid (5%), cholesterol (2%), menthol (10%), lipomulse 165 (2%) and cetyl alcohol (2%) are mixed at elevated temperatures and blended to homogeneity. A separate vessel containing hydroxyethylcellulose (2%) and propylene glycol is added to the first vessel to form an emulsion. A third mixture of tolazoline (0.1%), papaverine (0.2%), and tocopherol nicotinate (0.5%) is added in propylene glycol and water. The mixture is then blended to homogeneity for approximate 20 minutes at room temperature, then the preparation of the active drug molecule (e.g., 0.1% human recombinant insulin), dissolved in physiologic saline is added to the drug delivery formulation and again blended to homogeneity. This pharmaceutical formulation (0.1-2 g) is applied to a reservoir in a microneedle device, designed to deliver a precise amount of material. The device is placed in contact with the skin and the composite mixture of drug and the vasoactive drug delivery formulation vehicle are simultaneously administered.
|
This invention describes the simultaneous or sequential administration of therapeutic or diagnostic agents using different devices in combination with a chemical formulation that incorporates or uses vasomodulatory chemical agents as part of the drug delivery vehicle. Methods include the addition of various vasodilatory and vasoconstrictive agents to enhance the systemic or localized tissue delivery of therapeutic or diagnostic agents delivered into a body through the use of an apparatus or device.
| 0
|
TECHNICAL FIELD
This invention relates to a package of unwindable strands.
BACKGROUND ART
Packages for filaments, strands, or rovings of continuous glass fibers are numerous. The packages facilitate unwinding of the strand from the package and minimize related processing problems. The packages typically are a membrane surrounding wound strands. One package incorporates an adhesive between the membrane and outer layer of strand to retain the strand against the inner wall of the membrane. Often, however, the adhesive peels off the film. The adhesive then contaminates the strand rendering it useless for reinforcing plastics. Other packages used shrink film as the membrane. Heat shrinkable film allows the membrane to adhere to the outer periphery of the package to an extent sufficient to retain the strand in contact with the membrane until the strand is substantially completely withdrawn from the package.
All of these packages found wide acceptance in industry. However, at temperatures above 90° F. the exterior membrane in which the package is wrapped tends to relax with the result that the strand being withdrawn tends to birdnest and become entangled in a guide eye.
DISCLOSURE OF THE INVENTION
I have improved the film package concept even further by employing a stretch film which is tacky on the outside. By reverse winding the package, the tacky side holds the outside layer of strands. By using 2 or more layers of film, the tacky side also holds the package together to give the necessary support for complete unwinding of the strands. This differential cling eliminates the need to heat the stretch film. My packaging is a stretch film and it does not shrink.
The tacky side of the film holds the roving for 100% runout and holds the strand and for excellent package to package transfer. An overwrap machine applies three to five wraps of one sided tacky stretch film to each package. The tacky side of the film directly contacts the strands. Preferably, the stretch film is a linear low density polyethylene with a true one sided (outside) differential cling. The tack in my film is a part of the film and does not peel off as an adhesive would.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE is an isometric view of a cylindrical package of coiled continuous strands.
The package 10 of glass filaments shown in the FIGURE consists of a continuous glass roving wound in successive layers of coils to form a generally cylindrical tubular shape. The continuous roving has a free end 12 on the exterior of the wound package 10, and an internally exposed free end 14 which can be pulled to unwind the package from the inside. The package 10 has generally parallel inner 16 and outer 18 cylindrical surfaces.
As shown in the FIGURE, the roving is wound in successive layers with the roving in each layer being in side-by-side relationship, to provide a package having generally flat annular end surfaces perpendicular to the inner and outer surfaces. This square ended cylindrical package is a particularly economical and otherwise suitable configuration for the packaging of continuous glass fibers, especially glass rovings used in the reinforcement of plastics. However, some coiled packages have an outer surface having a gradual taper in one or both axial directions. The inner surface may also have a slight draft to facilitate removal from a winding drum.
DETAILED DESCRIPTION OF THE INVENTION
While the preferred embodiment of this invention pertains to continuous glass fiber rovings, this invention pertains to any wound body of strand from which the strand is withdrawn from the interior of the body. Such bodies can comprise natural or synthetic fibers, organic fibers or mineral fibers of any length, diameter or quality. Such packages are generally formed by winding a continuous strand on a rotatable collet to form a hollow core package from which the strand is pulled out through the opening formed by the position occupied by the rotating collet.
The package can be of any size and shape. Because such packages wound on a collet, they will generally be cylindrical in shape. The outer periphery of the wound body usually develops a plurality of undulations, or ridges, of irregular height which act to adhere to the outer wrap and, hence, to preserve the cylindrical shape of the package as it is being unwound.
The use of a stretch film herein is in contrast to the frequent use of shrink films to wrap food-stuffs. Shrink film packaging involves the use of thermoplastic films that have been stretched or oriented during manufacturing and have the property of shrinking during the application of heat. Shrink film is normally applied loosely because it does not stretch well at room temperatures.
Stretch film involves the use of thermoplastic film that has been specially formulated to easily stretch at room temperatures. Stretch film is normally produced in thickness ranging from 0.7 mils to 1.5 mils.
The membrane can be wrapped around the package in any number of convolutions, or portion thereof, and can be of any suitable thickness, for example, within from about 0.7 mil to about 1.35 mil, preferably from about 0.8 to about 1 mil. Applying the film under tension holds the film in position during formation of the package.
The wound body of strand can be encased fully or partially within the membrane. Preferably, the membrane will be positioned in contact with the entire longitudinal surface of the package although the membrane can extend over any portions of the ends of the package. The membrane can be wound on the package of strand by any suitable means and at any time after the formation of the package.
The one sided tacky film may be blown or cast, with blown film being preferred.
Both blown and cast film processes melt resin pellets (extrude) through basically the same method. They use a screw which conveys, compresses and pumps the resin through the extruder chamber to the die opening. Each process uses a different shaped die. The cast uses a flat or slot shaped die which forms a single flat sheet of film. The blown uses a circular die which forms a tube of film. These differences in die geometry are due to the process itself and they affect the films orientation. In the blown process film is oriented in an upward direction (machine) and an outward direction (cross/transverse). Whereas cast film is only oriented in the machine direction.
The next major process difference is the way in which the blown molten polymer (plastic) is cooled. Blown film is cooled by an air ring which surrounds a tube with cooler air. Whereas the cast film is cooled by chilled rolls--temperature is controlled internally with chilled water. Another processing differences is the temperature the molten polymer is at--cast 450°-600° F. vs. blown 350°-45° F. This is due to the different resin types used in each process.
The resins used in blown film have a higher molecular weight (the size of the molecule in relation to process. The lower the molecular weight the higher the melt index. (the flow characteristics of polymer at a certain temperature and pressure) therefore, the blown film resins have a lower melt index which allows it to stretch in both directions with greater strength than cast. These things combine to allow blown film to achieve greater levels of load retention and overall strength at higher levels of stretch than cast film. The blown film process uses a resin with a higher viscosity (lower melt index) than the cast film process.
The film has the ability to adhere to itself. This is necessary to interlock layers of film to one another and to secure the film to the package. The film has one-sided cling--only one side of the film contains a tackifier.
INDUSTRIAL APPLICABILITY
Preferably, the stretch film is a linear low density polyethylene blend with a true one sided (outside) differential cling. This thermoplastic is an extra strong, blown film. It has outstanding coil-cling properties that allow packaging at temperatures down to 0° F. Differential cling means the film has high cling on one side and virtually no cling on the other.
An overwrap machine applies three to five layers of film to each package. Because of the type of stretch film I use, no heating is necessary to shrink the package.
The wrapping operation runs at room temperature down to 0° F. The resulting package provides 100% runout and holds the strand for excellent package to package transfer.
The preferred film comes in rolls of standard lengths and widths (typically 6000 feet by 20 feet) and has the following properties:
______________________________________gauge (mils) 0.8manufacturing process blowntensile strength (p.s.i.) 6800cling (lbs./in.) 2.5use temperature range (°F.) 0-120______________________________________
|
A package having a stretch membrane convolutely position about an unwindable wound body of strand where a tacky surface of the membrane contacts the outer layer of strands. The tacky surface also interlocks multiple layers of the membrane together.
| 1
|
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a process for producing 1,1,1,5,5,5-hexafluoroacetylacetone with high purity, which is useful as a raw material for producing medicines, agricultural chemicals and low-boiling-point chelate compounds used in the process for manufacturing electric parts.
[0002] H. Gilman et al., J. Am. Chem. Soc., Vol. 78, pp. 2790-2792 (1956) teaches a process for producing 1,1,1,5,5,5-hexafluoroacetylacetone, which is shown by the following reaction formulas:
[0003] A. Henne et al., J. Amer. Chem. Soc., Vol. 69, pp. 1819-1820 (1947) discloses a process for producing anhydrous 1,1,1,5,5,5-hexafluoroacetylacetone by turning a sodium salt of 1,1,1,5,5,5-hexafluoroacetylacetone into a copper chelate compound, then recrystallizing the copper chelate compound, and then removing the copper with hydrogen sulfide.
[0004] R. Haszeldine et al., J. Chem. Soc. London, 1951, pp. 609-612 discloses that a reaction liquid is treated with dilute sulfuric acid and then extracted with ether, and the resulting organic layer is distilled to obtain distillates over the range 36-90° C. It is disclosed therein that the portion of boiling point 85-90° C. appears to be 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate.
[0005] H. Gilman et al., J. Am. Chem. Soc., Vol. 78, pp. 2790-2792 (1956) further discloses the precipitation of 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate by concentrating an organic layer extracted with ether.
[0006] In general, raw materials, including 1,1,1,5,5,5-hexafluoroacetylacetone, for producing medicines, agricultural chemicals and electronic parts are required to have higher purity, as compared with raw materials for other uses.
SUMMARY OF THE INVENTION
[0007] It is therefore an object of the present invention to provide a process for producing 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate with high purity, which is an intermediate for 1,1,1,5,5,5-hexafluoroacetylacetone.
[0008] According to the present invention, there is provided a first process for purifying a crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate containing an impurity. The first process comprises bringing said crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate into contact with a poor solvent, thereby removing said impurity from said crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate. In the specification, “poor solvent” means an organic solvent in which 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate is substantially insoluble.
[0009] According to the present invention, there is provided a second process for purifying a crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate containing an impurity. The second process comprises precipitating crystals of 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate from a specific solution of said crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0010] The process for producing a crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate, which is to be purified by the first or second process of the invention, is not particularly limited. For example, such crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate can be produced, as follows. At first, a reaction vessel is charged with a reaction solvent and a base. Then, a mixture of 1,1,1-trifluoroacetone, a trifluoroacetic acid ester and a solvent is gradually added to the reaction vessel with stirring or the like to homogenize the reaction mixture, while the reaction mixture was maintained at a predetermined temperature lower than the reaction temperature. Then, according to need, the temperature of the reaction vessel is raised to accelerate the reaction, thereby forming a salt of 1,1,1,5,5,5-hexafluoroacetylacetone.
[0011] In the process for producing a crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate, the reaction vessel may be made of glass, fluororesin or a material lined with one of these. The reaction solvent may be an ether having a boiling point preferably of about 30-140° C. Examples of such ether are diethyl ether, dibutyl ether, t-butyl methyl ether, diisopropyl ether, and tetrahydrofuran (THF). The base may be an inorganic base. Examples of this inorganic base are alkali metals and alkali earth metals, alkoxides of such metals, and hydrides of such metals. More concrete examples are sodium methoxide, sodium ethoxide, sodium hydride, sodium, potassium methoxide, potassium ethoxide, potassium hydride, potassium, and lithium hydride. The trifluoroacetic acid ester is not particularly limited, since its ester moiety acts as a leaving group. Its examples may be methyltrifluoroacetate and ethyltrifluoroacetate, which are easily available in an industrial scale. The solvent for dissolving 1,1,1-trifluoroacetone and the trifluoroacetic acid ester may or may not be the same ether as that for the reaction solvent. As mentioned above, a mixture of 1,1,1-trifluoroacetone, a trifluoroacetic acid ester, and a solvent may be added to the reaction vessel, in view of operability of the reaction. It is, however, not necessary to mix these components to be added to the reaction vessel. Furthermore, this solvent may be omitted. As mentioned above, it is preferable to cool the reaction mixture during the addition of these components in order to prevent the temperature increase. The reaction temperature is preferably about 0-90° C., more preferably about 20-70° C. If it is lower than 0° C., the reaction rate may become too low. If it is higher than 90° C., the yield of 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate may become too low.
[0012] After the completion of the above reaction, a salt of crude 1,1,1,5,5,5-hexafluoroacetylacetone is obtained by removing the reaction solvent. The removal of the reaction solvent is conducted by applying heat and/or vacuum. After that, the reaction liquid of the residue is put into another reaction vessel, followed by the addition of water and then acid (e.g., sulfuric acid, hydrochloric acid, or nitric acid), thereby decomposing the salt. Then, solvent extraction is conducted by adding a solvent to the reaction liquid. Then, the solvent is removed from the obtained organic layer, thereby obtaining a crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate containing impurities, in the form of solid.
[0013] In the first process, the manner of bringing the crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate into contact with a poor solvent is not particularly limited. For example, the crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate may be dispersed in the poor solvent. Then, the precipitated 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate can be separated by filtration. As another example, it is possible to apply the poor solvent as a washing liquid to the crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate supported on a filter of a filtration device. The resulting 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate is usually dried. However, if it is used as a raw material for producing 1,1,1,5,5,5-hexafluoroacetylacetone, the drying is not necessary.
[0014] In the second process, it is possible to dissolve the crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate in an organic solvent to form a solution. To this solution it is possible to add a poor solvent, thereby precipitating 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate. Then, this product can be separated by filtration. Alternatively, the above solution can be cooled to reduce solubility, thereby precipitating 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate.
[0015] The temperature for conducting the above-mentioned procedures is not particularly limited. It is preferably about 0-90° C., more preferably about 20-60° C. In view of operability, it is preferably a temperature requiring no heating nor cooling.
[0016] The above-mentioned poor solvent used in the first or second process can be selected from hydrocarbons and fluorine-containing solvents free from chlorine. It is needless to say that this poor solvent is in the form of liquid upon its use. This poor solvent is not particularly limited, and its boiling point is preferably not higher than about 200° C. Examples of the hydrocarbons are (1) aliphatic hydrocarbons such as n-pentane, n-hexane, n-heptane, n-octane, n-nonane, n-decane and isomers of these, the isomers being in liquid at about 5° C.; (2) aromatic hydrocarbons such as benzene, toluene, o-xylene, m-xylene, p-xylene, ethyl benzene, and mesitylene; (3) alicyclic hydrocarbons such as cyclopentane, cyclohexane, methylcyclopentane, methylcyclohexane, tetralin, and decalin; and (4) industrial gasolines (mixtures of hydrocarbon solvents) such as ligroin and petroleum ether. Examples of the fluorine-containing solvents are
[0017] 1,2-bis(trifluoromethyl)benzene,
[0018] 1,3-bis(trifluoromethyl)benzene,
[0019] 1,4-bis(trifluoromethyl)benzene, 1,1,1,3,3-pentafluoropropane,
[0020] 1,1,1,3,3-pentafluorobutane, heptafluorocyclopentane, and perfluorinated cyclic ethers (FLORINAT®). It is possible to use a mixture of at least two of these.
[0021] In the first process, it is optional to mix the poor solvent with a small amount of a good solvent in which solubility of 1,1,1,5,5,5-hexafluoroacetylacetone is higher than in the poor solvent. The amount of the good solvent may be not greater than 30 parts by weight per 100 parts by weight of the poor solvent. The good solvent in the invention is not particularly limited. Its examples are ethers such as diethyl ether, dibutyl ether, t-butyl methyl ether, diisopropyl ether, and tetrahydrofuran (THF); and alcohols such as methanol, ethanol, n-propanol, isopropanol, and n-butanol.
[0022] In the second process, it is optional to add a poor solvent to the solvent used for preparing the solution of the crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate, in order to adjust the solubility in the solution. This addition is particularly preferable, if crystals of 1,1,1,5,5,5-hexafluoroacetylacetone are precipitated by lowering the temperature of the solution.
[0023] It is possible to dehydrate 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate, which has been purified in accordance with the invention, by a conventional method, thereby obtaining its anhydride. R. Belford, J. Inorganic and Nuclear Chemistry, 1956, Vol. 2, pp. 11-31 discloses such method in which a dispersion is prepared by shaking 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate with approximately three times its volume of 98% sulfuric acid. After the dispersion has been allowed to stand overnight, dehydration of the product is repeated with a fresh batch of sulfuric acid. The resulting upper layer is siphoned off and distilled, thereby obtaining the anhydride (yield: 98%) as a distillate between 70.0-70.2° C. J. Amer. Chem. Soc., 78, 2790 (1956) discloses another method in which anhydrous calcium sulfate is mixed with 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate. Then, the resulting mixture is heated. The distillate is again treated with anhydrous calcium sulfate and distilled, thereby obtaining the anhydride of a boiling point of 68° C. (736 mm.). There is known a still another method in which 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate, together with phosphorus pentoxide, is heated in ether.
[0024] The following nonlimitative examples are illustrative of the present invention.
EXAMPLE 1
Production of
1,1,1,5,5,5-Hexafluoroacetylacetone Dihydrate
[0025] A 500-ml three-necked flask, equipped with a thermometer, a dropping funnel and a reflux condenser, was charged with 34.6 g (0.64 mol) of sodium methoxide and 240 ml of t-butyl methyl ether. A mixture was prepared by mixing together 71.7 g (0.64 mol) of 1,1,1-trifluoroacetone, 90.9 g (0.64 mol) of ethyltrifluoroacetate, and 120 ml of t-butyl methyl ether. Then, the mixture was dropped into the flask by spending 30 min, while the reaction mixture was maintained at a temperature of not higher than 30° C. with stirring by a magnetic mixer. After the completion of the dropping, the reaction was conducted for 4 hr at 40° C.. After the reaction, the reaction product was concentrated by distilling t-butyl methyl ether off using an evaporator, thereby obtaining a sodium salt of a crude 1,1,1,5,5,5-hexafluoroacetylacetone. This sodium salt was put into a 500-ml three-necked flask equipped with a thermometer and a reflux condenser. Then, 120 ml of water were added. Then, 160 g of 24% sulfuric acid aqueous solution were added at a temperature of not higher than 20° C. with stirring by a magnetic mixer. Then, the reaction was conducted for 6 hr at 60° C., followed by cooling to room temperature. The resulting reaction liquid was extracted with 200 ml of t-butyl methyl ether. The resulting water layer was again extracted with 100 ml of t-butyl methyl ether. The total of these organic layers was distilled with an evaporator to remove t-butyl methyl ether, thereby obtaining 118.8 g of a crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate.
Production of
1,1,1,5,5,5-Hexafluoroacetylacetone
[0026] As shown in Table, 12 ml of toluene were added to 6.0 g of the obtained crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate. The resulting mixture was stirred for 1 hr at room temperature with a magnetic mixer, followed by filtration and drying, thereby obtaining 5.3 g of 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate. Then, a 20-ml eggplant-type flask was charged with 5.3 g of the obtained 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate and 20 g of 98% sulfuric acid. Then, the flask was stopped, and the mixture was stirred for 4 hr at room temperature with a magnetic mixer, followed by standing still for 1 hr to have two layers separated from each other. Then, 4.0 g of 1,1,1,5,5,5-hexafluoroacetone were obtained from the organic layer. This product was found by a gas chromatography (detector: FID, column: DB-1, column size: 0.25 mm×60 m) to be 1,1,1,5,5,5-hexafluoroacetone having a purity of 99.9% (areal % in gas chromatography).
EXAMPLES 2-1- 2-8
Production of
1,1,1,5,5,5-Hexafluoroacetylacetone
[0027] In each of Examples 2-1 to 2-8, the production of 1,1,1,5,5,5-hexafluoroacetylacetone of Example 1 was repeated except that a solvent shown in Table was added to 6.0 g of the crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate obtained in Example 1. The results are shown in Table.
TABLE Purity of Yield after Yield after 1,1,1,5,5,5- Puri- De- Hexafluoro- fication hydration acetylacetone Solvent (g) (g) (areal %) Example 1 toluene 12 ml 5.3 4.0 99.9 Example 2-1 n-hexane 12 ml 5.4 4.1 99.8 Example 2-2 n-hexane 10 ml & 5.2 4.0 99.8 t-butyl methyl ether 2 ml Example 2-3 n-hexane 10 ml & 4.2 3.2 99.9 THF 2 ml Example 2-4 n-hexane 11 ml & 5.0 3.8 99.7 methanol 2 ml Example 2-5 toluene 10 ml & 3.9 3.0 99.9 THF 2 ml Example 2-6 toluene 10 ml & 4.8 3.7 99.9 t-butyl methyl ether 2 ml Example 2-7 toluene 10 ml & 5.3 4.1 99.9 dibutyl ether 2 ml Example 2-8 1,3-bis(trifluoro- 5.1 3.9 99.8 methyl)benzene 12 ml Example 3 toluene 70 ml 27.3 21.0 99.9 Com. Ex. No Solvent 29.1 21.3 93.5 Treatment
EXAMPLE 3
Production of
1,1,1,5,5,5-Hexafluoroacetylacetone Dihydrate
[0028] A 300-ml three-necked flask, equipped with a thermometer, a dropping funnel and a reflux condenser, was charged with 8.67 g (0.16 mol) of sodium methoxide and 60 ml of dibutyl ether. A mixture was prepared by mixing together 18.0 g (0.16 mol) of 1,1,1-trifluoroacetone, 22.8 g (0.16 mol) of ethyltrifluoroacetate, and 30 ml of dibutyl ether. Then, the mixture was dropped into the flask by spending 30 min, while the reaction mixture was maintained at a temperature of not higher than 30° C. with stirring by a magnetic mixer. After the completion of the dropping, the reaction was conducted for 4 hr at 40° C. After the reaction, the reaction product was concentrated by distilling dibutyl ether off with an evaporator, thereby obtaining a sodium salt of a crude 1,1,1,5,5,5-hexafluoroacetylacetone. This sodium salt was put into a 300-ml three-necked flask equipped with a thermometer and a reflux condenser. Then, 30 ml of water were added. Then, 40 g of 24% sulfuric acid aqueous solution were added at a temperature of not higher than 20° C. with stirring by a magnetic mixer. Then, the reaction was conducted for 6 hr at 60° C., followed by cooling to room temperature. The resulting reaction liquid was extracted with 50 ml of THF. The resulting water layer was again extracted with 40 ml of THF. The total of these organic layers was distilled with an evaporator to remove THF, thereby obtaining a crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate.
Production of
1,1,1,5,5,5-Hexafluoroacetylacetone
[0029] To the obtained crude 1,1,1,5,5,5 -hexafluoroacetylacetone dihydrate 70 ml of toluene were added, followed by stirring for 1 hr at room temperature with a magnetic mixer, then filtration and then drying, thereby obtaining 27.3 g of 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate (see Table). A 100-ml glass reaction vessel, equipped with a thermometer, a stirrer and a reflux condenser filled with glass spheres, was charged with 27.3 g of the obtained 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate and 55 g of 98% sulfuric acid, while nitrogen gas was allowed to flow through the reaction vessel. Then, the mixture was gradually heated to 80° C. with stirring by a magnetic mixer. During this heating, 21.0 g of a distillate of about 70° C. was collected. This distillate was found by the same gas chromatography as that of Example 1 to be 1,1,1,5,5,5-hexafluoroacetylacetone having a purity of 99.9%.
COMPARATIVE EXAMPLE
Production of
1,1,1,5,5,5-Hexafluoroacetylacetone Dihydrate
[0030] The production of 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate of Example 3 was repeated, thereby obtaining 29.1 g of a crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate.
Production of
1,1,1,5,5-Hexafluoroacetylacetone
[0031] A 100-ml glass reaction vessel, which is the same as that of Example 3, was charged with 29.1 g of the obtained crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate and 58 g of 98% sulfuric acid. Then, the mixture was gradually heated to 80° C. with stirring by a magnetic mixer. During this heating, 21.3 g of a distillate of 70° C. was collected. This distillate was found by the same gas chromatography as that of Example 1 to be 1,1,1,5,5,5-hexafluoroacetylacetone having a purity of 93.5%.
[0032] The entire disclosure of Japanese Patent Application No. 2000-000526 filed on Jan. 5, 2000, including specification, claims and summary, is incorporated herein by reference in its entirety.
|
The invention relates to a process for purifying a crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate containing an impurity. The process includes bringing the crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate into contact with a poor solvent in which 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate is substantially insoluble, thereby removing the impurity from the crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate. Alternatively, the process includes precipitating crystals of 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate from a solution of the crude 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate. Thus, it is possible to produce 1,1,1,5,5,5-hexafluoroacetylacetone dihydrate of high purity. This product makes it easy to produce 1,1,1,5,5,5-hexafluoroacetylacetone of high purity.
| 2
|
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. application Ser. No. 11/450,499, which claims priority under 35 USC 119(e) to U.S. provisional Application Ser. No. 60/688,967, filed on Jun. 9, 2005, and which is incorporated herein by reference.
TECHNICAL FIELD
The present invention relates generally to wireless communication systems, and more particularly to a method and system for access terminal (AT) hard handoffs in a wireless communication system.
BACKGROUND
Current wireless broadband data communications systems provide high bandwidth necessary for delivering high data rates (and high quality voice, such as VOIP) for both fixed and mobile applications. During a communication session, an access terminal (AT) or station subscriber (either fixed or mobile) may require or desire a connection to a different access network (AN) (sometimes referred to as a resource network (RN) or wireless access point) during a given session. This may occur as a result of the AT moving into a different coverage area or the current session having insufficient bandwidth for the application, or for some other reason. In accordance with some communications protocols, the procedure of terminating and establishing a new connection includes a hard handoff procedure. In a hard handoff, the communication path or session between the AT and the other endpoint is usually terminated or placed in a dormant state before the new path or session is established.
Existing High Rate Packet Data (HRPD) systems function in accordance with interface standards developed by 3GPP2/TIA (3rd Generation Partnership Project 2/Telecommunications Industry Association, namely the HRPD Interoperablility Specification (IOS) (3GPP2 A.S0007-A v.2.0 May 2003), which is incorporated herein by reference. HRPD systems typically employ air interfaces in accordance with TIA-856, while their network architectures are structured according to either the TIA-878 or the TIA-1878 specifications, also incorporated herein by reference. At present, the HRPD and associated specifications do not provide for active packet data session hard handoffs between access networks (AN) in HRPD networks.
Instead, the specifications require the packet data session to be transitioned to the dormant state (basically terminated) before hand off (dormant mode handoff) to a target AN, as described in United States Patent Application Publication No. 2006/0072506 to Sayeedi, et al., which is incorporated herein by reference. The connection between the AT and the source AN is broken resulting in the packet data session becoming dormant. This is done prior to establishing a connection with the target AN. Once a connection is established between the AT and the target AN, the session is re-activated.
The U.S. Patent Application Pub. No. 2006/0072506 states that the approached disclosed therein enables an AT with an active packet data session to perform a hard handoff from a source AN to a target AN without having to force the data session dormant. In an effort to reduce delays in hard handoff, additional A13 messaging (with data session information) between source and target ANs or PCFs is used.
FIG. 1 is a diagram (of representative call or message flows) that depicts an access terminal (AT) with an active packet data session handing off from a source AN to a target AN, in accordance with prior art signaling techniques. Not all flows may be shown. It will be understood that hard handoff procedures within different communications systems or in accordance with similar but different protocols may have different specific call or message flows than that shown. It will also be understood that the occurrence of the source AN/PCF and PDSN A9/A11 messaging flow (for releasing the A10 and/or A8 connections between the source AN/PCF and PDSN), shown in FIG. 1 as occurring after the TrafficChannelAssignment, may occur at other times in the flow, such as described in U.S. Patent Application Pub. No. 2006/0072506.
Referring back to FIG. 1 , a blackout period occurs during which data flow between the AT and the source AN is interrupted or terminated. This blackout period is shown in FIG. 1 and generally includes the time period between connection close or termination of the source AN-AT connection and/or source AN/PCF-PDSN connection (which usually occurs around the time of the traffic channel assignment) and establishment of the A10 connection between the target PCF and the PDSN (thereafter establishing an active session between the AT and target AN). As will be appreciated, a hard handoff may occur with or without A13 flows.
During the blackout period, no PCF-to-PDSN connection (RP connection) exists between the PDSN and the target PCF/AN (associated the target AN) and no AT-to-source AN connection exists. Though U.S. Patent Application Pub. No. 2006/0072506 states it is directed to reducing hard handoff delays, it does not appear to address such blackout period.
The blackout period may be on the order of 0.4 to 1 seconds, due to various actions necessary, such as reverse channel acquisition, source/target signaling, traffic channel generation and RP connection establishment. Once the DO or other connection (between the AT and target AN) and the RP connection (between the target PCF/AN and PDSN) are established, the packet data traffic once again flows between the AT and PDSN through the target AN.
During the blackout time period, data packets transmitted from other terminals (directed to the given AT) may still be received at the PDSN. Thus, the blackout period relates to connectivity, not necessarily data flow for the session. Delays in hard handoff and data blackouts may be unacceptable to applications with stringent QoS (quality of service) requirements, such as Voice over Internet Protocol (VoIP), Push to Talk (PTT), Video Telephony (VT) or other delay-sensitive applications. With no RP connection, these data packets are usually dropped. Though resends are possible in some applications, this loss of data is especially troubling in VoIP or other delay-sensitive applications.
Accordingly, there are needed methods and systems that reduce or minimize data loss during a hard handoff in wireless communications systems.
SUMMARY
In accordance with one embodiment, there is provided a method for facilitating handoff of an access terminal (AT) between a source access network (AN) and a target AN in a wireless communications network. The method includes receiving a message from the AT operable for initiating handoff of the AT. Prior to traffic channel assignment, establishment of a communications path between the target AN and a packet data node for carrying user data packets is initiated.
In accordance with another embodiment of the present invention, there is provided a computer program embodied on a computer readable medium and operable to be executed by a processor within a communications device or system, the computer program comprising computer readable program code for performing the method described above. In yet another embodiment, there is provided a source access network having means for performing the steps described above.
In another embodiment, there is provided, in a wireless communications system having a source access network (AN) and a target AN, a method for facilitating handoff of an access terminal (AT) between the source AN and the target AN. A message is received at the source AN from the AT, the message operable for initiating handoff of the AT. Prior to traffic control assignment, an A11 Registration Request is sent from the target AN to a packet data serving node (PDSN). A communications path between the PDSN and the target AN is established which is operable for carrying user data packet. This method may include bicasting user data packets to the target AN and the source AN when the bicasting information indicates bicasting, otherwise, unicasting the user data packets to a one of the target AN and the source AN. This method may also include wherein when the user data packets are unicast, generating a tunnel between the source AN and the target AN and transmitting the user data packets from one to the other. In yet another embodiment, there is provided an access terminal for a wireless communications network, wherein the access terminal is operable to transmit a signal resulting in establishment of a communications path between a target AN and a packet data node prior to assignment of a traffic channel between the target AN and access terminal.
Other technical features may be readily apparent to one skilled in the art from the following figures, descriptions, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, wherein like numbers designate like objects, and in which:
FIG. 1 illustrates call or message flow of a conventional prior art hard handoff procedure in a wireless communications network;
FIG. 2 depicts in block diagram form a wireless communications network in accordance with the present invention; and
FIG. 3 depicts call or message flow or method for hard handoff in the wireless communications network in accordance with the present invention.
DETAILED DESCRIPTION
FIG. 2 illustrates an example communications network architecture or system 100 in accordance with the present invention. The system or network 100 shown in FIG. 1 is for illustration purposes only. Other embodiments of the system 100 may be used without departing from the scope of this disclosure.
In this example, the system 100 includes packet data serving node (PDSN) 102 , radio access networks 104 , 106 and a network 108 . The radio access network 104 includes a packet control function (PCF) 110 and an access network (AN) 112 , while radio access network 106 includes a packet control function (PCF) 114 and an access network (AN) 116 . It will be understood that the radio access networks 104 , 106 may be configured to include various devices or configurations. The PDSN 102 provides a gateway function between the radio access networks 104 , 106 and the network 108 .
The network 108 may include one or more local area networks (“LAN”), metropolitan area networks (“MAN”), wide area networks (“WAN”), all or portions of a global network, or any other communication system or systems at one or more locations, or combination of these, including the public switched telephone network (PSTN), Internet, packet networks and the like. In one specific embodiment, the network 108 is an Internet protocol (IP) network.
The AN 112 has coupled thereto a plurality of access terminals (AT) 120 , 124 , while the AN 116 has coupled thereto a AT 122 . The ATs 120 , 122 , 124 are operable for communication wirelessly with the ANs 112 , 116 over an air interface. Additional or fewer PDSNs, radio access networks, PCFs, ANs and ATs may be included in the system 100 which communicate with the ANs 112 over wireless interfaces, and different configurations of system 100 may be utilized in accordance with the present invention (such as different TIA embodiments).
The structure and functionality of the PDSN 102 , radio access networks (sometimes referred to as RANs) 104 , 106 , access networks 112 , 116 and PCFs 110 , 114 are generally well-known. The PCFs 110 , 114 may include components such as processing units and PCF network interfaces, while the ANs 112 , 116 may include components such as controllers and access network transceiver systems (not shown). Such components may include, and are not limited to, microprocessors, microcontrollers, memory devices, and/or logic circuitry, and these may be adapted to implement various algorithms and/or protocols. No additional description of the conventional functionality and application of PDSN, RANs, ANs, and PCFs, other than as noted herein or relevant for an understanding of the present invention, is provided. As will be appreciated, an authorization, accounting and authentication (AAA) server or device (not shown in FIG. 2 ) may be included in system 100 .
It will be understood that the PDSN 102 , the radio access networks 104 , 106 , the PCFs 110 , 114 and the ANs 112 , 116 may be constructed or configured from any suitable hardware, software, firmware, or combination thereof for providing the functionality known to those of ordinary skill in the art. These devices will include additional functionality as described below in accordance with one or more embodiments of the present invention.
The network 108 , PDSN 102 , RANs 104 , 106 , ANs 112 , 116 and PCFs 110 , 114 are interconnected via communications lines which may be wired or wireless, or any combination thereof. The system 100 may utilize any suitable protocol or protocols, and in a specific embodiment, the wireless network portion of the system 100 functions in accordance with the HRPD protocol. The PDSN 102 and RANs 104 , 106 (and/or portions thereof) may also be collectively referred as an “access network.” In other embodiments, an AN and its associated PCF may be referred to as an “access network.”
As will be appreciated, other components, devices or networks may be included in the system 100 , and FIG. 1 only illustrates but one exemplary configuration to assist in describing the system and operation of the present invention to those skilled in the art. The system represented in FIG. 1 may be described using different nomenclature or system terminology, such as use of the terms mobile subscriber terminals (MS or MT) (an access terminal), base transceiver stations (BTS or BS) (an access network or node), base station controllers (BSC) and mobile switching centers (MSC), and the use of any given nomenclature to describe a device within the system 100 is not intended to limit the scope of this disclosure.
The access terminals or devices 120 , 122 , 124 represent devices utilized by users or subscribers during communication sessions over/within the system 100 . For example, each of the communication devices may include an input/output device having a microphone and speaker to capture and play audio information. Optionally, each of the communication devices 120 , 122 , 124 may also include a camera and/or a display to capture/display video information. During a communication session, the ATs 120 , 122 , 124 communicate with other devices connected to the network 108 (or within the system 100 ). In this way, the ATs 120 , 122 , 124 may exchange audio, video, graphical, or other information during a communication session.
Each access terminal 120 , 122 , 124 may be constructed or configured from any suitable hardware, software, firmware, or combination thereof for transmitting or receiving information over a network. As an example, the ATs could represent telephones, videophones, computers, personal digital assistants, and the like, etc.
As shown, an AT 124 is positioned near both the source AN 112 and the target AN 116 , whereby a communication session has been currently established with the source AN 112 . The dotted line refers to an eventual communication session that will be established between the AT 124 and the target AN 116 . As explained more fully below, the AT 124 will engage in a hard handoff from the source AN 112 to the target AN 116 . etc.
The general operation of a hard handoff in accordance with the present invention will now be described.
Now referring to FIG. 3 , with continued reference to FIG. 2 , the source RAN 104 is supporting an already active packet data session for AT 124 through the source AN 112 . For the purpose of illustration, assume that AT 124 determines that it desires to utilize a different RAN (or AN), such as the target RAN 106 .
The following is a detailed description of the signaling flow timeline shown in FIG. 3 .
An active packet data session is supported by the AT 124 , the source AN 112 , the source PCF 110 , and the PDSN 102 (a PPP connection exists between the AT 124 and PDSN 102 ). The AT 124 sends a Route Update message to the source AN 112 , and the source AN 112 acknowledges. The source AN 112 and target AN 116 perform A13 messaging for handoff. This generally includes an A13 Handoff Request and an Acknowledgement. Additional A13 messaging is usually included such as a Session Information Request and a Response. These Session requests/responses typically transfer certain date between the source AN 112 and target AN 116 , such as the AT's session information, target AN/cell information, the AN-ID of the source PCF 110 , the address of the PDSN 102 , the QoS contexts associated with AT's session(s), and may include the air interface version in use at the source so the target can format the air interface TCA message accordingly. If fast handoff is supported, it includes the anchor PDSN and Anchor P-P Addresses.
UATI Assignment and related flows, messages and procedures occur between the AT, source AN 112 , target AN 116 , source PCT 110 and/or target PCF 114 (identified generally using the UATI Assignment and UATI Complete notations). Additional messaging may also be involved.
Prior to traffic channel assignment, the target AN 116 sends an A9-Setup-A8 message to the target PCF 114 to establish an A8 connection therebetween. The target PCF 114 sends an A11-Registration Request message to the PDSN 102 . This message includes a non-zero lifetime value and an S-bit equal to 0 or 1, and may include other information. The PDSN 102 validates the A11-Registration Request and accepts the connection by returning an A11-Registration Reply message with an accept indication and the Lifetime field set to the configured value. The target PCF 114 responds by sending an A9-Connect-A8 message to the target AN 116 . This procedure establishes an A10 connection between the PDSN 102 and target PCF 114 and an A8 connection between the target PCF 114 and the target AN 116 .
In one embodiment of the present invention, the S-bit (or flag) referred to above is used to indicate or request (or invoke) unicasting or bicasting functionality of the PDSN 102 . When the S-bit equals zero, the PDSN 102 operates in the normal or unicast mode—transmitting data packets of the session to a single PCF (the target PCF 114 /target AN 116 ). When the S-bit equals one, the PDSN 102 operates in a bicast mode—transmitting data packets to two PCFs (the target PCF 114 /target AN 116 and the source PCF 110 /source AN 112 ). As such, the PDSN 102 of this embodiment of the present invention is configured or modified to utilize a bicast flag and includes bicasting functionality.
In other words, the PDSN 102 sends the same data packets to both the source and target RANs 104 , 106 over the existing and established A10 connections. As a result, the target RAN 106 may buffer the received data packets until the new connection between the AT 124 and target AN 116 is established Meanwhile, the source RAN 104 is also receiving the data packets and operably transmits them to the AT 124 for as long as the connection between source AN 112 and AT 124 exists. This reduces the effects of the blackout period by effectively shrinking the blackout period, as the new target RP connection is initiated or established prior to traffic channel assignment. Therefore, according to one embodiment of the present invention, early establishment of the target RP connection (connection between the PDSN 102 and the target PCF 114 ) is performed.
It will be understood that the A10 connection procedure for the target RP connection may be triggered from any of the aforementioned events, and not necessarily resulting from the A8 connection setup. It will be further understood that should the AN function and the PCF function be combined into a single function; the invention may still be applied while eliminating the A8/A9 interfaces.
At some point in time, the source RP connection is disconnected. In order to gain some benefits from bicasting, it will be understood that the termination of the source RP connection should occur sometime after the establishment of the target RP connection.
The additional messaging, flows and procedures shown in FIG. 3 as occurring after early establishment of the target RP connection (PDSN 102 to target PCF 114 ) are conventional flows known to those of ordinary skill in the art. Therefore, no further detailed description is provided for these. It will be understood that the termination of the source RP connection (A8/A10 connections involving the source AN 112 , source PCF 110 and PDSN 102 ) may occur at other times, than as shown in FIG. 3 . Similarly, it will be understood by those skilled in the art that certain of the flows or steps illustrated in the process of FIG. 3 may also occur at times different than that shown. However, in one embodiment disclosed herein, the establishment of the target RP connection (A10 connection) occurs prior to the initiation of traffic channel assignment activities. Another embodiment envisions initiation, not necessarily establishment, of the target RP connection prior to traffic channel assignment activities.
In accordance with another aspect of the present invention, there is contemplated a tunneling method. This method may be utilized with or without the early target RP connection establishment method. With the early establishment method, tunneling will likely be utilized when the above-described bicasting functionality described herein is unavailable or unused (unicasting).
A tunnel, or connection, is established between the source AN 112 and the target AN 116 (or between the source and target PCFs 110 , 114 ). Data packets from the PDSN 102 received at the source AN 112 are transmitted/forwarded through the tunnel to the target AN 116 . The target AN 116 may buffer the received data packets until the new connection between AT 124 and target AN 116 is established. Meanwhile, the source AN 116 may also be transmitting these same data packets to the AT 124 for as long as the connection between the source AN 112 and AT 124 exists. Optionally, the source AN 112 may not transmit the data packets to the target AN 116 until its connection with the AT 124 is terminated.
Alternatively, data packets from the PDSN 102 and received at the target AN 116 (via the early RP connection) are transmitted/forwarded through the tunnel to the source AN 112 . The source AN 112 then transmits these to the AT 124 via the current connection. Once this connection is terminated, the data packets will no longer be transmitted to the AT 124 . In the event, the target AN 116 should be notified.
As described above, the tunnel between the source AN 112 and target AN 116 may provide flow of data packets in either direction, depending on which AN is receiving the packets from the PDSN 102 in the unicast.
This tunneling/forwarding method may also reduce the effects of the blackout period by effectively shrinking the blackout period. Therefore, according to this aspect, relaying received data packets from the source AN to the target AN is performed. Tunneling combined with early establishment of the target RP connection (connection between the PDSN 102 and the target PCF 114 ) may provide additional benefits.
The connection or path (tunnel) for carrying user data packets (such as VOIP packets or other user data) between the source AN 112 and target AN 116 may be accomplished in any suitable manner. Other communications paths or protocols may be used to establish and maintain the tunnel. In one embodiment, A16 or A13 signaling is used to establish the tunnel. In one embodiment, an IP to IP communications path is established for carrying the data packets, and in another embodiment the tunnel is a GRE tunnel. Should the AN function and PCF function be combined into a single function, the connection path (tunnel) will be set up between the source AN/PCF function and the target AN/PCF function.
In general terms, one embodiment of the present invention is directed to establishment or initiation of the target RP connection earlier than done in the prior art. In another embodiment, this method further includes bicasting data packets to both the source and target ANs. In yet another embodiment, a tunneling method is used with the early establishment method when bicasting is inoperable (unicasting occurs).
In one embodiment, the method and system of the present invention is used in accordance with the HRPD or CDMA2000 protocol or specification. In other embodiments, the foregoing concepts and embodiments may not be limited to HRPD, but may be useful in other communications protocols and systems, such as UMTS, LTE, WiMax, WiFi, and the like.
In some embodiments, some or all of the functions or processes of the one or more of the devices are implemented or supported by a computer program that is formed from computer readable program code and that is embodied in a computer readable medium. The phrase “computer readable program code” includes any type of computer code, including source code, object code, and executable code. The phrase “computer readable medium” includes any type of medium capable of being accessed by a computer, such as read only memory (ROM), random access memory (RAM), a hard disk drive, a compact disc (CD), a digital video disc (DVD), or any other type of memory.
It may be advantageous to set forth definitions of certain words and phrases used throughout this patent document. The terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation. The term “or” is inclusive, meaning and/or. The phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like. The term “controller” means any device, system or part thereof that controls at least one operation. A controller may be implemented in hardware, firmware, software, or some combination of at least two of the same. The functionality associated with any particular controller may be centralized or distributed, whether locally or remotely.
While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure, as defined by the following claims.
|
Various embodiments are described to assist in reducing handoff delays and the blackout period(s) associated with inter AN (access network) hard handoffs. The hard handoff procedure of method disclosed herein establishes or initiates a connection (A10-type connection) between a target AN and a packet data serving node (PDSN), unlike known hard handoff approaches that wait until traffic channel assignment to establish or initiate such connection. The PDSN may optionally bicast data packets to both the source and target ANs since each is communicatively coupled to the PDSN during a given time period. In the event bicasting is unavailable or unused, a communication tunnel between the source and target ANs may be created and used to transmit data packets between them.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 62/085,857, filed on Dec. 1, 2014 entitled “Implantable Micro Power Generator (IMPG)” pursuant to 35 USC 119, which application is incorporated fully herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] N/A
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The invention relates generally to the field of Neuroprosthetics. More specifically, the invention relates to a device that will harvest power directly from a body process in the area of the sensor implant to allow operation of the implant without the need for batteries and without the risks and limitations associated with them.
[0005] 2. Description of the Related Art
[0006] Current medical implants that require electrical power to operate use power from either an implanted battery pack or from an external wired power source. Another method for powering medical implants involves generating electrical power from chemical reactions of body fluids or tissues with an implanted power generator. No device is known to use blood pressure fluctuations for in-body power harvesting.
BRIEF SUMMARY OF THE INVENTION
[0007] Applicant discloses an Implantable Micro Power Generator (IMPG) as a device that harvests energy directly from an innate process of the body, blood pressure fluctuations, to power implanted brain and other sensors while eliminating the drawbacks of using batteries.
[0008] IMPG is a small, round and sealed device that is implanted in proximity to the brain and with direct fluidic coupling with an artery. The MPG is electrically wired to nearby medical implants to provide power for their operation.
[0009] These and various additional aspects, embodiments and advantages of the present invention will become immediately apparent to those of ordinary skill in the art upon review of the Detailed Description and any claims to follow.
[0010] While the claimed apparatus and method herein has or will be described for the sake of grammatical fluidity with functional explanations, it is to be understood that the claims, unless expressly formulated under 35 USC 112, are not to be construed as necessarily limited in any way by the construction of “means” or “steps” limitations, but are to be accorded the full scope of the meaning and equivalents of the definition provided by the claims under the judicial doctrine of equivalents, and in the case where the claims are expressly formulated under 35 USC 112, are to be accorded full statutory equivalents under 35 USC 112.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] The invention and its various embodiments can now be better understood by turning to the following FIGS. 1-7 and the description of the preferred embodiments which are presented as illustrated examples of the invention in any subsequent claims in any application claiming priority to this application. It is expressly understood that the invention as defined by such claims may be broader than the illustrated embodiments described below.
[0012] FIG. 1 depicts the IMPG implanted in the head area and directly coupled with a major brain artery.
[0013] FIG. 2 depicts a cross section of the IMPG showing its main components and its direct coupling to a blood vessel in accordance with one preferred embodiment.
[0014] FIG. 3 is a data sheet of different off-the-shelf piezo disks that constitute the basis for the performance calculations presented in the detailed description of the invention.
[0015] FIG. 4 shows a medical textbook chart for typical blood pressure fluctuations in one major brain artery.
[0016] FIG. 5 in a block diagram of the power regulation and storage circuitry of the IMPG.
[0017] FIG. 6 presents a performance chart for a major electronic component of the regulation and storage circuit.
[0018] FIG. 7 illustrates one potential implementation of the regulation and storage printed circuit board's floorplan.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Turning now to the figures wherein like references define like elements among the several views, Applicant discloses an Implantable Micro Power Generator (IMPG) as a device that harvests energy directly from an innate process of the body. The IMPG will power implanted brain and other sensors while eliminating the drawbacks of using batteries.
[0020] IMPG is a small, round and sealed device that is implanted in proximity to the brain and with direct coupling with an artery in the head area such as the Common Carotid Artery. It is electrically wired to nearby sensors to provide power for their operation. The IMPG design is scalable to allow power generation levels as needed by the brain sensors. Although the description and image in FIG. 1 are for implantation in the head and for brain sensors, the IMPG can be implanted in any part of the body and be coupled with any artery.
[0021] The principle of operation of the Implantable Micro Power Generator is periodic spherical bending of a disk-shaped piezoelectric membrane resulting in generating a voltage differential across a power regulation and storage circuit. This voltage differential is harvested and stored in a capacitive storage means. The circuit then regulates the output power that is supplied to the end customers, the brain sensors.
[0022] The IMPG consists of a small sealed chamber in a mechanical housing. One wall of the sealed chamber holds a piezo disk while on one of the other walls there is a port that makes direct coupling with a fluid, blood or intermediary fluid as will be described below. The fluid floods the chamber on one side of the piezo disk and pressure fluctuations create the spherical bending of the disk at twice the heart rate frequency, in-and-out from the relaxed (center) position. FIG. 2 shows a schematic presentation of the IMPG coupled with an artery and blood flooding one side of the piezo membrane.
[0023] The thickness of the IMPG based on components' thickness buildup in the preferred embodiment is 4 mm Although FIGS. 1 and 2 show the IMPG's coupling with the artery done in the area of implantation, the actual coupling can be done through an implanted tube to a blood vessel farther away. The main reason for doing this is reduced health risk by connecting to an artery that is not part of the brain blood supply while at the same time keeping the IMPG close to the electrical consumers, minimizing electrical losses for such small power levels. This also allows more flexibility in selecting the area for implantation for the IMPG.
[0024] One concern that may rise from the above description is the risk of blood clots in the stagnant blood volume trapped in the pressure coupling tube. These blood clots may block the pressure coupling tube and turn the IMPG inoperable. Even worse, blood clots can be released into the blood stream and cause a stroke. In one embodiment of the invention, a second membrane will separate the fluid inside the pressure coupling tube, referred to as intermediary fluid, from the blood stream at the area of connection between the tube and the artery. Blood that flows over the membrane will never be stagnant thus will not create clots. The intermediary fluid inside the pressure coupling tube and the IMPG will not be blood and will therefore not introduce the risk of blocking the tube. The membrane at the end of the tube is very thin and flexible in order to minimize the amount energy lost to its bending.
[0025] FIG. 3 shows the data sheet for different off-the-shelf piezo disks while table 1 summarizes the main characteristics of some of the disks.
[0000]
TABLE 1
Performance characteristics of off-the-shelf piezo disks by
Piezo Systems Inc. at the nominal working point
(F disk = 1.2 N for all disks)
Piezo
A disk -
P - Native
disk
Diameter
Disk area
pressure (KPa)
designation
(mm)
(m 2 )
(P = 1.2 N/A)
-073
3.2
8e−6
150
-173
6.4
32.2e−6
37.2
-273
12.7
126e−6
9.5
-373
31.8
794e−6
1.5
-573
63.5
3.1e−3
0.387
[0026] Another input needed for performance calculations is the blood pressure. FIG. 4 shows typical blood pressure pulses in the Right Internal Carotid Artery (Source: Blood Flow in the Circle of Willis: Modeling and Calibration—Kristen DeVault et. Al.).
[0027] From FIG. 4 the blood pressure value is between 60 mmHg and 110 mmHg with a frequency of 1 Hz. For the performance calculation the pressure variations will be taken as 25 mmHg [(110-60)/2] at a frequency of 2 Hz. The blood pressure variation in KPa is: 25 mmHg=3.3 KPa
[0028] Size
[0029] The purpose of the blood pressure figure is to determine whether it is strong enough to deflect the disk and create the spherical bending needed to generate power at the working point. The working point is defined as the deflection at half the blocking force of the piezo disk. In the series of disks in FIG. 3 the blocking force is 2.4N and the working point is at a pressure that can generate 1.2N on a certain disk area.
[0030] From table 1 the pressure to reach the working point is proportional to the disk area. A disk that will achieve bending to the working point at the available pressure of 3.3 KPa needs to have an area A of:
[0000] A=F/P= 1.2/3300=363* e −6 m 2
[0031] This translates to a disk diameter of 21.5 mm. The IMPG diameter including the housing wall thickness is therefore 23 mm.
[0000]
I
M
P
G
Size
-
Diameter
=
23
mm
Thickness
=
4
mm
[0032] Power Generation
[0033] The native voltage of the piezo disk when used as an actuator is 180V (see FIG. 3 ). In the IMPG application with no room for large components and with a nano-power harvesting regulator as described in section 1.1.3 below, the voltage used in the calculations will be limited to 20V. This is well below the native voltage of the piezo device and is a conservative basis for power generation assessment.
[0034] The piezo disk power generation is calculated using the following formula (obtained from Piezo Systems Inc.)
[0000] P e =2*π* f*C*V 2
[0035] Where:
[0036] P e =Electrical power
[0037] F=Frequency
[0038] C=Disk capacitance
[0039] V=operating voltage
[0040] From FIG. 3 the capacitance is proportional to the disk area. The capacitance C of a 21.5 mm diameter disk is:
[0000] C 21.5 =C 12.7 *A 21.5 /A 12.7 =4.3 nF*363* e −6 m 2 /126* e −6 m 2 =12.4 nF
[0041] Therefore the IMPG power generation capacity in the proposed configuration is:
[0000] P e =2*π*2*12.4 e −9 *20 2 =62.3 μW
[0000]
IMPG
Power
Generation
-
P
e
=
62.3
μW
P
e
/
A
=
17
μW
/
cm
2
[0042] One way to address the issue of varying power requirements of implantable sensors is having a scalable solution that can generate different power levels. The IMPG concept is scalable and will produce different levels of power with different piezo disk diameters. Combined with the option described above of blood pressure coupling using a tube, different size IMPGs can be implanted in different areas in the head and power the brain sensors without having to squeeze a larger device in an area close to a brain artery.
[0043] The following is a brief description of the electrical circuitry needed for power harvesting, storage and supply, embedded in the 1 MPG.
[0044] The LTC3588 is a nano-power energy harvesting power supply. It includes rectification, storage cap switching, buck conversion, and voltage regulation into one chip. The LTC3588 is capable of storing up to 20V in the storage cap thereby maximizing the stored energy. In order to efficiently use this higher voltage, a built-in buck converter (followed by linear regulation) reduces the voltage down to 1.8V for system use. Typical start-up with 2 uA input current is shown below. Output quiescent current is less than 100 nA, and typical drain on the storage cap is less than 1000 nA.
[0045] The LTC3588 also provides a PGOOD signal, which can be used by the system as a wake-up trigger.
[0046] The MSP430FR5738 is packaged in a 2.2×2.2 mm CSP (chip scale package). It provides for uA level standby currents as contained in a 1K FRAM. The FRAM provides ultra-low power non-volatile memory storage and instant start-up. Typical current is 200 uA/MHz but ultra-low-power programming techniques can reduce average operating current <10 uA for basic required system functions. Included functions are A/D converters, SPI, UART, RTC, and 16-channel comparator.
[0047] The microprocessor provides a smart supercap charging function to charge a PAS3225P3R3113, 11 mF capacitor. External circuitry can be controlled via a FET switch, providing large, in the 10 mW range, power pulses from external circuitry. This greatly extends the operation of the otherwise low power piezo energy harvester to include low duty cycle, high power functions.
[0048] Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different elements, which are disclosed above even when not initially claimed in such combinations.
[0049] The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its use in a claim must be understood as being generic to all possible meanings supported by the specification and by the word itself.
[0050] The definitions of the words or elements of the following claims are, therefore, defined in this specification to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a subcombination or variation of a subcombination.
[0051] Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.
[0052] The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted and also what essentially incorporates the essential idea of the invention.
|
An implantable device for harvesting in-vivo blood pressure fluctuations' energy to generate electrical power for powering medical implants while avoiding the need for external power sources.
| 0
|
CROSS REFERENCE TO CORRESPONDING APPLICATIONS
[0001] This application is a division of the non-provisional application Ser. No. 12/705,989 filed Feb. 16, 2010 entitled BIS-(1(2)H-TETRAZOL-5-YL)AMINE AND PRODUCTION METHOD THEREOF which claims a priority to U.S. 61/153,011, filed Feb. 17, 2009 by applicants Toshiyuki TODA and Toru Kofukuda (both of Takasago Japan) and entitled BIS-(1(2)H-TETRAZOL-5-YL)AMINE AND PRODUCTION METHOD THEREOF, the contents of which is incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to bis-(1(2)H-tetrazol-5-yl)amine produced using an azide salt and a dicyanamide salt and to a production method therefor.
BACKGROUND ART
[0003] A bis-(1(2)H-tetrazol-5-yl)amine compound is useful as a gas generant, and a known production method uses an azide salt and a dicyanamide salt (for example, see Non-Patent Literature 1 and Patent Literatures 1 to 5).
[0004] In the production method described in Non-Patent Literature 1, a reaction is carried out under reflux for 23 hours using trimethylammonium chloride as an acid in an aqueous solvent, and then a treatment with hydrochloric acid is performed, thereby giving bis-(1(2)H-tetrazol-5-yl)amine monohydrate in a yield of 67%.
[0005] In the production method described in Patent Literature 1, a reaction is carried out under reflux for 48 hours using boric acid in a large excess in an aqueous solvent, and then a treatment with hydrochloric acid is performed, thereby giving bis-(1(2)H-tetrazol-5-yl)amine anhydrate in a yield of 80.3%.
[0006] In the production method described in Patent Literature 2, a reaction is carried out at 100 to 150° C. for 5 to 10 hours using an ammonium halide such as ammonium chloride as an acid in an aprotic solvent such as N,N-dimethylformamide, and then a treatment with hydrochloric acid is performed, thereby giving bis-(1(2)H-tetrazol-5-yl)amine monohydrate in a yield of 80 to 90%.
[0007] In the production method described in Patent Literature 3, a reaction is carried out at 95 to 105° C. for 24 hours using a protic acid such as hydrochloric acid and a metal chloride such as manganese chloride in water or a water-miscible solvent, the suspended solids of the metal salt are filtered off, and then a treatment with a protonic acid such as hydrochloric acid is performed, thereby giving bis-(1(2)H-tetrazol-5-yl)amine monohydrate in a yield of 80 to 90%.
[0008] In the production method described in Patent Literature 4, an acid having a pKa less than 2 is gradually mixed (usually for 12 to 24 hours) with a reaction solution at 65° C. or greater (desirably under reflux) in an aqueous solvent so as to maintain a high pH to keep the hydrazoic acid within the system. After the reaction, a treatment with a protonic acid such as hydrochloric acid is performed, thereby giving bis-(1(2)H-tetrazol-5-yl)amine monohydrate in a yield of about 86%.
[0009] In the production method described in Patent Literature 5, an acid of having a pKa of 3 to 9 is mixed with a reaction solution at 65° C. or greater (desirably under reflux) in an aqueous solvent, and after the reaction, the reaction solution is acidified so as to have a pH less than 3, thereby giving a bis-(1(2)H-tetrazol-5-yl)amine compound.
Citation List
[0010] Non-Patent Literature 1: “Journal of Organic Chemistry”, 1964, Vol. 29, pp. 650-660
[0011] Patent Literature 1: WO 95/18802
[0012] Patent Literature 2: JP 2004-67544 A
[0013] Patent Literature 3: JP 2004-323392 A
[0014] Patent Literature 4: US 2003/0060634 A
[0015] Patent Literature 5: U.S. Pat. No. 5,468,866
Problems to Be Solved By the Invention
[0016] The above-described conventional production methods, however, have the following disadvantages.
[0017] The production method described in Non-Patent Literature 1 uses expensive trimethylammonium and generates triammonium azide, which is sublimable and carries a risk of explosion.
[0018] The production method described in Patent Literature 1 requires a reaction time as long as 48 hours and uses boric acid. It is difficult to thermally dispose of boric acid.
[0019] The production method described in Patent Literature 2 performs the reaction using only an organic solvent, involving a high solvent cost and a troublesome post-treatment, resulting in a high production cost. Moreover, ammonium azide, which is sublimable and carries a risk of explosion, is generated.
[0020] The production method described in Patent Literature 3 uses a manganese salt that cannot be readily removed, thereby requiring a troublesome post-treatment and thus resulting in a high production cost.
[0021] The production method described in Patent Literature 4 requires a long period of time for the dropwise addition of a strong acid, resulting in a high production cost, and the dropwise addition of acid at high temperatures results in a high hydrogen azide concentration in the gaseous phase and the resulting product is of a poor quality. Moreover, the product is obtained only as a crystalline monohydrate, and high temperatures are required to convert it into an anhydrate. Furthermore, once exposed to a humidity of 10% or greater, the anhydrate is promptly converted back into the monohydrate.
[0022] The production method described in Patent Literature 5 uses an acid having a pKa of 3 to 9 and therefore the reaction proceeds slowly, requiring the reaction to be carried out for a long period of time. In addition, even after a reaction carried out for a long period of time, a product having a purity of 99.0% or greater is not obtained.
SUMMARY OF THE INVENTION
[0023] The present invention was conceived in light of these situations, and an object of the invention is to provide high-quality bis-(1(2)H-tetrazol-5-yl)amine and a method for easily, safely, and inexpensively producing the compound.
Means for Solving the Problems
[0024] One mole of a dicyanamide salt reacts with 2 moles of an azide salt and 2 moles of an acid and, via several intermediates, eventually forms 1 mole of a bis-(1(2)H-tetrazol-5-yl)amine metal salt and 1 mole of an acid.
[0025] That is, in the initial reaction stage where intermediates are generated, 1 mol of a dicyanamide salt reacts with 2 mol of an azide salt and 2 mol of an acid. However, from the reaction stage where 1 mol of a bis-(1(2)H-tetrazol-5-yl)amine metal salt and 1 mol of an acid are generated onwards, the amount of acid starts to become excessive due to this acid generation.
[0026] The use of the acid that becomes excessive during the reaction allows the reaction of 1 mol of a dicyanamide salt to proceed with 2 mol of an azide salt and 1 mol of a starting acid, giving 1 mol of a bis-(1(2)H-tetrazol-5-yl)amine metal salt.
[0027] However, if an acid is not present in a sufficient amount from the initial reaction stage, the reaction barely proceeds and an impurity resulting from an intermediate is generated in large amounts. In contrast, if a dicyanamide salt is not present in a sufficient amount, hydrogen azide may be generated.
[0028] To describe more specifically, as shown in FIG. 1 , the production of a bis-(1(2)H-tetrazol-5-yl)amine metal salt is attained via the generation of several intermediates, namely IM1, IM2, and IM3. While the bis-(1(2)H-tetrazol-5-yl)amine metal salt can be stably present within the reaction system, the dicyanamide salt and the intermediates IM1 and 1M2 are poorly stable. This tendency becomes more pronounced when the pH is low.
[0029] It is necessary to suppress the decomposition of the intermediates IM1 and IM2 to enhance the quality of the bis-(1(2)H-tetrazol-5-yl)amine metal salt, and therefore it is necessary to:
[0030] 1. maintain a high pH during the reaction, and
[0031] 2. keep the concentrations of the starting materials and the intermediates IM1 and IM2 in the reaction system low.
[0032] Firstly, an acid is used in an amount as little as possible to keep the pH high.
[0033] While 2 mol of H+is needed to form the tetrazole rings of the bis-(1(2)H-tetrazol-5-yl)amine metal salt, 1 mol of 1+ is released once the two tetrazole rings are formed (this may be because BTA-1Na is an acid stronger than NaN3).
[0034] Therefore, unless the released H+ is used in the reaction, the acidity of the system is increased as the reaction proceeds (the pH is decreased), thereby promoting the decomposition of the starting materials and the intermediates.
[0035] Therefore, the dropwise addition of the starting dicyanamide salt in divided amounts is a technique for forming the second tetrazole ring with the minimum amount of acid (equimolar relative to the dicyanamide salt) and for promptly converting the dicyanamide salt added in divided amounts into a bis-(1(2)H-tetrazol-5-yl)amine metal salt using the released H+.
[0036] If the reaction is carried out using a dicyanamide salt not in divided amounts and the minimum amount of an acid (equimolar relative to the dicyanamide salt), the pH of the reaction system is high, but the intermediate IM2, which has one tetrazole ring, is generated in a high concentration.
[0037] In such a reaction system, not only is the concentration of the unstable intermediate IM2 high and the quality of the desired product thus deteriorated, but also it takes a relatively long period of time to form a bis-(1(2)H-tetrazol-5-yl)amine metal salt due to the low concentration of the intermediate IM3.
[0038] The inventors, having conducted extensive research, found that a high-quality bis-(1(2)H-tetrazol-5-yl)amine metal salt can be obtained by starting a reaction using a portion of the necessary amount of a dicyanamide salt and by controlling the amount of a dicyanamide salt added or the amounts of a dicyanamide salt and an acid added thereafter according to the progress of the reaction so as to promote the reaction, and thus arrived at the present invention.
[0039] That is, to address the above-described problems, the method for producing bis-(1(2)H-tetrazol-5-yl)amine of the present invention includes the steps of heating to 50 to 120° C. a solution mixture in which the necessary amount of an azide salt and a dicyanamide salt in an amount corresponding to 1 to 80 wt % of the necessary amount are added to a solvent, adding an acid in an amount of 1.54 to 2.22 chemical equivalents of the dicyanamide salt in the solution mixture to carry out a reaction at 50 to 120° C., and then adding an acid and a dicyanamide salt solution in which the remaining dicyanamide salt is dissolved in a solvent to promote the reaction.
[0040] Examples of dicyanamide salts for use in the present invention include alkali metal salts, alkaline earth metal salts, and ammonium salts, and sodium dicyanamide is preferable.
[0041] Examples of azide salts for use in the present invention include alkali metal salts and alkaline earth metal salts, and sodium azide is preferable. The amount of azide salt is preferably in a range of 1.90 to 2.20 mol, and in particular 2.0 to 2.1 mol, per mol of the dicyanamide salt.
[0042] Examples of solvents for use in the present invention include water and water-miscible solvents such as aprotic polar solvents, N-substituted lactamic solvents, alcohols, and ethers, as well as mixtures of such solvents. Among such solvents, examples of aprotic polar solvents include N,N-dimethylformamide, N,N-diethylformamide, N,N-diisopropylformamide, N,N-dimethylacetamide, N,N-diethylacetamide, N,N-diisopropylacetamide, N,N-dimethylpropionamide, and N,N-diethylpropionamide. Examples of N-substituted lactamic solvents include N-methylpyrrolidone and N-ethylpyrrolidone. Examples of alcohols include methanol, ethanol, and isopropanol. Examples of ethers include tetrahydrofuran, dioxane, methylcellosolve, and ethylcellosolve. Such solvents may be used singly or as a mixture of two or more. Among such solvents, it is preferable to use water as a solvent to inexpensively produce the desired product. In this case, a water-miscible solvent may be added. The amount of solvent is usually in a range of 1 to 100 times, preferably 5 to 20 times, as much in weight as that of dicyanamide salt.
[0043] Examples of acids for use in the present invention include inorganic acids such as hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid and perchloric acid, and organic acids such as formic acid, acetic acid, propionic acid, methanesulfonic acid, toluenesulfonic acid, trifluoroacetic acid and trifluoromethanesulfonic acid. Acetic acid, hydrochloric acid, and sulfuric acid are preferable in terms of availability and cost on an industrial scale, and acetic acid is particularly preferable in terms of safety. Additives such as amines or amine salts are not added to such acids. The amount of acid is in a range of 1.0 to 1.2 chemical equivalents per mole of the dicyanamide salt. Therefore, the amount of acid is in a range of 1.0 to 1.2 mol in the case of a monovalent acid, and 0.5 to 0.6 mol in the case of a divalent acid, per mole of dicyanamide salt.
[0044] Next, the production method shall be described.
[0045] First, the entire amount of an azide salt necessary in a reaction, a dicyanamide salt in an amount corresponding to 1 to 80 wt % of the amount necessary in the reaction, a solvent, and an acid in an amount of 1.54 to 2.22 chemical equivalents of the dicyanamide salt that is present in the 1 to 80 wt % amount are mixed and reacted at 50 to 120° C.
[0046] In this regard, if a dicyanamide salt, an azide salt, a solvent, and an acid are mixed as 4 separate ingredients, the order of mixing the ingredients is not particularly limited. For example, the acid may be added to a solution mixture of the dicyanamide salt, the azide salt and the solvent, or a solution mixture of the azide salt and the acid may be added to a dicyanamide salt solution in which the dicyanamide salt is dissolved in the solvent. In the latter case, the solution mixture may be added to the dicyanamide salt solution at 50 to 120° C. over 30 minutes to 12 hours. Meanwhile, the acid may be added to the solution mixture over such a long period of time similar to that mentioned above, or the entire amount of the acid may be added at once at a specific temperature, or half the amount may be added at a low temperature, heating may be carried out, and then the other half may be added. In the case of performing mixing in this manner, it is preferably performed under vigorous stirring. As to the temperature-time relationship during mixing, high temperature conditions carry risks and therefore mixing needs to be performed over a long period of time, while low temperature conditions allow mixing to be accomplished in a short period of time. From the operation time viewpoint, performing mixing at low temperatures in a short period of time may be considered preferable, but the rate of intermediate generation is low at low temperatures, requiring an additional acid and impairing the yield. In contrast, the rate of intermediate generation is high at high temperatures, but impurities are generated in addition to the intermediates and mixing needs to be performed over a long period of time. Therefore, the temperature and the time for mixing are determined depending on which of factors such as operation time, safety, yield, or purity are prioritized.
[0047] The dicyanamide salt is used in an amount 1 to 80 wt %, and preferably 50 to 80 wt %, of the amount necessary for reaction. If the dicyanamide salt is added in an amount less than 1 wt %, controlling the addition of the remaining 99 wt % is troublesome. If the dicyanamide salt is added in an amount exceeding 80 wt % of the amount necessary for reaction, the dicyanamide salt concentration in the reaction system is high, and thus impurities resulting from the dicyanamide salt and reaction intermediates are likely to be generated.
[0048] The acid is used in an amount of 1.54 to 2.22 chemical equivalents of the dicyanamide salt present in the 1 to 80 wt % amount. If the amount of acid is less than 1.54 chemical equivalents, the acid present in the initial reaction stage is insufficient, and the reaction barely proceeds. If the amount exceeds 2.22 chemical equivalents, the acid is excessive and hydrogen azide is likely to be generated.
[0049] In the next step, an acid and a dicyanamide salt solution in which the remaining dicyanamide salt is dissolved in a solvent are added to promote the reaction.
[0050] At this time, when to add the acid and the dicyanamide salt solution is determined as follows.
[0051] (1) The reaction solution is regularly sampled, and the addition of the acid and the dicyanamide salt solution is controlled such that the amount of dicyanamide salt remaining in the reaction solution is 0.1 to 3 wt % in reference to the area percentage obtained by liquid chromatographic analysis. Insofar as the amount of dicyanamide salt in the reaction solution is within the range of 0.1 to 3 wt %, the rate, order, and other factors of adding the acid and the dicyanamide salt solution are not particularly limited. When the amount of dicyanamide salt is less than 0.1 wt %, an excessive amount of acid is present and hydrogen azide is likely to be generated. When the amount of dicyanamide salt exceeds 3 wt %, the amount of acid is likely to be insufficient and the reaction is likely to barely proceed, making it difficult to complete the reaction, and impurities resulting from reaction intermediates are likely to be generated.
[0052] (2) If the reaction temperature is from 50 to 100° C., a pH meter can be used. Thus, while controlling the acid such that the pH is 6 to 9, the reaction is promoted by the addition of the acid and the dicyanamide salt solution. Insofar as the pH is within the range of 6 to 9, the rate, order, and other factors of adding the acid and the dicyanamide salt solution are not particularly limited. If the pH exceeds 9, the acid is likely to be insufficient and the progress of the reaction is likely to be inhibited. Meanwhile, if the pH is less than 6, hydrogen azide may be generated.
[0053] (3) If the entire amount of acid necessary to carry out the reaction is used in the previous step and only a dicyanamide salt solution is added in this step, the reaction can be controlled by adding the dicyanamide salt solution according to reaction curve data constructed in advance based on the reaction times of the dicyanamide salt solution at various temperatures. A specific example is the data presented in FIG. 2 that are obtained in Example 1 below. In this case, neither liquid chromatography nor a pH meter is used, and thus efficient production can be attained when the desired product is repetitively produced on a large scale.
[0054] As described above, a reaction is started using a dicyanamide salt in an amount corresponding to 1 to 80 wt % of the necessary amount, and then a dicyanamide salt and an acid (in some cases, a dicyanamide salt only) are added in divided and controlled amounts, thereby allowing the acid that is generated during the reaction to be effectively used to construct a favorable reaction environment. It is thus possible to produce a bis-(1(2)H-tetrazol-5-yl)amine metal salt compound that enables bis-(1(2)H-tetrazol-5-yl)amine ammonium salt having a high purity of 99.0 wt % or greater as determined on a weight basis according to the area percentage obtained by liquid chromatographic analysis to be obtained.
[0055] The bis-(1(2)H-tetrazol-5-yl)amine metal salt compound obtained in this stage has a purity of 94.0 area % or greater and does not have a peak accounting for 0.1 area % or greater within a relative retention time starting at 1.08 and ending at 1.20 assuming that the retention time to the main peak is 1 according to the area percentage obtained by HPLC analysis. A peak indicating an impurity derived from an unstable starting material or intermediate appears within the relative retention time starting at 1.08 and ending at 1.20 assuming that the retention time to the main peak is 1. Therefore, an impurity concentration of less than 0.1 area % as determined by the area percentage within this retention time indicates the presence of a bis-(1(2)H-tetrazol-5-yl)amine metal salt compound from which a high-quality bis-(1(2)H-tetrazol-5-yl)amine ammonium salt can be obtained.
[0056] Note that the HPLC analysis conditions include detection with UV220 nm, a column of Inertsil ODS-3 (4.6 mm ID.times.250 mm), a column bath temperature of 40° C., a mobile phase of water/acetonitrile/phosphoric acid in a ratio of 800/200/0.1, a mobile phase flow rate of 0.7 mL/min, and an amount of sample injected of 10 .mu.L (loop). The relative retention time starting at 1.08 and ending at 1.20 assuming that the retention time to the main peak is 1 has been determined in consideration of every possible error of measurement, and the peaks of the aforementioned impurities do not appear outside this range.
[0057] The conditions of HPLC analysis are not particularly limited to those described above insofar as the conditions allow the bis-(1(2)H-tetrazol-5-yl)amine metal salt compound, the dicyanamide salt, and each reaction intermediate to be distinguished for a quantitative analysis thereof and various HPLC analysis conditions may be adopted.
[0058] The bis-(1(2)H-tetrazol-5-yl)amine metal salt compound thus obtained is heat-treated at 75° C. or greater to complete the reaction, and a second acid solution is added thereto to form bis-(1(2)H-tetrazol-5-yl)amine anhydrate and/or monohydrate.
[0059] The heat treatment is carried out at 75° C. or greater and preferably 90° C. or greater. The heat treatment is carried out for 10 to 48 hours and preferably 10 to 30 hours. Although the reaction proceeds at a temperature below 75° C., the reaction rate is low and the reaction may not complete even after a long period of time.
[0060] The second acid solution is preferably of the same type of acid used in the method for producing the reaction intermediate described above, and a different type of acid may be used as well.
[0061] The addition of the second acid may be carried out while the reaction intermediate is heated during the heat treatment to 75° C. or greater, or may be added after the heat treatment is terminated and the intermediate is cooled to a specific temperature.
[0062] Controlling the temperature of the reaction intermediate at the time of adding the acid enables a monohydrate and an anhydrate to be selectively prepared. That is, controlling the temperature of the reaction intermediate to less than 70° C. enables bis-(1(2)H-tetrazol-5-yl)amine monohydrate to be mostly prepared. Meanwhile, controlling the temperature of the reaction intermediate to 70° C. or greater at the time of adding the acid enables bis-(1(2)H-tetrazol-5-yl)amine anhydrate to be mostly prepared. The dropwise addition of the acid is performed over the course of 2 hours or longer, and desirably 4 to 12 hours, to complete the reaction in a short period of time. Moreover, the acid is added until the pH reaches 3 or less to complete the reaction to enhance the yield.
[0063] The bis-(1(2)H-tetrazol-5-yl)amine anhydrate and/or monohydrate obtained at this stage has a purity of 99.0 area % or greater and does not have a peak accounting for 0.1 area % or greater within a relative retention time starting at 1.08 and ending at 1.20 assuming that the retention time to the main peak is 1 according to the area percentage obtained by HPLC analysis. A peak indicating an impurity derived from an unstable starting material or intermediate appears within the relative retention time starting at 1.08 and ending at 1.20 assuming that the retention time to the main peak is 1. Therefore, an impurity concentration of less than 0.1 area % as determined by the area percentage within this retention time indicates the presence of bis-(1(2)H-tetrazol-5-yl)amine anhydrate and/or monohydrate from which high-quality bis-(1(2)H-tetrazol-5-yl)amine ammonium salt can be obtained.
[0064] Note that the HPLC analysis conditions include detection with UV220 nm, a column of Inertsil ODS-3 (4.6 mm ID.times.250 mm), a column bath temperature of 40° C., a mobile phase of water/acetonitrile/phosphoric acid in a ratio of 800/200/0.1, a mobile phase flow rate of 0.7 mL/min, and an amount of sample injected of 10 .mu.L (loop). The relative retention time starting at 1.08 and ending at 1.20 assuming that the retention time to the main peak is 1 has been determined in consideration of every possible error of measurement, and the peaks of the aforementioned impurities do not appear outside this range.
[0065] The conditions of HPLC analysis are not particularly limited to those described above insofar as the conditions allow the bis-(1(2)H-tetrazol-5-yl)amine anhydrate and/or monohydrate, the dicyanamide salt, and each reaction intermediate to be distinguished for a quantitative analysis thereof, and various HPLC analysis conditions may be adopted.
[0066] The bis-(1(2)H-tetrazol-5-yl)amine anhydrate and/or monohydrate can be generated as bis-(1(2)H-tetrazol-5-yl)amine ammonium salt by controlling the pH through the dropwise addition of an amine.
[0067] The bis-(1(2)H-tetrazol-5-yl)amine ammonium salt obtained at this stage has a purity of 99.0 wt % or greater as determined on a weight basis and does not show a peak accounting for 0.1 wt % or greater as determined on a weight basis within a relative retention time starting at 2.17 and ending at 2.24 assuming that the retention time to the main peak is 1 according to the area percentage obtained by HPLC analysis. A peak indicating an impurity derived from an unstable starting material or impurity appears within the relative retention time starting at 2.17 and ending at 2.24 assuming that the retention time to the main peak is 1. Therefore, an impurity concentration of less than 0.1 wt % as determined on a weight basis according to the area percentage within this retention time indicates the presence of high-quality bis-(1(2)H-tetrazol-5-yl)amine ammonium salt.
[0068] Note that the HPLC analysis conditions include detection with UV220 nm, a column of Inertsil ODS-3 having 4.6 mm ID.times.250 mm, a column bath temperature of 30° C., a mobile phase (solution A: 0.1% phosphoric acid solution/acetonitrile/methanol in a ratio of 950/25/25, and solution B: 0.1% phosphoric acid solution/acetonitrile in a ratio of 400/600), a gradient program (0-30 minutes: 100-50% solution A, 0-50% solution B, and 30-60 minutes: 50% solution A, 50% solution B), a mobile phase flow rate of 1.0 mL/min, and an amount of a sample injected of 20 μL (loop). The relative retention time starting at 2.17 and ending at 2.24 assuming that the retention time to the main peak is 1 has been determined in consideration of every possible error of measurement, and the peaks of the aforementioned impurities do not appear outside this range.
[0069] The conditions of HPLC analysis are not specifically limited to those described above insofar as the conditions allow the bis-(1(2)H-tetrazol-5-yl)amine salt, the dicyanamide salt, and each reaction intermediate to be distinguished and quantitatively analyzed, and various HPLC analysis conditions may be adopted.
Effects of the Invention
[0070] As described above, the present invention allows a reaction to safely and efficiently proceed because a solution mixture in which the necessary amount of an azide salt and a dicyanamide salt in an amount corresponding to 1 to 80 wt % of the necessary amount are added to a solvent is heated to 50 to 120° C., an acid is added in an amount of 1.54 to 2.22 chemical equivalents of the dicyanamide salt in the solution mixture to carry out a reaction at 50 to 120° C., and then an acid and a dicyanamide salt solution in which the remaining dicyanamide salt is dissolved in a solvent are added to promote the reaction. Moreover, the present invention reduces the impurities generated during the reaction process and allows bis-(1(2)H-tetrazole 5-yl)amine ammonium salt having a high purity of 99.0 wt % or greater to be obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0071] FIG. 1 is a reaction scheme showing the reaction process according to the method for producing bis-(1(2)H-tetrazol-5-yl)amine of the present invention.
[0072] FIG. 2 shows the change over time in the amounts of a dicyanamide salt and intermediates generated according to the method for producing bis-(1(2)H-tetrazol-5-yl)amine of the present invention.
[0073] FIG. 3( a ) is a chromatogram of the reaction solution in which the bis-(1(2)H-tetrazol-5-yl)amine metal salt compound of Example 6 according to the method for producing bis-(1(2)H-tetrazol-5-yl)amine of the present invention is dissolved, and FIG. 3( b ) is analytical data of the chromatogram.
[0074] FIG. 4( a ) is a chromatogram of the wet bis-(1(2)H-tetrazol-5-yl)amine of Example 6 according to the method for producing bis-(1(2)H-tetrazol-5-yl)amine of the present invention, and FIG. 4( b ) is analytical data of the chromatogram.
[0075] FIG. 5( a ) is a chromatogram of the bis-(1(2)H-tetrazol-5-yl)amine ammonium salt of Example 6 according to the method for producing bis-(1(2)H-tetrazol-5-y0amine of the present invention, and FIG. 5( b ) is analytical data of the chromatogram.
[0076] FIG. 6( a ) is a chromatogram of the reaction solution in which the bis-(1(2)H-tetrazol-5-yl)amine metal salt compound of Comparative Example according to a conventional method for producing bis-(1(2)H-tetrazol-5-yl)amine is dissolved, and FIG. 6( b ) is analytical data of the chromatogram.
[0077] FIG. 7( a ) is a chromatogram of the wet bis-(1(2)H-tetrazol-5-yl)amine of Comparative Example 2 according to a conventional method for producing bis-(1(2)H-tetrazol-5-yl)amine, and FIG. 7( b ) is analytical data of the chromatogram.
[0078] FIG. 8( a ) is a chromatogram of the bis-(1(2)H-tetrazol-5-yl)amine ammonium salt of Comparative Example 2 according to a conventional method for producing bis-(1(2)H-tetrazol-5-yl)amine, and FIG. 8( b ) is analytical data of the chromatogram.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0079] The present invention shall be described in detail below by way of examples although the present invention is not limited to the examples.
EXAMPLE 1
[0080] 11.57 g of sodium dicyanamide (hereinafter simply referred to as “NaDCA”, 0.13 mol, 65 wt % of the entire NaDCA used in the reaction), 26.39 g of sodium azide (0.406 mol, 2.03 times the molar amount of the entire NaDCA used in the reaction), and 90 mL of water were introduced into a 300 mL flask and heated while stirring until the internal temperature reached 100° C.
[0081] While the internal temperature was maintained at 100° C., 16.81 g of a 63% sulfuric acid solution (0.108 mol, 1.08 times the chemical equivalents of the entire NaDCA used in the reaction) was added over the course of 3 hours.
[0082] While the internal temperature was maintained at 100° C., an aqueous NaDCA solution in which remaining 6.24 g of NaDCA (0.07 mol, 35 wt % of the entire NaDCA used in the reaction) had been dissolved in 30 mL of water was added dropwise over the course of 26 hours.
[0083] At this time, the rate of the dropwise addition was controlled so as to maintain the NaDCA content of the reaction solution at 1 wt % or less according to HPLC analysis.
[0084] The reaction was further promoted by stirring at 100° C. for 10 hours, and the internal temperature was then lowered to near room temperature. FIG. 2 shows the results of HPLC analysis showing the change over time in the proportions of specific components eluted out.
[0085] 75 mL of water and 31.45 g (0.202 mol) of a 63% sulfuric acid solution were added to the reaction solution for crystallization, and 2.0 g of a 40% aqueous sodium nitrite solution was then added to decompose unreacted hydrogen azide. Crystals were filtered off at about 25.degree. C., thereby giving about 42 g of wet bis-(1(2)H-tetrazol-5-yl)amine.
[0086] This compound was vacuum-dried at 60° C., thereby giving 30.50 g of bis-(1(2)H-tetrazol-5-yl)amine having an HPLC purity of 99.4 area % in a yield of 89.2%.
EXAMPLE 2
Monohydrate
[0087] 11.57 g of NaDCA (0.13 mol, 65 wt % of the entire NaDCA used in the reaction), 26.39 g of sodium azide (0.406 mol, 2.03 times the molar amount of the entire NaDCA used in the reaction), and 90 mL of water were introduced into a 300 mL flask and heated while stirring until the internal temperature reached 100° C.
[0088] While the internal temperature was maintained at 100.degree. C., 14.28 g of 90% acetic acid (0.214 mol, 1.07 times the chemical equivalents of the entire NaDCA used in the reaction) was added over the course of 3 hours.
[0089] While the internal temperature was maintained at 100° C., an aqueous NaDCA solution in which remaining 6.24 g of NaDCA (0.07 mol, 35 wt % of the entire NaDCA used in the reaction) had been dissolved in 30 mL of water was added dropwise over the course of 26 hours.
[0090] At this time, the rate of the dropwise addition was controlled so as to maintain the NaDCA content of the reaction solution at 1 wt % or less according to HPLC analysis.
[0091] The reaction was further promoted by stirring at 100° C. for 10 hours, and the internal temperature was then lowered to near room temperature.
[0092] 75 mL of water was added, and while the internal temperature was maintained at 70° C., 48.3 g (0.31 mol) of a 63% sulfuric acid solution was added for crystallization, and 2.0 g of a 40% aqueous sodium nitrite solution was then added to decompose unreacted hydrogen azide. Crystals were filtered off at about 25° C. and dried, thereby giving 30.9 g of bis-(1(2)H-tetrazol-5-yl)amine monohydrate having an HPLC purity of 99.1 area % in a yield of 90.3%.
EXAMPLE 3
Anhydrate
[0093] 11.57 g of NaDCA (0.13 mol, 65 wt % of the entire NaDCA used in the reaction), 26.39 g of sodium azide (0.406 mol, 2.03 times the molar amount of the entire NaDCA used in the reaction), and 90 mL of water were introduced into a 300 mL flask and heated while stirring until the internal temperature reached 100° C.
[0094] While the internal temperature was maintained at 100° C., 14.28 g of 90% acetic acid (0.214 mol, 1.07 times the chemical equivalents of the entire NaDCA used in the reaction) was added over the course of 3 hours.
[0095] While the internal temperature was maintained at 100° C., an aqueous NaDCA solution in which remaining 6.24 g of NaDCA (0.07 mol, 35 wt % of the entire NaDCA used in the reaction) had been dissolved in 30 mL of water was added dropwise over the course of 26 hours.
[0096] At this time, the rate of the dropwise addition was controlled so as to maintain the NaDCA content of the reaction solution at 1 wt % or less according to HPLC analysis.
[0097] The reaction was further promoted by stirring at 100° C. for 10 hours, and the internal temperature was then lowered to near room temperature.
[0098] 75 mL of water was added, and while the internal temperature was maintained at 90° C., 48.3 g (0.31 mol) of a 63% sulfuric acid solution was added for crystallization, and 2.0 g of a 40% aqueous sodium nitrite solution was then added to decompose unreacted hydrogen azide. Crystals were filtered off at about 25.degree. C. and dried, thereby giving 27.4 g of bis-(1(2)H-tetrazol-5-yl)amine anhydrate having an HPLC purity of 99.2 area % in a yield of 89.4%.
EXAMPLE 4
[0099] 11.57 g of NaDCA (0.13 mol, 65 wt % of the entire NaDCA used in the reaction), 26.39 g of sodium azide (0.406 mol, 2.03 times the molar amount of the entire NaDCA used in the reaction), and 90 mL of water were introduced into a 300 mL flask and heated while stirring until the internal temperature reached 60° C.
[0100] While the internal temperature was maintained at 60° C., 16.81 g of 63% sulfuric acid (0.108 mol, 1.08 times the chemical equivalents of the entire NaDCA used in the reaction) was added over the course of 3 hours.
[0101] The internal temperature was increased to 100° C., and while the internal temperature was maintained at 100° C., an aqueous NaDCA solution in which 6.24 g of NaDCA (0.07 mol, 35 wt % of the entire NaDCA used in the reaction) had been dissolved in 30 mL of water was added dropwise over the course of 26 hours.
[0102] At this time, the rate of the dropwise addition was controlled so as to maintain the NaDCA content of the reaction solution at 1 wt % or less according to HPLC analysis.
[0103] The reaction was further promoted by stirring at 100° C. for 10 hours, and the internal temperature was then lowered to near room temperature.
[0104] 75 mL of water and 31.45 g (0.202 mol) of a 63% sulfuric acid solution were added for crystallization, and 2.0 g of a 40% aqueous sodium nitrite solution was then added to decompose unreacted hydrogen azide. Crystals were filtered off at about 25° C., thereby giving about 42 g of wet bis-(1(2)H-tetrazol-5-yl)amine.
[0105] This compound was vacuum-dried at 60° C., thereby giving 30.20 g of bis-(1(2)H-tetrazol-5-yl)amine having an HPLC purity of 99.2 area % in a yield of 88.3%.
EXAMPLE 5
[0106] 11.57 g of NaDCA (0.13 mol, 65 wt % of the entire NaDCA used in the reaction), 26.39 g of sodium azide (0.406 mol, 2.03 times the molar amount of the entire NaDCA used in the reaction), and 90 mL of water were introduced into a 200 mL flask and heated while stirring until the internal temperature reached 100° C.
[0107] While the internal temperature was maintained at 100° C., 12.5 g of acetic acid (0.208 mol, 1.04 times the chemical equivalents of the entire NaDCA used in the reaction) was added over the course of 2 hours.
[0108] While the internal temperature was maintained at 100° C., an aqueous NaDCA solution in which remaining 6.24 g of NaDCA (0.07 mol, 35 wt % of the entire NaDCA used in the reaction) had been dissolved in 30 mL of water was added dropwise over the course of 20 hours.
[0109] At this time, the rate of the dropwise addition of the aqueous NaDCA solution was changed every hour. Specifically, the rate of dropwise addition was gradually reduced so as to be 4.5 mL/hr for the 1st hour, 3.9 mL/hr for the 2nd hour, 3.4 mL/hr for the 3rd hour, 3.0 mL/hr for the 4th hour, and so on.
[0110] The rate of the dropwise addition was controlled so as to maintain the NaDCA content of the reaction solution at 1 wt % or less according to HPLC analysis.
[0111] The reaction was further promoted by stirring at 100° C. for 10 hours, and the internal temperature was then lowered to near room temperature.
[0112] 75 mL of water and 48.3 g (0.31 mol) of a 63% sulfuric acid solution were added for crystallization, and 2.0 g of a 40% aqueous sodium nitrite solution was then added to decompose unreacted hydrogen azide. Crystals were filtered off at about 25.degree. C., thereby giving about 42 g of wet bis-(1(2)H-tetrazol-5-yl)amine.
[0113] The entire amount of the wet bis-(1(2)H-tetrazol-5-yl)amine and 150 mL of water were introduced into a 200 mL flask to form a suspension. The pH was controlled so as to be 4 to 6 by adding a 28% ammonia solution. The suspension was cooled to 10° C. or lower and then subjected to filtration, thereby giving about 35 g of wet bis-(1(2)H-tetrazol-5-yl)amine ammonium salt.
[0114] This compound was vacuum-dried at 60° C., thereby giving 28.5 g of bis-(1(2)H-tetrazol-5-yl)amine ammonium salt having a purity of 99.7 wt % as determined on a weight basis from the results of HPLC analysis in a yield of 84%.
EXAMPLE 6
[0115] 0.18 g of NaDCA (0.002 mol, 1 wt % of the entire NaDCA used in the reaction), 26.39 g of sodium azide (0.406 mol, 2.03 times the molar amount of the entire NaDCA used in the reaction), and 90 mL of water were introduced into a 200 mL flask and heated while stirring until the internal temperature reached 100° C.
[0116] 52.96 g of 20% sulfuric acid (1.08 times the chemical equivalents of the entire NaDCA used in the reaction) was added dropwise over the course of 35 hours.
[0117] 40 minutes after the beginning of the dropwise addition of 20% sulfuric acid, an aqueous NaDCA solution in which 17.63 g of NaDCA (0.198 mol, 99 wt % of the entire NaDCA used in the reaction) had been dissolved in 85 mL of water was added dropwise over the course of 34 hours while the internal temperature was maintained at 100° C.
[0118] At this time, the rate of the dropwise addition was controlled so as to maintain the NaDCA content of the reaction solution at 1 wt % or less according to HPLC analysis. The HPLC conditions included detection with UV220 nm, a column of Inertsil ODS-3 (4.6 mm ID.times.250 mm), a column bath temperature of 40° C., a mobile phase of water/acetonitrile/phosphoric acid in a ratio of 800/200/0.1, a mobile phase flow rate of 0.7 mL/min, and an amount of sample injected of 10 μL (loop).
[0119] The reaction was further promoted by stirring at 100° C. for 10 hours, and the internal temperature was then lowered to near room temperature.
[0120] The reaction solution after cooling was subjected to HPLC analysis, and the results of which are presented in FIG. 3 . The results of the analysis showed that the bis-(1(2)H-tetrazol-5-yl)amine metal salt compound in the resulting reaction solution had a purity of 94.0 area % or greater and a peak derived from an impurity appearing within the relative retention time starting at 1.08 and ending at 1.20 assuming that the retention time to the main peak is 1 accounting for 0.1 area % or less according to the area percentage obtained by the HPLC analysis. Thereafter, 31.4 g (0.202 mol) of a 63% sulfuric acid solution was added to the reaction solution for crystallization, and 2.0 g of a 40% aqueous sodium nitrite solution was then added to decompose unreacted hydrogen azide. Crystals were filtered off at about 25.degree. C., thereby giving about 49 g of wet bis-(1(2)H-tetrazol-5-yl)amine.
[0121] The results of the HPLC analysis of the resulting wet bis-(1(2)H-tetrazol-5-yl)amine are presented in FIG. 4 . The HPLC conditions were the same as those used in the HPLC analysis of the reaction solution described above. The results of the analysis showed that the wet bis-(1(2)H-tetrazol-5-yl)amine in the resulting reaction solution had a purity of 99.0 area % or greater and a peak derived from an impurity appearing within the relative retention time starting at 1.08 and ending at 1.20 assuming that the retention time to the main peak is 1 accounting for 0.1 area % or less according to the area percentage obtained by the HPLC analysis.
[0122] Thereafter, the entire amount of the wet bis-(1(2)H-tetrazol-5-yl)amine and 150 mL of water were introduced into a 200 mL flask to form a suspension. The pH was controlled so as to be 4 to 6 by adding a 28% ammonia solution. The suspension was cooled to 10° C. or lower and then subjected to filtration, thereby giving about 35 g of wet bis-(1(2)H-tetrazol-5-yl)amine ammonium salt.
[0123] This compound was vacuum-dried at 60° C., thereby giving 29.2 g of bis-(1(2)H-tetrazol-5-yl)amine ammonium salt having a purity of 99.6 wt % on a weight basis as determined from the results of HPLC analysis in a yield of 86%. FIG. 5 shows the HPLC data obtained accordingly. Note that the HPLC conditions included detection with UV220 nm, a column of Inertsil ODS-3 having 4.6 mm ID.times.250 mm, a column bath temperature of 30° C., a mobile phase (solution A: 0.1% phosphoric acid solution/acetonitrile/methanol in a ratio of 950/25/25, and solution B: 0.1% phosphoric acid solution/acetonitrile in a ratio of 400/600), a gradient program (0-30 minutes: 100-50% solution A, 0-50% solution B, and 30-60 minutes: 50% solution A, 50% solution B), a mobile phase flow rate of 1.0 mL/min, and an amount of a sample injected of 20 μL (loop). The results of the analysis showed that the bis-(1(2)H-tetrazol-5-yl)amine ammonium salt in the resulting reaction solution had a purity of 99.0 wt % or greater and a peak derived from an impurity appearing within the relative retention time starting at 2.17 and ending at 2.24 assuming that the retention time to the main peak is 1 accounting for 0.1 wt % or less as determined on a weight basis according to the area percentage obtained by the HPLC analysis.
COMPARATIVE EXAMPLE 1
Boric Acid
[0124] 17.81 g (0.20 mol) of NaDCA, 26.00 g of sodium azide (0.40 mol, 2.0 times the molar amount of the entire NaDCA used in the reaction), 25.96 g of boric acid (0.42 mol, 1.05 times the chemical equivalents of the entire NaDCA used in the reaction), and 200 mL of water were introduced into a 300 mL flask and heated while stirring until the internal temperature reached 100° C.
[0125] While the internal temperature was maintained at 100° C., the reaction was promoted by stirring at 100° C. for 42 hours, and the internal temperature was then lowered to near room temperature.
[0126] 48.3 g (0.312 mol) of a 63% sulfuric acid solution was added for crystallization, and 8.3 g of a 40% aqueous sodium nitrite solution was then added to decompose unreacted hydrogen azide. 2.06 g of a 63% sulfuric acid solution was further added, and then crystals were filtered off at about 25° C., thereby giving about 44.6 g of wet bis-(1(2)H-tetrazol-5-yl)amine.
[0127] This compound was vacuum-dried at 60° C., thereby giving 27.25 g of bis-(1(2)H-tetrazol-5-yl)amine having an HPLC purity of 77.5 area % in a yield of 79.6%.
COMPARATIVE EXAMPLE 2
Conventional Method with the Use of Sulfuric Acid
[0128] 17.81 g (0.20 mol) of NaDCA, 26.39 g of sodium azide (0.406 mol, 2.03 times the molar amount of the entire NaDCA used in the reaction), and 120 mL of water were introduced into a 300 mL flask and heated while stirring until the internal temperature reached 100° C.
[0129] While the internal temperature was maintained at 100° C., 16.81 g (0.108 mol) of 63% sulfuric acid was added over the course of 3 hours.
[0130] While the internal temperature was maintained at 100° C., the reaction was promoted by stirring for 10 hours, and the internal temperature was then lowered to near room temperature.
[0131] The reaction solution after cooling was subjected to HPLC analysis, and the results of which are presented in FIG. 6 .
[0132] The HPLC analysis conditions included detection with UV220 nm, a column of Inertsil ODS-3 (4.6 mm ID.times.250 mm), a column bath temperature of 40° C., a mobile phase of water/acetonitrile/phosphoric acid in a ratio of 800/200/0.1, a mobile phase flow rate of 0.7 mL/min, and an amount of sample injected of 10 μL (loop). The results of the analysis showed that the bis-(1(2)H-tetrazol-5-yl)amine metal salt compound in the resulting reaction solution had a purity of 94.0 area % or greater but a peak derived from an impurity appearing within the relative retention time starting at 1.08 and ending at 1.20 assuming that the retention time to the main peak is 1 accounting for 0.4 area % or greater according to the area percentage obtained by the HPLC analysis.
[0133] Thereafter, 75 mL of water and 31.45 g (0.202 mol) of a 63% sulfuric acid solution were added to the reaction solution for crystallization, and 2.0 g of a 40% aqueous sodium nitrite solution was then added to decompose unreacted hydrogen azide. Crystals were filtered off at about 25° C., thereby giving about 42 g of wet bis-(1(2)H-tetrazol-5-yl)amine.
[0134] The results of the HPLC analysis of the resulting wet bis-(1(2)H-tetrazol-5-yl)amine are presented in FIG. 7 . The HPLC conditions were the same as those used in the HPLC analysis of the reaction solution described above. The results of the analysis showed that the wet bis-(1(2)H-tetrazol-5-yl)amine in the resulting reaction solution had a purity of 98.7 area % and a peak derived from an impurity appearing within the relative retention time starting at 1.08 and ending at 1.20 assuming that the retention time to the main peak is 1 accounting for 0.26 area % according to the area percentage obtained by the HPLC analysis.
[0135] Thereafter, the entire amount of the wet bis-(1(2)H-tetrazol-5-yl)amine and 150 mL of water were introduced into a 200 mL flask to form a suspension. The pH was controlled so as to be 4 to 6 by adding a 28% ammonia solution. The suspension was cooled to 10° C. or lower and then subjected to filtration, thereby giving about 32 g of wet bis-(1(2)H-tetrazol-5-yl)amine ammonium salt.
[0136] This compound was vacuum-dried at 60° C., thereby giving 28.8 g of a bis-(1(2)H-tetrazol-5-yl)amine ammonium salt having a purity of 98.4 wt % as determined on a weight basis according to the area percent obtained by the HPLC analysis in a yield of 84.8%. FIG. 8 shows the HPLC data obtained accordingly. Note that the HPLC conditions included detection with UV220 nm, a column of Inertsil ODS-3 having 4.6 mm ID.times.250 mm, a column bath temperature of 30° C., a mobile phase (solution A: 0.1% phosphoric acid solution/acetonitrile/methanol in a ratio of 950/25/25, and solution B: 0.1% phosphoric acid solution/acetonitrile in a ratio of 400/600), a gradient program (0-30 minutes: 100-50% solution A, 0-50% solution B, and 30-60minutes: 50% solution A, 50% solution B), a mobile phase flow rate of 1.0 mL/min, and an amount of a sample injected of 20 μL (loop). The results of the analysis showed that the bis-(1(2)H-tetrazol-5-yl)amine ammonium salt in the resulting reaction solution had a purity of 99.0 wt % or less and a peak derived from an impurity appearing within the relative retention time starting at 2.17 and ending at 2.24 assuming that the retention time to the main peak is 1 accounting for 1.1 wt % or greater as determined on a weight basis according to the area percentage obtained by the HPLC analysis.
INDUSTRIAL APPLICABILITY
[0137] The present invention is useful in producing a bis-(1(2)H-tetrazol-5-yl)amine compound that exhibits excellent properties as a gas generant for air-bags and as a foaming agent.
Description of Abbreviations
[0138] IM1, IM2, and IM3: intermediates
[0139] NaDCA: dicyanamide salt
[0140] BTA-2Na: bis-(1(2)H-tetrazol-5-yl)amine metal salt compound
|
High-quality bis-(1(2)H-tetrazol-5-yl)amine and a method for easily, safely, and inexpensively producing the compound are provided. The method for producing bis-(1(2)H-tetrazol-5-yl)amine includes the steps of heating to 50 to 120° C. a solution mixture in which a necessary amount of an azide salt and a dicyanamide salt in an amount corresponding to 1 to 80 wt % of a necessary amount are added to a solvent, adding an acid in an amount of 1.54 to 2.22 chemical equivalents of the dicyanamide salt in the solution mixture to carry out a reaction at 50 to 120° C., and then adding an acid and a dicyanamide salt solution in which the remaining dicyanamide salt is dissolved in a solvent to promote the reaction. Bis-(1(2)H-tetrazol-5-yl)amine is obtained according to the production method.
| 2
|
TECHNICAL FIELD
The invention relates to smart card field, more particularly relates to a method for detecting whether a contactless CPU card has left a radio frequency field.
PRIOR ART
Contactless card, which is called radio frequency card, is made up of IC chip and inductive antenna which are sealed in a standard PVC card. No part of the chip and the antenna are exposed. Contactless card is a new technology which is developed in recent years. The technology successfully combines radio frequency identification technology and IC card reader and writer together, which solves problem of powerlessness (no power inside a card) and avoids contact and is a great breakthrough in electronic component field. When a card is close to surface of a card reader and writer in a certain distance range (usually from 5-10 mm), data reading and writing operation is completed by transmission of radio wave.
Radio frequency identification performs contactless and bidirectional data transmission between a card reader and a contactless CPU card by radio frequency so as to achieve purpose of target identification and data exchange. Radio frequency identification is classified into low frequency (LF), high frequency (HF) and ultra high frequency (UHF) according to applied frequency; correspondingly, representative frequencies are low frequency lower than 135 KHz, high frequency of 13.56 MHz and ultra frequency of 860-960 MHz respectively; circuit of contactless CPU card includes main parts such as central processing unit (CPU), read only memory (ROM), Random Access Memory (RAM), Electrically Erasable Programmable Read-Only Memory (EEPROM) and chip operating system (COS), etc., which is like an ultra small computer.
In process of detecting contactless CPU card, inventors find that following problems exist in the prior art. After card seeking is activated, operation of detecting whether a card is in the radio frequency field cannot be performed at real time at the time interval of data interaction between the card and a master computer. General method is performing card seeking operation again which will disturb original operation status of the card.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a method for detecting whether a contactless CPU card has left a radio frequency field, which is a method for detecting whether a contactless CPU card leaves radio frequency field at real time without affecting original operation status of the contactless CPU card.
Therefore, the present invention provides a method for detecting whether a contactless CPU card has left radio frequency field, comprising
Step A, a card reader obtaining an instruction and determining whether the instruction is valid instruction, if yes, go to Step B; otherwise, go to Step C;
Step B, the card reader determining the type of the valid instruction;
If the type is instruction on informing to seek a card, to Step D;
if the type is APDU instruction, sending the APDU instruction to the card and sending a response returned by the card to a master computer via USB interrupting channel; go back to Step A;
if the type is extension instruction, performing operation according to the extension instruction and sending result of the operation to the master computer via USB interrupting channel; go back to Step A;
Step C, the card reader determining that whether flag of the card in the radio frequency field is set, if yes, go to Step E; otherwise, go to Step D;
Step D, the card reader sending card seeking instruction to the card and determining whether receives a card seeking response returned by the card, if yes, setting the flag of the card in the radio frequency field and sending the response that the card is in the radio frequency field to the master computer via USB interrupting channel; otherwise, resetting the flag of the card in the radio frequency field and sending the response that card leaves the radio frequency field to the master computer via USB interrupting channel; go back to Step A;
Step E, the card reader sending detecting instruction to the card and determining whether receives detecting response returned by the card successfully, if yes, storing the detecting response and go to Step F; otherwise, go to Step G;
Step F, the card reader setting the flag of the card in the radio frequency field, and sending the response that the card is in the radio frequency field to the master computer via USB interrupting channel; go back to Step A;
Step G, the card reader resetting the flag of the card in the radio frequency field and sending the response that the card leaves the radio frequency field to the master computer via USB interrupting channel; go back to Step A.
Preferably, sending response that the card is in the radio frequency field to the master computer via USB interrupting channel specifically comprises
determining whether recorded card status is that the card is in the radio frequency field, if yes, go back to Step A; otherwise, updating the recorded card status to be that the card leaves the radio frequency field and go back to Step A;
informing the master computer of the response that the card leaves the radio frequency field via USB interrupting channel specifically comprises
determining whether recorded card status is that card leaves radio frequency, if yes, go back to Step A; otherwise, updating the recorded card status to be that card leaves radio frequency field, go back to Step A.
Preferably, determining whether the instruction is valid instruction specifically comprises
the card reader receiving instruction sent from buffer via interrupting way; if the first byte of the instruction is identical to a predetermined character, the card reader receiving the valid instruction; otherwise, the card reader does not receive valid instruction.
Preferably, before Step A, the method comprises
the card reader being powered up and being initialized and switching on communication interruption enabling;
the method further comprises when the card reader detects communication interrupting, the card reader entering communication interrupting process, which comprises
StepS1, the card reader switching off communication interruption enabling and clearing communication interrupting flag;
StepS2, the card reader receiving an instruction issued by the master computer and determining whether the instruction is valid instruction, if yes, setting the flag of the instruction, switching on communication interruption enabling and exiting communication interrupting process; otherwise, switching on communication interruption enabling and exiting communicating interrupting process;
Step A specifically comprises the card reader determining whether the flag of the instruction is set, if yes, resetting the flag of the instruction and go to Step B; if no, go to Step C.
Preferably, determining whether the instruction is valid instruction in Step S2 specifically comprises
determining whether the first byte of the instruction is identical to a predetermined character, if yes, valid instruction being received, if no, valid instruction being not received.
Preferably, the card reader sending detecting instruction to the card in Step E specifically comprises
if it is the first time that the card reader sends the detecting instruction, the card reader sending a first predetermined character string to the card;
if it is not the first time that the card reader sends the detecting instruction, the card reader determining the detecting instruction to be sent according to the detecting response, if the value of the last bit of the detecting response is 0, the card reader sending a first predetermined character string to the card; if the value of the last bit of the detecting response is 1, the card reader sending a second predetermined character string to the card.
Preferably, determining whether successfully receives the detecting response returned by the card specifically comprises
if the detecting instruction is the first predetermined character, the card reader determining whether the received response returned by the card is a first detecting response, if yes, receiving the detecting response returned by the card successfully and storing the response; if no, receiving the detecting response returned by the card unsuccessfully;
if the detecting instruction is the second predetermined character, the card reader determining whether the received response returned by the card is a second detecting response, if yes, receiving the detecting response returned by the card successfully and storing the response; if no, receiving the detecting response returned by the card unsuccessfully.
Preferably, Step B specifically comprises
Step B11, the card reader determining type of the valid instruction, if the type is instruction on informing to seek a card, going to Step D; if the type is APDU instruction, going to Step B12; if the type is extension instruction, going to Step B13;
Step B12, the card reader sending the APDU instruction to the card and determining whether receives a response returned by the card; if yes, setting the flag of the card in the radio frequency field and returning the received response to the master computer via USB interrupting channel; go back to Step A; otherwise, resetting the flag of the card in the radio frequency field and sending the response that the card leaves the radio frequency field to the master computer via USB interrupting channel; go back to Step A;
Step B13, the card reader performing operation according to extension instruction and returning the result of operation to the master computer via USB interrupting channel; go back to Step A.
Preferably, Step D specifically comprises
Step D11, the card reader sending a first requesting instruction to the card and determining whether receives a first response returned by the card, if yes, go to Step D12; otherwise, closing the radio frequency field; waiting for automatically opening radio frequency field in a predetermined time, resetting the flag of the card in the radio frequency field and sending response that the card leaves the radio frequency field to the master computer via USB interrupting channel; go back to Step A;
Step D12, the card reader sending a second requesting instruction containing 0x93 and 0x20 to the card and obtaining first confirming information to the card;
Step D13, the card reader obtaining a first data according to the first confirming information and fixed data and determining whether the first data is 0x00, if yes, cascade level of the card being 1 and storing the card number information in buffer; go to Step D18; otherwise, go to Step D14;
Step D14, the card reader sending a third requesting instruction containing 0x95 and 0x20 to the card and obtaining second confirming information returned by the card;
Step D15, the card reader obtaining a second data according to the second confirming information and the fixed data and determining whether the second data is 0x00, if yes, cascade level of the card being 2 and storing the card number information in the buffer, go to Step D18; otherwise, go to Step D16;
Step D16, the card reader sending a fourth requesting instruction containing 0x97 and 0x20 to the card and obtaining a third confirming information;
Step D17, the card reader obtaining a third data according to the third confirming information and the fixed data and determining whether the third data is 0x00, if yes, cascade level of the card being 3 and storing the card number information in the buffer and go to D 18 ; otherwise, closing radio frequency field; waiting for automatically opening the radio frequency field in a predetermined time, resetting the flag of the card in the radio frequency field and sending the response that the card leaves the radio frequency field to the master computer via USB interrupting channel; go back to Step A;
Step D18, the card reader sending a request selecting and answering instruction to the card and determining whether receives a selecting and answering response returned by the card, if yes, going to Step D19; otherwise, resetting the flag of the card in the radio frequency field and sending the response that card leaves the radio frequency field to the master computer via USB interrupting channel; go back to Step A;
Step D19, the card reader setting the flag of the card in the radio frequency field and sending the selecting and answering response and the response that the card is in the radio frequency field to the master computer via USB interrupting channel; go back to Step A.
Preferably, Step D specifically comprises
Step D21, the card reader sending a fifth requesting instruction to the card and determining whether receives a fifth response returned by the card, if yes, go to Step D22; otherwise, closing the radio frequency field, waiting for automatically opening radio frequency field in a predetermine time, resetting the flag of the card in the radio frequency field and sending the response that the card leaves the radio frequency field to the master computer via USB interrupting channel, go back to Step A;
Step D22, the card reader sending the request selecting and answering instruction and determining whether receives the selecting and answering response returned by the card, if yes, goes to Step D23; otherwise, resetting the flag of the card in the radio frequency field and sending the response that the card leaves the radio frequency field to the master compute via USB interrupting channel; go back to Step A;
Step D23, the card reader setting the flag of the card in the radio frequency field and sending the selecting and answering response and the response that the card is in the radio frequency field to the master computer via USB interrupting channel; go back to Step A.
According to another aspect of the present invention, the present invention provides a method for detecting whether a contactless CPU card has left radio frequency field, comprising
Step a, a card reader switching on regular interruption enabling;
Step b, the card reader receiving instruction sent by the master computer and determining whether receives valid instruction, if yes, determining the type of the valid instruction, if the type is instruction on informing to seek a card, goes to Step c; if the type is APDU instruction, go to Step d; if the type is extension instruction, go to Step e; otherwise, go to Step f;
Step c, the card reader switching off regular interruption enabling, sending card seeking instruction to the card and determining whether receives a card seeking response returned by the card, if yes, setting the flag of the card in the radio frequency field and switching on regular interruption enabling, goes to Step f; otherwise, resetting the flag of the card in the radio frequency field and switching on regular interruption enabling, go to Step f;
Step d, the card reader switching off regular interruption enabling, sending the APDU instruction to the card and determining whether receives a response returned by the card, if yes, setting the flag of the card in the radio frequency field, sending the received response to the master computer via USB interrupting channel and switching on regular interruption enabling, go to Step f; otherwise, resetting the flag of the card in the radio frequency field and switching on regular interruption enabling, go to Step f;
Step e, the card reader switching off regular interruption enabling, performing operation according to the extension instruction, sending the operation result to the master computer via USB interrupting channel and switching on regular interruption enabling, go to Step f;
Step f, the card reader determining whether the flag of the card in the radio frequency field is set, if yes, sending the response that the card is in the radio frequency field to the master computer via USB interrupting channel, go back to Step a; otherwise, sending the response that the card leaves the radio frequency field to the master computer via USB interrupting channel, go back to Step a;
when the card reader receives triggering of regular interrupting, entering regular interrupting process, comprising
Step g, the card reader switching off regular interruption enabling and clearing regular interrupting flag
Step h, the card reader determining whether the flag of the card in the radio frequency field is set, if yes, go to Step l otherwise, sending card seeking instruction to the card and determining whether receiving a card seeking response returned by the card, if yes, go to Step l; otherwise, go to Step m;
Step i, the card reader sending detecting instruction to the card and determining whether receives a detecting response returned by the card, if yes, storing the detecting response and go to Step l; otherwise, go to Step m;
Step l, the card reader switching on regular interruption enabling, exiting regular interrupting process;
Step m, the card reader resetting the flag of the card in the radio frequency field, switching on regular interruption enabling, exiting regular interrupting process.
Preferably, Step c specifically comprises
Step c11, the card reader switching off regular interruption enabling, sending a first requesting instruction to the card, determining whether receives a first response returned by the card, if yes, go to Step c12; otherwise, closing radio frequency field, waiting for automatically opening radio frequency filed in a predetermined time, resetting the flag of the card in the radio frequency field and switching on regular interruption enabling, go to Step f;
Step c12, the card reader sending a second requesting instruction containing 0x9 3 and 0x20 to the card and obtaining a first confirming information returned by the card;
Step c13, the card reader obtaining a first data according to a first confirming information and fixed data and determining whether a first data is 0x00, if yes, cascade level of the card being 1, storing card number information in buffer, go to Step c18; otherwise, go to Step c14;
Step c14, the card reader sending a third requesting instruction containing 0x95 and 0x20 to the card and obtaining a second confirming information returned by the card;
Step c15, the card reader obtaining a second data according to the second confirming information and the fixed data and determining whether the second data is 0x00, if yes, cascade level of the card being 2 and storing card number information in the buffer, go to Step c18; otherwise, go to Step c16;
Step c16, the card reader sending a fourth requesting instruction containing 0x97 and 0x20 to the card and obtaining a third confirming information;
Step c17, the card reader obtaining a third data according to the third confirming information and fixed data and determining whether the third data is 0x00, if yes, cascade level of the card being 3 and storing card number information in the buffer, go to Step c18; otherwise, closing the radio frequency field, waiting for automatically opening radio frequency field in a predetermined time, resetting the flag of the card in the radio frequency field and switching on regular interruption enabling, go to Step f;
Step c18, the card reader sending request selecting and answering instruction to the card and determining whether receives a selecting and answering response returned by the card, if yes, go to Step c19; otherwise, resetting the flag of the card in the radio frequency field and switching on regular interruption enabling; go to Step f;
Step c19, the card reader setting the flag of the card in the radio frequency field and sending the selecting and answering response to the master computer via USB interrupting channel and switching on regular interruption enabling, go to Step f.
Preferably, Step c specifically comprises
Step c21, the card reader switching off regular interruption enabling, sending a fifth requesting instruction to the card and determining whether receives a fifth response returned by the card, if yes, go to Step c22, otherwise, closing radio frequency field and waiting for automatically opening radio frequency field, resetting the flag of the card in the radio frequency field and switching on regular interruption enabling; go to Step f;
Step c22, the card reader sending a request selecting and answering instruction to the card and determining whether receives a selecting and answering response returned by the card, if yes, goes to Step c23; otherwise, resetting the flag of the card in the radio frequency field and switching on regular interruption enabling; go to Step f;
Step c23, the card reader setting the flag of the card in the radio frequency field, sending the selecting and answering response to the master computer and switching on regular interruption enabling, go to Step f.
Preferably, if no valid instruction is received in Step b, going on waiting for receiving instruction;
Steps c to f, Steps l to m are replaced with Steps c′ to e′ and Steps l′ to m′ respectively;
Step c′, the card reader switching off regular interruption enabling and sending card seeking instruction to the card and determining whether a card seeking response is returned by the card, if yes, setting the flag of the card in the radio frequency field and sending the response that the card is in the radio frequency field to the master computer via USB interrupting channel; go back to Step a; otherwise, resetting the flag of the card in the radio frequency field and sending a response that the card leaves radio frequency field to the master computer via USB interrupting channel, go back to Step a;
Step d′, the card reader switching off regular interruption enabling, sending the APDU instruction to the card and determining whether receives a response returned by the card, if yes, setting the flag of the card in the radio frequency field and sending the received response and the response that the card is in the radio frequency field to the master computer via USB interrupting channel, go back to Step a; otherwise, resetting the flag of the card in the radio frequency field and sending the response that the card is in the radio frequency field to the master computer via USB interrupting channel, go back to Step a;
Step e′, the card reader switching off regular interruption enabling, performing operation according to the extension instruction and sending the operation result to the master computer via USB interrupting channel, go back to Step a;
Step l′, the card reader setting the flag of the card in the radio frequency field, sending the response that the card is in the radio frequency field to the master computer via USB interrupting channel, switching on regular interruption enabling and exiting regular interrupting process;
Step m′, the card reader resetting the flag of the card in the radio frequency field, sending the response that the card leaves the radio frequency field to the master computer via USB interrupting channel, switching on regular interruption enabling and exiting regular interrupting process.
Preferably, Step c′ specifically comprises
Step c′11, the card reader switches off regular interruption enabling, sending a first requesting instruction to the card and determining whether receives a first response returned by the card, if yes, go to Step c′12; otherwise, closing radio frequency field, waiting for automatically opening radio frequency field in a predetermined time, resetting the flag of the card in the radio frequency field and sending the response that the card leaves the radio frequency field to the master computer via USB interrupting channel, go back to Step a;
Step c′12, the card reader sending a second requesting instruction containing 0x93 and 0x20 to the card and obtaining first confirming information returned from the card;
Step c′13, the card reader obtaining a first data according to the first confirming information and fixed data and determining whether the first data is 0x00, if yes, cascade level of the card being 1 and storing the card number information in buffer, go to Step c′18; otherwise, go to Step c′14;
Step c′14, the card reader sending a third requesting instruction containing 0x95 and 0x20 to the card and obtaining second confirming information returned by the card;
Step c′15, the card reader obtaining a second data according to the second confirming information and the fixed data and determining whether the second data is 0x00, if yes, cascade level of the card is 2 and storing the card number information in the buffer, go to Step c′18; otherwise, go to Step c′16;
Step c′16, the card reader sending a fourth requesting instruction containing 0x97 and 0x20 to the card and obtaining a third confirming information;
Step c′17, the card reader obtaining a third data according to the third confirming information and the fixed data and determining whether the third data is 0x00, if yes, cascade level of the card being 3 and storing the card number information in buffer, go to Step c′18; otherwise, closing radio frequency field, waiting for automatically opening radio frequency field in a predetermined time, restoring the flag of the card in the radio frequency field and sending the response that the card leaves the radio frequency field to the master computer via USB interrupting channel, go back to Step a;
Step c′18, the card reader sending a request selecting and answering instruction to the card and determining whether receives a selecting and answering response returned by the card, if yes, go to Step c′19; otherwise, resetting the flag of the card in the radio frequency field and sending the response that card leaves the radio frequency field to the master computer via USB interrupting channel, go back to Step a;
Step c′19, the card reader setting the flag of the card in the radio frequency field and sending the selecting and answering response and the response that the card is in the radio frequency field to the master computer via USB interrupting channel; go back to Step a.
Preferably, Step c′ specifically comprises
Step c′21, the card reader switching off regular interruption enabling and sending a fifth requesting instruction to the card and determining whether receives a fifth response returned from the card, if yes, go to Step c′22; otherwise, closing radio frequency field, waiting for automatically opening on radio frequency field in a predetermined time, resetting the flag of the card in the radio frequency field and sending the response that the card leaves the radio frequency field to the master computer via USB interrupting channel, go back to Step a;
Step c′22, the card reader sending a request selecting and answering instruction to the card and determining whether receives the selecting and answering response returned by the card, if yes, go to Step c′23; otherwise, resetting the flag of the card in the radio frequency field and sending the response that the card leaves the radio frequency field to the master computer via USB interrupting channel; go back to Step a.
Preferably, sending the response that the card is in the radio frequency field to the master computer via USB interrupting channel specifically comprises
determining whether the recorded card status is that the card is in the radio frequency field, if yes, go back to Step a, otherwise, updating the recorded card status to be that the card is in the radio frequency field, go back to Step a;
sending the response that the card leaves the radio frequency field to the master computer via USB interrupting channel specifically comprises
determining whether recorded card status is that card leaves radio frequency field, if yes, go back to Step a; otherwise, updating the recorded card status to be that card leaves radio frequency field; go back to Step a.
Preferably, determining whether the instruction is valid instruction specifically comprises
the card reader receiving an instruction sent from the buffer via interrupting; if the first byte of the instruction is identical to a predetermined character, the valid instruction is received; otherwise, no valid instruction is received.
Preferably, the card reader sending a detecting instruction to the card specifically comprises
if it is the first time that the card sends the detecting instruction, the card reader sending a first predetermined character to the card;
if it is not the first time that the card sends the detecting instruction, the card reader determines the detecting instruction to be sent according to the detecting response, if the value of the last bit of the detecting response is 0, the card reader sends the first predetermined character string to the card; if the value of the last bit of the detecting response is 1, the card reader sending a second predetermined character string to the card.
Preferably, determining whether successfully receives the detecting response returned by the card specifically comprises
if the detecting instruction is the first predetermined character string, the card reader determines whether the response returned by the card is a first detecting response, if yes, successfully receiving the detecting response returned by the card and storing the response; if no, unsuccessfully receiving the detecting response returned by the card;
if the detecting instruction is the second predetermined character string, the card reader determines whether the response returned by the card is a second detecting response, if yes, successfully receiving the detecting response returned by the card and storing the response; if no, unsuccessfully receiving the detecting response returned by the card.
The advantage of the present invention is that in free time, the card reader will send a detecting instruction to the card regularly so as to realize detecting whether the card is in the radio frequency field at real time.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
FIG. 1 is a flow chard of a method for detecting whether a contactless CPU card has left radio frequency field provided by Embodiment 1 of the present invention;
FIG. 2A and FIG. 2B are flow charts of a detailed method for detecting whether a contactless CPU card has left radio frequency field provided by Embodiment 2 of the present invention;
FIG. 2 ′A and FIG. 2 ′B are flow charts of a detailed method for detecting whether a contactless CPU card has left radio frequency field provided by a variation of Embodiment 2 of the present invention; and
FIG. 3A and FIG. 3B are flow charts of a detailed method for detecting whether a contactless CPU card has left radio frequency field provided by Embodiment 3 of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In order to make the purpose, technical solution and advantages of the present invention become more clear, further detailed description of the embodiment of the present invention is presented by combining accompany drawings.
In the embodiments of the present invention, for example, mentioned card reader is a contactless card reader and mentioned card is a contactless CPU card.
Embodiment 1
Referring to FIG. 1 , Embodiment 1 provides a method for detecting whether a card has left radio frequency field, which specifically includes following steps.
Step 101, a card reader is power up and initialized;
In Embodiment 1, the initial value of flag of the card being in radio frequency (RF) field is 0.
Step 102, receive an instruction and determine whether receives a valid instruction;
if yes, goes to Step 110; if no, goes to Step 103.
In Embodiment 1, the card reader receives an instruction sent from buffer via USB interrupting channel. If the first byte of the instruction is in a predetermined category (from 0x01 to 0x03), a valid instruction is received. For example, if the first byte of the received instruction is 0x01, a valid instruction is received. If the card reader does not receive an instruction or the first byte of a received instruction does not satisfy a predetermined value, the received instruction is not valid instruction.
Step 103, determine whether the flag of the card in the radio frequency field is 1;
if yes, go to Step 104; if no, go to Step 111.
Step 104, perform operation of detecting card;
in Embodiment 1, if it is the first time that the card reader performs operation of detecting card, an issued detecting instruction is 0xB2;
If it is not the first time that the card reader performs operation of detecting card, the card reader determines the issued detecting instruction according to the value of the last bit of the first byte of detecting instruction response returned by the card last time. For example, when the value of the last bit is 1, the card reader issues an instruction of 0xB2 to the card; while when the value of the last bit is 0, the card reader issues instruction of 0xB3 to the card.
In process that the card reader sends detecting instruction at regular time, if a detecting instruction is interrupted, when the card reader sends next detecting instruction, the instruction will be changed. For example,
the card reader sends detecting instruction 0xB2 to the card; after the card successfully makes corresponding response 0xA3, interruption is caused by interruption instruction; the card reader executes an interruption instruction; after completing of executing the interruption instruction, the card reader sends detecting instruction of 0xB3.
Operation of detecting card specifically includes following steps.
Step A, the card reader sends a detecting instruction at regular time;
In Embodiment 1, the card reader sends a detecting instruction to the card at a predetermined regular time interval; preferably, the predetermined regular time interval is 5 ms.
Step B, receive detecting instruction response made by the card and then go to Step 105;
in Embodiment 1, the received response is 0xA3, or 0xA2, or other data.
Step 105, determine whether the detecting instruction response made by the card is received successfully;
if yes, go to Step 107; otherwise, go to Step 106.
Specific determining method includes
if the card reader sends detecting instruction of 0xB2 to the card, the card reader receives 0xA3 returned from the card reader, which means that the card reader receives the detecting instruction response made by the card successfully;
if the card reader sends detecting instruction of 0xB3 to the card, the card reader receives 0xB2 returned from the card reader, which means that the card reader receives the detecting instruction response made by the card successfully; and
if the card reader receives other response or a response which does not match its sent detecting instruction, it is regarded that the card reader receives the detecting instruction response unsuccessfully.
Step 106, inform the master computer of a response that the card leaves the radio frequency field via USB interrupting channel, clear flag of the card being in radio frequency field to be 0 and go to Step 109 or go to Step 102;
in Embodiment 1, specifically the response that the card leaves the radio frequency field is 0x50, 0x02.
Step 107, inform the master computer of a response that the card is in the radio frequency field via USB interrupting channel, set the flag of the card in the radio frequency field as 1; then go to Step 108 or go to Step 102;
in Embodiment 1, specifically, the response that the card is in the radio frequency field is 0x50, 0x03.
Step 108, receive an instruction and determine whether receives valid instruction;
if yes, go to Step 110; otherwise, go to Step 104.
Determining method of Step 108 in Embodiment 1 can refer to Step 102. No more detail is given here.
Step 109, receive an instruction and determine whether receives a valid instruction,
if yes, go to Step 110; otherwise, go to Step 111.
Determining method of Step 110 in Embodiment 1 can refer to Step 102. No more detail is given here.
Step 110, determine instruction type;
in Embodiment 1, if the first byte of data received by the card reader is 0x01, the type is instruction on informing to seek a card and goes to Step 111;
if the first byte of the received data is 0x02, the data is APDU instruction and goes to Step 115;
if the first byte of the received data is 0x03, the data is extension instruction and goes to Step 118.
In Embodiment 1, extension instruction includes open/close radio frequency field instruction, lamp on/lamp off instruction, buzz instruction, etc.
Step 111, perform operation of the card seeking and determine whether the operation is successful;
in Embodiment 1, for A type card, operation of the card seeking specifically includes
Step A-1, sending a first requesting instruction to the card;
in Embodiment 1, the first requesting instruction specifically is 0x52.
Step A-2, determining whether a first response made by the card is received;
in Embodiment 1, the first response is predetermined data which corresponds to the first requesting instruction; preferably, the predetermined data is data with two bytes, for example, 0x02, 0x00;
if yes, goes to Step B-1;
otherwise, closing radio frequency field and the card reader will wait for automatically opening radio frequency field in a predetermined time and then perform Step 106; preferably, the predetermined time period is 10 ms.
Step B-1, sending data packet of 2 bytes, e.g. 0x93, 0x20, to the card;
Step B-2, obtaining a first confirming information returned by the card;
In Embodiment 1, process of obtaining a first confirming information returned by the card includes
Step B-21, sending data packet of two bytes, e.g. 0x93 and 0x20, to the card;
Step B-22, determining whether receives a second response data;
In Embodiment 1, the second response data includes UID1 and BCC1; UID1 is a set of fixed data of segment of the card number with four bytes or a random number dynamically generated by the card; BCC1 is check byte of UID1;
if yes, goes to Step B-23;
if no, close radio frequency field; the card reader will wait for automatically opening radio frequency field in a predetermined time and then goes to Step 106; preferably, the predetermined time is 10 ms.
Step B-23, sending data packet made up of 0x93, 0x70, UID1, BCC1 and CRC1 to the card; CRC1 is check detecting code;
Step B-24, determining whether receives a first confirming information returned by the card;
if yes, obtaining the first confirming information and goes to Step C-1;
if no, closing radio frequency field; the card reader will wait for automatically opening radio frequency field in a predetermined time and goes to Step 106; preferably, the predetermined time is 10 ms;
In Embodiment 1, the first confirming information is made up of S and CRC1; S1 represents starting communication.
Step C-1, obtaining a first data which is obtained by performing AND operation on the first confirming information and fixed data;
In Embodiment 1, the fixed data is 0x40.
Step C-2, determining whether the first data is 0x00;
if yes, cascade level of the card is 1 and storing the card information in buffer and goes to Step 112;
if no, goes to Step D-1.
Step D-1, sending data packet with 2 bytes, e.g. 0x95 and 0x20, to the card;
Step D-2, obtaining a second confirming information returned by the card;
In Embodiment 1, process of obtaining the second confirming information includes
Step D-21, sending data packet with two bytes, e.g. 0x95 and 0x20, to the card;
Step D-22, determining whether receives a third response data returned by the card;
In Embodiment 1, the third response data include UID2 and BCC2; UID2 is card number segment of 4 bytes; BCC2 is check byte of UID2.
if yes, goes to Step D-23;
if no, closing frequency field; the card reader will wait for automatically opening radio frequency field in a predetermined time and go to Step 106; preferably, the predetermined time is set as 10 ms;
Step D-23, sending data packet made up of 0x95, 0x70, UID2, BCC2 and CRC2 to the card;
Step D-24, determining whether receives a second confirming information returned by the card;
if yes, obtaining the second confirming information returned by the card and goes to Step E-1;
if no, closing radio frequency field; the card reader will wait for automatically opening the radio frequency field in a predetermined time and goes to Step 106; preferably, the predetermined time is set as 10 ms;
in Embodiment 1, the second confirming information is made up of S2 and CRC2; S2 represents starting communication.
Step E-1, obtaining the second data by performing AND operation on the second confirming information and fixed data;
In embodiment 1, the fixed data is 0x40.
Step E-2, determining whether the second data is 0x00;
if yes, the cascade level of the card is 2 and storing the card information in buffer and goes to Step 112;
if no, goes to Step F-1.
Step F-1, sending data packet with two bytes, e.g. 0x97 and 0x20, to the card;
Step F-2, obtaining a third confirming information;
In embodiment 1, process of obtaining the third confirming information includes
Step F-21, sending data packet with two bytes e.g. 0x97 and 0x20, to the card;
Step F-22, determining whether receives a fourth response data returned from the card;
in Embodiment 1, the fourth response data includes UID3 and BCC3; UID3 is card number segment with four bytes; BCC3 is check byte of UID3;
if yes, goes to Step F-23;
if no, closing radio frequency field; the card reader will wait for automatically opening the radio frequency field in a predetermined time and goes to Step 106; preferably, the predetermined time is set as 10 ms;
Step F-23, sending data packet made up of 0x97, 0x70, UID3, BCC3 and CRC3 to the card;
Step F-24, determining whether receives the third confirming information returned from the card;
In Embodiment 1, the third confirming information is made up of S3 and CRC3; S3 represents starting communication.
if yes, obtaining the third confirming information and goes to Step G-1;
if no, closing radio frequency field; the card reader will wait for automatically opening radio frequency field in a predetermined time and goes to Step 106; preferably, the predetermined time is set as 10 ms.
Step G-1, obtaining a third data obtained by performing AND operation on the third confirming information and fixed data to obtain a third data;
in Embodiment 1, the fixed data is 0x40.
Step G-2, determining whether the third data is 0x00;
if yes, cascade level is 3 and storing the card number information in buffer and goes to Step 112;
if no, closing radio frequency field; the card reader will wait for automatically opening radio frequency field in a predetermined time and goes to Step 106; preferably, the predetermined time is set as 10 ms.
In Embodiment 1, the cascade level corresponds to UID1; four bytes of UID1 are all card numbers;
cascade level 2 corresponds to the cascade of UID1 and UID2; the first byte of the UID1 is invalid and only the last three bytes are taken; all four bytes of UID2 are taken; cascade level 2 has data of 7 bytes;
cascade level 3 corresponds to cascade of UID1, UID2 and UID3; the first bytes of the UID1 and UID2 are invalid, only the last three bytes of UID1 and UID2 are taken respectively; all four bytes of UID3 are taken; cascade level 3 has data of 10 bytes.
For B type card, the way of implementation is as the following.
Step I, the card reader sends B type requesting instruction to the card;
In Embodiment 1, specifically, B type requesting instruction is data with 5 bytes: 0x05, 0x00, 0x08, CRC (2 byte).
Step II, determine whether receives a response of B type request returned by the card;
if yes, goes to Step 112, if no, goes to Step 106.
In Embodiment 1, response of B type request specifically includes 0x1d, PUPI (4 bytes), 0x00, 0x08, 0x01, 0x00, CRC (2 bytes); PUPI represents card information.
Step 112, send request selecting and answering instruction to the card;
in Embodiment 1, specifically, the request selecting and answering instruction is E0, 80, CRC.
Step 113, determine whether receives selecting and answering response;
if yes, goes to Step 114; if no, goes to Step 106.
Step 114, send selecting and answering response to the master computer via USB interrupting channel; and goes to Step 107.
Step 115, send data A in specified format to the card;
in Embodiment 1, specified format includes PCB, NAD/CID, data A, CRC; PCB represents Protocol Control Byte; NAD represents Node address; CID represents Card Identifier; CRC represents check detecting code.
Step 116, determine whether receives data B returned by the card;
if yes, goes to Step 117; if no, goes to Step 106.
Step 117, send data B to the master computer via USB interrupting channel; then goes to Step 107.
Step 118, execute corresponding instruction and send executing result to the master computer via USB interrupting channel.
In Embodiment 1, requesting lamp on instruction is taken as an example. After the card reader receives a requesting lamp on instruction sent by the master computer, the card reader performs lamp on operation and sends information of successful operation or failed operation to the master computer via USB interrupting channel. The information of successful operation is 0x00 and the information of failed operation is 0x01.
In Embodiment 1 of the present invention, a response that the related card is in or is not in the radio frequency field is informed to the master computer via USB interrupting channel and the informed response that the card is in the radio frequency field is stored; before preparing for informing next time, determine whether the stored response is identical to a response to be sent, if they are identical, the informing need not be uploaded; otherwise, inform the master computer that the card is in the radio frequency field and stores response.
Embodiment 2
Referring to FIG. 2A and FIG. 2B , Embodiment 2 provides a method for detecting whether a card has left radio frequency filed, which specifically includes
Step 201, the card is powered up and initialized;
Switch on regular interrupting.
In Embodiment 2, the initial value of flag of the card in the radio frequency field is 0.
Step 202, receive instruction;
In Embodiment 2, the instruction received by the card reader can be instruction on informing to seek a card, APDU instruction, extension instruction, which are sent by the master computer.
Step 203, determine whether receives valid instruction;
if yes, go to Step 204; otherwise, go to Step 213.
The method of determining is the same as Step 102 in Embodiment 1.
Step 204, determine type of the instruction;
in Embodiment 2, if the first byte of the instruction received by the card reader is 0x01, the type of the instruction is instruction on informing to seek a card and go to Step 205;
If the received first byte of the instruction is 0x02, the type is APDU instruction and go to Step 217;
If the received first byte of the instruction is 0x03, the type is extension instruction and goes to Step 223;
In Embodiment 2, the extension instruction can be open/close frequency field; lamp on/off instruction, buzz instruction, etc.
Step 205, switch off regular interrupting;
Step 206, clear flag of the card in the radio frequency field to be 0;
Step 207, perform card seeking operation and determine whether the operation is successful;
if yes, go to Step 208; otherwise, go to Step 216.
In Embodiment 2, specific card seeking operation is the same as Step 111 in Embodiment 1.
Step 208, sending request selecting and answering instruction to the card;
in Embodiment 2, specifically, the request selecting and answering instruction is E0, 80, CRC.
Step 209, receive and determine whether receives a selecting and answering response;
if yes, go to Step 210; otherwise, go to Step 216.
Step 210, send the selecting and answering response to the master computer via USB interrupting channel;
Step 211, set the flag of the card in the radio frequency field as 1;
Step 212, switch on regular interrupting;
Step 213, determine whether the flag of the card in the radio frequency field is 1;
if yes, go to Step 214; otherwise, go to Step 215.
Step 214, sending a response that the card is in the radio frequency field to the master computer via USB interrupting channel;
then go to the Step 202.
In Embodiment 2, specifically the response that the card is in the radio frequency field is 0x50, 0x03.
Step 215, send response that the card leaves the radio frequency field to the master computer via USB interrupting channel; and then go to Step 202.
In Embodiment 2, specifically, the response that the card leaves the radio frequency field is 0x50, 0x02.
Step 216, clear the flag of the card in the radio frequency field to be 0 and then go to Step 212;
Step 217, switch off regular interrupting;
Step 218, send data A to the card in specified format;
In Embodiment 2, specified format includes PCB, NAD/CID, data A, CRC; PCB represents Protocol Control Byte; NAD represents Node address; CID represents Card Identifier; CRC represents Check detecting code.
Step 219, determine whether receive data B returned by the card;
if yes, go to Step 220; if no, go to Step 222.
Step 220, send data B to the master computer via USB interrupting channel;
Step 221, set flag of the card in the radio frequency field as 1, and then go to Step 212;
Step 222, clear flag of the card in the radio frequency field to be 0, and then go to Step 212;
Step 223, switch off regular interrupting;
Step 224, execute corresponding instruction, and send the executing result to the master computer via USB interrupting channel; and then go to Step 212.
Specific operation method is the same as Step 118 in Embodiment 1.
Shown by FIG. 2B , operation of regular interrupting specifically includes
Step 2 - 1 , entering regular interrupting;
In Embodiment 2, performing interrupting period is predetermined time; preferably, interrupting is performed every 5 ms.
Step 2 - 2 , switching off interrupting;
Step 2 - 3 , clear interrupting;
Step 2 - 4 , determining whether the flag of the card in the radio frequency field is 1;
if yes, go to Step 2 - 5 ; if no, go to Step 2 - 9 .
Step 2 - 5 , performing operation of detecting card;
in Embodiment 2, specific operation of detecting card is the same as Step 104 in Embodiment 1.
Step 2 - 6 , determine whether successfully receives response of the card detecting instruction;
if yes, go to Step 2 - 7 ; otherwise, go to Step 2 - 8 .
In Embodiment 2, specific operation is the same as Step 105 in Embodiment 1.
Step 2 - 7 , switch on interrupting and exit;
Step 2 - 8 , clear the flag of the card in the radio frequency field to be 0 and then go to Step 2 - 7 ;
Step 2 - 9 , perform operation of the card seeking and determine whether the operation is successful;
in Embodiment 2, specific operation is the same as Step 111 in Embodiment 1.
If yes, go to Step 2 - 10 ; otherwise, go to Step 2 - 7 .
Step 2 - 10 , send request selecting and answering instruction to the card;
in Embodiment 2, specific request selecting and answering instruction is E0, 80, CRC.
Step 2 - 11 , determine whether receives a selecting and answering response from the card;
If yes, go to Step 2 - 12 ; otherwise, go to Step 2 - 7 .
Step 2 - 12 , send the selecting and answering response to the master computer via USB interrupting channel and then go to Step 2 - 13 ;
Step 2 - 13 , set the flag of the card in the radio frequency field as 1 and then go to Step 2 - 7 .
In Embodiment 2 of the present invention, a response that the related card is in or is not in the radio frequency field is informed to the master computer via USB interrupting channel and the informed response that the card is in the radio frequency field is stored; before preparing for informing next time, determine whether the stored response is identical to a response to be sent, if they are identical, the informing need not be uploaded; otherwise, inform the master computer that the card is in the radio frequency field and store the response.
Embodiment 2 can be Implemented in Another Method as the Following.
Referring to FIG. 2 ′A,
Step 201′, the card reader is powered up and initialized;
Switch on regular interrupting.
In Embodiment 2, initial value of flag of the card in the radio frequency field is 0.
Step 202′, receive instruction;
In Embodiment 2, the instruction received by the card reader can be instruction on informing to seek a card, APDU instruction and extension instruction, which are sent by the master computer.
Step 203′, determine whether receives a valid instruction;
if yes, go to Step 204′; if no, go to Step 202′.
The determining method is the same as Step 102 in Embodiment 2.
Step 204′, determine type of instruction;
in Embodiment 2, if the first byte of the instruction received by the card reader is 0x01, the type of the instruction is instruction on informing to seek a card and go to Step 205′;
if the first byte of the received instruction is 0x02, the instruction is APDU instruction and go to Step 214′;
if the first byte of the received instruction is 0x03, the instruction is extension instruction and go to Step 218′;
In Embodiment 2, extension instruction can be open/close radio frequency field instruction, lamp on/lamp off instruction, buzz instruction, etc.
Step 205′, switch off regular interrupting;
Step 206′, clear flag of the card in the radio frequency field to be 0;
Step 207′, perform operation of the card seeking and determine whether the operation is successful;
if yes, go to Step 208′; if no, go to Step 212′.
In Embodiment 2, specific operation of the card seeking is the same as Step 111 in Embodiment 1.
Step 208′, send request selecting and answering instruction to the card;
in Embodiment 2, specific request selecting and answering instruction is E0, 80, CRC.
Step 209′, receive and determine whether receives the selecting and answering response;
if yes, go to Step 210′; if no, go to Step 212′.
Step 210′, send the selecting and answering response to the master computer via USB interrupting channel;
Step 211′, send a response that the card is in the radio frequency field to the master computer via USB interrupting channel; set the flag of the card in the radio frequency field as 1, and go to Step 213′;
in Embodiment 2, specifically the response that the card is in the radio frequency field is 0x50, 0x03.
Step 212′, send a response that the card leaves radio frequency field to the master computer via USB interrupting channel; clear flag of the card in the radio frequency field to be 0;
in Embodiment 2, specifically, the response that the card leaves the radio frequency field is 0x50, 0x02.
Step 213′, switch on regular interrupting, and go to Step 202′;
Step 214′, switch off regular interrupting;
Step 215′, send data A to the card in specific format;
in Embodiment 2, specified format includes PCB, NAD/CID, data A, CRC; PCB represents Protocol Control Byte; NAD represents Node address; CID represents Card Identifier; CRC represents Check detecting code.
Step 216′, determine whether receives data B returned from the card;
if yes, go to Step 217′; if no, go to Step 212′.
Step 217′, send data B to the master computer via USB interrupting channel and go to Step 211′.
Step 218′, switch off regular interrupting;
Step 219′, execute corresponding instruction, and send executing result to the master computer via USB interrupting channel and go to Step 213′.
Specific operation method is the same as Step 118 in Embodiment 1.
Referring to FIG. 2 ′B, specifically, operation of regular interrupting includes
Step 2 - 1 ′, enter regular interrupting;
in Embodiment 2, period of performing regular interrupting is a predetermined time. Preferably, the regular interrupting is performed every 5 ms.
Step 2 - 2 ′, switch off interrupting;
Step 2 - 3 ′, clear interrupting;
Step 2 - 4 ′, determine whether flag of the card in the radio frequency field is 1;
if yes, go to Step 2 - 5 ′; if no, go to Step 2 - 10 ′.
Step 2 - 5 ′, perform operation of detecting card;
in Embodiment 2, specifically the operation of detecting card is the same as Step 104 in Embodiment 1.
Step 2 - 6 ′, determine whether receives response of detecting card instruction successfully;
if yes, go to Step 2 - 7 ′; if no, go to Step 2 - 8 ′.
in Embodiment 2, specific determining operation is the same as Step 105 in Embodiment 1.
Step 2 - 7 ′, inform the master computer of the response that the card is in the radio frequency field via USB interrupting channel; set flag of the card in the radio frequency field as 1 and go to Step 2 - 9 ′;
Step 2 - 8 ′, inform the master computer of the response that the card leaves the radio frequency field via USB interrupting channel; clear flag of the card in the radio frequency field to be 0;
Step 2 - 9 ′, switch on interrupting and exit;
Step 2 - 10 ′, perform operation of the card seeking and determine whether the operation is successful;
if yes, go to Step 2 - 11 ′; if no, go to Step 2 - 8 ′.
In embodiment 2, specific operation is the same as Step 111 in Embodiment 1.
Step 2 - 11 ′, send request selecting and answering instruction to the card;
In Embodiment 2, specifically, request selecting and answering instruction is E0, 80, CRC.
Step 2 - 12 ′, determine whether receives requesting selecting and answering response from the card;
if yes, go to Step 2 - 13 ′; if no, go to Step 2 - 8 ′.
Step 2 - 13 ′, send selecting and answering response to the master computer via USB interrupting channel and go to Step 2 - 7 ′.
In Embodiment 2 of the present invention, a response that the related card is in or is not in the radio frequency field is informed to the master computer via USB interrupting channel and the informed response that the card is in the radio frequency field is stored; before preparing for informing next time, determine whether the stored response is identical to a response to be sent, if they are identical, the informing need not be uploaded; otherwise, inform the master computer that the card is in the radio frequency field and store the response.
Embodiment 3
Referring to FIG. 3A and FIG. 3B , Embodiment 3 provides a method for detecting a card leaving radio frequency field, which specifically includes
Step 301, a card reader is power up and initialized;
Switch on communication interrupting.
In Embodiment 3, initial value of instruction flag is 0; the initial value of flag of the card in the radio frequency field is 0.
Step 302, determine whether instruction flag is 1;
if yes, go to Step 311; if no, go to Step 303.
Step 303, determine whether the flag of the card in the radio frequency field is 1;
If yes, go to Step 304; if no, go to Step 311.
Step 304, perform operation of detecting card;
in Embodiment 3, specifically operation of detecting card is the same as Step 104 in Embodiment 1.
Step 305, determine whether receives a response of the card detecting instruction successfully;
if yes, go to Step 306; if no, go to Step 308.
In Embodiment 3, specifically determining operation is the same as Step 105 in Embodiment 1.
Step 306, inform the response that the card is in the radio frequency field to the master computer via USB interrupting channel; set the flag of the card in the radio frequency field as 1; go to Step 307 or Step 302;
in Embodiment 3, specifically, the response that the card is in the radio frequency field is 0x50, 0x03.
Step 307, determine whether the instruction flag is 1;
if yes, goes to Step 310; if no, go to Step 304.
Step 308, inform the master computer of the response that the card leaves radio frequency field and clear flag of the card in the radio frequency field to be 0; go to Step 309 or Step 302;
Step 309, determine whether the instruction flag is 1;
if yes, go to Step 310; if no, go to Step 311.
Step 310, clear instruction flag to be 0 and determine type of instruction; in Embodiment 3, if the first byte of the data received by the card reader is 0x01, the type is instruction on informing to seek a card and go to Step 311;
if the first byte of the data received by the card reader is 0x02, the type is APDU instruction and go to Step 315;
if the first byte of the data received by the card reader is 0x03, the type is extension instruction and go to Step 318;
In Embodiment 3, the extension instruction includes open/close radio frequency field instruction, lamp on/lamp off instruction, buzz instruction, etc.
Step 311, perform operation of the card seeking and determine whether the operation of determining is successful;
if yes, go to Step 312; if no, go to Step 308.
In Embodiment 3, specific operation of the card seeking is the same as Step 111 in Embodiment 1.
Step 312, send a request selecting and answering instruction to the card;
In Embodiment 3, specifically, the request selecting and answering instruction is E0, 80, CRC.
Step 313, determine whether receives a selecting and answering response from the card;
if yes, go to Step 314; if no, go to Step 308.
Step 314, send the selecting and answering response to the master computer via USB interrupting channel;
Then, go to Step 306.
Step 315, send data A to the card in specified format;
in Embodiment 3, specified format includes PCB, NAD/CID, data A, CRC; PCB represents Protocol Control Byte; NAD represents Node address; CID represents Card Identifier; CRC represents Check detecting code.
Step 316, determine whether receives data B returned from the card;
if yes, go to Step 317; if no, goes to Step 308.
Step 317; send data B to the master computer via USB interrupting channel and go to Step 306.
Step 318, execute corresponding instruction and send corresponding result to the master computer via USB interrupting channel and go to Step 302.
Specific operation method is the same as Step 118 in Embodiment 1.
In Embodiment 3, if communication interrupting happens, enter interrupting processing. Shown by FIG. 3B , specific steps are as the following.
Step 3 - 1 , enter communication interrupting;
Step 3 - 2 , switch off interrupting;
Step 3 - 3 , clear interrupting;
Step 3 - 4 , receive instruction and determine whether receives valid instruction;
if yes, go to Step 3 - 5 ; if no, go to step 3 - 6 .
In Embodiment 3, specifically determining method is the same as Step 307.
Step 3 - 5 , set instruction flag as 1;
Step 3 - 6 , switch on interrupting and exit.
In Embodiments of the present invention, a response that the revolved card is in or not in the radio frequency field is informed to the master computer via USB interrupting channel and the informed response that the card is in the radio frequency field is stored; before preparing for informing next time, determine whether the stored response is identical to a response to be sent, if they are identical, the informing need not be uploaded; otherwise, inform the master computer that the card is in the radio frequency field and stores the response.
|
A method for detecting that a contactless CPU card leaves a radio-frequency field relates to the field of smart cards. The method comprises: receiving and judging whether a valid instruction sent by an upper computer is received, and conducting a corresponding operation according to the received instruction; as a notification card search instruction, conducting a card search operation, and judging whether returned information is received; obtaining card number information about a contactless card according to the returned information; as an APDU instruction, sending A data to the card in accordance with a designated format, judging whether a response is received, and sending the operation result to the upper computer; as an extension instruction, executing a corresponding operation, and sending the operation result to the upper computer; when a valid instruction is not received, judging the mark of the card in the radio-frequency field, and if the card is in the radio-frequency field, conducting a card detection operation, and sending the operation result to the upper computer; and if the card is not in the radio-frequency field, conducting a card search operation. The present invention can detect the problem that a CPU card leaves a radio-frequency field in real time.
| 6
|
INCORPORATION BY REFERENCE
[0001] This application is a continuation-in-part application of international patent application Serial No. PCT/JP2005/002163 filed Feb. 14, 2005, which claims priority to Japanese patent application Serial No. JP 2004-044540 filed Feb. 20, 2004.
[0002] The foregoing applications, and all documents cited therein or during their prosecution (“appln cited documents”) and all documents cited or referenced in the appln cited documents, and all documents cited or referenced herein (“herein cited documents”), and all documents cited or referenced in herein cited documents, together with any manufacturer's instructions, descriptions, product specifications, and product sheets for any products mentioned herein or in any document incorporated by reference herein, are hereby incorporated herein by reference, and may be employed in the practice of the invention.
FIELD OF THE INVENTION
[0003] The present invention relates to a medicine, an organic material having physiological activity, α-aminooxyketone compounds which are materials of liquid crystal and the like, and a process for producing α-hydroxyketone compounds induced therefrom; as to a catalyst used for producing α-aminooxyketone compounds, specifically α-aminooxyketone compounds which can give optical isomers with high purity, and a process for producing α-hydroxyketone compounds induced therefrom, and a catalyst used for producing α-aminooxyketone compounds.
BACKGROUND OF THE INVENTION
[0004] α-hydroxycarbonyl compounds are frequently found in natural organic compounds and the molecule skeletons of pharmaceuticals. They are synthetic equivalents for monosaccharides and pentoses, and are very important synthetic building blocks which can lead to various physiologically active materials, intermediates in the synthesis of medicines and liquid crystalline materials. The α-hydroxycarbonyl compounds easily lead to synthesis of optical isomers with high purity by asymmetric oxygenation of carbonyl compounds. However, asymmetric oxygenation at the α-position of the carbonyl group by the usual methods requires a two-step process: first, synthesizing and isolating enolate intermediates from carbonyl compounds, and second, performing with the use of a relatively expensive oxygen-introducing reagent; therefore, the asymmetric oxygenation has problems of low atom efficiency and the like.
[0005] In contrast, as a method for asymmetric oxygenation of ketones, methods for directly obtaining asymmetric oxygenation products of ketones without synthesizing and isolating enolate intermediates have been reported. The asymmetric oxygenation is to obtain α-aminooxyketones using amino acid, proline as a catalyst and nitrosobenzene as an oxygen-introducing reagent (see e.g. non-patent documents 1-3). However, many problems have thus far not been resolved in these systems, including low catalytic efficiency (10 to 20 mol % catalyst are needed), poor reproducibility and the like. Moreover, it is known that double oxygenation by nitrosobenzene progresses a side reaction.
[0006] Alternatively, it has been reported that α-aminooxyketone can be obtained in high yield from an alkylsilyl enol ether and nitrosobenzene with alkylsilyl triflate as a Lewis Acid catalyst (see e.g. Nonpatent document 4) and also from an alkyltin enolate and nitrosobenzene with Ag-BINAP complex as a catalyst (see e.g. Nonpatent document 5). Additionally, other methods have been disclosed to produce aldol products from the condensation reaction of carbonyl compounds: using a compound which has an ether and alcohol units within a certain molecule, in liquid CO 2 or supercritical CO 2 , in the presence of an acid catalyst (see e.g. Patent document 1); performing the reaction in water, in the presence of boron acid, a surfactant or a Brönsted acid (see e.g. Patent document 2); using a lanthanide trifluoromethanesulfonate and a chiral crown ether as a catalyst (see e.g. Patent document 3); and the like.
Patent document 1: Japanese Laid-Open Patent Application No. 2002-284729 Patent document 2: Japanese Laid-Open Patent Application No. 2002-275120 Patent document 3: Japanese Laid-Open Patent Application No. 2002-200428 Nonpatent document 1: Brown, S. P., Brochu, M. P., Sinz, C. J., & MacMillan, D. W. C. (2003) J. Am. Chem. Soc. 125, 10808-10809 Nonpatent document 2: Zhong, G. (2003) Angew. Chem. Int. Ed. 42, 4247-4250 Nonpatent document 3: Hayashi, Y., Yamaguchi, J., Hibino, K., & Shoji, M. (2003) Tetrahedron Lett. 44, 8293-8296 Nonpatent document 4: Momiyama, N., Yamamoto, H. (2002) Angew. Chem. Int. Ed. 41, 2986-2987 Nonpatent document 5: Momiyama, N., Yamamoto, H. (2003) J. Am. Chem. Soc. 125, 60 38-6039
[0015] Citation or identification of any document in this application is not an admission that such document is available as prior art to the present invention.
SUMMARY OF THE INVENTION
[0016] The object of the present invention is to provide a method for easily obtaining α-aminooxyketone compound which is a synthetic equivalent for monosaccharide and pentoses, and an equivalent of α-hydroxyketone compound that can be a synthetic intermediate of various physiologically active materials, in high yield; to pave the way for the synthesis of monosaccharide and furthermore of oligosaccharide from the resulting α-hydroxyketone compound induced from α-aminooxyketone compound; and to open new possibilities for the synthesis of various sugar medicines such as anticancer agents, antithrombogenic agents, anti-viral agents, anti-HIV agents, inhibitors of cholesterol synthesis, verotoxin neutralizing agents.
[0017] The applicant has shown, as displayed in the following formula, in an asymmetric nitroso aldol reaction between 3.0 equivalents of cyclohexanone (2a) and 1.0 equivalent of nitrosobenzene (3) using pyrrolidine tetrazole type catalyst (1) (5 mol %) induced from proline, in dimethyl sulfoxide (DMSO) at room temperature 25-30° C., the reaction was almost completed in only one hour, and the desired product (4a) was obtained in 94% chemical yield and >99% ee optical purity.
[0018] When proline was used as a catalyst under the exactly equal reaction condition, chemical yield stayed at 35% and at the same time almost 2% of the production of double additional product (5a) was identified. Even when the amount of catalyst to be used (1) was converted from 5 mol % to 3 mol %, and to 2 mol %, the reactions were progressed to observe a little decrease of the chemical yield to 72% and 50% respectively, but the optical purities were very high at >99% ee. Further, various carbonyl compounds were subjected to reaction, although reaction conditions should be adjusted slightly for aldehydes, high optical purities were obtained in any of the examples. The present invention has been thus completed based on this knowledge.
[0019] That is, the present invention relates to:
a process for producing an α-aminooxyketone compound wherein a carbonyl compound is reacted with a nitroso compound by using a catalyst containing a heterocyclic compound shown in the general formula (I) (wherein: X1, X2 and X3 independently represent nitrogen, carbon, oxygen or sulfur; Z represents a substituted or unsubstituted 5- to 10-membered ring) (“1”);
preferably relates to:
the process for producing an α-aminooxyketone compound according to “1”, wherein the heterocyclic compound is a tetrazole derivative shown in the general formula (II) (wherein Z represents a substituted or unsubstituted 5- to 10-membered ring) (“2”);
the process for producing an α-aminooxyketone compound according to “2”, wherein the tetrazole, derivative is a compound shown in the general formula (III) (“3”);
the process for producing an α-aminooxyketone compound according to any one of “1” to “3”, wherein the nitroso compound is nitrosobenzene (“4”); the process for producing an α-aminooxyketone compound according to any one of “1” to “4”, wherein the carbonyl compound is a compound shown in the general formula (IV) (wherein R1 and R2 independently represent hydrogen, or a substituted or unsubstituted alkyl group, a substituted or unsubstituted alkenyl group, a substituted or unsubstituted alkoxy group, a substituted or unsubstituted amide group, or a substituted or unsubstituted aryl group; and R1 and R2 may bind to each other to form a ring) (“5”);
the process for producing an α-aminooxyketone compound according to “5”, wherein the α-aminooxyketone compound contains R asymmetric carbon, where R1 represents hydrogen in the general formula (IV) (“6”); the process for producing an α-aminooxyketone compound according to “5”, wherein the α-aminooxyketone compound contains S asymmetric carbon; where R1 represents a substituted or unsubstituted alkyl group, a substituted or unsubstituted alkenyl group, a substituted or unsubstituted alkoxy group, a substituted or unsubstituted amide group, or a substituted or unsubstituted aryl group, and either one of these groups bind to R2 to form a ring in the general formula (IV) (“7”); the process for producing an α-aminooxyketone compound according to any one of “1” to “7”, wherein a solvent containing dimethyl sulfoxide or methyl nitrile, or both of them is used (“8”); the process for producing an α-aminooxyketone compound according to any one of “1” to “8”, wherein reaction is performed at room temperature (20-30° C.) (“9”); and a process for producing an α-hydroxyketone compound wherein an α-aminooxyketone compound obtained from the process according to any one of “1” to “9” is reacted in a solvent by using CuSO 4 as a catalyst (“10”).
[0026] The present invention also relates to:
a catalyst for producing an α-aminooxyketone compound by which a carbonyl compound is reacted with a nitroso compound, wherein the catalyst contains a heterocyclic compound shown in the general formula (I) (wherein: X1, X2 and X3 independently represent nitrogen, carbon, oxygen or sulfur; Z represents a substituted or unsubstituted 5- to 10-membered ring) (“11”);
preferably relates to:
the catalyst for producing an α-aminooxyketone compound according to “11”, wherein the heterocyclic compound is a tetrazole derivative shown in the general formula (II) (wherein Z represents a substituted or unsubstituted 5- to 10-membered ring) (“12”),
the catalyst for producing an α-aminooxyketone compound according to “12”, wherein the tetrazole derivative is a compound shown in the general formula (III) (“13”)
the catalyst for producing an α-aminooxyketone compound according to any one of claims “11” to “13”, wherein the nitroso compound is nitrosobenzene (“14”), the catalyst for producing an α-aminooxyketone compound according to any one of “11” to “14”, wherein the carbonyl compound is a compound shown in the general formula (IV) (wherein R1 and R2 independently represent hydrogen, or a substituted or unsubstituted alkyl group, a substituted or unsubstituted alkenyl group, a substituted or unsubstituted alkoxy group, a substituted or unsubstituted amide group, or a substituted or unsubstituted aryl group; and R1 and R2 may bind to each other to form a ring) (“15”),
the catalyst for producing an α-aminooxyketone compound according to “15”, wherein the α-aminooxyketone compound contains R asymmetric carbon, where R1 represents hydrogen in the general formula (IV) (“16”), the catalyst for producing an α-aminooxyketone compound according to “15”, wherein the α-aminooxyketone compound contains S asymmetric carbon, where R1 represents a substituted or unsubstituted alkyl group, a substituted or unsubstituted alkenyl group, a substituted or unsubstituted alkoxy group, a substituted or unsubstituted amide group, or a substituted or unsubstituted aryl group, or where either one of these groups bind to R2 to form a ring in the general formula (IV) (“17”).
[0033] By using heterocyclic compound shown in the general formula (I) as a catalyst, without isolating intermediates, at a stage in an asymmetric oxygenation of carbonyl compounds, the amount of catalyst was reduced, the efficiencies of catalyst, atom and the like were increased, and consequently α-aminooxyketone compounds can be obtained in high chemical yield and high optical purity. The present invention paves the way for artificially and freely producing oligosaccharides, hexose and pentose skeletons which can be found in unit structures in DNA and RNA; and gives possibilities to develop various sugar medicines such as anticancer agents, antithrombogenic agents, anti-viral agents, anti-HIV agents, inhibitors of cholesterol synthesis, and verotoxin neutralizing agents.
[0034] It is noted that in this disclosure and particularly in the claims and/or paragraphs, terms such as “comprises”, “comprised”, “comprising” and the like can have the meaning attributed to it in U.S. Patent law; e.g., they can mean “includes”, “included”, “including”, and the like; and that terms such as “consisting essentially of” and “consists essentially of” have the meaning ascribed to them in U.S. Patent law, e.g., they allow for elements not explicitly recited, but exclude elements that are found in the prior art or that affect a basic or novel characteristic of the invention.
[0035] These and other embodiments are disclosed or are obvious from and encompassed by, the following Detailed Description.
DETAILED DESCRIPTION
[0036] A process for producing α-aminooxyketone compounds of the present invention is a process by using so-called nitroso aldol reaction which produces α-aminooxyketone compounds by an asymmetric oxygenation reaction of carbonyl compounds and nitroso compounds.
[0037] A process for producing α-aminooxyketone compound of the present invention is not especially limited as long as it is a process for producing an α-aminooxyketone compound wherein a carbonyl compound is reacted with a nitroso compound by using a catalyst containing a heterocyclic compound shown in the general formula (I) (wherein: X1, X2 and X3 independently represent nitrogen, carbon, oxygen or sulfur; Z represents a substituted or unsubstituted 5- to 10-membered ring).
[0038] A carbonyl compound used for a process for producing α-aminooxyketone compounds of the present invention is not especially limited as long as it has a carbonyl group, and may be a compound in a soluble form or a compound easily forming hydrates. Specifically, aldehyde compounds and ketone compounds, preferably carbonyl compounds shown in the general formula (IV) can be exemplified.
[0039] In the general formula (IV), R1 and R2 independently represent hydrogen, or a substituted or unsubstituted alkyl group, a substituted or unsubstituted alkenyl group, a substituted or unsubstituted alkoxy group, a substituted or unsubstituted amide group, or a substituted or unsubstituted aryl group; and R1 and R2 may bind to each other to form a ring. As an alkyl group represented by R1, R2 in the general formula (IV), it may be linear or cyclic, and alkyl groups with 1-30 carbons such as methyl, ethyl, n-propyl, n-butyl, n-pentyl, n-hexyl, n-heptyl, n-octyl, n-nonyl and n-decyl, and such as cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclononyl and cyclodecyl can be exemplified. As an alkenyl group represented by R1, R2 in the general formula (IV), alkenyl groups with 1-30 carbons such as vinyl, 1-propenyl, allyl, 1-butenyl, 2-butenyl, 1-pentenyl, and 1-hexynyl can be exemplified.
[0040] Further, as an alkoxy group, an alkoxycarbonyl group and an aryl group represented by R1, R2 in the general formula (IV), alkoxy groups with 1-30 carbons such as methoxy, ethoxy, n-propoxy, n-butoxy, n-pentyloxy, n-hexyloxy, cyclohexyloxy and phenyloxy; alkoxycarbonyl group with 1-30 carbons such as methoxy carbonyl, ethoxy carbonyl, butoxy carbonyl and pentyloxy carbonyl; and aryl groups with 1-30 carbons such as phenyl, 1-naphtyl, 2-naphthyl, 1-anthryl, 2-anthryl, 9-anthryl, 1-phenanthryl, 2-phenanthryl, benzyl and phenethyl; can be exemplified respectively.
[0041] As a substituent of alkyl group, alkenyl group, alkoxy group, alkoxy-carbonyl group and aryl group represented by R1, R2 in the general formula (IV), alkyl groups such as methyl, ethyl, n-propyl, n-butyl, cyclopentyl, cyclohexyl and cycloheptyl; alkenyl groups such as vinyl, 1-propenyl, allyl, and 1-butenyl; aryl groups such as phenyl, 1-naphthyl, 2-naphthyl, 1-anthryl, 2-anthryl, 9-anthryl, 1-phenanthryl, 2-phenanthryl and benzyl; halogen atoms such as F, Cl and Br; alkoxy groups such as methoxy, ethoxy, propoxy and butoxy; and other ones such as hydroxyl, carboxyl, acyl, amino, thio and nitro groups can be exemplified. Further, as a ring system which is formed by binding of R1 and R2, cyclic alkyl groups such as cyclopentane, cyclohexane, cycloheptane, cyclooctane, cyclononane and cyclodecane; aromatic rings such as benzene, naphthalene and anthracene; and heterocycles such as pyridine, pyrrolidine, piperidine, furan, pyran, tetrahydrofuran and tetrahydropyran can be exemplified.
[0042] As a carbonyl compound represented in the general formula (IV), specifically aldehydes such as acetaldehyde, propionaldehyde, butylaldehyde, isobutylaldehyde, valeraldehyde, isovaleraldehyde, caproicaldehyde, heptaldehyde, caprylaldehyde, pelargonicaldehyde, capricaldehyde, undecylaldehyde, lauraldehyde, tridecylaldehyde, myristaldehyde, pentadecylaldehyde, palmiticaldehyde, margaricaldehyde, stearicaldehyde, succindialdehyde, acrolein, crotonaldehyde, benzaldehyde, o-tolualdehyde, m-tolualdehyde, p-tolualdehyde, salicylaldehyde, cinnamaldehyde, 1-naphthoaldehyde, 2-naphthoaldehyde and furfural can be exemplified.
[0043] Further, as a carbonyl compound represented in the general formula (IV), specifically ketones such as acetone; ethylmethylketone; propylmethylketone; isopropylmethylketone; butylmethylketone; isobutylmethylketone; diethylketone; diisopropylketone; 2-undecanone; methylvinylketone; mesityloxide; fluoroacetone; chloroacetone; 2,4-pentanedione; cyclobutanone; cyclopentanone; cyclohexanone; 2-methylcyclohexanone; cyclodecanone; 2-norbornanone; 2-adamantanone; tetrahydropyrane-4-one; spiro[4,5]-1,4-dioxy-decane-8-one; 1-benzylcarbonylpyperidine-4-one; benzylacetone; 1-indanone; 2-indanone; α-tetralone; β-tetralone; 7-methoxy-2-tetralone; acetophenone; propiophenone; benzylphenone; dibenzylketone; 3,4-dimethylacetophenone; 2-acetonaphthone; and 2-choroloacetophenone can be exemplified.
[0044] As a nitroso compound used in a process for producing α-aminooxyketone compounds of the present invention, it may be either of an aliphatic nitroso compound or an aromatic nitroso compound as long as the compound contains a nitroso group. As an aliphatic nitroso compound, an alkyl nitroso compound which may contain substituents can be exemplified and those in which a nitroso group is attached to the tertiary carbon are preferred with specific examples being 2-nitroso-isobutane and 2-nitroso-2-methylpentane. Further, as an aromatic nitroso compound, nitroso benzene which may contain substituents, and 1-nitrosonaphthalene and 2-nitrosonaphthalene which may contain substituents, can be exemplified. As a substituent of aromatic nitroso compound, alkyl groups such as methyl, ethyl, propyl, isopropyl, n-butyl, isobutyl, s-butyl, and t-butyl; alkoxy groups such as methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, s-butoxy, isobutoxy, t-butoxy, phenoxy, benzyloxy, andphenethyloxy; and halogen atoms such as F, Cl, Br, and I can be exemplified. As a nitrosobenzene containing substituent group, specifically o-nitrosotoluene; m-nitrosotoluene; p-nitrosotoluene; 3,5-dimethylnitrosobenzene; o-nitrosoethylbenzene; o-nitrosostyrene; o-nitrosoanisole; m-nitrosoanisole; p-nitrosoanisole; o-nitrosophenetol; m-nitrosophenetol; p-nitrosophenetol; o-fluoronitrosobenzene; m-fluoronitrosobenzene; p-fluoronitrosobenzene; o-chrolonitrosobenzene; m-chrolonitrosobenzene; p-chloronitrosobenzene; o-bromonitrosobenzene; m-bromonitrosobenzene; p-bromonitrosobenzene; and the like can be exemplified.
[0045] A heterocyclic compound used in the process for producing α-aminooxyketone compounds of the present invention is shown in the general formula (I) wherein X1, X2 and X3 independently represent nitrogen, carbon, oxygen or sulfur; Z represents a substituted or unsubstituted 5- to 10-membered ring, and is a compound in which a 5-membered heterocycle and 5- to 10-membered heterocycle both having nitrogen atom at the respective a position are bound through carbons constituting the heterocycles. The heterocyclic compound is also called an N—H acid-N—H base combined catalyst where the NH functional group at the a position of the heterocycle acts as an acid and the NH functional group at the a position of the cycloalkyl heterocycle acts as a base. As a 5-membered heterocycle (acid ring) of the heterocyclic compound, tetrazole, 1,2,3-triazole, 1,2,4-triazole, pyrazole, pyrazoline, imidazole, indazoline, thiotriazoline and oxatriazoline can be exemplified, and 1H-tetrazole as shown in the genenral formula (II) is especially preferable as a heterocyclic compound. As a 5-10 membered heterocycle (base ring), pyrrolidine, piperidine, hexamethyleneimine, heptamethyleneimine, oxazoline and oxazole can be exemplified; and as a substituent of these heterocycles, alkyl groups such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, and t-butyl, alkoxy groups such as methoxy and ethoxy, phenyl groups, aryl groups such as condensed ring system condensed to heterocycle can be exemplified. Smaller substituents are preferable since a compound with a bulky heterocyclic moiety including substituents would lower the yield.
[0046] As the above heterocyclic compound, specifically 5-(2′-pyrrolidinyl)-1H-1,2,3,4-tetrazole; 5-(4H,5H-2′-oxazolyl)-1H-1,2,3,4-tetrazole; 5-(2′-piperidinyl)-1H-1,2,3,4-tetrazole; 5-(benzo[c]-2′-piperidinyl)-1H-1,2,3,4-tetrazole; 5-2′-pyrolidinyl-1H-1,2,3-triazole; 5-2′-pyrolidinyl-1H-1,2,4-triazole; 2-2′-pyrolidinyl-1H-imidazole; 5-2′-pyrolidinyl-1H-imidazole; 5-2′-pyrolidinyl-1H,4H,5H-1,2,3,4-thiotriazoline; 5-2′-pyrolidinyl-4H,5H-1,2,3,4-oxatriazoline; and 5-2′-pyrolidinyl-4H,5H-pyrazoline; can be exemplified. Particularly, 5-(2′-pyrolidinyl)-1H-1,2,3,4-tetrazole as shown in the formura (III) can be preferably exemplified.
[0047] The heterocyclic compound can be prepared from natural or synthesized proline. The tetrazole derivative shown in the formula (III) can be prepared by a previous method (Roczniki Chemii Ann. Soc. Chim. Polpnorum, 1971, 45, 967; J. Med. Chm. 1985, 28, 1067). Thus, N-(benzyloxycarbonyl)-L-proline, which is commercially available as a carboxylic acid of proline having nitrogen atom protected by a benzyloxycarbonyl group, is converted to an amide via a reaction with ammonia and dehydrated with phosphoryl chloride to give nitrile. The obtained nitrile is reacted with sodium azide to give a tetrazole, and finally the N-benzyloxycarbonyl group is deprotected with HBr/AcOH or Pd/C, H2 to give a tetrazole derivative shown in the formula (III). The tetrazole derivative can also be obtained according to the previous method from Organic Letters, 2001, Vol. 3, No. 25, 4091-4094; Organic Letters, 2002, Vol. 4 No. 15, 2525-2527; and the like.
[0048] A process for producing α-aminooxyketone compounds of the present invention is a method of performing the reaction of carbonyl compound and nitroso compound generally in solvent in the presence of the heterocyclic compound shown in the general formula (I) or preferably in the presence of the tetrazole derivative shown in the formula (III). The amount of nitroso compound can be in a range of 2-4 mol equivalents, preferably 2.5-3.5 mol equivalents for the carbonyl compound, and the amount of catalyst containing the heterocyclic compound shown in the formula (I) can be 1-30 mol %, preferably 2-20 mol % for carbonyl substrate. As a solvent, water; halogenated hydrocarbons such as dichloromethane, chloroform, dichloroethane, and chlorobenzene; aromatic hydrocarbons such as benzene, toluene, xylene; aliphatic hydrocarbons such as cyclohexane, n-hexane, and n-heptane; esters such as ethylacetate; nitrites such as acetonitrile; dimethylsulfoxide; and the like can be exemplified; and among them dimethylsulfoxide and acetonitrile are preferable. The amount of solvent can be 15-30 equivalents but the reaction can be done without solvent.
[0049] The reaction temperature can be 0-50° C., preferably 20-30° C. and the reaction can be done at room temperature. The reaction time can be 30 minutes to 3 hours, for example, around 1 hour, and a method stirring in the open air can be exemplified. Strict conditions are not required for a reaction, furthermore, water does not suppress the reaction to proceed, so there is no need for dehydrating the material and catalyst, and the reaction is easy to be controlled. After the reaction is complete, the resulting product was extracted with ethylacetate and the like, and dried and purified by known methods.
[0050] In a process for producing α-aminooxyketone compounds of the present invention, carbonyl compounds such as methylisopropylketone and acetophenone, and aldehydes such as water-soluble aldehyde and aldehyde that forms hydrate easily, which could not be used for the materials in conventional methods, can be used as materials. Since there are not many limitations for carbonyl compounds used as a material, the resulting products, α-aminooxyketone compounds, range over a wide scope and have a high chemical yield and optical purity. As an absolute configuration of asymmetric carbons of the resulting product, α-aminooxyketone compound; where aldehyde is used as a material, the resulting product has a R-configuration; where ketone is used as a material, the resulting product has a S-configuration.
[0051] Specific examples of the α-aminooxyalketone obtained from the present invention are as follows: (N-isobutylaminooxy)acetaldehyde; [N-(1,1-dimethylbutyl)]aminooxyacetaldehyde; (N-phenylaminooxy)acetaldehyde; 2-(N-isobutylaminooxy)propanal; 2-[N-(1,1-dimethylbutyl)aminooxy]propanal; 2-N-phenylaminooxypropanal; 2-(N-isobutylaminooxy)butanal; 2-[N-(1,1-dimethylbuthyl)aminooxy]butanal; 2-(N-phenylaminooxy)butanal; 2-(N-isobutylaminooxy)-2-methylpropanal; 2-[N-(1,1-dimethylbuthyl)aminooxy]-2-methylpropanal; 2-(N-phenylaminooxy)-2-methylpropanal; 2-(N-isobutylaminooxy)-4-methylbutanal; 2-[N-(1,1-dimethylbutyl)aminooxy]-4-methylbutanal; 2-(N-phenylaminooxy)-4-methylbutanal; 2-(N-isobutylaminooxy)hexanal; 2-[N-(1,1-dimethylbutyl)aminooxy]hexanal; 2-(N-phenylaminooxy)hexanal; 2-(N-isobutylaminooxy)heptanal; 2-[N-(1,1-dimethylbutyl)aminooxy]heptanal; 2-(N-phenylaminooxy)heptanal; 2-(N-isobutylaminooxy)octanal; 2-[N-(1,1-dimethylbutyl)aminooxy]octanal; 2-(N-phenylaminooxy)octanal; 2-(N-isobutylaminooxy)nonanal; 2-[N-(1,1-dimethylbutyl)aminooxy]nonanal; 2-(N-phenylaminooxy)nonanal; 2-(N-isobutylaminooxy)decanal; 2-[N-(1,1-dimethylbutyl)aminooxy]decanal; 2-(N-phenylaminooxy)decanal; 2-(N-isobutylaminooxy)undecanal; 2-[N-(1,1-dimethylbutyl)aminooxy]undecanal; 2-(N-phenylaminooxy)propanal; 2-(N-isobutylaminooxy)dodecanal; 2-[N-(1,1-dimethylbutyl)aminooxy]dodecanal; 2-(N-phenylaminooxy)dodecanal; 2-(N-isobutylaminooxy)tridecanal; 2-[N-(1,1-dimethylbutyl)aminooxy]tridecanal; and 2-(N-phenylaminooxy)tridecanal.
[0052] Further specific examples of the α-aminooxyketone compound obtained from the present invention are as follows: 2,3-bis(N-isobutylaminooxy)butanedial; 2,3-bis[N-(1,1-dimethylbutyl)aminooxy]butanedial; 2,3-bis[N-phenylaminooxy]butanedial; 2-N-isobutylaminooxy-2-propenal; 2-N-(1,1-dimethylbutyl)aminooxy-2-propenal; 2-N-phenylaminooxy-2-propenal; 2-N-isobutylaminooxy-2-butenal; 2-N-(1,1-dimethylbutyl)aminooxy-2-butenal; 2-N-phenylaminooxy-2-butenal; 3-phenyl-2-N-isobutylaminooxy-2-propenal; 3-phenyl-2-N-(1,1-dimethylbutyl)aminooxy-2-propenal; and 3-phenyl-2-N-phenylaminooxy-2-propenal.
[0053] Furthermore, examples of the α-aminooxyketone obtained from the present invention are as follows: (N-isobutylaminooxy)acetone; [N-(1,1-dimethylbutyl)aminooxy]acetone; (N-phenylaminooxy)acetone; 3-(N-isobutylaminooxy)butane-2-one; 3-[N-(1,1-dimethylbutyl)aminooxy]butane-2-one; 3-(N-phenylaminooxy)butane-2-one; 3-(N-isobutylaminooxy)pentane-2-one; 3-[N-(1,1-dimethylbutyl)aminooxy]pentane-2-one; 3-(N-phenylaminooxy)pentane-2-one; 3-(N-isobutylaminooxy)-4-methylbutane-2-one; 3-[N-(1,1-dimethylbutyl)aminooxy]-4-methylbutane-2-one; 3-(N-phenylaminooxy)-4-methylbutane-2-one; 3-(N-isobutylaminooxy)hexane-2-one; 3-[N-(1,1-dimethylbutyl)aminooxy]hexane-2-one; 3-(N-phenylaminooxy)hexane-2-one; 3-(N-isobutylaminooxy)-4-methylpentane-2-one; 3-[N-(1,1-dimethylbutyl)aminooxy]-4-methylpentane-2-one; 3-(N-phenylaminooxy)-4-methylpentane-2-one; 2-(N-isobutylaminooxy)pentane-3-one; 2-[N-(1,1-dimethylbutyl)aminooxy]pentane-3-one; 2-(N-phenylaminooxy)pentane-3-one; 2-(N-isobutylaminooxy)-2,4-dimethylpentane-3-one; 2-[N-(1,1-dimethylbutyl)aminooxy]-2,4-dimethylpentane-3-one; 2-(N-phenylaminooxy)-2,4-dimethylpentane-3-one; 3-(N-isobutylaminooxy)undecane-2-one; 3-[N-(1,1-dimethylbutyl)aminooxy]undecane-2-one; and 3-(N-phenylaminooxy)undecane-2-one.
[0054] Further examples of the α-aminooxyketone compound obtained from the present invention are as follows: 3-N-isobutylaminooxy-3-butene-2-one; 3-N-(1,1-dimethylbutyl)aminooxy-3-butene-2-one; 3-N-phenylaminooxy-3-butene-2-one; 3-N-isobutylaminooxy-4-methyl-3-pentene-2-one; 3-N-(1,1-dimethylbutyl)aminooxy-4-methyl-3-pentene-2-one; 3-N-phenylaminooxy-4-methyl-3-pentene-2-one; 1-fluoro-1-(N-isobutylaminooxy)acetone; 1-fluoro-1-[N-(1,1-dimethylbutyl)aminooxy]acetone; 1-fluoro-1-(N-phenylaminooxy)acetone; 1-chloro-1-(N-isobutylaminooxy)acetone; 1-chloro-1-[N-(1,1-dimethylbutyl)aminooxy]acetone; 1-chloro-1-(N-phenylaminooxy)acetone; 3-(N-isobutylaminooxy)-2,4-pentanedione; 3-[N-(1,1-dimethylbutyl)aminooxy]-2,4-pentanedione; 3-(N-phenylaminooxy)-2,4-pentanedione; 2-(N-isobutylaminooxy)cyclobutanone; 2-[N-(1,1-dimethylbutyl)aminooxy]cyclobutanone; 2-(N-phenylaminooxy)cyclobutanone; 2-(N-isobutylaminooxy)cyclopentanone; 2-[N-(1,1-dimethylbutyl)aminooxy]cyclopentanone; 2-(N-phenylaminooxy)cyclopentanone; 2-(N-isobutylaminooxy)cyclohexanone; 2-[N-(1,1-dimethylbutyl)aminooxy]cyclohexanone; 2-(N-phenylaminooxy)cyclohexanone; 2-(N-isobutylaminooxy)-2-methylcyclohexanone; 2-[N-(1,1-dimethylbutyl)aminooxy]-2-methylcyclohexanone; 2-(N-phenylaminooxy)-2-methylcyclohexanone; 2-(N-isobutylaminooxy)cyclodecanone; 2-[N-(1,1-dimethylbutyl)aminooxy]cyclodecanone; 2-(N-phenylaminooxy)cyclodecanone; 1-(N-isobutylaminooxy)-2-norbornanone; 1-[N-(1,1-dimethylbutyl)aminooxy]-2-norbornanone; 1-(N-phenylaminooxy)-2-norbornanone; 1-(N-isobutylaminooxy)-2-adamantanone; 1-[N-(1,1-dimethylbutyl)aminooxy]-2-adamantanone; and 1-(N-phenylaminooxy)-2-adamantanone.
[0055] And more examples are as follows: 2-(N-isobutylaminooxy)-4-tetrahydropyranone; 2-[N-(1,1-dimethylbutyl)aminooxy]-4-tetrahydropyranone; 2-(N-phenylaminooxy)-4-tetrahydropyranone; 7-(N-isobutylaminooxy)-spiro[4.5]-1,4-dioxy-decane-8-one; 7-[N-(1,1-dimethylbutyl)aminooxyl-spiro[4.5]-1,4-dioxy-decane-8-one; 7-(N-phenylaminooxy)-spiro[4.5]-1,4-dioxy-decane-8-one; 3-(N-isobutylaminooxy)-1-benzylcarbonylpiperidine-4-one; 3-[N-(1,1-dimethylbutyl)aminooxy]-1-benzylcarbonylpiperidine-4-one; 3-(N-phenylaminooxy)-1-benzylcarbonylpiperidine-4-one; 3-(N-isobutylaminooxy)-4-phenylbutane-2-one; 3-[N-(1,1-dimethylbutyl)aminooxy-4-phenylbutane-2-one; 3-(N-phenylaminooxy)-4-phenylbutane-2-one; 2-(N-isobutylaminooxy)-1-indanone; 2-[N-(1,1-dimethylbutyl)aminooxy]-1-indanone; 2-(N-phenylaminooxy)-1-indanone; 1-(N-isobutylaminooxy)-2-indanone; 1-[N-(1,1-dimethylbutyl)aminooxy-2-indanone; 1-(N-phenylaminooxy)-2-indanone; 2-(N-isobutylaminooxy)-1-ketotetrahydronaphthalene; 2-[N-(1,1-dimethylbutyl)aminooxy-1-ketotetrahydronaphthalene; 2-(N-phenylaminooxy)-1-ketotetrahydronaphthalene; 1-(N-isobutylaminooxy)-2-ketotetrahydronaphthalene; 1-[N-(1,1-dimethylbutyl)aminooxy]-2-ketotetrahydronaphthalene; 1-(N-phenylaminooxy)-2-ketotetrahydronaphthalene; 1-(N-isobutylaminooxy)-7-methoxy-2-ketotetrahydronaphthalene; 1-[N-(1,1-dimethylbutyl)aminooxy-7-methoxy-2-ketotetrahydronaphthalene; 1-(N-phenylaminooxy)-7-methoxy-2-ketotetrahydronaphthalene; 2′-(N-isobutylaminooxy)-1-acetophenone; 2′-[N-(1,1-dimethylbutyl)aminooxy]-1′-acetophenone; 2′-(N-phenylaminooxy)-1′-acetophenone; 2′-(N-isobutylaminooxy)-1′-propiophenone; 2′-[N-(1,1-dimethylbutyl)aminooxy]-1′-propiophenone; 2′-(N-phenylaminooxy)-1′-propiophenone; 2-(N-isobutylaminooxy)-1,2-bisphenylethane-1-one; 2-[N-(1,1-dimethylbutyl)aminooxy]-1,2-bisphenylethane-1-one; 2-(N-phenylaminooxy)-1,2-bisphenylethane-1-one; 1-(N-isobutylaminooxy)-1,3-bisphenylpropane-2-one; 1-[N-(1,1-dimethylbutyl)aminooxy]-1,3-bisphenylpropane-2-one; 1-(N-phenylaminooxy)-1,3-bisphenylpropane-2-one; 6-(N-isobutylaminooxy)-3,4-dimethylacetophenone; 6-[N-(1,1-dimethylbutyl)aminooxy]-3,4-dimethylacetophenone; 6-(N-phenylaminooxy)-3,4-dimethylacetophenone; 3′-(N-isobutylaminooxy)-2′-acetonaphthone, 3′-[N-(1,1-dimethylbutyl)aminooxy]-2′-acetonaphthone; 3′-(N-phenylaminooxy)-2′-acetonaphthone; 3′-(N-isobutylaminooxy)-2′-chloroacetonaphthone; 3′-[N-(1,1-dimethylbutyl)aminooxy]-2′-acetonaphtone; and 3′-(N-phenylaminooxy)-2′-acetonaphtone.
[0056] Further, the process for producing α-hydroxyketone compounds of the present invention is a process using an α-aminooxyketone compound obtained from the above mentioned process for producing α-aminooxyketone compounds of the present invention in a solvent with the use of CuSO 4 as a catalyst, and to which known methods can be applied to convert aminooxyketone compound to hydroxyketone compound. Alcohols like methanol and ethanol can be exemplified as a solvent to use. The reaction temperature can be about 0-25° C., and the reaction time can be about 3-10 hours.
[0057] The compounds of the invention may be useful for treating or preventing a variety of cancers, including, but not limited to, leukemias, including but not limited to acute leukemia, acute lymphocytic leukemia, acute myelocytic leukemia, myeloblastic, promyelocytic, myelomonocytic, monocytic, erythroleukemia, chronic leukemia, chronic myelocytic, (granulocytic) leukemia, chronic lymphocytic leukemia, Polycythemia vera, Lymphomas including but not limited to Hodgkin's disease, non-Hodgkin's disease, Multiple myeloma, Waldenstrom's macroglobulinemia, Heavy chain disease, Solid tumors including but not limited to sarcomas and carcinomas, fibrosarcoma, myxosarcoma, liposarcoma, chondrosarcoma, osteogenic sarcoma, chordoma, angiosarcoma, endotheliosarcoma, lymphangiosarcoma, lymphangioendotheliosarcoma, synovioma, mesothelioma, Ewing's tumor, leiomyosarcoma, rhabdomyosarcoma, colon carcinoma, pancreatic cancer, breast cancer, ovarian cancer, prostate cancer, squamous cell carcinoma, basal cell carcinoma, adenocarcinoma, sweat gland carcinoma, sebaceous gland carcinoma, papillary carcinoma, papillary adenocarcinomas, cystadenocarcinoma, medullary carcinoma, bronchogenic carcinoma, renal cell carcinoma, hepatoma, bile duct carcinoma, choriocarcinoma, seminoma, embryonal carcinoma, Wilms' tumor, cervical cancer, uterine cancer, testicular tumor, lung carcinoma, small cell lung carcinoma, bladder carcinoma, epithelial carcinoma, glioma, astrocytoma, medulloblastoma, craniopharyngioma, ependymoma, pinealoma, hemangioblastoma, acoustic neuroma, oligodendroglioma, meningioma, melanoma, and neuroblastomaretinoblastoma.
[0058] In another embodiment, the compounds of the present invention may be useful in preventing or treating cardiovascular diseases, such as, but not limited to, hypertension, heart failure, pulmonary hypertension and renal diseases. For example, bosentan, an endothelin receptor antagonist, has received approval by the Food and Drug Administration (FDA) for use in pulmonary artery hypertension (see, e.g., Vatter et al., Methods Find Exp Clin Pharmacol. May 2004;26(4):277-86). The compounds of the present invention, or a derivative thereof, may be used as an endothelin receptor antagonist (see, e.g., Niiyama et al., Bioorg Med Chem. November 2002;10(11):3437-44).
[0059] In another embodiment, the compounds of the present invention may be useful in neutralizing toxins, such as, but not limited to, SLTs, verotoxins, cholera toxin, clostridium difficile toxins A and B, bacterial pili from enteropathogenic E. coli (EPEC) and enterotoxigenic E. coli (ETEC).
[0060] Due to their activity, the compounds of the invention are advantageously useful in veterinary and human medicine.
[0061] When administered to a patient, a compound of the invention is preferably administered as component of a composition that optionally comprises a pharmaceutically acceptable vehicle the present compositions, which comprise a compound of the invention, are preferably administered orally. The compositions of the invention may also be administered by any other convenient route, for example, by infusion or bolus injection, by absorption through epithelial or mucocutaneous linings (e.g., oral mucosa, rectal, and intestinal mucosa, etc.) and may be administered together with another biologically active agent. Administration can be systemic or local. Various delivery systems are known, e.g., encapsulation in liposomes, microparticles, microcapsules, capsules, etc., and can be used to administer the compounds of the invention.
[0062] In certain embodiments, the present compositions may comprise one or more compounds of the invention.
[0063] Methods of administration include but are not limited to intradermal, intramuscular, intraperitoneal, intravenous, subcutaneous, intranasal, epidural, oral, sublingual, intranasal, intracerebral, intravaginal, transdermal, rectally, by inhalation, or topically, particularly to the ears, nose, eyes, or skin. The mode of administration is left to the discretion of the practitioner. In most instances, administration will result in the release of a compound of the invention into the bloodstream.
[0064] In specific embodiments, it maybe desirable to a compound of the invention locally. This may be achieved, for example, and not by way of limitation, by local infusion during surgery, topical application, e.g., in conjunction with a wound dressing after surgery, by injection, by means of a catheter, by means of a suppository, or by means of an implant, said implant being of a porous, non-porous, or gelatinous material, including membranes, such as sialastic membranes, or fibers.
[0065] In certain embodiments, it may be desirable to introduce a compound of the invention into the central nervous system by any suitable route, including intraventricular, intrathecal and epidural injection. Intraventricular injection may be facilitated by an intraventricular catheter, for example, attached to a reservoir, such as an Ommaya reservoir.
[0066] Pulmonary administration can also be employed, e.g., by use of an inhaler or nebulizer, and formulation with an aerosolizing agent, or via perfusion in a fluorocarbon or synthetic pulmonary surfactant. In certain embodiments, the compounds of the invention can be formulated as a suppository, with traditional binders and vehicles such as triglycerides.
[0067] In another embodiment, the compounds of the invention can be delivered in a vesicle, in particular a liposome (see Langer, 1990. Science 249:1527-1533; Treat et al, in Liposomes in the Therapy of Infectious Disease and Cancer, Lopez-Berestein and Fidler (eds.), Liss, N.Y., pp. 353-365 (1989); Lopez-Berestein, ibid., pp. 317-327; see generally ibid).
[0068] In yet another embodiment, the compounds of the invention can be delivered in a controlled release system (see, e.g., Goodson, in Medical Applications of Controlled Release, supra, vol. 2, pp. 115-138 (1984)). Other controlled-release systems discussed in the review by Langer, 1990, Science 249:1527-1533) may be used. In one embodiment, a pump may be used (see Langer, supra; Sefton, 1987, CRC Crit. Ref. Biomed. Eng. 14:201; Buchwald et al., 1980, Surgery 88:507 Saudek et al., 1989, N. Engl. J. Med. 321:574). In another embodiment, polymeric materials can be used (see Medical Applications of Controlled Release, Langer and Wise (eds.), CRC Pres., Boca Raton, Fla. (1974); Controlled Drug Bioavailability, Drug Product Design and Performance, Smolen and Ball (eds.), Wiley, N.Y. (1984); Ranger and Peppas, 1983, J. Macromol. Sci. Rev. Macromol. Chem. 23:61; see also Levy et al., 1985, Science 228:190; During et al., 1989, Ann. Neurol. 25:351; Howard et al., 1989, J. Neurosurg. 71:105). In yet another embodiment, a controlled-release system can be placed in proximity of a target of a compound of the invention, thus requiring only a fraction of the systemic dose.
[0069] The present compositions can optionally comprise a suitable amount of a pharmaceutically acceptable vehicle so as to provide the form for proper administration to the patient.
[0070] In a specific embodiment, the term “pharmaceutically acceptable” means approved by a regulatory agency of the Federal or a state government or listed in the U.S. Pharmacopeia or other generally recognized pharmacopeia for use in animals, mammals, and more particularly in humans. The term “vehicle” refers to a diluent, adjuvant, excipient, or carrier with which a compound of the invention is administered. Such pharmaceutical vehicles can be liquids, such as water and oils, including those of petroleum, animal, vegetable or synthetic origin, such as peanut oil, soybean oil, mineral oil, sesame oil and the like. The pharmaceutical vehicles can be saline, gum acacia, gelatin, starch paste, talc, keratin, colloidal silica, urea, and the like. In addition, auxiliary, stabilizing, thickening. lubricating and coloring agents may be used. When administered to a patient, the pharmaceutically acceptable vehicles are preferably sterile. Water is a preferred vehicle when the compound of the invention is administered intravenously. Saline solutions and aqueous dextrose and glycerol solutions can also be employed as liquid vehicles, particularly for injectable solutions. Suitable pharmaceutical vehicles also include excipients such as starch, glucose, lactose, sucrose, gelatin, malt, rice, flour, chalk, silica gel, sodium stearate, glycerol monostearate, talc, sodium chloride, dried skim milk, glycerol, propylene, glycol, water, ethanol and the like. The present compositions, if desired, can also contain minor amounts of wetting or emulsifying agents, or buffering agents.
[0071] The present compositions can take the form of solutions, suspensions, emulsion, tablets, pills, pellets, capsules, capsules containing liquids, powders, sustained-release formulations, suppositories, emulsions, aerosols, sprays, suspensions, oranyother form suitable for use. In one embodiment, the pharmaceutically acceptable vehicle is a capsule (see e.g., U.S. Pat. No. 5,698,155). Other examples of suitable pharmaceutical vehicles are described in Remington's Pharmaceutical Sciences, Alfonso R. Gennaro ed., Mack Publishing Co. Easton, Pa., 19th ed., 1995, pp. 1447 to 1676, incorporated herein by reference.
[0072] In a preferred embodiment, the compounds of the invention are formulated in accordance with routine procedures as a pharmaceutical composition adapted for oral administration to human beings. Compositions for oral delivery may be in the form of tablets, lozenges, aqueous or oily suspensions, granules, powders, emulsions, capsules, syrups, or elixirs, for example. Orally administered compositions may contain one or more agents, for example, sweetening agents such as fructose, aspartame or saccharin; flavoring agents such as peppermint, oil of wintergreen, or cherry; coloring agents; and preserving agents, to provide a pharmaceutically palatable preparation. Moreover, where in tablet or pill form, the compositions can be coated to delay disintegration and absorption in the gastrointestinal tract thereby providing a sustained action over an extended period of time. Selectively permeable membranes surrounding an osmotically active driving compound are also suitable for orally administered compositions. In these later platforms, fluid from the environment surrounding the capsule is imbibed by the driving compound, which swells to displace the agent or agent composition through an aperture. These delivery platforms can provide an essentially zero order delivery profile as opposed to the spiked profiles of immediate release formulations. A time delay material such as glycerol monostearate or glycerol stearate may also be used. Oral compositions can include standard vehicles such as mannitol, lactose, starch, magnesium stearate, sodium saccharine, cellulose, magnesium carbonate, etc. Such vehicles are preferably of pharmaceutical grade. Typically, compositions for intravenous administration comprise sterile isotonic aqueous buffer. Where necessary, the compositions may also include a solubilizing agent.
[0073] In another embodiment, the compounds of the invention can be formulated for intravenous administration. Compositions for intravenous administration may optionally include a local anesthetic such as lignocaine to lessen pain at the site of the injection. Generally, the ingredients are supplied either separately or mixed together in unit dosage form, for example, as a dry lyophilized powder or water free concentrate in a hermetically sealed container such as an ampoule or sachette indicating the quantity of active agent. Where the compounds of the invention are to be administered by infusion, they can be dispensed, for example, with an infusion bottle containing sterile pharmaceutical grade water or saline. Where the compounds of the invention are administered by injection, an ampoule of sterile water for injection or saline can be provided so that the ingredients may be mixed prior to administration.
[0074] The amount of a compound of the invention that will be effective in the treatment of a particular disorder or condition disclosed herein will depend on the nature of the disorder or condition, and can be determined by standard clinical techniques. In addition, in vitro or in vivo assays may optionally be employed to help identify optimal dosage ranges. The precise dose to be employed will also depend on the route of administration, and the seriousness of the disease or disorder, and should be decided according to the judgment of the practitioner and each patient's circumstances. However, suitable dosage ranges for oral administration are generally about 0.001 milligram to about 200 milligrams of a compound of the invention or a pharmaceutically acceptable salt thereof per kilogram body weight per day. In specific preferred embodiments of the invention, the oral dose is about 0.01 milligram to about 100 milligrams per kilogram body weight per day, more preferably about 0.1 milligram to about 75 milligrams per kilogram body weight per day, more preferably about 0.5 milligram to 5 milligrams per kilogram body weight per day. The dosage amounts described herein refer to total amounts administered; that is, if more than one compound of the invention is administered, or if a compound of the invention is administered with a therapeutic agent, then the preferred dosages correspond to the total amount administered. Oral compositions preferably contain about 10% to about 95% active ingredient by weight.
[0075] Suitable dosage ranges for intravenous (i.v.) administration are about 0.01 milligram to about 100 milligrams per kilogram body weight per day, about 0.1 milligram to about 35 milligrams per kilogram body weight per day, and about 1 milligram to about 10 milligrams per kilogram body weight per day. Suitable dosage ranges for intranasal administration are generally about 0.01 pg/kg body weight per day to about 1 mg/kg body weight per day. Suppositories generally contain about 0.01 milligram to about 50 milligrams of a compound of the invention per kilogram body weight per day and comprise active ingredient in the range of about 0.5% to about 10% by weight.
[0076] Recommended dosages for intradermal, intramuscular, intraperitoneal, subcutaneous, epidural, sublingual, intracerebral, intravaginal, transdermal administration or administration by inhalation are in the range of about 0.001 milligram to about 200 milligrams per kilogram of body weight per day, Suitable doses for topical administration are in the range of about 0.001 milligram to about 1 milligram, depending on the area of administration. Effective doses may be extrapolated from dose-response curves derived from in vitro or animal model test systems. Such animal models and systems are well known in the art.
[0077] The invention also provides pharmaceutical packs or kits comprising one or more vessels containing one or more compounds of the invention. Optionally associated with such container(s) can be a notice in the form prescribed by a governmental agency regulating the manufacture, use or sale of pharmaceuticals or biological products, which notice reflects approval by the agency of manufacture, use or sale for human administration. In a certain embodiment, the kit contains more than one compound of the invention. In another embodiment, the kit comprises a therapeutic agent and a compound of the invention.
[0078] The compounds of the invention are preferably assayed in vitro and in vivo, for the desired therapeutic or prophylactic activity, prior to use in humans. For example, in vitro assays can be used to determine whether it is preferable to administer a compound of the invention alone or in combination with another compound of the invention and/or a therapeutic agent. Animal model systems can be used to demonstrate safety and efficacy.
[0079] Other methods will be known to the skilled artisan and are within the scope of the invention.
[0080] In certain embodiments of the present invention, a compound of the invention can be used in combination therapy with at least one other therapeutic agent. The compound of the invention and the therapeutic agent can act additively or, more preferably, synergistically. In a preferred embodiment, a composition comprising a compound of the invention is administered concurrently with the administration of another therapeutic agent, which can be part of the same composition as or in a different composition from that comprising the compound of the invention. In another embodiment, a composition comprising a compound of the invention is administered prior or subsequent to administration of another therapeutic agent. As many of the disorders for which the compounds of the invention are useful in treating are chronic, in one embodiment combination therapy involves alternating between administering a composition comprising a compound of the invention and a composition comprising another therapeutic agent, e.g., to minimize the toxicity associated with a particular drug. The duration of administration of the compound of the invention or therapeutic agent can be, e.g., one month, three months, six months, a year, or for more extended periods. In certain embodiments, when a compound of the invention is administered concurrently with another therapeutic agent that potentially produces adverse side effects including, but not limited to, toxicity, the therapeutic agent can advantageously be administered at a dose that falls below the threshold at which the adverse side is elicited.
[0081] The therapeutic agent can be an anti-cancer agent. Useful anti-cancer agents include, but are not limited to, methotrexate, taxol, mercaptopurine, thioguanine, hydroxyurea, cytarabine, cyclophosphamide, ifosfamide, nitrosoureas, cisplatin, carboplatin, mitomycin, dacarbazine, procarbizine, etoposides, campathecins, bleomycin, doxorubicin, idarubicin, daunorubicin, dactinomycin, plicamycin, mitoxantrone, asparaginase, vinblastine, vincristine, vinorelbine, paclitaxel, and docetaxel, .gamma.-radiation, alkylating agents including nitrogen mustard such as cyclophosphamide, Ifosfamide, trofosfamide, Chlorambucil, nitrosoureas such as carmustine (BCNU), and Lomustine (CCNU), alkylsulphonates such as busulfan, and Treosulfan, triazenes such as Dacarbazine, platinum containing compounds such as Cisplatin and carboplatin, plant alkaloids including vinca alkaloids, vincristine, Vinblastine, Vindesine, and Vinorelbine, taxoids including paclitaxel, and Docetaxol, DNA topoisomerase inhibitors including Epipodophyllins such as etoposide, Teniposide, Topotecan, 9-aminocamptothecin, campto irinotecan, and crisnatol, mytomycins such as mytomycin C, and Mytomycin C, anti-metabolites, including anti-folates such as DHFR inhibitors, methotrexate and Trimetrexate, IMP dehydrogenase inhibitors including mycophenolic acid, Tiazofurin, Ribavirin, EICAR, Ribonuclotide reductase Inhibitors such as hydroxyurea, deferoxamine, pyrimidine analogs including uracil analogs 5-Fluorouracil, Floxuridine, Doxifluridine, and Ratitrexed, cytosine analogs such as cytarabine (ara C), cytosine arabinoside, and fludarabine, purine analogs such as mercaptopurine, thioguanine, hormonal therapies including receptor antagonists, the anti-estrogens Tamoxifen, Raloxifene and megestrol, LHRH agonists such as goscrclin, and Leuprolide acetate, anti-androgens such as flutamide, and bicalutamide, retinoids/deltoids, Vitamin D3 analogs including EB 1089, CB 1093, and KH 1060, photodyamic therapies including vertoporfin (BPD-MA), Phthalocyanine, photosensitizer Pc4, Demethoxy-hypocrellin A, (2BA-2-DMHA), cytokines including Interferon-.alpha., Interferon-.gamma., tumor necrosis factor, as well as other compounds having anti-tumor activity including Isoprenylation inhibitors such as Lovastatin, Dopaminergic neurotoxins such as 1-methyl-4-phenylpyridinium ion, Cell cycle inhibitors such as staurosporine, Actinomycins such as Actinomycin D and Dactinomycin, Bleomycins such as bleomycin A2, Bleomycin B2, and Peplomycin, anthracyclines such as daunorubicin, Doxorubicin (adriamycin), Idarubicin, Epirubicin, Pirarubicin, Zorubicin, and Mitoxantrone, MDR inhibitors including verapamil, and Ca2+ ATPase inhibitors such as thapsigargin.
[0082] The therapeutic agent can be an antiviral agent. Useful antiviral agents include, but are not limited to, nucleoside analogs, such as zidovudine, acyclovir, gangcyclovir, vidarabine, idoxuridine, trifluridine, and ribavirin, as well as foscarnet, amantadine, rimantadine, saquinavir, indinavir, ritonavir, and the alpha-interferons.
[0083] The therapeutic agent can be an anti-inflammatory agent. Useful anti-inflammatory agents include, but are not limited to, non-steroidal anti-inflammatory drugs such as salicylic acid, acetylsalicylic acid, methyl salicylate, diflunisal, salsalate, olsalazine, sulfasalazine, acetaminophen, indomethacin, sulindac, etodolac, mefenamic acid, meclofenamate sodium, tolmetin, ketorolac, diclofenac, ibuprofen, naproxen, naproxen sodium, fenoprofen, ketoprofen, flurbinprofen, oxaprozin, piroxicam, meloxicam, ampiroxicam, droxicam, pivoxicam, tenoxicam, nabumetome, phenylbutazone, oxyphenbutazone, antipyrine, aminopyrine, apazone and nimesulide; leukotriene antagonists including, but not limited to, zileuton, aurothioglucose, gold sodium thiomalate and auranofin; and other anti-inflammatory agents including, but not limited to, colchicine, allopurinol, probenecid, sulfinpyrazone and benzbromarone.
[0084] The invention will now be further described by way of the following non-limiting examples.
EXAMPLES
Example 1
[0085] Pyrrolidine-2-tetrazole 1 was prepared from proline. One mL dimethyl sulfoxide (DMSO) solution at room temperature (25-30° C.) in which 5 mol % Pyrrolidine-2-tetrazole and 1.5 mmol (3 equivalents) cyclohexanone was dissolved and was added dropwise 1 mL DMSO solution with 0.5 mmol (1 equivalent) nitrosobenzene for 1 hour. The mixture was stirred at room temperature and allowed to react for 1 hour. The nitrosobenzene was completely consumed, as determined by TLC (hexane/ethyl acetate=3/1). The desired product (4), 2-(N-phenylaminooxy)-1-cyclohexanone was obtained. It was 94% chemical yield and >99% ee optical purity. The results are shown in Table 1. In Table 1, chemical yield ratio (4/6) shows the yield ratio of isolated isomer, optical purity (ee %) of the desired product shows the measurement of HPLC, and absolute configuration (R/S) of asymmetric carbon of the desired products shows the yield of diol converted from the desired products. Even where the amount of catalyst 1 to be used was changed to 3 mol % and 2 mol %, the reactions progressed. The chemical yield of the desired products was 72% and 50% respectively, but the optical purities were >99% ee.
Comparative Example 1
[0086] Reaction was performed in the same manner as Example 1 with the exception of using proline as a catalyst. The chemical yield of the resulting desired product stayed at 35%, and the production of double additional product (5a) of about 2% of 2,6-bis(N-phenylaminooxy)-1-cyclohexanone was identified.
Example 2
[0087] Reaction was performed in the same manner as Example 1 with the exception of using tetrahydropyrane-4-one as a carbonyl compound. Chemical yield and optical purity of the desired products are shown in Table 1.
Example 3
[0088] Reaction was performed in the same manner as Example 1 with the exception of using spiro[4.5]-1,4-dioxy-decane-8-one as a carbonyl compound. Chemical yield and optical purity of the desired products are shown in Table 1.
Example 4
[0089] Reaction was performed in the same manner as Example 1 with the exception of using 1-benzylcarbonylpiperidine-4-one as a carbonyl compound. Chemical yield and optical purity of the desired products are shown in Table 1.
Example 5
[0090] Reaction was performed in the same manner as Example 1 with the exception of using methylethylketone as a carbonyl compound and the amount of 20 mol % catalyst. Chemical yield and optical purity of the desired products are shown in Table 1.
Example 6
[0091] Reaction was performed in the same manner as Example 1 with the exception of using phenylpropionaldehyde as a carbonyl compound, acetonitrile as a solvent, and the amount of 10 mol % catalyst. Chemical yield and optical purity of the desired products are shown in Table 1. In the Table, chemical yield of the desired products shows the yield of primary alcohol obtained by reduction of the desired products.
Example 7
[0092] Reaction was performed in the same manner as Example 6 with the exception of using isobutyraldehyde as a carbonyl compound and the amount of 20 mol % catalyst. Chemical yield and optical purity of the desired products are shown in Table 1.
Example 8
[0093] Reaction was performed in the same manner as Example 6 with the exception of using caproicaldehyde as a carbonyl compound. Chemical yield and optical purity of the desired products are shown in Table 1.
TABLE 1 Optical Yield Yield purity4 R/S Example 2 1 (mol %) Solvent (%) ratio4/6 (ee %) configuration 1 5 DMSO 94 >99/— >99 S 2 5 DMSO 87 >99/— >99 S 3 5 DMSO 97 >99/— 99 S 4 5 DMSO 95 >99/— >99 S 5 20 DMSO 75 72/28 >99 S 6 10 MeCN 67 >99/— 98 R 7 20 MeCN 65 >99/— 98 R 8 10 MeCN 69 >99/— 98 R
Example 9
[0094] DMSO solution containing 1 mmol of the resulting products from Example 1 was directly cooled to 0° C., added 47.9 mg (0.3 mmol) CuSO 4 and 3.0 mL methanol, and stirred at 0° C. for 10 hours. The reaction mixture was added 20 mL cooled saline solution as aftertreatment, and extracted 3 times with 10 mL ethyl acetate. The extracted organic phase was all collected and washed with saline solution, filtered after drying with Na 2 SO 4 , and distilled the resulting filtrate with evaporator under reduced pressure. After the residue was purified with silica gel chromatography (developing solvent: ethyl acetate/hexane), corresponding α-hydroxyketone was obtained. The yield was 90%, and optical yield was 99% or more.
[0095] The invention is further described by the following numbered paragraphs:
[0096] 1. A process for producing an α-aminooxyketone compound wherein a carbonyl compound is reacted with a nitroso compound by using a catalyst containing a heterocyclic compound shown in the general formula (I) (wherein: X1, X2 and X3 independently represent nitrogen, carbon, oxygen or sulfur; Z represents a substituted or unsubstituted 5- to 10-membered ring).
[0097] 2. The process for producing an α-aminooxyketone compound according to paragraph 1, wherein the heterocyclic compound is a tetrazole derivative shown in the general formula (II) (wherein Z represents a substituted or unsubstituted 5- to 10-membered ring).
[0098] 3. The process for producing an α-aminooxyketone compound according to paragraph 2, wherein the tetrazole derivative is a compound shown in the general formula (III).
[0099] 4. The process for producing an α-aminooxyketone compound according to any one of paragraphs 1-3, wherein the nitroso compound is nitrosobenzene.
[0100] 5. The process for producing an α-aminooxyketone compound according to any one of paragraphs 1-4, wherein the carbonyl compound is a compound shown in the general formula (IV) (wherein R1 and R2 independently represent hydrogen, or a substituted or unsubstituted alkyl group, a substituted or unsubstituted alkenyl group, a substituted or unsubstituted alkoxy group, a substituted or unsubstituted amide group, or a substituted or unsubstituted aryl group; and R1 and R2 may bind to each other to form a ring).
[0101] 6. The process for producing an α-aminooxyketone compound according to paragraphs 5, wherein the α-aminooxyketone compound contains R asymmetric carbon, where R1 represents hydrogen in the general formula (IV).
[0102] 7. The process for producing an α-aminooxyketone compound according to paragraphs 5, wherein the α-aminooxyketone compound contains S asymmetric carbon; where R1 represents a substituted or unsubstituted alkyl group, a substituted or unsubstituted alkenyl group, a substituted or unsubstituted alkoxy group, a substituted or unsubstituted amide group, or a substituted or unsubstituted aryl group, and either one of these groups bind to R2 to form a ring in the general formula (IV).
[0103] 8. The process for producing an α-aminooxyketone compound according to any one of paragraphs 1-7, wherein a solvent containing dimethyl sulfoxide or methyl nitrile, or both of them is used.
[0104] 9. The process for producing an α-aminooxyketone compound according to any one of paragraphs 1-8, wherein reaction is performed at room temperature (20-30° C.).
[0105] 10. A process for producing an α-hydroxyketone compound wherein an α-aminooxyketone compound obtained from the process according to any one of paragraphs 1-9 is reacted in a solvent by using CuSO 4 as a catalyst.
[0106] 11. A catalyst for producing an α-aminooxyketone compound by which a carbonyl compound is reacted with a nitroso compound, wherein the catalyst contains a heterocyclic compound shown in the general formula (I) (wherein: X1, X2 and X3 independently represent nitrogen, carbon, oxygen or sulfur; Z represents a substituted or unsubstituted 5- to 10-membered ring).
[0107] 12. The catalyst for producing an α-aminooxyketone compound according to paragraph 11, wherein the heterocyclic compound is a tetrazole derivative shown in the general formula (II) (wherein Z represents a substituted or unsubstituted 5- to 10-membered ring).
[0108] 13. The catalyst for producing an α-aminooxyketone compound according to paragraph 12, wherein the tetrazole derivative is a compound shown in the general formula (III).
[0109] 14. The catalyst for producing an α-aminooxyketone compound according to any one of paragraphs 11-13, wherein the nitroso compound is nitrosobenzene.
[0110] 15. The catalyst for producing an α-aminooxyketone compound according to any one of paragraphs 11-14, wherein the carbonyl compound is a compound shown in the general formula (IV) (wherein R1 and R2 independently represent hydrogen, or a substituted or unsubstituted alkyl group, a substituted or unsubstituted alkenyl group, a substituted or unsubstituted alkoxy group, a substituted or unsubstituted amide group, or a substituted or unsubstituted aryl group; and R1 and R2 may bind to each other to form a ring).
[0111] 16. The catalyst for producing an α-aminooxyketone compound according to paragraph 15, wherein the α-aminooxyketone compound contains R asymmetric carbon, where R1 represents hydrogen in the general formula (IV).
[0112] 17. The catalyst for producing an α-aminooxyketone compound according to paragraph 15, wherein the α-aminooxyketone compound contains S asymmetric carbon, where R1 represents a substituted or unsubstituted alkyl group, a substituted or unsubstituted alkenyl group, a substituted or unsubstituted alkoxy group, a substituted or unsubstituted amide group, or a substituted or unsubstituted aryl group, or where either one of these groups bind to R2 to form a ring in the general formula (IV).
[0113] Having thus described in detail preferred embodiments of the present invention, it is to be understood that the invention defined by the above paragraphs is not to be limited to particular details set forth in the above description as many apparent variations thereof are possible without departing from the spirit or scope of the present invention.
|
The present invention provides a method for easily obtaining α-aminooxyketone compound which is a synthetic equivalent for monosaccharide and pentoses, and a equivalent of α-hydroxyketone compound that can be synthetic intermediates of various physiologically active materials, in high yield; to pave the way for the synthesis of monosaccharide and furthermore of oligosaccharide from the resulting α-hydroxyketone compound induced from α-aminooxyketone compound; and to open new possibilities for the synthesis of various sugar medicines such as anticancer agents, antithrombogenic agents, anti-viral agents, anti-HIV agents, inhibitors of cholesterol synthesis, verotoxin neutralizing agents. According to the invention, a carbonyl compound is allowed to react with a nitroso compound to produce an α-aminooxyketone compound using a catalyst containing a heterocyclic compound shown in the general formula (I) (wherein X1, X2 and X3 independently represent nitrogen, carbon, oxygen or sulfur; and Z represents a substituted or unsubstituted 5- to 10-membered ring).
| 2
|
FIELD OF THE INVENTION
This invention relates to an active material releasing preparation which gradually releases an active material, such as perfumes, growth regulating substances, pheromones, hormones, vitamines, glycosides, enzymes, aminoglucosides, pesticides, etc. More particularly, it relates to an active material releasing preparation for sustained release of an active material while controlling rapid deactivation of the active material or to an active material releasing preparation in which solubility of the active material is changed so as to permit its use in a solvent that has never been applied.
BACKGROUND OF THE INVENTION
Various attempts have been made to control deactivation of an active material to make the release slow or to change solubility of an active ingredient. For instance, it has been proposed that volatile active materials, such as perfumes, can be modified by adsorption onto a porous substance, conversion to a clathrate compound thereof, entrapping in gel, or the like technique. These techniques do not involve chemical reaction of the active material.
On the other hand, it is known to obtain controlled release of an active material or to change solubility of an active material through chemical modification. For example, there have been proposed a process in which amino groups or carboxyl groups of proteins, such as enzymes, are reacted with a modified polyethylene glycol having a specific structure as disclosed in Japanese Patent Application (OPI) No. 104323/84 (the term "OPI" as used herein means "unexamined published Japanese patent application") and Biochemical and Biophysical Research Communications, Vol. 121, 261-265 (1984) as to reaction of amino groups, and in Japanese Patent Publication No. 7649/83 as to reaction of carboxyl groups; and a process in which amino groups of proteins are reacted with a copolymer having an acid anhydride group, e.g., an olefin-maleic anhydride copolymer, as reported in Macromolecules as Drugs and as Carriers for Biologically Active Materials, 160-181, The New York Academy of Sciences (1985).
SUMMARY OF THE INVENTION
The inventors have conducted studies on controlled release of an active material from a system obtained by chemical reaction of an active material. As a result, it has now been found that a reaction product obtained by reacting an active material with a copolymer of maleic anhydride and a copolymerizable polyalkylene glycol ether is soluble in water and/or an organic solvent and capable of slowly releasing the active material upon hydrolysis.
The present invention relates to a controlled release preparation of an active material comprising a reaction product obtained by reacting (a) a copolymer consisting essentially of maleic anhydride and at least one polyalkylene glycol ether represented by formula (I): ##STR2## wherein B represents a residue of a compound having from 2 to 8 hydroxyl groups; R 1 represents an alkenyl group having from 2 to 5 carbon atoms; AO represents an oxyalkylene group having from 2 to 18 carbon atoms or a combination thereof which may be linked together in blocks or at random; R 2 represents a hydrocarbon group having from 1 to 24 carbon atoms; a represents a positive integer, b and c each represents 0 or a positive integer, and a+b+c=2 to 8; l≧0, m≧0, n≧0, and l+m+n=1 to 1000, and (b) an active material.
DETAILED DESCRIPTION OF THE INVENTION
In formula (I), alkenyl groups represented by R 1 include a vinyl group, an allyl group, a methallyl group, a 1,1-dimethyl-2-propenyl group, a 3-methyl-3-butenyl group, etc.
Compounds having 2 to 8 hydroxyl groups per molecule which provide the residue Z in formula (I) include polyhydric phenols such as catechol, resorcine, hydroquinone, and phloroglucine; polyhydric alcohols, such as ethylene glycol, propylene glycol, butylene glycol, dodecylene glycol, octadecylene glycol, neopentyl glycol, styrene glycol, glycerine, diglycerine, polyglycerine, trimethylolethane, trimethylolpropane, 1,3,5-pentanetriol, erythritol, pentaerythritol, dipentaerythritol, sorbitol, sorbitan, sorbide, a sorbitol-glycerine condensate, adonitol, arabitol, xylitol and mannitol; saccharides, such as xylose, arabinose, ribose, rhamnose, glucose, fructose, galactose, mannose, sorbose, cellobiose, maltose, isomaltose, trehalose, sucrose, raffinose, gentianose, and melezitose; and partial ethers or partial esters thereof.
Oxyalkylene groups represented by AO include an oxyethylene group, an oxypropylene group, an oxybutylene group, an oxytetramethylene group, an oxystyrene group, an oxydodecylene group, an oxytetradecylene group, an oxyhexadecylene group, an oxyoctadecylene group, etc.
Hydrocarbon groups represented by R 2 include a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, an isobutyl group, a tert-butyl group, an amyl group, an isoamyl group, a hexyl group, a heptyl group, a 2-ethylhexyl group, an octyl group, a nonyl group, a decyl group, an undecyl group, a dodecyl group, an isotridecyl group, a tetradecyl group, a hexadecyl group, an isohexadecyl group, an octadecyl group, an isooctadecyl group, an oleyl group, an octyldodecyl group, a dococyl group, a decyltetradecyl group, a benzyl group, a cresyl group, a butylphenyl group, a dibutylphenyl group, an octylphenyl group, a nonylphenyl group, a dodecylphenyl group, a dioctylphenyl group, a dinonylphenyl group, a styrenated phenyl group, etc. In formula (I) (AO) l , (AO) m , and (AO) n , respectively, may be the same or different.
The copolymer which can be used in the present invention can be prepared by copolymerizing maleic anhydride and the polyalkylene glycol ether represented by formula (I) and, if desired, other copolymerizable monomers in the presence of a radical polymerization catalyst, e.g., benzoyl peroxide, azobisisobutyronitrile, etc. The copolymerization may be carried out in a solvent such as toluene. In case of using a liquid polyalkylene glycol ether, the use of solvent may be eliminated.
Other monomers which may be used include vinyl monomers which are copolymerizable with maleic anhydride and the polyalkylene glycol ether of formula (I). Specific examples of the vinyl monomers are acrylic acid, methacrylic acid, itaconic acid, crotonic acid, maleic acid; salts of these acids with a monovalent or divalent metal, ammonium or an organic amine, esters of these acids with an alcohol having from 1 to 24 carbon atoms, or esters of these acids with a polyoxyalkylene glycol; aromatic vinyl compounds such as styrene and methylstyrene; vinyl halides such as vinyl chloride and vinylidene chloride; olefins such as isobutylene and diisobutylene; vinyl acetate, acrylonitrile, acrylamide, and the like.
Active materials which are reacted with the above-described copolymers include compounds having a hydroxyl group and compounds having an amino group.
Examples of the compounds having a hydroxyl group include perfumes such as linalool, geraniol, citronellol, eugenol, benzyl alcohol, phenethyl alcohol, and cinnamic alcohol; growth regulating substances such as n-decanol, p-menthane-3,8-diol, gibberellin, cytokinin, indol-3-ethanol, etc.; pheromones such as 9-tetradecene-1-ol, 6-nonene-1-ol, and 6-methyl-5-heptene-1-ol, etc.; hormones such as oestradiol, testosterone, hydroxytestosterone, and cortisone; vitamines such as vitamines A, B 6 and C; glycosides such as saponine, anthocyan; and the like.
Examples of the compounds having an amino group include various enzymes, such as hydrolases (e.g., amylase, protease, cellulase, hemicellulase, lipase, pectinase, lysozyme, hesperidinase, anthocyanase, aminoacylase, urease, invertase, melibiase, dextranase, peptidase, ribonuclease, lactase, etc.), oxidoreductases (e.g., glucose oxidase, uricase, catalase, lipoxygenase, cytochrome C, peroxidase, etc.), isomerases (e.g., glucose isomerase, etc.), transferases (e.g., cyclodextrin glucosyltransferase, transaminase, etc.), and eliminases (e.g., aspartase, hyaluronidase, chondroitinase, etc.); other peptides; aminoglucosides; and pesticides, such as 3,5-dichloroaniline, and 2,6-dichloro-4-nitroaniline.
The reaction product of the copolymer and the active material can easily be obtained by mixing them in the presence or absence of a solvent under heating.
In the maleic anhydride-polyalkylene glycol ether copolymer according to the present invention, the maleic acid unit exists in the form of an acid anhydride. This acid anhydride unit functions to chemically react with a hydroxyl group, an amino group, etc. of the active material to form an ester linkage, an amide linkage, etc., while the polyalkylene glycol ether unit determines the form of the controlled active material release preparation, i.e., whether it is solid or liquid, and also determines solubility of the preparation in water or organic solvents. In more detail, when a polyalkylene glycol ether having an oxyethylene group is used in a high proportion, the resulting preparation is water soluble. When a polyalkylene glycol ether containing no or a slight amount of an oxyethylene group is used, the resulting preparation is water insoluble. In particular, the polyalkylene glycol ether of formula (I) having two or more alkenyl groups represented by R 1 , which may be the same or different, provides a solid reaction product.
The controlled release preparation of the active material of this invention comprises a reaction product obtained by the chemical reaction between the maleic anhydride-polyalkylene glycol ether copolymer and the active material and releases the active material, slowly and continuously, upon being hydrolyzed. Further, solubility of the preparation in water or organic solvents can be determined by appropriately selecting solubility of the copolymer. Accordingly, the controlled release preparation of the active material of the invention makes it possible to markedly broaden the range of application of the active material.
The present invention is now explained in greater detail with reference to the preparation examples and the working examples, but it should be understood that the present invention is not deemed to be limited thereto.
PREPARATION EXAMPLE 1
______________________________________CH.sub.2 ═CHCH.sub.2 O(C.sub.3 H.sub.6 O).sub.5 (C.sub.2 H.sub.4O).sub.15 CH.sub.3 1022 g (1 mol)Maleic anhydride 103 g (1.05 mol)Benzoyl peroxide 12 g (0.05 mol)______________________________________
The above components were dissolved in 1 l of toluene. The solution was transferred to a fournecked flask equipped with a condenser, an inlet for nitrogen, a thermometer, and a stirrer. The solution was stirred at 80°±2° C. for 7 hours in a nitrogen atmosphere to effect polymerization. The toluene and the unreacted maleic anhydride were removed from the reaction mixture by distillation under reduced pressure to obtain 980 g of a copolymer. The resulting copolymer was designated as Copolymer 1. Copolymer 1 was a viscous liquid and had a saponification value of 99.9.
PREPARATION EXAMPLE 2
______________________________________CH.sub.2CHCH.sub.2 O(C.sub.2 H.sub.4 O).sub.20 CH.sub.2 CHCH.sub.2 96 g (0.1 mol) ##STR3## 1008 g (0.9 mol)Maleic anhydride 108 g (1.1 mol)Benzoyl peroxide 12 g (0.05 mol)______________________________________
The above components were subjected to polymerization reaction in the same manner as in Preparation Example 1. As the reaction proceeded, a polymer began to precipitate. After completion of the reaction, the reaction mixture was centrifuged to remove the toluene. The residual precipitate was washed successively with 300 ml of toluene and 500 ml of hexane and then vacuum dried at 60° C. for 10 hours to obtain 1010 g of a copolymer. The resulting copolymer, designated as Copolymer 2, had a saponification value of 103.
In the same way as for Copolymer 2, Copolymers 3 to 9 were prepared as shown in Table 1 below.
TABLE 1__________________________________________________________________________ MaleicCopolymer Polyalkylene Glycol Ether Andydride Other Comonomer SaponificationNo. (mol) (mol) (mol) Value__________________________________________________________________________1 CH.sub.2CHCH.sub.2 O(C.sub.3 H.sub.6 O).sub.5 (C.sub.2 H.sub.4 O).sub.15 CH.sub.3 1.0 1.0 -- 99.92 CH.sub.2CHCH.sub.2 O(C.sub.2 H.sub.4 O).sub.20 CH.sub.2 CHCH.sub.2 0.1 1.0 -- 103 ##STR4## 0.93 CH.sub.2CHO{(C.sub.4 H.sub.8 O).sub.2 (C.sub.2 H.sub.4 O).sub.10 }C.sub.4 H.sub.9 0.2 1.0 -- 118 CH.sub.2CHCH.sub.2 O(C.sub.2 H.sub.4 O).sub.20 CH.sub.3 0.84 CH.sub.2CHCH.sub.2 O(C.sub.2 H.sub.4 O).sub.200 CH.sub.2 CHCH.sub.2 0.1 1.0 styrene 1.0 197 CH.sub.2CHCH.sub.2 O(C.sub.2 H.sub.4 O).sub.20 CH.sub.3 0.8 ##STR5## 0.2 1.0 glycerin diallyl ether 0.05 212 ##STR6## 0.756 ##STR7## 0.97 1.0 -- 260 ##STR8## 0.037 CH.sub.2CHCH.sub.2 O(C.sub.2 H.sub.4 O).sub.10 CH.sub.3 0.98 1.0 pentaerythritol 236 diallyl ether 0.028 CH.sub.2CHCH.sub.2 O(C.sub.3 H.sub.6 O).sub.5 (C.sub.2 H.sub.4 O).sub.5 CH.sub.3 0.98 1.0 -- 202 C[CH.sub.2 O(C.sub.2 H.sub.4 O).sub.3 CH.sub.2 CHCH.sub.2 ].sub.4 0.029 CH.sub.2CHCH.sub.2 O(C.sub.2 H.sub.4 O).sub.10 CH.sub.3 0.95 1.0 hyxaglycerine diallyl 230 ether 0.05__________________________________________________________________________ Note: The oxyalkylene groups in the braces { } are linked at random.
EXAMPLE 1
In 300 ml of pyridine was dissolved 110 g of Copolymer 1, and 10 g of β-phenethyl alcohol (0.,41 equivalent to the saponification value of Copolymer 1) was added thereto, then refluxed for 4 hours to obtain 110 g of an ester of Copolymer 1 and β-phenethyl alcohol.
Similarly, each of Copolymers 2 to 9 was esterified using β-phenethyl alcohol in an amount of 0.41 equivalent to the saponification value of the corresponding copolymer.
In 20 g of a 50 wt % methanolic aqueous solution was dissolved 0.2 g of each of the resulting copolymer esters, and the solution was put in a petri dish of 10 cm diameter and allowed to stand in a thermostat at 50° C. for 24 hours. Then, the solution remaining in the petri dish was dissolved in 20 g of a 50 wt % methanol aqueous solution having dissolved therein 0.2 g of sodium hydroxide, then refluxed for 1 hour. The β-phenethyl alcohol (a) in the resulting solution was quantitatively determined by gas chromatography. Separately, 0.2 g of the copolymer ester was dissolved in 20 g of a 50 wt % methanol aqueous solution having 0.2 g of sodium hydroxide dissolved therein, followed by refluxed for 1 hour, and then the β-phenethyl alcohol (b) in the solution was quantitatively determined. The percentage of the residual active material, β-phenethyl alcohol, was calculated by dividing (a) by (b).
For comparison, the same procedure as the above was repeated but using 0.02 g of β-phenethyl alcohol to which 0.18 g of polyoxyethylene (10 mols) nonylphenyl ether or 0.18 g of polyacrylamide is added.
The results obtained are shown in Table 2 below. It can be seen from the Table that the active material-copolymer preparation according to the present invention exhibits excellent persistency of activity.
TABLE 2______________________________________ RetentionCopolymer (%) Remark______________________________________1 48.5 Invention2 51.3 "3 49.5 "4 50.0 "5 48.7 "6 51.5 "7 52.3 "8 51.6 "9 51.4 "Polyoxyethylene (10 mols) 3.5 Comparisonnonylphenyl etherPolyacrylamide 7.5 "______________________________________
EXAMPLE 2
In the same manner as in Example 1, and ester formed between each of Copolymers 1 to 9 and geraniol was prepared, and the percentage of the residual active material was determined. For comparison, a composition of geraniol and polyoxyethylene (20 mols) sorbitan monooleate or polyacrylamide was evaluated in the same manner. The results obtained are shown in Table 3 below. As is apparent from Table 3, the active material-copolymer preparation according to the present invention exhibits excellent persistency of activity.
TABLE 3______________________________________ RetentionCopolymer (%) Remark______________________________________1 39.7 Invention2 42.4 "3 40.6 "4 41.8 "5 39.6 "6 40.9 "7 41.4 "8 42.3 "9 41.7 "Polyoxyethylene (20 mols) 2.4 Comparisonnonylphenyl etherPolyacrylamide 5.8 "______________________________________
EXAMPLE 3
In 300 ml of pyridine was dissolved 50 g of Copolymer 8, and 18 g of 2,6-dichloro-4-nitroaniline was added to the solution. The solution was heated under reflux for 4 hours, followed by concentration to a half volume. To the concentrate was added 300 ml of n-hexane while cooling in order to form a precipitate. The precipitate was collected by filtration and dried to recover an amide of Copolymer 8 and 2,6-dichloro-4-nitroaniline.
Ten grams of the resulting amide was charged in a 500-ml flask, and 100 ml of a 20% ethanolic aqueous solution having 0.1 g of sodium hydroxide dissolved therein was added thereto. After the mixture was boiled for 30 minutes, the liquid portion was removed. Then, 100 ml of a fresh ethanolic aqueous solution having the same composition as the above was added thereto, the mixture boiled for 30 minutes, and the liquid removed. This operation was repeated additional four times to obtain five liquid fractions 1 to 5.
For comparison, the same procedure was repeated, except for replacing the amide of Copolymer 8 with 3 g of 2,6-dichloro-4-nitroaniline adsorbed onto 50 g of polystyrene for chromatography.
The residual 2,6-dichloro-4-nitroaniline in each liquid fraction was determined by ultraviolet spectroscopy, and its ratio (%) to the initial amount of 2.7-dichloro-4-nitroaniline was calculated. The results obtained are shown in Table 4. As can be seen from the results in Table 4, the controlled release preparation of active material according to the present invention exhibits excellent persistency of activity.
TABLE 4______________________________________ Residual Active MaterialLiquid Invention ComparisonFraction No. (%) (%)______________________________________1 25.0 91.02 17.5 8.83 13.4 0.24 11.6 05 9.5 0______________________________________
EXAMPLE 4
To 4 ml of a 0.2M borate buffer (pH 8.5) containing 20 mg of horseradish peroxidase was added 200 mg of Copolymer 3 and stired at 25° C. for 30 minutes. To the reaction mixture was added 100 ml of phosphate buffered saline (pH 7.0) cooled to 0° C., in order to stop the reaction. Any unreacted copolymer was removed from the reaction mixture by filtration through Diaflo Membrane A- 50T (produced by Ulvac Service Co., Ltd.), and the residue was dried to obtain 170 mg of a modified peroxidase.
The degree of modification of the resulting peroxidase was determined in accordance with the method described in Analytical Biochemistry, Vol. 14, 328-336 (1966). As a result, it was found that 60% of the total amino groups in the peroxidase had been modified with Copolymer 3.
Further, the resulting modified peroxidase was quite soluble not only in water but even in benzene, toluene, chloroform, and trichloroethane in each of which unmodified peroxidase is insoluble.
Activity of the modified peroxidase in water and benzene was determined by using hydrogen peroxide and o-phenylenediamine as substrates, and the results being shown in Table 5, in which the activity of unmodified peroxidase in water was taken as a standard (100).
TABLE 5______________________________________ Relative Activity of PeroxidaseActive Material in Water in Benzene______________________________________Unmodified peroxidase 100 0Modified peroxidase 70 45______________________________________
It can be seen that the peroxidase preparation modified with the copolymer according to the present invention has solubility in each water and benzene and exhibits activity therein, indicating that the modification with the copolymer greatly improves properties of the unmodified enzyme.
While the invention has been described with reference to the specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the invention.
|
A controlled release preparation of an active material comprising a reaction product obtained by reacting (a) a copolymer consisting essentially of maleic anhydride and at least one polyalkylene glycol ether represented by formula (I): ##STR1## wherein B represents a residue of a compound having from 2 to 8 hydroxyl groups; R 1 represents an alkenyl group having from 2 to 5 carbon atoms; AO represents an oxyalkylene group having from 2 to 18 carbon atoms or a combination thereof which may be linked together in blocks or at random; R 2 represents a hydrocarbon group having from 1 to 24 carbon atoms; a represents a positive integer, b and c each represents 0 or a positive integer, and a+b+c=2 to 8; l≧0, m≧0, n≧0, and e+m+n=1 to 1000; and (b) an active material. The preparation is soluble both in water and in an organic solvent and exhibits activity for a prolonged period of time.
| 0
|
TECHNICAL FIELD
[0001] The present invention relates to a helmet. The helmet is primarily intended as a cycling helmet to provide head protection in the event of a cycling accident. However, it also finds application at any time when head protection is needed, for example ice skating, roller skating, skateboarding, caving, climbing, e.g. indoor climbing or mountain climbing, skiing, baseball, American football, ice hockey and head protection at work or when working at heights, e.g. in the construction industry.
Technical Background
[0002] Most bicycle helmets available have (a) a thin outer layer, which may be made, for example, out of polypropylene that is able to absorb initial peak impact forces, (b) a shell within the thin layer and composed of expanded polystyrene that absorbs both initial and subsequent impact forces and (c) padding within the expanded polystyrene shell both to provide comfort to the user and to adjust the shape of the internal cavity within the shell for different shaped and sized heads.
[0003] In general, a cycling helmet should fit closely over the cyclist's head so that any impact force is spread over as wide an area of the head as possible. The impact forces are absorbed by the thin polypropylene layer and the expanded polystyrene shell. In addition, some helmets fracture under impact, which also absorbs energy and reduces the energy transferred to the head.
[0004] Cycling helmets are often treated roughly and such rough treatment can impair the effectiveness of the helmet. However, there is often no outward visible sign of such impairment.
[0005] As mentioned, cycling helmets and helmets for other uses are generally made of synthetic plastics. Although it would be desirable to make the helmets at least partly out of natural material that could be recycled, it is counter-intuitive to use such materials in applications requiring the resistance of such strong forces.
[0006] Helmets should generally be light to be acceptable to wearers. Sports protective helmets should also be well ventilated so that sweat does not accumulate around the user's head and so that body heat generated due to the exertion of cycling or other sport can be displaced through the head.
[0007] Although the materials used for making the cycling helmets are not particularly expensive, it would advantageous to use cheaper materials, if possible.
DISCLOSURE OF THE INVENTION
[0008] The present invention uses the strength of flutes or hollow tubes, e.g. hollow cylinders, hollow cells and hollow frusto-cones, in a helmet to resist impact and also to crumple on impact, such crumpling absorbing significant energy which is thereby not transferred to the user's head.
[0009] In one embodiment, the flutes may be those present in corrugated material, e.g. corrugated fibre board can be used to absorb impact energy. In this case, an impact resistant shell of the helmet of the present invention can be made of such corrugated material, which may be in the form of intersecting arc shaped ribs overlying a head cavity of the helmet and extending outwards, optionally radially outwards, from the cavity. In this case, the arc-shaped ribs may be arranged to extend generally axially (front to back) and laterally (side to side). The arrangement of the flutes may be such that at the front, top and sides of the helmet, at least some of the flutes extend radially outwards from the cavity (e.g. forwardly and optionally also upwardly at the front and sideways and optionally also upwardly at the respective sides). The positioning of the flutes can be brought about by suitably locating the arc-shaped ribs and by selecting the direction of the flutes within those ribs.
[0010] However, sufficient impact resistance can be achieved using the above intersecting arc-shaped ribs but without the use of flutes. The arc-shaped ribs may each be made of one or more sheets. When two or more such sheets are present in a single rib, they will generally lie parallel to each other and may be joined together in a spaced apart relationship. When each rib has three or more sheets, each spaced may be apart from, and connected to, its neighbouring sheet. The material joining the sheets together and maintaining the sheets in a parallel spaced-apart configuration may be composed of cells. Such cells may be formed by a corrugated sheet, as discussed above, or by cells having walls and or axes that extend generally orthogonal to the planes of the sheets. For example, the sheets may be connected by an array of honeycomb cells where the individual cells are hexagonal, square or rectangle in cross-section. The honeycomb cells, which are connected to the sheets overlying them, increase the resistance to flexing of the ribs and thereby make them stiffer. They also maintain the sheets in a parallel spaced-apart configuration, which means that the sheets themselves can absorb greater impact forces than if the sheets were connected together by flutes that have lower ability to maintain the sheets in parallel.
[0011] The sheets are preferably semi-rigid, where the term “semi-rigid” material is used in the present specification in relation to a sheet to denote a material that will remain in a planar configuration but can be crumpled by a substantial force applied within the plane of the sheet. The force it can withstand before crumpling will depend on the nature of the ribs, and the arrangement of the sheets within each rib and the number and arrangement of the ribs within a helmet. The semi-rigid material should be such that the helmet overall can withstand the force required for the application concerned and the various standard that apply to these helmets. Typical materials include cardboard and stiff but flexible plastics.
[0012] The arc-shaped ribs may together form an intersecting array or lattice, with ribs extending axially between the front and the back of the head cavity and laterally between the two opposed sides of the head cavity; they can also extend diagonally. Naturally, the ribs will intersect in such an arrangement and, at the intersection point, the ribs preferably form crossed halved joints, which are made by forming a groove in the lower part of one rib and another groove in the upper part of the other rib so that the two ribs can be slotted into each other without severing either rib completely. The joint can be an interference fit between the two ribs or adhesive can be used to cement the two ribs at the joint. Alternatively, some of the grooves in the ribs may be larger than is necessary to accommodate the intersecting ribs, partly to make manufacture easier and partly to allow a limited amount of movement or play between the ribs, which helps absorb energy in a crash.
[0013] As mentioned above, when corrugations are provided, the corrugations provide the impact strength along the direction of the flutes. Therefore, at the centre of each arc-shaped rib, it is preferred that the flutes extend either parallel to the edge of the rib or at right angles to the edge of the ribs. The latter arrangement absorbs impact forces exerted on the centre of the rib at a right angle to the edge. The former arrangement provides strength at the ends of the rib rather than in the centre and can absorb impact forces exerted at right angles of the ends of the ribs. The flutes in adjacent ribs need not be parallel to each other and indeed it may be advantageous if that is not the case so that adjacent ribs can absorb impact forces applied from different directions. Thus, for example, the flutes of one arc-shaped rib can extend at right angles to the flutes on the adjacent rib.
[0014] The helmet may include a rim encircling the head cavity that may also be made of the same material as the ribs; if made of corrugated material containing flutes, the flutes preferably extend from the front to the back of the head cavity so as to absorb front impact forces.
[0015] Although the corrugated material may be made of plastic, it is preferred to use fibre board (e.g. corrugated cardboard) since the materials for making fibre board are natural and the helmet can be recycled after use. Corrugated fibreboard can be obtained commercially in a large number of different qualities but all qualities are relatively cheap. Honeycombed fibreboard can be made by forming a layer of honeycomb cells and adhering to this layer to the face sheets.
[0016] In a second embodiment, instead of flutes in corrugated boards, the strength of the impact resisting shell may be provided by an array of hollow tubes, e.g. cylinders or frusto-cones, typically made from sheet material, especially paper and cardboard. The ends of the cones or cylinders should point outwardly from the head cavity so that they are able to absorb impact and also crumple under that impact, thereby absorbing energy and reducing the force that is transmitted to the user's head in the event of an accident.
[0017] Cylinders, when packed together in a dome-shaped array, may not present a smooth external surface or a smooth inner surface that outlines the head cavity. In order to address this, it is possible to machine the external or internal surfaces to provide such a smooth domed shape. However, it is not necessary to produce a smooth dome shape to the outside surface.
[0018] Furthermore, an uneven dome shape within the cavity of the impact resistant shell can be tolerated if an inner shell is provided that has a matching outer surface; the inner shell may then provide a smooth domed inner surface. The role of the inner shell will be discussed below. A domed shape can be achieved more easily by using hollow frusto-cones instead of cylinders with the larger end face of the cones pointing outwardly while the smaller faces point inwardly.
[0019] The tubes (hollow frusto-cones or cylinders) can be held in a bundle or array with each tube being in contact with a neighbouring tube. A mixture of cones and cylinders can be used. Alternatively, the tubes can be held in position by a matrix material in which they are captured within the matrix material.
[0020] Hollow cylinders can be made by winding strips of flexible sheet material into a closed shape and retaining the closed shape, for example, by adhesive. The strips used to form such tubes will generally extend helically around the axis of the tube. The manufacture of hollow cylinders is widely practiced in the manufacture of the cores of paper rolls. Frusto-conical shapes can also be made by a similar winding technique.
[0021] The greater the number of tubes (cylinders or frusto-cones) used to make up the impact resistant shell, the greater is the impact strength of the shell. Therefore, the outside diameter of the cylinders or frusto-cones will generally not exceed 4 cm and, for example, will generally not exceed 3 cm. On the other hand, a greater number of tubes will increase the complexity of manufacturing the shell and accordingly the outside diameter of the cylinder should preferably be at least 0.5 cm, e.g. 1 cm. In the case of frusto-cones, the mean diameter of the cones should generally lie in the above ranges.
[0022] The tubes (cylinders or frusto-cones) should crumple on impact. In order to control the degree of crumpling, a line of weakness may be provided in the walls of the hollow tubes along which they can collapse. The lines of weakness are preferably helical in shape so that the crumpling will occur within the boundary of the tubes and the lines of weakness may be provided in the form of holes or openings spaced along the line of weakness.
[0023] As is the case in the first embodiment, cheap material used to make the tubes, which material may be plastic but preferably is paper or cardboard. Cork could also be used.
[0024] In fact, the distinction between the first embodiments and the second embodiment is not clear-cut since the above-described arrangement of intersecting ribs can also be seen as falling within the scope of the second embodiment since the intersecting ribs form an array of cells that are tubes having a 4 -sided cross-section.
[0025] In order to waterproof the helmet of the present invention, at least the outside edge regions of the crushable bodies may be covered with a waterproofing material, although optionally an outer shell may be provided that will provide such waterproofing, in which case it is preferred that ventilation openings are provided in the outer shell. The waterproofing material/outer shell is preferably made of a material having a stiffness coefficient higher than that of the material used for forming the crushable bodies so that it is less elastic. In this way, it can assist in resisting the peak force exerted on impact. The preferred materials are polypropylene, acrylic or ABS.
[0026] The helmet may include an inner shell, which may perform a number of functions. Firstly, it can add extra impact resistance to the impact resistant shell of the present invention, for example it could be made of moulded expanded polystyrene. Secondly, it can be used to tailor the helmets to the size of a particular user's head. This can be achieved by making the cavity within the impact resistant shell of the present invention in one standard size and providing an inner shell with an outside that matches the size of the impact resistant shell cavity and an inside that has a head cavity that is matched to the size of a user's head; thus a number of inner shells could be manufactured having variously sized internal cavities to fit various head sizes and shapes. Padding may also be provided for additional comfort and/or ensuring that a tight or snug fit is maintained between the user's head and the helmet, e.g. using insertable padding that can be adhered to the inside surface of the inner shell cavity, as is widely practiced with cycling helmets currently available.
[0027] A further use of the inner shell is to dissipate the impact forces that are transmitted to the inner ends of the crushable bodies, i.e. the ends lying in the head cavity, so they are not transmitted directly on the user's head. In addition, the shape of the cavity within the impact resistant shell may not be uniformly smooth and the outer surface of the inner shell can, as discussed above, be shaped to match the uneven surface of the cavity in the impact resistant shell. This avoids having to shape the head cavity of the impact resistant shell in an expensive manner. The inner shell may be permanently attached to the impact resistant shell of the present invention or may be releasable attached, e.g. using loop-and-hook fastenings, e.g. Velcro®, so that the impact resistant shell of the present invention is replaceable if dented.
[0028] Instead of a continuous inner shell, a series of pads may be used that lie between the array of crushable bodies and the user's head. Such pads may be made of relatively rigid foam material to provide a cushion between the crushable bodies and the user's head. The series of pads may be viewed as a discontinuous inner shell.
[0029] Generally, because the outside surface of the impact resistant shell (even with the waterproofing layer or outer shell), is made up of an array of crushable bodies rather than a uniform smooth surface, it will be more evident when the impact resistant shell has been damaged and therefore needs replacing.
[0030] The impact resistant shell can be recycled, if made of fibre based materials, such as paper or cardboard. The strength of the crushable bodies will depend on the nature and thickness of the sheet material used and so it is possible to adjust the impact strength and crumpling properties of the helmet by the choice of the sheet material used. in the present specification, the term “outer” shell does not necessarily mean that it forms the outermost layer of the helmet (although it can) and likewise the term “inner” shell does not necessarily mean that it forms the innermost layer of the helmet (although again it can). However, the outer shell will always lie outside the impact resistant shell and any inner shell in the helmet will always lie inside the impact resistant shell.
[0031] According to a further aspect of the present invention, there is provided a head protecting helmet comprising a shock indicator that gives it an indication when the helmet has been subject to a shock in excess of a threshold value, thereby indicating that the helmet or at least the shock absorbing part of the helmet should be replaced. Often, for convenience, the magnitude of a shock, which is a force exerted as a result of acceleration or deceleration, is stated as a multiple of the acceleration caused by earth's gravity, which is indicated by the symbol “G”. During a bicycle accident, the helmet can suffer shocks of 150 G and after any shock of 150 G should preferably be replaced.
[0032] The accelerometer contains at least five tubes or flasks each containing a viscous coloured liquid held in a chamber of the flask by a wall having a capillary bore extending through it that normally retains the liquid within the chamber as a result of the surface tension of the liquid and the small size of the bore. However, if a sufficient force is exerted on the liquid due to shocks, the liquid passes through the capillary into a further chamber; the presence of the coloured liquid in the further chamber indicates that the accelerometer has suffered a shock in excess of a threshold value. The at least five tubes or flasks communicate with a common further chamber and so the present of the coloured liquid in the common further chamber indicates that the helmet needs replacing. Tubes or flasks of the above type are already known and sold under the trademark “Shockwatch”. The viscosity of the liquid and the size of the capillary bore are preferably designed to allow the liquid to pass into the common chamber when subjected to a threshold shock that is selected from the range of 75-100 G.
[0033] We have found that at least five such tubes or flasks are needed to ensure that shock exerted in any direction on the helmet is captured and triggers the release of liquid into the common chamber and the use of a larger number is preferred, e.g. six, eight or more.
[0034] The common chamber may be located behind a magnified lens, which could be clear or diffusing, thereby making it easier to detect the triggering of accelerometer.
BRIEF DESCRIPTION OF DRAWINGS
[0035] There will now be described, by way of example only, several embodiments of the present invention by reference to the accompanying drawings in which:
[0036] FIG. 1 shows part of a helmet, that is to say an impact resistant shell in accordance with the present invention, viewed from the front and one side;
[0037] FIG. 2 shows the helmet of FIG. 1 viewed from below;
[0038] FIG. 3 is an end view of corrugated fibre board that may be used in the helmet of FIGS. 1 and 2 ;
[0039] FIG. 4 is a partly cutaway view of part of an arc-shaped rib made of fibre board having a honeycomb core that may be used in the helmet of FIGS. 1 and 2 ;
[0040] FIG. 5 shows the joint between two arc-shaped ribs used in the helmet of FIGS. 1 and 2 .
[0041] FIG. 6 is a schematic view of a helmet in accordance with the present invention using the shell shown in FIGS. 1 and 2 ;
[0042] FIGS. 7 and 8 show, schematically, an alternative arrangement to the impact resistant shell of FIGS. 1 and 2 ; and
[0043] FIGS. 9 a and 9 b shows schematically a shock indicator for use as a helmet.
DETAILED DESCRIPTION
[0044] The helmet of the present invention includes an impact resistant shell that is able to absorb some of the forces exerted on a helmet during a collision with another object, which may be the road, a pavement, a pedestrian or another vehicle. As mentioned above, the present invention is not limited to a cycling helmet but cycling will be used to exemplify the diverse applications for which the helmet may be used, some of which are set out above.
[0045] Referring initially to FIGS. 1 and 2 , which show the shell from one side and from below, respectively, the impact resistant shell 10 of the helmet includes a rim 12 made of a solid fibre board. The rim may be made in a single piece or in multiple pieces (as shown in FIGS. 1 and 2 ) that are joined together at connection 13 , which is most clearly shown in FIG. 2 . The joint 13 is a simple tongue-and-groove joint that includes a tongue 13 a on one piece of the rim that slots into a groove 13 b cut into the end of a second piece of the rim.
[0046] The rest of the impact resistant shell 10 is made up (a) of series of axial ribs 14 extending between the front 18 and the back 19 of the helmet and (b) a series of lateral ribs 16 extending between the two sides 20 of the helmet. As can be seen, the ribs are arranged in planes that extend radially outwards from the helmet and form an intersecting lattice of shock absorbing ribs; the lattice can be seen as an array of 4-sided shock-absorbing cells 23 . The axial ribs 1 of FIGS. 1 and 2 come together at the front 18 and the rear 1 of the helmet. Likewise, the lateral ribs 16 come together at the two sides 20 of the helmet. The ends of the ribs 14 , 16 slot into grooves 21 in the rim 12 . They may be held in the grooves 21 by adhesive.
[0047] The ribs 14 , 16 are arc shaped and the insides of the ribs forms a head cavity 30 . As is clear from FIGS. 1 and 2 , the ribs 14 , 16 intersect with each other. The joints at these intersecting points are shown in an exploded view in FIG. 5 . The axial ribs 14 have a groove 34 cut in the concave side of the rib while the lateral ribs 14 have a groove 32 cut in their convex faces. The grooves 32 , 34 can then be slotted into each other together to form a halved cross joint, which means that neither of the ribs 14 , 16 is cut completely through in order to provide the intersection. The grooves in the ribs 14 , 16 can extend radially from the centre of the cavity 30 . In FIG. 5 , the grooves 32 , 34 are shown to extend at right angles to the plane of the respective ribs but, as can be seen in FIG. 1 , the groove may extend in a non-orthogonal direction to the plane of the ribs that forming an intersection. The sizes of the grooves 32 , 34 should accommodate the other rib and the ribs may be held in place either by friction or by adhesive or by a mechanical element. As can be seen in FIG. 1 , some of the grooves 34 in the ribs 14 (as indicated by the reference number 34 a in FIG. 1 ) are larger than necessary to accommodate the corresponding lateral ribs 16 and this provides some play between the ribs which can therefore absorb more impact energy in the case of an accident. Furthermore, it assists in assembling the shell 10 .
[0048] The ribs 14 , 16 may be made of corrugated fibre board, as shown in FIG. 3 . Corrugated fibreboard includes at least one undulating section 28 sandwiched between flat fibre board layers 31 to form a series of flutes 29 . It possible to build up a number of such layers in a unitary corrugated fibre board ( FIG. 3 includes two such undulating sections). The thickness of the material forming the undulations 28 and the thickness of the flat board 1 should be chosen to give the degree of shock resistance and crumpling need to absorb the type of forces exerted during a collision.
[0049] Alternatively, the ribs can be made from honeycomb fibreboard, which is shown in FIG. 4 and has a pair of fibreboard face sheets 31 ; only one face sheets is shown in FIG. 4 and that face sheet is shown partly cut away so that the internal honeycomb array 33 is visible. The honeycomb connects together the face sheets 31 and may be made of plastic or paper or cardboard. It is glued to the face sheets 31 in a known manner. Again, it possible to build up a number of sheets and honeycomb layers in a unitary corrugated fibre board so that three or more sheets 31 are included in each rib, each adjacent pair of sheets sandwiching between them a honeycomb layer.
[0050] Turning back to FIGS. 1 and 2 and dealing with the case in which the ribs are made of corrugated fibreboard, the flutes 29 in the ribs may extend in horizontal, vertical, axial or lateral directions or diagonally within the helmet. The flutes in alternate lateral ribs 1 extend horizontally (i.e. in the direction between the two sides of the helmet) and such flutes resist especially lateral forces on the helmet. The flutes in the other lateral ribs 16 extend vertically and such flutes resist vertically acting forces. Likewise in some of the axial ribs 14 , the flutes extend horizontally which are resistant to forces impacting on the front or rear of the helmet while the flutes on the other ribs extend vertically and such flutes resist vertically acting forces. Generally, alternate ribs should have vertically-extending flutes and the remaining ribs should have horizontally-extending flutes, although the two central axial ribs 14 may have vertically extending ribs to resist forces exerted down onto the crown of the helmet.
[0051] When the ribs are made of the honeycomb material shown in FIG. 4 , the honeycomb cells will extend at right angles to the plane of the ribs.
[0052] The impact resistant shell shown in FIGS. 1 and 2 can absorb impact forces from any direction and can crumple as a result, thereby absorbing the energy of the impact and protecting the user's head.
[0053] In order to provide waterproofing to the fibre board, an outer shell or layer 50 (see FIG. 6 ) can overlay the shell 10 shown in FIGS. 1 and 2 and which can be fastened to the shell 10 , either permanently or temporary. The outer shell 50 should be provided with ventilation holes (not shown) that preferably line up with the spaces between the ribs 14 , 16 of the shell 10 . In addition, the cardboard used to make the shell 10 may be waterproof by the application of a waterproofing or water resistance layer (not shown).
[0054] The outer shell 50 may be made of acrylic material but it could also be made of other materials for example, polypropylene or ABS having a stiffness coefficient higher than that of the material used to make the impact resistant shell 10 and so absorbs part of the initial shock waves when an impact occurs. Slots 52 may he provided in the outer shell in order to attach straps (not shown) that can be secured under the user's chin to hold the helmet on the user's head
[0055] An inner shell 55 may be provided between the user's head and the cavity 30 within the impact resistant shell 10 in order to provide comfort to the user, to dissipate forces being transmitted through the edges of the ribs 14 , 16 directly to the user's head and to ensure that the helmet fits snugly. The inner shell may be made of padding, for example a layer of foam and or woven or non-woven fabric.
[0056] As is evident from the discussion above, the impact resistant shell 10 shown in FIGS. 1 and 2 , when made with the ribs of corrugated fibreboard, provides strength and impact resistance by means of the flutes within corrugated material. In addition impact strength is provided by holding the ribs in a fixed array of 4-sided cells 23 , each cell having an axis that extends away from the inner cavity 30 of the helmet and generally radially outward from the cavity. In the case of the ribs being made of the honeycomb material shown in FIG. 4 , the strength of the helmet will mostly be provided by this array of 4-sided cells, with the honeycomb pattern within the ribs resisting the collapse of the ribs and thereby maintaining the face sheets 31 in a space-apart parallel configuration, which increases the impact resistance of the individual ribs. In a variant of the cellular structure just described, the shell 10 may be made of an array of cylindrical tubes (see FIGS. 7 and 8 ) that are arranged in a dome shape and the under surface (not shown) forms a head cavity. The tubes 100 are collected in array with the inner ends of the tubes lying at different elevations in order to provide the shell with a hollow dome-shape. The axis of the various tubes shown in FIG. 9 all extend vertically and are intended to resist vertical forces. However, they can be embedded in a matrix so that they extend in different directions from the head in order to provide protection against forces from different directions.
[0057] The tubes, instead of being cylindrical, may be frustoconical, which has the advantage that, when the tubes are gathered together with the larger faces φx (see FIG. 8 ) pointing outwardly and the smaller faces φy pointing inwardly, the axes of the frusto cones point in different radial directions.
[0058] The tubes 100 are hollow and are generally made of fibre board such as paper or cardboard. Tubes made of this configuration can be incredibly strong and can transmit an impact force directly to the user's head without absorbing it. In order to provide some measure of impact absorption, a crumple zone may be introduced in the side walls of the tubes. So that the tubes crumple within their own diameter, it is preferred that the crumple zone is helical in shape and may be formed, as can be seen in FIG. 8 , by helically arranged holes 102 .
[0059] The tubes 100 formed into an impact resistant shell may be incorporated into a helmet with an outer shell 50 and padding 55 (see FIG. 6 ).
[0060] The outside and inside surfaces of an impact resistant shell formed from an array of tubes 100 may be sanded to provide the hollow dome shape.
[0061] Turning finally to FIGS. 9 a and 9 b, an arrangement is shown that can detect when a helmet has been subject to impact forces (or shock) exceeding a threshold, indicating that the helmet should be replaced or at least the impact resistant shell 10 should be replaced. As shown in FIG. 9 a, which shows the whole shock indicator; the indicator includes a central chamber 124 having a number of shock indicator flasks 120 spaced around it and preferably evenly spaced around it. FIG. 9 b, is a schematic drawing showing one of the flasks 120 and part of the central chamber 124 . Each flask includes a space 122 that is filled with coloured liquid that communicates with the central chamber 124 via a capillary bore 128 . The common chamber 124 is initially empty. Because of the size of the capillary bore 128 and the viscosity of the liquid, the liquid is generally retained within the space 122 . However, if a particular flask is subject to an acceleration or deceleration (in the case of the orientation shown in FIG. 9 a in the vertical direction), the coloured liquid can be forced through the capillary bore into the previously empty common chamber 124 . The presence of the coloured liquid within the chamber 124 indicates that the flask has been subject to excessive shock and that the helmet therefore needs replacing. The liquid may be such that it adheres to the walls in the common chamber 124 thereby clearly showing that one of the flasks 120 has been subject to an excessive shock. The indicator of FIGS. 9 a and 9 b can be incorporated into a holder that fits into a cavity within the helmet (not shown) and is held within that cavity by latches (again not shown). The indicator 120 can be small (of the order of a few centimetres) and so it can easily be accommodated in a relatively small cavity within a helmet. The common chamber 124 can be smaller than shown. A transparent or translucent lens (not shown) may be provided on the outside of the helmet to view the common indicator chamber 124 ; the magnification makes it easier to see whether or not liquid is located within the chamber 124 .
|
The present invention provides a head protection helmet comprising an impact resistant shell comprising:
a cavity for accommodating a user's head and an array of crushable bodies having a hollow closed configuration, e.g. flutes in corrugated material 14,16, the crushable bodies each having an axis that extends outwardly from the cavity to absorb impact forces exerted along the direction of the axis.
| 0
|
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation-in-part application of an application entitled "APPARATUS AND METHOD FOR COLLECTING, ANALYZING AND PRESENTING GEOGRAPHICAL INFORMATION", filed Oct. 22, 1996 and assigned Ser. No. 08/735,336, now U.S. Pat. No. 5,652,717 issued Jul. 29, 1997, which is a continuation of application Ser. No. 08/285,830, filed Aug. 4, 1994, now abandoned, and describing an invention of the present inventors.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the collection, integration, manipulation, modeling, and presentation of various local, regional, and/or global data and, more particularly, to acquisition and presentation of data relevant to an emergency incident requiring expeditious resolution to save lives and property.
2. Description of Related Art
Data acquisition and ingestion in support of an emergency event is normally performed manually and updated on white boards at a command center; although computers may be used to provide relational database information, such as names and addresses of affected citizens (who may need evacuation, for instance), there is no automatic acquisition of relevant and needed data. Multiple sources of relevant and needed data are neither combined nor integrated to provide robust information for use in resolving the incident. The command center is usually established at a specific location with all decisions made being based on the integration of data there present. The command center may be a commercial vehicle, such as a van or recreational vehicle specially equipped with desks, seating, computers, maps, white boards, phone lines, cellular phones, rest and sleeping areas, etc. Personnel to staff the command center are dispatched with the vehicle or otherwise to the specific location of the command center. To support such an operation, tremendous centralization of human and technical resources are necessary.
SUMMARY OF THE INVENTION
The present invention is directed to an advanced remote data sensing capability coupled with an emergency incident support system which can access remote sensed data to automatically acquire event related data in real time. The data may be processed for immediate presentation or stored for later use. The system includes the capability for simulating a variety of outcomes based upon the development of the emergency incident and attendant dynamic factors. Risks to public safety and attendant costs can be balanced against a variety of projected outcomes. Furthermore, the current situation can be presented as an image using real time data or other renderings on any of a plurality of presentation screens. Three-dimensional imagery can be portrayed on a further screen to represent a predicted outcome based on each of a variety of simulated event scenarios. The ability to move in real time within a three-dimensional environment and to view each of the different incident scenarios provides an extremely realistic presentation to each decisionmaker at the command center. Further imagery may be provided to present a two-dimensional map of the area involved with a zoom capability to permit regional or detailed views on command. Various local regional and global data sources permit acquisition on command of accurate data relevant to each query made that will enhance and clarify presentation of the factual situation to each decisionmaker. The tremendous amount of real time data available coupled with the capability for developing simulated scenarios will simplify the decisions that must be made to resolve complex inter-related problems attendant an emergency incident and thereby mitigate public risk.
It is therefore a primary object of the present invention to provide a method for making available to a command center during an emergency incident real time data and capability for simulating various scenarios based upon such data to make complex decisions with minimal public risk.
Another object of the present invention is to provide a method for assisting a command center to resolve an emergency incident.
Still another object of the present invention is to provide a method for making available real time data from a multiplicity of sources at a command center addressing resolution of an emergency incident.
Yet another object of the present invention is to provide a method for assisting the decisionmaking process at a command center addressing an emergency incident with the capability for simulating scenarios based upon potential decisions to be made.
A further object of the present invention is to provide a method for manipulating real time data attendant an emergency incident to assist decisionmakers at a command center in making each of a plurality of decisions to minimize the public risk.
A still further object of the present invention is to provide a method for presenting forecastable effects of each of a plurality of decisions that may be made at a command center handling an emergency incident to assist in the making of complex decisions to resolve the incident.
A yet further object of the present invention is to provide a method for expeditiously and effectively resolving an emergency incident with minimal loss of life and property.
These and other objects of the present invention will become apparent to those skilled in the art as the description thereof proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described with greater specificity and clarity with reference to the following drawings, in which:
FIG. 1 is a block diagram schematically representing the information gathering and routing system;
FIG. 2 is a block diagram depicting subsystems of the system shown in FIG. 1;
FIG. 3 is a block diagram illustrating an information center;
FIG. 4 illustrates a block diagram of the process for acquiring data, simulating scenarios and presenting images of an emergency incident resulting from the scenarios proposed; and
FIG. 5 illustrates a representative setting at a command center for reviewing, discussing, and approving each decision to be made to resolve an emergency incident.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown a block diagram schematically illustrating an enhanced geographical information system 10. In particular, it illustrates the gathering of the information to be processed and the flow of the information after the gathering, including the processing and distribution of the information to ultimate users. FIG. 2 illustrates some of the hardware and software modules embodied in and broadly shown in FIG. 1. Information in any of various formats may be received by a data reception ground station 20 from several different sources. These sources may include an earth circling satellite 12, an aircraft 14, and a helicopter 16. The helicopter represents a local aircraft or an earth bound fixed sensor, such as a sensor atop a mountain or a tall building, etc., which gathers essentially local information. Aircraft 14 may be a type of reconnaissance aircraft that may cover a relatively large area for data gathering purposes. For example, aircraft 14 may provide multispectral radar, and lidar information, infrared data, photographs, and/or other information and helicopter 16 may provide primarily photographic and video information of a local area or some part or parts thereof. Satellite 12 may provide multispectral radar data, radar data, photographic information, infrared data, lidar data, sidar data and the like. There are many kinds or sources of data that are now available, and more types of sources of data will be available in the future, which are representatively depicted by satellite 12, aircraft 14, and helicopter 16. With contemporary technology, data from any of these sources may be transmitted to one or more earth stations 20.
With respect to terminology, it will be noted that multispectral data or information is generally considered as passive systems for deriving information. Radar, lidar, and sidar are typically considered active systems for deriving information from a transmitted signal reflected by an object of interest and received at a receiving station. Global remote sensed information/data, including global positioning system (GPS) and global climate change models, may be received by ground station 20. A block 18 represents the source(s) for such information/data.
The information/data gathered is transmitted from ground station 20 through appropriate transmission elements 22, such as wireless, fiberoptics, or cable elements to a central location 40. The central location includes the software and hardware necessary for processing the received information incorporated in three primary systems. These primary systems are an acquisition system 50, an operations system 60, and a vision system 70. The acquisition system includes an interface module 52 for receiving information from an Internet and a NREN station 30 through transmission line 32 and from GIS station 34 through transmission line 36. These stations provide regional and global information, respectively. The information available from Internet and NREN station 30 may come from any number of centers or sources. The data is transmitted to the interface module 52 from stations 30,34 by appropriate communications channels or transmission lines, as depicted.
Data may be received from numerous sources, as indicated above, such as from land based, airborne or space based sensor platforms, or from data libraries of various types. The data may be fed directly to central location 40 in real time or near real time. Remote sensed data, such as multi-spectral radar, lidar, and sidar, is routed to central location 40 where it is processed, manipulated, and archived. At the central station, data is routed to the appropriate hardware and software elements, as desired or required. The information represented by the data is analyzed, collated, and processed appropriately for use. The "use" may be multiple uses, depending on the users. That is, different users may desire different information, and the information is processed to provide single or multiple users with virtually any type of information from the data. The data may be retrieved, further manipulated, and presented through use of software and hardware elements in an interactive venue, such as might be designed for group decision support in a setting, such as an information center 90 illustrated in FIG. 3.
Three primary systems are integrated, as best shown in FIG. 2. One system is acquisition system 50, the second system is operations system 60, and the third system is vision or visioning system 70. Acquisition system 50 includes an interface module 52 which may interface with a generic geographic information system (GIS) station 34. Module 52 provides the interface software for subroutines with the generic GIS and the communications software for direct linkage with remote sensors. It may link continuously with several different sensor instruments on satellites or aircraft that provide selective hyperspectral scanning of the electromagnetic spectrum, radar imagery, which may be multi-polarized, and laser imagery (lidar), which may be similarly polarized. The module may then provide instantaneous or prerecorded information of value to the users. Initial processing of raw multi-spectral, real time data from aerial and space based platforms is performed within this module and it includes the hardware necessary to run the software and to facilitate data movement. After initial processing of the Internet and NREN data received from station 30 by interface module 52, the module communicates with a module 54 that provides various functions, such as data ingestion and storage, archive and retrieval, command and control, and communications relevant to the processed data.
A plurality of direct display screens 92 may be used in information center 90 and controlled by interactive keyboards/LCD displays (consoles 100), as shown in FIG. 3. For example, a user may wish to see the aerial photography for a one mile buffer around a specific land address. The information is passed to the database query and interface engine 56 (FIG. 2) which locates the appropriate records. A unique identifier and task request is sent to block 80 wherein a graphics engine expands the geometry of the subject parcel of land for the one mile radius. Finally, the geometry of the buffer is passed to an image display engine and a data display engine which extracts only the portion of the image needed and sends the results on a transmission line 82 to a display screen 92 for display at information center 90.
Operations system 60 provides for remote sensed data transfer, manipulation, and display for current operations and user functions through software. Some of the functions include auto registration, spectral signature library, classification, and masking, as illustrated in block 62. The essential functions or sub modules for operations system 60, as listed in abbreviated form in block 62, include:
1. Automatic registration of multi-spectral, hyperspectral, radar, or lidar imagery:
a) This module contains the subroutines necessary to automatically identify the data imagery type and to auto register, or align, this imagery or attribute information with the GIS database; and
b) The GIS database provides known ground features to provide overall control points for rectification of the imagery. Only features with pronounced active or passive signatures, static physical characteristics and appropriate geographic locations will be identified, such as a canal, tree, vehicle, or building, etc. An algorithm then analyzes the imagery and matches the known ground control shapes, transferring the coordinate geometry of the GIS database features to the given image. This operation may be done through several correcting iterative processes by increasing the number of ground control features each time until an acceptable deviation is achieved.
2. High resolution multi-spectral, radar, and lidar imaging signature libraries:
a) This library provides reference data for atmospheric, land surface, and subsurface features, vegetation, life forms, conditions, and attributes within any desired region, such as, for example, the southwestern United States region. This is a reference library for comparison with new remote sensed data, permitting feature identification, whether atmospheric, land surface, or subsurface;
b) GIS registered, high resolution, multi spectral, and radar or lidar imagery is ground truthed and synthesized to build an optimal signature library. The imagery is superimposed with known features within the GIS database, such as pavement, roof tops, etc., to determine the most common signature return for the given feature;
c) Since many factors can affect the signature return of any given feature, such as angle or pitch of the camera, shadows, etc., variances in the signature library occur. These variances are mathematically calculated to determine allowable tolerances within the signature band for each feature. Each spectral band within the spectral range for a given feature is examined for return values and optimally predictive values are calculated. This depicts the most common spectral return for the given band; and
d) Next, tolerances are calculated by finding the minimum and maximum values in which a certain percentage of the returns for a given band belong. Finally, the signature library elements are tested and verified against or with known signatures for the region's known imagery to insure the classification accuracy of the data.
3. Classification module:
a) This module interprets the data stream and is equipped to recognize atmospheric, surface, and subsurface constituent features and attributes by spectral signature or reflected image comparison with reference to the signature library discussed above.
4. Masking module:
a) This module scans the data to produce an image which will present special features, such as a roof type or hydrant location, for example, and search for a given signature or indication, such as a particular pollutant, vegetation type, land characteristic, attribute, or object, or for a given coordinate set with a listing of selected attributes; and
b) Following classification and/or masking, data are sent to the vision system or to an integrated user interface module, discussed below, for display and dissemination to a user. Data may be returned to vision system 70 repeatedly for additional processing, as desired. Geographical addressing, coordinate selection, attribute queuing, and zoom or magnification features are contained within this module.
General applications developed using vision system 70 include:
1. Environmental change monitoring, compliance, and enforcement;
2. Transportation monitoring, analysis, and planning;
3. General planning, growth assessment, and management;
4. Zoning and building code enforcement; and
5. Public protection and emergency/disaster response services.
Sample applications of this vision system include: hazardous materials dumping by type, location, and time; police (law enforcement) transit, service, utility, or other vehicle location and status; watershed status; impending weather related events; regionally coordinated disaster incident management; traffic vehicle counts by time of day and location; tracking of vehicles, biological and nonbiological objects, or other entities; transportation planning; zoning monitoring and enforcement; crime evidence gathering; development plan review and tracking; air quality analysis; sources and movement of pollutants; long term trends of various types; construction progress monitoring; and permit and other violations.
Visioning system 70 may provide dynamic visual and financial simulations of a region's future, given an assumption set and a predetermined series of development or policy decisions. It is intended to project into a long range time frame and incorporate global change data through a high speed data channel. Global data is regionalized, utilizing special subprogram software to combine emerging local climatic models with larger data sets. This subprogram accesses global environmental information data and modeling to assist a municipality in developing long term strategies which integrate with global environmental trends and emerging guidelines for sustainable development.
The following subroutines, depicted in block 72, are a part of vision system 70:
1. Simulation:
a) Digital image manipulation and simulation capability utilizes advanced processing capabilities applied to environmental, economic, and social models developed as part of the module subroutines; and
b) Optical image manipulation and simulation also utilizes advanced processing, but filters the image of elements not requiring update for the next image. An image library is established for a local community to use for fly through/bys and "what if" scenario generations.
2. Assumption Set and Database:
Simulation scenarios derive from a set of assumptions, regarding, in part:
a) Global/regional/local environmental factors (climate change, costs assigned to pollutants, new pollutants, totally internalized resource costs);
b) Global/regional/local economic factors (rate of inflation, interest rates, sources of GNP and local incomes, new products and specification, existing material and product performance specifications, areas, tax rates); and
c) Global/regional/local social, cultural, demographic factors (population forecasts, health costs, educational levels and provisions).
3. Decision Support Module:
a) Simulation scenarios depend on the policy and development decisions made by a community, government, or user organization. These are categorized in this module to include likely outcomes for a variety of policies, development alternatives, and infrastructure projections with regard to cost, usage rates, and life cycle costing of materials.
This module includes group decision support software which may be user confidential and individually interactive at each user's console 100, (see FIG. 3), and at remote locations. A typical facility is depicted in FIG. 3 as information center 90 that may serve citizens, council commissions, senior management/planning meetings, etc. Obviously, this facility may be adapted to various user groups or organizations requiring the integration of multiple data sets, imagery, and group decision support software.
The entire system is appropriately interconnected, such as by fiber optics, to all appropriate user departments and offices to create a virtual network that integrates across user groups. As a national "Information Highway" is developed, the system may be connected to include other, or more, remote locations.
Information center 90 includes a plurality of interactive consoles 100 connected to the central location 40 by appropriate elements. A plurality of communications lines 130, 140, 150, and 160 are illustrated in FIG. 1 as extending to different centers 132, 142, 152, and 162, respectively, where the gathered and processed information may be used by users. One such user may be information center 90, connected to the central location 40 by an appropriate transmission line 82 from data/image/graphics display engines depicted in block 80. Block 80 represents the software and hardware which interfaces with the information center 90 and the central location 40. It will be understood that the various modules, engines, etc., within the central location 40 communicate with each other as required to analyze, retrieve, etc., the data as requested by users at consoles 100 . . . 106, etc.
At the front of the information center 90, and in front of the consoles 100, may be a large display screen 92. By use of the consoles 100, the users may call up and have displayed desired information on the display screen. Moreover, the information displayed on display screen 92 may be manipulated and otherwise used or varied as desired. A master control console or facilitator console 110 is shown in FIG. 3.
Some examples of the applications available are set out below. The examples are illustrative only, and not exclusive. Different users may sit at consoles 100. Facilitator console 110 may provide assistance for the users at the consoles. Hard copies of data may be provided by a plotter or printer 98 or similar image/data rendering device, or transmitted to a playback device for later usage, as desired.
On opposite sides of the display screen 92 are an assumption screen 94 and a decision screen 96. The purpose of these screens is to aid the users in making decisions based on provided data. The assumptions may include resource, pollutant costs as a minimum in arriving at proper decisions. Decision screen 96 will display the chosen decision tree, generally regarding changes to the natural environment. The display screen 92 will display visually and dynamically the long term results of the proposed changes.
Remote centers 132, 142, 152, and 162 are shown in FIG. 1. These remote centers may represent departments, agencies, private individuals or entities, schools and universities, federal agencies, other political units, etc., tied into or part of system 10.
The following examples set forth various and representative uses that may be accommodated by system 10:
EXAMPLE NO. 1
An "old" map shows water meters and sewer manholes at specific locations on a given street. With a hand held GPS transmitter, a person may walk along the street and activate the GPS transmitter at the water meters and manholes. GIS satellites receive the transmissions and relay the coordinates of the exact locations from where the transmissions were sent. The information is processed and is used to verify the "old" information and to correct any errors. The "new" information thus received and processed provides correct location information for the various water meter and sewer manholes.
EXAMPLE NO. 2
A new subdivision is planned for a section of land which includes hills, dry water courses and certain types of desired vegetation. The section of land has been photographed, etc., and the information is in the system memory. The information on the desired section is brought up on a computer screen and the information is analyzed. Appropriate printouts may be made for detailed analysis. The information provided includes details on the vegetation so that lot lines, roads, etc., may be plotted to have minimum adverse effect on the vegetation and on the natural water courses, etc.
EXAMPLE NO. 3
Aerial photographs of an area are processed with maps to show correct lot boundaries, misaligned walls and fences, and other desired information.
EXAMPLE NO. 4
Radar imagery is preprocessed and auto registered to a GIS mapping system which overlays parcel property lines. The resulting image can be automatically interpreted or "read" to determine the surface area and percent slope on any given ownership parcel. This yields buildable/unbuildable percentages and ultimately derives a slope analysis for the parcel. These parcels, and their attributes, can be aggregated to provide a basis for transaction negotiations, tax assessment, and other values which are slope dependent. The radar data provides highly accurate elevation data from the which the slope composite imagery is constructed.
EXAMPLE NO. 5
An agency responsible for reviewing, revising, approving, monitoring construction progress, and otherwise dealing with land use and architectural plans may require these to be submitted in computer assisted design (CAD) format on magnetic or optical media. Plans thus digitized may be merged into the GIS resident, remote sensed imagery to create dynamic, three-dimensional and realistic presentations of the finished development of a capital improvement project. The simulation software merges the digitized plan with change models and simulates visually how the project will look in the distant future. Plan check submodules approve, or disapprove the project based on its long term impacts as determined by this simulation capability.
EXAMPLE NO. 6
The visual simulations set forth in Example 5, above, may be integrated with economic, social, and environmental cost forecasts to determine a project's impact on the sustainability of the community, or ability to function without negatively impacting the future wellbeing of the community.
EXAMPLE NO. 7
A developer's plans are submitted on electronic optical or magnetic media and integrated with existing regulatory data and video of the proposed area to 1) verify plan compliance with city/state/federal codes, and 2) simulate how the proposed project, if built, would appear and impact the community in the distant future.
EXAMPLE NO. 8
City planners utilize the system to design and update the city's land use plan. Transportation planners, storm water planners, etc., will visualize the land use plan concurrently during the design phase and assess impacts of the plan with regard to transportation, storm water, etc. Recommendations and manipulations can be made by the transportation planner and the impact of such recommendations and manipulations can be visualized in three-dimensions. This process allows for group interaction in city planning through the integration of existing city models and the visualization of model inputs and outputs.
Referring to FIG. 4, there is illustrated a block diagram which depicts the process and components required to acquire and format remote sensed data for combination with other data to provide a presentation to command center personnel handling an emergency incident. Block 170 represents data sensed from remote sources and relevant directly or indirectly to the emergency incident. This data may be acquired as discussed above with respect to FIGS. 1 and 2. The remote sensed data may be inputted in real time, stored, and retrieved later. Alternatively, the data may be routed directly to incident support software module 180 for processing and use. Block 172 represents data relevant to the incident. This data may be entered manually or automatically from existing data sources. Furthermore, it may be data generated directly by personnel overseeing the emergency incident. Historical and/or ancillary information regarding aspects of the emergency incident may also be included. Block 174 represents data from a geographical information system (GIS) relevant to the emergency incident and related factors. The GIS data represents two-dimensional map information linked to a relational database to generate automatically ownership, tax, criminal, or other data relevant to the emergency incident and/or persons involved. Moreover, the information represented by the data may be relational or spatial (raster or vector). Block 176 represents data available from the Internet which has been filtered to be relevant to the emergency incident and to related or impinging factors. In addition, the data obtained from the Internet may include a two or multiple way exchange of information.
These multiple sources of data and information are integrated by incident support software module 180, which module responds to queries made by members of the team handling the emergency incident. In operation, module 180 determines by design algorithms which data source can provide the requested information. Should the request be for a simulation of an expected outcome based upon certain decisions or occurrences, the module routes the request to simulation module 182. The simulation module can connect and integrate all extant, but heretofore, isolated models descriptive of individual elements related to an emergency incident. Module 182 contains the software necessary to integrate, combine, and simplify the outputs of individual model elements which are representative of or relate to the emergency incident. This is accomplished by integrating and formatting software. It can also add a fourth dimension, time, to two- or three-dimensional models resident in the module. By applying a variety of assumptions and decision options to single or integrated models, the future results of current decisions can be developed. The methods of data simulation conducted include the ability to accept a different set of input factors and produce a simulated situation in a future time period for the emergency incident. The module will be capable of trend extrapolation (using a variety of methodologies, including linear, logarithmic, cross-index, etc.) for the variety of data sets within the module. Possible outcomes of the emergency incident may be generated for a range of alternative actions.
Visualization module 184 includes a user interface function to accommodate access by users, represented by block 186, to respond to queries made and provide responses to such queries, as represented by line 188. The visualization module provides a method of data presentation and includes two primary elements. First, it includes special software to move (give the perception of movement) a viewer in real time through a real or simulated three-dimensional representation of the jurisdiction in either time or future time. The module will also overlay or co-display charted two-dimensional data sets which change to portray data dynamically as the spatial or temporal aspects of the viewer varies. Thus, the visualization module will portray complex data using simple visual media. Second, special features can be viewed by all or selected members of the emergency incident team on one or more computer driven screens. Sufficient visually perceivable information is provided to permit rapid decisions to preserve life and property at the currently perceived risk.
Referring to FIG. 5, there is illustrated a facility 190, which may be similar to information center 90, for providing the information necessary and available to the members of the emergency incident team and permit the decisionmaker(s) to make decisions on an ongoing real time basis to resolve the emergency incident with minimal risk and cost. Block 192 represents an area wherein visual presentations are made and may include a plurality of screens represented by numeral 194 for depicting data in two- or three-dimensional formats along with any commentary or qualifying language pertinent to the depicted images. The support staff may be located in area 196 wherein they have visual access to screens 194. Real time data presentation and technical support available to the supporting staff is represented by block 198. The commander(s) for assessing the emergency incident and for making decisions as necessary may be located in an area proximate line 200. At this location, the commander(s) and the immediate supporting staff have visual access to screens 194 and any queries raised may be addressed to the supporting staff or to technicians represented by the designation technical support in block 198.
While the invention has been described with reference to several particular embodiments thereof, those skilled in the art will be able to make the various modifications to the described embodiments of the invention without departing from the true spirit and scope of the invention. It is intended that all combinations of elements and steps which perform substantially the same function in substantially the same way to achieve the same result are within the scope of the invention.
|
A method for resolving an emergency incident is described which is capable of providing projected results and effects based upon varying the inputted data as a function of the consequences of presently made or proposed decisions by the decisionmakers. Sources of data collected from a plurality of sources are converted into an electronic database which may be automatically and/or periodically updated during the course of the emergency incident. A series of software modules utilizes the data for a series of specific applications to reduce the public risk. The output provided by modeling and simulation modules may be in the form of two-dimensional or three-dimensional visual presentations in specially equipped multiple, computer-driven screens at a command center.
| 6
|
[0001] This application is based on, and claims priority to, provisional application having Ser. No. 60/559,787, a filing date of Apr. 6, 2004, and entitled Insert for Containers.
BACKGROUND OF THE INVENTION
[0002] It is known in the art to convert a structure, such as a transport container, into a shelter by inserting components within the structure such as wall, floor and ceiling panels. Existing products, however, do not adequately address temperature and humidity control. The containers are typically made of metal such as aluminum or steel, which do not insulate well against external temperatures. Panels are therefore made with insulating layers resulting in thicker, heavier panels. Alternatively, or in addition, a temperature control system, such as heating or air conditioning, is operated at great expense. A significant percentage of the available space is also utilized for the temperature control components.
[0003] Accordingly, there is a need for an insert system to transform a container into a habitable structure, wherein the interior space is maximized and environmental control is more efficient.
SUMMARY OF THE INVENTION
[0004] The present invention provides an insert system for transforming a transport container into a habitable structure. Advantageously, the components can reduce temperature and humidity problems associated with conventional systems. The system includes panels that are inserted into an existing container, wherein an insulating cavity remains between the container and the insert panels. The cavity promotes efficient environmental control as compared to tradition insert systems. The use of the cavity also allows thinner inserts, thereby maximizing habitable space.
DESCRIPTION OF THE DRAWINGS
[0005] The invention is best understood from the following detailed description when read with the accompanying drawings.
[0006] FIG. 1 depicts a portion of a container and insert panels according to an illustrative embodiment of the invention.
[0007] FIG. 2 depicts a frame component according to an illustrative embodiment of the invention.
[0008] FIG. 3 depicts a cross section of an exterior structure wall and insert panels according to an illustrative embodiment of the invention.
[0009] FIGS. 4 A-B depict an illustrative embodiment of insert panels connected by joining elements.
[0010] FIG. 5 depicts a joining element according to an illustrative embodiment of the invention.
[0011] FIGS. 6 A-B depicts corner or ceiling joining elements according to an illustrative embodiment of the invention.
[0012] FIG. 7 depicts a plurality of wall joining elements connecting a plurality of insert panels according to an illustrative embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] Embodiments of the present invention provide components to transform a structure such as a transport container or other suitable structure, into habitable space. The concept may provide a simple, quick and economical way to create habitable space.
[0014] In general, the habitable space is created by inserting panels into the container. Environmental control problems are addressed by providing an insulating cavity between the panels and the container walls, ceiling and/or floor. Advantageously, the insulating cavity reduces temperature control problems and provides more freedom in the panel construction. For example, panels can be thinner as their insulating function is reduced by the insulating cavity.
[0015] FIG. 1 depicts a portion of an illustrative container 100 and insert system 102 . Endwall panels 104 and sidewall panels 106 are positioned by angles 108 on the floor of container 100 . A container would typically have a floor, ceiling and sidewalls and endwalls to form a complete box. Panels can be inserted adjacent to any or all of the container faces to form the habitable space. The container can also be partitioned to form a smaller habitable space or a plurality of habitable spaces.
[0016] FIG. 2 depicts an illustrative embodiment of a frame component used to position panels in the enclosure. Angle 108 has an angle bottom portion 110 , which is mostly hidden in the figure, and an angle top portion 112 . Bottom portion 110 lies flat on the container floor. Angle top portion 112 extends upward from bottom portion 110 to provide a guide for positioning panels. Bottom portion 110 provides support for top portion 112 . In this particular embodiment, the angles are notched to facilitate fitting them together. As shown in FIG. 1 , the angles are preferably placed with the angle opened toward the container walls as opposed to the interior space. The panels can then be placed so that the top portion of the angle is flush with the interior side of the panel and the angle's bottom portion is flush with the panel's bottom surface. It will be understood by those skilled in the art that other alignment frames can be used. Frames may also have vertical components to provide additional support and alignment of panels.
[0017] FIG. 3 depicts a top view of a cross section of an exterior structure wall 302 and insert panels 304 and 306 . Joining element 308 joins adjacent panels such as 304 and 306 . Ribs 310 , which are preferably rigid, are positioned between exterior structure wall 302 and insert panels 304 and 306 to reduce panel flexing. It is also noted that the joining elements may contain the flex-reducing elements instead of the panels. Other component configurations that can join panels or other insert components, and reduce insert panel flexing, are within the spirit and scope of the invention. Insulating cavity 312 is provided between insert panels 304 , 306 and exterior structure wall 302 to enhance environmental control, such as control of temperature, humidity, and/or air quality.
[0018] FIGS. 4 A-B depict an illustrative embodiment of insert panels 402 connected by joining elements 404 . Internal surface 406 of joining element 404 faces into the interior of a container. Each joining element 404 connects at least two insert panels 402 . A single panel may be the height of the desired habitable space, or a plurality of insert panels may be stacked one above the other to reach the desired height. The joining elements may serve to connect panels that are adjacent in a side-by-side manner or align panels that are positioned on top of one another to form a wall.
[0019] FIG. 5 depicts a joining element 500 according to an illustrative embodiment of the invention. Slots 502 accommodate insert panels thereby connecting them to form a wall, ceiling or floor. A flex inhibiting portion 504 may be included to keep insert panels from flexing. One or more cut-outs 506 , such as shown on flex-inhibiting portion 504 , may be provided in any of the faces of joining element 500 . The cut-outs are most beneficial on flex-inhibiting portion 504 because they facilitate air flow between insert panels and container walls. Cut-outs may also decrease the weight of the joining elements. Joining elements 500 may be of any material having the integrity necessary for the application. Material examples include, but are not limited to, aluminum, plastic, and composites.
[0020] FIGS. 6 A-B depict corner or ceiling joining elements 600 according to an illustrative embodiment of the invention. Slots 602 connect insert panels at right angles to one another. If containers are not plumb or if a configuration other than that having right angles is desired, the corner or ceiling joining elements can be constructed to accommodate such arrangements. Joining elements 602 are depicted having curved corner portions 604 , which will provide air flow around the corners. The corner portions can also be formed to be flush with the container corners. Corner joining elements 600 may also have stiffener portions, such as are depicted on wall joining elements in FIGS. 4 A-B and FIG. 5 .
[0021] FIG. 7 depicts a plurality of wall joining elements 702 connecting a plurality of insert panels 704 . Corner joining elements 706 are also shown. Corner joining elements can also be placed on top of wall insert panels to connect ceiling insert panels to wall insert panels. Although corner joining elements can also be used to join floor insert panels to wall insert panels, they are not as necessary because the floor panels may stay properly positioned merely by placing them on the container floor. Joining elements are also optional to connect insert panels that are adjacent to one another in the same plane on the floor.
[0022] It is also understood that joining elements can be configured to put jogs in the walls, floors or ceilings. This can be to accommodate components behind insert panels or to form desired shapes of interior space. Joining elements may also contain slots or other mechanisms for positioning shelves or other components, such as utility-related components with respect to the insert panels.
[0023] In a preferred embodiment of the invention, the insert kit can be set up without damage or permanent modification to the container or exterior structure into which it is inserted, so that the insert may be removed, and the exterior structure may be used for other purposes.
[0024] The cavity may be ventilated to keep it at lower temperatures than would exist if an enclosed space was left in the sun. Although cavity ventilation may enhance the effect of the cavity under certain conditions, it is an optional component of the invention. A cavity without ventilation may be utilized in certain conditions. Ventilation may be provided by one or more fans. Fans may be directed to draw air from the cavity space or blow air into it. Cooling systems may be incorporated into conditioning of the cavity air. Likewise, when the outside air temperature is lower than would be desired for the habitable space, the cavity area may be heated to provide more efficient temperature control of the interior space. A gasket is preferably provided to seal the cavity between the insert and exterior structure. It is also understood that a cavity could be created by adding panels outside of the structure, but this approach may be more complicated and does not afford the ability to transform the container's interior walls to form habitable space with the same panels as are used to form the cavity.
[0025] In addition to the cavity providing enhanced temperature control, the cavity can serve to protect against harmful contaminants, such as chemicals or biological contaminants, by adding an additional layer of protection. Filters may also be incorporated into the apparatus for this purpose. Filters can be used to provide cleaner air in the cavity, and can also be used in an interior ventilation system.
[0026] Condensation in a structure converted to habitable space can also be a problem. By keeping the cavity at an appropriate temperature, condensation in the interior space will be reduced or eliminated. Incorporation of materials into the insert walls that allow transfer of moisture in only one direction can further alleviate the problem of condensation affecting the interior space. An example of such a material is Gortex® or a Gortex®-like material. Moisture absorbing materials may also be used on the panels or within the cavity to address humidity and condensation problems.
[0027] Preferably the insert does not touch the exterior structure walls so that heat is not transferred between the exterior structure walls and the insert walls. Although such a configuration is preferred, various degrees of contact between the insert walls and the exterior walls are within the scope of the invention. Some contact may be beneficial, for example to keep panels from flexing, which will be discussed in more detail below.
[0028] Insert components may be provided in a kit. The kit may include some or all of the following: insert panels such as walls, floors and ceiling; utility panel and components; environmental control components such as heating, air conditioning, fan, air handler, humidifier and dehumidifier; frames; joining elements; doors and door frames. In an illustrative embodiment of the invention, a kit includes 14 endwall, sidewall and ceiling panels; 1 door panel; 1 HVAC/electrical/telephone knock out panel (utility panel); 18 notched angles; and a plurality of screws.
[0029] Preferably the width of an insert panel is evenly divisible into the interior length of the exterior structure. For example, in an exemplary embodiment of the invention, panels are 90 inches tall by 45 inches wide. The container into which they are to be inserted is approximately 232″ deep. Therefore, five rows of panels can be placed side by side extending from the container front to the container rear. This leaves approximately 7 inches for storing miscellaneous items on the floor of the container. Similarly, stacks of panels can be placed in a container so they fill most of the vertical space in the container. In an illustrative example, a full insert kit has a height of approximately 16.5 inches. Kits are typically stacked on pallets in a container. Four units can be stacked on pallets in a container having a door height of 90 inches. This leaves additional room for utility components and miscellaneous items, or possibly another insert kit.
[0030] Use of the cavity to facilitate efficient temperature and/or condensation control, can reduce the necessary insert panel thickness, thereby further promoting efficient use of space. Insert panels may be constructed of various materials. The choice of material may depend on such factors as, cost, weight, environment in which the insert will be used and the type of exterior structure. Panels may be for example, composites or sandwiched materials such as laminates. In an exemplary embodiment, the outer surface is steel or aluminum. Synthetic materials may also be used. Panel materials may serve to protect occupants by being impenetrable by projectiles. Panels can also be constructed of combinations of material types.
[0031] Utility components may include for example, HVAC, electrical, telephone, cable and other communication provisions. Generators and fuel tanks can be included in kits or supplied separately. Various other components related to the utility systems can be supplied either with the kits or separately, such as telephones and computers.
[0032] Joining elements may include those necessary to join components to one another and/or to the exterior structure. Panels may need to be joined to one another or to the floor or ceiling. Utility components may need to be joined or affixed to a utility panel. Panels may be joined by various means, for example, hooks, hinges, snapable parts, screws or other fasteners, or combinations of joining elements. Panels may be joined directly to one another or by use of joining elements.
[0033] Depending on the materials used and the size of the insert panels, insert panels may not be totally rigid, allowing them to bend or flex. Flex-inhibiting components may prevent or reduce wall flexing. The flex-inhibiting components may be for example, spacers attached to the insert panels or otherwise positioned between the panels and the container, or they may be support components incorporated into the insert walls such as beams or cross pieces. Flex-inhibiting components may also be incorporated into insert component joining elements. Flex-inhibiting components will allow for use of relatively thin insert panel materials, which can help reduce weight and increase the habitable interior space.
[0034] It is noted that the structure floor may serve as the floor of the insert or a separate insert component may be used. The insert floor may sit directly on the exterior structure floor or there may be a cavity between the insert floor and the exterior structure floor.
[0035] Although it is preferable to have an insulating cavity between all insert panels and the container, it is within the scope of the invention to include an insulating cavity in only certain areas. This may be desirable for certain applications. For example, if a container is protected on one or more sides or is adjacent to another container, the insulating cavity may not be needed in that area. In such a case, no panel may be needed in the area except perhaps for aesthetic purposes or to incorporate a utility panel.
[0036] While the invention has been described by illustrative embodiments, additional advantages and modifications will occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to specific details shown and described herein. Modifications, for example, to the material types, sizes of the panels and joining elements may be made without departing from the spirit and scope of the invention. Accordingly, it is intended that the invention not be limited to the specific illustrative embodiments, but be interpreted within the full spirit and scope of the appended claims and their equivalents.
|
An insert system for transforming a transport container into a habitable structure. The system includes panels that are inserted into an existing container, wherein an insulating cavity remains between the container and the inert panels. The cavity provides efficient environmental control.
| 4
|
BACKGROUND OF THE INVENTION
U.S. Pat. No. 3,093,609 describes an aqueous dispersion of an organic binder in particulate form in a latex, which dispersion contains an emulsifying agent selected from the group consisting of sulfonated anionic agents and nonionic agents, in conjunction with a water soluble salt of an aliphatic polycarboxylic acid containing at least 36 carbon atoms. This system requires the absence of standard emulsifiers. This system provides aqueous dispersions (not latices) of particular organic binders for deposition onto papermaking fibers and the system is deficient as to freeness control.
SUMMARY OF THE INVENTION
In accordance with this invention there is provided an improved process wherein in fiber beater addition processes, particularly asbestos beater addition, a high Canadian standard freeness and a broad freeness response from a single storage stable latex is obtained so that fiber matrices of varying density are readily prepared from a single latex by use of a polymer latex containing both an alkali metal water-soluble salt of a polybasic fatty acid of dimer and trimer derivatives of oleic, linoleic, and conjugated linoleic acids to provide materials containing 36 to 54 carbon atoms and a water soluble alkali metal salt of derivatives of 2-alkyl imidazolines having the general structure ##STR1## wherein Y is H or an alkali metal and X is ##STR2##
DETAILED DESCRIPTION
In the practice of the invention the improvement is readily obtained by first preparing a fiber water blend of asbestos, cellulose polymer and like fiber in a beater or refiner to break down the fiber bundles, diluting the furnish to the required consistency, adding the latex binder and forming the sheet.
The fibers are prepared in accordance with the usual beater saturation technique and the fibers will be taken up in water so as to form a slurry having about 0.5 to 3% consistency, more preferably about 1.5 to 2.5%. In the case of asbestos the fibers are placed in a beater to break up the fiber bundles to their consistency as well as to decrease the size and this may also be done with a refiner. Fibers treated in accordance with the invention include, for example, asbestos fibers and cellulosic fibers, including wood fiber, rag fiber, polyacrylonitrile fibers, viscose fibers, nylon, cotton, Kraft and sulfite and the like normally used to make paper or felted products. As has been stated, in the case of asbestos fibers, normally no additional precipitation or coagulation agent is required to be added after the latex binder has been added to the furnish. The invention is of particular utility in controlling the Canadian freeness of treated asbestos dispersions. However, it may be necessary to add alum to other fiber slurries for coagulation.
The incorporation of synthetic polymer latices into fibrous slurries or dispersions before formation of a sheet therefrom is by wet-end or beater addition. This technique is used to incorporate in the fiber sheet from less than 1% to more than 50% polymer content, depending on the end use of the sheet. Controlled deposition of the latex particles is obtained by the addition of a coagulant such as papermaker's alum in water solution to fiber other than asbestos. The novel latices of this invention can be applied to a variety of techniques including direct addition, the inverted method, the Armstrong method, continuous addition, and the like.
In direct addition, after the furnish has been beaten to the desired degree of freeness, the pH of the pulp furnish is adjusted to between 8.5 and 9.0 with alkali. The latex is added to the pulp furnish and is dispersed by operating the beater. The latex may be diluted before addition. After the latex has been dispersed, a 1 to 10% solution of a coagulant, for example, alum, is added to coagulate the latex polymer which is deposited on the fibers. In the inverted method the furnish is beaten to the desired freeness, the pH is reduced to 4.5 using alum and dilute latex is added thereto. The Armstrong method is described in U.S. Pat. Nos. 2,375,245 and 2,613,190. In the continuous method the furnish is prepared, the pH reduced to 4.5 with alum and the latex is added after the furnish leaves the beater. It is understood by those skilled in the art that in commercial methods of latex wet-end addition, the latex is normally added as dilute as possible at a point of maximum agitation, in the range of about 10 to 60% total solids. In each case the anionic polymer is added prior to the latex addition.
This invention may be applied to any synthetic polymer latex of vinylidene monomers containing at least one terminal CH 2 < grouping used in wet-end addition to fibrous slurries, and improvement will be obtained thereby both in the process and resulting sheet product, particularly in more complete deposition and clear serum. These monomers and polymer thereof include vinyl chloride, styrene, vinyl acetate, vinylidene chloride, acrylic esters, conjugated dienes and like polymer latices, as is well known in the art, particularly latices of elastomeric polymers. Such latices include, for example, latices of alkyl acrylate polymers and copolymers, polychloroprene, copolymers of butadiene and acrylonitrile, butadiene and methyl methacrylate, butadiene and vinylidene chloride, butadiene and styrene, vinyl chloride polymer latices including copolymers of vinyl chloride and 5 to 40 parts of copolymerized alkyl acrylates and the like. Typical useful latices are described in "Synthetic Rubber", Whitby, 1954 and "Polymer Processes", Schildknecht, 1956.
This invention is particularly adapted to use of latices containing polymers of butadiene or alkyl acrylates and copolymers thereof. Alkyl acrylate polymers are valuable in providing improved fibrous articles containing the alkyl acrylate polymers dispersed thereon. Since some alkyl acrylates have some water solubility, polymerization thereof to form latices may be conducted in the presence of minimum amounts of surface active agents. In some systems more difficulty has been experienced in adequately depositing low surface active-containing or nonionic emulsifier-containing latices on fibrous materials in aqueous suspension than with latices containing larger amounts of ionic surface active agents. Such polymers include homo- and copolymers of alkyl acrylates wherein the alkyl groups of esters of acrylic acid contain from 1 to 8 carbon atoms. Improved polymer latices are prepared from copolymers of alkyl acrylates and butadiene with vinylidene monomers containing at least one terminal CH 2 < groups; including particularly, monomers such as styrene, α-methyl styrene, acrylonitrile, methacrylonitrile, ethyl methacrylate, butyl methacrylate, methyl ethacrylate, acrylic acid, itaconic acid, vinyl chloride, vinylidene chloride, vinyl acetate and the like. Such polymers may also include cure sites generally supplied by chlorine-containing monomers as vinyl chloroacetate, chloropropyl acrylate, chloroethyl vinyl ether, vinyl benzyl chloride and other known comonomers.
Excellent results are obtained with latices of butadiene or alkyl acrylates containing as much as 20% of reactive monomers, for example, acrylamide and methacrylamide, t-butyl acrylamide, octyl acrylamide and diacetone acrylamide, N-alkylol amides as N-methylol acrylamide and N-methylol methacrylamide, N-alkoxyalkyl acrylamides including for example, N-ethoxy methacrylamide and N-butoxy methacrylamide and α,β-unsaturated carboxylic acids containing 3 to 8 carbon atoms including, for example, acrylic acid and methacrylic acid, dicarboxylic acids as itaconic acid, and the like. Normally, at least about 0.2% of these comonomers are used. Useful are copolymers of ethyl, methyl and butyl acrylate containing about one part each of at least two such comonomers for example, N-butoxymethyl acrylamide and acrylamide, N-methylol acrylamide and acrylamide, N-methylol acrylamide and methacrylamide, N-methylol acrylamide and acrylic acid and the like. The total of such monomers normally being less than about 10% of the copolymer.
One of the necessary ingredients present in the binder dispersion is a water-soluble salt of an aliphatic polycarboxylic acid containing at least 36 carbon atoms. These acids are best illustrated by the ammonium and alkali metal dimerized and trimerized fatty acids which are readily available in commerce. These acids are prepared by the thermopolymerization of drying oil acids carried out in a pressure vessel in the presence of water in the form of steam. The resulting compositions contain dimer and trimer and may contain monomer. Such products are known as dimerized fatty acids and will generally have an iodine value of approximately 90, and an acid number of approximately 190. The dimerized acid itself is essentially a 36-carbon dicarboxylic acid obtained by dimerization of the linoleic acid of soya, cotton seed, corn, and linseed oils of commerce. The product is frequently referred to as dilinoleic acid. The dimerized acids and the trimerized acids resulting from the above-described pressurized process may be separated or further concentrated as desired. As a further variation on the dimer and trimer acids, any residual unsaturation in the carbon chain may be eliminated by hydrogenation. These are the polymerized long chain fatty acids containing a plurality of polycarboxylic acid groups and containing at least 36 carbon atoms which are to be added in the form of their alkali metal salts to the binder dispersion.
These polycarboxylic acids have the basic structure ##STR3##
In the commercially available dimer-trimer fatty acids, the ratio of C 36 dibasic dimer acid, C 54 tribasic trimer acid and C 18 monobasic fatty acid varies from about 10% of the dimer acid to about 97% and from about 3 to about 90% of the trimer acid and from about 0 to about 10% of the monobasic acid. The proportions of typical commercial materials given as percent of monobasic acid, dimer acid and trimer acid are, for example, 0-97-3, 10-87-3, 1-95-4, 0-87-13, 0-83-17, 0-75-25, 0-20-80, 0-10-90, 0-40-60.
The preferred polycarboxylic acids are those containing the dimer and trimer acid, that is, the dibasic C 36 and C 54 materials. While improved results are obtained when the polybasic acid contains as little as about 20% C 36 acid, it is preferred that the polybasic acid contain more than 50% C 36 -C 54 dimer and/or trimer acid, and more preferably greater than about 80 weight percent. In order to obtain a greater latitude in control of the Canadian standard freeness in polymer latices in beater addition, excellent results are obtained when the polybasic acids containing varying amounts of dimer and trimer acid, used in conjunction with the defined alkali metal salts of 2-imidazoline derivatives defined in this invention; with at least about 1 weight part each of these two components are used. As the trimer/dimer ratio is increased in a particular system, usually the Canadian freeness will range higher. Better results are generally obtained with larger amounts when used as the sole stabilizing agents or when added to polymer latices containing other emulsifying systems which are not precipitated when the water soluble polybasic salt and water soluble salt of the 2-imidazoline derivative are added to such polymer latices. These materials may be used in any alkaline, free radical emulsion polymerization and added to any polymer latex whose emulsifier system is stable to the addition of these materials.
The water-soluble 2-alkyl imidazoline derivatives have the general structure ##STR4## wherein X is an alkali metal or a ##STR5## wherein Y is an alkali metal and wherein R is an alkyl group derived from a fatty acid containing from about 6 to about 20 carbon atoms. Specific imidazolines are the monocarboxylates or dicarboxylates having the structure ##STR6## where in the monocarboxylate (I) R is an alkyl chain containing C 7 to C 17 , as lauryl C 11 H 23 , in (II) R is an alkyl chain as oleic C 17 H 33 , stearic C 17 H 35 and capric C 9 H 19 , that is, from C 7 to C 17 , and in (III) wherein R is alkyl as caprylic C 7 H 15 , coconut C 12 H 25 (C 8 -C 18 ), capric C 9 H 19 , and the like. R may contain normally from about 6 to about 20 carbon atoms, more preferably about 10 to 18 carbon atoms. The ammonium and alkali metal salts are normally employed.
The amounts of these acids and salts will be varied in amount so that the total of both is at least about 1 and more than 0.1 weight part of each per 100 weight parts of monomer or polymer in a given latex, more normally the amounts will be greater than about 0.5 to about 6 weight parts of each.
In accordance with this invention the Canadian freeness related to the gauge or density of the desired sheet is readily controlled in accordance with this invention by the use of polyacrylic acid so that the gauge sheet desired is formed. In any event, it will be understood that once the polymer is deposited on the fiber particles, a sheet of the coated fiber is then readily formed on conventional papermaking equipment such as a cylinder machine or Fourdrinier wire. As has been noted, the invention is of particular utility with asbestos furnish where problems have been previously observed in treating such materials with polymer latices because of the presence in the furnish of substantial amounts of metal ions.
The Canadian standard freeness value is a measure of the ease with which water passes through fibers while they are being formed into a wet mat on a perforated plate. The Canadian Standard Freeness Tester consists of an upper container of 1 liter capacity which holds the fiber-water slurry, a perforated plate at the bottom, a bottom cover, a hinged top and a petcock for air admission. When the bottom cover is dropped and the petcock is opened, the water draining from the fibers in the upper container drops into a funnel type receptacle with an overflow outlet in the side and flows through a standard orifice in the bottom. If the water drains into the funnel from the fibers at a rate greater than can be handled by the standard outlet, the excess flows through the overflow tube and is collected in a graduated cylinder. The volume of this overflow measured in milliliters is known as the Canadian standard freeness value.
EXAMPLE I
Several latices are prepared according to the following recipe with the amounts of reactants set forth in the table. All parts are weight parts per 100 weight parts of monomer.
______________________________________ RunIngredients 1 2 3 4______________________________________Soft water 133 133 133 133HCHO-Naphthalene sulfonic acid 1.0 1.0 1.0 1.0Tebrasodium EDTA* 0.2 0.2 0.2 0.2EDTA NaFe 0.004 0.004 0.004 0.004Trisodium phosphate 0.5 0.5 0.5 0.5KOH 0.8 0.8 0.8 0.8Potassium polybasic acidNo. 1 4.0 -- -- --No. 2 -- 4.0 -- --No. 3 -- -- 4.0 --No. 4 -- -- -- 4.0T-C.sub.12 mercaptan 0.3 0.3 0.3 0.3Acrylonitrile 32.8 32.8 32.8 32.8Butadiene 67.2 67.2 67.2 67.2Cumene hydroperoxide 0.6 0.6 0.6 0.6Sodium formaldehyde sulfoxylate 0.046 0.046 0.046 0.046______________________________________ 1 3% C.sub.54 trimer acid, 97% C.sub.36 dimer acid 2 17% C.sub.54 trimer acid, 83% C.sub.36 dimer acid 3 25% C.sub.54 trimer acid, 75% C.sub.36 dimer acid 4 60% C.sub.54 trimer acid, 40% C.sub.36 dimer acid *EDTA is ethylenediamine tetraacetic acid
The reaction was conducted at 8° C. for 24 hours to obtain substantially complete conversion. There was added to one portion of the latex 1 weight part of a monocarboxylate 2-imidazoline derivative wherein R is derived from coconut oil containing 8 to 18 carbon atoms with an average of C 12-14 . The Canadian freeness of these latices was determined after the addition of 5% sodium citrate solution in the amounts indicated in the table to the asbestos slurry and then the latex was added in amounts to add 20% on the asbestos.
______________________________________ No 2-imid- Addi- azolineLatices tives derivative______________________________________cc sodium citrate 10 10Canadian standard freeness - cc 715 610cc sodium citrate 20 20Canadian standard freeness - cc 595 515cc sodium citrate 30 30Canadian standard freeness - cc 430 380cc sodium citrate 40 40Canadian standard freeness - cc 350 315______________________________________
EXAMPLE II
Another butadiene-acrylonitrile latex containing 67.2% butadiene-1,3, 32.8% acrylonitrile polymerized with 4.0 weight parts of potassium polybasic acid containing 75% dimer acid and 25% trimer acid was treated by adding thereto 1.5 weight parts of a sodium salt of a dicarboxylic imidazoline of caprylic acid wherein R is C 7 H 15 . The Canadian standard freeness values obtained on the addition of 0, 10, 20 and 30 cc. of 5% sodium citrate are as follows: The control at 0 was 780, at 10 was 710 and at 30 was about 375. With the imidazoline additive, a straight line curve was obtained in contrast to the control not containing the imidazoline derivative, and the Canadian standard freeness values were, at 0 was 775 cc., at 10 cc. was 650 cc., at 20 cc. was 535 cc. and with 30 cc. was 410 cc.
EXAMPLE III
Another series of polymer latices were prepared in accordance with Example I wherein both the polybasic acid salt and 2-imidazoline derivative were present in the polymerization initially. The polymerization recipes of Example I were used and the amounts and types of the polybasic acids and 2-imidazoline derivatives are set forth in the table below.
______________________________________ RunStabilizers 1 2 3 4______________________________________Emery 33480 3.0 -- -- --10% dimer acid90% trimer acid -- 3.0 -- --75% dimer acid25% trimer acid -- -- 3.0 --75% dimer acid25% trimer acid -- -- -- 3.02-imidazoline coconutoil derivative, RC.sub.12.sub.-14 average 1.0 1.0 1.0 1.0______________________________________
These latices were then tested for Canadian standard freeness when the indicated amounts of sodium citrate solution was added thereto with the results shown in the data table below.
______________________________________ Run 1 Run 2 Run 3 Run 4______________________________________cc Sodium citrate 0 0 0 0CSF 765 790 760 760cc Sodium citrate 10 10 10 10CSF 650 700 655 650cc Sodium citrate 20 20 20 20CSF 500 580 480 500cc Sodium citrate 30 30 30 30CSF 360 420 370 370______________________________________
EXAMPLE IV
This example demonstrates the control of the Canadian standard freeness of a polymer latex of an alkyl acrylate wherein the polymer contains about 75% ethyl acrylate, 21% methyl methacrylate and 4% acrylonitrile. Run No. 1 contained potassium salt, a polybasic material containing 40% dimer, 60% trimer added in amounts of 2.5 weight parts. Run No. 2 contained the same polycarboxylic salt in the same amount and in addition one weight part of the sodium salt of the coco 2-imidazoline derivative and Run No. 3 contains 2.5 weight parts of the potassium polybasic acid containing 75% dimer, 25% trimer and one weight part of the 2-imidazoline derivative. This demonstrates both the improvement obtained when both the polybasic acid and 2-imidazoline derivative are present and that unexpectedly improved control of Canadian standard freeness is obtained with polybasic acids containing the higher dimer acid content. The data obtained when adding the listed cc. of 5% sodium citrate solution and the resulting Canadian standard freeness are set forth in the data table below.
______________________________________ Run 1 Run 2 Run 3______________________________________cc sodium citrate 0 0 0Canadian standard freeness 830 810 785cc sodium citrate 10 10 10Canadian standard freeness 830 790 740cc sodium citrate 20 20 20Canadian standard freeness 800 750 700cc sodium citrate 30 30 30Canadian standard freeness 730 695 645______________________________________
As a further demonstration of the Canadian standard freeness obtained with varying amounts of these additives, two samples of this latex were made up, one containing (1) 0.5 weight part of the 2-imidazoline derivatives and 1.8 weight part of the polybasic salt and (2) 1 weight part of the 2-imidazoline derivative and 2.5 weight parts of the potassium polybasic acid. The polybasic acid contained 75% dimer and 25% trimer. With 0 cc. of sodium citrate the CSF of No. 1 was 820 and No. 2 was 795; at 20 cc., No. 1 was about 795 and No. 2 was 700; at 30 cc., No. 1 was at 700 and No. 2 at 650; at 40 cc., No. 1 was about 530 and No. 2 was 400.
Fiber sheet formed in accordance with this invention has good drainage rates, good appearance and there is no stocking to screen or felt. The dry sheets have good tensile strengths.
|
In fiber beater addition processes, polymer latexes containing a water-soluble salt of polybasic fatty acid and a 2-alkyl imidazoline derivative have storage stability and provide a broad range of freeness response from the same latex for use in the fiber slurry beater addition of latices to form fiber sheet materials in which polymers in latex form are incorporated into water dispersions of fibers and deposited thereon by coagulation. These latexes are obtained by either polymerizing the monomers to form polymer in aqueous dispersion in the presence of the polybasic fatty acid and 2-alkyl imidazoline derivative, by the presence of at least one of them during such polymerization and the addition of the other to the latex before adding to a water dispersion of the fiber, or addition of the polybasic fatty acid salt and 2-alkyl imidazoline derivative to an already prepared latex.
| 3
|
INTRODUCTION
[0001] This invention relates to a client device capable of receiving a multicast stream through multiple communication networks. More particularly, this invention relates to a client device capable of receiving a multicast content through multiple communication networks, comprising at least one broadband network and one broadcast network for connection respectively to at least one broadband interface and one receive-only broadcast interface of the client device. Furthermore, the invention relates to a method for sending and/or receiving a multicast content through multiple communication networks.
BACKGROUND TO THE INVENTION
[0002] Multicast, unidirectional link, combination of multiple communication links, multicast proxy, and multicast router are concepts or components which are widely used in multicast streaming sessions. Within a multicast streaming session, a multicast traffic is sent as a data stream to various receivers. The group of receivers however may vary in time. Receivers indicate their desire to receive a given multicast session using the IGMP protocol (RFC 3376).
[0003] A unidirectional link is a transmission channel that does not offer a return path. Multicast routing protocols exist that route multicast traffic through the Internet. For example, DVMRP (RFC 1075) and PIM protocols can be applied. There is also a daemon called IGMP-Proxy that proxies IGMP requests from one network to another network and thus implements a kind of IGMP snooping similar to what is described in RFC 454.
[0004] Smart management of the delivery network for multicast and broadcast traffic in a client device, such as a gateway can be done by selecting the most appropriate network adapter.
[0005] Multicast IP is composed with two main features. Firstly, an addressing scheme based on the group address wherein the IP address identifies a multicast group that is a TV channel/stream when applied to IPTV and secondly a IP signaling companion protocol called IGMP (IP Group Management Protocol) that is used by a terminal/application to signal its connection and disconnection to a group which is for example a TV channel. The IGMP protocol allows an IP network which is composed of one or more routers to optimize the distribution of multicast IP traffic by forwarding multicast IP packet only over branches where at least one group member has been signaled. Broadcast network has evolved in a way that it can transport IP streams including multicast IP streams. Alternatively, in the context of IPTV, IGMP is also used for selecting a TV channel.
[0006] Various attempts have been made in order to improve multicast transmission to a client in order to optimize distribution of the multimedia content.
[0007] In CN 101521626 A, a method for stepping control of a multicast program is shown which includes the following steps. Sending a multicast program request message to the access device by the terminal device; referring and obtaining the program step parameter by an access device according to said multicast program request message; and generating the multicast program data by the access device according to said program step parameter. The manufacturer can therefore order some multicast programs according to the multicast program stepping control terminal device in priority and provides a differentiated service according to the program.
[0008] In US 2006/0098618 A1, a method, a bridging device, a network of devices as well as a computer program product and a computer program element are shown which can be used for prioritizing transportation of isochronous data streams from a first bus having a first bandwidth to a second bus using a medium having a second medium bandwidth lower than the first bandwidth. The bridging device monitors control traffic relating to data streams originating from devices connected to the buses, polls the registers made available by the devices connected to the buses, prioritizes streams for transfer based on relevant information transported in the bus control traffic and/or made available by the devices connected to a bus and transfers streams over the medium based on the prioritizing. Accordingly, prioritizing streams for transportation over a wireless bridge between two data buses that is transparent to devices connected to the buses is possible.
[0009] In US 2011/0058551 A1, a method for managing multicast traffic through a switch operating in the layer 2 of the OSI model, and routers and switches involved in the method are shown. In one implementation, a router sends to a switch a message containing identification of a specific equipment which has requested specific multicast traffic, and also containing a specification of the specific traffic, and when the switch receives data carrying multicast traffic, based on the destination and origin addresses of the data, and based on the identification of the specific equipment and of the specification of the specific multicast traffic that it has received in the message, the switch deduces if the data carry the specific traffic that has been requested by the specific equipment, and decides through which of its ports it transmits the data.
[0010] In U.S. Pat. No. 6,487,170 B1, a method and apparatus are provided for making admission decisions in a packet switched network, such as a Differentiated Services (DiffServ) Packet Network. According to one aspect, admission control decisions are based upon local information. An average premium service bandwidth utilized on an output link of a network device during a predetermined window of time is calculated. A determination regarding whether to accept or reject a request for a premium service flow involving the output link is made based upon the request, a total premium service bandwidth available on the output link, the average premium service bandwidth, and bandwidth request information associated with one or more flows that have been admitted within a predetermined holding time interval. According to another aspect, multicast flows are supported. A measure of utilized premium service bandwidth is calculated for each of the output links of a multicast-capable network device. A request for premium service bandwidth for a multicast session is forwarded onto those of the output links specified by a multicast routing protocol which have sufficient premium service bandwidth available to accommodate the request based upon the total premium service bandwidth available on the output link, the measure of utilized premium service bandwidth on the output link, and the request. For each of the output links associated with the multicast session, a link state is maintained. The link state indicates the current state of a state machine that determines the behavior of the multicast-capable network device for the corresponding output link of the multicast session. Multicast packets that are subsequently received are forwarded according to the link states associated with the output links.
[0011] The paper of Wan-Ki Park and Dae-Young Kim: “Convergence of Broadcasting and Communication in Home Network Using an EPON-Based Home Gateway and Overlay”, IEEE Transactions on Consumer Electronics, Vol. 51, no. 2, pages 485-493, 2005, describes home network systems including a home gateway which are expected to facilitate the convergence of broadcasting and communication services to complement the ubiquitous computing and services. A modified architecture is shown that integrates broadcasting and data services in a home network. For this architecture, an overlay transport mechanism in access network and IP multicast techniques of the Internet group management protocol (IGMP) and IGMP snooping in a home network is used.
[0012] Furthermore, it is known to select dynamically, in the head-end, the most appropriate network which is a broadcast unidirectional link like DVB-T, DVB-C or DVB-H or broadband link to deliver IP multicast traffic.
[0013] Such a concept has been described in EP 1298836 A1. Within this document, a principle is shown which attributes to privilege the broadcast link when a given number of users request the same content and save the broadband bandwidth.
[0014] This concept, however, presents some limitations. The multicast content available either over broadband or broadcast is selected by the operator. Consequently, the quantity and diversity of multicast contents concerned by this load balancing is limited. If the user wants to receive other multicast content, this last will be automatically delivered over broadband, even if it is much more queried than other multicast traffic delivered over broadcast. Furthermore, the client is seen as a simple terminal with a single broadcast adapter and receiving a single IP multicast service simultaneously. Optimizing can be done for the delivery of multiple IP multicast streams (and also broadcast ones) to the home network.
[0015] Accordingly, there is a need in the art to overcome, at least partially, the problems associated with the prior art systems.
SUMMARY OF THE INVENTION
[0016] According to the invention, there is provided a client device capable of receiving a multicast content through multiple communication networks, comprising at least one broadband network having a broadband bandwidth and one broadcast network for connection respectively to at least one broadband interface and one receive-only broadcast interface of the client device, wherein said client device comprises an adapter selector capable of selecting the interface to be used in order to save the broadband bandwidth.
[0017] The client device is, for example, a gateway.
[0018] According to an embodiment of the invention, the adapter selector is capable of sending a message using a protocol to permit signaling and activation of the selected interface and requesting a routing of the multicast content through the appropriate communication network.
[0019] According to a further embodiment of the invention, the adapter selector is able to capture and analyze a client request of a multicast stream and is further able to send, if needed, a control message towards a multicast proxy server, requesting that the multicast stream is served over the at least one broadcast network.
[0020] According to a further embodiment of the invention, the protocol is an extension of an IP Group Management Protocol.
[0021] In a further aspect of the invention, there is provided a method for sending and/or receiving a multicast content through multiple communication networks, comprising at least one broadband network having a broadband bandwidth and one broadcast network being connected respectively to at least one broadband interface and one receive-only broadcast interface of a client device, wherein said method comprises a step of selecting the interface to be used in order to save the broadband bandwidth. According to an embodiment of the invention, the method further comprises a step of receiving requests and redirecting the requests to a broadcast router such that a IP multicast stream is selected to be transmitted over the broadcast network to the broadcast interface of the client device.
[0022] According to a further embodiment of the invention, the method comprises a step of sending a message using a protocol to signal and to activate the selected interface and a step of requesting a routing of the multicast content through the appropriate communication network.
[0023] According to a further embodiment of the invention, the method comprises a step of capturing and analyzing a client request of a multicast stream and a step of sending, if needed, a control message towards the multicast proxy, requesting that the multicast stream is served over the at least one broadcast network.
[0024] According to a further embodiment of the invention, the method comprises a step of redirecting the client request to a corresponding broadcast router which builds a required distribution tree so as to send the multicast content to the client device over the broadcast network.
[0025] Advantageously, the protocol is an extension of an IP Group Management Protocol.
[0026] Preferably, the protocol includes a message to signal a request from the client device to receive or to stop receiving a multicast IP stream.
[0027] According to an embodiment, the protocol includes a message to signal a request received from the multicast proxy server indicating that a multicast IP stream is no longer available or is now available on the broadcast network.
[0028] Advantageously, the interface to be used is selected according to the multicast content bandwidth and/or the popularity of said multicast content.
[0029] The popularity of a content means here the number of clients interested by said content.
[0030] According to the invention, the behavior of the client device, particularly a home network gateway with at least one broadcast adapter when a client requests an IP multicast stream, knowing that other clients may be receiving simultaneously multicast or broadcast streams is described. The gateway attempts to affect the most bandwidth-consuming stream(s) on the broadcast channel. In order to do this, the gateway selects the network according to several criteria as the stream bandwidth, the type of service which is broadcast or multicast, the possibility to receive several streams on the same broadcast transport stream. Accordingly, the gateway is not a passive element and one can also manage the case in which a client requests for a broadcast content. At the head-end side, the multicast proxy behavior is globally the same as the one described in EP 1298836 A1. The difference comes from the fact that messages exchanged between the gateway and the multicast proxy are not the usual multicast signaling (IGMP) messages but new ones. IGMP messages are not sufficient to carry indeed all necessary information to allow the gateway to take the best decision. The new messages extend IGMP messages to solve this issue. Accordingly, the invention allows to dynamically adjusting the set of programs or services transmitted by a broadcast link based on requests issued by the target receivers, thus making optimal use of the available broadcast bandwidth.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The invention will now be described in greater detail by way of example with reference to the following drawing in which:
[0032] FIG. 1 shows a schematic view of a system for combining multiple communication links;
[0033] FIG. 2 shows a further schematic view of a system for combining multiple communication links according to an embodiment of the invention;
[0034] FIG. 3 shows a detail of a packet according to an embodiment of the invention;
[0035] FIG. 4 shows method steps performed in an embodiment of the invention in a flow chart;
[0036] FIG. 5 shows method steps performed in an embodiment of the invention in a further flow chart; and
[0037] FIG. 6 shows a further schematic view of a system for combining multiple communication links according to an embodiment of the invention.
[0038] In the drawing, alike reference numerals refer to alike parts, unless otherwise indicated.
[0039] FIG. 1 depicts a system 10 for combining multiple communication links for supporting the IGMP feature in a broadcast network. A terminal 12 that can be a TV set owns a broadcast interface 14 that is seen by the internal logic as a network interface supporting the IP protocol. This network interface 14 receives video packets and delivers RTP/UDP/IP multicast packets to a IP stack 16 . The application opens the multicast socket corresponding to one IP multicast group address assuming the application was able to associate a multicast IP address with a TV program thanks to metadata such as ESG—Electronic Service Guide.
[0040] Consequently, the IP stack 16 generates an IGMP request that is then tunneled up to an IGMP frontal called a multicast proxy 20 , a function owned by the broadcaster that is hooked to a broadcast network 18 . The multicast proxy 20 interacts with the broadcast network infrastructure 18 and possibly activates the forwarding of the TV program if not already activated. The decision to activate a program is done depending of other criteria like the numbers of receivers interested by this program. The part of the broadcast network 18 e.g. a transmitter that is concerned by the program forwarding is linked with the terminal location. This information can be based on GPS information if the terminal 12 is accordingly equipped or by any other means like for instance the identifier of the broadcast transmitter which is broadcast continuously as part of the system information.
[0041] Alternatively, when the user tunes to another TV program or when the user shutdowns the service, the application must close the socket. This generates an IGMP message indicating the disconnection from the associated IP multicast group/address. The message is sent again to the multicast proxy 20 that again controls the broadcast network implying a potential stop in forwarding the TV program in the part of the broadcast network 18 associated with the terminal location.
[0042] As introduced previously, the multicast proxy 20 permits an interaction between the terminal 12 and the broadcast network 18 through a method compliant with the IPTV state of the art (xDSL TV or DVB IPTV). Typically IGMP messages are received by multicast IP routers 22 , 22 ′, 22 ″ that decide to filter and forward multicast IP traffic accordingly. This proxy 20 is identified by an IP address which is known in advance by the home gateway just like the address of the DNS servers or the default gateway. The multicast proxy 20 can be either a separate box or a function embedded in one of the edge or broadcast routers 22 , 22 ′, 22 ″.
[0043] The multicast proxy 20 must be able to localize the terminal 12 in order to adopt a strategy associated with the IGMP message. The localization can be performed through different means and the information must be attached to the IGMP message. The multicast proxy 20 knows the capacity of the broadcast routers 22 , 22 ′, 22 ″ and the bandwidth consumed by each multicast service. It counts the number of candidate receivers for each multicast service and puts the “most wanted” services on the one of the broadcast links. For the services that must be served over a broadcast link 18 , it sends control messages to the dedicated broadcast router to make it join those multicast services. It informs the client gateways accordingly.
[0044] When a service is no longer candidate for broadcast distribution, for example it moved down in the “most wanted” list, the proxy 20 tells the broadcast router 22 , 22 ′, 22 ″ to leave the group and informs the gateways that they should request the service over a broadband link 24 using an IGMP report membership message.
[0045] The broadcast network 18 can be organized with a unique branch e.g. satellite, a simple tree composed with a set of transmitters distributed among a territory e.g. terrestrial TV or a multi level hierarchical tree e.g. a cellular network supporting multicast or a cable network.
[0046] Changing dynamically the content that is multicast over a branch has some implications. First it means that the overall set of programs distributed at a transmission point 26 changes from time to time. This advocates for a broadcast network 18 where the transport multiplex is formed at the extremities, i.e. the transmission points 26 .
[0047] Removing a program frees some bandwidth that can be used for various needs like downloading metadata (software updates, applications), allowing more bandwidth for statistical multiplexing programs and thus better quality, allowing more bandwidth for push VOD.
[0048] A broadcast network (DVB-C, DVB-T, DVB-S . . . ) is made up of several Transport Streams (TS), each one being delivered at a different frequency. A transport stream encapsulates packetized elementary streams. Each piece of data (e.g. tables) or elementary stream in a transport stream is identified by a 13-bit packet ID (PID). According to the invention, it is to be assumed that at least one of the transport streams delivers IP multicast traffic. IP multicast traffic may coexist with usual broadcast traffic within the same transport stream.
[0049] The broadcast adapter 14 can tune to only one frequency, i.e. it can receive only a single transport stream TS at the same time. It is considered that the broadcast adapter 14 is efficient enough to transmit the content carried over all the PIDs, i.e. it can demultiplex all the PIDs, within the selected transport stream.
[0050] For multicast traffic, a different PID can be assigned to each IP service. Consequently, each service is managed individually, the traffic contained in packets of a given value (PID) corresponding to a single multicast service. The gateway is not flooded with useless traffic but the broadcast adapter 14 has to filter as many PID as multicast services received simultaneously. The other solution consists in broadcasting all IP multicast traffic within the same PID. The broadcast adapter 14 needs to listen to only one PID but the gateway is flooded with useless traffic. The way to identify IP multicast packets, i.e. a single PID or a PID per IP stream, has no impact on the invention described herein as both concepts are conceivable.
[0051] In order to offload a broadband access from heavy multimedia multicast traffic, said traffic may be redirected to a broadcast transmission link 26 such as DVB-T whenever possible and judicious. In the previous, the optimization of the bandwidth in the broadband and broadcast networks through an aggregation point was described. This solution is sufficient and well adapted if there is only one multicast service received at a given moment by the gateway. But if there is a gateway 30 with several connected terminals 12 such as a home network 28 , each one is requesting for a different multicast service at the same time, as shown in FIG. 2 .
[0052] As it is not clear what will be the delivery behavior if all services are available on broadcast, as the first requested multicast stream may be delivered over broadcast and the others, by default, on the broadband, even if one would need more bandwidth.
[0053] Moreover, the case where the gateway 30 has several broadcast adapters is not dealt with. The gateway may privilege one broadcast link to another.
[0054] In the following, a system and method that optimizes the delivery of multicast traffic over a broadband and one or several broadcast networks if the gateway 30 fulfils at least one of the two above mentioned cases i.e. several broadcast adapters or/and several multicast streams requested simultaneously is presented. An overview of the system is shown in FIG. 2 .
[0055] In FIG. 2 , the home network 28 is made up with the gateway 30 and the terminals 12 . The gateway 30 gathers a broadband adapter 36 and one or more broadcast ones 34 , 34 ′. It contains also an adapter selector 32 , called virtual (or logical) adapter 32 , which hides the broadband 36 and broadcast(s) adapters 34 , 34 ′. All the terminals 12 see is this virtual adapter 32 . The virtual adapter 32 hides the plurality of interfaces 34 , 34 ′, 36 to the IP layer, one of them being bidirectional, the other ones being broadcast receive-only. That is, every IP packet sent out by the gateway 30 goes through the bidirectional link and all the traffic received on both interfaces is received by the virtual adapter 32 and presented to the IP layer.
[0056] Each time a terminal 12 requests for a multicast stream, the virtual adapter 32 has the responsibility to select smartly the best adapter. According to the requests emitted by the terminals 12 to join or leave a multicast group, the virtual adapter 32 can ask to change dynamically and seamlessly the physical adapter associated to a multicast stream. The virtual adapter 32 filters IGMP messages and processes the improved multicast proxying protocol.
[0057] The gateway 30 does not transmit a generic request (IGMP message) to the multicast proxy 20 but analyzes the request according to several criteria before sending the formatted message.
[0058] Criteria are based on home network 28 parameters which are IP multicast streams requested simultaneously, available broadcast adapters, multicast/broadcast stream bandwidth and broadcast multiplex organization.
[0059] Usually when a terminal 12 wishes to receive a particular multicast traffic, it issues an IGMP Membership Report message via its network adapter towards the edge router which then builds the required distribution tree (towards the multicast source) and sends the multicast traffic towards the terminal 12 . Instead, in the invention, the client IGMP message is captured and analyzed by the adapter selector 32 which sends, if needed, a control message via the broadband adapter 36 towards the multicast proxy 20 , requesting that the same multicast stream be served over a broadcast link 38 . According to a particular embodiment, the multicast proxy 20 sends a message to the corresponding broadcast router 22 , 22 ′ to build the required distribution tree (towards the multicast source) and send the multicast traffic to the terminal 12 .
[0060] From the terminal's perspective, the additional control messages are invisible. It requests a multicast flow using normal IGMP messages and receives the multicast traffic via the virtual adapter 32 .
[0061] IGMP messages as defined in RFC 1112 (v1), RFC 2236 (v2) or RFC 3376 (v3) are not sufficient to carry all needed information. Consequently, new control messages are introduced which are presented in the following.
[0062] IGMP messages are used to optimize the delivery of multicast traffic over the network. But IGMP messages are not sufficient to transmit all necessary data and need to be enriched with additional information. Hereafter is a description of this new protocol and the way messages are exchanged.
[0063] The virtual adapter 32 captures all the outgoing IGMP messages and replaces them by a custom protocol to request that the same multicast traffic be delivered over the broadcast link 38 .
[0064] All the communication between the virtual adapter 32 and the multicast proxy 20 is done by UDP messages sent to a predefined port (for example 5000). The virtual adapter's IP address is the gateway's public IP address. The Multicast Proxy's IP address is known in advance or received via DHCP.
[0065] The multicast proxy 20 knows what services are currently being served over the various broadcast links 38 and consequently the remaining capacity of each link. Thus, it can either acknowledge or refuse a join request depending on whether the service is already being delivered or otherwise the remaining bandwidth on the broadcast links 38 . When it acknowledges the request, the virtual adapter 32 must prepare to receive the multicast traffic over the associated broadcast adapter 34 , 34 ′.
[0066] When it refuses, then the virtual adapter 32 must join the multicast group with its broadband interface 36 using a normal IGMP membership report message (no matter which version of the IGMP protocol). When a terminal 12 is the first one to request a given multicast service and the request is acknowledged by the proxy 20 , the proxy 20 sends a message to the dedicated broadcast router 22 , 22 ′ to start delivering the service over the broadcast link 38 . When the terminal 12 receiving a given service leaves the service, the proxy 20 informs the broadcast router 22 , 22 ′ that it can stop delivering the service.
[0067] The protocol messages have the following syntax as depicted in FIG. 3 :
UDP/IP header (source/destination address and ports) Message type, 8 bits, described below Broadcast link field, 8 bits, described below Embedded IGMP message, depending on the message type Broadcast data, optional, depending on the message type
[0073] “Broadcast link” field is a bit mask where each bit corresponds to a type of broadcast transmission link. Its usage depends on the message type and it is given in the above message type description.
[0074] For instance, one can have the following correspondence table:
[0000]
Values
Broadcast link type
0x1
DVB-T
0x2
DVB-S
0x4
DVB-C
0x8
DVB-H
[0075] The following describes the message types and their use.
Client join request (membership report)
[0077] Message type: 0x01
[0078] Broadcast link lists all the gateway's available broadcast adapters selected by the virtual adapter 32 to receive the wanted multicast traffic.
[0079] Embedded IGMP message is the message sent by the client application and contains the multicast group the terminal 12 wishes to join.
[0080] Broadcast data: not applicable.
Client leave request
[0082] Message type: 0x02
[0083] Broadcast link: specify the broadcast link receiving the multicast stream.
[0084] Embedded IGMP message is the message sent by the client application and contains the multicast group the terminal 12 wishes to leave.
[0085] Broadcast data: not applicable.
Join acknowledged by proxy to client
[0087] Message type: 0x10
[0088] Broadcast link: specify the broadcast link on which the multicast traffic is available.
[0089] One and only one bit must be set to 1, the others being zeroed.
[0090] Embedded IGMP message is the message carried by the join request and contains the multicast group the terminal 12 wishes to join. Receiving this message, the virtual adapter 32 must prepare to receive the multicast traffic over the dedicated broadcast adapter.
[0091] Broadcast data contains the bandwidth required to receive the multicast stream and all parameters about the broadcast link to allow connecting quickly to the multicast stream. The set of parameters depends on the type of broadcast link (frequency, modulation, FEC parameters, polarization, PID . . . ).
Join denied by proxy (=go for normal multicast)
[0093] Message type: 0x11
[0094] Broadcast link: not applicable.
[0095] Embedded IGMP message is the message carried by the join request and contains the multicast group the terminal 12 wishes to join. Receiving this message, the virtual adapter 32 must issue a normal IGMP membership report to receive the multicast traffic normally over the broadband adapter.
[0096] Broadcast data: not applicable.
Proxy requests join from BC router
[0098] Message type: 0x12
[0099] Broadcast link: not applicable.
[0100] Embedded IGMP message is a membership report message and contains the multicast group that the broadcast router must join.
[0101] Broadcast data: not applicable.
Proxy requests leave from BC router
[0103] Message type: 0x13
[0104] Broadcast link: not applicable.
[0105] Embedded IGMP message is a leave group message and contains the multicast group that the broadcast router must leave.
[0106] Broadcast data: not applicable.
Proxy requests clients to report membership (membership query)
[0108] Message type: 0x14
[0109] Broadcast link: not applicable.
[0110] Embedded IGMP message is a membership query message and contains the multicast group for which the proxy wishes to count the members.
[0111] Broadcast data: not applicable.
[0112] In the following, the behavior of the virtual adapter 32 to select the appropriate adapter when it is requested to receive a multicast IP stream is described. The behavior is depicted in the flow chart of FIG. 4 , which is split in FIGS. 4.1 and 4 . 2 . The virtual adapter 32 receives only IGMP messages from the terminal 12 . IGMP request messages do not contain any information about the requested multicast stream itself like bandwidth, type of content and so on.
[0113] First of all, the virtual adapter 32 maintains a table with the list of information about the broadcast streams being received: broadcast adapter, multiplex description like frequency, required bandwidth and information about the multicast streams being received: multicast IP address, number of clients listening to each stream, required bandwidth, adapter and information about the adapter 34 , 34 ′ in case of broadcast one (multiplex description). This list is called “multicast/broadcast stream list”.
[0114] The virtual adapter 32 manages also a list of available broadcast adapters. This list is initialized with all existing broadcast adapters 34 , 34 ′, even if they are already used to receive streams. If this list is empty, that means there is no broadcast adapter 34 available. Hence, the virtual adapter 32 makes no sense because all IP multicast streams will be automatically delivered over the broadband network through broadband adapter 36 .
[0115] The initial state of the virtual adapter 32 is to wait for requests at 100 . Here, the virtual adapter 32 is waiting for an IGMP request from a terminal 12 . The “available broadcast adapters” list is initialized with all broadcast adapters 34 , 34 ′.
[0116] When a terminal 12 requests for a multicast stream, the virtual adapter 32 analyses the IGMP message and gets the multicast IP address as well as the terminal IP address at 102 .
[0117] Several cases emerge from thereon at decision unit 104 .
[0118] In the first case, the multicast stream is currently being received by another terminal 12 in the home network 28 . The virtual adapter 32 only has to increment the counter of terminals 12 listening to this stream via the update of multicast/broadcast stream list function at 106 . It has nothing else to do because the multicast stream is already being delivered to the home network. More particularly, the virtual adapter 32 only has to deliver the stream on the adequate link in the home network. It does not have to modify any other configuration parameter nor transmit a request to the proxy.
[0119] Consequently, it moves back to state 100 to wait for further requests.
[0120] In the second case, no other terminal 12 of the home network 28 is receiving this stream.
[0121] The virtual adapter 32 checks at 108 if the available broadcast adapters 34 list is empty.
[0122] If the list is empty, the virtual adapter 32 transmits an IGMP join request with the adequate multicast IP address at 110 on the broadband network, enters the “seamless re-affectation” steps at 112 (these steps are described later), updates the multicast/broadcast stream list at 106 and returns in the initial state 100 .
[0123] If the list is not empty, then the virtual adapter 32 transmits a “Client join request” (message type: 0x01) at 114 to the multicast proxy 20 , with the available broadcast adapters 34 list as parameter.
[0124] When receiving the answer message from the multicast proxy 20 at 116 , it analyzes it. Two cases happen at 118 : if the message is a “join denied by proxy”, the virtual adapter 32 transmits an IGMP join request with the adequate multicast IP address on the broadband network, enters the “seamless re-affectation” steps 112 (these steps are described later), and updates the multicast/broadcast stream list at 106 and returns in the initial state 100 .
[0125] If the message is a “join acknowledged by proxy to client” message, the virtual adapter 32 analyzes it and gets the broadcast adapter at 120 . Whether this last adapter is already in use to receive any broadcast or multicast stream is decided at 122 . If the broadcast adapter 34 is not used, then the virtual adapter 32 drives the broadcast adapter 34 to receive the requested multicast stream by passing all needed parameters (frequency, modulation, PID, . . . ) at 124 , enters the “seamless re-affectation” steps 112 (these steps are described later), updates the multicast/broadcast stream list at 106 and returns in the initial state 100 .
[0126] If the broadcast adapter 34 is currently used to receive one or several streams, the virtual adapter 32 analyzes the parameters of these last streams (transport stream parameters) at 126 . It checks if the multicast stream is available on the same transport stream (TS) than the stream(s) being received at 128 .
[0127] If the requested stream is also available on the same transport stream, then the virtual adapter 32 drives the broadcast adapter 34 to retrieve also the requested multicast stream by passing all needed parameters (notably the PID) at 124 , enters the “seamless re-affectation” steps 112 , updates the multicast/broadcast stream list at 106 and returns in the initial state 100 .
[0128] If not, the broadcast adapter 34 can't receive them simultaneously. Then, the virtual adapter 32 has to select the most appropriate one to be retrieved on the broadcast network. The selection criterion is the bandwidth at 130 . If the sum of the already received streams requires more bandwidth than the requested one at 132 , the virtual adapter 32 updates available broadcast adapters list by removing this broadcast adapter at 134 and returns to step 108 . The virtual adapter 32 will still continue to receive the already received streams over the selected broadcast link as before.
[0129] If the requested stream requires more bandwidth than the already received ones, then the virtual adapter checks if among all the currently received streams at 136 , there is at least one broadcast stream that is not available as a multicast service (e.g. IPTV service) at 138 . If it is the case, this broadcast adapter 34 will still continue to receive the currently received streams. The virtual adapter 32 updates available broadcast adapters list at 134 by removing this broadcast adapter and returns to step 108 .
[0130] If not, all streams are available as multicast services. This step is repeated for all streams individually. The virtual adapter 32 re-enters in the process, i.e. goes to step 104 for the already being received stream so as to receive it on another adapter 34 ′. The available broadcast adapters list is initialized with all existing broadcast adapters 34 , 34 ′ except this one and the multicast address that becomes the one of the already received IP multicast stream. This step 140 is done recursively. Then, the virtual adapter 32 affects the initial requested stream to the broadcast adapter 34 , i.e. it drives the broadcast adapter 34 to retrieve the requested multicast stream by passing all needed parameters (TS parameters, PID . . . ) at 124 , enters the “seamless re-affectation” steps 112 , updates the multicast/broadcast stream list at 106 and returns in the initial state 100 .
[0131] By proceeding as indicated above, it is guaranteed that the switch between the broadcast network and the broadband one is seamless for the terminal 12 , i.e. there is no content reception breakdown. For this, the virtual adapter 32 ensures that the already received stream is received on another adapter, which can be broadcast or broadband, before stopping its reception on the broadcast adapter affected to the new stream.
[0132] If the two streams bitrates are identical, it may be possible to take into account an additional differentiator, i.e. the terminal priority, e.g. the display in the lounge having priority on the child's bedroom one. This point is not taken into consideration in the flow chart.
[0133] Above, the “seamless re-affectation” steps 112 were mentioned which will be presented in the following. First, the virtual adapter 32 checks if the requested stream is already received on another adapter for the same client at 142 . This happens when a stream is re-affected from an adapter 34 to another. The algorithm ensures the stream will be received on the new adapter 34 before being stopped on the old one. If the requested stream is not received on another adapter 34 , then the virtual adapter 32 updates the multicast/broadcast stream list at 106 and returns in the initial state 100 .
[0134] If the requested stream is already received on another adapter 34 , then the virtual adapter 32 checks if this stream is also being received on the broadband adapter 36 for this client at 144 . If the stream is also received on another broadcast adapter and not on the broadband adapter for this client, then the virtual adapter 32 sends a “client leave request” (message 0x02) to the multicast proxy 20 at 146 . Then, the virtual adapter 32 updates the multicast/broadcast stream list at 106 and returns in the initial state 100 . If this stream is also being received on another broadband adapter 34 , then the virtual adapter 32 sends an “IGMP leave group” at 148 . Then the process goes to step 146 of sending a “client leave request”.
[0135] With reference to FIG. 5 , which is split in FIGS. 5.1 and 5 . 2 , the behavior of a virtual adapter 32 when it is requested to receive a broadcast stream is described. The initial state of the virtual adapter 32 is the same as in the previous section, i.e. it is waiting for a request at 200 . In this case, it is waiting for a request to receive a broadcast stream from a terminal 12 . It also initializes the available broadcast adapters list with all existing broadcast adapters.
[0136] When the virtual adapter 32 receives such a request, it gets information about the broadcast stream (TS, PID . . . ) at 202 and checks if the broadcast adapter 34 is available, i.e. it is not used to receive another stream, or not at 204 . If the broadcast adapter 34 is not used, then the virtual adapter 32 drives the broadcast adapter 34 to retrieve the requested broadcast stream by passing all needed parameters (TS parameters, PID . . . ) at 206 , updates the multicast/broadcast stream list and returns in the initial state 208 .
[0137] If the broadcast adapter 34 is currently used to receive other stream(s), the virtual adapter 32 analyzes the parameters of this last stream, called transport stream parameters, at 210 . It checks at 212 if the broadcast stream is available on the same transport stream (TS) than the stream(s) being received.
[0138] If all streams are on the same transport stream, then the virtual adapter drives the broadcast adapter to retrieve also the requested broadcast stream by passing all needed parameters (notably the PIDs) at 206 , updates the multicast/broadcast stream list at 208 and returns in the initial state 200 .
[0139] If they are not on the same transport stream, i.e. the broadcast adapter can't receive them simultaneously, then the virtual adapter 32 has to select the most appropriate stream(s) to be received on this broadcast network at 214 . It checks at 216 if among the currently received streams there is one broadcast stream that is not available as an IP stream (IPTV service). If there is at least one broadcast stream not available as an IP stream then the virtual adapter 32 privileges to continue to receive the currently received stream at 216 and checks if the requested broadcast stream is available as an IP stream (IPTV service) or not at 218 . As one does not want the broadcast stream to be stopped, the broadcast adapter will continue to receive the broadcast stream.
[0140] Then, the virtual adapter 32 updates the available broadcast adapters 34 list by removing this broadcast adapter 34 and checks if the <<available broadcast adapters list>> is empty or not 220 . If the list is empty, then the virtual adapter 32 checks at 222 if the requested broadcast stream is available as an IP stream (I PTV service) or not. If not, the virtual adapter 32 returns an error message 224 indicating that the requested stream is not available. If it is available as an IP stream, then it enters a process with the adequate IP address 228 and the list of available broadcast adapters 34 contains all the broadcast adapters except this one. If the list is not empty, then the virtual adapter 32 checks if the requested broadcast stream is available on another broadcast network or not at 226 . If it is available on another broadcast network, step 202 is entered through 230 so that the list of available broadcast adapters 34 contains all the broadcast adapters 34 except this one.
[0141] If all the currently received streams are available as IP streams at 216 , then the virtual adapter 32 checks at 232 if the requested broadcast stream bandwidth is greater than the sum of the bandwidths of the currently received ones. If it is the case at 234 , then the virtual adapter 32 enters the process at 236 with the adequate IP address and the list of the available broadcast adapters contains all the broadcast adapters for each already received stream. After, it drives the broadcast adapter to receive the requested broadcast stream by passing all needed parameters (frequency, modulation, PID, . . . ) at 206 , updates the multicast/broadcast stream list 208 and returns in the initial state 200 .
[0142] If it is not the case, the virtual adapter 32 checks if the requested broadcast stream is available as an IP stream (IPTV service) or not at step 218 .
[0143] Several steps which are described above are now outlined in more detail.
[0144] Step: Request from a Terminal 12 to Stop Receiving a Multicast IP Stream
[0145] When a terminal 12 wants to stop receiving a multicast IP stream, the virtual adapter 32 lowers the counter. If the counter is not null, then the virtual adapter 32 does nothing, to let the other terminal(s) continue to receive this multicast stream. If the counter is null, then the virtual adapter 32 sends a message to the “multicast proxy” to leave the group (message 0x02), sends an “IGMP leave group” message, updates the multicast/broadcast stream list by removing information about this Multicast IP stream, and process the algorithm as described above, for all the Multicast IP streams that are currently received on broadband to optimize the delivery of streams to the home network 28 . To do this, the virtual adapter 32 will select a stream and update the available broadcast adapters 34 list with all existing broadcast adapters 34 , the given multicast address that becomes the one of the already received Multicast IP streams, and the multicast/broadcast stream list by removing information about the already received Multicast IP stream.
[0146] Step: Request from a Terminal to Stop Receiving a Broadcast Stream
[0147] When a terminal 12 wants to stop receiving a broadcast stream, the virtual adapter 32 updates the multicast/broadcast stream list by removing information about this broadcast stream, processes the algorithm as described above for all the Multicast IP streams that are currently received on broadband to optimize the delivery of streams to the home network 28 . To do this, the virtual adapter 32 will select a stream and update the available broadcast adapters 34 list with all existing broadcast adapters 34 , the given multicast address that becomes the one of the already received Multicast IP streams, and the multicast/broadcast stream list by removing information about the already received Multicast IP stream.
[0148] Step: Request Received from the Multicast Proxy Indicating that a Multicast IP Stream is No Longer Available on the Broadcast Network
[0149] In the multicast proxy 20 , the algorithm of selection of broadcast IP multicast streams can lead to change the delivery network of a multicast IP stream and switch this last from broadcast to broadband. In this case, the proxy 20 must inform the virtual adapter 32 with the modifications (message 0x11). When such a message is received by the virtual adapter 32 , it starts listening the multicast IP stream on the broadband adapter (sends an “IGMP client join” message) and then stops listening this stream on the broadcast adapter 34 . If the broadcast adapter 34 is unused, the process described above is performed for all the other Multicast IP streams that are currently received to optimize the delivery of streams to the home network 28 .
[0150] Step: Request Received from the Multicast Proxy Indicating that a Multicast IP is Now Available on the Broadcast Network
[0151] In the multicast proxy 20 , the algorithm of selection of broadcast IP multicast streams can lead to change the delivery network of a multicast IP stream and switch this last from broadband to broadcast. In this case, the proxy 20 must inform the virtual adapter with the modifications, using a message 0x10. When such a message is received by the virtual adapter, it enters the process described above. In addition to the state of the art, the multicast proxy must manage the messages described above and must be able to interpret the messages received from the virtual adapters (0x01 and 0x02), answer to the virtual adapters (0x10, 0x11 and 0x14) and transmit request to the broadcast router(s) (0x12 and 0x13).
[0152] The broadcast router 22 is a typical router equipment that has been enhanced to become controllable by the protocol. When it receives the join message (type 0x12) from the proxy 20 , it reads the attached IGMP message to retrieve the multicast group. It uses the normal procedure (PIM, DVMRP, . . . ) to request the same multicast service from its neighbor routers 22 ′. It then performs the broadcast link configuration to carry the additional service.
[0153] Upon reception of the leave message (type 0x13) from the proxy 20 , it leaves the group indicated by the multicast address carried by the embedded IGMP message and stops sending the service over the broadcast link 38 . The way the broadcast router drives the equipment that manages the list of broadcast services (e.g. the IPE for DVB-H) and its signaling (e.g. SI/PSI tables) is out of scope of this disclosure.
[0154] In the previous description, the adapter selection is achieved in the gateway 30 . A variant consists in centralizing the selection in the multicast proxy 20 . Said proxy 20 must manage a table with the configuration of each gateway (broadcast adapters . . . ) and all streams received by each gateway so as to select the best link candidate. But the multicast proxy 20 does not know if broadcast streams are currently being received by the gateway. This could lead to select a broadcast adapter that is not the good candidate because it is receiving a broadcast stream. To fill this lack, the virtual adapter 32 must also inform the multicast proxy 20 with information about the currently received broadcast streams.
[0155] Mapping indicates which terminal belongs to which DVB-T router. Multicast proxy 20 knows localization of DSLAMs 300 and coverage area of broadcast routers and maps the terminal requests to the appropriate broadcast router. Control message flows are shown with a dashed line 302 , multicast traffic is represented by a solid line 304 to a content server 306 in FIG. 6 .
[0156] Alternatively, there could be one proxy per DVB-T/broadcast coverage area. This would imply configuring the virtual adapters in that area to always contact the right proxy. The proxy could be integrated in the DVB-T/broadcast router and would not have to perform any mapping operation.
[0157] The handoff to the broadcast link can also be network initiated: at some point in time, the proxy has refused a number of join requests for a specific group because of insufficient bandwidth on the broadcast link. When another service is terminated, the broadcast bandwidth frees up, giving the opportunity to carry another service. The proxy 20 sends an IGMP membership query for the previously refused group to reach the virtual adapters currently receiving this service. The virtual adapters 32 that are currently receiving the service respond with a “Client join request” (message type 0x01) towards the proxy 20 in addition to the normal IGMP membership report message. The proxy 20 can then decide to switch the service to the broadcast link depending on the number of interested clients.
[0158] In summary, the invention allows to dynamically adjusting the set of programs or services transmitted by a broadcast link based on requests issued by the target receivers, thus making optimal use of the available broadcast bandwidth. Although certain embodiments only of the invention have been described herein, it will be understood by any person skilled in the art that other modifications, variations, and possibilities of the invention are possible. Such modifications, variations and possibilities are therefore to be considered as falling within the spirit and scope of the invention and hence forming part of the invention as herein described and/or exemplified.
[0159] This invention having been described in its preferred embodiment, it is clear that it is susceptible to numerous modifications and embodiments within the ability of those skilled in the art and without the exercise of the inventive faculty. Accordingly, the scope of the invention is defined by the scope of the following claims.
|
This invention relates to a client device capable of receiving a multicast content through multiple communication networks, comprising at least one broadband network having a broadband bandwidth and one broadcast network for connection respectively to at least one broadband interface and one receive-only broadcast interface of the client device, wherein said client device comprises an adapter selector capable of selecting the interface to be used in order to save the broadband band-width.
| 7
|
FIELD OF THE INVENTION
[0001] This present invention relates to toys, and in particular, to a toy glider.
BACKGROUND OF THE INVENTION
[0002] Stick horses have been popular toys with children for many years. Stick horses essentially comprises a wooden stick with a plush horse head attached to one end. The idea behind the stick horse is that children place the wooden stick portion between their legs and ‘pretend’ to ride the horse.
[0003] Although the stick horse was a popular toy for many years, it is also a very outdated toy. Due to the fact that horses have been replaced as a means of transportation in modem society with automobiles, motorcycles, bus and planes, to name a few, the viability of a toy horse is diminished. With the modernization of transportation, children are more likely to gravitate to modem vehicles as playthings.
[0004] Although there exist toy cars and the like, there are presently no commercially available simple toys which allow children to ‘pretend’ to drive or pilot modem vehicles, such as cars, trucks, and airplanes. Thus, there is presently a need for toy which simulates this experience for children.
SUMMARY OF THE INVENTION
[0005] An exemplary embodiment of the present invention comprises a toy glider including a shaft, a roller attached to a first end of the shaft, and a housing attached to a second opposing end of the shaft.
[0006] An exemplary embodiment of the present invention also comprises a method for manufacturing a toy glider including the steps of providing a shaft, coupling at least one roller to a first end of the shaft, and coupling at least one housing to a second opposing end of the shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a left side view showing a toy glider according to a first exemplary embodiment of the present invention.
[0008] FIG. 2 is a back side isometric view showing the toy glider of FIG. 1 .
[0009] FIG. 3 is a back side isometric view showing the toy glider of FIG. 1 .
[0010] FIG. 4 is a left side exploded view showing the toy glider of FIG. 1 .
[0011] FIG. 5 is a top side exploded view showing the toy glider of FIG. 1 .
[0012] FIG. 6 is a front view showing the toy glider of FIG. 1 .
[0013] FIG. 7 is a rear view showing the toy glider of FIG. 1 .
[0014] FIG. 8 is a top view showing the toy glider of FIG. 1 .
[0015] FIG. 9 is a bottom view showing the toy glider of FIG. 1 .
[0016] FIG. 10 is an exploded view of exemplary embodiments of the toy glider showing interchangeable parts.
[0017] FIG. 11 is front view of a toy glider according to a second exemplary embodiment of the present invention.
[0018] FIG. 12 is a rear view of a the toy glider of FIG. 11 .
[0019] FIG. 13 is a front perspective view of the toy glider of FIG. 11 .
[0020] FIG. 14 is a rear perspective view of the toy glider of FIG. 11 .
[0021] FIG. 15 is a left side view of the toy glider of FIG. 11 .
[0022] FIG. 16 is a top view of the toy glider of FIG. 11 .
[0023] FIG. 17 is a bottom view of the toy glider of FIG. 11 .
[0024] FIG. 18 is an exploded view of the toy glider of FIG. 11 .
[0025] FIG. 19 is front view of a toy glider according to a third exemplary embodiment of the present invention.
[0026] FIG. 20 is a rear view of a the toy glider of FIG. 19 .
[0027] FIG. 21 is a front perspective view of the toy glider of FIG. 19 .
[0028] FIG. 22 is a rear perspective view of the toy glider of FIG. 19 .
[0029] FIG. 23 is a left side view of the toy glider of FIG. 19 .
[0030] FIG. 24 is a top view of the toy glider of FIG. 19 .
[0031] FIG. 25 is a bottom view of the toy glider of FIG. 19 .
[0032] FIG. 26 is an exploded view of the toy glider of FIG. 19 .
[0033] FIG. 27 is front view of a toy glider according to a fourth exemplary embodiment of the present invention.
[0034] FIG. 28 is a rear view of a the toy glider of FIG. 27 .
[0035] FIG. 29 is a front perspective view of the toy glider of FIG. 27 .
[0036] FIG. 30 is a rear perspective view of the toy glider of FIG. 27 .
[0037] FIG. 31 is a left side view of the toy glider of FIG. 27 .
[0038] FIG. 32 is a top view of the toy glider of FIG. 27 .
[0039] FIG. 33 is a bottom view of the toy glider of FIG. 27 .
[0040] FIG. 34 is an exploded view of the toy glider of FIG. 27 .
[0041] FIG. 35 is front view of a toy glider according to a fifth exemplary embodiment of the present invention.
[0042] FIG. 36 is a rear view of a the toy glider of FIG. 35 .
[0043] FIG. 37 is a front perspective view of the toy glider of FIG. 35 .
[0044] FIG. 38 is a rear perspective view of the toy glider of FIG. 35 .
[0045] FIG. 39 is a left side view of the toy glider of FIG. 35 .
[0046] FIG. 40 is a top view of the toy glider of FIG. 35 .
[0047] FIG. 41 is a bottom view of the toy glider of FIG. 35 .
[0048] FIG. 42 is an exploded view of the toy glider of FIG. 35 .
[0049] FIG. 43 is front view of a toy glider according to a sixth exemplary embodiment of the present invention.
[0050] FIG. 44 is a rear view of a the toy glider of FIG. 43 .
[0051] FIG. 45 is a front perspective view of the toy glider of FIG. 43 .
[0052] FIG. 46 is a rear perspective view of the toy glider of FIG. 43 .
[0053] FIG. 47 is a left side view of the toy glider of FIG. 43 .
[0054] FIG. 48 is a top view of the toy glider of FIG. 43 .
[0055] FIG. 49 is a bottom view of the toy glider of FIG. 43 .
[0056] FIG. 50 is an exploded view of the toy glider of FIG. 43 .
DETAILED DESCRIPTION
[0057] FIGS. 1-3 show a toy glider 100 according to a first exemplary embodiment of the present invention. FIG. 1 shows a left side view of the toy glider 100 , and FIGS. 2 and 3 show isometric views. The toy glider 100 comprises a shaft 110 , a roller 120 , a housing 130 , a front end 140 and a sound and/or light pad 150 .
[0058] The shaft 110 may comprise a unitary member, or may comprises a two-piece ‘snap-fit’ construction, as is well known in the art. The roller 120 is coupled to a first end 111 of the shaft 110 and includes at least one wheel 121 , which may be held in place by an axle (now shown) disposed in the roller body. The roller 120 may also include optional decorative members, such as decorative wings 122 , 123 shown. As will be explained in detail below, the decorative wings 122 , 123 may comprise a plurality of different designs, such as for example, the tail wings of a jet plane (or spaceship), the bumper and/or tail lights of an automobile, or other various designs.
[0059] The housing 130 preferably includes handles 133 , 134 for grasping and holding the toy glider 100 . As with the roller 120 , the housing 130 may also include optional decorative members, such as decorative wings 136 shown. As will be explained in detail below, the decorative wings 136 may comprise a plurality of different designs, such as for example, the wings of a jet plane (or spaceship), the rear view mirrors of an automobile, or other various designs.
[0060] The front end 140 preferably includes a toy windscreen 141 and a decorative bumper 142 . As will be explained in detail below, the decorative bumper 142 may comprise a plurality of different designs, such as for example, the front end of a jet plane, the front end of an automobile, or other various designs.
[0061] The sound and/or light pad 150 may be configured to emit sounds, light displays, or both. The sound and/or light pad 150 may also include buttons, switches or other members which serve to actuate the sound and/or light displays. For example, if the toy glider 100 is made to resemble a police car, the sound and/or light pad 150 may include a ‘siren’ sound and flashing red lights.
[0062] As shown in FIGS. 4 and 5 , the housing 130 may be formed of left half piece 131 , and a right half piece 132 which are preferably coupled together at one end of the shaft 110 , so as to secure a second end 112 of the shaft 110 therebetween. As also shown in FIGS. 4 and 5 , the first end 111 of the shaft 110 may be disposed and secured within an opening in the roller 120 .
[0063] FIGS. 6-9 show additional views of the toy glider 100 . In particular, FIG. 6 shows a front view of the toy glider 100 , and FIG. 7 shows a rear view. FIG. 8 shows a top view of the glider 100 , and FIG. 9 shows a bottom view.
[0064] FIG. 10 is an exploded view of the toy glider 100 showing parts which are interchangeable. For example, although the toy glider 100 is described above as including a roller 120 , decorative wings 136 , and a decorative bumper 142 , and alternate exemplary embodiment of the toy glider 100 ′ may be manufactured which includes roller 120 ′, decorative wings 136 ′, and decorative bumper 142 ′. As will be noted, the roller 120 , decorative wings 136 , and a decorative bumper 142 of the toy glider 100 are made to respectively resemble the front end, side wings and rear wings of a jet plane, and the roller 120 ′, decorative wings 136 ′, and a decorative bumper 142 ′ of the toy glider 100 ′ are made to respectively resemble the front end, rear view mirrors and rear bumper of an automobile.
[0065] It will be noted by those of ordinary skill in the art that a plurality of different rollers (e.g., 120 , 120 ′), wings (e.g., 136 , 136 ′) and bumpers (e.g., 142 , 142 ′) may be manufactured and provided to make the toy glider resemble different types of vehicles and/or objects (e.g., motorcycle, animal, cartoon character, etc.). The interchangeability of these parts permits the manufacturer of the toy glider to tailor the toy to different child's tastes with minimal effort and expense.
[0066] In operation, a child straddles the shaft 110 of the toy glider 100 and grasps the handles 133 , 134 . The child then moves the toy glider around using his or her feet while holding the handle 133 , 134 . The roller 120 is preferably disposed on the ground during operation, and the wheel 121 thereof rolls along the ground as the child moves the toy glider 100 about. As discussed above, the sound and/or light pad 150 may be activated during operation of the toy glider 100 . This may be accomplished either by the actuation of a button, switch or other means by the child, automatically upon movement of the wheel 121 , automatically upon grasping of the handles 133 , 134 , and/or by some other mechanism known to those of ordinary skill in the art.
[0067] FIGS. 11-18 show a toy glider 200 according to a second exemplary embodiment of the present invention. The toy glider 200 comprises a shaft 210 , a roller 220 , a housing 230 , a front end 240 and a sound and/or light pad 250 . The toy glider 200 is similar in appearance to the toy glider 100 , and like reference numerals denote like elements. However, the roller 220 , handles 233 , 234 , decorative wings 236 and decorative bumper 242 are made to resemble a spaceship.
[0068] FIGS. 19-26 show a toy glider 300 according to a third exemplary embodiment of the present invention. The toy glider 300 comprises a shaft 310 , a roller 320 , a housing 330 , a front end 340 and a sound and/or light pad 350 . The toy glider 300 is similar in appearance to the toy glider 100 , and like reference numerals denote like elements. However, the roller 320 , handles 333 , 334 , decorative wings 336 and decorative bumper 342 are made to resemble a police truck.
[0069] FIGS. 27-34 show a toy glider 400 according to a fourth exemplary embodiment of the present invention. The toy glider 400 comprises a shaft 410 , a roller 420 , a housing 430 , a front end 440 and a sound and/or light pad 450 . The toy glider 400 is similar in appearance to the toy glider 100 , and like reference numerals denote like elements. However, the roller 420 , handles 433 , 434 , decorative wings 436 and decorative bumper 442 are made to resemble a motorcycle.
[0070] FIGS. 35-42 show a toy glider 500 according to a fifth exemplary embodiment of the present invention. The toy glider 500 comprises a shaft 510 , a roller 520 , a housing 530 , a front end 540 and a sound and/or light pad 550 . The toy glider 500 is similar in appearance to the toy glider 100 , and like reference numerals denote like elements. However, the roller 520 , handles 533 , 534 , decorative wings 536 and decorative bumper 542 are made to resemble a fire truck.
[0071] FIGS. 43-50 show a toy glider 600 according to a sixth exemplary embodiment of the present invention. The toy glider 600 comprises a shaft 610 , a roller 620 , a housing 630 , a front end 640 and a sound and/or light pad 650 . The toy glider 600 is similar in appearance to the toy glider 100 , and like reference numerals denote like elements. However, the roller 620 , handles 633 , 634 , decorative wings 636 and decorative bumper 642 are made to resemble a delivery truck.
[0072] Although the invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly to include other variants and embodiments of the invention which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention.
|
A toy glider including a shaft, a roller attached to a first end of the shaft, and a housing attached to a second opposing end of the shaft. The roller, a front end portion of the housing, and other portions of the toy glider are interchangeable to create a variety of different designs.
| 0
|
CONTRACTUAL ORIGIN OF THE INVENTION
The United States Government has rights in this invention pursuant to the employee/employer relationship of the inventors to the United States Department of Energy at the Pittsburgh Energy Technology Center.
BACKGROUND OF THE INVENTION
The present invention relates to a new method for destroying high concentrations of nitric oxides in gas streams. These streams may be recycle streams from regenerable NO x scrubbers for flue gas applications, or they may be industrial waste streams such as those from nitrification processes in the chemical industry.
Flue gases resulting from the combustion of carbonaceous material typically contain substantial quantities of pollutants, including nitrogen oxides. These pollutants combine with other substances found in the atmosphere to produce serious environmental hazards, such as acid rain and smog. It is therefore desirable to remove these pollutants from flue gases before they are dispersed into the atmosphere. It is also desirable to decompose these pollutants into other substances not having the deleterious environmental consequences possessed by nitrogen oxides.
There are two types of methods by which the quantities of NO x dispersed from combustion systems may be reduced. One type, known in the art as combustion modification, requires control over the combustion reaction producing the pollutant. These techniques have generally achieved fifty to sixty percent reductions in NO x emissions from conventional combustion systems.
A specific type of combustion modification, known as reburning, has achieved reductions approaching seventy percent. Using this technique, a secondary fuel source as introduced downstream of the primary combustion zone in the combustor to achieve reductions of NO x . This technique, however, is disadvantageous in that it requires large amounts of secondary fuel to accomplish the reburning of NO x , and additionally requires downstream injection ports in the combustor to effectively control NO x levels in the effluent stream. This method is not effective when more than seventy percent removal of effluent NO x is required.
The second type of NO x removal methods is known as post-combustion cleanup, whereby the pollutant is removed downstream of its formation. These techniques are more complex and expensive than combustion modification techniques, but are useful when NO x reduction levels higher than seventy percent are necessary. In systems employing this technique, a dry scrubbing sorbent or an aqueous sorbent, such as an active metal chelate, are typically used to remove NO x and other pollutants. Certain systems, such as that proposed by Walker, U.S. Pat. No. 4,615,780, additionally incorporate the step of regenerating the sorbent and producing a concentrated stream of NO x which can be recycled as part of the combustion air. This concentrated NO x is destroyed in the combustor and elemental nitrogen and oxygen are produced. This system produces maximum reductions of 60 to 70 percent of the NO x produced by combustion, substantially less as compared to the present invention.
Another scrubber system, proposed by Harkness, et al, U.S. Pat. No. 4,612,175, uses active Fe(II)EDTA as the chelate to remove NO from flue gases simultaneously with the removal of SO 2 . This method, however, produces as an end product aqueous hydroxylamine disulfonate and other sulfonates in a sludge with the aqueous sorbent. These products in themselves create environmental hazards which render the process described by Harkness disadvantageous.
It should be noted that the source of the high concentration NO x stream may be, as described above, a recycle stream from a regenerable scrubber or an industrial waste gas stream, such as that from nitrification processes as used in the chemical industry, high temperature smelting plants, nitric acid manufacturing plants, and any other process where a high concentration of NO x is in the waste stream. The present invention relates to removal and destruction of NO x from such high NO x concentration waste gas streams.
SUMMARY OF THE INVENTION
The method described herein provides a technique for removing introgen oxides from gas streams, discharged from the combustion of carbonaceous materials, in greater quantities than previously known.
It is also an object of the invention to provide a method for the removal of NO x resulting in the production of effluent streams of elemental nitrogen and oxygen.
It is a further object of the invention to provide a method for NO x removal in which a reductant gas is used to further lower the concentration of NO x in the effluent stream.
Another object of the invention is to provide a method wherein unconverted NO x is removed from the discharge stream by a regenerable scrubber and recycled to the combustion device for conversion into elemental nitrogen and oxygen.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of one embodiment of a system using the method described and claimed herein, incorporating a scrubber to produce the concentrated NO x stream.
FIG. 2 is a cut-away view of a burner which may be used in the combustor, in accord with the method described and claimed herein.
DETAILED DESCRIPTION OF THE INVENTION
The invention is described with reference to the drawings. A system, such as that illustrated in FIG. 1, is provided, including a combustor 25. The combustor 25 is suitable for burning carbonaceous materials, such as coal. In the preferred embodiment of the invention, powdered or pulverized coal is mixed with substoichiometric quantities of air (ten to thirty percent of that required for full combustion) from a primary air source 20. The coal-air mixture is provided to combustor 25 through a primary air line 30 into one, or preferably more, burners 35. As illustrated more completely in FIG. 2, the coal-air mixture is provided to each burner through primary air line 30. Secondary air is also introduced into burners 35 via secondary air lines 40, having an outlet 43 downstream of primary air-carbonaceous material injection location (hereinafter "injection location") 45. NO x from outside sources, or from the recycle stream 50 (shown in FIG. 1) is injected into burners 35 through one of three gas lines: with the coat-air mixture, through primary air line 30; with the secondary air through line 40; or through auxiliary gas line 55. It is preferred to inject the NO x through auxiliary gas line 55 having outlet 60 upstream of injection location 45. The burner 35 also includes pilot gas line 70 and pilot gas igniter 75 to cause combustion. If more than one burner 35 is used in the combustor 25, as in FIG. 1 (using four burners), it is preferable to inject NO x through less than all of the burners 35 to allow the NO x to contact hydrocarbons or other reductants in the system, thereby increasing NO x reduction efficiency.
Referring back to FIG. 1, combustion gases are then passed out of combustor 25 via effluent gas line 80 into scrubber 85. Gases not absorbed in scrubber 85 pass through discharge line 90 to stack 95. These gases will typically include carbon dioxide, elemental nitrogen, elemental oxygen, and trace amounts of sulfur dioxide and nitrogen oxides.
In the preferred embodiment of the present invention, reductant gases 82, such as alkane gases, are combined with NO x stream 50 prior to injection into burners 35 with a large volume of air. The reductant gas is mixed with NO x stream 50 at a temperature below the combustion temperature of the gases. In the preferred embodiment of the invention, the molar ratio of reductant gas to NO x is greater than or equal to three, and less than fifteen, to permit sufficient reduction. The injection of reductant into the NO x stream 50 creates an oxygen deficient zone in the injection location 45 (shown in FIG. 2) in burner 35, to achieve maximum reduction of NO x . In the preferred embodiment of the invention, methane is used as the reductant gas. Other alkane gases up to butane may be used, and higher alkanes may also be used, but the higher alkanes will require vaporization before combination with NO x stream 50. Other reductant gases which will be less useful include elemental hydrogen, carbon monoxide and other hydrocarbon gases.
The present invention may also be used in conjunction with another burner, known as to low NO x burner. Such a burner (not illustrated) would consist of a primary air stream including carbonaceous material, a secondary air stream, and a tertiary air stream. As above, NO x would be injected into the burner with the primary air or through the auxiliary gas line, and reductant gases injected with the NO x .
This technique for NO x destruction can be used, for example, in conjunction with a regenerable scrubber, as shown in FIG. 1. In such an application, a scrubber 85 is provided for absorbing NO x in effluent stream 80. The outflow 105 of scrubber 85, containing sorbent and absorbed NO x , is directed to sorbent regeneration means 110, which removes NO x from the sorbent and returns the cleansed sorbent to scrubber 85 through sorbent line 115. Such a scrubber and regeneration means are described by Walker, U.S. Pat. No. 4,615,780, but other scrubber and regeneration means known in the art will function equally effectively. A concentrated stream 50 of NO x is also output from regeneration means 110, and is recycled to provide NO x input into the burners 35 at one or more of gas lines 30, 40 or 55 (as shown in FIG. 2).
The use of the system described above provides higher efficiency of NO x removal then previously known in the art. This is demonstrated by the specific examples set forth below.
EXAMPLE I
This example was performed in a 227 kg/h coal combustor 25 having four burners 35 (as shown in FIG. 1) set vertically within the combustor. The lowest two burners 35 were injected with NO x (to simulate an industrial waste gas stream or recycled NO x ) provided through the auxiliary gas line 55. No reductant gas was added to the system in this example. One and ninety-two hundredths moles NO x were injected per mole NO x produced in the initial combustion. A reduction of 93.9 percent of injected No x was observed.
EXAMPLE II
In this example, the lowest two of four vertically set burners 35 in a 227 kg/h coal combustor 25 were injected with NO x (to simulate an industrial waste gas stream of recycled NO x ), provided through the auxiliary gas line 55 of the burner. Two and five hundredths moles NO x were injected per mole of NO x produced in the initial combustion. Reductant gas, in the form of methane was introduced with the NO x through auxiliary gas line 55, in the amount of 3.9 moles CH 4 per mole NO x reduced. A reduction of 100 percent of the injected NO x was observed.
EXAMPLE III
The lowest two of four vertically set burners 35 in a 227 kg/h coal combustor 25 were again injected with NO x (to simulate an industrial waste gas stream or recycled NO x ) along with the coal-air mixture through inlet 30. Two and five hundredths moles NO x were injected per mole of NO x produced in the initial combustion. Reductant gas, in the form of methane was introduced with the NO x through inlet 30, in the amount of 3.9 moles CH 4 per mole NO x reduced. A reduction of 100 percent of the injected NO x was observed.
Although the present invention is described in terms of specific materials, embodiments and process steps, it will be clear to one skilled in the art that various modifications can be made within the scope of the invention as described in the following claims.
|
An improved method for removing nitrogen oxides from concentrated waste gas streams, in which nitrogen oxides are ignited with a carbonaceous material in the presence of substoichiometric quantities of a primary oxidant, such as air. Additionally, reductants may be ignited along with the nitrogen oxides, carbonaceous material and primary oxidant to achieve greater reduction of nitrogen oxides. A scrubber and regeneration system may also be included to generate a concentrated stream of nitrogen oxides from flue gases for reduction using this method.
| 5
|
FIELD OF THE INVENTION
[0001] The present invention relates to a process for improving the antioxidant activity of chocolate, in a natural way and without the need to add any antioxidant components to the chocolate mass.
[0002] The invention further relates to a novel method for conching and preparing chocolate, as well as to any chocolate prepared according to a method of the invention.
BACKGROUND OF THE INVENTION
[0003] In the art processes have been described to maintain the antioxidant content of cocoa.
[0004] As an example, U.S. Pat. No. 6,660,332 discloses a cocoa bean processing technique that preserves the beneficial flavonoid compounds of cocoa beans in finished, cocoa bean-based foodstuffs.
[0005] This method avoids the significant losses of polyphenols that occur during conventional cocoa processing by removing a significant amount of said polyphenols prior to fermentation and/or roasting and then adding a portion of these polyphenols back.
[0006] In other methods that have been disclosed, antioxidant components/molecules are added at the end of the chocolate production process.
[0007] Typical preparation of “quality” chocolate consists of three stages: (1) mixing and possibly pre-grinding, (2) refining and most importantly (3) conching.
[0008] In the first step, the ingredients are mixed together in a kneader in order to get a paste. Generally, cocoa mass is mixed with sugar and possibly a small percentage of cocoa butter.
[0009] This paste may be subjected to a pre-grinding process in a 2-roll mill in order to obtain an overall fineness of about 150 μm. Sugar could also be pre-refined in a sugar mill.
[0010] In the second step, the actual refining step, the paste is passed on a multiple-roll equipment (generally with five rolls), where the fineness is reduced to an average of 10 to 30 μm. The product obtained is in powder form.
[0011] Most chocolate and certainly all “quality” products are then submitted to a third step, known already for a long time as “conching”.
[0012] During conching, the chocolate is subjected to a prolonged mechanical mixing combined with heating. This is carried out in special vessels known as “conches”.
[0013] Optional ingredients like cocoa butter and flavours are generally added at this stage.
[0014] Lecithin is hereby frequently added as an emulsifier to improve the rheological properties of chocolate, and thereby possibly enabling the amount of cocoa butter to be reduced. Other emulsifiers may also be used, like for example polyglycerol polyricinoleate and ammonium phosphatide.
[0015] During conching, the kneading action combined with high temperature causes evaporation of residual moisture and of some undesired volatile components such as acids generated during the fermentation of the cocoa beans.
[0016] The kneading action also leads to a better dispersion of sugar and cocoa particles in the fat phase formed by the cocoa butter released from the cocoa mass and possibly added.
[0017] The conching process results in the decrease of the viscosity and the yield value. At the end of the conching step, the chocolate has developed the right flavour and the desired rheological properties.
[0018] There are two types of conching operations, respectively known in the art as “dry” conching and “wet” conching (EP 0 489 515). In the following paragraphs: a description of a wet and dry conching as generally applied.
[0019] In “wet” (conventional) conching all the cocoa butter and other ingredients such as lecithin are added early in the process to maintain the fluidity of the mass which is then mechanically worked for a prolonged time, typically for about 20 or 30 hours or more, and at a relatively low temperature, typically at about 40° C. up to about 60° C.
[0020] The (conventional) “dry” conching process on the other hand is operated for a shorter time e.g. up to 20 hours but at a higher temperature mostly above 70° C. and usually about 90° C. for dark chocolate, and above 55° C. and usually around 80° for milk chocolate.
[0021] In this case, the extra cocoa butter and other ingredients are added towards the end of the conching period, e.g. about one hour before the end of the conching period. This last step (after the actual “dry conching”) is commonly known as “liquid conching”.
[0022] The aim of this treatment (“liquid conching”) is to homogenize and to obtain a liquid pumpable mass (EP 0 489 515; Beckett, S. T., 1994; Information given on the britanniafood website, Ziegleder, G., 2006).
[0023] Due to the technological evolution of the process equipment these two conching operations are nowadays generally realized in a shorter period of about 8 up to about 24 hours.
[0024] In the course of this three-step process (mixing & pre-grinding; refining; conching) it is of utmost importance to protect and preserve the development of antioxidants in the chocolate, as these play an important role in the defence mechanism of the body against free radicals.
[0025] Free radicals are molecules or atoms with one or more unpaired electrons. Due to this characteristic they are very reactive.
[0026] Free radicals play an important role in a lot of biochemical reactions, such as the intracellular killing of bacteria's and in certain cell signalling processes (Van Sant, G., 2004; information given on “free radicals” at the wikipedia website).
[0027] However, because of their reactivity, free radicals can damage protein-, fat-, and DNA-molecules in the (human) body.
[0028] They are thought to be the cause of some of the aging symptoms and believed to induce a lot of diseases like Parkinson, schizophrenia and Alzheimer diseases (“free radicals”, wikipedia website).
[0029] Free radicals are further involved in some of the main dead causes in the western world like some cancers types, coronary heart disease and cardiovascular diseases in general.
[0030] The body has a number of mechanisms to minimize these radical damages.
[0031] One of these defence mechanisms occurs through antioxidants. Antioxidants react with free radicals and by so doing make them harmless.
[0032] The best known antioxidants are the vitamins C, E, carotenoids and the polyphenols (Van Sant, G., 2004).
[0033] Polyphenols are a complex group of molecules which can be naturally found in the plant world. More than 8000 polyphenolic structures are known.
[0034] Polyphenols can be divided into different classes based upon their chemical structure: flavonoids, phenolic acids, stilbenes and lignans (Roura, E. et al., 2005).
[0035] Cocoa, the main ingredient of dark chocolate is rich in polyphenols, particularly in flavan-3-ols such as epicathechins, cathechins and procyanidins (Mursu, J. et al., 2004).
[0036] The primary family of flavanoids contributing to the antioxidant activity of chocolates is the procyanidins (Counet, C. & Collin, S., 2003). Their basic unit is a three-ring molecular structure (U.S. Pat. No. 6,660,332).
[0037] Procyanidins can be present as oligomers (2 to up to 10 flavan-3-ol units) or in the form of polymers with a higher degree of polymerization, the so called tannins.
[0038] The antioxidant activity of cocoa polyphenols is even higher than that of the more well-known antioxidant products like tea or wine (Lee, K. W. et al., 2003).
[0039] In 1999, the USDA (United State Department of Agriculture) has put plain chocolate on top of the list of antioxidant food (USDA, 1999).
[0040] The antioxidant capacity of cocoa products is further strengthened by the presence of melanoidins (Counet, C. & Collin, S., 2003).
[0041] Melanoidins are polyfunctional macromolecules formed by Maillard reactions. These brown nitrogen containing polymers with a molecular weight between 1,000 and 100,000 Da may also have phenolic units included in their structure.
[0042] Lately, more and more evidence has been found for the health benefits of eating dark chocolate.
[0043] Dark chocolate or cocoa consumption is supposed to favourably affect cardiovascular disease risk by slowing down LDL oxidation (Mursu, J. et al., 2004; Wan, Y. et al., 2001; Kondo, K. et al., 1996; Waterhouse, A. L. et al., 1996), increasing serum total antioxidant activity and HDL-cholesterol concentrations, and not adversely affecting prostaglandins (Wan, Y. et al., 2001).
[0044] The antioxidant activity of cocoa products is also beneficial as a defence against reactive oxygen species which are involved in immune response (Sanbongi, C. et al., 1997), and it is associated with improvement in endothelial and platelet function (Engler, M. B. et al., 2004; Hemann, F. et al., 2006) and with lowered blood pressure (Grassi, D. et al, 2005; Buijsse, B. et al., 2006).
[0045] Chocolate is considered as a widely consumed food. It is therefore highly desirable to develop processes that will provide chocolate contributing to general health improvement.
AIMS OF THE INVENTION
[0046] Aim is to provide an improved chocolate which has greater ability to quench oxidative stress and destroy free radicals than chocolate produced by conventional methods.
[0047] It is yet another aim to provide adapted production processes which can achieve this.
[0048] Aim of these adapted processes is to conserve and even increase the antioxidant activity of a chocolate in a natural way, without (negatively) affecting the taste or any other desired properties of chocolate.
SUMMARY OF THE INVENTION
[0049] A first aspect of the invention relates to a modified conching process.
[0050] The invention in particular relates to a method for conching chocolate, e.g. dark chocolate, whereby a chocolate mass is submitted to a conching process comprising (consisting of) the following (successive) steps:
a dry conching step performed at a temperature of between about 50° C. and about 70° C., and subsequent a wet conching step performed at a temperature of between about 60° C. and about 110° C.
[0053] Preferably the dry and wet conching steps each last for about 1 to 2 hours up to about 12 hours, especially for about 6 up to about 12 hours. The conching process of the invention may be carried out in equipment conventionally used for this purpose. A different conche may be used for each of the conching steps, yet the dry and wet conching steps may also be performed in one and the same conche.
[0054] Preferably, the dry conching step is performed at about 60° C. and preferably lasts for about 6 hours.
[0055] According to a preferred embodiment, the wet conching step is performed at about 60° C. and preferably lasts for about 6 hours.
[0056] According to another and even more preferred embodiment, the wet conching step is performed at about 90° C. and preferably lasts for about 6 hours.
[0057] In case a cocoa mass is used that is very rich in flavanoids (such as the Madagascar type, e.g.) then the second step of the conching process (the wet conching phase or step at preferably 60° C. or 90° C.) may possibly be reduced in time to e.g. about 3 hours.
[0058] Often, cooling of the chocolate mass (e.g. through the use of water cooling) is necessary to (obtain and) maintain a temperature of between about 50° C. and about 70° C., preferably of about 60° C., during the dry conching step.
[0059] Similarly, the chocolate mass may have to be heated to (obtain and) maintain a temperature of between about 60° C. and about 110° C., preferably of about 60° C. or about 90° C. (e.g. by using water heating), during the wet conching step.
[0060] Advantageously, an (at least one) emulsifier and/or fat is added (immediately or just) after the dry conching step to obtain a paste that can be submitted to a wet conching step. Advantageously, emulsifiers and/or fat are added after the dry conching step, yet before the wet conching step. In particular said (at least one) emulsifier and/or said (at least one) fat is/are added to obtain a liquid pumpable mass, whereafter conching is continued (the second step, the wet conching, for the particular temperature conditions applied in a method of the invention see supra and infra). The amounts needed to pass from a dry to a liquid texture are well known in the art.
[0061] Typical emulsifiers are lecithin, polyglycerol polyricinoleate, ammonium phosphatide or any mixture of these. Typical fats are cocoa butter, milk fat and/or some allowed vegetable fats. Preferred emulsifiers/fats are traditionally lecithin and/or cocoa butter. Lecithin typically is added in a concentration of between 0.1% and 1%, more preferably between 0.4% and 0.6%, most preferably about 0.5 w/w % (percentage on the total chocolate mass).
[0062] An emulsifier that may be used in the invention is polyglycerol polyricinoleate. Yet a preferred emulsifier is lecithin. A preferred fat is cocoa butter.
[0063] In an embodiment of the invention lecithin was added (just) before starting a wet conching step according to the invention (at a temperature between about 60° C. and about 110° C., more preferably either at about 60° C. or about 90° C.) Lecithin typically is added in a concentration of between 0.1% and 1%, more preferably in an amount between 0.4% and 0.6%, most preferably about 0.5 w/w % of lecithin is added (percentage on the total chocolate mass).
[0064] In another embodiment of the invention only cocoa butter was added (and no lecithin or any other emulsifier) to change the texture from dry to liquid. Cocoa butter herein replaced the emulsifier (in particular lecithin). It is well known in the art that 1 part of lecithin has the same effect on viscosity as about 10 to about 20 parts, more in particular about 15 parts of cocoa butter.
[0065] In an embodiment of the invention, dry conching is performed at a temperature between about 50° C. and about 70° C., and wet conching at about 60° C. or about 90° C. Preferably the wet conching step lasts for about 6 hours. Preferably, also dry conching lasts for about 6 hours. Preferably dry conching is performed at a temperature between about 55° C. and about 65° C. and preferably lasts for about 6 to about 10 to 12 hours. Dry conching in this temperature range is advantageously followed by wet conching at about 60° C. or about 90° C.
[0066] Lactose and/or amino acids such as phenylalanine, arginine, glycine and lysine may be added during the conching process to enhance the production of antioxidant molecules such as melanoidins.
[0067] Advantageously, the viscosity of the chocolate is adjusted by adding fat and/or cocoa mass after conching. The required viscosity, and thus the amount of fat and/or cocoa mass to add, depends on the application as known in the art. Cocoa mass that is added preferentially has undergone a heating step for a prolonged time at an elevated temperature. Most preferably it has undergone a heating step for about 12 hours at about 90° C.
[0068] It was surprisingly found that a conching process according to the invention has no negative effect on the antioxidant activity of a chocolate or chocolate mass. To the contrary, the antioxidant activity is advantageously conserved (preserved, maintained, is not changing significantly over the whole conching period), or even increases (compared to the antioxidant activity just before the conching process, t=0) with such method.
[0069] Advantageously, the antioxidant activity increases by at least 5%, 10% or 15%. Increases of up to 20% or even up to 40% are possible.
[0070] Accordingly, a second aspect of the invention concerns a method to conserve and/or increase the antioxidant activity of a chocolate or a chocolate mass (during the conching process) by submitting a chocolate mass, e.g. a dark chocolate mass, to a conching process comprising (consisting of) the following steps:
a dry conching step performed at a temperature of between about 50° C. and about 70° C., and subsequent a wet conching step performed at a temperature of between about 60° C. and about 110° C.
In particular, the chocolate mass submitted to conching is a dark chocolate mass.
[0073] In particular, provided is a conching method in the production of chocolate (in particular dark chocolate) for conserving and/or increasing the antioxidant activity of a chocolate mass (in particular a dark chocolate mass), said method comprising the step of submitting a chocolate mass (in particular a dark chocolate mass) to a conching process that comprises the following steps:
a dry conching step performed at a temperature of between about 50° C. and about 70° C., and subsequent a wet conching step performed at a temperature of between about 60° C. and about 110° C.
[0076] With a method of the invention the antioxidant activity is conserved during conching. Advantageously said antioxidant activity is increased (compared to t=0, the moment of starting conching) with a method of the invention.
[0077] We refer to the paragraphs above (or infra) for the preferred conditions of temperature and time, the possible addition of further ingredients etc.
[0078] Typically in a method of the invention the dry and wet conching step each last for 1 to 2 hours up to 12 hours, especially for 6 up to 12 hours, or for 6 to about 10 to 12 hours. Typically, the dry and wet conching step each last for about 6 hours.
[0079] In some cases an increase in antioxidant activity (compared to t=0) was obtained when the wet conching step took only 1 hour, possibly 2 hours. In other cases, the wet conching step took preferably at least 3 hours, 4 hours or 5 hours. Optimal results were most often obtained when the wet conching step lasted for 6 hours, for 6 up to 12 hours, for 6 to about 10 to 12 hours.
[0080] With a method of the invention an increase in antioxidant activity (compared to t=0) could advantageously be obtained. Increases in antioxidant activity by at least 5%, 10% or 15% e.g. were obtained. Increases of up to 20% or even up to 40% are possible.
[0081] Preferably in a method of the invention (any of the above) the dry conching step is performed at about 60° C. and preferably lasts for 6 hours.
[0082] Preferably in a method of the invention (any of the above) the wet conching step is performed at about 60° C. and preferably lasts for 6 hours.
[0083] Preferably in a method of the invention (any of the above) the wet conching step is performed at about 90° C. and preferably lasts for 6 hours.
[0084] Particularly good results were obtained when a dry conching step at a temperature between about 50° C. and about 70° C., more in particular at a temperature between (about) 55° C. and (about) 65° C., and lasting in particular for about 6 to about 10 to 12 hours, was followed by a wet conching step at about 60° C. Excellent results were obtained when a dry conching step at about 60° C., which preferably lasted for (about) 6 hours, was followed by a wet conching step at about 60° C., which preferably also lasted for (about) 6 hours.
[0085] Particularly good results were also obtained when a dry conching step at a temperature between about 50° C. and about 70° C., more in particular at a temperature between (about) 55° C. and (about) 65° C. and lasting in particular for about 6 to about 10 to 12 hours, was followed by a wet conching step at about 90° C. Excellent results were obtained when a dry conching step at about 60° C., which preferably lasted for (about) 6 hours, was followed by a wet conching step at about 90° C., which preferably lasted for (about) 6 hours.
[0086] The chocolate (mass) may herein be a dark or a milk chocolate (mass), but most preferably is a dark chocolate (mass).
[0087] Examples of suitable dark chocolate recipes are given in the examples, where chocolates were prepared e.g. from a cocoa mass of the type Côte d'Ivoire or Madagascar. These examples are not limiting as a person skilled in the art will recognize. Other recipes may be used.
[0088] Advantageously in a method for conserving and/or increasing the antioxidant activity according to the invention (any of the above), the chocolate mass is cooled to (obtain and) maintain a temperature between (about) 50° C. and (about) 70° C., preferably of about 60° C., during the dry conching step.
[0089] Advantageously in such method (any of the above), the chocolate mass is heated to (obtain and) maintain a temperature between (about) 60° C. and (about) 110° C., preferably about 60° C. or about 90° C., during the wet conching step.
[0090] In a method for conserving and/or increasing the antioxidant activity according to the invention (any of the above) advantageously an emulsifier selected from the group consisting of lecithin, polyglycerol polyricinoleate and ammonium phosphatide and/or fat is added after the dry conching step, yet before the wet conching step. Polyglycerol polyricinoleate can e.g. be used as emulsifier. Yet a preferred emulsifier is lecithin. A preferred fat is cocoa butter.
[0091] Lecithin and/or cocoa butter advantageously are added after the dry conching step (to pass from a dry texture to a pumpable mass). In a preferred embodiment of the invention lecithin is added after the dry conching step and before the wet conching step to change the texture from dry to wet. In another embodiment of the invention only cocoa butter is employed for this reason. For preferred amounts of lecithin and cocoa butter according to these embodiments, see above/infra.
[0092] In a method of the invention for conserving and/or increasing antioxidant activity (any of the above), after conching the viscosity of the chocolate may be adjusted by adding fat and/or cocoa mass. Advantageously the cocoa mass that is then added has undergone a heating step for a prolonged time at an elevated temperature, most preferably has undergone a heating step for about 12 hours at about 90° C.
[0093] In a particular embodiment of the invention, dry conching is performed at a temperature between about 50° C. and about 70° C., and wet conching at about 60° C. or about 90° C. More preferably dry conching according to the invention takes place at a temperature between (about) 55° C. and (about) 65° C. and preferably lasts for about 6 to about 10 to 12 hours.
[0094] Apart from the specific examples provided above, the following also proved advantageous when a dark chocolate mass was dry conched at about 70° C., followed by a wet conching at about 60° C.; or dry conched at about 50° C., followed by a wet conching at about 90° C. e.g.
[0095] For some other combinations of dry and wet conching, no increase in antioxidant activity was found. Though the decrease in antioxidant activity (at the end of the conching process) was still (significantly) less than when applying a conching method of the art.
[0096] This finding led to a further investigation of suitable dry and wet conching temperature conditions to conserve and/or increase antioxidant activity of a dark chocolate during conching.
[0097] Surprisingly and unexpectedly a sand glass-type of correlation appeared to exist in the indicated temperature ranges of dry and wet conching (from about 50° C. to about 70° C. for dry conching and from about 60° C. to about 110° C., more in particular from about 60° C. to about 90° C. for wet conching).
[0098] FIG. 13 (hatched or shaded regions) gives a view on suitable combinations of dry and wet conching which result in the desired effect: conservation and/or increase of antioxidant activity during conching (reference value: t=0).
[0099] Because of the accuracy of the measuring method (5%) the cut-off is set at 95% (see checkerboard pattern) yet advantageously the antioxidant activity (at the end of the conching method) is increased compared to the activity at t=0 (see other shadings or hatchings, values >100%) with a method of the invention. Values of 95% or above are thus considered to fall within the scope of a method of the invention (for conserving and/or increasing the antioxidant activity).
[0100] Accordingly, another aspect of the invention concerns a method to conserve and/or increase the antioxidant activity of a chocolate mass, in particular a dark chocolate mass during conching, said method comprising the step of submitting a chocolate mass, in particular a dark chocolate mass to a conching process that comprises the following steps:
a dry conching step performed at a temperature of between about 50° C. and about 70° C., and subsequent a wet conching step performed at a temperature of between about 60° C. and about 110° C.,
wherein the dry conching temperature and the wet conching temperature (for conserving and/or increasing the antioxidant activity) are comprised within the range(s) defined by the graph of FIG. 13 . Advantageously both the temperatures (of dry and wet conching) are within the frame (or range(s)) defined by FIG. 13 . The wet conching step advantageously is performed at a temperature between about 60° C. and about 90° C.
[0103] FIG. 13 illustrates in particular which dry and wet conching temperatures may be combined in order to conserve and/or increase the antioxidant activity during conching.
[0104] In particular, provided is a method to conserve and/or increase the antioxidant activity of a chocolate mass, in particular a dark chocolate mass, during conching, said method comprising the step of submitting a chocolate mass, in particular a dark chocolate mass, to a conching process that comprises the following steps:
a dry conching step, in particular a dry conching step performed at a temperature of between about 50° C. and about 70° C., and subsequent a wet conching step, in particular a wet conching step performed at a temperature of between about 60° C. and about 110° C., more in particular a wet conching step performed at a temperature of between about 60° C. and about 90° C.,
wherein temperatures for dry and wet conching are comprised within the range(s) of the (following) list:
[0000]
Dry conching (about)
Wet conching (about)
1
50-69
88-90;
2
50-68
87-88;
3
51-67
86-87;
4
52-67
85-86;
5
53-66
83-85;
6
54-65
82-83;
7
55-65
81-82;
8
56-64
80-81;
9
56-63
79-80;
10
57-63
78-79;
11
58-62
76-78;
12
59-61
73-76;
13
60-61
71-73;
14
59-62
70-71;
15
58-63
68-70;
16
57-64
67-68;
17
57-65
66-67;
18
56-66
64-66;
19
55-67
63-64;
20
55-68
62-63;
21
54-69
61-62;
22
53-69
60-61
[0107] In particular, provided is a method to conserve and/or increase the antioxidant activity of a chocolate mass, in particular a dark chocolate mass during conching, said method comprising the step of submitting a chocolate mass, in particular a dark chocolate mass to a conching process that comprises the following steps:
a dry conching step and subsequent a wet conching step,
wherein temperatures for dry and wet conching are comprised within the range(s) of the list:
[0000] Dry conching (about) Wet conching (about) 1 50-69 88-90; 2 50-68 87-88; 3 51-67 86-87; 4 52-67 85-86; 5 53-66 83-85; 6 54-65 82-83; 7 55-65 81-82; 8 56-64 80-81; 9 56-63 79-80; 10 57-63 78-79; 11 58-62 76-78; 12 59-61 73-76; 13 60-61 71-73; 14 59-62 70-71; 15 58-63 68-70; 16 57-64 67-68; 17 57-65 66-67; 18 56-66 64-66; 19 55-67 63-64; 20 55-68 62-63; 21 54-69 61-62; 22 53-69 60-61
In the above table each row corresponds to advantageous combinations of dry and wet conching temperatures, to particular temperature ranges (or temperatures) for dry and wet conching respectively. For instance in a method of the invention (for conserving and/or increasing the antioxidant activity of a chocolate, in particular a dark chocolate) a dry conching step at a temperature between about 50° C. and about 69° C. advantageously is followed by a wet conching step at a temperature between about 88° C. and about 90° C. (row 1), a dry conching step at a temperature between about 50° C. and about 68° C. advantageously is followed by a wet conching step at a temperature between about 87° C. and about 88° C. (row 2), etc. For the term “about”, “around” or “near” as used herein when referring to temperatures: the temperature ±0.5° C., more preferably ±0.4° C.
[0109] In an embodiment of the invention, temperatures for dry and wet conching are comprised within the range(s) of the above list, with the proviso that the dry conching temperature is not about 60° C., or except the following: a dry conching step at about 60° C. followed by a wet conching step at about 60° C., or a dry conching step at about 60° C. followed by a wet conching step at about 90° C.
[0110] In particular temperatures for dry and wet conching are comprised within the range(s) of the (following) list:
[0000] Dry conching (about) Wet conching (about) 1 50-69 89-90; 2 50-69 88-89; 3 50-68 87-88; 4 51-67 86-87; 5 52-67 85-86; 6 53-66 83-85; 7 54-65 82-83; 8 55-65 81-82; 9 56-64 80-81; 10 56-63 79-80; 11 57-63 78-79; 12 58-62 76-78; 13 59-61 73-76; 14 60-61 71-73; 15 59-62 70-71; 16 58-63 68-70; 17 57-64 67-68; 18 57-65 66-67; 19 56-66 64-66; 20 55-67 63-64; 21 55-68 62-63; 22 54-69 61-62; 23 53-69 61; 24 53-69 60
Possibly temperatures for dry and wet conching are comprised within the range(s) of the (following) list:
[0000]
Dry conching (about)
Wet conching (about)
1
50-69
88-89;
2
50-68
87-88;
3
51-67
86-87;
4
52-67
85-86;
5
53-66
83-85;
6
54-65
82-83;
7
55-65
81-82;
8
56-64
80-81;
9
56-63
79-80;
10
57-63
78-79;
11
58-62
76-78;
12
59-61
73-76;
13
60-61
71-73;
14
59-62
70-71;
15
58-63
68-70;
16
57-64
67-68;
17
57-65
66-67;
18
56-66
64-66;
19
55-67
63-64;
20
55-68
62-63;
21
54-69
61-62;
22
53-69
61;
[0111] In a preferred embodiment of the invention temperatures for dry and wet conching are comprised within the range(s) of the (following) list:
[0000]
Dry conching (about)
Wet conching (about)
1
50-68
88-90;
2
51-67
87-88;
3
52-66
86-87;
4
53-66
85-86;
5
54-65
84-85;
6
55-64
83-84;
7
56-63
82-83;
8
57-62
81-82;
9
58-62
80-81;
10
60-62
66-67;
11
58-64
65-66;
12
57-65
64-65;
13
57-66
63-64;
14
56-67
62-63;
15
55-68
61-62;
16
54-68
60-61
[0112] In an embodiment of the invention, temperatures for dry and wet conching are comprised within the range(s) of the above list, with the proviso that the dry conching temperature is not about 60° C., or except the following: a dry conching step at about 60° C. followed by a wet conching step at about 60° C., or a dry conching step at about 60° C. followed by a wet conching step at about 90° C.
[0113] In particular temperatures for dry and wet conching are comprised within the range(s) of the (following) list:
[0000] Dry conching (about) Wet conching (about) 1 50-68 89-90; 2 50-68 88-89; 3 51-67 87-88; 4 52-66 86-87; 5 53-66 85-86; 6 54-65 84-85; 7 55-64 83-84; 8 56-63 82-83; 9 57-62 81-82; 10 58-62 80-81; 11 60-62 66-67; 12 58-64 65-66; 13 57-65 64-65; 14 57-66 63-64; 15 56-67 62-63; 16 55-68 61-62; 17 54-68 61; 18 54-68 60
Possibly temperatures for dry and wet conching are comprised within the range(s) of the (following) list:
[0000]
Dry conching (about)
Wet conching (about)
1
50-68
88-89;
2
51-67
87-88;
3
52-66
86-87;
4
53-66
85-86;
5
54-65
84-85;
6
55-64
83-84;
7
56-63
82-83;
8
57-62
81-82;
9
58-62
80-81;
10
60-62
66-67;
11
58-64
65-66;
12
57-65
64-65;
13
57-66
63-64;
14
56-67
62-63;
15
55-68
61-62;
16
54-68
61
[0114] In yet another preferred embodiment of the invention temperatures for dry and wet conching are comprised within the range(s) of the (following) list:
[0000]
Dry Conching (about)
Wet conching (about)
1
56-67
60-61;
2
57-66
61-62;
3
58-65
62-63;
4
59-64
63-64;
5
60-62
64-65;
6
50-68
89-90;
7
51-67
88-89;
8
52-66
87-88;
9
53-65
86-87;
10
54-64
85-86;
11
56-63
84-85;
12
57-62
83-84;
13
58-61
82-83
[0115] In an embodiment of the invention, temperatures for dry and wet conching are comprised within the range(s) of the above list, with the proviso that the dry conching temperature is not about 60° C., or except the following: a dry conching step at about 60° C. followed by a wet conching step at about 60° C., or a dry conching step at about 60° C. followed by a wet conching step at about 90° C.
[0116] In particular temperatures for dry and wet conching are comprised within the range(s) of the (following) list:
[0000] Dry Conching (about) Wet conching (about) 1 56-67 60; 2 56-67 61; 3 57-66 61-62; 4 58-65 62-63; 5 59-64 63-64; 6 60-62 64-65; 7 50-68 90; 8 50-68 89; 9 51-67 88-89; 10 52-66 87-88; 11 53-65 86-87; 12 54-64 85-86; 13 56-63 84-85; 14 57-62 83-84; 15 58-61 82-83
Possibly temperatures for dry and wet conching are comprised within the range(s) of the (following) list:
[0000]
Dry Conching (about)
Wet conching (about)
1
56-67
61;
2
57-66
61-62;
3
58-65
62-63;
4
59-64
63-64;
5
60-62
64-65;
6
50-68
89;
7
51-67
88-89;
8
52-66
87-88;
9
53-65
86-87;
10
54-64
85-86;
11
56-63
84-85;
12
57-62
83-84;
13
58-61
82-83
[0117] In yet another preferred embodiment of the invention temperatures for dry and wet conching are comprised within the range(s) of the (following) list:
[0000]
Dry conching (about)
Wet conching (about)
1
57-66
60-61;
2
59-64
61-62;
3
52-66
89-90;
4
53-66
88-89;
5
54-65
87-88;
6
55-64
86-87;
7
56-62
85-86;
8
58-61
84-85
[0118] In an embodiment of the invention, temperatures for dry and wet conching are comprised within the range(s) of the above list, with the proviso that the dry conching temperature is not about 60° C., or except the following: a dry conching step at about 60° C. followed by a wet conching step at about 60° C., or a dry conching step at about 60° C. followed by a wet conching step at about 90° C.
[0119] In particular temperatures for dry and wet conching are comprised within the range(s) of the (following) list:
[0000] Dry conching (about) Wet conching (about) 1 57-66 60; 2 57-66 61; 3 59-64 61-62; 4 52-66 90; 5 52-66 89; 6 53-66 88-89; 7 54-65 87-88; 8 55-64 86-87; 9 56-62 85-86; 10 58-61 84-85
Possibly temperatures for dry and wet conching are comprised within the range(s) of the (following) list:
[0000]
Dry conching (about)
Wet conching (about)
1
57-66
61;
2
59-64
61-62;
3
52-66
89;
4
53-66
88-89;
5
54-65
87-88;
6
55-64
86-87;
7
56-62
85-86;
8
58-61
84-85
[0120] In yet another preferred embodiment of the invention temperatures for dry and wet conching are comprised within the range(s) of the (following) list:
[0000]
Dry conching (about)
Wet conching (about)
1
60-63
60-61;
2
53-65
89-90;
3
54-64
88-89;
4
55-63
87-88;
5
57-61
86-87
[0121] In an embodiment of the invention, temperatures for dry and wet conching are comprised within the range(s) of the above list, with the proviso that the dry conching temperature is not about 60° C., or except the following: a dry conching step at about 60° C. followed by a wet conching step at about 60° C., or a dry conching step at about 60° C. followed by a wet conching step at about 90° C.
[0122] In particular temperatures for dry and wet conching are comprised within the range(s) of the (following) list:
[0000] Dry conching (about) Wet conching (about) 1 60-63 60; 2 60-63 61; 3 53-65 90; 4 53-65 89; 5 54-64 88-89; 6 55-63 87-88; 7 57-61 86-87
Possibly temperatures for dry and wet conching are comprised within the range(s) of the (following) list:
[0000]
Dry conching (about)
Wet conching (about)
1
60-63
61;
2
53-65
89;
3
54-64
88-89;
4
55-63
87-88;
5
57-61
86-87
[0123] In yet another preferred embodiment of the invention In particular temperatures for dry and wet conching are comprised within the range(s) of the (following) list:
[0000]
Dry conching (about)
Wet conching (about)
1
54-64
89-90;
2
56-62
88-89;
3
58-60
87-88
[0124] In an embodiment of the invention, temperatures for dry and wet conching are comprised within the range(s) of the above list, with the proviso that the dry conching temperature is not about 60° C., or except the following: a dry conching step at about 60° C. followed by a wet conching step at about 60° C., or a dry conching step at about 60° C. followed by a wet conching step at about 90° C.
[0125] In particular temperatures for dry and wet conching are comprised within the range(s) of the (following) list:
[0000] Dry conching (about) Wet conching (about) 1 54-64 90; 2 54-64 89; 3 56-62 88-89; 4 58-60 87-88
Possibly temperatures for dry and wet conching are comprised within the range(s) of the (following) list:
[0000]
Dry conching (about)
Wet conching (about)
1
54-64
89;
2
56-62
88-89;
3
58-60
87-88
[0126] In yet another embodiment of the invention a chocolate mass, in particular a dark chocolate mass is subjected to a conching method comprising: a dry conching step at a temperature between about 56° C. and about 62° C. and subsequent a wet conching step at a temperature between about 89° C. and about 90° C., at about 89° C., or at about 90° C.
[0127] In an embodiment of the invention, a dry conching step is performed at a temperature between about 50° C. and about 70° C., in particular at a temperature between about 50° C. and about 69° C., more in particular at a temperature between (about) 55° C. and (about) 65° C., and a wet conching step is performed at about 60° C. In a particular embodiment dry conching is performed at about 60° C. and wet conching at about 60° C.
[0128] In another embodiment of the invention, a dry conching step is performed at a temperature between about 50° C. and about 70° C., more particular at a temperature between (about) 55° C. and (about) 65° C., and a wet conching step is performed at about 90° C. In a particular embodiment dry conching is performed at about 60° C. and wet conching at about 90° C.
[0129] In another embodiment of the invention, a dry conching step is performed at a temperature between (about) 55° C. and (about) 65° C., followed by a wet conching step at a temperature between about 81° C. and about 90° C., more preferably between about 84° C. and about 90° C. or between about 84° C. and about 89° C.
[0130] In yet another embodiment of the invention, a dry conching step is performed at a temperature between (about) 55° C. and (about) 65° C., followed by a wet conching step at a temperature between about 60° C. and about 63° C., more preferably between about 61° C. and about 63° C.
[0131] In yet another embodiment of the invention, a dry conching step is performed at a temperature between about 59° C. and about 62° C., followed by a wet conching step at a temperature between about 60° C. and about 110° C., more preferably between about 60° C. and about 90° C., or between about 61° C. and about 89° C.
[0132] In yet another embodiment of the invention, a dry conching step is performed at a temperature between about 53° C. and about 59° C., followed by a wet conching step at a temperature between about 84° C. and about 110° C., more preferably between about 84° C. and about 90° C., or between about 84° C. and about 89° C.
[0133] In yet another embodiment of the invention, a dry conching step is performed at a temperature between about 62° C. and about 67° C., preferably between about 62° C. and about 66° C., followed by a wet conching step at a temperature between about 84° C. and about 110° C., more preferably between about 84° C. and about 90° C., or between about 84° C. and about 89° C.
[0134] In yet another embodiment of the invention, a dry conching step is performed at a temperature between about 55° C. and about 59° C., preferably between about 56° C. and about 59° C., followed by a wet conching step at a temperature between about 60° C. and about 62° C., more preferably between about 61° C. and about 62° C.
[0135] In yet another embodiment of the invention, a dry conching step is performed at a temperature between about 62° C. and about 66° C., preferably between about 62° C. and about 65° C., followed by a wet conching step at a temperature between about 60° C. and about 65° C., more preferably between about 60° C. and about 64° C. or between about 61° C. and about 64° C.
[0136] Typically the dry conching step and the wet conching step each last for 1 to 2 hours up to 12 hours, especially for 6 up to 12 hours, for 6 to about 10 to 12 hours. Typically dry conching lasts for about 4 hours, about 5 hours, more typically for about 6 hours. Alternatively the dry conching step may last for about 6 to about 10 to 12 hours.
[0137] Depending on the case, the wet conching step will last for at least 1 hour, at least 2 hours, preferably for at least 3 hours, at least 4 hours, at least 5 hours, most preferably lasts for about 6 hours, about 7 hours. Optimal results (excellent increases in antioxidant activity) were often obtained when the wet conching step lasted for about 6 hours.
[0138] In a method of the invention the chocolate mass is advantageously cooled to (obtain and) maintain a temperature of between about 50° C. and about 70° C., preferably of about 60° C., during the dry conching step.
[0139] In particular the chocolate mass is cooled throughout the dry conching step to (obtain and) maintain the dry conching temperature (or to keep the dry conching temperature more or less constant).
[0140] In a method of the invention the chocolate mass is advantageously heated to (obtain and) maintain a temperature of between about 60° C. and about 110° C., preferably of about 60° C. or about 90° C., during the wet conching step.
[0141] In particular the chocolate mass is heated throughout the wet conching step to (obtain and) maintain the wet conching temperature (or to keep the wet conching temperature more or less constant).
[0142] As mentioned above, cocoa butter, lecithin, or cocoa butter and lectithin is/are advantageously added after the dry conching step, yet before starting the wet conching step.
[0143] In an embodiment of the invention lecithin was added (just) before starting a wet (liquid) conching according to the invention (at a temperature between about 60° C. and about 110° C., between about 60° C. and about 90° C., more preferably either at about 60° C. or about 90° C.). Lecithin typically is added in a concentration of between 0.1% and 1%, more preferably in an amount between 0.4% and 0.6%, most preferably about 0.5 w/w % of lecithin is added (percentage on the total chocolate mass).
[0144] In another embodiment of the invention only cocoa butter was added (and no lecithin or any other emulsifier) to change the texture from dry to liquid. Cocoa butter herein replaced the emulsifier (in particular lecithin). It is well known in the art that 1 part of lecithin has the same effect on viscosity as about 10 to 20 parts, more in particular 15 parts of cocoa butter.
[0145] After conching the viscosity of the chocolate may be adjusted by adding fat and/or cocoa mass. Advantageously, the cocoa mass that is then added has undergone a heating step for a prolonged time at an elevated temperature, most preferably has undergone a heating step for about 12 hours at about 90° C.
[0146] Further provided is a method for conching dark chocolate, whereby a chocolate mass is submitted to a conching process as described above and wherein the wet conching step preferably lasts for at least 1 hour, preferably at least 3 hours, most preferably lasts for about 6 hours.
[0147] The dark chocolate mass is advantageously cooled throughout the dry conching step (to keep the dry conching temperature more or less constant).
[0148] The dark chocolate mass is advantageously heated throughout the wet conching step (to keep the dry conching temperature more or less constant).
[0149] Because the antioxidant activity advantageously is not decreasing during the conching process, the final antioxidant activity of the chocolate (at the end of the production process) will be higher than the antioxidant activity of a chocolate obtained by conventional conching methods.
[0150] A further aspect of the invention concerns a method for producing an (improved) chocolate. During the production process of the chocolate, a chocolate mass is hereby submitted to a conching process according to the invention and as described above. In particular, in a method of the invention different temperature conditions are applied for dry and wet (or liquid) conching as applied in the art. All other production steps such as mixing & grinding, refining, tempering, casting into moulds or further processing may be performed in a conventional way according to methods well known in the art.
[0151] In particular the present invention provides for a method for producing a dark chocolate, characterized in that during the production process a dark chocolate mass is submitted to a conching step as recited above (any of the above).
[0152] Another aspect of the invention concerns a chocolate or chocolate mass obtainable by any method as described above, wherein conching is performed according to the invention. In particular, the chocolate mass is a dark chocolate (mass).
[0153] As mentioned before, the (modified) conching process according to the invention conserves and/or increases the antioxidant activity of a chocolate or chocolate mass without (negatively) affecting its taste. The obtained chocolate is thus a healthier food product.
[0154] The invention also relates to any food product comprising (or consisting of) a chocolate thus obtainable or obtained.
SHORT DESCRIPTION OF THE FIGURES
[0155] FIG. 1 gives a view of the texture of a chocolate mass during dry conching.
[0156] FIG. 2 gives a view of the fluid chocolate mass during wet conching, said mass being mechanically worked for a longer period.
[0157] FIG. 3 shows how the inhibition time (Tinh) can be calculated from the abscissa of the intersection point of two straight lines that represent the slope at the beginning (inhibition phase) and the slope when the oxidation speed is maximal (propagation phase).
[0158] FIG. 4 shows the % of antioxidant activity of a chocolate extract in function of the conching time (hours), and this for a chocolate prepared by a traditional conching method. The antioxidant activity at t=0 was set at 100%. The data are the means of 2 replicates; standard deviations are indicated by error bars.
[0159] FIG. 5 shows the % of antioxidant activity of a chocolate extract in function of the conching time (hours), and this for a chocolate prepared by a method of the invention with a wet phase at 60° C. The antioxidant activity at t=0 was set at 100%. The data are the means of 2 replicates; standard deviations are indicated by error bars.
[0160] FIG. 6 shows the % of antioxidant activity of a chocolate extract in function of the conching time (hours), and this for a chocolate prepared by a method of the invention with a wet phase at 90° C. The antioxidant activity at t=0 was set at 100%. The data are the means of 2 replicates; standard deviations are indicated by error bars.
[0161] FIG. 7 shows the procyanidin content (in mg/kg chocolate/100) before conching (t=0) compared to the procyanidin content after a conching process according to the invention: dry conching for 6 hours at 60° C., followed by a wet conching step for another 6 hours at 60° C. (second bar) or at 90° C. (third bar), the total conching time thus being 12 hours.
[0162] FIG. 8 shows the % of antioxidant activity of a chocolate extract in function of the conching time (hours), and this for a chocolate prepared by a single conching step consisting of a dry conching at 60° C. for 12 hours. The antioxidant activity at t=0 was set at 100%. The data are the means of 2 replicates; standard deviations are indicated by error bars.
[0163] FIG. 9 shows the % of antioxidant activity of a chocolate extract in function of the conching time (hours), and this for a chocolate prepared by a single conching step consisting of a wet conching at 90° C. for 12 hours. The antioxidant activity at t=0 was set at 100%. The data are the means of 2 replicates; standard deviations are indicated by error bars.
[0164] FIG. 10 compares the antioxidant activity of a chocolate prepared according to the invention with that of a commercial chocolate to which antioxidant components were added. The antioxidant activity is expressed as the inhibition time (Tinh) in minutes per ppm chocolate extract. The data are the means of 2 replicates; standard deviations are indicated by error bars.
[0165] FIG. 11 shows the % of antioxidant activity of a chocolate extract in function of the conching time (hours), and this for a chocolate (type Madagascar) prepared by a method of the invention with a dry phase at 60° C. and a wet phase at 60° C. The antioxidant activity at t=0 was set at 100%. The data are the means of 2 replicates; standard deviations are indicated by error bars.
[0166] FIG. 12 shows the % of antioxidant activity of a chocolate extract in function of the conching time (hours), and this for a chocolate (type Madagascar) prepared by a method of the invention with a dry phase at 60° C. and a wet phase at 90° C. The antioxidant activity at t=0 was set at 100%. The data are the means of 2 replicates; standard deviations are indicated by error bars.
[0167] FIG. 13 shows the sand glass-type of correlation between dry and wet conching temperatures that lead to a conservation and advantageously an increase in antioxidant activity (expressed in % compared to t=0) during conching. Conching process: 6 hours dry conching, followed by 6 hours wet conching according to the invention.
DEFINITIONS AND DESCRIPTION
[0168] The present invention concerns a process to conserve and preferentially increase the antioxidant activity of chocolate by a using a new conching technique.
[0169] Throughout the invention the following definitions are used:
[0170] The term “chocolate” as used in the claims is used in a broader context and is meant to refer to chocolate types that contain cocoa solids such as dark chocolate, couverture chocolate, plain chocolate, milk chocolate, couverture milk chocolate and family milk chocolate. The names given here refer to common names and/or to names as used in the legislation (see e.g., the European directive 2000/36/EC). Preferred is a dark chocolate, for instance one prepared from a cocoa mass of the type Côte d'Ivoire or of the type Madagascar that is rich in flavanoids.
[0171] “Chocolate” (common name dark chocolate or plain chocolate) designates a product consisting of a mixture of cocoa products and sugars and/or sweeteners, preferably sugar, which contains not less than 35% total dry cocoa solids, including not less than 18% cocoa butter and not less than 14% of dry non-fat cocoa solids. Where this name ((dark) chocolate) is supplemented by the word “couverture”, the product must contain not less than 35% total dry cocoa solids, including not less than 31% cocoa butter and not less than 2.5% of dry non-fat cocoa solids.
[0172] The term “milk chocolate” designates a product obtained from cocoa products, sugars and/or sweeteners, preferably sugar, and milk or milk products, which contains not less than 25% total dry cocoa solids; not less than 14% dry milk solids obtained by partly or wholly dehydrating whole milk, semi- or full-skimmed milk, cream, or from partly or wholly dehydrated cream, butter or milk fat; not less than 2.5% dry non-fat cocoa solids; not less than 3.5% milk fat; and not less than 25% total fat (cocoa butter and milk fat). Where this name (milk chocolate) is supplemented by the word “couverture” the product must have a minimum total fat (cocoa butter and milk fat) content of 31%.
[0173] The term “family milk chocolate” designates a product obtained from cocoa products, sugars and/or sweeteners, preferably sugar, and milk or milk products and which contains not less than 20% total dry solids; not less than 20% dry milk solids obtained by partly or wholly dehydrating whole milk, semi- or full-skimmed milk, cream, or from partly or wholly dehydrated cream, butter or milk fat; not less than 2.5% dry non-fat cocoa solids; not less than 5% milk fat; and not less than 25% total fat (cocoa butter and milk fat). Apart from this it is allowed to add optional ingredients like nuts, lecithin, whey powder, etc to any of the above types of chocolate.
[0174] The “antioxidant activity” is a measure for the protective effect of (antioxidant) molecules or compounds against free radicals. By reacting with the free radicals, antioxidant molecules minimize their damaging potential and make them harmless.
[0175] The “inhibition time” (Tinh) is a measure for the antioxidant activity of the chocolate (extract). The longer the inhibition time the higher the antioxidant activity. The inhibition time can be derived from the abscissa of the intersection point of two straight lines that represent the slope at the beginning (inhibition phase) and the slope when the oxidation speed is maximal (propagation phase) ( FIG. 3 ).
[0176] In the present invention the antioxidant activity is most often expressed in percentages, whereby the antioxidant activity of the chocolate mass before conching (t=0) is put at 100%. As such, an increase/decrease in antioxidant activity can be determined/measured for any type of chocolate.
[0177] The term “conching” refers to a process typically associated to the production of chocolate. It is a prolonged mechanical mixing of the mass combined to a heating. Conching is carried out in special vessels called “conches”, well known in the art. Optional ingredients like cocoa butter and flavours are generally added at this stage. Lecithin is also frequently added as an emulsifier. Other emulsifiers may also be used like for example polyglycerol polyricinoleate and ammonium phosphatide.
[0178] “Dry conching” is known as a type of conching process that is carried out for a relatively short time, e.g. for a few hours up to about 20 hours, at high temperatures, mostly above 70° C. and usually about 90° C. for dark chocolate. For other types of chocolate the temperatures may slightly vary.
[0179] The chocolate is herein kept at a low fat content, generally between 25% and 30% (w/w percentage on the chocolate mass submitted to dry conching), depending on the ingredients and/or type of machinery used.
[0180] The purpose of “dry conching” is to generate a dry texture in order to increase the energy input by producing high shear forces, and finally to increase the temperature of the chocolate mass ( FIG. 1 ).
[0181] “Wet conching” is known as a type of conching process that is carried out at a relatively low temperature, usually around 60° C. All the cocoa butter and the other ingredients such as lecithin are added early in the process preferably within the first two hours.
[0182] The purpose of this treatment (“wet conching”) with relatively low energy input is to maintain the fluidity of the mass which is then mechanically worked for a prolonged time, e.g. 12 or 30 hours or more ( FIG. 2 ).
[0183] The above definitions relate to (conventional) dry and wet conching steps as they are generally applied in the art.
[0184] The present invention relates to an adapted conching process wherein a wet conching step follows dry conching. Preferred temperature conditions and the like are documented throughout the application.
[0185] As further documented below, in the present invention most often cooling is applied during the step of “dry conching”, and heating during the “wet conching” step, as thereby the antioxidant activity could be (further) increased.
[0186] In that respect the actually applied “dry” and “wet” conching steps thus differ from the conventional “dry” and “wet” conching steps applied in the field (and for which definitions are given).
DETAILED DESCRIPTION
[0187] Chocolate must undergo a conching process if one wants to produce a (quality) chocolate with the desired rheological properties and flavour.
[0188] The present invention relates in particular to this conching process and modifications thereto.
[0189] When submitting a chocolate mass to a conventional conching process, the antioxidant activity decreases after conching. In particular, the antioxidant activity decreases during a conching process as used in the art.
[0190] The present invention relates to the changes the inventors made to the conventional conching process with the aim of avoiding this decrease in antioxidant activity.
[0191] To their surprise, the inventors discovered that the antioxidant activity of chocolate was not only conserved, but most often increased with their method.
[0192] The examples below show that by using a conching process according to the invention, the antioxidant level of the chocolate can be significantly improved.
[0193] The newly developed conching process consists of two successive phases or steps:
[0194] In the first phase, the so called “dry conching step”, the chocolate with a low fat content (typically between 25 and 30%) is subjected to an intense kneading at elevated temperatures.
[0195] Temperatures applied during the dry conching step in the method of the invention may vary from about 50° C. to about 70° C., and the duration of this dry conching step may vary from a few hours (about 1 to 2 hours) up to about 12 hours. Preferably, dry conching according to the invention takes place at about 55° C. to about 65° C. and lasts for about 6 to about 10 to 12 hours. Most preferably the dry conching step lasts for about 6 hours at about 60° C.
[0196] Advantageously, in a method of the invention the chocolate mass is cooled to maintain these temperatures. If not, the temperature may rise up to e.g. 90° C. because of friction heat generated during the dry conching step.
[0197] (Immediately) after the dry conching step, and before the wet conching step, an emulsifier and/or some fat is advantageously added. Typical emulsifiers are lecithin, polyglycerol polyricinoleate, ammonium phosphatide or any mixture of these. Typical fats are cocoa butter, milk fat and/or some allowed vegetable fats. Preferred emulsifiers/fats are traditionally lecithin and/or cocoa butter. In an embodiment of the invention cocoa butter was added. In an even more preferred embodiment of the invention lecithin was added.
[0198] In the method of the invention, a “wet conching step” (immediately) follows, is subsequent to, the dry conching step. The wet conching step of the invention may last from a few hours (1 to 2 hours) up to about 12 hours with temperatures in the range of about 60 till about 110° C. Preferably “wet conching” according to the invention is performed at about 60° C. to about 105° C., at about 65° C. to about 100° C., and lasts for about 6 to about 10 to 12 hours. Most preferably the wet conching step of the invention lasts for about 6 hours at about 90° C. However, also at 60° C. an increase in antioxidant activity could be observed. According to another preferred embodiment, the wet conching step of the invention therefore lasts for about 6 hours at 60° C.
[0199] Advantageously, the chocolate mass is heated to maintain these temperatures. As mentioned above, conventional wet conching steps are performed at temperatures of about 40° C. to about 60° C.
[0200] After conching, the chocolate viscosity can still be adjusted by adding fat and/or cocoa mass in the conche itself or in any mixing unit.
[0201] When cocoa mass is added, it has preferably undergone a heating step for a prolonged time at an elevated temperature, most preferably it has undergone a heating step for about 12 hours at about 90° C.
[0202] Using the particular combinations of conching process steps as described above, a level of about 20% above the typical antioxidant activity can be obtained ( FIGS. 5 and 11 ). Even a level of about 40% above the typical antioxidant activity can be obtained with a method of the invention ( FIG. 6 ). The typical antioxidant activity is hereby the antioxidant activity just before conching (t=0).
[0203] Excellent results were obtained with a dark chocolate (increases of up to 40%). A method of the invention can also be used for milk chocolate, in particular when a dry conching at 60° C. is followed by a wet conching at 90° C. In said case an increase in antioxidant activity of about 7% was noted at the end of the conching process compared to t=0.
[0204] As demonstrated below (see the Examples), the typical combination of low and high temperatures, specifically linked to the respective textures of the product during the two phases of the conching process (“dry” and “wet” conching), results in the formation of highly antioxidative compounds (e.g. antioxidative polymers) in the chocolate.
[0205] As further demonstrated, the method of the invention results in a higher effectively measured antioxidant activity.
[0206] Where the traditional processes cause a degradation of the antioxidant components, the processes described in the present invention “naturally” increase the antioxidant activity of the chocolate. By “naturally” is meant that in order to conserve and/or increase the antioxidant activity, no antioxidative molecules need to be added (as additive) to the chocolate mass.
[0207] Where adapted (manufacturing) processes previously described only claim to preserve the amount of antioxidant components, the process of the present invention boosts (increases) the antioxidant activity.
[0208] As shown the level of “beneficial” antioxidants can be (further) improved by using a wet conching step at a higher temperature (preferred temperature ranges for methods of the invention given above). Preferably, this temperature in a method according to the invention lies around 90° C. At this temperature the increase in antioxidant activity was the highest, yet also a wet conching step at (about) 60° C. proved beneficial.
[0209] The inventors observed that a (chocolate) composition which was submitted to a method of the invention, with a “wet conching” at about 60° C. (preceded by a “dry” conching at 60° C.)) did not undergo any significant changes in procyanidin content, and not even in the repartition of the procyanidins in small oligomers (P2-P6) and in polymers (P+). However, the antioxidant activity was increased with about 20% (compared to the activity just before (“dry”) conching, t=0).
[0210] The composition which was submitted to a “wet” conching at 90° C. (preceded by a “dry” conching at 60° C.) contains significantly less procyanidin polymers (P+) whereas the antioxidant activity increased with about 40% (compared to the activity just before (“dry”) conching, t=0).
[0211] Although in the literature it is reported that the antioxidant activity of procyanidin oligomers was found to increase significantly with the degree of polymerisation, in both compositions the antioxidant activity of the chocolate was significantly increased with an equal or lower procyanidin polymer content.
[0212] It therefore appears that part(s) of the chocolate extract that remain(s) unidentified contributes greatly to the antioxidant activity. The method of the invention most probably also extracts melanoidins and perhaps higher-order tannins (Counet, C. & Collin, S., 2003).
[0213] A process temperature of about 90° C. is ideal to promote the development of these melanoidins and tannins. This may explain the higher increase in antioxidant activity at (about) 90° C. during the “wet” conching phase of the method of the invention.
[0214] The data below demonstrate that a high natural antioxidant activity of antioxidants in chocolate can be obtained, without the “addition” of any antioxidant molecules.
[0215] The invention will be described in further details in the following examples by reference to the enclosed drawings, which are not in any way intended to limit the scope of the invention as claimed.
EXAMPLES
Example 1
Chocolate Produced by a Traditional Conching Process
[0216] A chocolate was prepared comprising:
[0000]
Sugar
48.20%
Cocoa mass (Côte d'Ivoire)
38.90%
Cocoa butter
12.30%
Lecithin
0.60%
% (w/w) on the final chocolate mass
[0217] The chocolate was produced with the following steps:
Mixing: in this step all the sugar, cocoa mass and part of the cocoa butter (48.8% of the cocoa butter) were mixed together. Refining: the chocolate paste was refined on a three roll refiner with a grinding length of the rolls of 280 mm×600 mm. The fineness of the powder was between 15 and 20 μm. Filling: the conche was slowly filled with chocolate powder over a time period of 70 minutes. Immediately after this period another 3.3% of the cocoa butter amount was added. Conching: the chocolate was dry-conched for 6 h at 90° C. in a Frisse conche. Lecithin and the rest of the cocoa butter were added immediately after the dry conching step. The liquid step, following the conching step at dry texture, was operated for one hour at 60° C.
[0222] The antioxidant activity was measured by measuring the protective degree of the chocolate extract against a forced oxidation of linoleic acid according to a method described by Liégois, C. et al. (2000). For the extraction protocol, see example 2.
[0223] The oxidation of linoleic acid was induced by 2,2′-azobis(2-amidinopropane)dihydrochlorure (AAPH) in an aqueous dispersion in the absence or presence of antioxidant (chocolate extract). AAPH generates free radicals by spontaneous thermal decomposition.
[0224] The rate of oxidation at 37° C. was monitored by recording the increase in absorption at 234 nm caused by conjugated diene hydroperoxides.
[0225] From these data the inhibition time of the oxidative reaction of linoleic acid can be calculated ( FIG. 3 ) which is a measure for the antioxidant activity. The longer the inhibition time (Tinh), the higher the antioxidant activity.
[0226] The antioxidant activity was evaluated at various intervals during the process and finally expressed in the form of a percentage of the antioxidant activity at the beginning of the conching (point at 0 hours), as this allows to compare the effect of different conching processes for different chocolates. The antioxidant activity in this case corresponds to the following: [Tinh (t=x) /Tinh (t=0) ]*100.
[0227] FIG. 4 clearly shows that after 6 hours the antioxidant activity decreases round and about 40% (compared to the initial value at t=0) in a chocolate produced by a traditional conching process.
Example 2
Preparation of Chocolate with Increased Antioxidant Activity
[0228] Two chocolates were prepared as described in example 1 with the exception that the conching process includes first a dry conching step at 60° C. instead of 90° C. and secondly, after the addition of only the lecithin, a wet conching step either at 60° C. (for the first chocolate) or at 90° C. (for the second chocolate). Each conching step (“dry” and “wet”) lasted for about 6 hours. The remaining part of the cocoa butter was added after conching.
[0229] The antioxidant activity was once more evaluated at various intervals during the conching process. Results are presented in FIGS. 5 & 6 . In both cases the antioxidant activity (at the end of the conching process) is increased, with about 20% at 60° C. and about 40% at 90° C. (compared to the start point at t=0). Dry conching lasted for 6 hours and was followed by a wet conching according to the invention. After 1 hour of wet (or liquid) conching there was already an increase in oxidant activity (compared to the start point). Said increase was most pronounced if the wet conching step also lasted for about 6 hours.
[0230] The procyanidin content has been evaluated in both chocolates by NP-HPLC-UV. Briefly, the chocolate was transformed in powder with a mixer and introduced into a Soxhlet filtration cartridge to remove the lipids.
[0231] The defatted chocolate (1 g) was then extracted two times with 5 ml of solvent (2×10 min, 25° C. to avoid any thermal degradation of procyanidins). Three organic solvents are frequently used for procyanidin extraction mixed with water and acetic acid: acetone, ethanol or methanol (e.g. acetone/water/acetic acid: 70/28/2% (v/v)).
[0232] After each extraction, the suspension was centrifuged (3000 g, 10 min). The combined supernatants were concentrated by rotary evaporation under partial vacuum (40° C.)
[0233] Ten milligrams of procyanidin extract were then diluted in 1 ml of methanol and finally 20 μl of this solution was injected in a NP-HPLC (normal phase-HPLC). Procyanidins were separated on a Phenomenex 5 μm normal-phase Luna silica column, 250 mm×4.6 mm (inside diameter) (Bester) at 25° C.
[0234] Separations were carried out at a flow rate of 1 mL/min with a linear gradient from A (dichloromethane) to B (methanol) and a constant level of C (acetic acid and water, 1:1, v/v).
[0235] The NP-HPLC was coupled to a UV detector (280 nm) in order to determine the concentration of the different procyanidins present in the extract according to the method of Counet, C. & Collin, S. (2003).
[0236] In FIG. 7 , the repartition profile of the procyanidins is shown with P1 to P6 being the monomers to hexamers and P+ being the polymers.
[0237] This graph shows that the composition which was submitted to a wet conching at 60° C. did not undergo any significant changes in procyanidin content, and not even in the repartition of the procyanidins in monomers (P1), in small oligomers (P2-P6) and in polymers (P+).
[0238] The composition which was submitted to a wet conching at 90° C. clearly contains significantly less procyanidin polymers (P+).
Example 3
Chocolate Preparation with a Single Conching Step
[0239] Two chocolates were prepared as described in Example 2.
[0240] The first chocolate was conched by applying only a dry conching phase. Only step 1 of the method of the invention was thus performed. The dry conching step lasted for 12 hours and was performed at 60° C. The fat content was 29% (w/w % on the chocolate mass submitted to dry conching) and no emulsifier was added.
[0241] The second chocolate was conched by applying only a wet conching phase. Only step 2 of the method of the invention was thus performed. The wet conching step lasted for 12 hours and was performed at 90° C. The chocolate contained 0.5% w/w of lecithin as emulsifier (percentage on the total chocolate mass).
[0242] Results are shown in FIGS. 8 & 9 respectively.
[0243] In both cases, the antioxidant activity remained more or less stable during the conching process. There is no (consistent) decrease or increase of the antioxidant activity over the whole period of the conching process.
[0244] The data presented here—when compared with those of FIG. 6 —show that it is the combination of the 2 types of conching (a dry conching followed by a wet conching according to the invention) that results in an increase in antioxidant activity.
Example 4
Comparison with a Commercial Sample Claiming a High Antioxidant Sample
[0245] In the present example, the antioxidant activity of a commercial sample (“New Tree, Chocolat Noir, Eternity”) claiming a high antioxidant content in polyphenols was compared with that of a chocolate prepared by a method of the invention (see Example 2).
[0246] The chocolate prepared according to a method of the invention was submitted to a dry conching step at 60° C. (step 1), followed by a wet conching step at 90° C. (step 2).
[0247] The antioxidant activity of each sample was measured as described in example 1. Results, calculated for the same amount of non-fat dry cocoa content, are presented in FIG. 10 and are expressed as the inhibition time of the oxidative reaction of linoleic acid.
[0248] The process according to the present invention produced a chocolate having an antioxidant activity equivalent to that of the commercial chocolate claiming to have an increased content in antioxidant components.
[0249] The commercial sample is an example of a chocolate to which antioxidant components are added. By following a method of the invention an increased antioxidant activity can be obtained through a simple adaptation of the conching process. No antioxidants need to be added during (at the end of) the production process to achieve this effect. This is what is meant when saying that the antioxidant activity is conserved and preferentially increased in a “natural way”.
[0250] Advantageously the taste (and other properties) of chocolate is not influenced by the adapted production process (conching process) according to the invention.
Example 5
Dark Chocolate Prepared with Cocoa Mass from Madagascar
[0251] Two chocolates were prepared as described in example 2 with the exception that a cocoa mass of the type Madagascar was used instead of one of the type Côte d'Ivoire.
[0252] More particularly, a chocolate was prepared comprising:
[0000]
Sugar
48.20%
Cocoa mass (Madagascar)
38.90%
Cocoa butter
12.30%
Lecithin
0.60%
% (w/w) on the final chocolate mass
[0253] The chocolate was conched according to a method of the invention. The conching process includes first a dry conching step at 60° C. and secondly, after the addition of lecithin, a wet conching step either at 60° C. (for the first chocolate) or at 90° C. (for the second chocolate). Each conching step (“dry” and “wet”) lasted for about 6 hours.
[0254] The antioxidant activity was once more evaluated at various intervals during the conching process. Results are presented in FIGS. 11 & 12 . In the case of a wet conching at 60° C. the antioxidant activity at the end of the conching period was about 20% higher than at t=0. In the case of a wet conching at 90° C. an increase of about 15% was noted.
Example 6
Addition of Cocoa Butter Instead of Lecithin
[0255] A dark chocolate was prepared comprising:
[0000]
Sugar
44.46%
Cocoa mass (Côte d'Ivoire)
35.89%
Cocoa butter
19.65%
% (w/w) on the final chocolate mass
[0256] The way of preparing is in fact as indicated in Example 2, except that instead of lecithin there was an addition of cocoa butter after 6 hours of conching (before starting wet conching). The texture (fluidity) of the mass submitted to wet conching is comparable to that of Example 2.
[0257] Briefly, the chocolate was produced according to the following steps:
Mixing: in this step all the sugar, cocoa mass and part of the cocoa butter (28.2% of the cocoa butter) were mixed together. Refining: the chocolate paste was refined on a three roll refiner with a grinding length of the rolls of 280 mm×600 mm. The fineness of the powder was between 15 and 20 μm. Filling: the conche was slowly filled with chocolate powder over a time period of 70 minutes. Immediately after this period another 1.9% of the cocoa butter amount was added. Conching: the chocolate was dry-conched for 6 h at 60° C. in a Frisse conche. 42.3% of the cocoa butter was added immediately after the dry conching step (or the conching step at dry texture). The liquid phase (wet conching) was operated for 6 h at 90° C. The remaining part of the cocoa butter was added after conching.
[0263] At t=12 the antioxidant activity was increased by about 7% compared to the antioxidant activity at t=0.
Example 7
Conching Conditions for a Dark Chocolate
[0264] In the table below some examples are given of antioxidant activity for dry and wet conching temperature combinations applied in a method of the invention. Suitable temperatures (° C.) for dry and wet conching: results in bold italic. Preferred combinations for dry and wet conching: results in bold. For the chocolate recipe, see Example 1. Values of antioxidant activity (%) are those after 12 hours: 6 hours dry conching followed by 6 hours wet conching, see Example 2. The value at t=0 was set at 100% (value at the start of conching).
[0265] Similar results were obtained for other dark chocolates. Best results were obtained when a dry conching step at a temperature between about 50° C. and about 70° C., more preferably between about 55° C. and about 65° C., was followed by a wet conching step near 60° C. or near 90° C.
[0000]
TABLE
Antioxidant activity (% compared to t = 0) for dry and wet conching temperature
combinations applied in a method of the invention
Dry conching
50
52
54
56
58
60
62
64
66
68
70
Wet
60
81
93
103
111
116
119
119
118
114
107
conching
63
73
85
102
107
109
110
108
103
87
66
68
79
89
100
103
102
100
88
79
69
64
76
85
92
90
83
73
72
64
75
84
90
94
92
87
79
69
75
65
76
85
91
94
92
86
78
68
78
69
80
88
94
94
88
79
69
81
76
86
94
102
103
102
92
83
72
84
85
94
102
107
110
111
109
105
98
89
78
87
105
113
117
120
120
118
114
107
98
86
90
109
118
125
130
132
132
130
125
118
109
REFERENCES
[0000]
Beckett, S. T. Industrial chocolate manufacture and use. Second edition. Blackie Academic & Professional. 1994:118-121.
Ziegleder, G. Conching. Information on the britanniafood web site, accessible via http://www.britanniafood.com/download/?mode=dynamic&id=21, July 2006.
Van Sant, G. Vrije radicalen en antioxidanten: basisprincipes. Symposium—antioxidanten en voeding—Instituut Danone. 2004.
Information on ‘Free radicals’ on the wikipedia web site, accessible via http://www.wikipedia.org/wiki/Free radicals, July 2006.
Roura, E.; Andrés-Lacueva, C.; Jauregui, O.; Badia, E.; Estruch, R.; Izquierdo-Pulido, M.; Lamuela-Raventos, R. M. Rapid liquid chromatography tandem mass spectrometry assay to quantify plasma (−)-Epicatechin metabolites after ingestion of a standard portion of cocoa beverage in humans. J. Agric Food Chem. 2005, 53: 6190-6194.
Mursu, J.; Voutilainen, S.; Nurmi, T.; Rissanen, T. H.; Virtanen, J. K.; Kaikkonen, J.; Nyyssönen, K.; Salonen, J. Dark chocolate consumption increases HDL cholesterol concentration and chocolate fatty acids may inhibit lipid peroxidation in healthy humans. Free Radical Biology & Medicine, 2004, Vol 37, No. 9: 1351-1359.
Lee, K. W.; Kim, Y. J.; Lee, H. J.; Lee, C. Y. Cocoa has more phenolic phytochemicals and a higher antioxidant capacity than teas and red wine. J. Agric. Food Chem., 2003, 51: 792-7295.
USDA (US Department of Agriculture)-Mc Bride, J. High-ORAC foods may slow aging. 1999, 47: 15-17.
Counet, C.; Collin, S. Effect of the number of flavanol units on the antioxidant activity of procyanidin fractions isolated from chocolate. J. Agric. Food Chem. 2003, 51: 6816-6822.
Wan, Y.; Vinson, J. A.; Etherton, T. D.; Proch, J.; Lazarus, S. A.; Kris-Etherton, P. M. Effects of Cocoa Powder and Dark Chocolate in LDL Oxidative Susceptibility and Prostaglandin Concentrations in Humans. American Journal of Clinical Nutrition, 2001, Vol. 74, No. 5: 596-602.
Kondo, K.; Hirano, R.; Matsumoto, A., Igarashi, O.; Itakura, H. Inhibition of LDL oxidation by cocoa. Lancet, 1996, 348: 1514.
Waterhouse, A. L.; Shirley, J. R.; Donovan, J. L. Antioxidants in chocolate. Lancet, 1996, 348: 834.
Sanbongi, C.; Suzuki, N.; Sakane, T. Polyphenols in chocolate, which have antioxidant activity, modulate immune functions in humans in vitro. Cell Immunol, 1997, 177(2): 129-36.
Engler, M. B.; Engler, M. M.; Chen, C. Y.; Malloy, M. J.; Browne, A.; Chiu, E. Y.; Kwak, H. K.; Milbury, p.; Paul, S. M.; Blumber, J.; Mietus-Snyder, M. L. Flavonoid-rich dark chocolate improves endothelial function and increases plasma epicatechin concentrations in healthy adults. J. am. Coll. Nutr, 2004, 23: 197-204.
Hemann, F.; Spieker, L. E.; Ruschitzka, R.; Sudano, I.; Hermann, M; Binggeli, C.; Luscher, T. F.; Riesen, W.; Noll, G.; Corti, R. Dark chocolate improves endothelial and platelet function. Heart, 2006, 166: 411-417.
Grassi, D.; Lippi, C.; Necozione, S.; Desideri, G. Ferri, C. Short-term administration of dark chocolate is followed by a significant increase in insulin sensitivity and a decrease in blood pressure in healthy persons. Am. J. Clin. Nutr. 2005, 81: 611-614.
Buijsse, B.; Feskens, E. J. M.; Kok, F. J.; Kromhout, D. Cocoa intake, blood pressure, and cardiovascular mortality. Arch. Intern. Med., 2006, 166: 411-417.
Liégeois, C.; Lermusieau, G.; Collin, S. Measuring antioxidant efficiency of wort, malt and hops against the 2,2′-azobist(2-amidinopropane)dihydrochloride-induced oxidation of an aqueous dispersion of linoleic acid. J. Agric. Food Chem., 2000, 48: 1129-1134.
|
The present invention relates to a novel method for conching chocolate, whereby a chocolate mass is submitted to a conching method that comprises the following steps: —a dry conching step performed at a temperature of between 50° C. and 70° C., —and subsequent a wet conching step performed at a temperature of between 60° C. and 110° C., more in particular at a temperature between 60° C. and 90° C., wherein the dry conching temperature and the wet conching temperature are comprised within the range(s) defined by the graph of FIG. 13 (see shaded or hatched regions). Most preferably the dry conching step is performed at about 60° C. and the wet conching step at about 60° C. or about 90° C. Advantageously, this adapted conching process conserves and even increases the antioxidant activity of a chocolate, in particular a dark chocolate. Consequently, the present invention further relates to a method of conserving and/or increasing the antioxidant activity of chocolate and to chocolates processed accordingly.
| 0
|
BACKGROUND OF THE INVENTION
The invention pertains to a lawn care vehicle with a tool attachment that is supported by the vehicle frame.
Garden and lawn care vehicles usually contain attachments that are connected to the body of the vehicle by carrying devices. These attachments may consist of lawn care equipment, e.g., mowers with spiral or rotating blades, vertical cutters, raking devices or the like. The attachments are arranged on the body of the vehicle via the carrying devices such that their height can be adjusted, i.e., they can be moved between an operating position, whereby they are in contact with the ground, and a raised position for transport or service.
EP-A1 0,217,773 pertains to a riding lawn mower with a chassis that carries a drive unit. This drive unit drives the wheels as well as a cutting device that is separably attached to the chassis. The cutting device can be moved between a lower cutting position and an upper non-cutting position. This adjustment is realized by means of a lever arrangement that makes it possible to adjust the cutting height and completely raise the cutting device. In all these positions, the cutting device remains underneath the vehicle, i.e., the cutting device must be detached for maintenance and service purposes because it is not accessible.
U.S. Pat. No. 5,079,907 describes a riding lawn mower that contains a grass cutting device and a blade housing, both of which can be moved between an essentially horizontal mowing position and an upwardly tilted service position. The blade housing is suspended on an adjustment mechanism, one end of which is connected to the blade housing, and the other end of which is connected to the body of the vehicle. In its raised position, the blade housing is tilted toward the rear by the adjustment mechanism in order to gain access to the blades located in the housing. However, such a design can only be realized if the cutting device can be freely moved, i.e., if the cutting device is not entirely or only partially arranged underneath the vehicle.
U.S. Pat. No. 5,042,236 discloses a golf lawn mower with a total of five spiral-bladed mowing units. In this case, three spiral-bladed mowing units are arranged in front of the golf lawn mower, and two spiral-bladed mowing units are arranged laterally offset to the three front spiral-bladed mowing units, i.e., underneath the vehicle frame. This arrangement serves for mowing strips of lawn remain between the front spiral-bladed mowing units with the spiral-bladed mowing units offset such that a uniform lawn pattern can be achieved. Here, the front spiral-bladed mowing units are accessible for maintenance and service purposes, but access to the rear spiral-bladed mowing unit is very difficult.
EP-B1 0,182,229 pertains to a farm tractor with a so-called front hitch that is arranged on the frame of the farm tractor in horizontally movable fashion. The front hitch serves, for example, for accommodating a mowing mechanism, a soil cultivation device or the like. The horizontal movability makes it possible to alter the existing leverages in such a way that the front wheels can be subjected to a higher load and thus generate a higher tensile force. However, neither the front hitch nor the tool attachment carried by the front hitch is arranged underneath the farm tractor or is otherwise covered.
It would therefore be desirable to improve the accessibility of the tool attachments in known garden and lawn care vehicles.
SUMMARY OF THE INVENTION
The present invention provides a vehicle having a vehicle frame and elongate rail members mounted therewith. A tool frame is provided to which is coupled a tool attachment such as an offset arrangement of spiral bladed reel mower cutting units. The tool frame includes bars which shiftably engage the rails along the length of the elongate rails, and the rails support the bars of the tool frame as the bars and tool frame shift linearly within the rails. The tool frame shifts between a retracted operating position whereat the cutting units are in an operating position in close proximity to the vehicle, and an extended maintenance position whereat the cutting units are shifted outwardly from the vehicle frame for providing access to the cutting units. The bars are received within the respective rails and are shiftable therein in telescoping fashion. When the cutting units are in the operating position one of the cutting units is at least partially within the boundary of the vehicle.
The rails are oriented at an angle to a surface of the ground, and the tool frame shifts generally along the rails upwardly and outwardly away from the vehicle as the tool frame shifts to the extended maintenance position.
The rails according to the preferred embodiment extend generally longitudinally in the direction of vehicle travel and the tool frame is shiftable along the rails generally longitudinally in the direction of vehicle travel. A linear actuator or hydraulic cylinder engages one of the bars of the tool frame for shifting the tool frame between the extended and retracted positions.
A plurality of toothed wheels are provided in engagement with respective toothed rack members fixed with the bars. The wheels are fixed with a shaft supported by the vehicle, and the wheels and shaft rotate in unison to synchronize the shifting of the bars with respect to the rails.
A support is mounted with the vehicle frame and engages the tool frame in the retracted position for at least partially supporting the tool frame in the retracted position.
Each bar is movably carried within the rail between at least one lower and one upper support roller.
The present invention provides tool units located beneath the operating platform or the vehicle frame, and which can be displaced outwardly, i.e., beyond the contours of the lawn care vehicle. Consequently, the tool attachment is easily accessible to the operator. The tool may consist of a mower, e.g., a spiral-bladed or rotating blade lawn mower, a raking device, a clearing blade, a vertical cutter, a soil aerator, a manure spreader or the like. Depending on the position of the tool attachment, it may be practical to move said tool attachment outwardly from the front, the rear or the side of the vehicle in order to gain access.
Particular advantage is attained due to the use of an inclined guideway for the tool attachment on the vehicle frame. In this way, the tool attachment can not only be moved out of the area located underneath the lawn care vehicle, e.g., under a protective cover, under the vehicle frame, under an operating platform or the like, but also be raised such that it can be serviced even more easily.
The use of at least one bar according to the present invention that is movably accommodated in or on a rail of the vehicle frame represents a robust and simultaneously simple and inexpensive arrangement for carrying the tool attachment. A long guide way, e.g., a telescoping guide way, also helps prevent the occurrence of jams during movement.
If several offset tool units are provided, it is possible to arrange a central tool unit between adjacent tool units, i.e., offset toward the lawn care vehicle, so that the central tool unit occupies, for example, the space between two wheels. In this way, the structural length of the lawn care vehicle can be relatively short, i.e., the lawn care vehicle is more compact.
Within the spirit of the present invention, the adjustment of the frame may be carried out manually, with a mechanical winch or the like. When using heavy tool attachments, it is advantageous to carry out this adjustment by means of a motor that can preferably be remote-controlled.
Resistance against lateral forces can be achieved if the bar of the tool frame is movably arranged in a closed profile, i.e., a tube, wherein one or more longitudinal slots are provided in order to connect the motor if the motor is not arranged concentric with the bar or the rail. Alternatively, the bar may also be realized in the form of a tube, wherein the rail is realized in the form of a carrier, on which the tube is movably arranged.
The movement of two or more bars can be realized with the aid of only one motor if the respective bars are connected to one another such that they move synchronously and cannot become jammed. The shifting of the bars can be synchronized by a shaft to which geared wheels or friction wheels are fixed. The wheels can engage respective bars and by way of the shaft help insure that the bars shift together. Synchronous movement of the bars can be achieved since toothed wheels and toothed racks are used to lock the bars together, which results in no slippage.
The use of at least one abutment and at least one support on the tool attachment and the lawn care vehicle makes it possible to prevent the weight from affecting the steering when the tool attachment is retracted, i.e., in its normal position. In this way, shocks caused by uneven terrain are barely, if at all, introduced into the bars and rails.
A sensor may be provided in order to prevent accidents during the servicing of the tool attachment. This sensor detects when the tool attachment is moved out of its operating position, i.e., that the tool attachment is presumably moved into its maintenance and service position. This sensor may be coupled to motors for driving and/or retracting and/or pivoting the tool attachment by means of simple electrical or electronic switching elements or a computer-assisted control unit, in such a way that the motors are prevented from being activated when the tool attachment is out of its operating position.
According to an additional feature, a mechanical locking device that is manually actuated may be provided. This locking device secures the tool attachment to the vehicle frame when it is not in its operating position. This may be simply realized by means of a bolt that is inserted through aligned openings in the tool attachment and the vehicle frame.
If the tool attachment contains three spiral-mower tool units that are movably held on the tool frame in overlapping fashion, and if the outer tool units can be vertically pivoted into an idle position, the outer tool units will not only be easier to access because they are able to assume a vertical orientation, but they will also be able to be maintained or serviced in a narrow garage.
The bar is guided with little resistance to movement by means of a lower support roller and an upper support roller between the bar and the rail.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial schematic representation of a top view of a lawn care vehicle with vehicle frame and tool attachment.
FIG. 2 is a partial side view of the lawn care vehicle according to FIG. 1, wherein the tool attachment is in its retracted operating position.
FIG. 3 is a partial side view of the lawn care vehicle according to FIG. 1, wherein the tool attachment is in the extended position.
FIG. 4 is a detailed perspective representation of portions of the vehicle frame and the tool frame of the tool attachment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The lawn care vehicle 10 shown in FIG. 1 contains a vehicle frame 12 and a tool attachment 14 , wherein only the front end region of the lawn care vehicle is shown.
In the preferred embodiment, the lawn care vehicle 10 is realized in the form of a self-propelled lawn or golf course mower. However, the lawn care vehicle 10 could also be realized in the form of a towed vehicle. This lawn care vehicle 10 is provided with standard equipment (not shown) such as a motor, gearbox, driving platform and the like, i.e., this lawn care vehicle essentially corresponds in many ways to the initially described known vehicles.
The vehicle frame 12 serves for carrying the essential components of the lawn care vehicle 10 , of which merely a drivers seat 16 is schematically illustrated. The vehicle frame 12 is supported on wheels 18 in order to move as well as support the lawn care vehicle on the ground. However, only the two front wheels are shown in the figure, i.e., the two steerable rear wheels are not shown. The left and right rails 20 , 22 of the vehicle frame 12 which extend in the moving direction of the lawn care vehicle 10 are realized in the form of tubes with square or rectangular cross section in the embodiment shown and are of particular importance. However, it should be mentioned that it would also be possible to provide only one rail 20 , 22 or more than two rails 20 , 22 . It would also be conceivable to realize the rails 20 , 22 in the form of solid elements rather than tubes. FIG. 4 shows that the front ends 24 of the rails 20 , 22 are connected to one another in the form of a “U” via a plate-shaped crosspiece 26 such that a rigid frame is formed. However, the connection by means of the crosspiece 26 is by no means mandatory.
The rails 20 , 22 are positioned in the form of mirror images about the central longitudinal axis of the lawn care vehicle 10 and are arranged on the lawn care vehicle 10 in such a way that the vehicle frame 12 forms an angle with the ground. Consequently, the vehicle frame 12 is closer to the ground in the central region of the vehicle 10 than at the front end of the vehicle 10 . Although the figure shows the protrusion of the vehicle frame 12 beyond the front end of the vehicle 10 , this feature is also not mandatory; the vehicle frame 12 may also protrude laterally or toward the rear.
The right rail 22 , viewed in the driving direction, is provided with a longitudinal slot 28 between its open ends. This longitudinal slot extends in the side 30 which faces the other rail 20 , at least over the adjustment range of the tool attachment 14 .
An opening 32 , the purpose of which will be described below, is arranged on the underside of each rail 20 , 22 .
On the front side of the crosspiece 26 , i.e., on the side that faces the tool attachment 14 , a support 34 is arranged within the protruding region of each rail 20 , 22 , on each side. This support is realized in dimensionally stable fashion and provides a support surface 36 , wherein said support also contains an opening 37 that is realized in the form of a slot.
A bolt 38 that extends through the central longitudinal axis of the longitudinal slot 28 is arranged on the side 30 behind the crosspiece 26 .
Each rail 20 , 22 is provided with front and rear recesses 40 , 42 in the region of the crosspiece 26 and in the central region of the rail. The first recess is located at the bottom 44 of each rail 20 , 22 , the second at the top 46 of said rail. A plate 48 that contains a bore 50 is preferably welded or screwed to the side 30 within the region of each recess 40 , 42 .
A support roller 52 that is rotatably accommodated on a bolt member is assigned to each plate 48 and each recess 40 , 42 . Each bolt member is inserted into a corresponding 15 bore 50 and secured with a nut 56 . The support rollers and their respective positions relative to the rails 20 , 22 , are realized such that their circumferential surfaces slightly extend over the inner surface of the rail 20 , 22 .
A bearing bracket 58 is screwed or welded to each respective connecting rail (not shown) which connects the rails 20 and 22 to one another, within the region of the opening 32 in the bottom 44 of each rail 20 , 22 . These bearing brackets accommodate a rotatable shaft 60 . Of course, the bearing brackets 58 may also be directly arranged on the rails 20 , 22 . The respective ends of the shaft 60 are equipped with wheels 62 that are connected to the shaft without rotational play. In the preferred embodiment shown, these wheels are realized in the form of toothed wheels. The two wheels 62 are thus also connected without rotational play. The distance between the wheels 62 on the shaft 60 and their arrangement on the shaft 60 relative to the rails 20 , 22 are chosen such that the given wheel 62 protrudes into the interior of the respective rail 20 , 22 through the openings 32 . The shaft 60 is transverse to the longitudinal direction of the rails 20 , 22 . The mounting of the wheels 62 on the shaft 60 and the mounting of the bearing brackets 58 on the rails 20 , 22 or at another location of the lawn care vehicle 10 or the vehicle frame 12 is realized by means of known fasteners that are not shown in detail, e.g., wedges and screws.
In addition, holders, brackets and sheet metal that are not shown in detail are arranged on the rails 20 , 22 . These elements represent parts of the lawn care vehicle 10 which are not essential to the invention.
In the preferred embodiment shown, the tool attachment 14 is composed of several tool units 64 and a tool frame 66 .
The tool units 64 in the embodiment shown are realized in the form of known, hydraulically driven spiral-bladed mowers. Three tool units 64 are arranged adjacent to one another transverse to the driving direction, wherein the two outer tool units 64 are offset ahead of the central tool unit 64 , i.e., away from the lawn care vehicle 10 . In this way, it is possible for the central tool unit 64 to occupy the region between the wheels 18 during the operation of the lawn care vehicle, i.e., the tool attachment 14 will not protrude too far ahead of the lawn care vehicle 10 . As seen from the driving direction, the two outer tool units and the central tool unit 64 overlap, i.e., no unmoved strips of grass will remain during mowing. All tool units 64 are at the same distance from the ground; their height can be adjusted by means of a lifting device 68 in order to adjust the tool units to a different cutting height or move the tool units into the transport position. For reasons of simplicity, only one lifting device 68 is shown for the embodiment shown. However, a separate lifting device may be provided for each tool unit, which embodiment is also covered by the term lifting device.
The two outer tool units 64 are suspended in vertically pivoted fashion in schematically represented bearings 70 .
The design of the tool units 64 in the form of spiral-bladed mowers only represents an example of various types of tool units 64 . It would also be possible to use raking devices, rotating blade mowers, vertical cutters, pick-up implements, clearing blades and the like.
In the embodiment shown, the tool frame 66 is composed of at least left and right bars 72 , 74 and a carrier 76 . A front carrying arm 78 and a rear carrying arm 80 are connected to this carrier 76 in the form of a separate attachment bracket that serves as the carrier for all tool units 64 .
The tool frame 66 is essentially in the form of a U, wherein the base of the “U” extends transverse to the driving direction and the arms of the “U” extent in the driving direction. In addition, the tool frame can be moved relative to the vehicle frame 12 in the driving direction.
The left and right bars 72 , 74 form mirror images about the longitudinal axis of the lawn care vehicle 10 and are provided with mounting plates 82 at their front ends in order to connect the carrier 76 . Each mounting plate 82 is equipped with an abutment 84 on its rear side, i.e., on the side that faces the rails 20 , 22 . These abutments are arranged in such a way that they can be placed onto the respective supports 34 when the tool frame 66 is retracted. On the side of the abutment 84 which faces the vehicle frame 12 , a pin 85 is provided which is designed and arranged on the abutment 84 in such a way that it is held in the respective opening 37 with almost no play and remaining secure in its position when the tool attachment 14 is retracted. The support 34 may be provided with a hard rubber block in which the opening 37 is arranged. The positive connection between the pin 85 and the opening 37 absorbs torsional movements of the tool attachment 14 relative to the vehicle frame 12 and consequently reduces relative movements and vibrations between said components.
The cross section and the orientation of the bars bar 72 , 74 can be accommodated in a rail 20 , 22 that faces the respective bar in sliding fashion.
A cutout 86 is provided on the underside of each bar 72 , 74 . This cutout serves to accommodate a toothed rack 88 that is aligned with the longitudinal direction of the bars 72 , 74 . The length of the toothed rack 88 depends on the range of adjustment of the tool frame 66 .
Within the rear region of the right bar 74 , a bore 90 is arranged which serves for accommodating a screw 100 for mounting a linear actuator or motor 94 on the bar 74 . A holder 92 that is also arranged within this region may be utilized for mounting a valve or the like for controlling the motor 94 .
The carrier 76 is realized in the form of a plate that is screwed to the two mounting plates 82 and is provided with a series of openings for connecting the carrying arms 78 , 80 . However, the bars 72 , 74 may also be welded to the carrier 76 .
The front carrying arm 78 extends forward from the carrier 76 in order to accommodate the two front, outer tool units 64 in the bearings 70 .
The rear carrying arm 80 extends backward from the carrier 76 into the free space between the two wheels 18 in order to carry the central tool unit 64 .
Both carrying arms 78 , 80 may be engaged on the carrier 76 in rigid or vertically movable fashion or accommodate the tool units 64 such that they can be vertically moved in order to compensate for uneven areas in the ground.
A sensor (not shown) is arranged on the rails 22 and generates a signal as a function of whether the bars 72 , 74 are pushed into the rails 20 , 22 or not. However, it would suffice merely to detect a movement of one bar 72 or 74 relative to the given rail 20 or 22 respectively. The sensor may also be arranged at a different location, e.g., on the carrier 76 .
The motor 94 is realized in the form of a hydraulic cylinder and piston assembly, wherein said motor can be actuated by means of a hydraulic control circuit (not shown). The hydraulic cylinder can be loaded on both sides of the piston, i.e., it can be actively adjusted in both directions. One end of the motor 94 is held via the bolt 38 , and the other end is held on the bar 74 via the bolt 100 . The mounting of the motor 94 via the bolts 38 , 100 takes place as close as possible to the side 30 in order to keep bending moments to a minimum. However, it is also conceivable to use a pneumatic or electric motor, or equivalent structure, instead of the hydraulic motor 94 . In addition, a mechanical rod assembly, mechanical levers or a tackle may be utilized instead of the motor 94 .
The sensor is physically or logically coupled to the drive (not shown) of the tool units 64 , the lifting device 68 and a pivoting motor (not shown) for the outer tool units 64 , in such a way that said components cannot be actuated if the sensor indicates that the tool frame 66 is no longer in the retracted position. An additional connection of the sensor to the motor 94 and a safety interlock system (not shown) may also be provided.
The drive of the tool units 64 can alone be deactivated, or all of the drives can be deactivated.
According to the previous description, the lawn care vehicle has the following design and function.
The rails 20 , 22 and the plate 48 represent part of the vehicle frame 12 , i.e., fixed components of the lawn care vehicle 10 , and are already installed in the correct position.
The tool frame 66 is assembled in the form of a U; the assembly includes the toothed racks 88 , but not the bolt 100 and the holder 92 . Subsequently, the bars 72 and 74 of the tool frame 66 are pushed into the hollow spaces of the rails 20 , 22 such that the underside of each bar abuts the front support roller 52 and the upper side of each bar abuts the rear support roller 52 . Consequently, a rolling support is achieved instead of a sliding support. Contact with the underside and the upper side is automatically attained due to the leverages during the insertion of the bars 72 , 74 . As soon as the bars 72 , 74 are pushed into the rails 20 , 22 up to the adjustment range, the wheels 62 begin to mesh with the toothed racks 88 and, from this moment, ensure a synchronous movement of both bars 72 , 74 during the additional insertion. Consequently, tilting or jamming of the bars is hindered. As soon as the bars 72 , 74 are entirely pushed into the rails 20 , 22 , the bolt 100 is inserted into the longitudinal slot 28 and screwed onto the inner side of the right bar 74 . The motor 94 which is extended to its maximum length is then secured via the two bolts 38 , 100 and connected to the hydraulic system (not shown).
In this inserted state, the sensor is activated and the abutments 84 rest on the supports 34 in order to relieve the bars 72 , 74 that rest on the support rollers 52 in the rails 20 , 22 .
The carrying arms 78 , 80 are installed individually or in the form of an attachment bracket that contains both carrying arms, whereafter the tool units 64 are attached to the carrier 76 and connected to the corresponding drive.
FIGS. 1 and 2 show the lawn care vehicle 10 with a tool attachment 14 , the tool frame 66 of which is entirely pushed into the vehicle frame 12 and its respective rails 20 , 22 . In this position, the tool units 64 almost touch the ground and can be lowered onto the ground by means of at least one lifting device 68 . The central tool unit 64 is located between the wheels 18 , i.e., within a contour 98 of the lawn care vehicle 10 that, for example, is formed by the plate 26 , the front edge of the wheels 18 or a structure of the lawn care vehicle 10 and may have a quite irregular shape.
In order to extend the tool frame 66 , the hydraulic cylinder 94 extends such that it moves the bars 72 , 74 inside the rails 20 , 22 , i.e., such that the tool attachment 14 is moved from a position in which it is near the lawn care vehicle 10 into a position in which it is farther away from the lawn care vehicle. This means that the tool attachment 14 with its tool units 64 is moved out of the boundary 98 of the lawn care vehicle 10 so that it may be serviced. The connection between the left toothed rack 88 and the left wheel 62 and the right toothed rack 88 and the right wheel 62 via the shaft 60 helps ensure a synchronous movement of both bars 72 , 74 .
It is quite obvious that a second motor 94 , a second longitudinal slot 28 and a second set of bolts 38 , 100 may be used instead of the toothed rack 88 , the wheels 62 and the shaft 60 , whereby the motors 94 could operate synchronously, e.g., by means of a synchronizer.
In FIG. 3, the tool frame 66 is shown in its extended position, in which the central tool unit 64 is moved out of the region between the wheels 18 , and into a position in which it is easily accessible for maintenance and service. Although the inclined arrangement of the rails 20 , 22 is not absolutely mandatory, it is advantageous in that the tool units 64 can also be lifted off the ground in the extended position such that access to the tool units 64 is enhanced and maintenance simplified.
Since the sensor is no longer activated in this position, the drive cannot be actuated in the extended position in order to protect maintenance and service personnel.
|
A lawn care vehicle with a tool attachment such as spiral-bladed mowing units arranged in front and underneath the lawn care vehicle in offset fashion. A tool frame to which the tool attachments are mounted is received within rails for allowing the tool frame to shift longitudinally with respect to the rails, thereby allowing the tool frame and tool attachments to shift outwardly with respect to the vehicle frame to maintenance positions.
| 0
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application contains subject matter described in copending applications for Capacitive Liquid Level Sensor, Ser. No. 07/466,937 filed Jan. 18, 1990 and for Capacitive Liquid Level Sensor, Ser. No. 07/466,936, filed Jan. 18, 1990.
BACKGROUND OF THE INVENTION
This invention relates to capacitive liquid level sensors and, more particularly, to capacitive sensors capable of sensing the interface between different layers, including air. Such liquid level sensors find use in many instruments wherein a robotic probe is used to withdraw liquid from a container containing a sample to be analyzed or a reagent.
In such robotic systems, it is desirable to have knowledge of the level of the liquid or the interface between liquids in the container such that the probe used to withdraw the liquid can be controlled (1) to withdraw a particular layer of liquid in the container or (2) to minimize contact with an undesired portion or layer of the liquids in the container. In such systems one is dealing with generally immiscible liquids such as occurs in the collection of blood. In a typical blood system producing packed red blood cells the red blood cells will be in the lower portion of the container. Immediately above the packed cells is a commercial separation gel. Above the separation gel is the serum or plasma and finally air on the top. Contamination of the sampling probe by the separation gels is very undesirable. Often it is relatively difficult to remove the gel from the probe and can in fact cause clogging of the probe and missampling to occur. Therefore it is highly desirable to provide some system of locating the gel-serum interface so that the serum only can be withdrawn and the probe prevented from contacting the gel.
To accomplish this objective, it is necessary to be able to sense the level of the liquid interfaces at all times on a real time basis. Various level sensors have been developed for this purpose. Among those are the so-called capacitive level sensors. These are based on the fact that any conductor exhibits a finite electrical capacitance. This capacitance, when approaching a liquid having a higher dielectric constant, will increase. When the sensing probe is in close proximity to a liquid, the higher dielectric constant and greater surface area results in an increased capacitance of the probe. These capacitance changes caused by the liquid can be rather small so that sensitive detection devices are required.
Devices known in the prior art that are suitable for detecting small changes in capacitance include bridges, RC or LC oscillators and frequency meter counters (including heterodyning), phase locked loops, zero crossing periodometers, amplitude changes to an RC or LC filter, and phase shift changes through an RC or LC circuit.
Among the prior art capacitive liquid level sensors are Kingston U.S. Pat. No. 3,391,547 which discloses a capacitive liquid level probe for a liquid tank. He utilizes a capacitor probe, disposed in the liquid, as one leg of a bridge circuit. An unbalance in the circuit, as a result of change in capacitance of the probe, is detected by a phase sensitive detector which is referenced by the fixed frequency excitation oscillator through a variable phase shifter. The variable phase shifter allows for offset adjustment.
In similar manner, Oberli U.S. Pat. No. 3,635,094, discloses a capacitive level sense means for an automatic transfer pipette. The sample probe is utilized as the first element and a metal stand around the sample vessel is the second element which forms a capacitor in one leg of a bridge circuit. The remaining legs of the bridge consist of a variable capacitor leg and two resistor legs. The variable capacitor leg may be adjusted such that its capacitance matches that of the probe contacting the liquid. The bridge circuit is excited by a fixed frequency oscillator and a differential amplifier is utilized to determine when the bridge is balanced indicating that the probe has contacted the liquid.
Bello et al. U.S. Pat. No. 4,326,851 discloses a level sense apparatus and method for use in an automatic clinical analyzer in which a variable capacitor is formed by a grounded probe and a metal plate, which is connected to the detection circuit, disposed below the sample vessel. A fixed frequency excitation signal is utilized and the capacitance change resulting from the probe contacting the liquid is detected as a voltage change in the detection circuit. This arrangement presents a problem in that spills on the electrode or supply tray can change the circuit operation and the circuit requires the use of shielding pads.
Another U.S. patent, Okawa et al. U.S. Pat. No. 4,736,638 discloses a liquid level sense apparatus for use in an automatic clinical analyzer. A metal plate disposed under the sample vessel and connected to a fixed frequency oscillator emits low frequency electromagnetic radiation up through the sample. The dispense probe serves as an antenna and is connected to a detection circuit, having appropriate bandpass filtering, which detects a voltage amplitude change when the probe contacts the liquid sample. This circuit has many of the disadvantages of Bello. In addition, the use of low frequency limits the time response of the circuit.
Finally, Shimizu U.S. Pat. No. 4,818,492 discloses a capacitive liquid level sensor for an automatic clinical analyzer. He utilizes a resistor bridge with a fixed frequency oscillator exciting one diagonal of the bridge and the probe serving as a capacitor across the other diagonal. Phase shift across the capacitor (probe), as a result of change in capacitance of the probe, is detected by a phase detector which is referenced by the fixed frequency excitation oscillator through a variable phase shifter. The variable phase shifter allows for offset adjustment. The output of the phase detector is filtered and compared against a reference value to provide a signal indicating the presence of liquid at the probe.
None of these sensors are directed to sensing the liquid interfaces in any useful fashion as the probe must disturb such interfaces as it journeys down through the tube or container. To solve this problem, various systems have been devised which seek to determine liquid level from the exterior, of a container. Typical of these systems are those described in U.S. Pat. No. 4,099,167 and U.S. Pat. No. 4,002,996. In both of these systems electrodes are disposed on the exterior of the container and changes in the dielectric provided by the contained liquid as compared to air is sensed by causing a variation in a capacitance sensitive detector. Another system such as that described in U.S. Pat. No. 4,371,790 uses the electrical conductance of a liquid to determine the level of the liquid contained in a container.
Finally, U.S. Pat. No. 3,939,360 describes a similar system in which a tape is attached or fixed to the outside of a container whose liquid level is to be sensed. Unfortunately such system, as are the others of the prior art, is relatively inaccurate in sensing the location of the liquid interfaces and are unable to seek the level of liquid/air interface but must allow the interface to pass by its location before such is detected.
Optical sensors can be used, but they often are impractical for the simple reason that paper or other labels are usually affixed to the outside of the container and hence would prevent optical scanning. Furthermore, if the outside of the container is dirty as for example with dried blood, the optical ability to sense could be considerably decreased. Also any water that may condense on the exterior surface would interfere with optical sensing. This would be a particular problem when the sample has been refrigerated.
SUMMARY OF THE INVENTION
Many of these problems inherent in the prior art sensors inability to reliably sense the location of liquid interfaces are reduced with the use of the subject invention. This invention provides a means to estimate the position of multiple interfaces so that the movement of the probe can be restricted and prevented from entering undesired regions and/or directed to the precise location desired between layers of liquid.
In accordance with the preferred embodiment of this invention a capacitive sensor is used for determining the level of an interface between two liquids each having a different dielectric value, the liquids being held in a container having a generally vertical axis, the sensor comprising: an electrically conductive element, first drive means for translating the element along the outer surface of the container generally parallel to the axis, an oscillator coupled to the element for applying a high frequency signal to the element, the amplitude and/or phase of the oscillator being affected by the capacitance of the element, and comparator means for generating a level sense signal according to the amplitude or phase of the oscillator for signalling the element having reached a liquid interface, whereby such signal denotes the region along the container axis where there is a liquid interface.
The sensor may be an adjunct to a probe for withdrawing liquid from the container which has a second drive means for introducing the probe into the container and withdrawing liquid therefrom, the second drive means being responsive to the interface sense signal for directing and limiting the probe movement with respect to the interface. When a sensor of this type is used with an element that mechanically scans a blood collection tube from the outer surface of the tube, as the element encounters the base of the tube (end opposite the stopper) the capacitance increases because of the proximity of the packed red cells which medium is of high dielectric and conductive. Next the element encounters a separation gel which medium is of low dielectric and not conductive. For purposes of this invention, the gel is considered to be a liquid. The "gel" may be beads or other structures used for separating fluids of a different density.
Next the element encounters serum or plasma which medium is of high dielectric and conductive. Finally the element encounters a zone of air which medium is of low dielectric and not conductive. Thus the capacitance of the sensing element increases to some relatively high value through the red cell zone then abruptly decreases at the gel interface, then abruptly increases at the serum interface and finally abruptly decreases at the air interface. These abrupt changes are discriminated and correlated to the mechanical position of the sensing element.
The sensor has the advantage of being independent of the optical characteristics of the sample container. Sensing also can be achieved through a paper label such as a bar code identification label. Neither dried blood nor water condensation presents a problem.
According to the method of this invention the position of an interface between two liquids each having different dielectric values, where the liquids are held in a container having a vertical axis, includes the steps of: applying a high frequency signal to an electrically conductive element from a signal source, translating the element proximate the outer surface of the container generally parallel to the axis, detecting the phase difference between the signal from the source and that from the element, whereby a change in the phase difference denotes a liquid interface along the container axis.
In a preferred embodiment, the method also uses a probe for withdrawing liquid from the container and includes the additional steps of introducing the probe into the container and withdrawing liquid therefrom and limiting the probe movement in accordance with the sensor signal to prevent the probe from penetrating undesired interfaces yet selecting the portion from which the liquid is drawn.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the invention and its advantages may be understood in connection with the accompanying drawings in which:
FIG. 1 is a block diagram of a liquid interface sensor constructed in accordance with this invention;
FIG. 2 is a schematic diagram of a preferred embodiment of the liquid interface sensor constructed in accordance with this invention;
FIG. 3 is a flow chart depicting the manner in which the CPU controls the sensor of FIG. 1 to determine the nature and position of liquid interfaces; and
FIG. 4 is a flow chart depicting the manner in which the CPU controls the sensor of FIG. 1 to aliquot samples.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is now made to the drawings in which FIG. 1 illustrates a position sensing element 10 driven by a robotic arm 12 which is controlled by a servo drive 14 of conventional design. The element 10, translated in the X, Y, and Z directions by the servo drive 14 of conventional design, is adapted to be positioned adjacent any one of plural sample, reagent or reaction containers 16 (only one of which is shown).
Each sample or reagent containers 16 has an axis 19 and will be described in connection with a typical use of this invention which is the use in connection with a blood collection tube. In such a blood collection tube, the container 16 could have packed red cells in the lower portion 11 separated by a gel 13; a serum 15 would be above the gel layer 13 and finally air 17 would be on the top. The sensing element 10 is adapted to traverse the exterior portion of the container 16 in a direction generally parallel to the axis 19, i.e., the Z direction. The element 10 is a flat metallic plate preferably of some relatively inert material such as stainless steel or platinum and is shaped to partially conform to the exterior curvature of the container 16. The element 10 is relatively thin; typically 1/8 of an inch. The packed red cells constitute a relatively high dielectric and conductance. On the other hand the separation gel 13 is a medium of low dielectric and is not conductive. The serum medium 15 has a high dielectric and conductance. The air zone however 17 is of low dielectric and low conductance.
This invention deals with a method and sensor capable of distinguishing these changes in capacitance caused by the different dielectrics and hence the location of the interfaces between the several layers of liquids in the container 16.
A pipettor 48 for removing liquids from the container 16 is coupled through a flexible coupling such as a plastic tube to a fluid pump 46. The pipette is operated by a linkage 45 which in turn is positioned by a servo drive 44 which raises and lowers the pipette 48. The servo drive 44 and the fluid pump 46 are both actuated in turn by the CPU 42 using any known conventional system for this purpose. One such system is that known as the DimenSion™ Analyzer sOld by E. I. du Pont de Nemours and Company, Wilmington, Del.
An oscillator 30 is coupled to an electrically conductive element 10 through an isolating resistor 36 and coaxial cable 70 whose sheath is grounded. In turn the oscillator 30, which may be a voltage controlled oscillator (VCO), is connected to be swept in voltage by a sweep drive 32 which preferably provides a linear (e.g., triangular or sawtooth) waveform such that the oscillator is successively swept through a range of frequencies. Abrupt changes in the probe capacitance, which occur when the probe contacts a liquid, generate a spectrum of frequencies in the output of the detector. The sweep oscillator preferably sweeps the high frequency oscillator frequency at a repetition frequency above those frequency components generated by abrupt changes in probe capacitance.
The output of the oscillator is coupled to a phase detector 34 preferably capable of providing a D.C. output voltage. In this manner the phase detector is subjected to the shift in phase or amplitude caused by a change in the dielectric to which the element is subjected. There is a stray capacitance between the probe element and liquid in the container 16. When the element encounters a liquid of higher or lower dielectric constant, an interface is recognized and the output of the phase detector is a D.C. signal which varies in phase or amplitude in accordance with the changing capacitance sensed by the element.
A comparator 38 compares the signal from the phase detector 34 with a reference obtained by an adjustable voltage source 40. The output of the comparator is applied to a central processing unit (CPU) 42 which in turn is programmed to control the servo drive 14 in any conventional manner such as that described in U.S. Pat. No. 4,818,492. It controls the pipettor 48 to suck liquid from the container 16 at a height Z that was identified by the sensor. Thus the central processing unit 42 controls both the position of the pipettor 48 and whether the pipettor sucks up fluid from a container in accordance with the position sensed by element 10. Such central processing units are well known and will not be described further since they do not relate to the particular invention which is a liquid interface sensor.
In operation the element 10 as moved axially along the outer external surface of container 16 which by way of illustration may contain blood separated into red cells 11, gel 13, and serum 15. As the element 10 encounters the base of the tube 11 containing the packed red cells the capacitance increases because of the proximity to packed red cells which medium is of high dielectric and is conductive. Next the element 10 encounters the separation gel 13 which medium is of low dielectric and is not conductive. Next the element encounters the serum 15 which medium is of high dielectric and is not conductive. Finally the sensing element 10 encounters the zone of air 17 which medium is of low dielectric and is not conductive.
Correspondingly, the capacitance increases to some relatively high value through the red cell zone, abruptly decreases at the gel interface 13, then abruptly increases at the serum interface 13-16 and finally abruptly decreases at the air interface 15-17. These abrupt changes are discriminated and correlated to the mechanical position of the sensing probe 10.
The CPU is programmed to cause the sensing element of this invention to scan a vessel and to store for subsequent use the height and nature (increase or decrease in capacitance) of the transitions. Later, when the vessel previously scanned is to be accessed, the CPU commands the pipettor probe to be positioned over the vessel. If the last transition of the scan was a decrease in capacitance, then the CPU compares the height recorded with the transition against acceptable highest and lowest heights and further that the distance between the top and next to top transition is sufficient to allow the pipettor probe tip to be slightly submerged without being too close to the gel-serum interface. Having passed the acceptance tests, the pipettor probe is lowered to a height such that its tip is just below the serum-air interface. The desired aliquot is taken and the pipettor probe raised to the height for travel. After the sample has been acquired, it is placed in a reaction vessel along with additional reagents to form a color whose absorbance is related to the analyte concentration in the sample.
While the preferred embodiment of the invention described uses a phase detector and RC phase shift circuit it is to be understood that any of the devices known in the prior art using a source of electrical oscillations for detecting small changes in capacitance may be used. In each case, the high frequency signal is affected in some manner by the sensing element's capacitance and the affection is detected whether it be bridge unbalance, amplitude change in an RC or LC filter, phase shift in an RC or LC circuit or whatever. The signal 76 affection depicts a change in amplitude and/or phase over that of waveform 64, the degree of change being a function of a sample dielectric.
This invention solves the problem of seek-time by finding the approximate top of the fluid so that the probe 48 need only level sense from a short distance above the liquid. In many cases, this external level sense is all that is required, i.e., no additional level sense on the probe 48 is needed. This invention also eliminates the problem of contacting an undesired layer such as a gel because by locating the position of the gel, the probe can be inhibited from traveling into the gel.
Generally the container is scanned from the bottom up so that the sensing element always begins in a known state (i.e. vs. air). The top may be inaccessible or cluttered with stoppers.
In ordinary circumstances for a blood collection tube, the last capacitance transition is a decrease, corresponding to the serum to air interface. The previous transition will have been an increase in capacitance, corresponding to the gel to serum interface, or the bottom of the tube (i.e. absence of gel). In the former there will be an additional transition corresponding to packed-cell to gel interface. In all events, the pipettor probe would be positioned with the tip approximately 1 mm under the surface of the serum, but if that would position it within 5 mm of the gel then the sample procedure is not attempted because of its liability to clog and otherwise contaminate the sampling probe. The gel is distinguished from the bottom of the vessel by the known position of the bottom which is fixed by the design of the instrument. In the event of non-attempt to sample, the operator is expected to transfer the serum to another vessel which has no gel.
In some circumstances the last capacitance transition may be an increase. This may occur if the vessel is completely full such that the sensor element is unable because of mechanical constraints to scan to or past the top of the vessel. In this case, the serum to air interface is given a default value, however the gel to serum interface (if present) is still valuable information needed to prevent pipettor probe travel into the gel.
If a substantial amount of serum is to be taken, the pipettor probe is programmed to descend into the vessel at a rate to match the computed fall in height as the serum is withdrawn. Again, the maximum travel of the pipettor probe must be restricted to avoid contamination by gel.
FLOW CHART
The invention may be better understood with reference to FIGS. 3 and 4 in which flow charts are depicted which describe to software used by the CPU to control the acquisition of the position of the interfaces (FIG. 3) and aliquoting the sample fluid (FIG. 4). In FIG. 3, the sensor element is commanded 110 to start scanning up from below the bottom of the vessel. The status of the sensor is polled in decision point 120. If the probe element is at the top of 35 travel, then control is passed to process 150 where the sensor element is moved to a home position below the vessel. Otherwise the status of the sensor is polled for the occurance of a transition. If there was no transition, control is passed back to decision point 120. Otherwise a transition has occurred and the nature (increase or decrease in capacitance) is stored and the height of the transition is stored. Control is then passed back to decision point 120.
Having acquired the interface position information, initially (block 210 of FIG. 4), the pipettor probe is moved to the vessel but with the probe still above the vessel. Decision point 220 checks that the last stored transition from the level sensor was a decrease corresponding to a serum to air interface. If not a decrease, then the process is aborted because of possible pipettor probe contamination or other malfunction if the process is continued. If a decrease, then control is passed to decision point 230 where the height of the last transition is compared to the lowest acceptable height. If the height is too low, the process is aborted. Otherwise control is passed to decision point 240 where the height of the last transition is compared to the highest acceptable height If the height is too high, the process is aborted. Otherwise control is passed to decision point 250 where the height of the serum is calculated and compared to a minimum acceptable below which probable contamination of the pipettor probe would occur. If sufficient height of serum is present, control is passed to process 260 where the pipettor probe is lowered to a height that is computed such that only the tip of the pipettor probe is submerged into the serum so that the outside of the probe is minimally contaminated by the serum. When the pipettor probe has reached the computed height, control is passed to process 270 and the desired volume (aliquot) of fluid is withdrawn. Control is passed to (aliquot) of fluid is withdrawn. Control is passed to process 280 where the pipettor probe is raised to the travel height following which process 290 moves to pipettor probe to a position where the serum is delivered to a reaction vessel and the determination of the desired constituents of the serum can take place.
With reference to FIG. 2, a specific circuit constructed in accordance with the preferred embodiment of this invention for sensing liquid levels is illustrated. In this circuit essentially two integrated circuit chips are used. The first is phase-locked loop which may use, for example, a CD4046BM chip made by National Semiconductor. In addition a quad operational amplifier chip made by Texas Instrument Company, TLC274CN may be used. The phase-lock loop is designated by the dashed block 50. Similarly, the quad operational amplifier is designated by the dashed block 52. The phase-lock loop includes a voltage control oscillator 54 and several phase comparators only one of which, 56, is shown. The voltage controlled oscillator 54 has several inputs which have been selected to provide a nominal 1 MHz by choice of resistors R1 and R2 and capacitor C1. The selection of these values is described in the application notes for the chip from National Semiconductor. The VCO 54 is caused to sweep by a sweep oscillator in the form of an a stable oscillator which is constructed as part of the quad operational amplifier chip 52. The sweep oscillator, designated 58, is constructed such that the output is applied through resistor R7 and capacitor C6 to the inverting input of the amplifier labelled Q2. Further, the output of Q2 is applied through resistors R8 and R9 to the noninverting input of the amplifier. Suppose that the output of the amplifier goes high. The voltage at the noninverting input will go high. The voltage at the noninverting input will remain low because of capacitor C6. As charge accumulates on capacitor C6 a time will come when its voltage exceeds that of the noninverting input at which time the output of Q2 will swing low. In a similar fashion resistors R8 and R9 apply a low voltage to the noninverting input of Q2. Because of capacitor C6 the voltage at the inverting input will remain high.
This status will remain until the voltage across C6 is discharged to a voltage below that of the noninverting input at which time the output of Q2 will swing high and the cycle will repeat endlessly. In this circuit it is customary to take the voltage from the output which is a square wave 62. However to obtain a voltage sweep to provide a linear sweep of frequency of the oscillator, a sawtooth or triangular waveform is preferred. This is the signal found at the junction of R7 and C6. This approximately triangle wave 60 is applied to the VCO input. This signal causes the voltage controlled oscillator to sweep approximately 20 kHz around the nominal 1 MHz frequency. The rate at which it sweeps up and down is approximately 20 kHz and is determined by the values of the resistors R 7 , R 8 , and R 9 .
The output of the voltage controlled oscillator 54 is designated by the square waveform 64. The output of the VCO is applied to two portions. One portion is supplied to a phase comparator 56. This serves as the reference signal and is illustrated by the waveform 66. The other portion of the output of the VCO is supplied to an RC phase shifter composed of elements R3, C2 and the sensing element. Capacitor C2 is used as the D.C. blocking capacitor. The actual capacitance affecting the phase shift is composed of the capacitance of the coaxial cable labelled 70 and the capacitances to ground of the sensing element 10. The element is metal as described. The junction between R3 and C2 is a signal labelled 76 and the signal from the element that is affected by the dielectric of the sample. This signal 6 is an approximate triangle wave and is applied to the signal input of phase comparator 56.
Phase comparator 56 is of the exclusive OR variety. The output of the phase comparator is a series of pulses, the width of which depends on the phase difference between the reference signal 66 and the input signal 76. The output of the phase comparator 56, in the form of the square wave 78, is applied to an RC filter network 84 composed of resistor R4 and C3. The purpose of this filter is to remove the pulses from the phase comparator and produce an approximate D.C. level proportionate to the area of the waveform 78. If the pulse width of 78 changes then the approximate D.C. level of the filter 84 will change. The changing D.C. level is represented by the waveform 80 which is applied to a differentiator 90, the heart of which is an operational amplifier Q1, a member of the quad operational amplifier 52. Thus, to effect the differentiation, the output of the RC filter 84 is applied through resistor R5 and capacitor C4 to the input of the amplifier 90. The feedback portion of the amplifier 90 is composed of R6 and C5 in parallel. These components have been selected to form a differentiator for low frequencies, namely the changing portion of waveform 80. These components also filter out high frequency noise that might leak through the filter network 84.
The output of the differentiator 90 is in the form of pulses, the height of which is dependent on the rate of change and extent of change of waveform 80. This output signal is represented by the waveform 82. These pulses can then be discriminated with a window comparator to select pulses of sufficient amplitude to represent a useful transition in the capacitances at the probe which, of course, is sensitive to the dielectric effect of the sample. The window comparator is composed of amplifiers of operational amplifiers 52 labelled 94 and 96. In these amplifiers the signal level is compared against the voltage labelled V1 and V2. For example, if the input voltage to 94 is applied to the inverting input whenever the input voltage is below V1 the output will be high. For the period of time that the input voltage rises above V1 the output will remain low. Thus, the positive going pulse in waveform 82 causes a negative going pulse in waveform 98.
In a similar fashion the negative going pulse in waveform 82 appears as a negative going pulse from circuit 96 and has a waveform labelled 100. The two waveforms 98 and 100 are the outputs of the circuit. Waveform 98 has a negative going pulse whenever the element encounters an increase in capacitance as when it is proximate a high dielectric material. Waveform 98 has a negative going element whenever the probe encounters a liquid interface of increasing conductance or dielectric constant. In a similar fashion, waveform 100 is a negative going pulse whenever the element decreases in capacitance, i.e., when it encounters an interface of decreasing conductance or dielectric constant.
The sensor of this invention greatly facilitates the detection of the liquid interfaces which occur in any container with different layers, usually of immiscible liquids. The sensor does not interfere with the liquid interfaces and yet locates the interfaces such that a separate pipettor can quickly be introduced into the container and lowered the desired-level.
|
A capacitive sensor is described having an element which traverses the outside of a container of liquid to ascertain the vertical locations of liquid interfaces in the container. The sensor uses an oscillator whose amplitude or phase is a function of the capacitance of the element.
| 6
|
BACKGROUND OF THE INVENTION
[0001] Epoxy putty sticks typically comprise an epoxy resin, fillers (e.g., talc), a polyether polymercaptan and an accelerator (e.g., tri(dimethylaminomethyl)phenol). A typical epoxy putty formulation contains the following components: 1) standard bisphenol A epoxy resin (mol. wt. 370); 2) sodium, potassium, aluminum and/or silicate filler; 3) magnesium silicate hydrate (talc); 4) powdered quartz filler; 5) metal powder; 6) tri(dimethylaminomethyl)phenol; and 7) polyether polymercaptan.
[0002] Epoxy sticks are normally sold as extruded concentric cylinders with the epoxy resin and fillers on the outside, and polyether polymercaptan, tri(dimethylaminomethyl)phenol and fillers on the inside. Note that in Europe, for instance, all commodities which contain epoxy resin greater than 1% need to have hazard labeling, with the exception of epoxy resins with a molecular weight of greater than 700. The epoxy putty sticks to be used need to be mixed, or kneaded, by hand. Users of such products (e.g., consumers) usually do not wear or have readily available hand protection, so there is the consequent potential for skin irritation or sensitization if hands are not washed after use, or upon repeated usage.
[0003] Therefore, it would be advantageous to employ an epoxy resin which would not have the potential to cause skin irritation. This would be the case if one could utilize an epoxy resin with a molecular weight of greater than about 700, with a molecular weight of greater than about 800 preferred. Note further that there are many epoxy resins available commercially which have a molecular weight of greater than 700; however, these are solid in form, and could not be used to formulate an epoxy putty without significant additions of plasticizers or diluents which would adversely affect the physical properties of the cured product.
SUMMARY OF THE INVENTION
[0004] The present invention relates to an epoxy composition comprising an uncured epoxy resin composition including a liquid epoxy resin and a non-sensitizing mercaptan composition capable of curing said epoxy resin when combined with said mercaptan composition to form a substantially uniform mixture, wherein said epoxy resin has a molecular weight greater than about 700. In a preferred embodiment, the present invention relates to an epoxy composition comprising a first band of an uncured epoxy resin composition including a liquid epoxy resin and a second band, said bands being joined in close side-by-side relation throughout their entire length, said second band comprising a mercaptan composition capable of curing said epoxy resin when said first and second bands are combined to form a substantially uniform mixture, wherein the epoxy resin has a molecular weight of greater than about 700.
[0005] Preferably, the epoxy resin is about 20-30% by weight of the uncured epoxy resin composition, and possesses a molecular weight of from about 800 to 1,000. The epoxy resin may be admixed with fillers and colorants including talc, titanium dioxide, carbon black and mixtures thereof. A molecular weight of the epoxy resin of from about 900-950 is particularly preferred.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0006] The present invention relates to a sorbitol based epoxy resin which has a weight average molecular weight greater than about 700, and is still liquid. In a particularly preferred embodiment of the present invention, an epoxy resin with a molecular weight of 930 (available commercially as Erisys® GE-60 by CDC Specialty Chemicals, hereinafter sorbitol based epoxy resin) may be employed. This material is a sorbitol based epoxy resin, e.g., a sorbitol glycidyl ether-aliphatic polyfunctional epoxy resin. The epoxy compositions of the present invention may have the consistency of a stiff epoxy putty, or alternatively, a liquid or paste consistency. The following examples are included as being illustrative of the invention, and should not be construed as limiting the scope thereof.
EXAMPLE 1
[0007] The preferred material was incorporated into epoxy putty formulations as follows:
Sorbitol based epoxy resin 27.1% Quartz powder 28.3% Treated fumed Silica 1.4% Talc 47.8% Carbon Black 0.8% Metal powder 0.7%
[0008] In practice, when the above formulation was mixed 1/1 by weight with a standard mercaptan side containing the following materials, it cured in a manner similar to existing epoxy putties:
Polyether polymercaptan 18.8% Tri(dimethylaminomethyl)phenol 2.1% Sodium, Potassium, Aluminum Silicate filler 5.5% Carbon Black 0.05% Talc 33.2% Metal powder 38.7%
[0009] The mixed product above cured in about 10 minutes, and gave lapshear strengths on steel in 24 hours of 330 psi, 660 psi and 360 psi. After about one hour of cure, lapshear on steel of 360 psi and 380 psi resulted; after about three days of cure, lapshear on steel of 684 psi and 780 psi resulted.
[0010] A control example, as shown below, resulted in similar properties:
[0011] Control example:
Standard bisphenol A epoxy resin (MW 370) 27% Quartz powder 28% Treated Fumed Silica 1.4% Talc 48% Carbon Black 0.8% Metal powder 0.7% Polyether polymercaptan 18.8% Tri(dimethylaminomethyl)phenol 2.1% Sodium, Potassium, Aluminum Silicate filler 5.5% Carbon Black 0.05% Talc 33.2% Metal powder 38.7%
The mixed product cured in about 9 minutes and gave lapshear strengths on steel in 24 hours of 500 to 600 psi. On three days cure, lapshear on steel of 500-600 psi resulted.
EXAMPLE 2
[0013] In further testing, an additional epoxy formulation was prepared using the following materials:
Sorbitol based epoxy resin 24.5% {fraction (1/32)} inch chopped glass 19.2% Quartz powder 17.6% Titanium Dioxide pigment 7.1% Talc 31.6%
[0014] When the above was mixed 1/1 by weight with a standard mercaptan side containing the following components, the resulting combination cured in about four minutes:
Polyether polymercaptan 21.9% Talc 70.1% Sorbitol based epoxy resin 2.3% Tri(dimethylaminomethyl)phenol 1.2% Ultramarine blue pigment 0.1%
[0015] The combination product above had a Shore D hardness of 48 in 15 minutes, and a Shore D hardness of 76 in 24 hours. It also showed a lapshear strength of 375 psi to brass, 483 psi to steel and 535 psi to aluminum, after a 24-hour cure.
[0016] Thus, given that the epoxy putty formulations as described above contain only epoxy resin with a molecular weight of greater than about 700, these materials would fall into more acceptable handling categories. Note that these formulations may also be liquid, allowing further ease of handling the material.
[0017] In the testing of the present invention, the preferred epoxy resin with a molecular weight of 930 was found not to be a contact sensitizer. Specifically, dermal reactions in a group of guinea pigs subjected to dermal administration of the epoxy resin had dermal responses on the order of 0, as described below.
[0018] The experimental procedure was as follows:
[0019] Three pairs of intradermal injections were made in a shaved area on guinea pig animals used in the sensitization study. Injections for the test animals were as follows:
1. Injection Pair A—0.1 mL of FCA (Freund's Complete Adjuvant) emulsion. 2. Injection Pair B—0.1 mL of 5% w/v GE-60 epoxy resin/2% acetone/PEG 400. 3. Injection Pair C—0.1 mL of 5% w/v GE-60 epoxy resin/2% acetone/FCA emulsion.
[0023] Injections for the challenge and rechallenge control animals were as follows:
1. Injection Pair A—0.1 mL of FCA emulsion. 2. Injection Pair B—0.1 mL of 2% acetone/PEG 400. 3. Injection Pair C—0.1 mL of 5% w/v 2% acetone/PEG 400/FCA emulsion.
[0027] On the day prior to topical induction, the guinea pigs had hair removed, with care being taken to avoid abrading the skin during the clipping procedures. Following clipping, 0.5 ml of 10% w/w sodium lauryl sulfate in petrolatum was spread over the intradermal injection sites of all study animals. Any residual sodium lauryl sulfate preparation was subsequently removed with dry gauze, and the appropriate material was prepared and applied to the animals as follows:
Concentration Amount Group Material (%) Applied Patch Design Test Sorbitol based 100 0.8 mL 2 × 4 cm epoxy resin Webril patch Challenge Acetone 100 0.8 mL 2 × 4 cm Control Webril patch Rechallenge Acetone 100 0.8 mL 2 × 4 cm Control Webril patch
[0028] A patch was applied over the intradermal injection sites. Approximately 48 hours after dosing, the binding materials were removed; the tests sites were wiped with gauze moistened in deionized water, followed by dry gauze to remove the test article residue.
[0029] The sensitization potential of the material of the present invention was based on the dermal responses of the test and control animals. Generally, dermal scores greater than or equal to one in the test animals, with scores of about zero noted in the controls are considered indicative of sensitization. Dermal scores of about one in both the test and control animals are generally considered equivocal, unless a higher dermal response is noted in the test animals.
[0030] Following treatment with 100% sorbitol based epoxy resin, dermal reactions in the test and challenge control animals were limited to scores of approximately zero. Following rechallenge, dermal reactions produced similar results.
[0031] Using α-hexylcinnamaldehyde (HCA) as a positive control, and following intradermal induction at 5% w/v HCA in propylene glycol, topical induction at 5% w/v HCA in propylene glycol and challenge at 0.5% and 1% w/v HCA in propylene glycol resulted in a contact sensitization response being observed, thereby demonstrating the susceptibility of the test system to this sensitizing agent. Therefore, the preferred epoxy resin of the present invention was not considered to be a contact sensitizer in guinea pigs. The results of the HCA control study demonstrated that a valid test was performed, and indicated that the test design would detect potential contact sensitizers.
[0032] While this invention has been described with respect to particular embodiments thereof, it is apparent that numerous other forms and modifications of this invention will be obvious to those skilled in the art. The appended claims and this invention generally should be construed to cover all such obvious forms and modifications which are within the true spirit and scope of the present invention.
|
The present invention relates to a non-sensitizing epoxy composition including an uncured epoxy resin composition including a liquid epoxy resin and a non-sensitizing mercaptan composition capable of curing said epoxy resin when combined with said mercaptan composition to form a substantially uniform mixture, wherein said epoxy resin has a molecular weight greater than about 700.
| 2
|
BACKGROUND OF THE INVENTION
The present invention relates to an automatic apparatus for executing sewings according to a determined contour. Automatic units, arranged for executing sewing works of the mentioned type, are known in the art. In these, a sewing machine is mounted on an appropriate system of slides moving on corresponding guides perpendicular to each other so as to give the machine a composite movement along two orthogonal axes X and Y, so that the sewing machine needle will be able to occupy each desired point of a plane path.
Usually, the movement to the guide system was given by a follower connected to the slide system and forced to rotate along a fixed pattern reproducing the shape of the sewing to be executed. The coupling between follower and pattern might be either of the magnetic type or be formed by a pinion and toothing made out along the contour of the same pattern.
In the described automatic units known in the art, there are some drawbacks which compromise their efficiency and cost. First, it is necessary to arrange interchangeable patterns for executing sewings of different contour and, second, it is difficult, if not altogether impossible, for the operator to carry out the sewing preparation while the machine executes the sewing on a work piece previously arranged on the apparatus.
SUMMARY OF THE INVENTION
It is an object of the present invention to improve the already known apparatus and eliminate the above cited drawbacks. The proposed solution for attaining the object foresees an apparatus comprising a sewing machine arranged to carry out movements along two orthogonal axes following paths whose points are determined according to data stored in a memory and a work support comprising a sewing station and a loading station. The work support presents two symmetrically disposed and equally shaped portions on which the fabric to be worked is alternatively loaded and sewn and is axially rotatable 180° at the end of each sewing cycle executed by the sewing machine, which covers the sewing path being covered, every time along a direction opposite to the previous one.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a plan view of the apparatus of the invention; and
FIG. 2 is a sectional view taken along line 2--2 of the apparatus of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, the reference number 10 indicates the support of a sewing machine 12 which is mounted on two slides adapted to run along two guide systems, arranged perpendicular to each other, by means of two motors driven through an electronic control system in accordance with current signals piloted by data stored in a static memory.
The control system, as well as the guides, the slides and the motors have not been illustrated in the drawings as they are well known in the art and do not form the object of the inventive idea characterizing the invention.
A work suport generically indicated by 16 is arranged in appropriate position with respect to the machine support. The work support is on its upper part substantially circular in shape and is disposed partially within an opening 18 of the machine support 10. Within the same opening 18, the sewing machine carries out its displacements along the corresponding guides.
The work support 16 is formed by a U-shaped body 20 provided with two horizontal tongues 22, 24 placed on the upper part and protruding outside.
In the lower part of this body 20, there is connected a cylindrical standard 26 (FIG. 2) mounted for rotation on a proper seat borne by the sewing machine support 10, and not shown in the drawings.
A rotating pneumatic actuator, not shown, contained in the closed space 30, has the task, in synchronism with the operative cycle of the apparatus, of rotating the cylindrical standard 26 180° alternatively in the opposite direction.
The tongues 22 and 24 have an outer contour identical to the contour of the sewing to be executed, upon which the fabric to be sewn is placed. The fabric may be, for example, formed by a portion of a coat and by the revers, which has to be sewn upon it. In this case, the edge of the coat, upon which the revers is sewn, is placed upon the tongue 22 and the remaining portion is positioned upon the edge of the coat.
A clamp 42 is provided for clamping the fabric upon the tongue 22.
The clamping and opening movements of the clamp 42 are obtained by the operation of a couple of pneumatic cylinders 44 pivoted on a support bar 46 running over the body 20 and borne by the standards 48 and 50 fixed to the same body. The stems 52 of the cylinders 44 are connected to the upper portion of the clamp 42.
Below the tongue 22, pivoted on the vertical wall of the body 20, is a reference element 54 with its outer contour protruding from the edge of the tongue 22. The element is driven by the cylinder 56 arranged as illustated in FIG. 2, and has the task of helping the operator place the fabric in a correct position upon the tongue 22. To this purpose, the element 54 is moved by the couple of cylinders 56 into contact with the tongue 22, when the clamp 42 is open, and is rotated downwardly when the clamp 42 closes in order to clamp the fabric. Element 54 has a guide section 60 extending upwardly therefrom having a contour 62 identical to the contour of tongue 22. In preparing the fabric for sewing the operator places the fabric upon the tongue 22 and the edge of the fabric against contour 62 of the guide section 60. The clamp 42 is moved downwardly to clamp the fabric between clamp 42 and tongue 22 after which element 54 is pivoted downwardly so that when cylindrical standard 26 is rotated through 180° element 54 will not strike the machine support 10 or the sewing machine needle. The work support 16 presents an equal conformation symmetrically opposite to the aforedescribed, i.e., an upper couple of cylinders 45, the clamp 43, the reference element 55 and the couple of cylinders 57, all pertinent to the tongue 24.
By means of the aforedescribed apparatus, it is possible to prepare the fabric to be sewn while the machine is executing the sewing of the fabric previously placed upon the support 16. This is achieved because the support 16 stands still, while the sewing machine 12 moves over the clamp within the opening 18.
The machine 12 moves from right to left in performing the sewing, then stops in correspondence with the last stitch and gives the signal for the rotation of the support 16 in the way already explained.
The machine 12 then sews the new fabric while moving in a direction opposite to its previous direction.
|
Automatic apparatus for executing sewings according to a determined contour, comprising a sewing machine movable along two horizontal axes and a fixed work support capable of carrying out reversible axial rotations of 180° at the end of each sewing cycle for transferring the fabric from a loading station to a sewing station. The sewing machine covers the swing path, every time along a direction opposite to the previous one.
| 3
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This non-provisional application is related to co-pending non-provisional applications titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique” and “Method and Apparatus of Using Probabilistic Atlas for Cancer Detection” filed concurrently herewith, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a digital image processing technique, and more particularly to a method and apparatus for processing breast images and using a shape model for feature removal/positioning in breast images.
[0004] 2. Description of the Related Art
[0005] Mammography images are powerful tools used in diagnosis of medical problems of breasts. An important feature in mammography images is the breast shape. Clearly detected breast shapes can be used to identify breast abnormalities, such as skin retraction and skin thickening, which are characteristics of malignancy. Clear breast shapes also facilitate automatic or manual comparative analysis between mammography images. Accurate breast shapes may convey significant information relating to breast deformation, size, and shape evolution. The position of the nipple with respect to the breast can be used to detect breast abnormalities. Knowledge of the mammogram view is also important for analysis of breast images, since the mammogram view sets the direction and geometry of a breast in a mammogram image.
[0006] Unclear or inaccurate breast shapes may obscure abnormal breast growth and deformation. Mammography images with unclear, unusual, or abnormal breast shapes or breast borders pose challenges when used in software applications that process and compare breast images.
[0007] Due to the way the mammogram acquisition process works, the region where the breast tapers off has decreased breast contour contrast, which makes breast borders unclear and poses challenges for breast segmentation. Non-uniform background regions, tags, labels, or scratches present in mammography images may obscure the breast shape and create problems for processing of breast images. Reliable breast shape detection is further complicated by variations in anatomical shapes of breasts and medical imaging conditions. Such variations include: 1) anatomical shape variations between breasts of various people or between breasts of the same person; 2) lighting variations in breast images taken at different times; 3) pose and view changes in mammograms; 4) change in anatomical structure of breasts due to the aging of people; etc. Such breast imaging variations pose challenges for both manual identification and computer-aided analysis of breast shapes.
[0008] Disclosed embodiments of this application address these and other issues by using methods and apparatuses for feature removal and positioning in breast images based on a shape modeling technique for breasts. The methods and apparatuses also use an atlas for location of features in breasts. The methods and apparatuses automatically determine views of mammograms using a shape modeling technique for breasts. The methods and apparatuses perform automatic breast segmentation, and automatically determine nipple position in breasts. The methods and apparatuses can be used for automatic detection of other features besides nipples in breasts. The methods and apparatuses can be used for feature removal, feature detection, feature positioning, and segmentation for other anatomical parts besides breasts, by using shape modeling techniques for the anatomical parts and atlases for locations of features in the anatomical parts.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to methods and apparatuses for processing images. According to a first aspect of the present invention, an image processing method comprises: accessing digital image data representing an image including an object; accessing reference data including a shape model relating to shape variation of objects from a baseline object, the objects and the baseline object being from a class of the object; and removing from the image an element not related to the object, by representing a shape of the object using the shape model.
[0010] According to a second aspect of the present invention, an image processing method comprises: accessing digital image data representing an object; accessing reference data including a shape model relating to shape variation from a baseline object shape; and determining a view of the object, the determining step including performing shape registration for the object and for a mirror object of the object, by representing shapes of the object and of the mirror object using the shape model, to obtain an object registered shape and a mirror object registered shape, and identifying the view by performing a comparative analysis between at least one of the shape of the object, the shape of the mirror object, and the baseline object shape, and at least one of the object registered shape, the mirror object registered shape, and the baseline object shape.
[0011] According to a third aspect of the present invention, an image processing method comprises: accessing digital image data representing an object; accessing reference data including a baseline object including an element, and a shape model relating to shape variation from the baseline object; and determining location of the element in the object, the determining step including generating a correspondence between a geometric part associated with the baseline object and a geometric part associated with the object, by representing a shape of the object using the shape model, to obtain a registered shape, and mapping the element from the baseline object onto the registered shape using the correspondence.
[0012] According to a fourth aspect of the present invention, an image processing apparatus comprises: an image data input unit for providing digital image data representing an image including an object; a reference data unit for providing reference data including a shape model relating to shape variation of objects from a baseline object, the objects and the baseline object being from a class of the object; and a feature removal unit for removing from the image an element not related to the object, by representing a shape of the object using the shape model.
[0013] According to a fifth aspect of the present invention, an image processing apparatus comprises: an image data input unit for providing digital image data representing an object; a reference data unit for providing reference data including a shape model relating to shape variation from a baseline object shape; and a view detection unit for determining a view of the object, the view detection unit determining a view by performing shape registration for the object and for a mirror object of the object, by representing shapes of the object and of the mirror object using the shape model, to obtain an object registered shape and a mirror object registered shape, and identifying the view by performing a comparative analysis between at least one of the shape of the object, the shape of the mirror object, and the baseline object shape, and at least one of the object registered shape, the mirror object registered shape, and the baseline object shape.
[0014] According to a sixth aspect of the present invention, an image processing apparatus comprises: an image data input unit for providing digital image data representing an object; a reference data unit for providing reference data including a baseline object including an element, and a shape model relating to shape variation from the baseline object; and an element detection unit for determining location of the element in the object, the element detection unit determining location by generating a correspondence between a geometric part associated with the baseline object and a geometric part associated with the object, by representing a shape of the object using the shape model, to obtain a registered shape, and mapping the element from the baseline object onto the registered shape using the correspondence.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Further aspects and advantages of the present invention will become apparent upon reading the following detailed description in conjunction with the accompanying drawings, in which:
[0016] FIG. 1 is a general block diagram of a system including an image processing unit for feature removal/positioning according to an embodiment of the present invention;
[0017] FIG. 2 is a block diagram of an image processing unit for feature removal/positioning according to an embodiment of the present invention;
[0018] FIG. 3 is a flow diagram illustrating operations performed by an image processing unit for feature removal/positioning according to an embodiment of the present invention illustrated in FIG. 2 ;
[0019] FIG. 4 is a block diagram of an image processing unit for nipple detection according to an embodiment of the present invention illustrated in FIG. 2 ;
[0020] FIG. 5 is a flow diagram illustrating operations performed by an image operations unit included in an image processing unit for feature removal/positioning according to an embodiment of the present invention illustrated in FIG. 4 ;
[0021] FIG. 6 is a flow diagram illustrating operations performed by a shape registration unit included in an image processing unit for feature removal/positioning according to an embodiment of the present invention illustrated in FIG. 4 ;
[0022] FIG. 7 is a flow diagram illustrating exemplary operations performed by a feature removal and positioning unit included in an image processing unit for feature removal/positioning according to an embodiment of the present invention illustrated in FIG. 4 ;
[0023] FIG. 8A illustrates an exemplary baseline breast atlas shape with identified baseline nipple position for the ML view for a shape model stored in a reference data unit;
[0024] FIG. 8B illustrates exemplary deformation modes for a shape model stored in a reference data unit;
[0025] FIG. 8C illustrates another set of exemplary deformation modes for a shape model stored in a reference data unit;
[0026] FIG. 8D illustrates exemplary aspects of the operation of calculating a cost function by a shape registration unit for a registered shape according to an embodiment of the present invention illustrated in FIG. 6 ;
[0027] FIG. 8E illustrates exemplary results of the operation of performing shape registration for breast masks by a shape registration unit according to an embodiment of the present invention illustrated in FIG. 6 ;
[0028] FIG. 8F illustrates an exemplary ML view probabilistic atlas for probability of cancer in breasts stored in a reference data unit;
[0029] FIG. 8G illustrates an exemplary CC view probabilistic atlas for probability of cancer in breasts stored in a reference data unit;
[0030] FIG. 8H illustrates exemplary aspects of the operation of detecting nipple position for a breast image by an image processing unit for feature removal/positioning according to an embodiment of the present invention illustrated in FIG. 4 ;
[0031] FIG. 8I illustrates exemplary aspects of the operation of warping a breast mask to an atlas using triangulation by a feature removal and positioning unit according to an embodiment of the present invention illustrated in FIG. 7 ;
[0032] FIG. 8J illustrates exemplary aspects of the operation of bilinear interpolation according to an embodiment of the present invention illustrated in FIG. 7 ;
[0033] FIG. 9 is a block diagram of an image processing unit for artifact removal and breast segmentation according to a second embodiment of the present invention illustrated in FIG. 2 ;
[0034] FIG. 10A illustrates an exemplary output of an image processing unit for artifact removal and breast segmentation according to a second embodiment of the present invention illustrated in FIG. 9 ;
[0035] FIG. 10B illustrates another exemplary output of an image processing unit for artifact removal and breast segmentation according to a second embodiment of the present invention illustrated in FIG. 9 ;
[0036] FIG. 11 is a block diagram of an image processing unit for view detection according to a third embodiment of the present invention illustrated in FIG. 2 ; and
[0037] FIG. 12 is a block diagram of an image processing unit for feature removal/positioning including a training system according to a fourth embodiment of the present invention.
DETAILED DESCRIPTION
[0038] Aspects of the invention are more specifically set forth in the accompanying description with reference to the appended figures. FIG. 1 is a general block diagram of a system including an image processing unit for feature removal/positioning according to an embodiment of the present invention. The system 100 illustrated in FIG. 1 includes the following components: an image input unit 28 ; an image processing unit 38 ; a display 68 ; an image output unit 58 ; a user input unit 78 ; and a printing unit 48 . Operation of the system 100 in FIG. 1 will become apparent from the following discussion.
[0039] The image input unit 28 provides digital image data. Digital image data may be medical images such as mammogram images, brain scan images, X-ray images, etc. Digital image data may also be images of non-anatomical objects, images of people, etc. Image input unit 28 may be one or more of any number of devices providing digital image data derived from a radiological film, a diagnostic image, a photographic film, a digital system, etc. Such an input device may be, for example, a scanner for scanning images recorded on a film; a digital camera; a digital mammography machine; a recording medium such as a CD-R, a floppy disk, a USB drive, etc.; a database system which stores images; a network connection; an image processing system that outputs digital data, such as a computer application that processes images; etc.
[0040] The image processing unit 38 receives digital image data from the image input unit 28 and performs feature removal/positioning in a manner discussed in detail below. A user, e.g., a radiology specialist at a medical facility, may view the output of image processing unit 38 , via display 68 and may input commands to the image processing unit 38 via the user input unit 78 . In the embodiment illustrated in FIG. 1 , the user input unit 78 includes a keyboard 85 and a mouse 87 , but other conventional input devices could also be used.
[0041] In addition to performing feature removal/positioning in accordance with embodiments of the present invention, the image processing unit 38 may perform additional image processing functions in accordance with commands received from the user input unit 78 . The printing unit 48 receives the output of the image processing unit 38 and generates a hard copy of the processed image data. In addition or as an alternative to generating a hard copy of the output of the image processing unit 38 , the processed image data may be returned as an image file, e.g., via a portable recording medium or via a network (not shown). The output of image processing unit 38 may also be sent to image output unit 58 that performs further operations on image data for various purposes. The image output unit 58 may be a module that performs further processing of the image data; a database that collects and compares images; a database that stores and uses feature removal/positioning results received from image processing unit 38 ; etc.
[0042] FIG. 2 is a block diagram of an image processing unit 38 for feature removal/positioning according to an embodiment of the present invention. As shown in FIG. 2 , the image processing unit 38 according to this embodiment includes: an image operations unit 128 ; a shape registration unit 138 ; a feature removal and positioning unit 148 ; and a reference data unit 158 . Although the various components of FIG. 2 are illustrated as discrete elements, such an illustration is for ease of explanation and it should be recognized that certain operations of the various components may be performed by the same physical device, e.g., by one or more microprocessors.
[0043] Generally, the arrangement of elements for the image processing unit 38 illustrated in FIG. 2 performs preprocessing and preparation of digital image data, registration of shapes of objects from digital image data, and feature removal and positioning for objects in digital image data. Image operations unit 128 receives digital image data from image input unit 28 . Digital image data can be medical images, which may be obtained through medical imaging. Digital image data may be mammography images, brain scan images, chest X-ray images, etc. Digital image data may also be images of non-anatomical objects, images of people, etc.
[0044] Operation of image processing unit 38 will be next described in the context of mammography images, for feature removal/positioning using a probabilistic atlas and/or a shape model for breasts. However, the principles of the current invention apply equally to other areas of image processing, for feature removal/positioning using a probabilistic atlas and/or a shape model for other types of objects besides breasts.
[0045] Image operations unit 128 receives a set of breast images from image input unit 28 and may perform preprocessing and preparation operations on the breast images. Preprocessing and preparation operations performed by image operations unit 128 may include resizing, cropping, compression, color correction, etc., that change size and/or appearance of breast images. Image operations unit 128 may also extract breast shape information from breast images, and may store or extract information about breast images, such as views of mammograms.
[0046] Image operations unit 128 sends the preprocessed breast images to shape registration unit 138 , which performs shape registration for breasts in the breast images. For shape registration, shape registration unit 138 represents breast shapes using a shape model, to obtain registered breast shapes. Shape registration unit 138 retrieves information about the shape model from reference data unit 158 , which stores parameters that define the shape model. Reference data unit 158 may also store one or more probabilistic atlases that include information about probability of breast structures at various locations inside breasts, and for various views of breasts recorded in mammograms. Breast structures recorded in probabilistic atlases may be, for example, cancer masses in breasts, benign formations in breasts, breast vessel areas, etc.
[0047] Feature removal and positioning unit 148 receives registered breast shapes from shape registration unit 138 . Feature removal and positioning unit 148 retrieves data for a baseline breast image and/or data for a probabilistic atlas, from reference data unit 158 . Using retrieved data from reference data unit 158 , feature removal and positioning unit 148 performs removal of features and/or geometric positioning and processing for registered breast shapes. The output of feature removal and positioning unit 148 are breast images with identified features, and/or breast images from which certain features were removed. The output of feature removal and positioning unit 148 may also include information about locations of removed features or locations of other features of interest in breasts, information about orientation/view of breast images, etc. Feature removal and positioning unit 148 outputs breast images, together with positioning and/or feature removal information. Such output results may be output to image output unit 58 , printing unit 48 , and/or display 68 .
[0048] Operation of the components included in image processing unit 38 illustrated in FIG. 2 will be next described with reference to FIG. 3 . Image operations unit 128 , shape registration unit 138 , feature removal and positioning unit 148 , and reference data unit 158 are software systems/applications. Image operations unit 128 , shape registration unit 138 , feature removal and positioning unit 148 , and reference data unit 158 may also be purpose built hardware such as FPGA, ASIC, etc.
[0049] FIG. 3 is a flow diagram illustrating operations performed by an image processing unit 38 for feature removal/positioning according to an embodiment of the present invention illustrated in FIG. 2 .
[0050] Image operations unit 128 receives a breast image from image input unit 28 (S 201 ). Image operations unit 128 performs preprocessing and preparation operations on the breast image (S 203 ). Preprocessing and preparation operations performed by image operations unit 128 may include resizing, cropping, compression, color correction, etc., that change size and/or appearance of breast images. Image operations unit 128 also extracts breast shape information from the breast image (S 205 ), and stores or extracts information about the view of the breast image (S 207 ).
[0051] Image operations unit 128 sends the preprocessed breast image to shape registration unit 138 , which performs shape registration for the breast in the image to obtain a registered breast shape (S 209 ). For shape registration, shape registration unit 138 uses a shape model for breast shapes (S 211 ). The shape model describes how shape varies from breast to breast. The shape model is retrieved from reference data unit 158 (S 211 ).
[0052] Feature removal and positioning unit 148 receives the registered breast shape from shape registration unit 138 . Feature removal and positioning unit 148 retrieves data describing a baseline breast image, which is included in the shape model, from reference data unit 158 (S 215 ). Feature removal and positioning unit 148 may also retrieve from reference data unit 158 data describing a probabilistic feature atlas (S 215 ). The probabilistic atlas includes information about probability of features at various locations inside breasts. Using the retrieved data from reference data unit 158 , feature removal and positioning unit 148 performs removal of features from the breast image and/or geometric positioning and processing for the registered breast shape (S 217 ). Feature removal and positioning unit 148 outputs the breast image with identified geometrical orientations, and/or from which certain features were removed (S 219 ). Such output results may be output to image output unit 58 , printing unit 48 , and/or display 68 .
[0053] FIG. 4 is a block diagram of an image processing unit 38 A for nipple detection according to an embodiment of the present invention illustrated in FIG. 2 . As shown in FIG. 4 , the image processing unit 38 A according to this embodiment includes: an image operations unit 128 A; a shape registration unit 138 A; an atlas warping unit 340 ; a nipple detection unit 350 ; and a reference data unit 158 A. The atlas warping unit 340 and the nipple detection unit 350 are included in a feature removal and positioning unit 148 A.
[0054] Image operations unit 128 A receives a set of breast images from image input unit 28 , and may perform preprocessing and preparation operations on the breast images. Preprocessing and preparation operations performed by image operations unit 128 A may include resizing, cropping, compression, color correction, etc., that change size and/or appearance of breast images. Image operations unit 128 A creates breast mask images including pixels that belong to the breasts in the breast images. Breast mask images are also called breast shape silhouettes in the current application. Breast mask images may be created, for example, by detecting breast borders or breast clusters, for the breasts shown in the breast images. Image operations unit 128 A may also store/extract information about breast images, such as views of the mammograms.
[0055] Image operations unit 128 A sends the breast mask images to shape registration unit 138 A, which performs shape registration for breast mask images. For shape registration, shape registration unit 138 A describes breast mask images using a shape model, to obtain registered breast shapes. Shape registration unit 138 A retrieves information about the shape model from reference data unit 158 A, which stores parameters that define the shape model.
[0056] Each mammogram view is associated with a shape model. A shape model may consist of a baseline breast atlas shape and a set of deformation modes. In one embodiment, the baseline breast atlas shape is a mean breast shape representing the average shape of a breast for a given mammogram view. Other baseline breast atlas shapes may also be used. The deformation modes define directions for deformation from contour points of breasts in the breast images, onto corresponding contour points of the breast in the baseline breast atlas shape. The shape model is obtained by training off-line, using large sets of training breast images. A baseline breast atlas shape can be obtained from the sets of training breast images. Deformation modes, describing variation of shapes of training breast images from the baseline breast atlas shape, are also obtained during training. Details on generation of a breast shape model using sets of training breast images can be found in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference.
[0057] A baseline breast atlas shape is generated during off-line training from a large number of training breast mask images. The baseline breast atlas shape may be, for example, a mean breast shape obtained by aligning centers of mass of training breast mask images. The alignment of centers of mass of training breast mask images results in a probabilistic map in which the brighter a pixel is, the more likely it is for the pixel to appear in a training breast mask image. A probability threshold may be applied to the probabilistic map, to obtain a mean breast shape in which every pixel has a high probability of appearing in a training breast mask image. Hence, the baseline breast atlas shape illustrates a baseline breast. Additional details regarding generation of a baseline breast atlas shape/mean breast shape can be found in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference. The baseline breast atlas shape also includes a baseline nipple for the baseline breast. The baseline nipple position is identified in the baseline breast atlas shape during off-line training.
[0058] To extract deformation modes for a shape model, training breast mask images are warped onto the baseline breast atlas shape during off-line training, to define parameterization of breast shape. Control points may be placed along the edges of the baseline breast atlas shape. A deformation grid is generated using the control points. Using the deformation grid, the control points are warped onto training breast mask images. Shape representations for the training breast mask images are generated by the corresponding warped control points, together with centers of mass of the shapes defined by the warped control points. Additional details about generating shape representations for training breast images can be found in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference.
[0059] Principal modes of deformation between training breast mask images and the baseline breast atlas shape may be determined using the shape representations for the training breast mask images. Principal modes of deformation can be found using Principal Components Analysis (PCA) techniques. The principal components obtained from PCA represent modes of deformation between training breast mask images and the baseline breast atlas shape. Additional details regarding extraction of deformation modes are found in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference.
[0060] The baseline breast atlas shape, and the modes of deformation between training breast mask images and the baseline breast atlas shape define a shape model. Shape models can be obtained during off-line training, for each mammogram view. Shape models are stored in reference data unit 158 A.
[0061] A new breast mask shape received from image operations unit 128 A may then be represented using a shape model from reference data unit 158 A. A breast mask shape may be expressed as a function of the baseline breast atlas shape, which may be a mean breast shape (B a ) in an exemplary embodiment, and of the shape model deformation modes, as:
[0000]
Breast
Shape
=
p
+
B
a
+
∑
i
=
1
k
α
i
L
i
(
1
)
[0000] where p is an offset (such as a 2D offset) to the mean breast shape B a to account for a rigid translation of the entire shape, L i , i=1 . . . k is the set of deformation modes of the shape model, and α i , i=1 . . . k are a set of parameters that define the deviations of Breast Shape from the mean breast shape along the axes associated with the principal deformation modes. The parameters α i , i=1 . . . k are specific to each breast mask. Hence, an arbitrary breast mask may be expressed as a sum of the fixed mean breast shape (B a ), a linear combination of fixed deformation modes L i multiplied by coefficients α i , and a 2D offset p. Details on how a mean breast shape/baseline breast atlas shape B a and deformation modes L i , i=1 . . . k are obtained during training, using training breast images can be found in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference.
[0062] Each mammogram view v i is associated with a mean breast shape (B a — vi ) specific to that view, and with a set of deformation modes L i — vi , i=1 . . . k vi specific to that view.
[0063] For each breast mask image B mask — new received from image operations unit 128 A, shape registration unit 138 A retrieves the mean breast shape (B a — vi ) and the set of deformation modes L i — vi , i=1 . . . k vi associated with the view v i of the breast mask image B mask — new Shape registration unit 138 A next identifies the parameters α i , i=1 . . . k vi and the 2D offset p for the breast mask image B mask — new , to fit the breast mask image B mask — new with its correct shape representation of the form:
[0000]
Breast
Shape
=
B
a_vi
+
p
+
∑
i
=
1
k
vi
α
i
L
i_vi
.
[0064] Atlas warping unit 340 receives the registration results for the breast mask image B mask — new from shape registration unit 138 A. Registration results for the breast mask image B mask — new include the parameters α i , i=1 . . . k vi for the breast mask image B mask — new and the functional representation
[0000]
Breast
Shape
=
B
a_vi
+
p
+
∑
i
=
1
k
vi
α
i
L
i_vi
[0000] for the breast mask image B mask — new Atlas warping unit 340 then warps the breast mask image B mask — new to the mean breast shape B a — vi . Atlas warping unit 340 may, alternatively, warp the breast mask image B mask — new to a probabilistic feature atlas A vi specific to the view v i of the breast mask image B mask — new . The probabilistic feature atlas data is stored in reference data unit 158 A.
[0065] The probabilistic feature atlas A vi includes an image of the mean breast shape B a — vi for view v i , together with probabilities for presence of a feature at each pixel in the mean breast shape B a — vi . Hence, the probabilistic atlas A vi is a weighted pixel image, in which each pixel of the mean breast shape B a — vi is weighted by the feature probability for that pixel.
[0066] The probabilistic feature atlas is obtained by training off-line, using large sets of training breast images with previously identified feature structures. Features recorded in probabilistic atlases may be cancer masses in breasts, benign formations in breasts, breast vessel areas, etc. The shapes of training breast images are represented as linear combinations of deformation modes obtained in training. Using the shape representations for the training breast images, previously identified features in the training breast images are mapped to the baseline breast atlas shape obtained in training. By overlapping feature positions from the training images onto the baseline breast atlas shape, a probabilistic atlas containing probabilities for presence of a feature in the baseline breast atlas shape is obtained. Additional details on generation of a probabilistic atlas using sets of training breast images with previously identified features can be found in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference.
[0067] After atlas warping unit 340 warps the breast mask image B mask — new to the probabilistic atlas A vi or to the mean breast shape B a — vi , a warped breast mask image B mask — new — warped is obtained. Feature probability weights from the probabilistic atlas A vi are associated with pixels in the warped image B mask — new — warped . The baseline nipple position from the mean breast shape B a — vi is also associated with pixels in the warped image B mask — new — warped .
[0068] Nipple detection unit 350 receives the warped breast mask image B mask — new warped, together with shape registration information of the form Breast Shape=
[0000]
B
a_vi
+
p
+
∑
i
=
1
k
vi
α
i
L
i_vi
,
[0000] that establishes a correspondence between pixels of B mask — new — warped and pixels of B mask — new .
[0069] Nipple detection unit 350 warps the B mask — new — warped image back to the original B mask — new , and an image P mask — new , is obtained. Since the baseline nipple position has been identified in the baseline breast atlas shape during off-line training, and since B mask — new — warped has the shape of the baseline breast atlas shape, the image P mask — new includes a warped nipple position from B mask — new — warped to B mask — new . Hence, the image P mask — new is an image of the breast mask image B mask — new , in which the position of the nipple has been identified. Therefore, the image P mask — new includes nipple detection results for the original breast mask B mask — new .
[0070] If atlas warping unit 340 warped the breast mask image B mask — new to probabilistic atlas A vi , the image P mask — new includes feature probabilities for various breast features, at various pixel locations inside the breast mask image B mask — new . Hence, in this case, the image P mask — new is a weighted pixel image, in which each pixel of the breast mask image B mask — new is weighted by the feature probability for that pixel. If the feature is a cancer structure for example, the image P mask — new is a weighted pixel image, in which each pixel of the breast mask image B mask — new is weighted by the probability for cancer at that pixel. Additional details on mapping feature probabilities from a probabilistic atlas A vi to a breast mask image B mask — new to obtain a probability map for a feature in a breast mask image B mask — new can be found in the co-pending non-provisional application titled “Method and Apparatus of Using Probabilistic Atlas for Cancer Detection”, the entire contents of which are hereby incorporated by reference.
[0071] The identified nipple position in image P mask — new provides very useful information for detection of the nipple and for the position of the nipple with respect to the breast. If the image P mask — new includes cancer probabilities associated with pixels of the B mask — new breast mask from a probabilistic cancer atlas, image P mask — new provides information about the nipple position with respect to probable locations of cancer masses in the B mask — new breast mask. The position of the nipple with respect to the breast can be used to detect breast abnormalities. Since the position of the nipple with respect to the breast is influenced by breast abnormalities, information about nipple position and nipple proximity to high probability cancer regions in breast help in identification of cancer masses, structural changes, breast abnormalities, etc.
[0072] The initially identified nipple position in image P mask — new (and hence in breast mask image B mask — new ) can also be a starting point for performing a refinement of the nipple position. Refinement of the nipple position can be performed, for example, in regions adjacent to or including the initially identified nipple position in image P mask — new .
[0073] Nipple detection unit 350 outputs the image P mask — new . The image P mask — new may be output to image output unit 58 , printing unit 48 , and/or display 68 .
[0074] Image operations unit 128 A, shape registration unit 138 A, atlas warping unit 340 , nipple detection unit 350 , and reference data unit 158 A are software systems/applications. Image operations unit 128 A, shape registration unit 138 A, atlas warping unit 340 , nipple detection unit 350 , and reference data unit 158 A may also be purpose built hardware such as FPGA, ASIC, etc.
[0075] FIG. 5 is a flow diagram illustrating operations performed by an image operations unit 128 A included in an image processing unit 38 A for feature removal/positioning according to an embodiment of the present invention illustrated in FIG. 4 .
[0076] Image operations unit 128 A receives a raw or preprocessed breast image from image input unit 28 (S 401 ). The breast image may be retrieved by image operations unit 128 A from, for example, a breast imaging apparatus, a database of breast images, etc. Image operations unit 128 A may perform preprocessing operations on the breast image (S 403 ). Preprocessing operations may include resizing, cropping, compression, color correction, etc.
[0077] Image operations unit 128 A creates a breast mask image for the breast image (S 405 ). The breast mask image includes pixels that belong to the breast. The breast mask image may be created by detecting breast borders for the breast shown in the breast image. Image operations unit 128 A may create a breast mask image by detecting breast borders using methods described in the U.S. patent application titled “Method and Apparatus for Breast Border Detection”, application Ser. No. 11/366,495, by Daniel Russakoff and Akira Hasegawa, filed on Mar. 3, 2006, the entire contents of which are hereby incorporated by reference. With the techniques described in the “Method and Apparatus for Breast Border Detection” application, pixels in the breast image are represented in a multi-dimensional space, such as a 4-dimensional space with x-locations of pixels, y-locations of pixels, intensity value of pixels, and distance of pixels to a reference point. K-means clustering of pixels is run in the multi-dimensional space, to obtain clusters for the breast image. Cluster merging and connected components analysis are then run using relative intensity measures, brightness pixel values, and cluster size, to identify a cluster corresponding to the breast in the breast image. A set of pixels, or a mask, containing breast pixels is obtained. The set of pixels for a breast forms a breast mask B mask .
[0078] Other breast border detection techniques may also be used by image operations unit 128 A to obtain a breast mask image.
[0079] Image operations unit 128 A also stores information about the breast image, such as information about the view of the mammogram (S 407 ). Examples of mammogram views are MLL (medio-lateral left), MLR (medio-lateral right), CCL (cranio-caudal left), CCR (cranio-caudal right), RCC, LRR, LMLO (left medio-lateral oblique), and RMLO (right medio-lateral oblique). Image operations unit 128 A outputs the breast mask image, and information about the view of the breast image (S 409 ), to shape registration unit 138 A.
[0080] FIG. 6 is a flow diagram illustrating operations performed by a shape registration unit 138 A included in an image processing unit 38 A for feature removal/positioning according to an embodiment of the present invention illustrated in FIG. 4 .
[0081] Shape registration unit 138 A receives from image operations unit 128 A a preprocessed breast image, represented as a breast mask image B mask — new (S 470 ). Information about the mammogram view v i of the breast image is also received (S 470 ). Shape registration unit 138 A retrieves from reference data unit 158 A data that defines the shape model for that view, including a mean breast shape (B a — vi ) and shape model deformation modes L i — vi , i=1 . . . k vi for the view v i of the breast mask image B mask — new (S 472 ).
[0082] Shape registration unit 138 A fits the breast mask image B mask — new with its correct shape representation as a linear combination of the deformation modes,
[0000]
Shape
=
B
a_vi
+
p
+
∑
i
=
1
k
vi
α
i
L
i_vi
,
[0000] by determining parameters α i , i=1 . . . k vi and the 2D offset p.
[0083] To fit the breast mask image B mask — new with its correct shape representation, shape registration unit 138 A optimizes the α i values, together with an x offset p x and a y offset p y , for a total of k+2 parameters: (p x , p y , α), where α=(α 1 , α 2 , . . . , α k ) and p=(p x , p y ) (S 478 ). For optimization, shape registration unit 138 A uses a cost function defined as the mean distance to edge. For a (p x , p y , α) parameter set, shape registration unit 138 A calculates the new shape resulting from this parameter set by formula
[0000]
Shape
=
B
a_vi
+
p
+
∑
i
=
1
k
vi
α
i
L
i_vi
(
S
480
)
.
[0084] The center of mass (Shape.COM) of Shape is then calculated (S 480 ). For each shape point on the exterior (border) of Shape, shape registration unit 138 A generates a ray containing the Shape.COM and the shape point, finds the intersection point of the ray with the edge of B mask — new , and calculates how far the shape point is from the intersection point obtained in this manner. This technique is further illustrated in FIG. 8D . In an alternative embodiment, the minimum distance from the shape point to the edge of B mask — new is calculated. The mean distance for the Shape points to the edges of the breast mask image B mask — new is then calculated (S 482 ). Optimized α i values and 2D offset p are selected for which the mean distance of shape points of Shape to the breast mask image B mask — new edges attains a minimum (S 484 ).
[0085] Shape registration unit 138 A may use the downhill simplex method, also known as the Nelder-Mead or the amoeba algorithm (S 486 ), to fit the breast mask image B mask — new with its correct shape representation, by minimizing distances of the edge shape points of Shape to the edges of the breast mask image B mask — new . The downhill simplex method is a single-valued minimization algorithm that does not require derivatives. The downhill simplex algorithm is typically very robust.
[0086] With the Nelder-Mead method, the k+2 parameters (p x , p y , α) form a simplex in a multi-dimensional space. The Nelder-Mead method minimizes the selected cost function, by moving points of the simplex to decrease the cost function. A point of the simplex may be moved by reflections against a plane generated by other simplex points, by reflection and expansion of the simplex obtained from a previous reflection, by contraction of the simplex, etc.
[0087] Once parameters of the shape model are optimized for the breast mask image B mask — new , shape registration unit 138 A outputs the shape registration results for the breast mask image B mask — new to atlas warping unit 301 (S 492 ).
[0088] FIG. 7 is a flow diagram illustrating exemplary operations performed by a feature removal and positioning unit 148 A included in an image processing unit 38 A for feature removal/positioning according to an embodiment of the present invention illustrated in FIG. 4 . FIG. 7 illustrates exemplary operations that may be performed by an atlas warping unit 340 and a nipple detection unit 350 included in a feature removal and positioning unit 148 A.
[0089] Atlas warping unit 340 warps the registered shape for breast mask image B mask — new to a probabilistic atlas A vi , or to a baseline breast atlas shape B a — vi , associated with the view v i of the breast mask image B mask — new . Warping to probabilistic atlas A vi or to the baseline breast atlas shape B a — vi may be performed by triangulating the breast mask B mask — new based on its center of mass and edge points (S 501 ). After shape registration has been performed by shape registration unit 138 A, each triangle in the breast mask B mask — new corresponds to a triangle in the probabilistic atlas A vi and to a triangle in the baseline breast atlas shape B a — vi (S 503 ), as the probabilistic atlas A vi has the shape of the baseline breast atlas shape B a — vi . Pixels inside corresponding triangles of the atlas A vi (or B a — vi ) can be warped back and forth into triangles of breast mask B mask — new , using a bilinear interpolation in 2D (S 503 ). In an exemplary implementation, the bilinear interpolation in 2D may be performed by multiplying each of the triangle vertices by appropriate relative weights, as further described at FIG. 8J .
[0090] Nipple detection unit 350 warps back corresponding triangles of the atlas A vi (or B a — vi ), to triangles in breast mask B mask — new (S 505 ). The nipple position for the breast mask image B mask — new is the warped nipple position from triangles of the baseline breast atlas shape B a — vi (or probabilistic atlas A vi ) to triangles of the breast mask image B mask — new (S 507 ). Hence, an image with a location for the nipple is obtained for the breast mask B mask — new (S 507 ).
[0091] Feature probabilities associated with pixels in triangles of the atlas image A vi may become associated with pixels in triangles of breast mask B mask — new , as further described in the co-pending non-provisional application titled “Method and Apparatus of Using Probabilistic Atlas for Cancer Detection”, the entire contents of which are hereby incorporated by reference. Hence, the image with an identified nipple location may also contain feature probability values associated with image pixels, for features such as cancer structures, benign structures, etc.
[0092] FIG. 8A illustrates an exemplary baseline breast atlas shape for the ML view, with identified nipple position. The exemplary baseline breast atlas shape for the ML view is included in a shape model stored in a reference data unit 158 . The baseline breast atlas shape in FIG. 8A is a mean breast shape representing the set of pixels that have 95% or more chance of appearing in a breast mask image in the ML view. The nipple N has been identified on the mean breast shape.
[0093] FIG. 8B illustrates exemplary deformation modes for a shape model stored in the reference data unit 158 . The breast shape in figure I 510 is an exemplary baseline breast atlas shape (mean shape, in this case) for the ML view.
[0094] The first 3 modes (L 1 , L 2 , L 3 ) of deformation are shown. The first mode of deformation is L 1 . Contours D 2 and D 3 define the deformation mode L 1 . The deformation mode L 1 consists of directions and proportional length of movement for each contour point from the D 2 contour to a corresponding contour point from the D 3 contour. Contours D 4 and D 5 define the second deformation mode L 2 , and contours D 6 and D 7 define the third deformation mode L 3 .
[0095] The deformation modes shown in FIG. 8B may be obtained by training, using techniques described in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference.
[0096] FIG. 8C illustrates another set of exemplary deformation modes for a shape model stored in the reference data unit 158 . The deformation modes shown in FIG. 8C were obtained by training a shape model using 4900 training breast images of ML view, using techniques described in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference. 17 deformation modes, capturing 99% of the variance in the breast images data set, were obtained. The representations of the first 4 modes L 1 , L 2 , L 3 and L 4 are shown in FIG. 8C . The representations of the first 4 modes L 1 , L 2 , L 3 and L 4 together capture 85% of the data's variance. For each mode shown in FIG. 8C , the mean breast shape (baseline breast atlas shape) for the ML view is plotted with dots (points), while the arrows represent the distance traveled by one point for that mode from −2 standard deviations to +2 standard deviations of the mean breast shape. Mode L 1 captures 52% of the variance in the breast images data set, mode L 2 captures 18% of the variance in the breast images data set, mode L 3 captures 10% of the variance in the breast images data set, and mode L 4 captures 4% of the variance in the breast images data set. The rest of the deformation modes (L 5 to L 17 ) are not shown.
[0097] FIG. 8D illustrates exemplary aspects of the operation of calculating a cost function by a shape registration unit 138 A for a registered shape according to an embodiment of the present invention illustrated in FIG. 6 . Shape registration is performed for the breast mask B mask — new I 511 using an α i , i=1 . . . k parameter set and a 2D offset p. A shape bounded by contour C 512 is obtained from formula
[0000]
Shape
=
B
a_vi
+
p
+
∑
i
=
1
k
α
i
L
i_vi
,
[0000] where B a — vi is a mean breast shape for view v i of the breast mask B mask — new , and L i — vi , i=1 . . . k vi are shape model deformation modes. The center of mass COM for the Shape bounded by contour C 512 is found. For a point S 1 on the contour (perimeter) of Shape, a line is drawn through the COM point. The line intersects the contour of breast mask B mask — new I 511 at point S 2 . The distance to edge is the distance d between points S 1 and S 2 . Distances d are obtained for all points on the contour (perimeter) C 512 of Shape, and a cost function is obtained as the mean of all distances d.
[0098] FIG. 8E illustrates exemplary results of the operation of performing shape registration for breast masks by a shape registration unit 138 A according to an embodiment of the present invention illustrated in FIG. 6 . As shown in FIG. 8E , breast masks I 513 and I 514 are fit with shape representations. The shape registration results bounded by contours C 513 and C 514 are effectively describing the shapes of breast masks I 513 and I 514 . The downhill simplex algorithm was used by shape registration unit 138 A to obtain the shape registration results shown in FIG. 8E .
[0099] FIG. 8F illustrates an exemplary ML view probabilistic atlas for probability of cancer in breasts stored in the reference data unit 158 . For the ML view probabilistic atlas in FIG. 8F , the contour C 515 is the contour of the mean breast shape (baseline breast atlas shape) B a — ML for the ML view. The region R 515 A indicates the highest probability of cancer, followed by regions R 515 B, then R 515 C, and R 515 D. As shown in the probabilistic atlas, the probability for cancer is largest in the center of a breast, and decreases towards edges of the mean breast shape.
[0100] FIG. 8G illustrates an exemplary CC view probabilistic atlas for probability of cancer in breasts stored in the probabilistic atlas reference data unit 158 . For the CC view probabilistic atlas in FIG. 8G , the contour C 516 is the contour of the mean breast shape for the CC view. The region R 516 A indicates the highest probability of cancer, followed by regions R 516 B, then R 516 C, and R 516 D. As shown in the probabilistic atlas, the probability for cancer is largest in the center left region of a breast, and decreases towards edges of the mean breast shape.
[0101] FIG. 8H illustrates exemplary aspects of the operation of detecting nipple position for a breast image by an image processing unit 38 A for feature removal/positioning according to an embodiment of the present invention illustrated in FIG. 4 . As illustrated in FIG. 8H , a breast image I 518 is input by image operations unit 128 A. Image operations unit 128 A extracts a breast mask image I 519 for the breast image I 518 . Shape registration unit 138 A performs shape registration for the breast mask image, by representing the shape of the breast mask using a shape model. The shape registration contour C 520 fits the shape of the breast mask from image I 519 . Atlas warping unit 340 warps the breast mask registered shape I 520 to a probabilistic atlas (or alternatively to a baseline breast atlas shape) I 522 that includes a detected baseline nipple N. Atlas warping unit 340 performs warping by generating a correspondence between pixels of the breast mask registered shape I 520 and pixels of the probabilistic atlas (or of the baseline breast atlas shape) I 522 . Using the correspondence, nipple detection unit 350 warps the probabilistic atlas (or baseline breast atlas shape) I 522 onto the breast mask registered shape I 520 , hence obtaining an image I 523 with detected nipple position N′ corresponding to the baseline nipple position N, for the breast image I 518 .
[0102] FIG. 8I illustrates exemplary aspects of the operation of warping a breast mask to an atlas using triangulation by a feature removal and positioning unit 148 A according to an embodiment of the present invention illustrated in FIG. 7 .
[0103] Atlas warping unit 340 warps a registered shape S 530 for a breast mask image B mask — new I 530 to a probabilistic atlas A vi (or to a baseline breast atlas shape) A 532 shown in image I 532 . Warping to probabilistic atlas A vi (or to baseline breast atlas shape) A 532 is performed by triangulating the breast mask shape S 530 based on its center of mass COM_ 530 and edge points. A test point P_ 530 is used to generate a triangle in the breast mask shape S 530 . For example, a triangle T_ 530 is generated using the center of mass COM_ 530 and the test point P_ 530 and touching the edges of mask shape S 530 . The triangle is warped to probabilistic atlas A vi (or to baseline breast atlas shape) A 532 onto a corresponding triangle T_ 532 , with the COM_ 530 and the test point P_ 530 mapped to corresponding points PC_ 532 and P_ 532 . The probabilistic atlas A vi (or baseline breast atlas shape) A 532 is then warped onto registered shape S 530 by warping each triangle T_ 532 back onto the corresponding triangle T_ 530 of the breast mask B mask — new I 530 . The nipple position the probabilistic atlas A vi (or baseline breast atlas shape) A 532 is hence warped onto registered shape S 530 associated with the breast mask image B mask — new I 530 .
[0104] FIG. 8J illustrates exemplary aspects of the operation of bilinear interpolation according to an embodiment of the present invention illustrated in FIG. 7 . The pixels inside corresponding triangles of the atlas A vi (or baseline breast atlas shape B a — vi ) can be warped back and forth to triangles in breast mask B mask — new , using a bilinear interpolation. For a correspondence between two triangles, bilinear interpolation in 2D is performed by multiplying each of the vertices by appropriate relative weights as described in FIG. 8J . Given a triangle with vertices A, B, and C, the pixel intensity at point D can be obtained as:
[0000] D=A*wA/T abc +B*wB/T abc +C*wC/T abc (2)
[0000] where A, B, and C are pixel intensities at triangle vertices, T abc is the area of triangle ABC, wA is the area of triangle BCD, wB is the area of triangle ACD, and wC is the area of triangle ABD, so that T abc =wA+wB+wC. Hence, given pixels A, B, and C of a triangle inside atlas A vi (or inside B a — vi ), and corresponding pixels A′, B′, and C′ of a corresponding triangle in breast mask B mask — new , a pixel D inside triangle ABC can be warped to a pixel D′ inside triangle A′B′C′, using equation (2) in triangle A′B′C′.
[0105] FIG. 9 is a block diagram of an image processing unit 38 B for artifact removal and breast segmentation according to a second embodiment of the present invention illustrated in FIG. 2 . As shown in FIG. 9 , the image processing unit 38 B according to this embodiment includes: an image operations unit 128 B; a shape registration unit 138 B; an optional atlas warping unit 340 ; an artifact removal unit 360 ; and a reference data unit 158 B. The atlas warping unit 340 and the artifact removal unit 360 are included in a feature removal and positioning unit 148 B.
[0106] Image operations unit 128 B receives a breast image from image input unit 28 , and may perform preprocessing and preparation operations on the breast image. Preprocessing and preparation operations performed by image operations unit 128 B may include resizing, cropping, compression, color correction, etc., that change size and/or appearance of the breast image. Image operations unit 128 B creates a breast mask image. Breast mask images may be created, for example, by detecting breast borders or breast clusters for the breasts shown in the breast image. Image operations unit 128 B may also store/extract information about the breast image, such as view of mammogram.
[0107] Image operations unit 128 B may perform preprocessing and breast mask extraction operations in a similar manner to image operations unit 128 A described in FIG. 5 . Image operations unit 128 B may create a breast mask image by detecting breast borders using methods described in the U.S. patent application titled “Method and Apparatus for Breast Border Detection”, application Ser. No. 11/366,495, by Daniel Russakoff and Akira Hasegawa, filed on Mar. 3, 2006, the entire contents of which are hereby incorporated by reference. Other methods may also be used to create a breast mask image.
[0108] Image operations unit 128 B sends the breast mask images to shape registration unit 138 B, which performs shape registration for the breast mask image. For shape registration, shape registration unit 138 B describes the breast mask image using a shape model, to obtain a registered breast shape. Shape registration unit 138 B retrieves information about the shape model from reference data unit 158 B, which stores parameters that define the shape model.
[0109] The reference data unit 158 B is similar to reference data unit 158 A from FIG. 4 . Reference data unit 158 B stores shape models, and may also store probabilistic atlases for breast features. A shape model and an optional probabilistic atlas stored by reference data unit 158 B can be generated off-line, using training breast images. Details on generation of a breast shape model and a probabilistic atlas using sets of training breast images can be found in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference. A shape model stored by reference data unit 158 B includes a baseline breast atlas image and a set of deformation modes. A shape model stored by reference data unit 158 B is similar to a shape model stored by reference data unit 158 A as described at FIG. 4 , with two differences. One difference is that the nipple of the baseline breast atlas shape need not be identified and marked for the baseline breast atlas shape stored by reference data unit 158 B. The second difference pertains to the method of generation of the shape model during off-line training. The training breast images used to generate the shape model for reference data unit 158 B off-line are preferably breast images without artifacts (such as tags, noise, frames, image scratches, lead markers, imaging plates, etc.), anomalies, or unusual structures. Training breast images without artifacts may be obtained by removing artifacts, anomalies, or unusual structures from the images manually or automatically, before off-line training. In that case, the baseline breast atlas shape obtained as described in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference, illustrates a baseline breast without artifacts, anomalies, or unusual structures. The deformation modes obtained as described in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference, describe variations between shapes of training breast images and the baseline breast atlas shape. Hence, linear combinations of the deformation modes will produce breast shapes without artifacts, anomalies, or unusual structures, because the deformation modes were obtained from training breast images that did not include artifacts, anomalies, or unusual structures. Reference data unit 158 B stores information for shape models for breasts, for various views of mammograms.
[0110] Shape registration unit 138 B may perform shape registration in a manner similar to shape registration unit 138 A, as described at FIG. 6 . Optional atlas warping unit 340 receives the registration results for a breast mask image from shape registration unit 138 B, and warps the breast mask image to the baseline breast atlas shape from the shape model associated with the view of the breast mask image. Atlas warping unit 340 performs warping of breast mask images to baseline breast atlas shapes or to probabilistic atlases, as described in FIG. 4 and FIG. 7 .
[0111] Using the image processing unit 38 B it is possible to remove artifacts, such as tags, noise, frames, image scratches, lead markers, imaging plates, etc., from a breast image and perform an accurate segmentation of the breast in the breast image. For a breast image I T including artifacts, image operations unit 128 B obtains a breast mask image B T — mask . Shape registration unit 138 B then performs shape registration for the breast mask image B T — mask . Shape registration unit 138 B expresses the breast mask image B T — mask as a function of the baseline breast atlas shape, which may be a mean breast shape (B a ), and shape model deformation modes, as:
[0000]
Breast
Shape
=
B
+
p
+
∑
i
=
1
k
α
i
L
,
[0000] where L i , i=1 . . . k is the set of deformation modes of the shape model, α 1 , i=1 . . . k are a set of parameters optimized by shape registration unit 138 B for breast mask image B T — mask , and p is an offset (such as a 2D offset) to the mean breast shape B a to account for a rigid translation of the entire shape. Shape registration unit 138 B retrieves baseline breast atlas shape data and deformation modes from reference data unit 158 B. Since the shape model stored in reference data unit 158 B was generated using training breast shape images without artifacts, anomalies, or unusual structures, the Breast Shape obtained from
[0000]
Breast
Shape
=
B
+
p
+
∑
i
=
1
k
α
i
L
[0000] with optimized α i and p parameters will not include artifacts, anomalies, or unusual structures. In other words, the Breast Shape will optimize a fit to the original breast mask image B T — mask , except for the artifacts that were present in the original breast mask image B T — mask . The artifacts present in the original breast mask image B T — mask have not been learned by the shape model stored in reference data unit 158 B, and will not be fit. Hence, the Breast Shape represents a segmentation of the breast in the breast mask image B T — mask , without the artifacts may have been present in breast mask image B T — mask .
[0112] Artifact removal unit 360 receives the Breast Shape together with the breast mask image B T — mask from shape registration unit 138 B, and may extract artifacts by subtracting the Breast Shape from the breast mask image B T — mask , to obtain an artifact mask image I Art
[0113] Artifact removal unit 360 can then apply the artifact mask image I Art to the original breast image I T , to identify artifact positions in the original breast image I T and remove the artifacts. Artifact removal unit 360 outputs a breast image I T ′ without artifacts.
[0114] If the reference data unit 158 B contains a probabilistic feature atlas, and atlas warping unit 340 is present in image processing unit 38 B, breast segmentation with artifact removal may be combined with feature detection. For example, artifact removal may be achieved for an original breast image I T together with cancer detection using a probabilistic cancer atlas and/or comparative left-right breast analysis, as described in the co-pending non-provisional application titled “Method and Apparatus of Using Probabilistic Atlas for Cancer Detection”, the entire contents of which are hereby incorporated by reference.
[0115] Image operations unit 128 B, shape registration unit 138 B, optional atlas warping unit 340 , artifact removal unit 360 , and reference data unit 158 B are software systems/applications. Image operations unit 128 B, shape registration unit 138 B, optional atlas warping unit 340 , artifact removal unit 360 , and reference data unit 158 B may also be purpose built hardware such as FPGA, ASIC, etc.
[0116] FIG. 10A illustrates an exemplary output of an image processing unit 38 B for artifact removal and breast segmentation according to a second embodiment of the present invention illustrated in FIG. 9 . A breast mask I 581 with a tag T 582 is segmented by image processing unit 35 B using a shape model that was constrained to remain within the shape space of typical breasts without artifacts. The final segmented breast shape I 583 obtained by image processing unit 35 B does not contain the tag T 582 , as the segmented breast shape is constrained by the shape model to resemble a breast.
[0117] FIG. 10B illustrates another exemplary output of an image processing unit 38 B for artifact removal and breast segmentation according to a second embodiment of the present invention illustrated in FIG. 9 . A breast mask I 591 with a skin fold T 592 is segmented by image processing unit 35 B using a shape model that was constrained to remain within the shape space of typical breasts without artifacts. The final segmented breast shape I 593 obtained by image processing unit 35 B does not contain the skin fold T 592 , as the segmented breast shape is constrained by the shape model to resemble a breast.
[0118] FIG. 11 is a block diagram of an image processing unit 38 C for view detection according to a third embodiment of the present invention illustrated in FIG. 2 . As shown in FIG. 11 , the image processing unit 38 C according to this embodiment includes: an image operations unit 128 C; a shape registration unit 138 C; a view decision unit 148 C; and a reference data unit 158 C. The view decision unit 148 C is a feature removal and positioning unit.
[0119] Image operations unit 128 C receives a breast image from image input unit 28 , and may perform preprocessing and preparation operations on the breast image. Preprocessing and preparation operations performed by image operations unit 128 C may include resizing, cropping, compression, color correction, etc., that change size and/or appearance of the breast image. Image operations unit 128 C creates a breast mask image. Breast mask images may be created, for example, by detecting breast borders or breast clusters for the breasts shown in the breast image. Image operations unit 128 C may also store/extract information about the breast image, such as view of mammogram.
[0120] Image operations unit 128 C may perform preprocessing and breast mask extraction operations in a similar manner to image operations unit 128 A described in FIG. 5 . Image operations unit 128 C may create a breast mask image by detecting breast borders using methods described in the U.S. patent application titled “Method and Apparatus for Breast Border Detection”, application Ser. No. 11/366,495, by Daniel Russakoff and Akira Hasegawa, filed on Mar. 3, 2006, the entire contents of which are hereby incorporated by reference.
[0121] Image operations unit 128 C sends the breast mask images to shape registration unit 138 C, which performs shape registration for the breast mask image. For shape registration, shape registration unit 138 C describes the breast mask image using a shape model, to obtain a registered breast shape. Shape registration unit 138 C retrieves information about the shape model from reference data unit 158 C, which stores parameters that define the shape model.
[0122] The reference data unit 158 C is similar to reference data unit 158 A from FIG. 4 . The reference data unit 158 C stores shape models, and may also store probabilistic atlases.
[0123] A shape model stored by reference data unit 158 C can be generated off-line, using training breast images. Details on generation of a breast shape model using sets of training breast images can be found in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference. A shape model stored by reference data unit 158 C includes a baseline breast atlas image and a set of deformation modes.
[0124] Shape registration unit 138 C may perform shape registration in a manner similar to shape registration unit 138 A, as described at FIG. 6 . Shape registration unit 138 C receives from image operations unit 128 C a breast mask image B mask of unknown mammogram view. B mask could be, for example, an ML mammogram view for which the view direction of left or right is not known.
[0125] Shape registration unit 138 C fits the breast mask image B mask to a shape model M associated with one of left or right views, and obtains a registered image R 1 . Shape registration unit 138 C then flips the breast mask image B mask about a vertical axis to obtain a flipped breast mask B mask — Flipped , and then fits the flipped breast mask image B mask — Flipped to the same shape model M, to obtain a registered image R 2 .
[0126] View detection unit 148 C receives breast mask images B mask and B mask — Flipped , and registered images R 1 and R 2 . View detection unit 148 C then compares the fit of R 1 to B mask , and the fit of R 2 to B mask — Flipped . If the fit of R 1 to B mask is better than the fit of R 2 to B mask — Flipped , then the view associated with shape model M is the view of the breast image B mask . On the other hand, if the fit of R 2 to B mask — Flipped is better than the fit of R 1 to B mask , then the view associated with shape model M is the view of breast image B mask — Flipped . The view direction of the breast mask image B mask is hence detected. View detection results are output to printing unit 48 , display 68 , and/or image output unit 58 .
[0127] The view of breast mask image B mask may also be detected by comparison to a baseline shape. Let B a be the baseline breast atlas shape associated with the shape model M. View detection unit 148 C compares the differences between R 1 and B a , and the differences between R 2 and B a . If the differences between R 1 and B a are smaller than the differences between R 2 and B a , then the view associated with baseline breast atlas shape B a (and hence with shape model M) is the view of breast image B mask . On the other hand, if the differences between R 2 and B a are smaller than the differences between R 1 and B a , then the view associated with baseline breast atlas shape B a (and hence with shape model M) is the view of breast image B mask — Flipped .
[0128] The view of breast mask images B mask may also be detected by direct comparison of B mask and B mask — Flipped with B a , without performing shape registration of B mask and B mask — Flipped . If the differences between B mask and B a are smaller than the differences between B mask — Flipped and B a , then the view associated with baseline breast atlas shape B a is the view of breast image B mask . On the other hand, if the differences between B mask and B a are larger than the differences between B mask — Flipped and B a , then the view associated with baseline breast atlas shape B a is the view of breast image B mask — Flipped .
[0129] FIG. 12 is a block diagram of an image processing unit 39 for feature removal/positioning including a training system 772 according to a fourth embodiment of the present invention. As shown in FIG. 12 , the image processing unit 39 includes the following components: an image operations unit 620 ; a baseline shape unit 710 ; a shape parameterization unit 720 ; a deformation analysis unit 730 ; a training shape registration unit 740 ; an atlas output unit 750 ; an image operations unit 128 ; a shape registration unit 138 ; a feature removal and positioning unit 148 ; and a reference data unit 158 . Image operations unit 620 , baseline shape unit 710 , shape parameterization unit 720 , deformation analysis unit 730 , training shape registration unit 740 , and atlas output unit 750 are included in a training system 772 . Training shape registration unit 740 and atlas output unit 750 are optional, and may be included depending on the application. Image operations unit 128 , shape registration unit 138 , feature removal and positioning unit 148 , and reference data unit 158 are included in an operation system 38 .
[0130] Operation of the image processing unit 39 can generally be divided into two stages: (1) training; and (2) operation for positioning and for feature removal or detection.
[0131] The principles involved in the training stage have been described in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference. In accordance with this fourth embodiment illustrated in FIG. 12 , the image operations unit 620 , baseline shape unit 710 , shape parameterization unit 720 , deformation analysis unit 730 , training shape registration unit 740 , and atlas output unit 750 train to generate a shape model and a probabilistic feature atlas for breast shapes. The knowledge accumulated through training by training system 772 is sent to reference data unit 158 . Image operations unit 620 and shape model unit 630 trains to generate a shape model. Optional probabilistic atlas generation unit 640 trains to generate a probabilistic atlas. The shape model and the probabilistic atlas are sent and stored in reference data unit 158 .
[0132] In accordance with this fourth embodiment of the present invention, the image operations unit 128 , the shape registration unit 138 , the feature removal and positioning unit 148 , and the reference data unit 158 may function in like manner to the corresponding elements of the first, second, or third embodiments illustrated in FIGS. 4 , 9 , and 11 , or as a combination of two or more of the first, second, and third embodiments illustrated in FIGS. 4 , 9 , and 11 . During regular operation of image processing unit 39 , reference data unit 158 provides reference data training knowledge to shape registration unit 138 and to feature removal and positioning unit 148 , for use in nipple detection, view detection, and artifact removal from breast images. The principles involved in the operation for nipple detection for new breast images have been described in FIGS. 4 , 5 , 6 , 7 , 8 A, 8 B, 8 C, 8 D, 8 E, 8 F, 8 G, 8 H, 8 I and 8 J. The principles involved in the operation for artifact removal from breast images have been described in FIGS. 9 , 5 , 6 , 7 , 8 A, 8 B, 8 C, 8 D, 8 E, 8 F, 8 G, 8 H, 8 I and 8 J. The principles involved in the operation for view detection for new breast images have been described in FIGS. 11 , 5 , 6 , 7 , 8 A, 8 B, 8 C, 8 D, 8 E, 8 F, 8 G, 8 H, 8 I and 8 J.
[0133] During the training stage, image operations unit 620 receives a set of training breast images from image input unit 28 , performs preprocessing and preparation operations on the breast images, creates training breast mask images, and stores/extracts information about breast images, such as view of mammograms. Additional details regarding operation of image operations unit 620 are described in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference. Image operations unit 620 may create breast mask images by extracting breast borders using methods described in the U.S. patent application titled “Method and Apparatus for Breast Border Detection”, application Ser. No. 11/366,495, by Daniel Russakoff and Akira Hasegawa, filed on Mar. 3, 2006, the entire contents of which are hereby incorporated by reference. Other breast border detection techniques can also be used by image operations unit 620 to obtain shape mask images for breast images.
[0134] Baseline shape unit 710 receives training breast mask images from image operations unit 620 , and generates a baseline breast atlas shape such as, for example, a mean breast shape, from the training breast mask images. Baseline shape unit 710 may align the centers of mass of the training breast mask images. The alignment of centers of mass of training breast mask images results in a probabilistic map in which the brighter a pixel is, the more likely it is for the pixel to appear in a training breast mask image. A probability threshold may then be applied to the probabilistic map, to obtain a baseline breast atlas shape, such as, for example, a mean breast shape. Additional details regarding operation of baseline shape unit 710 are described in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference.
[0135] Shape parameterization unit 720 receives the training breast mask images and the baseline breast atlas shape, and warps the training breast mask images onto the baseline breast atlas shape, to define parameterization of breast shape. Shape parameterization unit 720 may use shape parameterization techniques adapted from “Automatic Generation of Shape Models Using Nonrigid Registration with a Single Segmented Template Mesh” by G. Heitz, T. Rohlfing and C. Maurer, Proceedings of Vision, Modeling and Visualization, 2004, the entire contents of which are hereby incorporated by reference. Control points may be placed along the edges of the baseline breast atlas shape. A deformation grid is generated using the control points. Using the deformation grid, the control points are warped onto training breast mask images. Shape information for training breast mask images is then given by the corresponding warped control points together with centers of mass of the shapes defined by the warped control points. Warping of control points from the baseline breast atlas shape onto training breast mask images may be performed by non-rigid registration, with B-splines transformations used to define warps from baseline breast atlas shape to training breast mask images. Shape parameterization unit 720 may perform non-rigid registration using techniques discussed in “Automatic Construction of 3-D Statistical Deformation Models of the Brain Using Nonrigid Registration”, by D. Rueckert, A. Frangi and J. Schnabel, IEEE Transactions on Medical Imaging, 22(8), p. 1014-1025, August 2003, the entire contents of which are hereby incorporated by reference. Shape parameterization unit 720 outputs shape representations for training breast mask images. Additional details regarding operation of shape parameterization unit 720 are described in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference.
[0136] Deformation analysis unit 730 uses breast shape parameterization results to learn a shape model that describes how shape varies from breast to breast. Using representations of shape for the training breast mask images, deformation analysis unit 730 finds the principal modes of deformation between the training breast mask images and the baseline breast atlas shape. Deformation analysis unit 730 may use Principal Components Analysis (PCA) techniques to find the principal modes of deformation. The principal components obtained from PCA represent modes of deformation between training breast mask images and the baseline breast atlas shape. Additional details regarding operation of deformation analysis unit 730 are described in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference.
[0137] The baseline breast atlas shape and the modes of deformation between training breast mask images and the baseline breast atlas shape, define a shape model. A shape model can be obtained for each mammogram view. Shape model information is sent to reference data unit 158 , to be used during operation of image processing unit 39 .
[0138] Training shape registration unit 740 receives data that defines the shape model. Training shape registration unit 740 then fits training breast mask images with their correct shape representations, which are linear combinations of the principal modes of shape variation. Shape registration unit 740 may use the downhill simplex method, also known as the Nelder-Mead or the amoeba algorithm, to optimize parameters of the shape model for each training breast mask image in the training dataset, and optimally describe training breast mask images using the shape model. Additional details regarding operation of training shape registration unit 740 are described in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference.
[0139] Atlas output unit 750 receives from training shape registration unit 740 the results of shape registration for the set of training breast mask images analyzed. The set of training breast mask images have features that have been previously localized. Features could be cancer structures, benign structures, vessel areas, etc. Using shape registration results, the localized features in the training breast mask images are mapped from the training breast mask images onto the baseline breast atlas shape. An atlas is created with locations of the features in the baseline breast atlas shape. Since a large number of training breast mask images with previously localized features are used, the atlas is a probabilistic atlas that gives the probability for feature presence at each pixel inside the baseline breast atlas shape. One probabilistic atlas may be generated for each mammogram view. The probabilistic feature atlases for various breast views are sent to reference data unit 158 , to be used during operation of image processing unit 39 . Additional details regarding operation of atlas output unit 750 are described in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference.
[0140] Image operations unit 620 , baseline shape unit 710 , shape parameterization unit 720 , deformation analysis unit 730 , training shape registration unit 740 , atlas output unit 750 , image operations unit 128 , shape registration unit 138 , feature removal and positioning unit 148 , and probabilistic atlas reference unit 158 are software systems/applications. Image operations unit 620 , baseline shape unit 710 , shape parameterization unit 720 , deformation analysis unit 730 , training shape registration unit 740 , atlas output unit 750 , image operations unit 128 , shape registration unit 138 , feature removal and positioning unit 148 , and probabilistic atlas reference unit 158 may also be purpose built hardware such as FPGA, ASIC, etc.
[0141] Methods and apparatuses disclosed in this application can be used for breast segmentation, artifact removal, mammogram view identification, nipple detection, etc. Methods and apparatuses disclosed in this application can be combined with methods and apparatuses disclosed in the co-pending non-provisional application titled “Method and Apparatus of Using Probabilistic Atlas for Cancer Detection”, the entire contents of which are hereby incorporated by reference, to perform breast segmentation, artifact removal, mammogram view identification, nipple detection, together with cancer detection for mammography images. Shape models and probabilistic atlases generated using techniques described in the co-pending non-provisional application titled “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, the entire contents of which are hereby incorporated by reference, can be used for breast segmentation, artifact removal, mammogram view identification, nipple detection, and cancer detection. Additional applications, such as temporal subtraction between breast images can be implemented using methods and apparatuses disclosed in this application, and methods and apparatuses disclosed in “Method and Apparatus of Using Probabilistic Atlas for Cancer Detection”.
[0142] The methods and apparatuses disclosed in this application can be used for automatic detection of other features besides nipples in breasts. The methods and apparatuses can be used for feature removal, feature detection, feature positioning, and segmentation for other anatomical parts besides breasts, by using shape modeling techniques for the anatomical parts and atlases for locations of features in the anatomical parts. The methods and apparatuses disclosed in this application can be coupled with methods and apparatuses from “Method and Apparatus of Using Probabilistic Atlas for Cancer Detection” using shape models and probabilistic atlases generated as described in “Method and Apparatus for Probabilistic Atlas Based on Shape Modeling Technique”, to perform feature removal, feature detection, feature positioning, and object segmentation for other objects and anatomical objects besides breasts, and other features besides cancer structures or breast features.
[0143] Although detailed embodiments and implementations of the present invention have been described above, it should be apparent that various modifications are possible without departing from the spirit and scope of the present invention.
|
Methods and apparatuses process images. The method according to one embodiment accesses digital image data representing an image including an object; accesses reference data including a shape model relating to shape variation of objects from a baseline object, the objects and the baseline object being from a class of the object; and removes from the image an element not related to the object, by representing a shape of the object using the shape model.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This utility patent application filed under 35 USC §111 is a continuation-in-part of U.S. non-provisional application Ser. No. 13/207,392 filed on Aug. 10, 2011 and claims priority to U.S. provisional patent application Ser. No. 61,372,168 filed on Aug. 10, 2010, which is incorporated by reference herein.
TECHNICAL FIELD
[0002] The technology relates to fabrics with antimicrobial properties, in particular, fabrics to reduce chances of infection.
BACKGROUND
[0003] The spread of infectious disease through direct skin contact and open wounds is a well-known problem. In addition, the spread of “superbugs” such as methicillin-resistant Staphylococcus aureus (MRSA) has become a major problem in U.S.
[0004] MRSA can spread in hospitals and other health care facilities, and it can also be picked up in fitness centers, schools, and other public places. MRSA bacteria are resistant to most common antibiotics.
[0005] Hospitals typically take precautions to stop the spread of MRSA by stepping up infection control procedures. For example, hospitals implement various infection control procedures that include hand washing, skin disinfectants, sterilization, barrier protection, protective clothing and garments, sterile wound dressings and linen laundering procedures.
[0006] Despite these efforts at infection control, certain microbes and bacteria persist and continue to cause infection at an alarming rate. Thus, improvements in products and procedures to further inhibit the spread of infections are desired.
SUMMARY
[0007] Antimicrobial and antibacterial textiles can play a part in a strategic plan to reduce healthcare associated infections. The present invention relates to the developments of fabrics, wraps and dressings that have improved antimicrobial/antimicrobial properties by combinations of bamboo, heavy metal and other fibers in the textile product.
[0008] The natural antibacterial/antimicrobial properties of bamboo fabric come from inherent qualities of bamboo. One of the compounds found in bamboo is coconut oil, which may contribute to the antimicrobial properties. Bamboo does not require the use of pesticides due to this natural antifungal antibacterial agent. It is rarely attacked by pests or infected by pathogens. The same natural substance that protects bamboo growing in the field, functions in the spun bamboo fibers.
[0009] In addition, the anti-infective activity of some heavy metals is well known. For example, heavy metals such as silver have been used as a topical therapy for burn wounds as an antiseptics or disinfectant. Inactivation of bacteria on surfaces containing silver and zinc ions has also been demonstrated.
[0010] In one general aspect, a method of producing a fabric with antimicrobial properties includes liquefying bamboo to produce a slurry, adding an antimicrobial element to the slurry, adding a non-bamboo fiber to the slurry to create a mixture and extruding the mixture to produce a fiber.
[0011] Embodiments may include one or more of the following features. For example, the method may include crushing the bamboo into fibers or small pieces. Liquefying the bamboo may include adding water and/or a solvent mixture.
[0012] The slurry may also be pressurized and/or heated to a high temperature. Impurities can also be removed from the slurry.
[0013] The antimicrobial element may be a heavy metal, such as, for example, silver. The silver may be silver ions or silver nanoparticles.
[0014] Extruding the mixture may be performed by passing the mixture through spinnerets to create the fiber. The fiber can also be spun to produce a thread and the thread weaved produce the antimicrobial fabric.
[0015] In another general aspect, an antimicrobial fabric includes bamboo fiber, a non-bamboo fiber and an antimicrobial element. The antimicrobial element may be a heavy metal such as silver and the non-bamboo fiber may cotton. The antimicrobial fabric may be composed of 69% bamboo, 30% cotton and 1% silver. Other natural and synthetic fibers may also be used.
[0016] In one general aspect, an incontinence pad, includes at least one antimicrobial layer, at least one fluid absorption layer, a waterproof barrier and a seam that attaches the at least one antimicrobial layer, the at least one fluid absorption layer, and the waterproof barrier.
[0017] Embodiments may include one or more of the following features. For example, the antimicrobial layer may be a fabric impregnated with one or more metal composition or metal ions having antimicrobial properties. The metal may be of a type that has antimicrobial effects, such as, ions of mercury, silver, copper, iron, lead, zinc, bismuth, gold, aluminum and other metals. More particularly, the metal may be silver particles, a silver compound, silver ions or nanoparticles that include silver. The antibacterial properties may be increased by ionizing the impregnated metal during fabrication or as part of a post-fabrication process.
[0018] As another feature, the antimicrobial layer may include a combination of natural fabrics such as cotton and bamboo. The fabric may also include synthetic materials. One or more metal, metal compound, metal composition or type of metal ion may be bonded to or attached to the fabric. The combination of fabric and metal may include, for example, a composition of 69% bamboo, 30% cotton and 1% silver by weight, respectively. In another embodiment, the fabric includes a combination with a range of approximately 10-95% bamboo, 5-90% other other type of natural or synthetic fiber and 0.001-5% metal by weight, respectively.
[0019] There can be more than one fluid absorption layer and more than one antimicrobial layer. For example, there may be two fluid absorption layers between the antimicrobial layer and the waterproof barrier. The fluid absorption layer may include natural or synthetic fabrics. For example, the fabric may be microfiber. However, other absorbent fabrics may be used.
[0020] In another embodiment, antimicrobial layers are also positioned between each fluid absorption layer.
[0021] The incontinence pad may be a number of different shapes, such as, for example, square or rectangular with rounded corners. It may have other configurations and may also be part of a wearable garment.
[0022] In another general aspect, a method of laundering a fabric that includes a metal to enhance bactericidal properties of the fabric includes immersing the fabric in water and adding a peroxide solution. Embodiments may include one or more of the following features.
[0023] The water may be at a temperature of 160° F. or more and the fabric may be immersed for at least six minutes.
[0024] The peroxide solution can be added so that the hydrogen peroxide is approximately 2% of a total volume of liquid.
[0025] As another feature, acid may be added to the water to produce hydrogen ions. A detergent may also be added to the water.
DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 illustrates a method of producing an antimicrobial fabric;
[0027] FIGS. 2-6 are tables that provide test results for the antimicrobial fabric; and
[0028] FIGS. 7 and 8 are graphs that illustrate test results for the antimicrobial fabric.
[0029] FIGS. 9 and 10 illustrate the incontinence pad sketch.
[0030] FIG. 11 illustrates a method of enhancing antibacterial properties of the fabric of FIG. 1 .
DETAILED DESCRIPTION
[0031] In one embodiment, a textile with antimicrobial properties is produced by a process described with respect to FIG. 1 . First, the bamboo is liquefied into a slurry (operation 110 ). Typically, the bamboo is crushed into fibers or small pieces. The slurry may be produced by, for example, using water and a solvent mixture. The water and solvents may be added in a vat that is pressurized and heated until the bamboo fibers dissolve.
[0032] Impurities are then removed from the slurry. Silver is added to the liquefied bamboo (operation 120 ). The silver may be particles or silver nanoparticles that are added to the slurry. Silver oxide or silver ions may also be used. In other embodiments, other heavy metals may be used such as copper.
[0033] Then, cotton is added to the mixture (operation 130 ). Other fibers may be added to increase the absorption of silver particles into the fibers.
[0034] The composite is then woven into fabric (operation 140 ). For example, it may be extruded through spinnerets to create a thin and strong fiber. The fibers are then spun into a thread and weaved into the fabric.
[0035] The fabric may be further processed such as, for example, dyed to a desired color or cut to size for use in sheets or bandages.
[0036] In one of the embodiments of the novel material, the fabric is approximately 69% bamboo, 30% cotton and 1% silver. Other combinations of bamboo, cotton and an antimicrobial element such as a heavy metal may be used. For example, the composition may be 49% bamboo, 50% cotton and 1% silver. In other embodiments, synthetic fibers, such as spandex, may be added to the fabric.
[0037] Test reports have demonstrated that the fabric made of bamboo, cotton and silver has improved antimicrobial properties.
[0038] FIGS. 2-6 are tables that illustrate test results showing the antibacterial properties of the novel material as compared to other fabrics. Swatches of treated and untreated fabric were cut into 4.8 cm diameter discs which were inoculated with 1 ml of a test organism in a concentration of 1-2×105. Each stack was aseptically transferred to sterile screw cap jars and incubated at 35° C. Treated and untreated samples with no inoculums were also set up as control. After specified time period the set of treated and untreated swatches were removed from the incubator and were neutralized with 100 ml of a neutralizer. Plate counts were performed and incubation was carried out according to requirements for each organism.
[0039] Percent reduction of bacteria was calculated by the following formulas:
[0000] % R= 100( B−A )/ B where: R: % reduction A: the number of bacteria recovered from the inoculated treated test specimen swatches in the jar incubated over the desired contact period B: the number of bacteria recovered from the inoculated treated test specimen swatches in the jar immediately after inoculation (at “0” contact time).
[0042] The data is presented in Colony Forming Units (CFU)/ml after control and test samples were exposed to organisms. In all cases, the novel material (B++) showed significant inhibition of the four bacterial species tested at 24 hours after inoculation. Additionally, the novel materials showed significant antimicrobial activity at 6 hours after inoculation and two orders of magnitude inhibition at 18 and 24 hours against Staphylococcus Aureus MRSA. These results strongly suggest that both the B++ and the treated B++ Bandage could play a significant role in reducing the rate of nosocomial infections.
[0043] Another test result is shown graphically in FIGS. 7 and 8 . The results shown in FIG. 7 are a comparison of the novel material to bamboo material and cotton-nylon mixtures respectively.
[0044] FIGS. 9 and 10 show the antibacterial fabric configured as an incontinence pad 900 . The incontinence pad is made of multiple fabric layers and the edges are attached by a seam 910 .
[0045] In the embodiment shown in FIG. 10 , the incontinence pad has four layers. The top layer is an antimicrobial layer 1010 . The antimicrobial layer 1010 can be made of the antimicrobial fabric mentioned above. The antimicrobial layer is permeable to fluid so that any fluid passes through the bottom 1020 to the layers below.
[0046] The next layers are first and second absorbent layers 1030 , 1040 . The absorbent layers 1030 , 1040 are made of microfiber which traps and holds moisture. In other embodiments, the layers can be made of terrycloth, woven cotton, acrylic or other mixtures of synthetic and natural fibers.
[0047] The absorbent layers, 1030 , 1040 , may include various other types of nonwoven fabrics. Nonwoven fabric is a fabric-like material made from long fibers, bonded together by chemical, mechanical, heat or solvent treatment. This includes fabric such as felt, which is neither woven nor knitted. Nonwoven materials typically lack strength unless densified or reinforced by a backing. In recent years, nonwovens have become an alternative to polyurethane foam. Absorbency rate and absorbent capacity are the two most important performance parameters to be considered for selection of material. The absorbent capacity is mainly determined by the interstitial space between the fibers, the absorbing and swelling characteristics of the material and the resiliency of the web in the wet state. The absorbency rate is governed by the balance between the forces exerted by the capillaries and the frictional drag offered by the fiber surfaces.
[0048] For non-swelling materials, these properties are largely controlled by the capillary sorption of fluid into the structure until saturation is reached. The absorbency rate and absorbent capacity are affected by fiber mechanical and surface properties, structure of the fabric, such as, for example, the size and the orientation of flow channels, and the nature of fluids imbibed. Among those factors, the surface wetting characteristics (contact angle) of the fibers in the web and the structure of the web, such as the size, shape, orientation of capillaries, and the extent of bonding, are significant.
[0049] The polymer type of the fibers in the fabrics, hydrophilic or hydrophobic, influences the inherent absorbent properties of the fabrics. A hydrophilic fiber provides the capacity to absorb liquid via fiber imbibitions, giving rise to fiber swelling. It also attracts and holds liquid external to the fiber, in the capillaries, and structure voids. On the other hand, a hydrophobic fiber has only the latter mechanism available to it normally [7]. The effect of the small amount of fiber finish (generally 0.1 to 0.5% by weight) is also important since it is on the fiber surface. The particular finish applied on the fiber can significantly change surface wetting property of the fiber.
[0050] Fiber linear density and its cross-section area affect void volume, capillary dimensions and the total number of capillaries per unit mass in the fabrics. Fiber surface morphology, surface ruggedness, and core uniformity can influence the absorbency performance to some extent. Fiber crimps influence the packing density of the fabrics and further affect the thickness per unit mass that affects the absorbency of the nonwoven fabrics. The nature of the crimps, whether it is two-dimensional or three-dimensional, also has some effect.
[0051] The size of capillaries is affected by the thickness per unit mass and the resiliency of the web, and the size, shape and the mechanical properties of the fibers. The resiliency of the web is influenced by the nature and level of bonding of the fabrics as well as the size, shape, and mechanical properties of the constituent fibers.
[0052] The bottom layer is a waterproof layer 1050 . The waterproof layer may incorportate waterproof fabric that inherently, or has been treated to become, resistant to penetration by water and wetting. It can be made of natural or synthetic fabrics that are laminated to or coated with a waterproofing material such as rubber, polyvinyl chloride (PVC), polyurethane (PU), silicone elastomer, fluoropolymers, and/or wax. Other examples include rubberised fabric used in sauna suits and inflatable boats.
[0053] If the incontinence pad 900 is configured as, for example, a diaper, the waterproof fabric may be breathable to resist liquid water passing through, but allowing water vapor to pass through.
[0054] In use, the incontinence pad 900 may be placed on, for example, a hospital bed. The incontinence pad 900 is positioned between the mattress and the patient with the antibacterial layer 1010 facing the patient and the waterproof layer 1050 facing down toward the bed. If fluids are released on the incontinence pad 900 , the fluid passes through the antibacterial layer 1010 and is absorbed by the absorbent layers 1030 , 1040 . The waterproof layer 1050 prevents the fluid from seeping into the mattress.
[0055] Since the antibacterial layer 1010 has active bactericidal properties, the incontinence pad 900 can reduce the risks of infection caused by bed sores and/or a moist environment. In other words, bacteria in the absorbent layers 1030 , 1040 is not transmitted back to the patient.
[0056] FIG. 11 illustrates a method of laundering a fabric impregnated with a metal element that enhances bactericidal properties of the fabric. In operation 1110 , a fabric is impregnated with a metal, such as, for example, silver, silver oxide or silver nanoparticles. If silver particles are used, the fabric may be impregnated with more than 600 milligrams of silver per ounce of fabric. If nanoparticles are impregnated into the fabric, the silver content may be about 75 mg per ounce of fabric.
[0057] In operation 1120 , the fabric is placed in a tub of a washing machine and water is added to the tub. During the wash process, the water may be at a temperature of at least 160° F. and the fabric may be immersed for at least six minutes. This temperature and immersion time should kill most pathogens.
[0058] In operation 1130 , hydrogen peroxide is added to the water. In one embodiment, the hydrogen peroxide is added at a concentration of 35% by volume. The total peroxide that is added may be approximately 2 oz. per each 100 lbs in weight of fabric. As described in more detail below, the amount of peroxide can be adjusted depending on the desired concentration and pH levels to produce optimal results.
[0059] Note that these operations may be completed in a different order. For example, the hydrogen peroxide may be added to the tub and mixed with the water prior to adding the fabric.
[0060] As explained in more detail above, the fabric is impregnated with a heavy metal such as, for example, silver particles, and it may also be a mix of materials such as cotton and bamboo. Bamboo is known to have antimicrobial properties. In addition, fibrous or absorbent materials may have more capacity to hold silver particles. In other embodiments, the silver is chemically bonded to the fabric and/or silver nanoparticles are used.
[0061] As the total amount of hydrogen peroxide is added, the pH drops as the solution becomes more acidic as shown in Table 1.
[0000]
TABLE 1
H 2 O 2 Conc.
0
10
20
30
40
50
60
70
80
90
100
pH @ 25° C.
7.0
5.3
4.9
4.7
4.6
4.5
4.5
4.5
4.6
4.9
6.2
[0062] When hydrogen peroxide is added, hydrogen ions are formed. A reaction is represented as follows:
[0000] 2Ag+H 2 O 2 (aq)+2H + (aq) 2Ag + +2H 2 O
[0000] where Ag is silver, H 2 O 2 is hydrogen peroxide, H + is hydrogen ions and H 2 O is water. Thus, the silver becomes a silver ion with more active bactericidal properties. The metal ions have a more toxic effect on living cells, algae, molds, spores, fungi, viruses, prokaryotic and eukaryotic microorganisms, even in relatively low concentrations. Other types of metals, such as copper or gold, may be ionized to produce more active antimicrobial properties.
[0063] In some cases, hydronium ions (H 3 O + ) react with the silver (Ag) to produce the silver ions. In certain cases, a metal oxide, such as, for example, silver oxide, may be involved in the process of reducing bacteria.
[0064] As another feature, an acid may be added to the water to produce additional hydrogen ions. In operation 1140 a wash and rinse cycle is completed. For example, a detergent may be added to the water and the tub may be agitated. The fabric is then dried and is ready for use.
[0065] Since certain changes may be made in the above process without departing from the scope of the invention herein involved, it is intended that all matter contained in the above description or shown in the accompanying drawing shall be interpreted in an illustrative and not in a limiting sense. Accordingly, other implementations are within the scope of the following claims.
|
A method of producing a fabric with antimicrobial properties that includes liquefying bamboo to produce a slurry, adding an antimicrobial element to the slurry, adding a non-bamboo fiber to the slurry to create a mixture and extruding the mixture to produce a fiber. The antimicrobial element may be silver particles that are ionized with a peroxide solution. The fabric may be incorporated into incontinence pads, garments and linens.
| 3
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to a voltage sensing method, which can be applied to a control circuit of a power supply which converts a voltage by a transformer, such as a photoflash charger control circuit.
[0003] 2. Description of Related Art
[0004] Power supplies which convert a voltage by a transformer are applied in many applications. One of the applications is chargers such as a photoflash charger. The basic structure of such charger is shown in the upper part of FIG. 1 . A capacitor Cout at the output terminal Vout is charged from an input terminal Vin via a transformer. The charging time is controlled by a power switch 21 in a charger control circuit 20 . The charger control circuit 20 is typically integrated as an integrated circuit (IC). In the prior art shown in FIG. 1 , the power switch 21 is controlled by a switch control circuit 25 , and the switch control circuit 25 determines whether to enable the power switch 21 according to a voltage detection at the secondary side of a transformer 10 . More specifically, a feedback voltage is obtained through resistors R 1 and R 2 by voltage division. A comparator 23 compares the feedback voltage with a reference voltage Vref; then the switch control circuit 25 determines whether to enable the power switch 21 according to the result of the comparison.
[0005] The drawback of the prior art mentioned above is that resistors R 1 and R 2 (particularly, R 1 ) need to sustain high voltage, because the dividend voltage is obtained from the secondary side which is the high voltage side. Some prior art proposes to divide the resistor R 1 to two resistors, but the fact that they need to sustain high voltage remains the same.
[0006] U.S. Pat. Nos. 7,292,005; 6,636,021; and 6,518,733 disclose another type of approach as shown in FIG. 2 . This approach obtains a signal from the primary side, and compares the signal with a reference signal Vref in the comparator 23 . The result of the comparison is transmitted to the switch control circuit 25 , which determines whether to enable a power switch 22 based on the comparison. In this prior art, the power switch is implemented by a bipolar junction transistor 22 , but the basic principle remains the same. This prior art also discloses a one-shot circuit 24 for masking a switching ringing.
[0007] One drawback of the second prior art is that, even though the feedback voltage is not obtained from the secondary side, and the resistor specification for sustaining high voltage can be relatively lower, but it requires two external resistors R 3 and R 4 .
[0008] With respect to switching ringing, U.S. Patent Publication No. 2006/0250824 discloses a method to filter such noise by a low-pass filter circuit.
[0009] Even though the second and third prior art avoid the problem in the first approach which obtains the feedback signal from the secondary side, i.e., the requirement of devices capable of sustaining high voltage, they still have one common drawback as described below. The transformer employed in the charger may have different turn ratios in different applications. The prior art power supply control circuit can not adjust its output voltage detection and setting in correspondence with different turn ratios (the detection determines where the output voltage is balanced at, and therefore the adjustment of the detection can be regarded as the adjustment on the output voltage setting). If the transformer turn ratio is different, it is necessary to modify the internal circuitry of the charger control circuit, and re-produce a different integrated circuit to cope with it. In other words, the same integrated circuit can only be applied to one single application.
[0010] In view of the above drawbacks, it is desired to provide a power supply control circuit and a method for sensing voltage in a power supply control circuit, which do not require a device sustaining high voltage, and furthermore the output voltage detection and setting can be flexibly adjusted in correspondence to the transformer turn ratio.
SUMMARY OF THE INVENTION
[0011] A first objective of the present invention is to provide a power supply control circuit with flexibility on output voltage setting to overcome the drawbacks of the aforementioned prior art circuits.
[0012] A second objective of the present invention is to provide a method for sensing voltage in a power supply control circuit.
[0013] To achieve the above and other objectives, from one perspective, the present invention provides a power supply control circuit, the power supply providing an output voltage to an output terminal from an input terminal through a transformer having a primary winding and a secondary winding. The power supply control circuit comprises: a power switch electrically connected to the primary winding; a switch control circuit controlling the power switch; and a sensing circuit supplying an output signal to the switch control circuit according to voltage signals obtained from two sides of the primary winding, wherein the sensing circuit includes a setting circuit for deciding the output voltage according to a reference signal.
[0014] In a preferred embodiment of the power supply control circuit, the setting circuit provides a setting current signal, and the sensing circuit converts the voltage signals obtained from the two sides of the primary winding to a first and a second current signals, and supplies the output signal to the switch control circuit according to the first, the second, and the setting current signals.
[0015] From another perspective, the present invention provides a method for sensing voltage in the power supply control circuit, comprising the steps of: providing a power supply, the power supply providing an output voltage to an output terminal from an input terminal through a transformer having a primary winding and a secondary winding; providing a power switch electrically connecting to the primary winding; generating a first and a second signals according to voltage signals obtained from two sides of the primary winding; generating a setting signal; controlling the power switch according to the first, the second, and the setting signals; and deciding the output voltage according to the setting signal.
[0016] The power supply control circuit and the voltage sensing method may further comprise a circuit or a step for masking a switching ringing noise generated when the power switch is switching.
[0017] The objectives, technical details, features, and effects of the present invention will be better understood with regard to the detailed description of the embodiments below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a schematic circuit diagram of a prior art power supply circuit.
[0019] FIG. 2 is a schematic circuit diagram of another prior art power supply circuit.
[0020] FIG. 3 and FIG. 4 are schematic circuit diagrams which show two embodiments of the present invention, respectively.
[0021] FIG. 5 shows a more specific embodiment of the circuit in FIG. 3 .
[0022] FIG. 6 shows an example of the setting circuit 361 .
[0023] FIGS. 7 to 10 show several other embodiments of the present invention.
[0024] FIG. 11 shows switching ringing in the voltage signal Vsw.
[0025] FIG. 12 shows an example of a noise masking circuit formed by a low-pass filter.
[0026] FIG. 13 shows an example to mask a noise by a masking signal.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] FIG. 3 shows the first embodiment of the present invention. A power supply control circuit 30 according to the present invention comprises a power switch 31 , a switch control circuit 35 , and a sensing circuit 32 . The sensing circuit 32 obtains a signal from the primary side of a transformer and generates an output signal which is supplied to the switch control circuit 35 for controlling the power switch 31 . More specifically, a signal obtained from an input voltage Vin is processed by a first signal conversion circuit 36 , and thereafter input to an input terminal of a comparator 33 . Another signal obtained from the other side of the transformer primary winding is processed by a second signal conversion circuit 37 and thereafter input to the other input terminal of the comparator 33 . The comparator 33 compares the two signals, and the comparison result is transmitted to the switch control circuit 35 so that it can determine whether to enable the power switch 31 accordingly. Note that it is not necessary for the two signal conversion circuits 36 and 37 to provide sophisticated signal processing functions. It suffices to make the input voltage signal Vin and the signal obtained from the other side of the transformer primary winding matching to each other for the comparison purpose. In one embodiment, the two signal conversion circuits 36 and 37 are voltage to current conversion circuits (gm) with appropriate conversion ratios, respectively. More details will be depicted later with reference to FIG. 5 .
[0028] One feature of the present invention is that the sensing circuit 32 includes a setting circuit 361 . The setting circuit 361 can decide the output voltage sensing result in the control circuit 30 according to a reference signal. By adjusting the reference signal, the detection and setting with respect to the output voltage can be adjusted flexibly in correspondence to the turn ratio of the transformer.
[0029] FIG. 4 shows another embodiment of the present invention. In this embodiment, a signal obtained from the input voltage Vin and a signal obtained from the other side of the transformer primary winding are converted by one single conversion circuit 38 . The conversion performed by this circuit includes, for example, converting both signals to current signals with an appropriate ratio and then obtaining a difference between them by subtracting one from the other. The converted signal is input to one input terminal of the comparator 33 . A setting signal generated by the setting circuit 361 is input to another input terminal of the comparator 33 . Similarly, after the comparator 33 compares the two input signals, the result is output to the switch control circuit 35 . The switch control circuit 35 determines whether to enable the power switch 31 according to the result.
[0030] FIG. 5 shows a more specific embodiment of the circuit in FIG. 3 . Referring to FIG. 5 , we will explain how a setting signal generated by the setting circuit 361 sets an output voltage. In this embodiment, the comparator 33 is a current comparator, and the first and second signal conversion circuits 36 and 37 respectively include a first and a second voltage to current conversion circuits (gm 1 362 and gm 2 37 ), each with an appropriate conversion ratio. The first voltage to current conversion circuit 362 converts the input voltage Vin to the current Ia, and the second voltage to current conversion circuit 37 converts the voltage Vsw at the other side of the primary winding to the current Ib. The setting signal generated by the setting circuit 361 is the current signal Iset, which for example is determined by a resistor Rset. Suppose the ratios by which the first and second conversion circuits 362 and 37 convert the voltage signals to the current signals are both gm:
[0000] Ia=gm 1 *Vin=gm*Vin
[0000] Ib=gm 2 *Vsw=gm*Vsw
[0000] Then when the circuit is stable, Ib=Ia+Iset, and therefore:
[0000]
gm*Vsw=gm*Vin+Iset
[0000] gm* ( Vsw−Vin )= Iset
[0000] Vsw−Vin= (1 /gm )* Iset
[0000] And, let the turn ratio of the transformer secondary winding to the primary winding be N, then
[0000] Vout= ( Vsw−Vin )* N
[0000] Vsw−Vin= (1 /N )* Vout= (1 /gm )* Iset
[0000] □ Vout= (1 /gm )* N*Iset
[0031] That is, regardless what the turn ratio N is, the setting signal Iset can be determined according to any given N and the desired output voltage Vout. In other words, the output voltage Vout can be flexibly adjusted according to the setting signal Iset in the present invention.
[0032] Those skilled in this art can readily understand that the concept of FIG. 5 can be applied to the embodiment of FIG. 4 . The only difference is that, in FIG. 4 , the difference between Ia and Ib is input to one input terminal of the comparator 33 , and the signal Iset is input to the other input terminal of the comparator 33 ; when the circuit reaches a stable and balanced state, the same relationship Ib=Ia+Iset is reached, which leads to the same equation Vout=(1/gm)*N*Iset.
[0033] The setting circuit 361 may be embodied in many ways. FIG. 6 shows one example. An operational amplifier 363 and a transistor 364 constitute a circuit follower 365 which generates a current Iset. The current Iset is equal to Vset/Rset. When Vset is fixed, Iset can be determined by adjusting Rset. A current mirror 366 duplicates Iset to output a setting signal.
[0034] Referring to FIG. 11 , when the power switch 31 is switching, a switching ringing occurs in the voltage Vsw, which should preferably be masked or filtered. To this end, according to the present invention, a noise masking circuit 39 is provided. The noise masking circuit 39 can be arranged in various ways as shown in FIGS. 7-10 : to filter the noise in the voltage Vsw and then convert the filtered signal (as the embodiments shown in FIG. 7 and FIG. 9 ), or to convert the voltage Vsw and then filter the noise in the converted signal (as the embodiments shown in FIG. 8 and FIG. 10 ). The noise masking circuit 39 , for example, can be embodied by a low-pass filter as shown in FIG. 12 , or by masking a short beginning period of the voltage signal Vsw in each time the power switch 31 switches. Referring to FIG. 13 for the latter case, taking the arrangement shown in FIG. 7 and FIG. 9 as an example, the noise masking circuit 39 generates a masking signal each time when the power switch 31 switches high. Masked by the masking signal, the voltage signal Vsw becomes the third waveform as shown in FIG. 13 , which is output as the output signal of the noise masking circuit 39 . Thus, the comparator 33 will not misjudge and generate an incorrect output because of the switching ringing. A similar arrangement can be applied to the noise masking circuits 39 shown in FIG. 8 and FIG. 10 such that the noise does not affect the circuit operation.
[0035] From the above description of the embodiments, one can readily recognize the advantages of this invention over prior art. First, the output voltage can be set flexibly in correspondence to the transformer winding ratio. Second, the setting can be easily achieved by one resistor Rset.
[0036] The present invention has been described in considerable detail with reference to certain preferred embodiments thereof. It should be understood that the description is for illustrative purpose, not for limiting the scope of the present invention. Those skilled in this art can readily conceive variations and modifications within the spirit of the present invention. For example, the application of the invention is not limited to photoflash chargers, but can be applied to any power supply which converts a voltage by a transformer. And, a circuit or device represented by a single block in the figures can be integrated with another circuit, or dismantled to separate circuits (for example, the switch control circuit 35 and the comparator 33 can be integrated into one single circuit; the setting circuit 361 can be moved out from the sensing circuit 32 , etc.). In view of the foregoing, the spirit of the present invention should cover all such and other modifications and variations, which should be interpreted to fall within the scope of the following claims and their equivalents.
|
The present invention discloses a power supply control circuit, the power supply providing an output voltage to an output terminal from an input terminal through a transformer having a primary winding and a secondary winding, the power supply control circuit comprising: a power switch electrically connected with the primary winding; a switch control circuit controlling the power switch; and a sensing circuit supplying an output signal to the switch control circuit according to voltage signals obtained from two sides of the primary winding, wherein the sensing circuit includes a setting circuit for deciding the output voltage according to a reference signal. The present invention also relates to a voltage sensing method in the power supply control circuit.
| 7
|
BACKGROUND OF THE INVENTION
This invention relates to an impact absorption apparatus and especially to an energy absorption device for a vehicle bumper impact system.
It is typical for an automotive bumper system to include three key components. The first is a decorative fascia, usually of plastic, mounted on the exterior of the front end module. The second is a rigid impact beam, typically constructed of roll formed or stamped steel. And the third is an energy absorption device connecting the impact beam to the vehicle frame rails. These three components are designed together to meet the performance requirements for low and high speed impacts.
It is beneficial to design the bumper system in such a way that limited damage is transferred to the vehicle frame rails under impact by properly engineering the energy absorption device. One guideline provided for this design process is for the bumper system to have a peak loading capability equivalent to 85% of the combined rail capacity. This assures that the energy absorption unit will crush first upon impact before loading is imparted on the rails. It is also beneficial to design the bumper system to provide this energy absorption in a controlled and repeatable manner. This allows for consistency in vehicle crash behavior.
There is substantial prior art regarding energy absorption units and bumper systems including U.S. Pat. Nos. 5,427,214; 5,732,801; and 4,272,114. These disclosures depict various methods of meeting the energy absorption targets for the bumper system. Shortcomings of these designs include inconsistency in deformation and resultant energy absorption, instability in lateral loading, high associated manufacturing costs, and post impact damage visibility.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a vehicle energy absorption unit which achieves a controlled and consistent energy absorption characteristic in a bumper impact system.
A cylindrical tube, preferably of steel or aluminum metal, and preferably round in cross section, is preferably grooved, i.e., scored, to provide channels in multiple locations around its periphery to a controlled depth of the tube thickness, but extending lengthwise, i.e., axially of the tube. These channels or grooves can significantly influence the deformation and energy absorption characteristics, to achieve a predetermined load deflection curve. Deformation control is further achieved by the depth of the channels, their locations and quantity, the material of the tube and the thickness of the tube. The tube is partially slit or notched, and flared, preferably along these grooves, at one end of the tube, to form extending mounting flanges, i.e., flange segments. The tube is placed at an opening in an inner reinforcement plate which is of substantially rigid material, usually steel, or alternatively at the forward end of the vehicle frame rail, and the flared end flanges are welded to this plate or frame rail. The opposite outer end of the tube is welded to a secondary outer plate of substantially rigid material such as steel, or directly to the rigid impact beam. If the inner plate is used, it is fastened to the forward end of a hollow vehicle frame rail, with the tube and outer plate being outward of the frame rail. The tube is axially aligned with the hollow interior of the vehicle frame rail. Two of these energy absorption units, i.e., crush boxes, are to be used as portions of a vehicle bumper assembly, usually a front bumper assembly, and are secured as by welding or mechanical attachment to the rigid bumper impact beam, on opposite sides of the vehicle, so as to be in alignment with the two frame rails.
When an impact force is applied to the impact beam, the load is transferred to the outer plates of the two energy absorption units. The tubes are compressed by the load, causing each of them to have portions progressively radially outwardly deflecting and tearing from the cylinder and inverting so the tube passes axially through the inner plate opening. The tube inverts, i.e., turns inside out, through this deflection and tearing process, being contained within the hollow body of the frame rail. The grooved channels in the tube cause the tube to split and tear in a controlled manner along these channels during deformation. The resultant deformation can create a load deflection curve with generally square wave characteristics to allow a controlled peak load near 85% of the rail capacity. This resultant generally square load curve, and the controlled failure mechanism that causes it, are believed particularly unique in the industry.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional diagrammatic view of portions of one embodiment of the novel impact unit on a vehicle frame rail;
FIG. 2 is an end elevational view of the impact unit in FIG. 1, viewing it toward the inner end of the impact cylinder;
FIG. 3 is a sectional view showing the deformed, impact absorbing element in FIGS. 1 and 2 after impact;
FIG. 4 is a sectional side elevational view of a first embodiment bumper assembly employing the invention of FIGS. 1 and 2;
FIG. 5 is a sectional, side elevational view of a second embodiment bumper assembly employing the invention of FIGS. 1 and 2;
FIG. 6 is a sectional, side elevational view of a third embodiment impact bumper assembly employing the invention of FIGS. 1 and 2;
FIG. 7 is a perspective view of a deformed impact unit of FIGS. 1 and 2 as actually tested;
FIG. 7A is a fragmentary, enlarged, sectional view of the cylinder wall and one grooved channel;
FIG. 8 is a diagram showing a theoretical load curve having a desired square wave configuration;
FIG. 8A is a diagram showing the impact absorption results of an experimental impact unit;
FIG. 9 is a generic diagrammatic side elevational view of the embodiments in FIGS. 1-6;
FIG. 10A is a diagrammatic side elevational view of the device with the flanges extending outwardly generally normal to the tube axis and peripheral wall, and on the wall face of the inner plate most adjacent to the tube body;
FIG. 10B is a diagrammatic, side elevational view of the device with the flanges extending outwardly generally normal to the tube axis and peripheral wall, and on the wall face of the inner plate opposite the tube body;
FIG. 11 is a side elevational view of an embodiment in which the tube flanges are welded to an inner plate;
FIG. 12 is a side elevational diagrammatic view of a variation of the embodiment in FIG. 11 where the flanges are welded directly to the outer ends of the vehicle frame rail, using no inner plate; and
FIG. 13 is a side elevational diagrammatic view of another variation of the embodiment in FIG. 12 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now specifically to the drawings, FIG. 1 shows a novel impact absorbing unit 10 mounted on a vehicle frame rail 12 . The impact unit is shown to include an inner rigid plate 14 , a cylindrical deformable tube 16 , and an outer rigid plate 18 . The inner end of tube 16 is segmented by slitting or notching at several spaced intervals around the tube circumference into a plurality of flanges 16 a shown in FIG. 2 to be four in number and separated by circumference notches 20 . These flanges 16 a are shown to be flared radially outwardly to form mounting weld flanges secured by weld joints 16 b to the inner face 14 ′ of inner plate 14 , i.e., the face opposite the tube 16 , and around the perimeter of opening 14 ′, as shown in FIG. 1 . Plate 14 has an opening 14 a of a size to receive crush cylinder 16 . Inner plate 14 can be secured to the forward open end of the frame rail 12 as by welding. Flanges 16 a may be formed into an arcuate configuration as depicted in FIG. 1, even extending back about 180° as shown, or may simply be flat, i.e., extending radially outwardly generally normal to the outer peripheral wall of cylinder 16 . Variations are depicted and explained hereafter relative to other drawing figures. Cylinder 16 is preferably a right cylinder having a circular cross sectional configuration although polygonal cross sections can be employed. At the outer axial end of cylinder 16 is preferably positioned an outer rigid plate member 18 which may be attached to cylinder 16 by welding.
One of these crush units as depicted is preferably located on each of the two laterally spaced, fore-to-aft frame rails of the vehicle, these frame rails being conventionally located toward opposite sides of the vehicle. These frame rails extend longitudinally of the vehicle and have a hollow interior 12 ′ larger in diameter, i.e., transverse dimensions, than cylinder 16 .
In FIGS. 4, 5 and 6 are depicted three possible alternative embodiments of the relationship between the rigid transverse rolled or stamped bumper member 24 and the impact crush members of FIGS. 1 and 2. The crush units are attached to the frame rails 12 as previously noted. In FIG. 4, the vertical center of bumper 24 is shown secured by weldment 26 to outer plate 18 , with the upper and lower extremities of bumper 24 straddling the upper and lower edges, respectively, of inner plate 14 , thereby aesthetically enclosing the crush units. In FIG. 5, bumper 124 is not only welded at its vertical center by weldment 126 to outer plate 18 , but is also welded to plate 114 at 128 at the upper and lower extremities of bumper 124 . Plate 114 has a greater vertical height than plate 14 in FIG. 4 . Also, the weld flanges 16 a of the inner end of crush cylinder 16 are welded by weld joints 16 b to the inner face 114 ′ of inner plate 114 . Opening 114 a in plate 114 is of a size to receive cylinder 16 , as previously noted relative to FIG. 4 .
In the third embodiment in FIG. 6, bumper 224 is welded at its extremities by weldments 228 to the outer face of outer plate 218 which has a vertical dimension greater than plate 18 in FIG. 4 . Again, the inner face of outer plate 218 is attached to the outer axial end of crush cylinder 16 , while the inner weld flanges 16 a of cylinder 16 are welded at 16 b to the inner face of inner plate 214 . Cylinder 16 extends through opening 214 ′ in plate 214 . Plate 214 is attached to the front open end of frame rail 12 .
Conceivably, the outer end of crush tube 16 could be attached directly to the bumper beam member without outer plate member 18 . I.e., the outer impact receiving member can be considered as the outer plate, or as the combination outer plate and bumper, or as the bumper.
Upon impact of a force against bumper 24 , 124 , or 224 , the impact will be applied in the embodiments in FIGS. 4 and 6 entirely against the inner plate 18 and 218 and from thence to the crush cylinder 16 . Cylinder 16 is thus forced inwardly through the orifice 14 a (FIG. 4 ), or 214 a (FIG. 6 ), causing the cylinder 16 to progressively peel into segments and become inverted as shown in FIGS. 3 and 7. In the FIG. 5 embodiment, the impact force is partially applied to crush cylinder 16 , and partially applied to plate 114 and thence directly to frame rail 12 .
In the preferred form of the crush tube, the tube is axially scored at a plurality of peripheral locations, preferably on its outer periphery, e.g., four locations in the tube depicted in FIG. 7, to form axially elongated, channeled grooves 16 g. These channels or grooves are preferably of triangular or square cross section (FIG. 7 A). They have been found to assure a desirable flattening of the force curve to result in a relatively constant load resistance following the initial rapid ramp up of the load resistance curve, rather than a steadily increasing load resistance, since these control grooves serve as crack initiators in the tube. The number of the grooves can vary, although four grooves were found to be satisfactory, resulting in four weld flanges separated as by V-shaped notches. In other words, the channels are aligned with and extend axially along the tube from these notches, causing the tube to split and “peel” uniformly as it becomes inverted by being forced axially through the opening 14 a, 114 a, or 214 a in the inner rigid plate 14 , 114 , or 214 , respectively, into the hollow frame rail.
As previously noted, the desired load curve is a substantially square wave load curve as in FIG. 8 . That is, the load versus deflection characteristics is represented by a square wave wherein the load response has a rapid ramp up to a predetermined load, followed by a generally constant load value for the duration of the deflection. In reality, the load curve is not this exact, but similar thereto. Specifically, representative test results from impact applied to FIG. 7 type versions of the novel system are shown in FIG. 8 A. Specifically, in FIG. 8A, after the initial ramp up impact load, the resistance load of the impact cylinder to the impact force was generally level, i.e., a substantially square wave function. The impact curve can be controlled by the material of the crush box cylinder. e.g., a selected steel or aluminum, the hardness of the material, the diameter of the cylinder, the wall thickness of the cylinder, the depth of the score channels and the remaining thickness of the cylinder metal, the number of grooved score channels, and by the impact force being optionally partially applied to crush cylinder 16 and partially applied to plate 114 and thence directly to frame rail 12 as in FIG. 5 .
Regarding selection of cylinder materials, if steel is used, it may be hardened as by induction hardening, as another parameter. Thus, material with a strength of from about 30 ksi to about 200 ksi can be employed. Wall thickness should preferably vary in the general range of between about 1.0 mm and about 5.0 mm. If a material of low strength is employed, the cylinder can tear without the need for tear grooves. As noted, the number of grooves can also be varied, with satisfactory tests having been made using zero, four, six and eight grooves. Test groove depths have ranged from about 10% to about 50% of the wall thickness. Optimally, the groove depth is limited to that which allows tearing consistency while maintaining maximum energy absorption in the remaining thickness. The presence of grooves of any depth has been shown to increase tearing consistency versus no grooves. The groove shape if preferably a V-shape.
The mounting flanges can be variously configured, and can be attached in various ways. In FIGS. 1-6, the flanges are shown attached to the inner plate, extending radially outwardly and reverse bent at about 180° to form a U-shaped configuration. This is also represented by FIG. 9 . In FIG. 10B the flanges 16 b are shown extending simply radially outwardly from the cylinder to be generally normal thereto, all flanges generally in the same plane, i.e., flat, and welded to the inner plate 14 , on the inner plate face, i.e., the face on the opposite side of the inner plate as the crush cylinder 16 . In FIG. 10C the flanges 16 b are again shown flat, but welded to the inner plate 14 on its face which is on the same side as the crush cylinder 16 . In FIG. 11, the structure is generally similar to that in FIG. 1 except that the flanges are flat, i.e., extending radially outwardly, generally normal to the crush cylinder 16 , rather than in the U-shape as in FIG. 1 .
In some instances it may be desirable to eliminate the inner reinforcing plate so that the crush cylinder is mounted directly to the vehicle frame rails. Thus, in FIGS. 12 and 13, the flanges 16 c are shown attached directly to the outer ends of the frame rails. Specifically, in FIG. 12 the flanges 16 c extend radially outwardly but then the outer ends of the flanges extend parallel to the crush cylinder axis, to lie against the frame rail 12 inside periphery where the flanges are welded to the frame rail. In FIG. 13 the flanges 16 d extend radially outwardly and then the outer flange ends extend parallel to the crush cylinder axis to lie against the outside periphery of the frame rail 12 , where the flanges are welded to this frame rail.
The above description is considered that of the preferred embodiments only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and not intended to limit the scope of the invention, which is defined by the following claims as interpreted according to the principles of patent law, including the doctrine of equivalents.
|
A channeled energy absorption unit for a vehicle bumper impact system to absorb impact energy and forestall or minimize damage to vehicle frame rails under impact. The basic embodiment is a tube with one end flared and welded at a hole in one end plate or directly to the vehicle frame rail. When loaded axially, the tube splits, peels and is inverted to absorb impact in a generally square wave energy absorption. Preferred channels in the tube stabilize the failure mode during this process to assure a predetermined energy absorption characteristic.
| 1
|
RELATED APPLICATION
[0001] The present invention claims priority to U.S. Provisional Application No. 61/755,382, “A SYSTEM OF MULTIPLE VOLTAGE REFERENCES USING A SINGLE ANALOG LINE,” filed Jan. 22, 2013, which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to wireless communication system and wireless communication radio frequency (RF) equipment, and in particular, relates to a system of providing multiple voltage references to a RF device using a single analog line.
BACKGROUND
[0003] Modern RF devices, such as mixers, upconverters, downconverters, power amplifiers and the latest highly integrated multifunction ICs, often require operation mode tuning using multiple independent voltage references (VREF). In some circumstances, the reference voltages need to be re-adjusted at runtime for various operation environments such as temperature, frequency, power level, etc. Such devices are usually calibrated during product manufacturing, for example, individually calibrated for each manufactured unit, and the values of the reference voltages are stored inside the on-board electrically erasable programmable read-only memory (EEPROM).
[0004] A most common approach to provide multiple reference voltages to the controlled device is illustrated in FIG. 1 , where a digital-to-analog converter (DAC) with multiple channels is used.
[0005] In a modular design approach, a CPU/MPU with a DAC are disposed on one board referred as the “control board”, while the controlled device, such as mixers, upconverters, etc., are disposed on a different board referred as the “controlled board”. The physical interface between the control board and the controlled board is predefined so that the same type of the control board can be connected to different predefined types of the controlled board. FIG. 2 depicts a structure of a revised system to provide reference voltage to a mixer on a controlled board.
[0006] However, a connector of the control board has a limited and fixed number of analog lines determined by the original design of the controlled board. Future revisions or new types of the controlled board may require more reference voltages than originally designed. Therefore, the interface of a current controlled board may not be able to provide enough analog lines to meet the new design requirements. FIG. 3 depicts a compatibility problem of the revised system to provide reference voltage to a mixer on a controlled board. Note that the mixer needs two reference voltage signals but the control board can only provide one.
SUMMARY
[0007] The present invention provides a cost effective method to provide two different reference voltages from the control device using a single analog line, a single digital line, and two erasable programmable read-only memory (EEPROM) disposed on the controlled board.
[0008] In accordance with some embodiments, a system of providing multiple voltage references to a radio-frequency device using a single analog line includes a control board, a controlled board, and a connector connecting the control board to the controlled board. The control board includes: a processing unit that configures the reference voltage signals; a non-volatile memory that stores information about the reference voltage signals; and a digital-to-analog converter (DAC) that outputs the reference voltage signals in accordance with instructions from the processing unit. The controlled board includes: a first voltage reference device that receives a first reference voltage signal; a second voltage reference device that receives a second reference voltage signal; and a RF device that receives a first frequency signal and a second frequency signal, and outputs a third frequency signal based on one of the first and second reference voltage signals. The connector includes an analog line reference voltage signals to the first and second voltage reference devices and a digital line for providing control signals to the first and second voltage reference devices.
[0009] In accordance with some embodiments, a method of providing multiple voltage references to a radio-frequency device using a single analog line includes the steps of setting the analog line voltage level to be a first reference voltage signal; instructing a first voltage reference device to memorize the first reference voltage signal by sending a first digital control signal to a digital line; providing the first reference voltage signal to the RF device via the first voltage reference device; re-setting the analog line voltage level to be a second reference voltage signal; instructing a second voltage reference device to memorize the second reference voltage signal by sending a second digital control signal to the digital line, wherein the second digital control signal is different from the first digital control signal; and providing the second reference voltage signal to the RF device via the second voltage reference device. The RF device is configured to receive a first frequency signal and a second frequency signal, and output a third frequency signal based on one of the first and second reference voltage signals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Different aspects of the present invention as well as features and advantages thereof will be more clearly understood hereinafter because of a detailed description of embodiments of the present invention when taken in conjunction with the accompanying drawings, which are not necessarily drawn to scale. Like reference numerals refer to corresponding parts throughout the several views of the drawings.
[0011] FIG. 1 depicts a structure of a conventional system to provide N reference voltages to a mixer.
[0012] FIG. 2 depicts a structure of a revised system to provide reference voltage to a mixer on a controlled board.
[0013] FIG. 3 depicts a compatibility problem of the revised system to provide reference voltage to a mixer on a controlled board.
[0014] FIG. 4 depicts a structure of a system of providing multiple voltage references to a mixer using a single analog line in accordance with some embodiments of the present invention.
DESCRIPTION OF EMBODIMENTS
[0015] Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous non-limiting specific details are set forth in order to assist in understanding the subject matter presented herein. It will be apparent, however, to one of ordinary skill in the art that various alternatives may be used without departing from the scope of the present invention and the subject matter may be practiced without these specific details. For example, it will be apparent to one of ordinary skill in the art that the subject matter presented herein can be implemented on many types of outdoor radios systems.
[0016] FIG. 1 depicts a structure of a conventional system to provide N reference voltages to a mixer. The system includes a CPU/MPU 101 , an EEPROM 102 , a DAC 103 with N multiple analog lines, and a mixer 104 . The CPU/MPU 101 configures the voltage for each of the DAC 103 outputs using data stored in the EEPROM 102 . Further, the DAC 103 is configured to provide the reference voltage, for example, V REF1 to the mixer 104 through one of the analog lines. The mixer 104 receives a first frequency signal F 1 and a second frequency signal F 2 , and generates a third frequency signal F 3 based on the reference voltage V REF1 .
[0017] FIG. 2 depicts a structure of a revised system to provide a reference voltage to a mixer on a controlled board. The revised system includes a control board 201 , a controlled board 203 , and a connector 202 to connect the control board 201 to the controlled board 203 . A CPU/MPU 204 , an EEPROM 205 , and a DAC 206 are disposed on the control board 201 , and a mixer 207 is disposed on the controlled board 203 . The DAC 206 provides a reference voltage V REF1 to the mixer 207 via an analog line. The mixer 207 receives a first frequency signal F 1 and a second frequency signal F 2 , and generates a third frequency signal F 3 based on the reference voltage V REF1 .
[0018] FIG. 3 depicts a compatibility problem of the revised system to provide reference voltage to a mixer on a controlled board. The connector 302 connecting the control board 301 and the controlled board 302 has a limited number of the analog lines determined by the original design of the controlled board 303 . As illustrated in FIG. 3 , the control board 301 cannot provide a second reference voltage V REF2 to the mixer 307 due to the limited number of the analog lines at the physical interface of the controlled board 303 .
[0019] FIG. 4 depicts a structure of a system of providing multiple voltage references to a mixer using a single analog line in accordance with some embodiments of the present invention. The system includes a control board 401 , a controlled board 403 , and a connector 402 that connects the control board 401 to the controlled board 403 . A CPU/MPU 404 , an EEPROM 405 , and a DAC 406 are disposed on the control board 401 , and a first voltage reference device (EPVR device #1) 407 , a second voltage reference device (EPVR device #2) 408 , and a mixer 409 are disposed on the controlled board 403 . As shown in FIG. 4 , the DAC 406 provides reference voltages to the first voltage reference device 407 and the second voltage reference device 408 via a single analog line. The first voltage reference device 407 and the second voltage reference device 408 are configured to provide a first reference voltage signal V REF1 and a second reference voltage signal V REF2 to the mixer 409 , respectively. Note that there is an inverter 410 before the second voltage reference device 408 . The mixer 409 receives a first frequency signal F 1 and a second frequency signal F 2 , and generates a third frequency signal F 3 based on the first reference voltage signal V REF1 and the second reference voltage signal V REF2 .
[0020] In some embodiments, the voltage reference device is an electronically programmable voltage reference device (EPVR). The EPVR is an integrated circuit (IC) that can read and memorize the level of the input analog signal, and provide a memorized level of signal on the analog output even when the voltage level of the input analog signal changes, or after the input analog signal is removed.
[0021] In some embodiments, the analog line within the connector 402 and between the control board 401 and the controlled board 403 is only used during a short time period for the reference voltages configuration. The voltage level at the analog line is initially set to be the first reference voltage signal V REF1 . Once the voltage level at the analog line is initially set, the CPU/MPU 404 sends a first digital control signal to the first voltage reference device (EPVR device #1) 407 through the digital line within the connector 402 to memorize the initially set voltage level, and to provide the first reference voltage signal V REF1 to the mixer 409 . In some embodiments, after the first reference voltage signal V REF1 is configured, the voltage level at the analog line is changed to the second reference voltage signal V REF2 . By resetting the digital line to its original state, the CPU/MPU 404 sends a second digital control signal to the second voltage reference device (EPVR device #2) 408 through the digital line within the connector 402 to memorize the newly set voltage level, and to provide the second reference voltage signal V REF2 to the mixer 409 . In this example, the second digital control signal is different from (e.g., opposite to) the first digital control signal. After both the first reference voltage signal V VREF1 and the second reference voltage signal V REF2 are configured, the DAC 406 at the control board 401 can be shutdown to preserve power. The digital line will remain in its current state until the next reconfiguration of the reference voltage.
[0022] In some embodiments, when at least two digital lines are available between the control board and the controlled board, one more DACs may be directly disposed on the controlled board, which will be programmable via an inter-integrated circuit (I 2 C) interface.
[0023] The key advantages of this invention include:
Multiple reference voltages configuration using a single analog line. Reduced power consumption of the control board. Ability to reconfigure reference voltage at any moment. Easy reference voltage configuration process.
[0028] While particular embodiments are described above, it will be understood it is not intended to limit the invention to these particular embodiments. On the contrary, the invention includes alternatives, modifications and equivalents that are within the spirit and scope of the appended claims. Numerous specific details are set forth in order to provide a thorough understanding of the subject matter presented herein. But it will be apparent to one of ordinary skill in the art that the subject matter may be practiced without these specific details. In other instances, well-known methods, procedures, components, and circuits have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.
[0029] The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, operations, elements, components, and/or groups thereof.
[0030] As used herein, the term “if” may be construed to mean “when” or “upon” or “in response to determining” or “in accordance with a determination” or “in response to detecting,” that a stated condition precedent is true, depending on the context. Similarly, the phrase “if it is determined [that a stated condition precedent is true]” or “if [a stated condition precedent is true]” or “when [a stated condition precedent is true]” may be construed to mean “upon determining” or “in response to determining” or “in accordance with a determination” or “upon detecting” or “in response to detecting” that the stated condition precedent is true, depending on the context.
[0031] Although some of the various drawings illustrate a number of logical stages in a particular order, stages that are not order dependent may be reordered and other stages may be combined or broken out. While some reordering or other groupings are specifically mentioned, others will be obvious to those of ordinary skill in the art and so do not present an exhaustive list of alternatives. Moreover, it should be recognized that the stages could be implemented in hardware, firmware, software or any combination thereof.
[0032] The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.
|
A system includes a control board, a controlled board, and a connector connecting the control board to the controlled board. The control board includes a processing unit that configures the reference voltage signals, a non-volatile memory that stores information about the reference voltage signals, and a DAC that outputs the reference voltage signals in accordance with instructions from the processing unit. The controlled board includes: first and second voltage reference devices that receive first and second reference voltage signals, respectively, and a radio-frequency device that receives a first frequency signal and a second frequency signal and outputs a third frequency signal based on one of the first and second reference voltage signals. The connector includes an analog line for providing reference voltage signals to the first and second voltage reference devices and a digital line for providing control signals to activate one of the first and second voltage reference devices.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. provisional application Ser. No. 60/726,669 filed Oct. 14, 2005, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an extruded netting and to a water management building wrap incorporating an extruded netting.
2. Background Art
Buildings, both residential and commercial, typically have a frame structure, a sheathing over the frame structure, and an exterior building covering over the sheathing. Building wraps have been widely used in the construction of buildings. The building wraps are typically placed between the sheathing and the exterior building covering to serve as a moisture barrier by inhibiting water intrusion into the building. These building wraps can also help to prevent energy loss by inhibiting air intrusion into the building. Popular building wraps include Tyvek® Homewrap, available from DuPont, and Typar® Housewrap, available from BBA Fiberweb.
Water can sometimes get behind the exterior building covering through cracks in the exterior building covering or by the window and door joints. Also, moisture from the relatively warm interior of the building can penetrate through the sheathing and the building wrap and condense into water upon contacting the relatively cold exterior building cover. The water can become trapped between the building wrap and the exterior building covering, possibly causing water damage to the building. Also, trapped water can encourage growth of mold and mildew, as well as water damage to building components.
It would be advantageous to provide a building wrap that would not trap water that gets between the sheathing and the exterior building covering of a building.
SUMMARY OF THE INVENTION
The present invention relates to a plastic netting that, in conjunction with various building wrap membranes, provides one or more vertical drainage paths within the exterior layers of a building envelope.
In at least one aspect, the present invention provides a water management building wrap for use between a frame structure of a building and an exterior building covering. In at least one embodiment, the building wrap comprises a permeable membrane disposable over at least a portion of the frame structure which, when disposed over the frame structure, has a first side facing the frame structure and a second side facing away from the frame structure. In this embodiment, the building wrap further comprises a drainage structure secured to the second side of the membrane, wherein the drainage structure includes a plurality of generally vertical members having a first thickness and being spaced apart from each other such that adjacent pairs of the generally vertical members form boundaries for a generally vertical water drainage channel. In this embodiment, the drainage structure further includes a plurality of generally horizontal members attached to the generally vertical members and having a second thickness less than the first thickness. In this embodiment, the drainage structure is an extruded polymeric material forming integral joints at intersections of the generally vertical members and the generally horizontal members, with the joints providing dimensional stability to maintain the orientation of the generally vertical members and form stable vertical water drainage channels.
In at least another embodiment, the building wrap comprises a permeable membrane having a first side and a second side, and an extruded polymeric netting structure secured to one of the sides of the membrane. In this embodiment, the netting structure includes a plurality of generally vertical members having a first average thickness and being spaced apart from each other such that adjacent pairs of the generally vertical members form boundaries for a generally vertical water drainage channel. In this embodiment, the netting structure further includes a plurality of generally horizontal members extending between and attached to the generally vertical members and having a second average thickness less than the first thickness In this embodiment, the netting structure has integral joints at intersections of the generally vertical members and the generally horizontal members, with the joints providing dimensional stability to maintain the orientation of the generally vertical members and form stable vertical water drainage channels.
In at least another embodiment, the generally vertical members are spaced apart from each other with a first frequency and the generally horizontal members are spaced apart from each other with a second frequency greater than the first frequency.
In at least one embodiment, the first average thickness is 1.25 to 25 times the second average thickness. In at least another embodiment, the first average thickness is 1.5 to 10 times the second average thickness. In at least yet another embodiment, the first average thickness is 2 to 5 times the second average thickness.
In at least one embodiment, each of the joints have an average thickness of 5 to 300 mils. In at least one embodiment, the first average thickness of the generally vertical members is 4 to 290 mils. In at least one embodiment, the second average thickness of the generally horizontal members is 0.5 to 50 mils.
In at least another embodiment, the present invention provides a water management building wrap for use between a sheathing of a building and an exterior building covering. In at least this embodiment, the building wrap comprises a permeable membrane disposable on at least a portion of the sheathing, the membrane having a first side and a second side, wherein the first side, when the membrane is disposed on the sheathing, faces the sheathing, and an extruded polymeric netting structure secured to the second side of the membrane. In this embodiment, the netting structure includes a plurality of generally vertical members having a first thickness and being spaced apart from each other such that adjacent pairs of the generally vertical members form boundaries for a generally vertical water drainage channel, and a plurality of generally horizontal members extending between and attached to the generally vertical members and having a second thickness less than the first thickness. In this embodiment, the netting structure has integral joints at intersections of the generally vertical members and the generally horizontal members, with the joints providing dimensional stability to maintain the orientation of the generally vertical members and form stable vertical water drainage channels.
In at least another aspect, the present invention also relates to a method for making a water management building wrap. In this embodiment, the building wrap may be disposed between a frame structure or sheathing of a building and an exterior building covering, before the exterior building covering is applied. In this embodiment, the building wrap is made by securing an extruded netting to a permeable membrane. In this embodiment, the membrane, when the membrane is disposed between a frame structure and an exterior building covering, has a first side facing the frame structure and a second side facing away from the frame structure. In this embodiment, the netting includes a plurality of generally vertical members having a first thickness and being spaced apart from each other such that adjacent pairs of the generally vertical members form boundaries for a generally vertical water drainage channel, and a plurality of generally horizontal members attached to the generally vertical members and having a second thickness less than the first thickness. In this embodiment, the netting is an extruded polymeric material forming integral joints at intersections of the generally vertical members and the generally horizontal members, with the joints providing dimensional stability to maintain the orientation of the generally vertical members and form stable vertical water drainage channels.
In at least another embodiment, the positioning of the netting and the membrane could be reversed, so that the netting faces towards the frame structure while the membrane faces towards the exterior building covering.
In at least another embodiment, the building wrap comprises a first membrane disposable on at least a portion of the sheathing, the membrane having a first side and a second side, the first side, when the membrane is disposed on the sheathing, facing the sheathing, a second membrane spaced from the first membrane, and an extruded polymeric netting structure between the first and second membrane. In this embodiment, the netting structure includes a plurality of generally vertical members having a first thickness and spaced apart from each other such that adjacent pairs of the generally vertical members form boundaries for a generally vertical water drainage channel. In this embodiment, the netting structure further includes a plurality of generally horizontal members extending between and attached to the generally vertical members and having a second thickness less than the first thickness, with the netting structure having integral joints at intersections of the generally vertical members and the generally horizontal members, the joints providing dimensional stability to maintain the orientation of the generally vertical members and form stable vertical water drainage channels. In this embodiment, the netting could face either towards the frame structure (or the sheathing) or towards the exterior building covering. In some embodiments, when the channels face towards the frame structure this construction tends to occlude less surface area on the breathable membrane layer thereby tending to enhance breathability.
In at least one embodiment, the members are extruded to have a rectangular net configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cut-away perspective view of an embodiment of the building wrap of the present invention as applied to an exemplary building structure;
FIG. 2 is a perspective view of a component of the building wrap of FIG. 1 ;
FIG. 3 is a side view of the building wrap of FIG. 1 ;
FIG. 4 is a sectional view taken along line 4 - 4 of FIG. 1 ;
FIG. 5 is a cross-sectional view of an exemplary strand of the component of FIG. 2 ;
FIG. 6 is a view similar to FIG. 3 illustrating another embodiment of the present invention; and
FIG. 7 is a view similar to FIG. 4 illustrating another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to presently preferred compositions, embodiments and methods of the present invention, which constitute the best modes of practicing the invention presently known to the inventors. The Figures are not necessarily to scale. However, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for any aspect of the invention and/or as a representative basis for teaching one skilled in the art to variously employ the present invention.
Except in the examples, or where otherwise expressly indicated, all numerical quantities in this description indicating amounts of material or conditions of reaction and/or use are to be understood as modified by the word “about” in describing the broadest scope of the invention. Practice within the numerical limits stated is generally preferred. Also, unless expressly stated to the contrary: percent, “parts of,” and ratio values are by weight; the term “polymer” includes “oligomer,” “copolymer,” “terpolymer,” and the like; the description of a group or class of materials as suitable or preferred for a given purpose in connection with the invention implies that mixtures of any two or more of the members of the group or class are equally suitable or preferred; description of constituents in chemical terms refers to the constituents at the time of addition to any combination specified in the description, and does not necessarily preclude chemical interactions among the constituents of a mixture once mixed; the first definition of an acronym or other abbreviation applies to all subsequent uses herein of the same abbreviation and applies mutatis mutandis to normal grammatical variations of the initially defined abbreviation; and, unless expressly stated to the contrary, measurement of a property is determined by the same technique as previously or later referenced for the same property.
Referring to FIG. 1 , a cut away perspective view of an exemplary building structure 10 is illustrated. The exemplary building structure 10 includes a plurality of spaced apart framing members 12 that form a frame structure. A sheathing 14 is suitably secured to the framing members 12 . An exterior building covering 16 is secured to the sheathing 14 . Between the sheathing 14 and the exterior building covering 16 is disposed a building wrap 20 made in accordance with at least one embodiment of the present invention. In at least one embodiment the building wrap 20 comprises a permeable membrane 22 and an extruded plastic netting 24 .
The frame members 12 can be made of any suitable framing material, including wood, wood composites, or metal.
The sheathing 14 may be made of any suitable material and may comprise any suitable construction, such as sheets or boards. Some examples of suitable materials include, but are not necessarily limited to, thin composite laminations, fiberboard, oriented-strand board (OSB), plywood, polyisocyanurate foam, extruded polystyrene (XPS) foam and molded expanded polystyrene (EPS) foam. The sheathing 14 may be secured to the frame members 12 by any suitable fasteners such as nails, screws or staples.
The exterior building covering 16 may comprise any suitable exterior building covering and may have any suitable configuration. Some examples of suitable exterior coverings include, but are not necessarily limited to, siding, vinyl siding, brick, stucco, stone, masonry, concrete veneers, and cement based siding planks and panels. The exterior building covering 16 can be secured to the sheathing 14 in any suitable manner, such as by nails, screws or staples.
As shown in the embodiment illustrated in FIG. 3 , the building wrap 20 comprises a membrane 22 and an extruded plastic netting 24 . The membrane 22 has a first side 26 and an opposed second side 28 . As best seen in FIGS. 3 and 4 , when the building wrap 20 is secured to the sheathing 14 , the first side 26 of the membrane 22 faces the exterior building covering 16 while the second side 28 of the membrane 22 faces the sheathing 14 . The building wrap 20 can be secured to the sheathing 14 by any suitable means, such as by nails, staples or screws. In at least one embodiment, the membrane 22 has an average thickness of 1 to 75 mils, and in other embodiments of 5 to 40 mils.
The membrane 22 may be vapor permeable or impermeable. In embodiments where the membrane 22 is impermeable, the membrane may be any suitable impermeable membrane, such as films or sheets of PP, PE or PVC or other impermeable weather resistant building papers.
In embodiments where the membrane 22 is vapor permeable, the vapor permeable membrane 22 may be any suitable vapor permeable membrane that is water resistant. The vapor permeable membrane 22 may be any suitable breathable sheet material made of spun bonded synthetic fibers such as polyethylene, polypropylene or polyester fibers, sheets of spun bonded-melt blown-spun bonded (“SMS”) polymer fibers (or other non-woven fabricated products), perforated polymer films, woven slit film, microporous film laminates, and building papers. The permeable membrane 22 could also be a rolled on and/or sprayed on liquid that dries or cures as a film directly on the sheathing 14 . In at least certain embodiments, particularly preferred permeable membrane 22 comprise Tyvek® Homewrap or Typar® Housewrap.
In at least one embodiment, the netting 24 may be secured by any suitable securing means to the first side 26 of the membrane 22 , such as by nails, staples, screws or adhesive. In another embodiment, the membrane 22 may be first secured to the sheathing 14 with the netting 24 then being secured over the membrane 22 and/or sheathing 14 . In yet another embodiment, the netting 24 may first be secured to the sheathing 14 with the membrane 22 then being secured over the netting and/or sheathing.
In at least one embodiment, the netting 24 is laminated to the membrane 22 prior to application of the building wrap 20 to the building structure 10 . While any suitable lamination process can be used, one example of such a lamination process comprises thermal laminating the netting to the membrane. Techniques other than lamination could be employed to join the netting 24 and the membrane 27 . These techniques include extrusion coating the netting onto the membrane, employing a layer of thermal adhesive, either on the membrane or the netting, and/or employing a hot melt or other adhesive sprayed onto the membrane and/or netting.
As can best be seen in FIGS. 1 , 3 - 4 and 6 - 7 , the netting 24 in cooperation with the membrane 22 helps to provide a drainage structure comprising a plurality of generally vertical drainage channels 34 . If water condenses, or is otherwise disposed onto the building wrap 20 , the channels 34 will allow the water to drain down the wrap 20 and outside the building covering 16 .
In the illustrated embodiment, as can be seen in FIGS. 1-4 and 6 - 7 , the netting 24 comprises strands 30 extending in one direction and strands 32 extending in a generally crosswise or transverse direction. When the building wrap 20 is applied to a building structure 10 , the strands 30 comprise vertical members extending down the building structure and the strands 32 comprise horizontal members running across the building structure.
When the netting 24 is secured to the membrane 22 , the horizontal strands 32 tend to be offset towards (in some cases attached or bonded to) the membrane 22 , thereby with the vertical strands 30 forming channels 34 facing away from the membrane 22 . For instance, in the embodiment illustrated in FIG. 4 , the channels 34 face towards the exterior building covering 16 as the membrane 22 is adjacent the sheathing 14 . In the alternative embodiment illustrated in FIG. 7 , the channels 34 face towards the sheathing 14 .
The strands 30 and 32 are extruded polymeric elongate members which cross and intersect during extrusion to form the net-like structure. In at least one embodiment, the strands 30 and 32 are made of the same material. In other words, 100% of the strands are made of the same material.
In at least another embodiment, strands 30 are made of a different material than strands 34 . In this embodiment, the netting 24 may comprise 10 to 90 wt. % of the material comprising strands 30 and 90 to 10 wt. % of the material comprising strands 32 . In other embodiments, the netting 24 may comprise 35 to 65 wt. % of the material comprising strands 30 and 65 to 35 wt. % of the material comprising strands 32 . In yet other embodiments, the netting 24 may comprise 45 to 55 wt. % of the material comprising strands 30 and 55 to 45 wt. % of the material comprising strands 32 . In this embodiment, strands 30 may be made of a relatively durable material, such as PP (polypropylene) or PE, and strands 32 may be made of a lower melting point material, such as EVA (ethylene vinyl acetate), EMA or VLDPE, which can act as an adhesive for bonding the netting 24 to the membrane 22 .
In at least one embodiment, the vertical strands 30 have an average thickness which is 1.25 to 25 times the average thickness of the horizontal strands 32 . This helps to form the water drainage channels 34 . In at least another embodiment, the average thickness of the vertical strands 30 is 1.5 to 10 times the average thickness of the horizontal strands 32 . In still yet another embodiment, the average thickness of the vertical strands 30 is 2 to 5 times the average thickness of the horizontal strands 32 .
In some embodiments, the extruded netting 24 has horizontal strands 32 that have an average thickness of 0.5 to 50 mils, in other embodiments 0.75 to 15 mils, and in yet other embodiments 1 to 10 mils.
In some embodiments, the extruded netting 24 has vertical strands 32 that have an average thickness of 4 to 290 mils, in other embodiments 10 to 175 mils, and in yet other embodiments 15 to 100 mils.
In some embodiments, the extruded netting 24 has joints that have an average thickness of 5 to 300 mils, in other embodiments 15 to 200 mils, and in yet other embodiments 20 to 150 mils. The joints, as can been from the figures, are integral between the strands 30 and 32 . The integral joints help to provide a stable netting 24 which preserves the relatively uniform spacing of the strands to provide uniform water channels 34 .
In at least one embodiment, the strands 30 and 32 are made of any suitable polymeric material. In at least one embodiment, the strands 30 and 32 are made of a non-coated polymeric material. In at least certain embodiments, the polymeric material comprises a relatively durable, relatively high melting point material such as PP or PE.
In some embodiments, as shown in FIG. 5 , the strands 30 and 32 include a layer 40 of lamination polymer, such as EVA or EMA, covering at least a portion of a polymeric material (i.e., PP or PE) of the core 42 . The layer 42 of lamination polymer has a lower melting point than the polymeric material of the core 42 so that it melts during the lamination process to secure the netting 24 to the membrane 22 .
The polymeric material may include suitable additives, as are known in the art. Examples of suitable additives include, but are not necessarily limited to, colorant, heat stabilizers, UV light stabilizers, flame retardants and anti-microbials.
In at least one embodiment, the extruded netting 24 has a machine direction strands (horizontal strands 32 ) per inch (i.e., strand count) of 0.5 to 40 strands/inch, in other embodiments 1 to 20 strands per inch, and in yet other embodiments 5 to 15 strands/inch.
In at least one embodiment, the extruded netting 24 has a cross direction strands (vertical strands 30 ) per inch of 0.5 to 30 strands/inch, in other embodiments 1 to 15 strands/inch, and in yet other embodiments 2 to 10 strands per inch.
In certain embodiments, the netting 24 will have one side that is generally flat. In this embodiment, the side of the netting 24 contacting the membrane 22 is generally flat.
In at least one embodiment, the extruded netting 24 can be made by any suitable reciprocating netting extrusion process. In at least another embodiment, the extruded netting 24 can be made by any suitable rotary extrusion process, where the netting is bias cut, forming machine direction and cross direction strands. In at least one embodiment, the extruded netting is then uniaxially oriented (i.e., in only one direction) by any suitable axial orienting process. Suitable examples of these processes are well known.
Generally, suitable methods for making the netting 24 comprise extruding the polymeric material through dies with reciprocating parts to form the general netting configuration. This creates cross machine direction strands 30 that cross the machine direction strands 32 , which flow continuously. After the extrusion, the netting is then typically stretched in the machine direction only using a speed differential between two sets of nip rollers. Alternatively, after extrusion, the netting 24 can be stretched in the cross-direction only using a tenter frame. It should be understood, that the above described method is just one of many suitable methods that can be employed to manufacture reciprocating extruded netting 24 in accordance with the present invention. In an alternative embodiment, the extruded netting 24 may be oriented in both directions so long as the vertical strands 30 are substantially greater in thickness than the horizontal strands 32 . Also, while the principles of this invention can apply to any net geometry, the present invention has excellent applicability to square netting and rectangular netting.
An alternative embodiment of a building wrap 120 is shown in FIG. 6 . The building wrap 120 comprises a first membrane 22 , a second membrane 122 spaced from the first membrane 22 and a netting 24 disposed between the first and second membrane 22 and 122 . The first membrane 22 is the same as the first membrane 22 described above, and thus could be permeable or impermeable. The netting 24 is the same as the netting 24 described above. The second membrane 122 can be a permeable membrane or an impermeable membrane, such as the membrane 22 described above. In at least one embodiment, the first membrane 22 , which is adjacent the sheathing 14 when in use, is a vapor permeable membrane and the second membrane 122 , which is adjacent the exterior covering 16 when in use, is an impermeable membrane.
The building wrap 20 made in accordance with the present invention has many potential uses, such as wrapping houses and commercial buildings, as well as under layments for roofs.
In one embodiment, the building wrap 20 may be secured to sheathing 14 via any suitable fastener such as nails, screws or staples. In an alternative embodiment, the wrap 20 may be secured to the frame structure 12 , if no sheathing is present. In at least one embodiment, the components of the wrap 20 may be applied to the building structure in separate steps wherein the membrane 22 is secured to the building structure 10 first via any suitable fastener and then the netting 24 is secured to the membrane by any suitable fastener.
The present invention may be further appreciated by consideration of the following, non-limiting examples, and certain benefits of the present invention may be further appreciated by the examples set forth below.
While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.
|
The present invention provides a water management building wrap that may be useable between a frame structure of a building and an exterior building covering. In at least one embodiment, the building wrap comprises a permeable membrane and an extruded polymeric drainage structure secured to the second side of the membrane. In at least one embodiment, the drainage structure includes a plurality of generally vertical members having a first thickness and forming boundaries for generally vertical water drainage channels, and a plurality of generally horizontal members attached to the generally vertical members and having a second thickness less than the first thickness and forming integral joints at intersections of the generally vertical members and the generally horizontal members that provide dimensional stability to maintain the orientation of the generally vertical members and form stable vertical water drainage channels.
| 8
|
CROSS-RELATED APPLICATION
[0001] This application is a Non-Provisional Application claiming the benefits of U.S. Provisional Patent Application Ser. No. 61/939,775 filed Feb. 14, 2014, the entirety of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. TECHNICAL FIELD
[0003] The invention relates generally to startup burners and specifically to startup burners used in chemical recovery boilers in the pulp and paper industry.
[0004] 2. RELATED ART
[0005] Chemical recovery boilers isolate useful compounds from manufacturing byproducts. In the pulp and paper industry, pulp mills typically use a manufacturing process in which wood chips or other lignocellulosic biomass are treated with chemical liquor comprising cooking chemicals. The wood chips or other lignocellulosic materials are then cooked in a digester at predetermined temperature and pressure to form a slurry comprising spent liquor and a rough pulp with inconsistent particle size. After cooking, equipment washes the spent chemical liquor from the rough pulp. The spent liquor is commonly known as “black liquor” and comprises organic and inorganic chemicals left over from the cooking process. The pulp is generally sent to other equipment for further refinement. The black liquor is eventually pumped to a chemical recovery boiler and processed to recover the cooking chemicals. Without recovering and reusing the cooking chemicals from the black liquor, the cost of industrial paper-making processes would be prohibitive.
[0006] Chemical recovery boilers generally evaporate excess moisture from black liquor solids, burn organic liquor components, supply heat for steam generation, and recover inorganic compounds—notably sodium sulfide and sodium carbonate. Some of these compounds can be re-causticized and used elsewhere in the manufacturing process.
[0007] In the recovery process, the black liquor is typically concentrated into a solution containing a solids concentration of above sixty percent by mass. Nozzles in the furnace wall then spray black liquor into a furnace. The nozzles are generally located in the bottom quarter of the furnace and may be several meters above the bottom of the furnace. The furnace is a reactor that generally dries and partially pyrolyzes the liquor droplets as they fall toward the bottom of the furnace. The furnace also evaporates, gasifies, oxidizes, and reduces, components within the black liquor to recover the cooking chemicals.
[0008] The partially dried and reacted black liquor accumulates in a mound at the bottom of the furnace known as a “char bed”. Nozzles typically permit airflow into the furnace at a low, middle, and upper elevation. The air, together with the lignin, wood extracts, and other organic compounds maintain combustion in the furnace. Inorganic compounds are often reduced in the char bed into a molten smelt. The smelt may accumulate and flow out of the furnace through a smelt spout and into a collection tank. These reactions consume heat. As such, operators generally regulate and redistribute airflow and black liquor input, to promote and maintain combustion for efficient chemical recovery.
[0009] In traditional recovery boilers, the furnace is internally lined with a series of densely-arranged, high-pressure coolant-filled tubes. The coolant is commonly water and a collective series of tubes is generally known as a “water wall.” To regulate temperature efficiently, the water wall tends to cover a large internal surface area. In some existing chemical recovery boilers, three inch coolant tubes are generally separated by one inch filler bars so as to form a gas-tight barrier enclosing the furnace.
[0010] To operate safely and efficiently, the furnace generally operates under negative pressure. A constant inflow of air near the base of the furnace is generally required to maintain combustion and to replace air and other gases that exit the recovery boiler near the top of the furnace. Air generally enters the otherwise gas-tight furnace through openings in the furnace water walls. Such openings include air ports and throats, which are designed to inject pressurized air. Ambient air generally flows through other openings, such as those for smelt spouts, due to the negative pressure in the furnace. For most such openings, the coolant tubes generally bend around the opening in the furnace wall.
[0011] Air manifolds or windboxes generally flank the throat and air port openings on the outer wall of the furnace. Large fans ducted to the windboxes can cause air to flow into the furnace through the various throats and air ports in the furnace walls.
[0012] Airflow is the primary variable of operation aside from the rate of black liquor input. Large quantities of air are generally forced through the narrow throat and air port openings to maintain combustion. The flow of air through a throat and, diffuser, or swirler is desirable to maintain auxiliary combustion from active startup burners. Unfortunately, conditions within the furnace contribute to the gradual obstruction of air flow as smelt slowly accumulates over the various openings. Over time, accumulations of frozen smelt on and around the coolant tubes can grow to obstruct the openings, thereby reducing an operator's ability to regulate combustion. Recovery boilers may need to be deactivated when smelt accumulations significantly interfere operation. This extensive maintenance period results in loss of production.
[0013] Temperature is another variable of operation. Startup burners help regulate internal furnace temperature. Startup burners are auxiliary burners that commonly fire natural gas, propane, and/or fuel oil, and are generally used to initiate combustion within the furnace after a period of dormancy. Once the startup burners increase furnace temperature to an established minimum, liquor firing can commence. Liquor firing is then increased until the liquor itself sustains combustion. The startup burners are then generally deactivated. Startup burns have also been used to provide supplementary heat to the furnace when liquor flow is interrupted or insufficient to meet boiler demand.
[0014] When inactive, the startup burner generally rests in the windbox within a burner housing adjacent to the throat opening. Radiant heat from the furnace can damage inactive startup burners. Moreover, splashes of black liquor through the throat openings can cause smelt fouling directly on the startup burner, particularly on the firing end of the startup burner, comprising, for example, the fuel nozzles, swirler, igniter assembly, and flame detection equipment. Smelt fouling can render the startup burner ineffective, unsafe, and unreliable.
[0015] There is a need to increase the intervals between recovery boiler maintenance and to reduce the amount of maintenance time while preserving or improving the operability of the recovery boiler after said maintenance.
SUMMARY OF THE INVENTION
[0016] The problems of loss of production caused by deactivating a chemical recovery boiler for the purpose of manually dislodging accumulations of smelt, airflow interference in the chemical recovery boiler, exposing operators to hot air from the furnace and windbox, and startup burner damage due to smelt spattering and radiant heat from the furnace is mitigated by using a system of isolation chambers engaged to the outer wall of a windbox to extract startup burners from windboxes engaged to the outer wall of the furnace of the chemical recovery boiler, such that the isolation chambers are configured to partially isolate the startup burner from the windbox and furnace environment before extraction. In alternative embodiments, the isolation chambers may isolate the extractable startup burner substantially completely from the windbox and furnace environment.
[0017] Some conventional startup burners may have a retraction feature whereby the burner can be manually or automatically retracted from an active position. That is, while the firing ends of the startup burners can be retracted from the furnace, the body and firing ends remain in the windbox proximate to the furnace and directly behind the wall openings in the furnace. Retracted firing ends are typically eight to sixteen inches from the furnace. By retracting an inactive conventional startup burner from the furnace, conventional burners have sought to reduce exposure to furnace temperature and smelt fouling. While conventional burners have been somewhat effective in prolonging the useful life of startup burners, conventional burners have significant drawbacks.
[0018] Conventional burners preclude startup burner maintenance while the recovery boiler is operational. The potential for smelt splatter renders human intervention unsafe. Hot air in the pressurized windbox and radiant heat from the furnace complicate human intervention. Conventional startup burners generally require constant exposure to moving air to prevent overheating. This tramp air flowing from the windbox through the throats and into the furnace can also provide oxygen to maintain combustion. Operators generally consider the amount of air entering the furnace as a variable when attempting to maintain a desirable combustion rate. To this end, some conventional startup burners are placed within housings having variable position dampers. The housings are likewise placed within the windbox. The variable position dampers can allow operators to affect the amount of air flowing over the startup burner to the boiler. However, the desire to preserve the startup burner from overheating prevents operators from closing variable position dampers completely.
[0019] Airflow within the windbox may become dynamic and irregular based partially on the oxygen demands of the furnace. Additionally, the startup burner obstructs the air flow in the housing, thereby facilitating an irregular and unpredictable insertion of air into the recovery boiler.
[0020] With regard to retracted startup burners, smelt fouling still occurs due to residual splashing of black liquor droplets through the throats and onto the firing end. The firing end generally includes a diffuser, or swirler, which can be used to direct or shape the flame emanating from the startup burner. The swirler's large surface area relative to the throat can increase the incidence of smelt accumulation on the swirler. Additionally, radiant heat from the furnace can damage the startup burner. The presence of retracted startup burners directly behind the occluded throats can interfere with operator's ability to clear the occlusions and perform necessary maintenance of the burners while the boiler remains operational.
[0021] Embodiments of the current disclosure comprise an isolation chamber located behind an extractable startup burner in a windbox. The assembly separates an operator from the pressurized hot air in the windbox and furnace thereby permitting operators to remove inactive startup burners safely while the recovery boiler is operational. Once the startup burner is removed, operators may use a rod, a cleaning brush mounted on a pole, or other suitable cleaning means to clean the throats manually. If the width of the isolation chamber is sufficiently wide, operators may clean multiple openings in the furnace wall through a single isolation chamber. Additionally, the exemplary assembly allows operators to replace or repair startup burners, as needed for optimal boiler operation, between scheduled outages.
[0022] Further, use of an extractable startup burner with an isolation chamber may eliminate or reduce the need for burner-cooling air. In conventional burners, variable position dampers in burner housings remain partially opened when the startup burner is inactive. The variable position dampers allow air from the windbox to cool the inactive startup burner and to counter effects of radiant heat. Throats in the furnace wall are generally uncovered when a startup burner is not in use, so tramp air in the burner housing used to cool the inactive startup burner may also flow into the furnace uncontrollably. This undesirable influx of air into the furnace can complicate an operator's ability to control and maintain optimal combustion conditions. Additionally, the presence of a conventional retracted startup burner in the windbox can interfere with desirable airflow.
[0023] Use of an extractable startup burner and isolation chamber as set forth in the present disclosure may allow operators to close fully variable position dampers in the burner housing and reduce or prevent tramp air from entering the furnace, thus improving air distribution control. Accordingly, it is an object of the present disclosure to improve air distribution control in a chemical recovery boiler—particularly in the windbox and through openings in the furnace wall.
[0024] A recovery boiler startup burner assembly has been conceived comprising: a furnace having areas defining openings in a furnace wall, a windbox exteriorly engaging the furnace wall, wherein the windbox is configured to contain pressurized combustion air, an isolation chamber exteriorly engaging a windbox wall, wherein the isolation chamber is aligned with an area defining an opening in the windbox wall and an area defining an opening in the furnace wall, a startup burner disposed within the windbox, the startup burner having a firing end and a supply end, wherein the firing end is aligned with the area defining an opening in the furnace wall and the supply end is aligned with the area defining an opening in the windbox wall, wherein the startup burner is configured to be extracted through the isolation chamber, and wherein the isolation chamber is configured to isolate an extracted portion of the startup burner from the windbox.
[0025] The isolation chamber may comprise a multi-door isolation chamber. In another exemplary embodiment, the isolation chamber may comprise a burner guide sleeve having a hinged door at one end and a seal plug at the other end. In still other exemplary embodiments, the isolation chamber may be configured to isolate the startup burner partially from the windbox. In yet other exemplary embodiments, the isolation chamber may be configured to isolate the startup burner from the windbox substantially completely.
[0026] In still other exemplary embodiments, the assembly for a recovery boiler may further comprise a cooling carriage comprising a structural brace having a first end and a second end, the second end being mounted to an outer wall of the recovery boiler and the first end being engaged to a first end of a main support beam, a second end of the main support beam being engaged to the outer wall of the recovery boiler, the cooling carriage may further comprise a carrier assembly linkage having at least one first end and at least one second end having at least one roller rotatably mounted to the at least one second end of the carrier assembly linkage.
[0027] The cooling carriage may further comprise a local temperature display. The local temperature display may be a contact-type temperature display, such as a resistance temperature detector (“RTD”) or a thermocouple detector. In other exemplary embodiments, the local temperature display may be a non-contact type display such as an infrared thermometer or a laser thermometer.
[0028] A method has been conceived for extracting a startup burner comprising: deactivating a startup burner, disconnecting wires and hoses from the startup burner and an igniter assembly, withdrawing the startup burner from a throat in a furnace wall, removing the igniter assembly from the startup burner, lowering a support brace to the startup burner, withdrawing the startup burner into an inner space defined by the multi-door isolation chamber, closing at least one inner door of the multi-door isolation chamber to support the startup burner, withdrawing the startup burner through the inner space defined by the multi-door isolation chamber, opening at least one outer door of the multi-door isolation chamber, closing the inner door of the multi-door isolation chamber, and removing the startup burner from the inner space of the multi-door isolation chamber.
[0029] A multi-door isolation chamber for use with a recovery boiler windbox has been conceived comprising: a multi-door isolation chamber disposed proximate to a windbox opening defined by an outer wall of a windbox, at least one inner door configured to occlude partially the windbox opening and support a startup burner, and at least one outer door configured to occlude a multi-door isolation chamber opening defined by an outer face of the multi-door isolation chamber.
[0030] Another method has been conceived for extracting a startup burner from a recovery boiler comprising: shutting down a startup burner; disconnecting wires and hoses from the startup burner and an igniter assembly; withdrawing the startup burner from a throat in a furnace wall; removing the igniter assembly from the startup burner; lowering a support brace to the startup burner; closing the first inner door of the multi-door isolation chamber to support the support brace and startup burner; withdrawing the support brace with the startup burner through a first inner door of a multi-door isolation chamber into an inner space defined by the multi-door isolation chamber; closing a second inner door of the multi-door isolation chamber to substantially isolate the support brace with the startup burner in the inner space of the multi-door isolation chamber; opening at least one outer door of the multi-door isolation chamber; and removing the startup burner from the inner space of the multi-door isolation chamber.
[0031] A method for cleaning smelt accumulations in a recovery boiler during operation has been conceived comprising: shutting down a startup burner, disconnecting wires and hoses from the startup burner and an igniter assembly, withdrawing the startup burner from a throat in a furnace wall, removing the igniter assembly from the startup burner, withdrawing the startup burner into an inner space defined by the multi-door isolation chamber, closing at least one inner door of the multi-door isolation chamber, withdrawing the startup burner through the at least one inner door of a multi-door isolation chamber to substantially isolate the startup burner in an inner space defined by the multi-door isolation chamber, opening at least one outer door of the isolation chamber, removing the startup burner from the isolation chamber, and extending a rod through the multi-door isolation chamber to dislodge smelt accumulations from the throat in the furnace wall.
[0032] The method for cleaning smelt accumulations may further comprise extending a carrier assembly linkage of a cooling carrier into a path of the startup burner, placing the startup burner on rollers extending from the carrier assembly linkage, and allowing a hot end of the startup burner to cool on the rollers.
[0033] A method has been conceived for replacing an extractable startup burner in a recovery boiler during operation comprising: aligning a support brace with an outer door of an isolation chamber; mounting a startup burner on a support brace, opening at least one outer door of the isolation chamber, inserting a startup burner into an inner space of the isolation chamber, closing the at least one outer door of the isolation chamber to support the startup burner, closing a second outer door of the isolation chamber to substantially isolate the startup burner in the inner space of the isolation chamber; extending the startup burner from the at least one inner door toward a throat in a furnace wall; and connecting wires and hoses to a startup burner and an igniter assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] The foregoing will be apparent from the following more particular description of exemplary embodiments of the disclosure, as illustrated in the accompanying drawings. The drawings are not necessarily to scale, with emphasis instead being placed upon illustrating the disclosed embodiments.
[0035] FIG. 1 is a side-view of an exemplary embodiment of a recovery boiler with windboxes and several multi-door isolation chambers engaged to the sides of the windboxes.
[0036] FIG. 2 a is a perspective view of an exemplary embodiment of the multi-door isolation chamber, the windbox, and the path by which the startup burner may be removed from the windbox.
[0037] FIG. 2 b is a cross-sectional view of an exemplary embodiment of the multi-door isolation chamber, the windbox, and the path by which the startup burner may be removed from the windbox.
[0038] FIG. 3 is a burner end view of an exemplary embodiment of the multi-door isolation chamber, the throat, and the swirler with the outer doors of the multi-door isolation chamber engaged to the front plate of the multi-door isolation chamber via hinges.
[0039] FIG. 4 is a top-down view of an exemplary embodiment of the multi-door isolation chamber mounted to the outer wall of the chemical recovery boiler and the startup burner extending through the windbox and into the furnace.
[0040] FIG. 5 a is a front view of an exemplary first inner door and second inner door of the multi-door isolation chamber configured to substantially completely isolate a startup burner in the multi-door isolation chamber.
[0041] FIG. 5 b a front view of an exemplary embodiment of the first inner door and second inner door of the multi-door isolation chamber that are slidably engaged proximate to the windbox along a track.
[0042] FIG. 6 a is a side view of an exemplary cooling carriage affixed to the outer wall of a windbox.
[0043] FIG. 6 b is a front view of an exemplary cooling carriage depicting the extended carriage's position relative to the multi-door isolation chamber.
[0044] FIG. 7 is a side view of an exemplary burner guide sleeve with a plug and flapper seal.
DETAILED DESCRIPTION OF THE INVENTION
[0045] The following detailed description of the preferred embodiments is presented only for illustrative and descriptive purposes and is not intended to be exhaustive or to limit the scope and spirit of the invention. The embodiments were selected and described to best explain the principles of the invention and its practical application. One of ordinary skill in the art will recognize that many variations can be made to the invention disclosed in this specification without departing from the scope and spirit of the invention.
[0046] Although the drawings represent embodiments of various features and components according to the present disclosure, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate embodiments of the present disclosure, and such exemplifications are not to be construed as limiting the scope of the present disclosure.
[0047] The present disclosure describes an isolation chamber that may be used with a startup burner configured to be removed or replaced while the boiler is operating. Natural gas, oil, propane, or other fuel known to those having ordinary skill in the art may fuel the startup burner. Although the startup burner may be used in boilers or process furnaces generally, subsequent exemplary uses will refer to recovery boilers used in the pulp and paper industry.
[0048] FIG. 1 depicts an exemplary embodiment of the isolation chamber 106 attached to windboxes 190 of a recovery boiler 107 . The windboxes 190 generally span the sides of the furnace 199 horizontally and may contain throats ( FIG. 2 , 240 ), housings ( FIG. 4 , 491 ), startup burners ( FIG. 2 , 200 ), or other instruments such as air nozzles or probes to record furnace conditions (not depicted). Recovery boilers 107 generally have a primary windbox 190 a , a secondary windbox 190 b , and tertiary windbox 190 c spanning the sides of the furnace 199 . The primary windbox 190 a is generally closest to the ground and the tertiary windbox 190 c is generally furthest from the ground. In certain exemplary embodiments, exemplary isolation chambers 106 may be attached to the primary windbox 190 a and secondary windbox 190 b . In other embodiments, at least one exemplary isolation chamber 106 may be attached to the primary windbox 190 a . In still other embodiments, exemplary isolation chambers 106 may be attached to any one of the primary windbox 190 a , secondary windbox 190 b , or tertiary windbox 190 c . In other exemplary embodiments, at least one exemplary isolation chamber 106 may be attached to each of the primary windbox 190 a , secondary windbox 190 b , and tertiary windbox 190 c.
[0049] FIG. 2 a depicts a perspective view of the exemplary multi-door isolation chamber 206 engaged to a mounting plate 218 secured to the outer wall 222 of the windbox 290 . In this exemplary embodiment, the multi-door isolation chamber 206 is generally in the shape of a rectangular prism (i.e. box-shaped); however, on other embodiments, the multi-door isolation chamber 206 may be generally cylindrical, generally in the shape of a geometric prism having greater than three edges, or generally irregularly shaped. A generally irregularly shaped isolation chamber 206 may have a sample cross sectional area at a first position (e.g. a measurement of cross sectional area measured along a first plane) that differs from a sample cross sectional area at a second position (e.g. a measurement of cross sectional area measured along a second plane parallel to the first plane).
[0050] The startup burner 200 may comprise an inlet 207 through which natural gas, air, or other fuel enters the startup burner 200 . The inlet 207 is generally located at the supply end of the startup burner. The fuel generally flows along the length of the startup burner 200 and into the furnace 299 . Air enters the furnace through throat 240 , and may flow across swirler 250 . The swirler rotates thereby aiding fuel and air mixing. Operators may monitor the fuel input and amount of air entering the furnace 299 from the windbox 290 to increase furnace temperature and melt or burn away smelt accumulations. During operation, a startup burner 200 may extend through the multi-door isolation chamber 206 and traverse the windbox 290 . Water wall tubes 270 may bend to create an open area, which defines a throat 240 . In other embodiments, the throats 240 may be further defined by a reinforcing element (not depicted) disposed within the opening defined by the water wall tubes 270 . The reinforcing element may generally conform to the hole defined by the bend water wall tubes 270 and may be made from carbon steel or other material configured to withstand furnace heat.
[0051] An exemplary startup burner assembly 241 may have an observation port 260 through which operators may view the inside of the windbox 290 , throat 240 , and furnace 299 . An operator may look through the observation port 260 to determine the amount of smelt accumulation around the throat 240 . If smelt has accumulated, an operator may insert a rod (not depicted) through port 251 to dislodge the smelt accumulations while the recovery boiler is operational. In an exemplary method, an operator may insert the rod through the multi-door isolation chamber 206 .
[0052] In the exemplary startup burner assembly 241 of FIG. 2 a , the multi-door isolation chamber 206 is configured isolate the startup burner 200 from the furnace 299 and windbox 290 by using outer doors 210 , 216 and inner doors ( FIG. 2 b 220 , 226 ). The outer door comprises a bottom outer door 210 engaging handle 230 b and a top outer door 216 engaging handle 230 c . Handle 230 d engages top inner door 226 , while handle 230 a engages bottom inner door 220 . The outer doors 210 , 216 and inner doors 220 , 226 desirably open inwardly toward the furnace 299 and windbox 290 . In this configuration, pressure generated by the furnace 299 and windbox 290 exerts an outward force on the inner doors 220 , 226 and outer doors 210 , 216 . Inwardly opening doors may reduce the risk of sudden release of hot air and potential smelt splatter if the pivot mechanism 266 fails. If both inner doors 220 , 226 and outer doors 210 , 216 were configured to open outwardly, the pivot mechanisms 266 keeping the inner doors 220 , 226 and outer doors 210 , 216 closed would be more likely to experience prolonged stress due to the windbox-pressure and therefore be more likely to fail spontaneously and expose personnel and nearby equipment to hot, high-pressure air from the windbox 290 . Although the inner doors 220 , 226 and outer doors 210 , 216 desirably open inwardly, other exemplary embodiments may comprise one or more inner doors 220 , 226 and outer doors 210 , 216 opening outwardly away from the windbox 290 and furnace 299 . The bottom inner door 220 and bottom outer door 210 pivot at the bottom of the multi-door isolation chamber 206 in FIG. 2 a . Likewise, the top inner door 226 and top outer door 216 pivot at the top of the multi-door isolation chamber 206 . In other exemplary embodiments, the outer and inner door may comprise two or more doors, one or more of which may pivot on the right side of the isolation chamber 206 , and one or more of which may pivot on the left side of the isolation chamber 206 (see FIG. 5 ). In other exemplary configurations, an odd number of outer doors may be used. In yet other embodiments, an odd number of inner doors may be used. The bottom outer door 210 may have a cut-out portion 213 configured to support the startup burner 200 . The outer door may be a singular outer door. The inner door may be a singular inner door. Nothing in this disclosure limits the combination of aspects of one embodiment with aspects of one or more other embodiments.
[0053] FIG. 2 b is a cross sectional view of an exemplary startup burner assembly 241 . The startup burner 200 may be extracted through the windbox 290 and bottom inner door 220 of the multi-door isolation chamber 206 . Operators may then use handle 230 a to close the bottom inner door 220 of the multi-door isolation chamber 206 . In this exemplary embodiment, the bottom inner door 220 may be a plate of carbon steel or other material suitable to withstand the heat and pressure of the windbox 290 and an occasional splatter of black liquor (not pictured) through the throats 240 of the furnace 299 . Bottom inner door 220 may be configured to provide support for the startup burner 200 as the startup burner 200 is extracted from the windbox 290 . The bottom inner door 220 , when closed, may occupy a portion of the opening 221 created in windbox mounting plate 218 . In other exemplary embodiments, the bottom inner door 220 , when closed, may be configured to occupy substantially all of the opening 221 ; in this manner, a portion of the startup burner 200 may be substantially completely isolated in the internal space 225 of the multi-door isolation chamber 206 .
[0054] In still other exemplary embodiments, the bottom inner door 220 , when closed, may be configured to occupy half of the opening 221 . In yet other exemplary embodiments, the bottom inner door 220 , when closed, may be configured to occupy a portion of the opening 221 . In this manner, a portion of the startup burner 200 may be partially isolated in the internal space 225 defined by the multi-door isolation chamber 206 .
[0055] Thus protected from the furnace environment and so isolated from the windbox 290 , an operator may open the outer door 210 of the multi-door isolation chamber 206 and remove the startup burner 200 from the multi-door isolation chamber 206 with reduced risk of burns due to hot air or molten smelt. In addition to being protected, the operator, by extracting the startup burner 200 , may extend the useful life of the startup burner 200 by removing the startup burner 200 from the recovery boiler completely. By having the startup burner 200 completely removed from the recovery boiler, the operator may maintain, repair, or replace the startup burner 200 while the recovery boiler is operational, while substantially eliminating the risk of injury from the recovery boiler.
[0056] The outer doors 210 , 216 and inner doors 220 , 226 desirably open inwardly toward the windbox 290 and furnace 299 . The pressure created by the furnace 299 and moving air within the windbox 290 exerts a force against the closed inner doors 220 , 226 and outer doors 210 , 216 . By opening inwardly, the closed inner doors 220 , 226 and outer doors 210 , 216 remain locked in position, thereby reducing the risk that door failure will expose operators to immediate harm. An insulating liner 273 may be disposed within the multi-door isolation chamber 206 .
[0057] FIG. 3 depicts a burner end view of an exemplary multi-door isolation chamber 306 in which the outer doors 310 , 316 and inner doors 320 , 326 of the multi-door isolation chamber 306 have pivot mechanisms (see 266 ), which rotate outer doors 310 , 316 and inner doors 320 , 326 of the multi-door isolation chamber 306 . This embodiment further comprises an observation port 360 . The swirler 350 is disposed around the fuel nozzle tip 398 and of the startup burner 300 . The fuel nozzle tip 398 is located at the firing end of the startup burner 300 . In an exemplary method, an operator may look through the observation port 360 to determine the amount of smelt accumulation around the throat 340 . If smelt has accumulated, an operator may insert a rod through the multi-door isolation chamber 306 to dislodge the smelt accumulations while the recovery boiler is operational. By inserting a rod through the exemplary multi-door isolation chamber 306 , an operator may have a more direct path to the throat 340 and may avoid damage to the swirler 350 , which may have been previously caused by poor visibility and suboptimal access due to mechanical interference. An operator may close the bottom inner door 320 to support the startup burner 300 while dislodging smelt. The closed bottom inner door 320 partially protects the operator from stray smelt splatter from the furnace 299 . An operator may desirably close either the top outer door 316 or bottom outer door 310 to provide additional protection from stray smelt splatter when cleaning the throat 340 . In other embodiments, an operator may extend the rod through a port 351 in the outer wall 322 of the windbox 290 . When operators desire to ignite the startup burner 300 , operators generally insert an igniter assembly ( FIG. 4 , 480 ) through mounting tube 383 .
[0058] FIG. 4 is a top-down view of an exemplary startup burner 400 and the swirler 450 extending through the multi-door isolation chamber 406 and the windbox 490 to engage the throat 440 . Water wall tubes 470 form the envelope of the furnace 499 and absorb furnace heat. The startup burner 400 may be removed from the windbox 490 through a housing 491 that spans the length of the windbox 490 . In some embodiments, the housing 491 may have a variable position damper 492 that may be opened and closed to allow air from the windbox 490 into the housing 491 and into the furnace 499 through the swirler 450 and throat 440 . This air maintains combustion at the fuel nozzle tip 498 of the startup burner 400 when active. When the startup burner 400 is dormant or extracted, the variable position damper 492 may be closed substantially completely to prevent air from entering the furnace 499 through the throat 440 . In other embodiments, the variable position dampener 492 may be partially open to accommodate a desired air flow.
[0059] The startup burner 400 may further be removed from the windbox 490 and housing 491 by using the handle 430 a to open the bottom inner door 220 of the multi-door isolation chamber 406 and by pulling the startup burner 400 through the internal space 425 of the multi-door isolation chamber 406 . After closing the inner doors 220 , 226 the startup burner 400 may be partially or substantially completely isolated. Once isolated, the startup burner 400 may be removed through the outer doors 210 , 216 of the multi-door isolation chamber 406 .
[0060] An igniter assembly 480 of the startup burner 400 is depicted in this exemplary embodiment. The igniter assembly 480 may comprise an ionizing flame rod and spark rod 481 and intake ports 482 . Air and natural gas may flow through these intake ports 482 . A mounting tube 483 can position the igniter assembly 480 . This igniter assembly 480 may further comprise safety equipment used to ensure continuous ignition at the fuel nozzle tip 498 of the startup burner 400 . The swirler 450 stabilizes and shapes the main flame within the furnace 499 . In an exemplary embodiment, the mounting tube 483 of the igniter assembly 480 can engage the outer wall 422 of the windbox 490 outside insolation chamber 406 . In another exemplary embodiment, the igniter assembly 480 may be co-extensive with the startup burner 400 and access the windbox 490 through the isolation chamber 406 . In an exemplary embodiment, a flapper valve 484 may be engaged to at least one end of the mounting tube 483 . This flapper valve 484 may be used to prevent pressure loss from the windbox 490 when the igniter assembly 480 is not in place.
[0061] FIG. 5 a is an exemplary embodiment of the multi-door isolation chamber 206 comprising a first inner door 526 and a second inner door 527 that may rotate on a pivot mechanism 535 such as a hinge or slide along tracks 532 (shown in FIG. 5 b ). It is to be understood by one skilled in the art that outer doors (see FIG. 2 , 210 , 216 ) may be configured in similar manner to the inner doors 526 , 527 as described herein. A multi-door isolation chamber 206 comprising two or more inner doors 526 , 527 may be desirable to isolate the startup burner 500 completely in the multi-door isolation chamber 206 prior to extraction. By closing the two or more inner doors 526 , 527 , operators substantially reduce the probability that operators will contact stray droplets of liquor flung through the throat 440 of the furnace 499 because these inner doors 526 , 527 may be used to close the opening 221 defined by the outer walls of the windbox 290 . The first inner door 526 may have a cut-out section 523 configured to complement the perimeter 504 of the startup burner 500 . The outer doors may have a cut-out section (see 213 ) configured to support the startup burner. The first inner door 526 may be substantially closed when removing the startup burner 500 (shown in FIG. 5 b ) such that the cut-out section 523 may be used to support the startup burner 500 as the startup burner 500 is extracted from the windbox 290 of the recovery boiler 107 . Once the startup burner 500 is inside the multi-door isolation chamber 206 , the second inner door 527 may be closed to substantially completely isolate the startup burner 500 in the multi-door isolation chamber 206 . In this embodiment, the second inner door 527 has a flange 528 configured to complement the cut-out section 523 of the first inner door 526 . In other embodiments, this flange 528 may be omitted. Although two inner doors 526 , 527 are used, it is understood that configurations of inner and outer doors known to those having ordinary skill in the art may be used to isolate the startup burner 500 from the windbox environment and furnace environment.
[0062] FIG. 5 b depicts an exemplary multi-door isolation chamber 206 , which comprises a first inner door 526 and a second inner door 527 , each having runners 531 configured to slide along tracks 532 disposed on the windbox mounting plate 218 . In other embodiments, these tracks 532 may be engaged to the inner wall of the multi-door isolation chamber 406 . In still other embodiments, one track per first and second inner door may be utilized. The first inner door 526 may have a cut-out section 523 configured to complement the perimeter 504 of the startup burner 500 . The first inner door 526 may be substantially closed when removing the startup burner 500 such that the cut-out section 523 may be used to support the startup burner 500 as the startup burner 500 is extracted from the windbox 290 of the recovery boiler 107 . Once the startup burner 500 is inside the multi-door isolation chamber 206 , the second inner door 527 may be closed to substantially isolate the startup burner 500 in the multi-door isolation chamber 206 . In this embodiment, the second inner door 527 has a flange 528 configured to complement the cut-out section 523 of the first inner door 526 . In other embodiments, this flange 528 may be omitted.
[0063] FIG. 6 a is a side view of an exemplary cooling carriage 642 that may be used to hold the startup burner 600 and permit cooling after the startup burner 600 has been removed from the multi-door isolation chamber 606 . In this exemplary embodiment, a structural brace 644 having a first end 643 and a second end 645 may be mounted to the outer wall 622 of the windbox 690 . In another exemplary embodiment, the second end 645 may be mounted to the recovery boiler 107 such that the cooling carriage 642 remains aligned with the isolation chamber 606 as the recovery boiler expands during operations. A main support beam 648 may have a first end 647 attached to the first end of the structural brace 643 and a second end 649 perpendicularly attached to the outer wall 622 of the windbox 690 . In another exemplary embodiment, the second end 649 may be mounted to the recovery boiler 107 such that the cooling carriage 642 remains aligned with the isolation chamber 606 as the recovery boiler expands during operations. A carriage assembly linkage 655 may be rotatably mounted to the main support beam 648 such that the carriage assembly linkage 655 may be secured away from the path 602 of the startup burner 600 when not in use. Rollers 657 may be mounted on at least one end of the carriage assembly linkage 655 . These rollers 657 may extend below the path 602 of the startup burner 600 and support the startup burner 600 after the startup burner 600 has been removed from the multi-door isolation chamber 606 . Operators may remove the startup burner 600 from the cooling carriage 642 after the fuel nozzle tip 698 of the startup burner 600 has cooled. In other embodiments, at least one clamp, ring, hook, or other similar securing means (not shown) may be used singularly or in combination with other securing means to support the startup burner 600 as it cools.
[0064] In an exemplary method, operators may deactivate the startup burner 600 and extract the startup burner 600 and swirler 650 through the housing 691 . Operators may then close an inner door 620 and rest the bottom of the startup burner 603 on a cut-out portion 623 of an inner door 620 . Once the inner door 620 is closed, operators may pull the startup burner 600 through the internal space 425 of the multi-door isolation chamber 606 and through the outer door of the multi-door isolation chamber 610 . Operators may then place the startup burner 600 on the rollers 657 of the carriage assembly linkage 655 and allow the startup burner 600 to cool. Once cool, the operators may remove the startup burner 600 from the cooling carriage 642 and store the cooling carriage 642 away until further needed.
[0065] In another exemplary method, the inner door 620 need not be closed before the operator removes the startup burner 600 from the multi-door isolation chamber 606 .
[0066] FIG. 6 b is a front view of an exemplary cooling carriage 642 . The elements correspond to the elements described in FIG. 6 a . In this exemplary embodiment, the rollers 657 may be contoured to support the startup burner 600 either singularly or in combination with at least one other roller.
[0067] FIG. 7 depicts an alternative exemplary isolation chamber in the form of a burner guide sleeve 775 . This exemplary burner guide sleeve 775 comprises a plug 771 at an outer end 777 of the burner guide sleeve 775 and a flapper valve 784 at an inner end 778 of the burner guide sleeve 775 . The burner guide sleeve 775 generally extends into the windbox 790 and may support the startup burner 700 at least partially. The plug 771 may be used to prevent hot air flow from the windbox 790 when the startup burner 700 is in use. The plug 771 may be fixed to the startup burner 700 . In another embodiment, the plug 770 may be slidably engaged to the startup burner 700 . The plug may be made from a high-density, lightweight material configured to withstand air temperature in the windbox 790 . The plug 771 may desirably fill the inner perimeter of the guide sleeve 775 so as to form a seal. In embodiments where the plug 771 is fixed to the startup burner 700 , the length 708 of the plug may be at least the length 709 of the distance between the flapper valve 776 and the throat 740 . In embodiments where the plug 771 is not fixed to the startup burner 700 but is still configured to maintain a seal, the length 708 of the plug 771 may be less than the length 709 between the flapper valve 776 to the throat 740 . In exemplary embodiments in which the startup burner has been extracted from the windbox, the plug 771 may desirably fill the inner perimeter of the guide sleeve and extend through the windbox in substantially the same manner as the startup burner 700 such that the plug 771 may have an end corresponding to the firing end of the startup burner 700 and swirler 750 that substantially blocks the hole left by the extracted swirler 750 . The plug 771 may be made of a material generally known in the art, including a poly-amide-based plastic, or other suitable material configured to withstand the heat of the recovery boiler.
[0068] The flapper valve 784 may rest on the startup burner 700 when the startup burner 700 interfaces with the throat 740 and furnace 799 . When the startup burner 700 is removed past the flapper valve 784 , the flapper valve 784 generally closes and rests on the front lip 794 of the guide sleeve 775 at an angle 9 . The burner guide sleeve 775 may extend partially through the housing 791 within the windbox 790 .
[0069] It will be understood that the modifications of FIGS. 3 through 7 could be employed in combination with one another as well as individually in the assembly of FIG. 1 and the assembly illustrated in FIG. 2 .
[0070] While this invention has been particularly shown and described with references to exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
|
The present disclosure describes a recovery boiler startup burner assembly that can mitigate the harmful effects of smelt fouling, airflow interference, and operator exposure to hot air from the furnace and win box through use of an extractable startup burner and an isolation chamber engaged to a windbox. The present disclosure also describes a method for safely extracting a startup burner from an active recovery boiler as has method for inserting an extractable startup burner into a recovery boiler during operation.
| 3
|
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a U.S. National Phase Application pursuant to 35 U.S.C. §371 of International Application No. PCT/GB2011/000643 filed Apr. 26, 2011, which claims priority to British Patent Application No. 1007023.3 filed on Apr. 27, 2010. The entire disclosure contents of these applications are herewith incorporated by reference into the present application.
FIELD OF THE INVENTION
The present invention relates generally to a seal for a container and particularly to a seal which is intended to be pierced in order to allow access to product in a container.
BACKGROUND
It is known to provide container seals for preserving the contents of the container prior to opening. In many cases the seal is pierced to gain access to the product. When the seal is pierced, the material of the seal may come into direct contact with the product. Depending on the type of seal there may be certain layers which must be present in order to provide it with certain properties, such as the ability to be sealed to the rim of the container and the ability to prevent ingress and/or egress of material to and from the product. These requirements may conflict with the desire to avoid contact of certain materials in the seal with the product.
SUMMARY
The present invention seeks to address the problems with known container seals.
According to a first aspect of the present invention there is provided a pierceable, induction sealable seal for a container opening, the seal comprising a plurality of layers at least one of which is metallic and at least one of which is non-metallic, at least one of the non-metallic layers is complete and in use extends across a container opening to seal it, in which the area over which the at least one of the metallic layers extends is restricted to the region of the periphery of the seal whereby to facilitate induction sealing to the opening but to remain isolated from product in a container upon piercing of the seal.
By having one or more layers with incomplete coverage, the material from the seal which is torn and pushed down during piercing can be controlled. Therefore material which may be incompatible with a product in a container can be present but isolated from the product following piercing. One of the layers is complete. In other words, the layer may extend over substantially the entire area of the seal when viewed in plan or at least over the entire area of a container opening.
The restricted layer(s) may be restricted to the region of the periphery of the liner. This is particularly useful where the layer(s) are involved in fixing the seal to a container rim and/or sealing because they may only be required at the periphery.
The restricted layer(s) may be formed as an annulus. The annulus may therefore define a piercing zone at its centre which does not include any material from the restricted layer(s).
The seal may include a layer of polyethylene terephthalate (PET). The layer of PET may be complete.
The liner may include a layer of aluminium. Aluminium or a similar conductive material may be required for certain applications, such as when the seal will be induction welded to the container rim. The layer of aluminium may be incomplete.
The seal may include a layer of foam such as foamed polyethylene or polypropylene. The layer of foam may be incomplete.
The layers may be secured to each other by adhesive, wax or the like. In use one or more of the layers may separate from each other. For example, some layers may remain on a container and others may be retained in an associated closure.
The seal may be formed as a liner for a container closure. The closure may be a self-piercing closure, with a mechanism for piercing through the seal.
The seal may be formed as an induction seal liner, for example a heat induction sealed liner.
According to a further aspect there is provided a seal as described herein in combination with a container.
According to a further aspect there is provided a seal as described herein in combination with a closure. The closure may be a self-piecing closure.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be more particularly described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a section of a seal formed according to an embodiment of the present invention;
FIG. 2 is a bottom perspective view showing the underside of the seal of FIG. 1 ;
FIG. 3 is a section of the seal of FIGS. 1 and 2 shown fitted into a closure as a liner;
FIG. 4 is a section of the closure/seal of FIG. 3 shown attached to a container neck;
FIG. 5 is a section of the closure/seal/container of FIG. 4 following first removal of the closure;
FIG. 6 is a section of the container/seal of FIG. 6 following piercing of the seal;
FIG. 7 is a side elevation of a seal formed according to an alternative embodiment of the present invention;
FIG. 8 is a top perspective view of the seal of FIG. 7 ;
FIG. 9 is a side view of the seal of FIGS. 7 and 8 shown attached to a container neck rim;
FIG. 10 is a partial section of the seal of FIG. 9 shown following piercing;
FIG. 11 is a partial section of a closure incorporating a liner formed according to the present invention;
FIG. 12 is a perspective section of the closure of FIG. 11 ;
FIG. 13 is a further section of the closure of FIG. 12 ;
FIG. 14 is a section of a body part of the closure of FIG. 11 shown in an unactivation position; and
FIG. 15 is a section of the part of FIG. 14 shown in an activated position.
DETAILED DESCRIPTION
Referring first to FIG. 1 there is shown a disc-shape seal generally indicated 10 . The seal 10 comprises a layer of polyethylene terephthalate (PET) 20 and a layer of foam 30 secured to each other by a layer of adhesive 40 .
The PET layer 20 is complete, in other words it extends completely over the area of the seal in plan. The foam layer 30 is formed as an annulus secured to the underside of the PET layer. Accordingly the layer 30 is incomplete and defines a central region 22 of the PET layer over which the foam layer 30 does not extend.
Referring now to FIG. 3 , the seal 10 is shown to be formed as a liner and 10 is secured into the top of a closure generally indicated 50 . The closure 50 comprises a disc-shape top plate 60 with a cylindrical skirt 70 depending from the periphery thereof. The skirt 70 includes screw thread formations 80 . The seal 10 is weakly adhered to the underside of the top plate 60 by an adhesive layer 15 on top of the PET layer 20 .
In FIG. 4 the closure 50 is shown applied to a container neck 90 . The closure is applied using screw thread formations 95 on the neck corresponding to the formations 80 on the closure.
To secure the seal 10 to the container rim 97 , heat curable adhesive 25 is applied to the rim before application of the closure. Subsequently heat is applied to the top plate 60 to cure the adhesive which bonds the foam layer 30 to the rim 97 .
With the closure fully applied to the liner, in particular the foamed layer 30 , is compressed and forms a seal around the container neck 90 . The heating process also weakens/removes the adhesion between the PET layer 20 and the top plate 60 by at least partly melting the adhesive layer 15 .
FIG. 5 shows the closure and container neck following first removal of the closure. Because the adhesive layer 15 is weakened/removed, when the closure 50 is unscrewed the seal 10 remains on the container neck 90 .
When access to the contents of the container 90 is required the seal must be pierced. In this embodiment, the seal is pierced by a separate tool 95 as shown in FIG. 6 . It will be seen that as the central region of the seal is torn by the tool it will be pushed into the mouth of the container.
Because the foam layer 30 is restricted to the periphery of the seal, this layer will not be pushed into the container mouth and will not potentially come into contact with the product. Therefore only the PET layer 20 will potentially contact the product 85 .
Referring now to FIGS. 7 and 8 there is shown a seal 110 formed according to an alternative embodiment. The seal comprises a layer of PET 120 , a layer of aluminium foil 125 and a layer of foamed polyethylene 127 . The layer of PET 120 is formed as a complete disc, whereas the aluminium and foam layers 125 , 127 are formed as rings which extend around the peripheral region of the PET layer.
The PET layer is present as a barrier layer, to prevent ingress of gases which are deleterious to the container product.
The foam layer is present to form a physical seal around the container rim when a closure is applied.
The aluminium layer is required to attach the seal to a container rim.
The seal is formed as a heat induction sealed liner therefore in the first instance is fitted into a closure, which in this embodiment is a self-piercing closure (not shown). In use the closure is fitted onto a container neck so that the PET layer 120 abuts and fits around the top of the container neck rim 195 as shown in FIG. 9 . Thereafter the seal is secured to the container rim by a heat induction process. The induction process requires the aluminium layer to facilitate bonding of the PET layer to the container rim.
Subsequently, when the self-piercing closure is activated the seal will be pierced. However, because the aluminium and foam layers 125 , 127 are restricted to the periphery of the seal, only the PET layer is in fact pierced and pushed down into the mouth of the container as shown in FIG. 10 . Therefore, only the PET layer 120 will come into contact with product in the container.
Referring now to FIGS. 11 to 13 there is shown a closure generally indicated 210 . The closure 210 comprises a generally cylindrical base 220 .
The closure 210 is intended to be fitted to a container neck (not shown) which at its open end is sealed by a laminar disc-shape liner 260 which in this embodiment will be induction heat sealed into position.
The base 220 comprises a cylindrical sidewall 221 which includes internal screwthread formations 222 for engaging corresponding external screwthread formations on the container neck.
At the closed end of the sidewall, a platform 229 extends radially inwardly. From the inner edge of the platform 229 an upstanding collar 223 is provided. At the opposite end of the collar 223 to the platform 229 a sealing portion 224 extends radially inwardly and defines at its centre an aperture 225 . Approximately half way along the portion 224 an annular sealing leg 226 depends and terminates with a sealing bead 227 . The arm 224 terminates with a wedge-shape portion 228 which includes a downwardly depending section.
A self-closing valve 270 is provided. The valve 270 is of standard construction and briefly comprises a generally triangular section support ring 271 , a J-shape connecting wall 272 and a generally disc-shape concave valve head 273 .
The valve 270 is fitted into the base 220 so that the segment 271 abuts against the portion 228 and the opposingly inclined surfaces allow for a stable interaction.
A piercing member 280 is provided. The member 280 is generally annular and comprises a retention band 281 from which depends a cutting region comprising a plurality of teeth 282 . At the end of the collar 281 opposite the teeth 282 a bead 284 projects radially inwardly. Extending parallel to the collar 281 on the opposite side of the teeth 282 is a retention jaw 285 . In use, with the self-closing valve assembled into the base, the member 280 is snap fitted on to the base so that the bead 284 clips over the bead 227 . At the same time, the jaw 285 engages the segment 271 so that it is held firmly between the portion 228 and the jaw 285 . For this purpose the jaw 285 includes an inclined surface oppositely inclined to that side of the segment 271 .
A liner 260 is provided and fits into the closure under the platform 229 . The liner includes: an annular layer of foamed polyethylene 207 which seals against the platform; an annular layer of aluminium foil 205 attached to the layer 207 ; and a disc-shape layer of PET 202 attached to the layer 205 .
In use the closure 210 is applied to a container neck so that the liner 260 contacts the neck rim. The liner 260 can then be induction sealed onto the neck rim.
The neck 223 is formed as a flexible membrane so that it can be pushed down from the position shown in FIG. 14 to the position shown in FIG. 15 . In doing so, the piercing member 280 is pushed down to contact the panel 260 . This pierces only the PET layer 202 of the panel because the layers 207 , 205 are confirmed to the peripheral region not contacted by the piercing member. Subsequently product can flow from the container under the control of the self-closing valve 270 .
|
A pierceable, induction sealable seal for a container opening, the seal comprising a plurality of layers at least one of which is metallic and at least one of which is non-metallic, at least one of the non-metallic layers is complete and in use extends across a container opening to seal it. The area over which the at least one of the metallic layers extends is restricted to the region of the periphery of the seal whereby to facilitate induction sealing to the opening but to remain isolated from product in a container upon piercing of the seal.
| 1
|
FIELD OF THE INVENTION
This invention is related generally to swimming pool cleaners and, more particularly, to swimming pool cleaners capable of operation without human assistance.
BACKGROUND OF THE INVENTION
Automatic swimming pool cleaners are widely used to relieve swimming pool owners of the time-consuming and arduous task of hand-operated vacuuming of underwater pool surfaces. Such manual task, which typically involved the use of long extension handles and clumsy manipulation of a water-suction head held under water and at a distance, have largely been made a thing of the past by automatic systems. In recent decades, many automatic swimming pool cleaners of various types have been available and in wide use around the world.
A typical automatic swimming pool cleaner has a suction head including a housing, a chamber open at its lower side, and a pivotable connector to which a long flexible hose is attached to allow movement of the swimming pool cleaner in the pool. The hose typically extends toward a remote pump which causes water flow from along the pool bottom surface, through the chamber and into the hose, removing dirt and debris from the bottom surface of the pool. The flow of water caused by the pump is harnessed in various ways to cause movement of the swimming pool cleaner.
While automatic swimming pool cleaners are highly beneficial, there are times, regardless of which cleaner may be in use for automatic cleaning, when it may be considered desirable for various reasons to engage in some manual cleaning, particularly of limited areas of underwater pool surfaces. It may be desirable, for example, to engage in manual cleaning in order to overcome a specific problem, such as a particularly bad deposit of algae, or to clean an area where dirt or debris has just been deposited. It some cases it may be considered desirable to complete an underwater surface area without waiting for the automatic pool cleaner to reach such area.
In some cases, it may be desirable to clean certain underwater surfaces which are not reachable by the automatic pool cleaner. An example of such unreachable surfaces would be the underwater surfaces of a hot tub or spa which is adjacent to the swimming pool, as is often the case. Another example may be the surfaces of underwater steps in the swimming pool itself.
Because of the nature of various automatic pool cleaners, adapting such cleaners for use in manual cleaning would be problematic at best. Certain pool cleaners have wheels, tracks and/or various other drive mechanisms which engage the pool bottom surface, making it unreasonable and impractical to adapt them for manual use. Certain other pool cleaners, because they are rather tightly held against the pool bottom surface during operation, could not be effectively manipulated even if otherwise adapted for manual use. Various automatic pool cleaners are also unreasonably bulky and heavy to even consider adaptation for manual use.
Furthermore, typical manual pool cleaning suction heads are devoid of powered scrubbing devices. Such devices typically depend on the suction flow of water and/or mechanical force provided by manipulation of such devices by the user--through the handle. Thus, manual pool cleaning devices are often less effective than might be desired and can require considerable operator exertion.
There has been a clear need for improved swimming pool cleaning apparatus, and it is such need to which the invention described herein is addressed.
OBJECTS OF THE INVENTION
It is an object of this invention to provide a swimming pool cleaner which overcomes some of the problems and shortcomings of devices of the prior art.
Another object of this invention is to provide a dual-use swimming pool cleaner, that is, a swimming pool cleaner usable in both automatic cleaning and manual cleaning.
Another object of this invention is to provide a dual-use swimming pool cleaner which reliably and effectively cleans the underwater surfaces of a swimming pool.
Another object of this invention is to provide improved manual swimming pool cleaning apparatus.
Another object of this invention is to provide manual swimming pool cleaning apparatus having improved cleaning effectiveness.
Another object of this invention is to provide a manual swimming pool cleaning apparatus requiring less operator exertion than with certain other manual pool cleaning apparatus.
Another object of this invention is to provide an improved automatic swimming pool cleaner which is also usable manually to clean usually unreachable surfaces such as the underwater surfaces of hot tubs and spas adjacent to the swimming pool in which the automatic pool cleaner operates.
Still another object of this invention is to provide dual-use swimming pool cleaning apparatus which is free of turbines, gears, wheels and other similar moving mechanical devices.
Another object of this invention is to provide dual-use swimming pool cleaning apparatus which is simple in construction and highly reliable in operation.
These and other important objects will be apparent from the descriptions and drawings herein.
SUMMARY OF THE INVENTION
This invention is an improvement in swimming pool cleaning apparatus of the type powered by water flow therethrough. More specifically, this invention, in one form, is a dual-use swimming pool cleaner--that is, an automatic pool cleaner which is also effectively and easily usable for manual pool cleaning, as selected by the operator. In another form, this invention is an improvement in manual pool cleaning apparatus, providing powered scrubbing of underwater pool surfaces.
The apparatus of this invention includes a housing forming a chamber open at its lower side, a hose connection device on the housing, a handle attachment device on the housing, and a handle detachably secured to the handle attachment device. The pool cleaning apparatus of this invention can be used in an automatic mode without attachment of the handle, or the apparatus can be withdrawn from autocratic operation and used for manual cleaning of various underwater surfaces, including those of an adjacent hot tub or spa, such use being facilitated by attachment of the handle. And, the apparatus of this invention is a manual cleaner with powered scrubbing.
A highly preferred dual-use pool cleaner of this invention includes: a vibrator device secured to the housing to vibrate the head in response to water flow through the chamber; main bristles secured with respect to the housing and projecting downwardly to terminate in main-bristle ends for supporting the pool cleaner on a surface to be cleaned, such main bristles inclined in a first direction such that vibration causes forward movement; and secondary bristles in fixed position with respect to the housing and projecting downwardly to terminate in secondary-bristle ends positioned for engagement with the surface to be cleaned, such secondary bristles inclined in a second direction such that, upon contact thereof with the surface to be cleaned, vibration causes a turning away from the forward direction.
This sort of automatic pool cleaner drive system makes an effective and efficient dual-use pool cleaner possible. Such pool cleaner is light in weight and has no drive wheels, treads or other devices. Each of these favorable characteristics facilitates adaptation for manual cleaning when desired.
In certain of such preferred embodiments, the secondary-bristle ends are positioned with respect to the common plane to at least periodically engage off-planar portions of the surface to be cleaned. In automatic-mode usage, this allows turning to at least intermittently occur.
In highly preferred embodiments, the housing has a lower edge surrounding the chamber and the secondary flexible bristles are affixed along the lower edge. In certain preferred dual-use pool cleaners in accordance with this invention, the secondary bristles project both outwardly and downwardly and are disposed at a rotational angle such that their engagement with pool side surfaces causes a turning deflection in pool cleaner movement. In such embodiments, it is highly preferred that the main bristles be secured along the lower edge of the housing, with the secondary bristles positioned outside the main bristles. The main bristles are preferably secured to a main-bristle ring which is removably secured to the housing. Likewise, the secondary bristles are preferably secured to a secondary-bristle ring which is removably secured to the housing.
In certain preferred embodiments, the hose and the handle are pivotably connected to the housing. Most preferably, the hose connection device is a spherical joint and the handle is attached to the spherical joint.
This invention, in another form, is manual pool cleaning apparatus of the type having a housing forming a chamber open at its lower side, a hose connection device on the housing allowing water to be drawn through the chamber, and a handle secured to the housing to allow an operator to move the apparatus along underwater surfaces to be cleaned. The invention includes a vibrator secured to the housing to vibrate the housing and flexible bristles secured with respect to the housing at off-center positions, such bristles projecting downwardly to terminate in bristle ends for supporting the pool cleaner on a surface to be cleaned. The vibration of the housing and bristles enhances cleaning action of the brush. In a particularly preferred form, the bristles are inclined such that, when their ends engage a horizontal surface, they deviate from vertical in a substantially common rotational direction. This allows vibration to cause rotation of the apparatus, thereby giving an extra scrubbing action in a manual pool cleaner.
In such pool cleaning apparatus, the vibrator is preferably a device which vibrates in response to water flow through the chamber. The housing preferably has a lower edge surrounding the chamber and the bristles are affixed along the lower edge. Most preferably, the bristles are secured to a bristle ring which is removably secured to the housing. Preferably, the hose and the handle are pivotably connected to the housing. Most preferably, the hose connection device is a spherical joint and the handle is attached to the spherical joint; this facilitates the aforementioned rotational motion.
As manual or dual-use pool cleaners, the devices of this invention provide capabilities and performance unlike anything known to date.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective of a preferred dual-use automatic swimming pool cleaner in accordance with this invention.
FIG. 2 is a front elevation of the device of FIG. 1.
FIG. 3 is a rear elevation.
FIG. 4 is a side elevation.
FIG. 5 is a top plan view.
FIG. 6 is a bottom plan view.
FIG. 7 is an exploded view.
FIG. 8 is a sectional view taken along section 8--8 as indicated in FIG. 5.
FIG. 9 is a sectional view taken along section 9--9 as indicated in FIG. 5.
FIG. 10 is a side view of an adjustment device which is used for adjusting the vertical position of a portion of the secondary-bristle ring.
FIG. 11 is a right side elevation of FIG. 10, showing the head of the adjustment device.
FIG. 12 is a left side elevation of FIG. 10, showing the other end of the height adjustment device.
FIG. 13 is an enlarged exploded perspective view of the vibrator device used in the dual-use automatic swimming pool cleaner.
FIG. 14 is a partially cutaway side elevation of the main-bristle ring.
FIG. 15 is a partially cutaway side elevation of the secondary-bristle ring.
FIG. 16 is a partially cutaway side elevation of a secondary-bristle group.
FIG. 17 is a side elevation of a preferred manual pool cleaner in accordance with this invention.
As will be noted, for reasons of convenience several of the figures represent bristles somewhat schematically, rather than in actual form. The required characteristics of such bristles, however, is disclosed by such figures and by the written descriptions herein.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1-16 illustrate a dual-use automatic swimming pool cleaner suction head 20 in accordance with this invention. Suction head 20 has a housing 22, a chamber 24 (see FIGS. 6, 8 and 9) which is open at the lower side of housing 22, and a pivotable hose connection 26, more specifically, a spherical joint, on housing 22 allowing pivotable connection of a hose 28 through which a remote suction pump (not shown) causes water flow through chamber 24 and into hose 28, removing dirt and debris from the underwater surface of the pool.
Lugs 27 at hose connection (spherical joint) 26 are used to removably attach an elongate handle (pole) 27a to housing 22. Handle 27a is removed during automatic pool cleaning operations and attached for manual operations. Handle 27a is attached by means of a removable pin 27b.
As shown best in FIGS. 5, 6, 8 and 9, chamber 24 includes a central outflow portion 24a and a surrounding inflow portion 24b which extends to the periphery of housing 22. As shown in FIGS. 6-9 and 13, suction head 20 includes a vibrator 30 in outflow portion 24a of chamber 24. Vibrator 30 is pivotably secured to housing 22 by means of a shaft 30a, and is designed to freely oscillate within outflow chamber portion 24a in response to water flow through chamber portion 24a. As shown best in FIGS. 7 and 8, shaft 30a is journaled in holes 30b in housing 22 and is held in place by retainer plates 30c which are engaged with housing 22.
As shown in FIGS. 7, 9 and 13, vibrator 30 has a crescent-like or airfoil-like cross-section and is located in dome-like outflow chamber portion 24, with the convex side of vibrator 30 oriented toward hose connection 26. The profile and dimensions of vibrator 30 have been developed to provide a self-starting and relatively constant speed vibration which is powered by the flow of water up toward outlet hose 28. Flow of water causes an oscillation of vibrator 30, and the oscillatory momentum and impact forces (including movements of water mass) are imparted to housing 22 to cause vibratory motion.
As shown in FIGS. 6-8 and 13, a pair of arc-like sliding seals 30d are carried in lateral slots 30e on either opposite edge of vibrator 30 in position to engage opposed inner side walls 30f of chamber portion 24. Sliding seals 30d serve to seal vibrator 30 to side walls 30f and prevent excessive by-pass of water and yet allow sand or other small particles to escape to avoid clogging and lock-up and to avoid damage to parts. Sliding seals 30d can move inwardly as necessary to accommodate the passing of sand or other particles.
Sliding seals 30d are forced toward side walls 30f by the difference in hydraulic pressure between opposite edges of each of the sliding seals. Lower pressure fluid is exposed to seal outer edges 30g than is exposed to seal inner edges 30h (see FIGS. 6, 7, 8 and 13), and the higher pressure along seal inner edges 30h pushes seals 30d outwardly toward the lower pressure or suction sides of seal 30d (that is, in the direction toward seal outer edges 30g), causing engagement with side walls 30f.
As shown in FIGS. 6-9 and 13, best in FIG. 13, the lateral slot-forming portions of vibrator 30 have deep notches 30i which facilitate effective operation of the pressure differential in allowing pressure-driven outward movement of sliding seals 30d. Notches 30i also serve to fully expose much of the surfaces of seals 30d, allowing seals 30d to remain free to move within lateral slots 30e--by reducing or eliminating spaces where sand or dirt particles could accumulate to interfere with operation.
As already noted, vibrator 30 causes vibration of housing 22 as water passes through suction head 20. And, vibration acts through inclined bristles or other like flexures to cause forward movement of suction head 20. Housing has a lower edge 32 which surrounds chamber 24, and secured along lower edge 32 are main bristles 34 such bristles forming something of an annulus of main bristles 34. More specifically, main bristles 34 are secured to a main-bristle ring 34a and such ring is removably secured to housing 22 along lower edge 32.
Main bristles 34 project downwardly to terminate in free main-bristle ends 34b which are disposed in a common plane and support suction head 20 on an underwater swimming pool surface to be cleaned. FIGS. 2-4 include a reference line 36 which is representative of a planar horizontal pool bottom surface, that is, a surface to be cleaned; as shown in FIGS. 2-4, such line is also representative of the common plane in which main-bristle ends 34b are disposed, given that in such views suction head 20 is supported by surface 36. The orientation of bristles will be described herein by reference to a vertical direction with respect to a horizontal surface such as that represented by reference line 35.
Main bristles 34 are affixed to main-bristle ring 34a at an angle; they deviate from vertical in a common direction at all locations about ring 34a. Such inclination, or deviation from vertical, is preferably about 8° to 18°, more preferably about 10° to 14°, with about 12° most preferred. This inclination of main bristles 34 about main-bristle ring 34a is illustrated best in FIG. 14, the breakaway portion of which shows that bristles on the far side of main-bristle ring 34a are angled in the same direction as those on the near side. Vibration of housing 22, acting through the combined rapid small motions of the many main bristles 34 about ring 34b, causes forward motion of suction head 20.
Suction head 20 has three groups of secondary bristles. These include two inside secondary-bristle groups 38 and 40 and an outer annulus of side secondary bristles 42 on secondary-bristle ring 42a. All of such secondary bristles, during operation of suction head 20, are in fixed vertical positions, although adjustment is possible with respect to bristles 42 of secondary-bristle ring 42a. All of such secondary bristles are inclined, that is, deviate with respect to the vertical direction. Such angle of inclination is preferably about 8° to 18°, more preferably about 10° to 14°, with about 12° most preferred, but such bristles are mounted so that most are inclined in a direction or directions different than the direction of inclination of main bristles 34.
As earlier described, contact of secondary-bristle ends with the surface to be cleaned as suction head 20 moves therealong such surface causes turning in the direction of movement of suction head 20. That is, the vibration causes a turning of the head away from the forward direction by virtue of the vibratory action of the secondary bristles--as with the main bristles, but in a different, and therefore turning, direction. The extent of turning depends on the extent of secondary bristle end contact with the surface to be cleaned.
Secondary-bristle groups 38 and 40 are secured to the downwardly-facing middle surface 22a of housing 22, a surface surrounded by housing lower edge 32. See FIGS. 6-9 and 16. Secondary bristle groups 38 and 40 are secured to bristle blocks 38a and 40a, respectively, which are secured with respect to housing 22 such that the bristles of bristle groups 38 and 40 are in fixed vertical positions, with their bristle ends 38b and 40b at or about at the aforementioned common plane which is defined by main-bristle ends 34b.
As shown best in FIG. 6, bristle blocks 38a and 40a are attached within securement walls 38c and 40c, respectively, which are formed on (and are part of) downwardly-facing middle surface 22a of housing 22. Securement wall 38c is shaped with a tapered corner such that one of the bristle blocks, in this case bristle block 38a, can be secured therein in only one orientation--that is, with its secondary bristles 38 inclined in a direction different than the direction of inclination of main-bristles 34. Bristle block 38a cannot be reversed in its orientation. On the other hand, securement wall 40c is generally rectangular in shape without any irregular features which would limit the manner in which bristle block 40a is inserted therein.
Thus, bristle block 40a may be removed, reversed in orientation, reinserted and reattached within securement wall 40c, allowing its secondary bristles to be in either of at least two different, orientations. The illustrated arrangement has secondary bristle groups 38 and 40 inclined in opposite directions--that is, in a common direction when considered rotationally--and this serves to impart an enhanced rotational motion to suction head 20, thus facilitating turning of suction head 22 from its direction of forward movement.
It has been found that the irregularities in the otherwise flat underwater surfaces of swimming pools--that is, portions which are off-flat or off-smooth surfaces--interact with secondary bristles as suction head 20 moves about a swimming pool under the vibratory action of main-bristles 34. More turning is achieved if the ends of the secondary bristles protrude more from the bottom of housing 22; less turning is achieved if the secondary-bristle ends are recessed a bit. It has been found that locating secondary bristle groups 38 and 40 such that bristle ends 38b and 40b are at or very near the aforementioned common plane provides ample random turning action. This turning action can be either enhanced or controlled by reversal of the orientation of bristle group 40.
As shown in FIGS. 2-4 and 6-9, best in FIGS. 8 and 9, ring 42a to which secondary bristles 42 (that is, "side" secondary bristles) are secured, is secured to housing lower edge 32 in a position which is concentric with main-bristle ring 34a at a position outside (that is, radially outside) main-bristle ring 34a. Both rings 34a and 42a are removably secured along lower edge 32, and may therefore be replaced when worn.
Side secondary bristles 42 project both outwardly and downwardly and terminate short of the common plane indicated by reference line 36 (in FIGS. 2-4). As shown in FIG. 15, which includes a breakaway portion allowing illustration of bristle orientations on both the near side and the far sidle of secondary-bristle ring 42a, secondary bristles 42 are disposed at a common rotational angle--about 12° to vertical--such that engagement of bristle ends 42b with pool bottom surfaces causes a turning deflection of suction head 20. And, in addition to such rotational angle, bristles 42 are oriented to project radially outwardly, preferably about 16° to 24° from vertical, most preferably about 20°. This facilitates engagement with pool side walls as they are approached by suction head 20, and the combination of rotational and radial angling causes turning of suction head 20 when such bristles hit a side wall.
As shown in FIGS. 2-4, 6 and 9, secondary-bristle ring 42a is in a tilted orientation such that the ends of its rear bristles 42r, that is, its bristles generally along the rear circumferential portion of ring 42a, are at a lower position than are the ends of its front bristles 42f, that is, its bristles generally along the front circumferential portion of ring 42. The ends of the bristles of secondary-bristle ring 42 at circumferential portions between the front and the rear are at levels therebetween. The rear circumferential portion of secondary-bristle ring 42a is referred to herein as a low circumferential portion. Its level is because of the tilt of ring 42; all bristles 42 are of substantially equal lengths.
Not only is ring 42a tilted, but the extent of tilt of ring 42a is adjustable. As shown in FIGS. 8 and 9, the upper surface of ring 42a is against ring-placement surface 42c which is part of the under surface of housing 22 along housing lower edge 32. Ring-placement surface 42c, while planar, is tilted with respect to a horizontal plane such that ring 42a is tilted.
As illustrated best in FIG. 9, between the rear circumferential portion of ring 42a and the adjacent portion of ring-placement surface 42c is a tilt-adjuster 44. Tilt-adjuster 44, shown in detail in FIGS. 10-12, has an inner end which is rotatably secured to housing 22, an outer end 44b by which the rotational orientation of tilt-adjuster 44 is set (for example, by using a screw driver), and a middle camming portion 44c. As shown best in FIG. 12, camming portion 44c has four sides, each of such sides having a different spacing from the axis of tilt-adjuster 44.
In the embodiment illustrated, tilt-adjuster 44 adjusts the tilt of secondary-bristle ring 42a between an orientation in which the ends of rear bristles 42r are at about the level of common plane 36 (and, thus, at about the level of main-bristle ends 34b) and an orientation in which the ends of rear bristles 42r are about three millimeters above common plane 36. Adjustments can be made to intermediate positions in which the ends of rear bristles 42r are either one or two millimeters above common plane 36. Outer end 44b of tilt-adjuster 44 is marked as a guide for such adjustment. When in its highest position of adjustment, the ends of front bristles 42f are still at a level about three millimeters above the level of the ends of rear bristles 42r.
This adjustability in the vertical positions of secondary-bristle ends 42b provides a further way to assure that the turning action provided by the secondary bristles of suction head 20 is appropriate for effective cleaning of a particular swimming pool.
As illustrated in FIGS. 6-9, a skirt 46, which is concentric with bristle rings 34a and 42a, projects downwardly from housing 22 at a position radially inside main-bristle ring 34. Bristle rings 34a and 42a and skirt 46 are configured and dimensioned for engagement with one another to facilitate assembly of suction head 20. Skirt 46 extends downwardly to a skirt lower edge 46a which is spaced well above the ends of both main bristles 34 and secondary bristles 42, that is, above the ends of the bristles of both bristle rings. Such spacing determines the gap through which water and debris will pass in entering housing chamber 24, and the gap must be small enough to assure sufficient turbulence of water flow at and between bristles as they engage the pool surface to be cleaned, and large enough to allow passage of dirt and debris.
FIG. 17 illustrates a simpler suction head 50 which is designed for manual use. Suction head 50 has a single removable ring of bristles 52 about the lower edge of its housing. Unlike suction head 20, suction head 50 has no tilt adjustment feature. However, in most other respects, including the presence of vibrator 30, suction head 50 is similar to suction head 20 of the dual-use automatic pool cleaner described above.
Bristles 52 are similar to secondary bristles 42 (described above) in that they are disposed at a common rotational angle--about 12° to vertical--such that engagement of bristle ends 52a with underwater pool surfaces causes a turning deflection of suction head 50. Such turning, which occurs while the operator grips handle 27a to manipulate suction head 50, is allowed to occur by virtue of the aforementioned spherical joint 26. Furthermore, such turning is facilitated by the vibratory forces described above. The turning of suction head 50 provides enhanced scrubbing action.
Unlike secondary bristles 42, bristles 52 are not outwardly (radially) inclined; they are only rotationally inclined; that is, bristles 52 are essentially tangential to an imaginary cylinder generally at their location and each bristle is generally along a line which is a skew line with respect to the axis which is defined by the bristle ring. Outward (radial) inclination of the bristles would be acceptable, but for a manual-use pool cleaner such inclination would provide no important advantage.
In certain embodiments, the bristles of a manual cleaner in accordance witch this invention need not be inclined, either rotationally or outwardly. Vibratory action alone is sufficient to enhance the cleaning action. Furthermore, movement of the suction head along underwater surfaces tends to be facilitated by such vibratory action.
Many variations are possible in arrangement and configuration of bristles and other parts as required. The parts of this invention may be made using known materials and molding and forming methods well known to those skilled in the art. The housings, vibrators, hose connectors, tilt-adjuster, and the rings and blocks for bristle mounting are preferably made of suitable rigid plastics. The housings can be molded with all or most of their required functional elements and features integrally formed as parts or features thereof. The bristles are preferably made of common bristle materials which are flexible and resilient, and thus facilitate the moving actions described above. Sliding seals 30d are made of fairly rigid seal materials, one preferred material being a Dupont Delrin acetal material.
A wide variation of materials, part manufacturing methods and assembly methods can be used.
While the principles of this invention have been described in connection with specific embodiments, it should be understood clearly that these descriptions are made only by way of example and are not intended to limit the scope of the invention.
|
An automatic swimming pool cleaner of the type driven by water flow, having a housing forming a chamber open at its lower side, pivotable attachment of a hose, and a handle pivotably and detachably secured to the housing, such that the pool cleaner can be used manually or automatically as desired. Various embodiments of the invention include vibratory bristle drive to provide forward motion, directional change, rotational scrubbing, and/or vibratory scrubbing action for dual-use (automatic or manual) and manual cleaning apparatus.
| 4
|
This is a divisional application based on the application bearing application Ser. No. 08/554,037 filed Nov. 6, 1995, now U.S. Pat. No. 5,630,803.
BACKGROUND
This invention relates to safety cap assemblies for needles, and in particular, safety cap assemblies for needles used in health-care related procedures.
Needles are, of course, employed in a wide variety of dental and medical procedures, including giving vaccines to patients, the injection of antibiotics, anesthetics, medicines, etc., the drawing of blood samples, intravenous feedings, and so on. Virtually all of these procedures subject medical personnel to the dangers of accidental sticking of the needle into a portion of their own bodies. The danger to the medical professional is primarily due to the possibility of accidentally injecting him or herself with an infectious pathogen derived from the patient after an injection has been delivered to the patient. At the present time, one need only mention the dread acronym "AIDS", (Acquired Immune Deficiency Syndrome) to understand the very real fears of the health professional.
Numerous devices have been suggested and employed to alleviate this problem. However, these devices and techniques require the knowledgeable, conscious cooperation of the physician, dentist, or nurse. Any distraction at the moment a used needle should be safety capped can result in a needle remaining uncapped, and hence a danger to anyone who might come in contact with it. This invention overcomes these disadvantages by providing a safety cap for needles that automatically safety caps the needle at the precise moment the needle is withdrawn from the patent.
The primary object of this invention is to provide a safety cap assembly for needles which automatically safety caps the needle at the moment the needle is withdrawn from the patient, thereby significantly reducing the posssibility of accidental injection.
A further object of the invention is to provide for automatic safety capping of used needles without the requirement of any operator attention.
An additional object of the invention is to provide for automatic safety capping of used needles without the requirement of any operator manipulation to accomplish this safety capping.
Still another object is to provide an automatic safety cap assembly for needles which is light in weight and inexpensive to manufacture.
An additional object of the invention, is to provide an automatic safety cap assembly that cannot inadvertently expose a used needle.
Another object of the invention is to provide an automatic safety cap assembly for virtually any length and gauge of needle.
SUMMARY
These and other objects are obtained in the instant invention of a safety needle cap for needles used in health-care related procedures.
Syringes, medicine delivery systeis, etc. (hereinafter referred to as a "system") are supplied to the medical professional in a variety of ways. They may be made of glass or plastic, with attached, or to be attached needles usually being fabricated in metal, often stainless steel. A system may be supplied filled with appropriate medications, etc., or empty, depending upon the use to be employed. In any case, when a system combined with a needle is being used, the needle is connected to the base of the system by means of an enlarged structure (relative to the diameter of the needle itself) which is either a structural part of the needle, or the system to which the needle is affixed. This enlarged structure which connects the needle to the system, providing a conduit within this structure for fluid flow between the needle and the syringe, is commonly referred to as the needle "hub".
I have found that a safety cap means and an elastic sheath means combination can be fabricated so as to be put in place on virtually any needle assembly, including needle-hub assemblies and individual needles packaged in their own sterile environment. And, of course, the safety cap-elastic sheath assembly combination can be supplied already in place on systems with needles previously connected. The safety cap means of the invention consists essentially of a cap, which can be fabricated in metal or preferably economically molded in a suitable plastic such as, for example, polycarbonate, or any material, which is impenetrable for the particular gauge needle to be enclosed. The elastic sheath means attached to the safety cap means can be fabricated in a variety of resilient materials, such as for example, latex or natural rubber, plastic elastomers, or even plastic or metal springs. By the term "elastic", it is meant a material or structure which is capable of being stretched or compressed, and which, upon release of the stretching or compressing forces, returns substantially to its original shape.
In a first version of the invention to be described, one end of a latex rubber sleeve is attached over the needle hub, while at the other end of the sleeve, a safety needle cap is attached. The safety needle cap can be in a variety of shapes and sizes, a tubular shape being considered practical. This tubular shaped cap is completely open at one end and is connected to the elastic latex sleeve. The other end of the cap is closed except for an opening just large enough to accommodate passage of the particular gauge needle being used. The safety needle cap is attached to the sleeve so that the needle opening at the end of the cap is sufficiently misaligned from axial alignment with the needle, when the latex sleeve is not being compressed, so as to preclude accidental, re entry of the needle through the hole.
In this embodiment, to use the system, the operator would manually position the safety cap so that its opening is in axial alignment with the needle. He would then push the needle through the opening in the cap- the elastic, latex sleeve now being compressed and put under tension by this action of the operator. Depending on the inherent resilience of the elastomeric material employed, axially extending slits, if necessary, running partially along the length of the latex sheath, can facilitate this compression of the sheath. With the needle now exposed, the health professional can now proceed and insert the needle into the patient. The safety needle cap now is in contact with the patient, as for example, the arm of the patient, the cap simply riding back over the needle as the sheath is further contracted by the force applied by the health professional in inserting the needle to the required depth. After the injection, the operator simply withdraws the needle from the patient without the necessity of any thought being given to the safety needle cap. The instant the needle is free of the patient, the elastic tension in the compressed latex sheath is released, causing the safety cap to snap back to its original, off-axis or quiescent position. The needle tip is now safely contained within the needle cap where, of course, it cannot, inadvertently reenter the cap opening. The enclosed needle-hub combination can now be safely disposed of by a health professional, or technician, without any danger of accidentally causing the tip of the needle to protrude from the cap. The entire capping procedure is accomplished automatically, and without reference to the alertness or lack thereof of the operator.
Additional conveniences can be added to the above described device and procedure. For example, in a second version to be described, the safety needle cap-elastic sheath assembly can be supplied with a safety needle assembly enclosure having slots along its length to accommodate oppositely positioned projecting arms affixed to the safety needle cap. In this version, the cap and sheath means and needle would be supplied enclosed within this needle assembly enclosure. This is done with or without the assembly already in place on a system. The projecting arms on the safety needle cap would project through the slots within the safety needle assembly enclosure, the needle is in axial alignment with the needle opening within the cap, the tip of the needle now protruding through this needle opening. In this manner, the device is supplied in a ready-to-operate configuration. To use this version of the invention, the operator places his or her fingers on the projecting arms of the safety needle cap, removes the safety needle assembly enclosure, and proceeds as described in the first version of the invention with the injection. Again, after the needle is removed from the patient, the safety needle cap automatically snaps back to an off-axis position where the cap opening is out of axial alignment position with the needle, so that it is safely captured within the cap.
Two basic designs for the safety cap are disclosed. The first is relatively simple and includes a front face portion including an axially disposed, needle hole of sufficient size so as to accommodate the needle gauge employed. As described, the tubular cap includes cylindrical sidewall means that connects to the elastic sheath means. The sidewall means as assembled to the elastic sheath means extends backwards, in the direction of the needle hub, a sufficient distance so that the needle tip is captured within the volume defined by said front face portion and the distal end of the sidewall.
A second cap design includes a front face portion wherein the needle opening comprises a frusto-conically shaped opening, including a smaller opening on the interior surface of said front face portion and a larger opening on the exterior surface of said face portion. A second, rearwardly disposed face portion includes a second opening and a tubular extension extending rearwardly therefrom, the axis of the second opening and tubular extension being offset from the axis of the openings in the front face portion. This axis offset feature leverages the safety cap, in relation to the needle, so that when the elastic sheath means is in its released, quiescent disposition, the axis of the needle is offset from the axis of the opening in the front face portion of the cap.
The frusto-conical opening in the front face portion is adaptable to be able to retain gauze or similar material to capture and absorb body fluids as the needle, after use, is enveloped within the cap volume defined by the front face portion and sidewalls.
Additional safety enhancing features for use with the cap of either design are disclosed. These include a flap member, hingedly connected to the cap sidewall and disposed in relation to the needle to close off the opening in the front face portion after the device is released from the compressed, sheath means, position. Alternately, the area in the vicinity of the juncture of the sidewall and face portion can be packed with styrofoam or similar material which will capture the needle tip in the sheath means-released position.
In a third version of the invention to be described, the elastic sheath means can be in the form of a metal or plastic spring. The purpose of this spring type of elastic sheath means is the same as for the previous two versions, i.e., to maintain the safety cap in a position so that it will automatically snap back over the needle, with the needle opening within the cap out of alignment with the axial alignment of the needle, after the needle has been withdrawn from the patient. The spring can be enclosed in its own fabric sheath so as to facilitate its connection to the safety cap and needle hub.
A further embodiment depicts the safety cap configured in an "elbow" form. In this version the axial misalignment as is necessary between the cap and the needle in the relaxed, quiescent state is inherent in the cap design.
As will be more fully discussed, the structure of the safety needle cap assembly of the invention can have further modifications to virtually rule out any possibility of inadvertently repositioning the safety needle cap after use in a way that would permit the tip of the needle to re-emerge from the needle opening within the cap. Obviously, on all versions cited above, a sterile safety package, such as a safety foil, can be provided to enclose any described safety needle cap means and elastic sheath means assembly as supplied with or without needles and syringes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational, sectional view of one version of the safety needle cap assembly of the invention.
FIG. 2 is an elevational, partial sectional view of the version of the safety needle cap assembly of FIG. 1, illustrating the device ready for use.
FIG. 3 is an elevational view of the device shown in FIGS. 1 and 2, illustrating the position of the safety needle cap after use.
FIG. 4 is an elevational, partial sectional view of a version of the invention, showing a safety needle cap assembly enclosure and modified safety needle cap positioning the needle in ready for use, axial alignment with the needle opening within the cap.
FIG. 4A is a top plan view of the safety needle cap assembly enclosure and syringe depicted in FIG. 4.
FIG. 4B is a view of the cap assembly of FIG. 4A, taken along lines 4B--4B in that view.
FIG. 5 is an elevational view of the invention depicted in FIG. 4, illustrating the position of the safety needle cap after use.
FIG. 6 is an elevational, partial sectional view of a version of the invention which employs a spring for the elastic sheath means, and depicts a second embodiment of the safety needle cap means.
FIG. 6A is a top plan view of a part of the safety needle cap assembly enclosure and syringe depicted in FIG. 6.
FIG. 7 is an elevational view of the invention depicted in FIG. 6, showing the position of the safety needle cap after use.
FIG. 8 is a perspective view of one version of the invention as being used to deliver an injection to the arm of a patient.
FIG. 9 illustrates the version of the invention as depicted in FIG. 8 after the needle has been withdrawn from the patient's arm.
FIGS. 10, 11(a), 11(b), 12(a), 12(b) depict in elevational views a modification to the safety cap feature of the invention.
FIG. 13 depicts yet another modification of the safety cap feature of the invention; and, an adaptation of the elastic sheath means portion.
FIGS. 14(a) and 14(b) depict in front elevational and side, sectional elevational views the details of one embodiment of the safety cap feature of the invention.
FIG. 15 is a partial, elevational view depicting a further embodiment of the safety cap which is formed in an elbow configuration to accommodate the purposes of the invention.
DETAILED DESCRIPTION
As noted above, the present invention has broad application. For purposes of illustration only, the needle system to be described hereinafter will focus on the syringe system which includes a syringe barrel and plunger. The needle-hub in this system can be formed as part of the barrel or be separate therefrom and which, together with the needle, inserted typically into an opening in the syringe barrel.
Turning now to the drawings wherein similar structures, having identical functions, are denoted with the same numerals, FIG. 1 illustrates a complete first version 10 of the safety needle cap assembly of the invention. A syringe 12 is shown with an attached needle 22. The needle 22 is shown enclosed within an elastic sheath means 16, the elastic sheath means being connected at one end to the hub 20 of the needle, and at its other end to a safety needle cap 18. The elastic sheath means can be affixed to the needle hub and safety cap by any convenient means, such as with suitable adhesives, clips (not shown), etc. Where the elastic sheath is formed of an elastomeric material such as latex, the connection can be; made by any suitable means including a frictional fit between the two pieces. The elastic sheath means 16 can be fabricated in a variety of suitable elastomers, e.g. latex rubbers, capable of being easily compressed under tension, and including a good "memory" so as to enable the elastic sheath means to return to its original shape when the tension is released. Other resilient means, for example, a spring, can be employed as the elastic sheath means as will be more fully described and illustrated in FIGS. 6, 6A and 7.
The safety needle cap 18 itself can be fabricated out of a number of hard materials, which will be impenetrable to the needle tip, for example, a clear plastic such as polycarbonate. The shape and size of the safety needle cap can vary depending on applications and design preferences, a tubular shape being suitable for some applications as depicted in FIG. 1. See also FIG. 15 and the attending description.
The tubular shaped safety needle cap is shown fully open 27 at one end for attachment to the elastic sheath 16. As is the case with the needle hub, the other end of the elastic sheath 29 can be attached to the safety needle cap by any convenient means, such as with a suitable adhesive, clips (not shown), frictional fit, etc. The other end of the safety needle cap is closed except for an interior opening 28 within the cap of just sufficient diameter as to permit the passage of the syringe needle 22 through this opening. As will be more fully illustrated and explained, this is an important feature of the invention. It virtually precludes the possibility of inadvertent, re-emergence of the tip 21 of the needle after the needle 22 has been used.
The exterior portion 26 of the interior cap opening 28 is an enlarged frusto-conical shape. It precludes body fluids on the needle from contacting the surface 31 of face portion 33. Gauze or other absorbent mesh work, (see FIG. 14(a) and FIG. 14(b)), can be secured within the frusto-conically shaped opening to absorp any remaining body fluids on the exterior of the needle as the needle withdraws within the cap after use.
The safety needle cap 18 is affixed to the end of the elastic sheath means. The length of the sheath means between its points of attachment to the cap 18 and the hub 20 is such that the needle tip is enclosed in the volume defined by the face/portion of the cap 33 and the sidewall 35 when the sheath is in its released condition, i.e. not under compression forces. In this relaxed state, the needle opening 28 within the cap is offset from the axial alignment of the syringe 12 and attached syringe needle 22. This arrangement positions the tip 21 of the needle along the upper wall 32 of the tubular side wall of the cap. The elastic sheath means is shown as a tube of latex rubber having slits 24, if necessary, along a portion of the length of the elastic sheath so as to facilitate compressing the sheath when required. The slits can also facilitate a "drooping" of the cap end of the sheath when the system is in the released condition. Where elastomeric material is used, the requirement for slits will depend in part on the gauge, thickness, density, etc. of the material. The entire safety needle cap 18, elastic sheath 16 and syringe needle 22, are shown enclosed in a sterile enclosure 14, which is removed at an appropriate time before use.
FIG. 2 illustrates the version of the invention depicted in FIG. 1, now ready to be utilized with a patient. The sterile metal foil 14 has been removed, and the safety needle cap 18 has been manually moved (not shown) so that the needle opening 28 in the cap is in axial alignment with the hypodermic needle 22, the cap being moved longitudinally along the axis alignment with the needle, causing the elastic sheath 16 to be compressed 30 and therefore under tension, while at the same time exposing the tip 21 of the needle 22. With the hypodermic needle 22 in this position, the needle can now be inserted into the patient to perform the required medical procedure.
FIG. 3 illustrates the version of the invention depicted in FIGS. 1 and 2 after the needle has been withdrawn from the patient. This procedure is best understood from FIGS. 8 and 9. The moment the needle is withdrawn from the patient, the elastic tension within the elastic sheath 16 is released which causes the safety needle cap 18 to snap back into its original position. In returning to its original position, the hypodermic needle is caused to be withdrawn to a position within the cap, with the tip 21 of the needle now harmlessly in contact with the inner surface of the upper wall 32 of the safety needle cap 18. The syringe 12 and needle 22 combination, including the safety needle cap 18 and elastic sheath 16, can now be disposed of safely. It is to be noted that the securing of the now potentially dangerous hypodermic needle within the safety needle cap of the invention is accomplished without any manual manipulations by the health professional, or even active consciousness of performing this often extremely important safety procedure.
FIG. 4 illustrates a second version of the invention in which a safety needle enclosure assembly 37 cooperates with a modified safety needle cap 39. The modified safety needle cap 39 includes arms 40 attached to and projecting radially outward from the side wall 46 of the modified cap. The attached arms 40 project through slots 42 in the safety needle enclosure assembly 37 (FIG. 4A). The axial length of the enclosure assembly 37 and length of slots 42 are such, that, when the assembly 37 and sheath-cap combination 16-39 is in place on the syringe-needle combination, with the one end of the sheath means secured to the needle hub 20, the arms 40 cooperate with the closed ends of slots 42 to maintain the elastic sheath in a contracted condition under elastic tension. The safety needle enclosure assembly 37 itself can be fabricated in a variety of plastic materials. The safety needle enclosure assembly 37 can have a smaller diameter tubular extension 36 sealed at one end, forming a safety cover for the now exposed tip 21 of the needle. The smaller diameter tubular extension 36 is confluent with a larger diameter tubular extension 34. The open end of the latter contacts the syringe barrel at surface 41 when the assembly-cap-sheath combination, 37-39-16, are in place.
The enclosure 37 including its length and the relative diameter of tubular extension 36, can be designed so that the outside surface of the face portion of cap 39 (corresponding to surface 31--see FIG. 1) contacts the interior surface of the vertical section (as seen in FIG. 4) disposed between the tubular extensions 34 and 36 and before arms 40 ever reach the closed ends of the slots. This design, alternately, can maintain the safety needle cap assembly in a ready condition.
To use the device illustrated in FIGS. 4 and 4A, once the sheath is connected to the hub 20, the operator would grasp the arms 40 extending through the slots 42 in the safety needle enclosure assembly with his or her fingers, then pull the safety needle enclosure 37 off from its contact with the syringe barrel with his or her free hand. With the tip 21 of the needle 22 now exposed and properly aligned, the operator can now proceed with the medical procedure.
As shown in FIG. 5, after the needle is withdrawn from the patient, the elastic tension is in the elastic sheath 16, which causes the modified safety needle cap 39 to move forward to a position where it encloses the needle tip, the tip of the needle now resting within the cap on the inside surface 46 of the side wall.
In FIGS. 6, 6A and 7, a further version of the invention is illustrated depicting the use of a spring 56 as the elastic sheath means, and illustrating a further modified safety needle cap 54. As described above for FIGS. 4 and 4A a safety needle enclosure assembly 37 encloses the further modified cap 54 and spring elastic sheath 56. One or more arms 58 on the further modified cap project through matching slots 42 in the safety needle enclosure assembly, thereby putting compression tension on the spring 56. Needle 50 is aligned with rear opening 66. The needle is axially aligned with a smaller internal needle opening 64 and a larger, exterior frusto-conical needle opening 62 in a front face portion 63 of cap 54 so that the needle extends through the cap with the tip of the needle 60 now exposed beyond the cap 54, but protected by the tubular extension 36 of the safety needle enclosure assembly 37. The principal modification shown to the cap 54 is that, instead of having a fully opened rear portion of the cap as described in FIGS. 1-5, the rear portion of the cap is substantially closed, by a back face portion 67 which includes a tubular extension 65 having an opening 66. One end of the spring 56 is attached to this tapered tube 65 again in any convenient manner, such as adhesively or with a clamp (not shown), with the other end of the spring 56 similarly attached to needle-hub 50. The spring can be enclosed in a sleeve 69 made of compliant material such as nylon or the like, or even an elastomeric material, such as latex. One end of the fabric enclosure is attached to the extension 65 and the other end to needle hub 50. The spring 56 itself can be fabricated in a variety of suitable materials, including metal or plastic.
As can best be seen in FIG. 6, with the arms 58 secured in the slots 42 within the safety needle enclosure assembly 37, and the one end of the assembly 37 in contact with the surface 71 of the syringe 48, the spring 56 is put under elastic tension. The needle 52 enters the cap through the opening 66 in the tubular extension 65 of the cap 54 and is axially aligned with the internal needle opening 64 and external needle cap opening 62, with the tip 60 of the needle now protruding into the smaller diameter portion 36 of the safety needle enclosure assembly 37. Operator manipulations of the arms 58 and removal of the safety needle enclosure assembly 37 now permits direct utilization of the syringe 48 in the delivery of a medical procedure to a patient.
As illustrated in FIG. 7, after the needle is withdrawn from the patient, the spring tension is released, and the tip 60 of the needle now automatically is positioned within the further modified safety needle cap 54. The opening 64 in the front of the cap and the opening 66 at the rear of the cap are now misaligned to a degree that virtually precludes any possibility of accidentally realigning the needle with the opening 64.
FIGS. 8 and 9 illustrate the second version of the invention depicted in FIGS. 4, 4A and 5 in actual use on a patient. The tip 21 of the needle is shown penetrating the skin on the arm 78 of a patient with the lower bottom edge 38 of the tubular shaped modified safety needle cap 39 in contact with the skin. This serves to aid in maintaining the cap in a withdrawn position, thus sustaining the tension in the elastic sheath means 16 while a medical procedure is in progress. Once the procedure is completed and the needle withdrawn, FIG. 9, the safety needle cap of the invention snaps over the tip of the needle, safely enclosing the potentially dangerous needle.
FIGS. 10 through 12 depict supplementary adaptations of the cap member which, if necessary, could be used to ensure the capture of the needle tip after use. FIGS. 10, 11(a), (b) and 12(a) (b) illustrate a modified version of the safety cap 79. This modification depicts the incorporation of a closure means 80 including a flap member 82 hinged at 84 to the sidewall 86. The flap member is of sufficient size and hinged to the sidewall in a manner that it closes off the interior side 88 of the opening 90 when the cap-sheath assembly is in its extended position as shown in FIG. 12(a) and 12(b). FIG. 10 shows the relationship of the flap member 82 to the needle 92 when the cap-sheath assembly is first connected to the needle-syringe assembly. The needle contacts surface 94 of the flap member and captures the flap member 82 between itself and the sidewall 96. This permits the subsequent operation of aligning the needle 92 with the opening 90 in readying the syringe-sheath assembly for use.
FIG. 11(a) and 11(b) indicate the relationship when the needle is axially aligned and positioned through the opening 90. In this view, the flap member 82 rests on the surface of the needle 92.
The hinged flap member can be included as part of the plastic mold used in forming the cap so that the formed cap product would include the flap member as an integral part. The flap member can be employed with any of the cap members, 18, 39 and 54 described above or as described below in FIG. 15.
FIG. 13 illustrates the use of an annular ring of styrofoam or similar material 98 to capture and retain the needle point after the medical procedure. The ring is placed inside the cap and secured with appropriate means such as adhesive, at the juncture between the sidewall and interior surface of the face portion. The annular ring as positioned and constructed of course, would permit needle access to opening 100 during set up.
FIGS. 14(a) and 14(b) disclose in close-up a cap member 102 which depicts the preferred construction of the frusto-conical opening 104 in the front face portion 106 and how gauze 108 or other similarly, absorbent material is disposed therein. The gauze is positioned in the frusto-conical opening and secured by a suitable adhesive. Although the cap style depicted is similar to cap 54 above, the configuration of the opening 104 is also appropriate, of course, for the front face portion of any cap configuration including 18 and 39 described earlier or as described below for the cap design of FIG. 15.
The opening 104 includes a first, larger opening 110, which tapers back to a second opening 112, which may be further reduced in size to a third opening 114 by an annular shelf portion 116. The shelf portion can be included in the cap design, if necessary, to facilitate the placement and retention of the gauze 108. Of course, third opening 114 is of sufficient diameter to permit passage therethrough of the particular needle to be used. Preferably the diameter of the first opening 110 is sufficiently large, so that droplets of body fluid which may adhere to the needle as it is withdrawn from the patient do not bridge the space between the needle and the outer surface 118 of the face portion 106.
FIG. 14(b) is also helpful in illustrating an important feature of the style cap depicted (and style 54 of FIG. 6). Tubular extension 120 formed in back face portion 122, is centered on axis 124 which is offset in relation to the axis of the frusto-conical opening 104 on the front face portion. Both before readying the cap-sheath assembly and the needle-syringe assembly prior to use, and after withdrawing the needle from the patient when the sheath means relaxes and the needle tip is captured within the volume defined by the front face portion 106, back face portion 122 and the sidewall 126, the tubular extension 120 serves a useful purpose. The tubular extension 120 and more particularity the angular orientation of back face portion 122 in relation to the front face portion, ensures that the needle is orientated in a direction essentially parallel to axis 124, and necessarily, is, offset to the axis 128 that the needle aligns itself to when it is inserted through the opening 114. In effect, the cap 102 pivots about the needle 130 at point 132 of the opening 134 on the interior surface 136 of the back face portion 122 whenever the needle tip is positioned in the interior volume 138 as defined by the face portions and sidewall. This occurs, again, prior to readying the assembled cap-sheath-needle-syringe assembly and after the relaxed sheath means moves the cap forward, after use, and the needle enter the volume 138, offset from axis 128. This precludes reentry through opening 114.
Finally, referring for the moment to FIGS. 10 and 12(b) assume the sheath means therein depicted, 140, is fabricated from an elastomeric material such as latex. For the particular cap design illustrated and cap design 18 and 39 above, i.e. designs without the back face portion such as 122 in FIG. 14(b), it is of benefit, depending on its thickness and material, that the elastomeric sleeve tends to arc, as depicted, due to the weight of the cap when the needle withdraws into the interior volume of the cap. Thus in this relaxed state the effect of gravity can cause the cap end of the sheath to droop or arc so that the needle opening 100 within the cap is offset from axial alignment with the needle 92. Alternately, the elastomeric sleeve can be formed at manufacture to include the arc. This inherently results in the opening in the cap, 90, being offset to the axis of the needle, thus advancing the purposes of the invention.
FIG. 13 depicts an alternate sheath means 142. The sheath means in this embodiment is fabricated with a suitable bend 146 formed in the material to ensure that opening 100 will be offset from the needle axis when the needle tip is positioned within the cap volume.
In order to provide the offset from the needle axis as required, yet another embodiment as seen in FIG. 15 depicts the cap 148 as fabricated with an angular offset 150 between a front portion 152 and rear portion 154. Here, of necessity, irrespective of the orientation assumed by the sheath means 156 in the relaxed condition, the needle 158 is offset from the axis 160 of the opening 162. The needle is thus precluded from re entering the opening unintendedly.
Thus, it can be seen that a new and economical safety device is provided to health professionals in the utilization of virtually any type of syringe. The safety needle cap-sheath assembly of the invention can be supplied either for field connection to existing syringe and needle assemblies, or, of course, as a complete package including the needle and syringe. In use, the instant invention provides the new and important advantage of safely enclosing a potentially dangerous, used needle, automatically, without any necessity for conscious safety precautions on the part of the health professional.
While the present invention has been disclosed in connection with versions shown and described in detail, various modifications and improvements will become readily apparent to those skilled in the art. Accordingly, the spirit and scope of the present invention is to be limited only by the following claims.
|
A safety needle cap assembly for needles is described. In place of the usual safety cap which requires a doctor, dentist or nurse to manually place it in position on a used syringe needle, the safety needle cap assembly of the invention automatically caps the used needle the instant the needle is withdrawn from the patient. An elastic sheath or spring attached to a safety needle cap is kept under tension, retracting the cap and allowing the needle tip to be exposed. Once used and removed from the patient, the elastic tension is released, causing the safety needle cap to snap over the used needle tip automatically, without any operator assistance. The design of the safety needle cap assembly as described virtually preclude accidental re-emergence of the used needle tip during disposal of the needle-cap assembly.
| 0
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to certain 2-phenylpiperidine compounds, more particularly to certain 2-[2-hydroxy-4-(ZW-substituted)phenyl]piperidines of the formula ##STR3## or a pharmaceutically acceptable acid addition salt thereof, useful as CNS agents, especially as analgesics, antiemetic and antidiarrheal agents for use in mammals, including man, methods for their pharmaceutical compositions containing them and intermediates therefore.
2. Description of the Prior Art
Despite the current availability of a number of analgesic agents, the search for new and improved agents continues, thus pointing to the lack of an agent useful for the control of broad levels of pain and accompanied by a minimum of side-effects. The most commonly used agent, aspirin, is of no practical value for the control of severe pain and is known to exhibit various undesirable side-effects. Other, more potent analgesics such as d-propoxyphene, codeine, and morphine, possess addictive liability. The need for improved and potent analgesics is, therefore, evident.
More recently, great interest in cannabinol-type compounds as analgesic agents has been exhibited, see, for example, R. Mechoulam, Ed., "Marijuana Chemistry, Pharmacology, Metabolism and Clinical Effects", Academic Press, New York, N.Y., 1973; Mechoulam, et al., Chemical Reviews, 76, 75-112 (1976).
U.S. Pat. No. 4,147,872, issued Apr. 23, 1979, discloses a series of 3-[2-hydroxy-4-(substituted)phenyl]piperidine CNS agents of the formula ##STR4## where R 2 and R 3 have certain values in common with R 2 and R 3 , respectively, as defined for the instant compounds of formula (I). The compounds of formula (II) are active analgesics, tranquilizers, sedatives and antianxiety agents for use in mammals, and/or as anticonvulsants, diuretics and antidiarrheal agents.
U.S. Pat. No. 4,306,097, issued Dec. 15, 1981, discloses 3-[2-hydroxy-4-(substituted)phenyl]cycloalkanol analgesic agents.
SUMMARY OF THE INVENTION
It has now been found that certain 2-[2-hydroxy-4-(substituted)phenyl]piperidines and derivatives thereof are effective CNS agents, especially as analgesics, tranquilizers, sedatives and antianxiety agents in mammals, including humans and/or anticonvulsants, diuretics and antidiarrheal agents in mammals, including man. They are especially effective in said mammals as analgesics, antidiarrheals and as agents for treatment and prevention of emesis and nausea, especially that induced by antineoplastic drugs. Said invention compounds, which are nonnarcotic and free of addiction liability, are of the formula ##STR5## or a pharmaceutically acceptable acid addition salt thereof, wherein R 1 is H, benzyl, benzoyl, formyl, (C 2 -C 7 )alkanoyl or CO(CH 2 ) p NR 4 R 5 where p is zero or is 1-4 and R 4 and R 5 are each H or (C 1 -C 4 )alkyl or taken together with the nitrogen atom to which they are attached, they form a piperidino, pyrrolo, pyrrolidino, morpholino or N-[(C 1 -C 4 )alkyl]piperazino group;
R 2 is H, formyl, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 2 -C 7 )hydroxyalkyl, (C 2 -C 7 )alkylcarbonyl, (C 3 -C 7 )alkenylcarbonyl, (C 3 -C 7 )alkynylcarbonyl, (C 1 -C 6 )alkylsulfonyl, (C 2 -C 7 )alkoxycarbonyl or (C 2 -C 7 )hydroxyalkylcarbonyl;
R 3 is two atoms of hydrogen, a carbonyl oxygen atom, ##STR6## Z is (C 1 -C 13 )alkylene or -(alk 1 ) m -O-(alk 2 ) n - where each of (alk 1 ) and (alk 2 ) is (C 1 -C 13 )alkylene with the proviso that the sum of carbon atoms in (alk 1 ) plus (alk 2 ) is not greater than 13, and each of m and n is 0 or 1; and
W is hydrogen, pyridyl or W 1 C 6 H 4 where W 1 is H, F or Cl.
Particularly preferred compounds of formula (I) are those wherein:
R 1 is hydrogen or alkanoyl, especially hydrogen or acetyl;
R 2 is (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 2 -C 7 )alkylcarbonyl, (C 2 -C 7 )alkoxycarbonyl or (C 1 -C 6 )alkylsulfonyl, especially n-propyl, 2-propenyl, 2-propynyl, (C 2 -C 5 )alkylcarbonyl or (C 2 -C 4 )alkoxycarbonyl;
R 3 is ##STR7## Z is said alkylene or O(alk 2 ); and W is hydrogen or phenyl;
especially preferred ZW are C(CH 3 ) 2 (CH 2 ) 5 CH 3 or OCH(CH 3 )(CH 2 ) 3 C 6 H 5 .
More particularly preferred compounds of the invention because of their enhanced biological activity relative to other compounds described herein are the cis isomers of the formula ##STR8## where R 2 is as shown in the table.
R 2
CH 2 CH 2 CH 3
CH 2 CH═CH 2
CH 2 C.tbd.CH
CO 2 CH 3
CO 2 CH 2 CH 3
SO 2 CH 3
COCH 3
COCH 2 CH 3
COCH 2 CH 2 CH 3
CO(CH 2 ) 3 CH 3
Most particularly preferred such compounds are N-butyryl cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol and N-ethoxycarbonyl cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol.
More particularly preferred compounds of the invention which are useful as intermediates in preparation of the above biologically active compounds, are of the formula ##STR9## where R 2 and ZW are as previously defined. Especially preferred such intermediates are those wherein R 2 is COOCH 3 or COOC 2 H 5 and ZW is C(CH 3 ) 2 (CH 2 ) 5 CH 3 or OCH(CH 3 )(CH 2 ) 3 C 6 H 5 .
Also included in the present invention are the pharmaceutically acceptable acid addition salts of the compounds of formula (I) which contain a basic group. In compounds having two or more basic groups present, such as those wherein W is pyridyl and/or R 1 represents a basic ester moiety, polyacid addition salts are possible. Representative of such pharmaceutically acceptable acid addition salts are the mineral acid salts such as the hydrochloride, hydrobromide, sulfate, phosphate, nitrate; organic acid salts such as the citrate, acetate, sulfosalicylate, tartrate, glycolate, malate, malonate, maleate, pamoate, salicylate, stearate, phthalate, succinate, gluconate, 2-hydroxy-3-napthoate, lactate, mandelate and methanesulfonate.
Compounds of formula (I) contain an asymmetric center at the 2-position and, when R 3 is a secondary alcohol group, at the 4-position. They may contain additional centers of asymmetry in the R 1 , R 2 and ZW substituents. For convenience, the above formulae depict the racemic compounds. However, the above formulae are considered to be generic and embracive of racemic modifications of the compounds of the invention, the diastereomeric mixtures, the pure enantiomers and diastereomers thereof. The utility of the racemic mixture, the diastereomeric mixture as well as the pure enantiomers and diastereomers is determined by the biological evaluation procedures described below.
As mentioned above, the compounds of the invention are particularly useful as analgesics, antidiarrheals and as antiemetic and antinausea agents for use in mammals, including man. The invention further provides a method for producing analgesia in mammals and a method for prevention and treatment of nausea in a mammal subject to nausea, in each case by oral or parenteral administration of an effective amount of a compound of formula (I) or a pharmaceutically acceptable salt.
Also provided are pharmaceutical compositions for use as analgesics, as well as those suitable for use in prevention and treatment of nausea, comprising an effective amount of compound of the invention and a pharmaceutically acceptable carrier.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of this invention having formula (I) wherein R 3 is a carbonyl oxygen atom are prepared from the appropriate hydroxy-protected 2-bromo 5-(Z-W substituted)phenol. Suitable hydroxy protecting groups are those which do not interfere with subsequent reactions and which can be removed under conditions which do not cause undesired reactions at other sites of said compounds or of products produced therefrom. Representative of such protective groups are methyl, ethyl, benzyl or substituted benzyl wherein the substituent is, for example, alkyl having from one to four carbon atoms, halo (Cl, Br, F, I) and alkoxy having from one to four carbon atoms.
The exact chemical structure of the protecting group is not critical to this invention since its importance resides in its ability to perform in the manner described above. The selection and identification of appropriate protecting groups can easily and readily be made by one skilled in the art. The suitability and effectiveness of a group as a hydroxy protecting group are determined by employing such a group in the herein-illustrated reaction sequences. It should, therefore, be a group which is easily removed to regenerate the hydroxy groups. The benzyl group is a preferred group since it can be removed by catalytic hydrogenolysis or acid hydrolysis.
Detailed procedures for preparing the hydroxy-protected 2-bromo-5(ZW-substituted)phenol starting materials, including those of formula (V) wherein the hydroxy-protecting group is benzyl, are described in U.S. Pat. Nos. 4,147,872 and 4,306,097 each of which are hereby incorporated herein by reference.
The protected 2-bromo-5-(ZW-substituted)phenol (V) is subjected to a copper catalyzed Grignard reaction in a reaction-inert solvent with the appropriate N-R 2 -substituted-4-oxo-1,2,3,4-tetrahydropyridine (IV) as shown in Scheme A for the preferred case where the hydroxy protecting group is benzyl. Suitable reaction-inert solvents are cyclic and acyclic ethers such as, for example, tetrahydrofuran, dioxane, diethyl ether and ethylene glycol dimethyl ether. ##STR10##
The Grignard reagent is formed in known manner, as, for example, by refluxing a mixture of one molar proportion of the bromo reactant and two molar proportions of magnesium in a reaction-inert solvent, e.g., tetrahydrofuran at reflux temperature. The resulting mixture is then cooled to about -20° to 25° C. and a cuprous salt, for example, cuprous iodide or cuprous bromide, added in a catalytic amount. The appropriate 4-oxo-1,2,3,4-tetrahydropyridine[2,3-dihydro-4-(1H)pyridinone (IV)] is then added at a temperature of from about -20° to 0° C.
The product of the Grignard reaction of formula (III) can then be treated with an appropriate reagent to remove the protecting group. If desired, the benzyl group on the phenolic hydroxy group is conveniently removed by catalytic hydrogenation over palladium-on-carbon. Alternatively, the phenolic benzyl group can be removed by acid hydrolysis using, for example, trifluoroacetic acid.
The preferred intermediate (III) can also be reacted under reducing conditions known to convert ketones to secondary alcohol groups. For example, catalytic hydrogenation over a noble metal catalyst, for example, platinum, palladium or nickel; or reduction with an alkali metal hydride, for example, lithium aluminum hydride, sodium borohydride, potassium borohydride. A preferred reducing agent for this conversion is sodium borohydride because it gives rise to a predominantly di-cis-product (VI). The reaction is carried out in a polar solvent, for example, a lower alcohol such as methanol, ethanol or 2-propanol; water, an ether such as diethyl ether, tetrahydrofuran, diglyme or mixtures thereof; and at a temperature of from about -70° C. up to the reflux temperature of the solvent. An especially preferred temperature is in the range of from -50° to 25° C., at which temperature the reaction is substantially complete in a few hours. The resulting 4-piperidinol is separated by known methods and purified, if desired, for example, by silica gel column chromatography.
Alternatively, the intermediate ketones of formula (III) can be reduced to the corresponding piperidine derivatives of formula (IX) by methods known to reduce ketones to hydrocarbons. Examples of such methods are the well known Clemmensen method employing amalgamated zinc and hydrochloric acid (see e.g., "Organic Reactions", Academic Press, New York, Vol. 1, 1942, page 155) and the Wolff-Kishner reduction employing hydrazine and a strong base such as potassium hydroxide [see, e.g., "Organic Reactions", Vol. 4, page 378 (1948)]. A particularly preferred method is the Wolff-Kishner reduction employing hydrazine hydrate and potassium hydroxide in ethylene glycol as solvent. A preferred temperature for this reaction is from 50° to 250° C., especially 100°-200° C., at which temperature the reaction is complete within a few hours. The benzyl ether of the 2-phenylpiperidine compound of formula (IX) is then isolated by methods well known in the art and the benzyl group removed by methods described above.
As mentioned above, the benzyl hydroxy-protecting group such as that present in the above compounds of formulae (III) or (VI), for example, are preferably removed by catalytic hydrogenolysis. The hydrogenolysis of such compounds is ordinarily carried out by means of hydrogen in the presence of a noble metal catalyst. Examples of noble metals which may be employed are nickel, palladium, platinum and rhodium. The catalyst is ordinarily employed in catalytic amounts, e.g., from about 0.01 to 10 weight-percent and preferably from about 0.1 to 2.5 weight-percent, based on the starting compound, e.g. the benzyl ether (III) or (VI). It is often convenient to suspend the catalyst on an inert support, a particularly preferred catalyst is palladium suspended on an inert support such as carbon.
One convenient method of carrying out this transformation is to stir or shake a solution of the starting compound, e.g. (III) or (VI), under an atmosphere of hydrogen in the presence of one of the above noble metal catalysts. Suitable solvents for this hydrogenolysis reaction are those which substantially dissolve the starting compound but which do not themselves suffer hydrogenation or hydrogenolysis. Examples of such solvents include the lower alkanols such as methanol, ethanol and isopropanol; ethers such as diethyl ether, tetrahydrofuran, dioxane and 1,2-dimethoxyethane; low molecular weight esters such as ethyl acetate and butyl acetate; tertiary amides such as N,N-dimethylformamide, N,N-dimethylacetamide and N-methylpyrrolidone; and mixtures thereof. Introduction of the hydrogen gas into the reaction medium is usually accomplished by carrying out the reaction in a sealed vessel, containing the starting compound, the solvent, the catalyst and the hydrogen. The pressure inside the reaction vessel can vary from about 1 to about 100 kg/cm 2 . The preferred pressure range, when the atmosphere inside the reaction vessel is substantially pure hydrogen, is from about 2 to about 5 kg/cm 2 . The hydrogenolysis is generally run at a temperature of from about 0° to about 60° C., and preferably from about 25° to about 50° C. Utilizing the preferred temperature and pressure values, hydrogenolysis generally takes place in a few hours, e.g., from about 2 hours to about 24 hours.
The product is then isolated by standard methods known in the art, e.g., filtration to remove the catalyst and evaporation of solvent or partitioning between water and a water immiscible solvent and evaporation of the dried extract.
As illustrated in Scheme B, above, an N-alkoxycarbonyl intermediate of formula (X) can be subjected to hydrolysis and decarboxylation to provide the corresponding base of formula (XI). The free base can then be alkylated or acylated by reaction with a compound of formula R 2 L wherein R 2 may have any of the values given above, but preferably is not H, and L is a leaving group, to provide the corresponding compound of formula (VI).
The hydrolysis and decarboxylation of the N-alkoxycarbonyl compounds such as the N-ethoxycarbonyl compound of formula (X) is carried out in an aqueous solvent, and a strong base. Preferred solvents for this conversion are a lower alcohol, e.g., methanol, ethanol or isopropanol; a glycol such as ethylene glycol or diethylene glycol, water or mixtures thereof. Preferred as strong base for the hydrolysis are potassium hydroxide, sodium hydroxide, calcium hydroxide or potassium carbonate. In an especially preferred such method the N-ethoxycarbonyl compound of formula (X) in ethanol is added to ethylene glycol containing a molar excess of potassium hydroxide and water. The mixture is evaporated to remove alcohol and then heated at reflux for 1-2 days. The decarboxylated product of formula (XI) is then isolated, e.g. by extraction and purified by column chromatography, if desired.
The 2-phenyl-4-(R 3 substituted)piperidine free base, for example that of formula (XI), may then be converted to the analogous N-alkyl, N-alkenyl, N-alkynyl, N-alkylsulfonyl or N-acyl derivative of formula (I, R 1 =H) by well known alkylation, sulfonylation or acylation techniques, as shown in Scheme B, above.
For the reagents of formula R 2 L preferred leaving groups, L, are the halogens, Cl, Br, or I; HO or acyloxy. For these reagents wherein R 2 is said alkyl, alkenyl, alkynyl, hydroxyalkyl, alkylcarbonyl, alkenylcarbonyl, alkynylcarbonyl, hydroxyalkylcarbonyl or alkylsulfonyl, an especially preferred leaving group is Cl, Br or I.
When R 2 is said alkylcarbonyl, alkenylcarbonyl, alkynylcarbonyl or hydroxyalkylcarbonyl, preferred leaving groups, L, are OH or acyloxy where said acyl is the residue of an acid anhydride or a mixed anhydride.
The reactions of reagents R 2 L with free bases such as those of formula (X) for example, are carried out by methods well known in the art for alkylation or acylation of secondary amines to form tertiary amines or amides, respectively.
For acylation of the piperidine free bases of formula (XI) the acylating agent, R 2 L, is preferably the appropriate carboxylic acid or activated derivative thereof, for example, the acid chloride, acid bromide or acid anhydride. The reaction is preferably carried out in the presence of a reaction inert solvent, preferably, methylene chloride, chloroform, ethyl ether, tetrahydrofuran, acetone or acetonitrile and optionally in the presence of an acid acceptor which may be organic or inorganic. Suitable binding agents are, for example, the alkali metal carbonates and hydroxides, pyridine, 4-N,N-dimethylaminopyridine, triethylamine and N-methylmorpholine. The acylation is preferably carried out at a temperature of from 0° up the the reflux temperature of the solvent. When the acylation agent, R 2 L, is a carboxylic acid it is preferred to carry out the reaction in the presence of one of the condensing agents known to be useful in forming amides, e.g., dicyclohexylcarbodiimide.
When the piperidine free base (XI) is to be alkylated with the reagent R 2 L an especially preferred reagent is R 2 Cl or R 2 Br. The reaction is conducted in a solvent, e.g. an alkanol such as ethanol, n-butanol or isoamylalcohol at a temperature of from about room temperature up to the reflux temperature of the solvent. An acid acceptor, e.g. those set forth above and especially potassium carbonate or triethylamine, is also preferably employed in this reaction.
An alternative method for obtaining invention compounds wherein R 2 is alkyl or hydroxyalkyl is to carry out the above described acylation of, e.g. a compound of formula (XI), followed by reduction of the resulting amide of formula (XII) with, e.g. lithium aluminum hydride, to provide the desired compound of formula (XII) wherein R 2 is said alkyl, alkenyl or alkynyl. When the acylation is carried out with an hydroxyalkyl carboxylic acid, the hydroxy group of which is protected, or an activated derivative thereof, e.g. a benzyloxyalkyl carboxylic acid or an activated derivative such as the acid chloride, and the resulting amide is reduced with lithium aluminum hydride and the benzyl protecting groups subsequently removed, e.g. by hydrogenolysis, the product obtained is of formula (I) wherein R 1 is hydrogen and R 2 is hydroxyalkyl.
The requisite N-R 2 -substituted 4-oxo-1,2,3,4-tetrahydropyridine starting materials of formula (IV) are obtained by methods described by Haider et al., Helvetica Chimica Acta, 58, 1287 (1975) and in references set forth therein. A preferred method is by sodium borohydride reduction of the corresponding N-R 2 -substituted-pyridone in an alcoholic solvent, e.g. t-butanol. At 25° C. the reaction proceeds in high yield after 2 days, and the product is isolated by standard methods. ##STR11## A preferred 4-oxopyridone reagent for this reaction is one where R 2 is alkoxycarbonyl, e.g. ethoxycarbonyl.
Esters of compounds of formula (I) wherein R 1 is benzoyl, alkanoyl or --CO--(CH 2 ) p --NR 4 R 5 are readily prepared by reacting forumla (I) compounds wherein R 1 is hydrogen with benzoic acid, the appropriate alkanoic acid or acid of formula HOOC--(CH 2 ) p --NR 4 R 5 in the presence of a condensing agent such as dicyclohexylcarbodiimide. Alternatively, they are prepared by reaction of the formula (I) (R 1 =H) compound with the appropriate acid chloride or anhydride, e.g., benzoyl chloride, acetyl chloride or acetic anhydride, in the presence of a base such as pyridine.
The presence of a basic group in the ester moiety (OR 1 ) in the compounds of this invention permits formation of acid-addition salts involving said basic group. When the herein described basic esters are prepared via condensation of the appropriate amino acid hydrochloride (or other acid addition salt) with the appropriate compound of formula (I) in the presence of a condensing agent, the hydrochloride salt of the basic ester is produced. Careful neutralization affords the free base. The free base form can then be converted to other acid addition salts by known procedures.
Acid addition salts can, of course, as those skilled in the art will recognize, be formed with the invention compounds of formula (I) having a basic nitrogen moiety. Such salts are prepared by standard procedures. The basic ester derivatives of these piperidine compounds are, of course, able to form mono- or di-acid addition salts because of their dibasic functionality.
The analgesic properties of the compounds of this invention are determined by tests using thermal nociceptive stimuli, such as the mouse tail flick procedure, or chemical nociceptive stimuli, such as measuring the ability of a compound to suppress phenylbenzoquinone irritant-induced writhing in mice. These tests and others are described below.
TESTS USING THERMAL NOCICEPTIVE STIMULI
(a) Mouse Hot Plate Analgesic Testing
The method used is modified after Woolfe and MacDonald, J. Pharmacol. Exp. Ther., 80, 300-307 (1944). A controlled heat stimulus is applied to the feet of mice on a 1/8" thick aluminum plate. A 250 watt reflector infrared heat lamp is placed under the bottom of the aluminum plate. A thermal regulator, connected to thermistors on the plate surface, programs the heat lamp to maintain a constant temperature of 57° C. Each mouse is dropped into a glass cylinder (61/2" diameter) resting on the hot plate, and timing is begun when the animal's feet touch the plate. At 0.5 and 2 hours after treatment with the test compound, the mouse is observed for the first "flicking" movements of one or both hind feet, or until 10 seconds elapse without such movements. Morphine has an MPE 50 =4-5.6 mg/kg (s.c.).
(b) Mouse Tail Flick Analgesic Testing
Tail flick testing in mice is modified after D'Amour and Smith, J. Pharmacol. Exp. Ther., 72, 74-79 (1941), using controlled high intensity heat applied to the tail. Each mouse is placed in a snug-fitting metal cylinder, with the tail protruding through one end. This cylinder is arranged so that the tail lies flat over a concealed heat lamp. At the onset of testing, an aluminum flag over the lamp is drawn back, allowing the light beam to pass through the slit and focus onto the end of the tail. A timer is simultaneously activated. The latency of a sudden flick of the tail is ascertained. Untreated mice usually react within 3-4 seconds after exposure to the lamp. The end point for protection is 10 seconds. Each mouse is tested at 0.5 and 2 hours after treatment with morphine and the test compound. Morphine has an MPE 50 of 3.2-5.6 mg/kg (s.c.).
(c) Tail Immersion Procedure
The method is a modification of the receptacle procedure developed by Benbasset, et. al., Arch. int. Pharmacodyn., 122, 434 (1959). Male albino mice (19-21 g) of the Charles River CD-1 strain are weighed and marked for identification. Five animals are normally used in each drug treatment group with each animal serving as its own control. For general screening purposes, new test agents are first administered at a dose of 56 mg/kg intraperitoneally or subcutaneously, delivered in a volume of 10 ml/kg. Preceding drug treatment and at 0.5 and 2 hours post drug, each animal is placed in the cylinder. Each cylinder is provided with holes to allow for adequate ventilation and is closed by a round nylon plug through which the animal's tail protrudes. The cylinder is held in an upright position and the tail is completely immersed in the constant temperature waterbath (56° C.). The endpoint for each trail is an energetic jerk or twitch of the tail coupled with a motor response. In some cases, the endpoint may be less vigorous post drug. To prevent undue tissue damage, the trail is terminated and the tail removed from the waterbath within 10 seconds. The response latency is recorded in seconds to the nearest 0.5 second. A vehicle control and a standard of known potency are tested concurrently with screening candidates. If the activity of a test agent has not returned to baseline values at the 2-hour testing point, response latencies are determined at 4 and 6 hours. A final measurement is made at 24 hours if activity is still observed at the end of the test day.
TEST USING CHEMICAL NOCICEPTIVE STIMULI
Suppresion of Phenylbenzoquinone Irritant-Induced Writhing
Groups of 5 Carworth Farms CF-1 mice are pretreated subcutaneously or orally with saline, morphine, codeine or the test compound. Twenty minutes (if treated subcutaneously) or fifty minutes (if treated orally) later, each group is treated with intraperitoneal injection of phenylbenzoquinone, an irritant known to produce abdominal contractions. The mice are observed for 5 minutes for the presence or absence of writhing starting 5 minutes after the injection of the irritant. MPE 50 's of the drug pretreatments in blocking writhing are ascertained.
TESTS USING PRESSURE NOCICEPTIVE STIMULI EFFECT ON THE HAFFNER TAIL PINCH PROCEDURE
A modification of the procedure of Haffner, Experimentelle Prufung Schmerzstillender. Mittel Deutch Med. Wschr., 55, 731-732 (1929) is used to ascertain the effects of the test compound on aggressive attacking responses elicited by a stimulus pinching the tail. Male albino rats (50-60 g) of the Charles River (Sprague-Dawley) CD-strain are used. Prior to drug treatment, and again at 0.5, 1, 2 and 3 hours after treatment, a Johns Hopkins 2.5-inch "bulldog" clamp is clamped onto the root of the rat's tail. The endpoint at each trial is clear attacking and biting behavior directed toward the offending stimulus, with the latency for attack reported in seconds. The clamp is removed in 30 seconds if attacking has not yet occurred, and the latency of response is recorded as 30 seconds. Morphine is active 17.8 mg/kg (i.p.).
TESTS USING ELECTRICAL NOCICEPTIVE STIMULI THE "FLINCH-JUMP" TEST
A modification of the flinch-jump procedure of Tenen, Psychopharmacologia, 12, 278-285 (1968) is used for determining pain thresholds. Male albino rats (175-200 g) of the Charles River (Sprague-Dawley) CD strain are used. Prior to receiving the drug, the feet of each rat are dipped into a 20% glycerol/saline solution. The animals are then placed in a chamber and presented with a series of 1-second shocks to the feet which are delivered in increasing intensity at 30-second intervals. These intensities are 0.26, 0.39, 0.52, 0.78, 1.05, 1.31, 1.58, 1.86, 2.13, 2.42, 2.72, and 3.04 mA. Each animal's behavior is rated for the presence of (a) flinch, (b) squeak and (c) jump or rapid forward movement at shock onset. Single upward series of shock intensities are presented to each rat just prior to, and at 0.5, 2, 4 and 24 hours subsequent to drug treatment.
Results of the above tests are recorded as percent maximum possible effect (% MPE). The % MPE of each group is statistically compared to the % MPE of the standard and the predrug control values. The % MPE is calculated as follows: ##EQU1##
As mentioned above, the compounds of the invention are especially useful as antiemetic and antinausea agents in mammals. They are particularly useful in preventing emesis and nausea induced by antineoplastic agents.
The antiemetic properties of the compounds of formula (I) are determined in unanesthetized unrestrained cats according to the procedure described in Proc. Soc. Exptl. Biol. and Med., 160, 437-440 (1979).
ANTAGONISM OF PGE 2 * DIARRHEA IN MICE
The antidiarrheal activity of the invention compounds is determined by a modification of the method of Dajani et al., European Jour. Pharmacol., 34, 105-113 (1975). This method reliably elicits diarrhea in otherwise untreated mice within 15 minutes. Pretreated animals in which no diarrhea occurs are considered protected by the test agent. The constipating effects of test agents are measured as an "all or none" response, diarrhea being defined as watery unformed stools, very different from normal fecal matter, which consists of well-formed boluses, firm and relatively dry.
Male albino mice of the Charles River CD-1 strain are used. They are kept in group cages and tested within one week following arrival. The weight range of the animals when tested is between 20-25 g. Pelleted rat chow is avilable ad libitum until 18 hours prior to testing, at which time food is withdrawn.
Animals are weighed and marked for identification. Five animals are normally used in each drug treatment group. Mice weighing 20-25 g are housed in group cages, and fasted overnight prior to testing. Water is available ad libitum. Animals are challenged with PGE 2 (0.32 mg/kg i.p. in 5% ETOH) one hour after drug treatment, and immediately placed individually in transparent acrylic boxes of 15×15×18 cm. A disposable cardboard sheet on the bottom of the box is checked for diarrhea on an all or nothing basis at the end of 15 minutes. A vehicle +PGE 2 treatment group and a vehicle treatment group serve as controls in each day's testing.
The data are analyzed using weighted linear regression of probit-response onlog dose, employing the maximum likelihood procedure. A computer program prints results in an analysis of linear regression format, including degrees of freedom, sum of squares, mean squares and critical values of F 05 and Chi square. If the regression is significant, the ED 30 , ED 50 , ED 70 , and ED 90 and then 95% confidence limits are calculated.
The compounds of the present invention are active analgesics, antidiarrheals, antiemetics or antinauseants via oral and parenteral administration and are conveniently administered for these uses in composition form. Such compositions include a pharmaceutical carrier selected on the basis of the chosen route of administration and standard pharmaceutical practice. For example, they may be administered in the form of tablets, pills, powders or granules containing such excipients as starch, milk sugar, certain types of clay, etc. They may be administered in capsules, in admixtures with the same or equivalent excipients. They may also be administered in the form of oral suspensions, solutions, emulsions, syrups and elixirs which may contain flavoring and coloring agents. For oral administration of the therapeutic agents of this invention, tablets or capsules containing from about 0.01 to about 100 mg are suitable for most applications.
Suspensions and solutions of these drugs, particularly those wherein R 1 is hydrogen, are generally prepared just prior to use in order to avoid problems of stability of the drug (e.g. oxidation) or of suspensions or solution (e.g. precipitation) of the drug upon storage. Compositions suitable for such are generally dry solid compositions which are reconstituted for injectable administration.
The physician will determine the dosage which will be most suitable for an individual patient and it will vary with the age, weight and response of the particular patient and the route of administration. Generally, however, the initial analgesic dosage, as well as the initial dosage for prevention or treatment of nausea, in adults may range from 0.01 to 500 mg per day in single or divided doses. In many instances, it is not necessary to exceed 100 mg daily. The favored oral dosage range is from about 0.01 to about 300 mg/day; the preferred range is from about 0.10 to about 50 mg/day. The favored parenteral dose is from about 0.01 to about 100 mg/day; the preferred range from about 0.01 to about 20 mg/day.
The invention is further illustrated by the following Examples. Abbreviations used in the Examples are: PMR, proton magnetic resonance; s, singlet; d, doublet; dd, double doublet; t, triplet; q, quartet; m, multiplet; Ar, aromatic; b, broad; IR, infrared spectrum; HRMS, high resolution mass spectrum; M + , molecular ion.
EXAMPLE 1
N-Ethoxycarbonyl-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinone
To 3.45 (0.142 mole) of magnesium is added a solution of 27.6 g (0.071 mole) of 2-benzyloxy-1-bromo-4-(1,1-dimethylheptyl)benzene in 71 ml of tetrahydrofuran, at such a rate that gentle reflux occurs. The Grignard solution is allowed to cool to 25° C. over 30 minutes, diluted with 71 ml of ether, the mixture cooled to -12° C. and 2.13 g (0.0112 mole) cuprous iodide is added followed by addition of 8.00 g (0.0473 mole) of N-ethoxycarbonyl-2,3-dihydro-4(1H)-pyridinone in 47 ml of ether over 20 minutes. The reaction is stirred 30 minutes longer at -12° C. and then added to 2 liters ether and 600 ml saturated ammonium chloride. The organic extract is washed with three 600 ml portions of saturated ammonium chloride, dried over magnesium sulfate and evaporated to an oil. This crude product is purified via column chromatography on 2 kg of silica gel eluting in 500 ml fractions with 50% ether-hexane to yield (fractions 17-24) 16.0 g (71%) of the title compound as an oil.
PMR (CDCl 3 ) ppm (delta): 1.22 (s, gem CH 3 ), 2.47 (dd, J=7 and 5 Hz, CH 2 ), 2.91 (d, J=5 Hz, CH 2 ), 3.3-4.4 (m, CH 2 ), 4.09 (q, J=7 Hz, CH 2 ), 5.10 (s, OCH 2 ), 5.77 (t, J=6 Hz, CH), 6.8 (m, Ar, 2H), 7.10 (d, J=8 Hz, Ar, 1H), 7.39 (m, Ar, 5H).
IR (CHCl 3 ) 1721, 1681, 1605, 1570 cm -1 .
HRMS (m/e) 479.3278 (M + , Calcd. for C 30 H 41 NO 4 : 479.3025), 406, 388, 91.
EXAMPLE 2
N-Ethoxycarbonyl-cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol
To a -50° C. solution of 12.1 g (25.1 mmol) of N-ethoxycarbonyl-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinone in 90 ml methanol and 90 ml of tetrahydrofuran is added 1.04 g (27.5 mmole) of sodium borohydride. The reaction is stirred 2 hours at -50° C. and then allowed to warm to 25° C. The reaction is quenched by addition to 300 ml saturated sodium chloride and the mixture extracted with ethyl ether (2 liters). The organic extract is washed with 300 ml saturated sodium chloride, dried over magnesium sulfate and the ether evaporated in vacuo. The crude product is purified via column chromatography on 2 kg silica gel eluting in 500 ml fractions with 2% methanol-5% ether-93% dichloromethane to yield (fractions 20-26) 6.04 g (50%) of the title compound as an oil and 3.75 g (31% of a mixture of the title compound and its trans-isomer. Further chromatography yields pure trans-isomer.
Cis-Isomer
PMR (CDCl 3 ), ppm (delta): 1.22 (s, gem CH 3 ), 3.2-4.2 (m, CH 2 , CH), 4.02 (q, J=7 Hz, CH 2 ), 5.07 (s, OCH 2 ), 5.35 (t, J=6 Hz, CH), 6.8 (m, Ar, 2H), 7.06 (d, J=8 Hz, Ar, 1H), 7.35 (m, Ar, 5H).
IR (CHCl 3 ) 3559, 3443, 1672, 1610, 1572 cm -1 .
HRMS (m/e) 481.3154 (M + , Calcd. for C 30 H 43 NO 4 : 481.3181), 408, 390, 91.
Trans-Isomer
PMR (CDCl 3 ) ppm (delta): 1.22 (s, gem CH 3 ), 2.55 (m), 3.0-4.3 (m), 4.02 (q, J=7 Hz, CH 2 ), 5.08 (s, OCH 2 ), 5.68 (bd, J=6 Hz, 1H), 6.8 (m, Ar, 3H), 7.35 (m, Ar, 5H).
HRMS (m/e) 481.3275 (M + , Calcd. for C 30 H 43 NO 4 : 481.3181), 463, 408, 390, 91.
EXAMPLE 3
Cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol
To a solution of 4.62 g (9.59 mmole) of N-ethoxycarbonyl-cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol in 5 ml ethanol is added a solution of 4.2 g (75 mmole) of potassium hydroxide in 25 ml ethylene glycol and 4.2 ml water. The resultant mixture is evaporated at reduced pressure to remove ethanol and is then heated to reflux (bath 185° C.). After 24 hours material boiling at 80°-100° C. is removed by distillation, 6 ml ethylene glycol is added and the reaction continued at reflux for 17 hours. After cooling, the mixture is added to 500 ml dichloromethane and 80 ml water. The organic extract is washed with 80 ml saturated sodium chloride, dried over magnesium sulfate and evaporated in vacuo. The resulting crude oil is purified via column chromatography on 300 g of silica gel eluting in 20 ml fractions with 2.5% triethylamine, 2.5% methanol, 95% ethyl ether (fractions 1-109) and 5% triethylamine, 5% methanol, 90% ethyl ether (fractions 110-200). Fractions 138-190 gave 3.13 g (83%) of the title compound.
PMR (CDCl 3 ) ppm (delta): 1.22 (s, gem CH 3 ), 3.8 (m, 1H), 4.0 (m, 1H), 5.05 (s, OCH 2 ), 6.9 (m, Ar, 2H), 7.35 (m, Ar, 6H).
IR (CHCl 3 ) 3546, 3279, 1608, 1621 cm -1 .
HRMS (m/e) 409.2886 (M + , Calcd. for C 27 H 39 NO 2 : 409.2971), 392, 364, 318, 135, 91.
EXAMPLE 4
N-Ethoxycarbonyl-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinone
A mixture of 369 mg (0.77 mmole) of N-ethoxycarbonyl-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinone and 414 mg of 5% palladium on carbon (50% wet) in 5 ml ethanol was stirred under 1 atmosphere of hydrogen at 25° C. until the hydrogen uptake is complete (approximately 3 hours). The reaction is filtered through a filter aid, washing with ethanol and the filtrate evaporated in vacuo. The residual crude oil is purified via column chromatography on 22 g of silica gel eluting in 4 ml fractions with 15% ethyl ether in dichloromethane to yield (fractions 28-42) 174 mg (57%) of the title compound as an oil.
PMR (CDCl 3 ) ppm (delta): 0.83 (m, CH 3 ), 1.25 (s, gem --CH 3 ), 3.7-4.4 (m), 5.45 (m, 1H), 6.7-7.2 (m, Ar, 3H).
IR (CHCl 3 ) 3559, 3333, 1678, 1623, 1575 cm -1 .
HRMS (m/e) 389.2544 (M + , Calcd. for C 23 H 35 NO 4 : 389.2557), 316, 304, 300, 273, 258, 161, 142.
EXAMPLE 5
N-Methyl-cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol
To a 25° C. slurry of 267 mg (7.04 mmole) of lithium aluminum hydride in 12 ml ethyl ether is added dropwise over 30 minutes a solution of 1.50 g (3.11 mmole) of N-ethoxycarbonyl-cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol. The reaction is stirred for 0.5 hour at 25° C., then two hours at reflux. The reaction is quenched by addition of wet magnesium sulfate followed by decantation and washing of the salts with two 30 ml portions of ether. The ether extract is washed with 10 ml saturated sodium chloride, dried over magnesium sulfate and evaporated to give 1.19 g (91%) of the title compound as a solid.
PMR (CDCl 3 ) ppm (delta): 0.82 (m, CH 3 ), 1.24 (s, gem --CH 3 ), 2.00 (s, N--CH 3 ), 3.0 (m, 1H), 3.4-4.0 (m, 2H), 5.04 (s, OCH 2 ), 6.9 (m, Ar, 2H), 7.35 (m, Ar, 6H).
IR (CHCl 3 ) 3571, 3378, 1613, 1575 cm -1 .
HRMS (m/e) 423.3100 (M + , Cacld. for C 28 H 41 NO 2 : 423.3127), 408, 332, 314, 300, 246, 91.
EXAMPLE 6
N-Methyl-cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol
Using the procedure of Example 4, 1.13 g (2.68 mmole) of N-methyl-cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol and 452 mg of 5% palladium on carbon (50% wet) affords 0.752 g (84%) of the title compound as an oil.
PMR (CDCl 3 ) ppm (delta): 0.80 (m, CH 3 ), 1.22 (s, gem CH 3 ), 2.16 (s, NCH 3 ), 2.9-4.0 (m), 6.7 (m, Ar, 3H).
IR (CHCl 3 ) 3571, 3425, 1623, 1572, 1502 cm -1 .
HRMS (m/e) 333.2650 (M + , Calcd. for C 21 H 35 NO 2 : 333.2659), 318, 316, 249, 114.
EXAMPLE 7
A. N-Ethoxycarbonyl-cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol
Using the procedure of Example 4, 423 mg (0.878 mmole) of N-ethoxycarbonyl-cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol and 210 mg of 5% palladium on carbon (50% wet) provides 265 mg (77%) of the title compound as an oil.
PMR (CDCl 3 ) ppm (delta): 0.82 (m, CH 3 ), 1.22 (s, gem CH 3 ), 3.0-4.2 (m), 4.04 (q, J=7 Hz, CH 2 ), 5.26 (t, J=6 Hz, CH), 6.75 (m, Ar, 2H), 7.51 (d, J=8 Hz, Ar, H).
IR (CHCl 3 ) 3684, 3589, 3216, 1649, 1564 cm -1 .
HRMS (m/e) 391.2699 (M + , Calcd. for C 23 H 37 NO 4 : 391.2713), 318, 306, 300, 161.
B. Cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol
Similarly, 758 mg (1.85 mmol) of cis-2-[2-benzyloxy-4-(1,1-dimetylheptyl)phenyl]-4-piperidinol and 303 mg of 5% palladium-on-carbon (50% wet) yields 403 mg (68%) of the title compound, M.P. 97°-102° (dichloromethane-pentane).
PMR (CDCl 3 ) ppm (delta): 0.80 (m, CH 3 ), 1.22 (s, gem --CH 3 ), 1.22-4.8 (m), 6.8 (m, Ar, 3H).
IR (CHCl 3 ) 3559, 3378, 3279, 1623, 1570, 1493 cm -1 .
HRMS (m/e) 319.2465 (M + , Calcd. for C 20 H 33 NO 2 : 319.2503), 302, 274, 163, 161, 148, 100.
EXAMPLE 8
N-Propionyl-cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-propionylpiperidine
To a 25° C. solution of 689 mg (1.68 mmole) cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol and 1.02 g (8.36 mmole) 4-N,N-dimethylaminopyridine in 2.6 ml dichloromethane is added, at once, 0.64 ml (5.0 mmole) of propionic anhydride. The reaction is stirred 3 hours and then added to a mixture of 20 ml 1N hydrochloric acid and 100 ml ethyl ether. The organic layer is washed with 15 ml 1N hydrochloric acid, 25 ml saturated sodium bicarbonate, 20 ml saturated sodium chloride, dried over magnesium sulfate and the solvent is evaporated to afford an oil. The crude product is purified via column chromatography on 50 g of silica gel eluting in 10 ml fractions with 20% hexane in ethyl ether to give 768 mg (88%) of the title compound as an oil.
PMR (CDCl 3 ) ppm (delta): 0.62-1.3 (m, all CH 3 ), 4.5 (m, 1H), 5.05 (s, OCH 2 ), 5.37 (m, 1H), 6.8 (m, Ar, 2H), 7.00 (d, J=8 Hz, Ar, H), 7.35 (q, Ar, 5H).
IR (CHCl 3 ) 1736, 1639, 1575 cm -1 .
EXAMPLE 9
N-Propyl-cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol
A. N-Propyl-cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol
Using the procedure of Example 5, 723 mg (1.46 mmole) of N-propionyl-cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-propionyloxypiperidine and 129 mg (3.40 mmole) of lithium aluminum hydride gives 582 mg (88%) of the title compound as an oil.
PMR (CDCl 3 ) ppm (delta): 0.6-1.22 (m, all CH 3 ), 2.9-4.0 (m, 4H), 5.04 (s, OCH 2 ), 6.85 (m, Ar, 2H), 7.35 (m, Ar, 6H).
IR (CHCl 3 ) 3571, 3390, 1613, 1575 cm -1 .
HRMS (m/e) 451.3449 (M + , Calcd. for C 30 H 45 NO 2 : 451.3439), 422, 404, 91.
B. Employing the procedure of Example 4, 535 mg (1.18 mmole) N-propyl-cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol and 212 mg 5% palladium on carbon (50% wet) gives 402 mg (94%) of the title compound as an oil.
PMR (CDCl 3 ) ppm (delta): 0.65-1.25 (m, all CH 3 ), 3.0-4.0 (m, 3H), 6.75 (s, Ar, 3H).
IR (CHCl 3 ) 3521, 3367, 1613, 1565 cm -1 .
HRMS (m/e) 361.2963 (M + , Calcd. for C 23 H 39 NO 2 : 361.2971), 332, 314, 271.
EXAMPLE 10
N-(2-Propenyl)-cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol
A mixture of 778 mg (1.90 mmole) of cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol, 160 microliters (1.84 mmole) of 1-bromo-2-propene and 300 mg (2.17 mmole) of potassium carbonate in 10 ml ethanol is stirred at 25° C. for 20.5 hours. An additional 4 microliters of 1-bromo-2-propene is added to the reaction and stirring continued for 7 hours. The reaction mixture is then added to 50 ml saturated sodium chloride and extracted with 250 ml ethyl ether. The ether extract is dried over magnesium sulfate and the solvent is evaporated. The resulting oil is purified via column chromatography on 28 g of silica gel eluted in 7 ml fractions with 1:3 methanol/ethyl ether to yield (fractions 10-35) 518 mg (61%) of the title compound as an oil.
PMR (CDCl 3 ) ppm (delta): (m, CH 3 ), 1.22 (s, gem --CH 3 ), 3.0-4.0 (m, 5H), 4.8-5.2 (m, vinyl 2H), 5.02 (s, OCH 2 ), 5.3-6.2 (m, vinyl H), 6.9 (m, Ar, 2H), 7.35 (m, Ar, 6H).
IR (CHCl 3 ) 3584, 3436, 1675, 1647, 1618, 1580 cm -1 .
HRMS (m/e) 449.3199 (M + , Calcd. for C 30 H 43 NO 2 : 449.3283), 432, 408, 390, 358, 340, 328, 140, 91.
EXAMPLE 11
N-(2-Propenyl)-cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol
A solution of 6.8 ml (74.6 mmole) of propanethiol in 75 ml of tetrahydrofuran is degassed by three freeze-thaw cycles at 0.1 torr. The resultant solution is cooled to -78° C. and 28 ml of 2.5M n-butyllithium in hexane is added. The reaction is then allowed to warm to 25° C. and stirred 3 hours longer. The reaction is evaporated to dryness under high vacuum and the residue dissolved in 70 ml of degassed hexamethylphosphoramide. To a 25° C. degassed solution of 218 mg (0.486 mmole) of N-(2-propenyl)-cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol in 1 ml of hexamethylphosphoramide is added 2.2 ml of the above prepared solution of lithium propanethiolate. The reaction is stirred 30 minutes at 25° C. and 1.5 hour at 105° C. followed by cooling to 25° C. The reaction is quenched by addition to 30 ml water and the mixture extracted with 150 ml ethyl ether. The ether extract is washed twice with 30 ml water, once with 30 ml saturated sodium chloride, dried over magnesium sulfate and evaporated to an oil. The crude product is purified via column chromatography on 48 g of silica gel eluting in 8 ml fractions with ethyl ether to give (fractions 12-24) 101 mg (58%) of the title compound as an oil.
PMR (CDCl 3 ) ppm (delta): 0.80 (m, CH 3 ), 1.24 (s, gem --CH 3 ), 2.9-4.2 (m, 5H), 5.15 (m, vinyl 2H), 5.4-6.3 (m, vinyl H), 6.85 (m, Ar, 3H).
IR (CHCl 3 ) 3546, 3390, 1618, 1572, 1495 cm -1 .
HRMS (m/e) 359.2830 (M + , Calcd. for C 23 H 37 NO 2 : 359.2815), 318, 300, 275, 140.
EXAMPLE 12
N-Methoxycarbonyl-cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol
A. N-Methoxycarbonyl-cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol
To a 0° C. solution of 193 mg (0.471 mmole) of cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol and 0.29 ml triethylamine in 2.2 ml tetrahydrofuran is added dropwise 40 microliters (0.518 mmole) of methyl chloroformate. The reaction is stirred 40 minutes and then another 10 microliters of methyl chloroformate is added. The reaction is stirred 40 minutes longer, diluted with ether and filtered. The filtrate is washed with saturated sodium bicarbonate and saturated sodium chloride, dried over magnesium sulfate and evaporated to an oil. The crude product is purified via column chromatography on 10.4 g of silica gel eluting in 3 ml fractions with 1:3 ethyl ether/hexane to yield (fractions 16-30) 198 mg (80%) of the title compound as an oil.
PMR (CDCl 3 ) ppm (delta): 0.82 (m, CH 3 ), 1.20 (s, gem CH 3 ), 3.57 (s, OCH 3 ), 4.1 (m, CH), 5.02 (s, OCH 2 ), 5.33 (bt, J=6 Hz, CH), 6.85 (m, Ar, 2H), 7.00 (d, J=8 Hz, Ar, H), 7.27 (s, Ar, 5H).
IR (CHCl 3 ) 3521, 3390, 1681, 1597, 1570, 1490 cm -1 .
HRMS (m/e) 467.3070 (M + , Calcd. for C 29 H 41 NO 4 : 467.3025), 449, 409, 408, 376, 158, 91.
B. Debenzylation of 177 mg (0.377 mmole) of N-methoxycarbonyl cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol with 144 mg of 5% palladium on carbon (50% wet) by the procedure of Example 4 affords 81.3 mg (57%) of the title compound as an oil, 4.1 mg (3%) of by-product 5-(1,1-dimethylheptyl)-2-[3-hydroxy-5-(N-methoxycarbonylamino)pentyl]phenol as an oil, and 49.2 mg (35%) of a mixture of the two.
Title Compound
PMR (CDCl 3 ) ppm (delta): 0.8 (m, CH 3 ), 1.22 (s, gem --CH 3 ), 3.66 (s, OCH 3 ), 4.15 (m, CH), 5.36 (bt, J=7 Hz, CH), 6.8 (m, Ar, 2H), 7.55 (d, J=8 Hz, Ar, H).
IR (CHCl 3 ) 3534, 3145, 1647, 1616, 1560 cm -1 .
HRMS (m/e) 377.2565 (M + , Calcd. for C 22 H 35 NO 4 : 377.2557), 318, 292, 260, 161.
By-Product
HRMS (m/e) 379.2699 (M + , Calcd. for C 22 H 37 O 4 : 379.2713), 361, 347, 318, 147.
EXAMPLE 13
N-Methylsulfonyl-cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol
A. N-Methylsulfonyl-cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol
Reacting 409 mg (0.997 mmol) of cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol and 81 microliters (1.05 mmole) of methanesulfonyl chloride by the procedure of Example 12, Part A, gives 130 mg (27%) of the mesylate as an oil.
PMR (CDCl 3 ) ppm (delta): 0.82 (m, CH 3 ), 1.22 (s, gem --CH 3 ), 2.51 (s, SCH 3 ), 5.07 (s, OCH 2 ), 6.9 (m, Ar, 2H), 7.31 (m, Ar, 6H).
IR (CHCl 3 ) 3509, 3378, 1751, 1605, 1567, 1488.
HRMS (m/e) 487.2696 (M + , Calcd. for C 28 H 41 NO 4 S: 487.2746), 408, 402, 390, 91.
B. Hydrogenolysis of 121 mg (0.248 mmol) of N-methylsulfonyl-cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol with 110 mg of 5% palladium on carbon (50% wet) by the procedure of Example 4 gives 85.3 mg (86%) of the title compound as an oil.
PMR (CDCl 3 ) ppm (delta): 0.8 (m, CH 3 ), 1.22 (s, gem --CH 3 ), 2.46 (s, SCH 3 ), 4.67 (t, J=7 Hz, CH), 6.85 (m, Ar, 2H), 7.22 (d, J=8 Hz, Ar, H).
IR (CHCl 3 ) 3534, 3344, 1613, 1563, 1493 cm -1 .
HRMS (m/e) 397.2253 (M + , Calcd. for C 21 H 35 NO 4 S: 397.2313), 318, 312, 300, 294, 161.
EXAMPLE 14
N-(3-Hydroxypropionyl)-cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol
A. N-(3-Benzyloxy)propionyl-cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol
To a solution of 789 mg (1.93 mmole) of cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol and 347 mg (1.93 mmole) of 3-benzyloxypropionic acid in 2.5 ml of dichloromethane is added 403 mg (1.95 mmole) of dicyclohexylcarbodiimide. The reaction is stirred for 3.5 hours and then an additional 42.9 mg of dicyclohexylcarbodiimide is added. The reaction is stirred 18 hours longer and then filtered. The filtrate is washed with 1N hydrochloric acid, saturated sodium bicarbonate solution, dried over magnesium sulfate and evaporated to an oil. This crude product is purified via column chromatography on 78 g of silica gel, eluting in 16 ml fractions with 1:3 ethyl ether/hexane to give 712 mg (65%) of the desired amide as an oil which is used in the next step.
PMR (CDCl 3 ) ppm (delta): 0.82 (m, CH 3 ), 1.20 (s, gem CH 3 ), 4.47 (s, OCH 2 ), 5.08 (s, OCH 2 ), 5.4 (m, 1H), 6.95 (m, Ar, H), 7.23 (s, Ar, 5H), 7.36 (s, Ar, 5H).
IR (CHCl 3 ) 3623, 3460, 1626, 1572, 1481 cm -1 .
HRMS (m/e) 571.3584 (M + , Calcd. for C 37 H 49 NO 4 : 571.3649), 480, 408, 318, 91.
B. Hydrogenolysis of 710 mg (1.24 mmole) of N-(3-benzyloxypropionyl)-cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol with 700 mg of 5% palladium on carbon (50% wet) by the method of Example 4 yields 429 mg (88%) of the title compound.
M.P. 119°-121° C.
PMR (CDCl 3 ) ppm (delta): 0.82 (m, CH 3 ), 1.22 (s, gem CH 3 ), 3.3-4.3 (m), 5.59 (t, J=7 Hz, CH), 6.8 (m, Ar, 2H), 7.57 (d, J=8 Hz, Ar, H).
IR (CHCl 3 ) 3571, 3125, 1587 cm -1 .
HRMS (m/e) 391.2716 (M + , Calcd. for C 23 H 37 NO 4 : 391.2713), 374, 319, 318, 302, 161.
Analysis: Calcd. for C 23 H 37 NO 4 : C, 70.55; H, 9.53; N, 3.58. Found: C, 70.66; H, 9.19; N, 3.61.
EXAMPLE 15
N-Butyryl-cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol
A. N-Butyryl-cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol
Acylation of 421 mg (1.03 mmole) of cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol with 110 mg (1.03 mmol) of butyryl chloride by the procedure of Example 12, Part A, gives 530 mg (96%) of the desired amide as an oil.
PMR (CDCl 3 ) ppm (delta): 0.8-1.2 (m, all CH 3 ), 5.10 (s, OCH 2 ), 5.35 (m, CH), 6.85 (m, Ar, 2H), 7.04 (d, J=8 Hz, Ar, H), 7.35 (s, Ar, 5H).
IR (CHCl 3 ) 3655, 3587, 3451, 1627, 1572 cm -1 .
HRMS (m/e) 479.3418 (M + , Calcd. for C 31 H 45 NO 3 : 479.3388), 408, 388, 372, 318, 300, 100, 91.
B. Debenzylation of 529 mg (1.10 mmol) of the product of Part A, above with 301 mg of 5% palladium on carbon (50% wet) by the method of Example 4 affords 334 mg (78%) of the title compound as an oil.
PMR (CDCl 3 ) ppm (delta): 0.7-1.2 (m, all CH 3 ), 3.55 (m, CH 2 ), 4.05 (m, CH), 5.61 (t, J=7 Hz, CH), 6.8 (m, Ar, 2H), 7.62 (d, J=8 Hz, Ar, H).
IR (CHCl 3 ) 3686, 3591, 3448, 1548, 1499 cm -1 .
HRMS (m/e) 389.2903 (M + , Calcd. for C 24 H 39 NO 3 : 389.2920), 372, 318, 302, 284, 274, 257, 234, 217, 161, 100.
Employing the appropriate acid chloride in place of butyryl chloride in the procedure of Part A, above and debenzylation by the method of Part B similarly provides the following amides:
______________________________________ ##STR12## Yield,R.sub.1 R.sub.2 % Physical Data______________________________________benzyl acetyl 99 PMR (CDCl.sub.3) ppm (delta): 0.8 (m, CH.sub.3), 1.22 (s, gem CH.sub.3), 1.91 (s, CH.sub.3), 5.08 (s, OCH.sub.2), 5.27 (m, CH), 6.82 (m, Ar, 2H), 7.03 (d, J = 8 Hz, Ar, H), 7.35 (s, Ar, 5H). IR (CHCl.sub.3) 3587, 3420, 1630, 1573, 1495 cm.sup.-1. HRMS (m/e) 451.3089 (M.sup.+, Calcd. for C.sub.29 H.sub.41 NO.sub.3 : 451.3076), 408, 360, 344, 318, 300, 91.H acetyl 91 PMR (CDCl.sub.3) ppm (delta); 0.8 (m, CH.sub.3), 1.22 (s, gem CH.sub.3), 2.08 (s, CH.sub.3), 3.55 (m, 2H), 4.08 (m, CH), 5.57 (t, J = 7 Hz, CH), 6.81 (m, Ar, 2H), 7.63 (d, J = 8 Hz, Ar, H). IR (CHCl.sub.3) 3598, 3405, 1603, 1499 cm.sup.-1. HRMS (m/e) 361.2596 (M.sup.+ Calcd. for C.sub.22 H.sub.35 NO.sub.3 : 361.2608), 344, 318, 302, 234, 217, 199, 162, 161.benzyl propionyl 100 PMR (CDCl.sub.3) ppm (delta): 1.20 (s, gem CH.sub.3), 5.06 (s, OCH.sub.2), 5.29 (m, CH), 6.78 (m, Ar, 2H), 6.98 (d, J = 8 Hz, Ar, H), 7.30 (m, Ar, 5H). IR (CHCl.sub.3) 3591, 3444, 1630, 1572, 1496 cm.sup.-1. HRMS (m/e) 465.2646 (M.sup.+, Calcd. for C.sub.30 H.sub.43 NO.sub.3 : 465.3232), 408, 318, 91.H propionyl 91 PMR (CDCl.sub.3) ppm (delta): 1.22 (s, gem CH.sub.3), 3.53 (m, 2H), 4.1 (m, CH), 5.63 (bt, J = 7 Hz, CH), 6.82 (m, Ar, 2H), 7.63 (d, J = 8 Hz, Ar, H). IR (CHCl.sub.3) 3595, 3400, 1601, 1499 cm.sup.-1. HRMS (m/e) 375.2711 (M.sup.+, Calcd. for C.sub.23 H.sub.37 NO.sub.3 : 375.2764), 358, 346, 318, 302, 300, 284, 234, 217, 199.benzyl n-pentanoyl 99 PMR (CDCl.sub.3) ppm (delta): 0.8-1.2 (m, all CH.sub.3), 5.10 (s, OCH.sub.2), 5.30 (bt, J = 6 Hz, CH), 6.87 (m, Ar, 2H), 7.02 (d, J = 8 Hz, Ar, H), 7.36 (m, Ar, 5H). IR (CHCl.sub.3) 3593, 3457, 1629, 1573, 1495 cm.sup.-1. HRMS (m/e) 493.3224 (M.sup.+, Calcd. for C.sub.32 H.sub.47 NO.sub.3 : 493.3544), 408, 402, 386, 318, 91.H n-pentanoyl 47 PMR (CDCl.sub.3) ppm (delta): 1.22 (s, gem CH.sub.3), 3.55 (m, 2H), 4.15 (m, CH), 5.60 (bt, J = 6 Hz, CH), 6.79 (m, Ar, 2H), 7.60 (d, J = 8 Hz, Ar, H). IR (CHCl.sub.3) 3595, 3420, 1598, 1499 cm.sup.-1. HRMS (m/e) 403.3072 (M.sup.+, Calcd. for C.sub.25 H.sub.41 NO.sub.3 : 403.3076), 387, 324.______________________________________
EXAMPLE 16
N-(3-Hydroxypropyl)-cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol
Reduction of 593 mg (1.51 mmole) of N-(3-hydroxypropionyl)-cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol with 152 mg (4.01 mmole) of lithium aluminum hydride by the procedure of Example 5 provides 398 mg (70%) of the title compound as an oil.
PMR (CDCl 3 ) ppm (delta): 1.24 (s, gem --CH 3 ), 3.0-4.6 (m), 6.75 (s, Ar, 3H).
IR (CHCl 3 ) 3592, 3462, 1622, 1605, 1573 cm -1 .
HRMS (m/e) 377.2933 (M + , Calcd. for C 23 H 39 NO 3 : 377.2920), 332, 314, 271, 161, 158, 88.
EXAMPLE 17
N-Formyl-cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol
A. N-Formyl-cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol
Using the procedure of Example 14, Part A, 1.81 g (4.42 mmole) of cis-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinol, 206 mg (4.48 mmole) of formic acid and 1.04 g (5.04 mmole) of dicyclohexylcarbodiimide gives 1.32 g (70%) of the corresponding formamide.
M.P. 119.5°-122.5° C. (recrystallized from methanol).
PMR (CDCl 3 ) ppm (delta): 0.82 (m, CH 3 ), 1.23 (s, gem --CH 3 ), 5.02 (s, OCH 2 ), 6.88 (m, Ar, 2H), 7.25 (m, Ar, 6H), 7.58 (s, CHO).
IR (CHCl 3 ) 3687, 3586, 3426, 1648, 1611, 1571, 1494 cm -1 .
HRMS (m/e) 437.2935 (M + , Calcd. for C 28 H 39 NO 3 : 437.2920), 408, 347, 91.
B. Debenzylation of 1.31 g (2.99 mmol) of the product of Part A with 830 mg of 5% palladium on carbon (50% wet) gives 752 mg (72%) of the title compound.
M.P. 149°-150° C. (recrystallized from methanol-water).
PMR (CDCl 3 ) ppm (delta): 0.80 (m, CH 3 ), 1.25 (s, gem --CH 3 ), 6.75 (m, Ar, 2H), 7.10 (d, J=8 Hz, Ar, H), 7.49 (s, CHO).
IR (CHCl 3 ) 3593, 3250, 1644, 1585 cm -1 .
HRMS (m/e) 347.2415 (M + , Calcd. for C 21 H 33 NO 3 : 347.2452), 346, 330, 262, 161.
Analysis: Calcd. for C 21 H 33 NO 3 : C, 72.60; H, 9.57; N, 4.03. Found: C, 73.38; H, 9.24; N, 3.95.
EXAMPLE 18
N-Propioloyl-cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol
Repeating the procedure of Example 10, but with 760 mg (2.38 mmole) of cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol, 970 mg (11 mmole) of propynoyl chloride and 2.07 g (15 mmole) of potassium carbonate in 70 ml of tetrahydrofuran yields 430 mg (38%) of the title compound as an oil.
PMR (CDCl 3 ) ppm (delta): 0.82 (m, CH 3 ), 1.22 (s, gem --CH 3 ), 3.11 (s, CH), 5.65 (bt, J=6 Hz, CH), 6.80 (m, Ar, 2H), 7.60 (d, J=8 Hz, Ar, H).
IR (CHCl 3 ) 3595, 3296, 3200, 2110, 1621, 1602, 1500 cm -1 .
HRMS (m/e) 371.2495 (M + , Calcd. for C 23 H 33 NO 3 : 371.2452), 354, 287, 286, 233, 199, 187, 161.
EXAMPLE 19
N-(2-Propynyl)-cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol
Employing the procedure of Example 10 with 321 mg (1.01 mmole) of cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol, 82 microliter (1.06 mmole) or propynyl bromide and 292 mg (2.12 mmole) of potassium carbonate affords 205 mg (57%) of the title compound as an oil.
PMR (CDCl 3 ) ppm (delta): 0.82 (m, CH 3 ), 1.25 (s, gem --CH 3 ), B 2.22 (t, J=2 Hz, .tbd.CH), 3.35 (d, J=2 Hz, 2H), 6.78 (Ar, 3H).
IR (CHCl 3 ) 3595, 3303, 1627, 1576, 1502 cm -1 .
HRMS (m/e) 357.2682 (M + , Calcd. for C 23 H 35 NO 2 : 357.2659), 340, 318, 233, 138.
EXAMPLE 20
N-Ethoxycarbonyl-2-[2-benzyloxy-4-(5-phenyl-2-pentyloxy)phenyl]-4-piperidon
Repeating the procedure of Example 1 but preparing the Grignard reagent with 2-benzyloxy-4-(5-phenyl-2-pentyloxy)bromobenzene, affords the title compound in like manner.
EXAMPLE 21
Similarly, the following products are prepared by the procedure of Example 1 ##STR13## where Z and W are as defined below.
______________________________________ Z W______________________________________C(CH.sub.3).sub.2 (CH.sub.2).sub.2 HC(CH.sub.3).sub.2 (CH.sub.2).sub.10 HC(CH.sub.3).sub.2 (CH.sub.2).sub.4 C.sub.6 H.sub.5C(CH.sub.3).sub.2 (CH.sub.2).sub.4 4-pyridylC(CH.sub.3).sub.2 (CH.sub.2).sub.3 2-pyridylC(CH.sub.3).sub.2 (CH.sub.2).sub.10 C.sub.6 H.sub.5CH(CH.sub.3)(CH.sub.2).sub.2 C.sub.6 H.sub.5CH(C.sub.2 H.sub.5)(CH.sub.2).sub.2 4-ClC.sub.6 H.sub.5CH(C.sub.2 H.sub.5)(CH.sub.2).sub.4 4-FC.sub.6 H.sub.4(CH.sub.2).sub.5 HCH.sub. 2 C.sub.6 H.sub.5(CH.sub.2).sub.11 H(CH.sub.2).sub.13 H(CH.sub.2).sub.4 C.sub.6 H.sub.5(CH.sub.2).sub.8 HO(CH.sub.2).sub.4 4-FC.sub.6 H.sub.4O(CH.sub.2).sub.8 C.sub.6 H.sub.5O(CH.sub.2).sub.10 4-ClC.sub.6 H.sub.4OCH(CH.sub.3)(CH.sub.2).sub.8 C.sub.6 H.sub.5OCH(CH.sub.3)CH.sub.2 4-FC.sub.6 H.sub.4OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5OCH.sub.2 CH(CH.sub.3 )CH.sub.2 C.sub.6 H.sub.5OCH(CH.sub.3)(CH.sub.2).sub.10 HOC(CH.sub.3).sub.2 (CH.sub.2).sub.5 HOC(CH.sub.3).sub.2 (CH.sub.2).sub.7 HO(CH.sub.2).sub.13 HO(CH.sub.2).sub.13 C.sub.6 H.sub.5OCH(CH.sub.3)(CH.sub.2).sub.6 4-FC.sub.6 H.sub.4OC(CH.sub.3).sub.2 (CH.sub.2).sub.10 4-FC.sub.6 H.sub.4O(CH.sub.2).sub.12 C.sub.6 H.sub.5O(CH.sub.2).sub.6 C.sub.6 H.sub.5O(CH.sub.2).sub.2 4-pyridylOCH(CH.sub.3)(CH.sub.2).sub.3 2-pyridylO(CH.sub.2).sub.5 3-pyridylO(CH.sub.2).sub.10 2-pyridylOCH(C.sub.2 H.sub.5)(CH.sub.2).sub.2 4-pyridyl______________________________________
EXAMPLE 22
In like manner the following congeners are prepared by the procedure of Example 1 from the appropriate N-substituted-2,3-dihydro-4(1H)pyridinone and 2-benzyloxy-4-ZW-substituted bromobenzene.
______________________________________ ##STR14##R.sub.2 Z W______________________________________CH.sub.3 C(CH.sub.3).sub.2 (CH.sub.2).sub.6 H(CH.sub.2).sub.2 CH.sub.3 C(CH.sub.3).sub.2 (CH.sub.2).sub.6 HCH.sub.2 CH(CH.sub.3).sub.2 C(CH.sub.3).sub.2 (CH.sub.2).sub.6 H(CH.sub.2).sub.4 OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5CH.sub.2 CH(C.sub.2 H.sub.5).sub.2 OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5CH(CH.sub.3)CH.sub.2 CH.sub.3 CH.sub.2 OCH.sub.2 H(CH.sub.2).sub.5 CH.sub.3 CH.sub.2 O(CH.sub.2).sub.4 C.sub.6 H.sub.5CH.sub.2 CH(CH.sub.3)(CH.sub.2).sub.2 CH.sub.3 CH.sub.2 O(CH.sub.2).sub.12 4-FC.sub.6 H.sub.4CHCH.sub.2 CH.sub.2 OCH.sub.2 CH(C.sub.2 H.sub.5)CH.sub.2 4-pyridylCH.sub.2 CHCH.sub.2 CH.sub.2).sub.2 O(CH.sub.2).sub.2 HCH.sub.2 CHCHCH.sub.3 (CH.sub.2).sub.3 O(CH.sub.2).sub.3 H(CH.sub.2).sub.2 CHCH.sub.2 (CH.sub.2).sub.3 O(CH.sub.2).sub.5 HCH.sub.2 CHCH(CH.sub.2).sub.2 CH.sub.3 (CH.sub.2).sub.5 O(CH.sub.2).sub.8 HCH.sub.2 CHCH.sub.2 (CH.sub.2).sub.6 O(CH.sub.2).sub.7 C.sub.6 H.sub.5C(CH.sub.3)CHCH.sub.2 CH(CH.sub.3)(CH.sub.2).sub.2 O(CH.sub.2).sub.4 HC(CH.sub.3)CHCHCH.sub.3 (CH.sub.2).sub.6 O C.sub.6 H.sub.5CH.sub.2 C(CH.sub.3)CH.sub.2 (CH.sub.2).sub.13 O 2-pyridyl(CH.sub.2).sub.4 CHCH.sub.2 CH(CH.sub.3)(CH.sub.2).sub.2 O C.sub.6 H.sub.5CHCHCH.sub.3 (CH.sub.2).sub.8 O 4-pyridylCH.sub.3 CO (CH.sub.2).sub.3 O 2-pyridylCH.sub.3 CH.sub.2 CO (CH.sub.2).sub.3 OCH(CH.sub.3) C.sub.6 H.sub.5CH.sub.3 (CH.sub.2).sub.2 CO C(CH.sub.3).sub.2 (CH.sub.2).sub.5 H(CH.sub.3).sub.2 CHCH.sub.2 CO O(CH.sub.2).sub.5 4-FC.sub.6 H.sub.4CH.sub.3 (CH.sub.2).sub.5 CO O(CH.sub.2 ).sub.13 C.sub.6 H.sub.5(CH.sub.3).sub.2 CHCO OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5(CH.sub.3).sub.2 C(CH.sub.3)CO OCH(CH.sub.3)(CH.sub.2).sub.3 4-ClC.sub.6 H.sub.4(C.sub.2 H.sub.5).sub.2 CHCO (CH.sub.2).sub.4 O(CH.sub.2).sub.5 4-pyridyl(C.sub.2 H.sub.5).sub.2 CHCH.sub.2 CO (CH.sub.2).sub.8 O(CH.sub.2).sub.5 4-pyridylHCO CH.sub.2 HCH.sub.3 OCO CH.sub.2 C.sub.6 H.sub.5C.sub.2 H.sub.5 OCO OCH.sub.2 HC.sub.2 H.sub.5 OCO OCH.sub.2 C.sub.6 H.sub.5CH.sub.3 OCO (CH.sub.2).sub.4 OCH.sub.2 HCH.sub.3 OCO CH.sub.2 O(CH.sub.2).sub.12 Hn-C.sub.3 H.sub.7 OCO CH.sub.2 OCH.sub.2 C.sub.6 H.sub.5n-C.sub.3 H.sub.7 OCO (CH.sub.2).sub.2 O(CH.sub.2).sub.2 Hi-C.sub.4 H.sub.9 OCO C(CH.sub.3).sub.2 (CH.sub.2).sub.6 Hn-C.sub.5 H.sub.11 OCO C(CH.sub.3).sub.2 (CH.sub.2).sub.6 Hn-C.sub.6 H.sub.13 OCO OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5i-C.sub.4 H.sub.9 OCO OCH(CH.sub.3)(CH.sub.2).sub.3 4-ClC.sub.6 H.sub.4sec-C.sub.5 H.sub.11 OCO (CH.sub.2).sub.5 H______________________________________
EXAMPLE 23
Sodium borohydride reduction of the 4-piperidones prepared in Examples 20-22 by the method of Example 2 similarly provides the corresponding 4-hydroxypiperidines of the formula below where R 1 is benzyl. ##STR15## Catalytic hydrogenolysis employing a palladium catalyst and the method of Example 4 likewise provides the corresponding phenols where R 1 is hydrogen. In each case R 2 , Z and W are as defined in Examples 20-22.
EXAMPLE 24
cis-2-[(5-phenyl-2-pentyloxy)-2-hydroxyphenyl]-4-piperidinol
Hydrolysis of N-ethoxycarbonyl-2-[2-benzyloxy-4-(5-phenyl-2-pentyloxy)phenyl]-4-piperidinol by the procedure of Example 3 and subsequent hydrogenolysis by the procedure of Example 4 provides the title compound in like manner.
Similarly the compounds of the formula below are obtained from the remaining N-alkoxycarbonyl compounds provided in Example 23 ##STR16## where Z and W are as defined in Examples 21 and 22.
EXAMPLE 25
cis-N-Methyl-2-[4-(5-phenyl-2-pentyloxy)-2-hydroxyphenyl]-4-piperidinol
Lithium aluminum hydride reduction of N-ethoxycarbonyl-2-[4-(5-phenyl-2-pentyloxy)-2-benzyloxyphenyl]-4-piperidone or the corresponding 4-piperidinol by the method described in Example 5 and debenzylation by the method of Example 6 provides the title compound.
In similar manner the compounds of the formula below are obtained ##STR17## where R 1 is H or benzyl, R 2 is methyl and Z and W are as defined for the starting materials provided in Examples 21-23. In like manner the corresponding N-alkyl compounds [R 2 =(C 2 -C 6 )alkyl] are obtained when the alkanoylamides provided in Example 22 are employed as starting material.
EXAMPLE 26
N-Propyl-cis-2-[4-(5-phenyl-2-pentyloxy)-2-hydroxyphenyl]-4-piperidinol
Acylation of 2-[4-(5-phenyl-2-pentyloxy)-2-benzyloxyphenyl]-4-piperidinol with propionic anhydride by the method of Example 8, followed by lithium aluminum hydride reduction of the resulting N,O-dipropionyl intermediate by the method of Example 9, Part A, and finally, debenzylation by the method of Example 9, Part B, provides the title compound in like manner.
Similarly, the reaction of piperidinol bases provided in Examples 3 and 24 by the above reaction sequence, but employing the appropriate acid anhydride or acid chloride in place of propionic anhydride, provides the corresponding compounds as shown in the following reaction sequence: ##STR18## Z and W are as defined in Examples for the starting piperidinol and R 6 is an (C 1 -C 6 )alkyl residue.
EXAMPLE 27
N-Isobutyl-2-[2-hydroxy-4-(1,1-dimethylheptyl)phenyl]piperidine
A. N-Isobutyl-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]piperidine
A mixture of 2.32 g (5 mmoles) of N-isobutyl-2-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidone, 10.2 ml hydrazine hydrate and 20 ml ethylene glycol is heated at 100° C. for one hour. The mixture is cooled to 60° C, and 4.05 g (72.3 mmoles) solid potassium hydroxide is added. After heating at 200° C. for two hours, the reaction mixture is cooled and added to 500 ml 1N hydrochloric acid and 300 ml ethyl ether. The ether layer is separated, washed with brine, sodium bicarbonate solution, dried over magnesium sulfate and the solvent evaporated at reduced pressure. The crude product is purified, if desired, by column chromatography on silica gel.
B. Debenzylation of the product obtained in Part A by the method of Example 4 provides the title compound.
C. In like manner the remaining N-alkyl piperidones and N-alkenylpiperidones provided in Example 22 are converted to the corresponding piperidine compounds of the formula ##STR19## where R 2 is an alkyl or alkenyl residue as defined in Example 22.
EXAMPLE 28
Employing the appropriate alkenyl bromide, alkenyl chloride or alkenyl iodide and the appropriate 2-[2-benzyloxy-4-(ZW-substituted)phenyl]-4-piperidinol in the procedure of Example 10 provides the corresponding compound of the formula below where R 1 is benzyl. Removal of the benzyl group by the procedure of Example 4 yields the compound where R 1 is H. In each case R 2 is a (C 2 -C 6 )alkenyl group and Z and W are as defined in Example 22. ##STR20##
EXAMPLE 29
By means of the procedures of Examples 12 through 19, above, but employing the appropriate starting materials in each case, the following compounds are obtained in like manner.
______________________________________ ##STR21##R.sub.2 Z W______________________________________CH.sub.3 OCO CH.sub.2 HC.sub.2 H.sub.5 OCO OCH.sub.2 C.sub.6 H.sub.5CH.sub.3 OCO (CH.sub.2).sub.4 O(CH.sub.2).sub.2 Hn-C.sub.3 H.sub.7 OCO CH.sub.2 OCH.sub.2 C.sub.6 H.sub.5i-C.sub.4 H.sub.9 OCO OCH.sub.2 (CH.sub.3)(CH.sub.2).sub.3 4-ClC.sub.6 H.sub.4n-C.sub.6 H.sub.13 OCO OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5C.sub.2 H.sub.5 OCO C(CH.sub.3).sub.2 (CH.sub.2).sub.4 4-pyridylCH.sub.3 CH.sub.2 SO.sub.2 C(CH.sub.3).sub.2 (CH.sub.2).sub.6 HCH.sub.3 SO.sub.2 OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5i-C.sub.3 H.sub.7 SO.sub.2 (CH.sub.2).sub.11 Hn-C.sub.3 H.sub.7 SO.sub.2 C(CH.sub.3).sub.2 (CH.sub.2).sub.10 C.sub.6 H.sub.5n-C.sub.4 H.sub.9 SO.sub.2 O(CH.sub.2).sub.4 4-FC.sub.6 H.sub.4i-C.sub.4 H.sub.9 SO.sub.2 CH.sub.2 OCH(CH.sub.3)(CH.sub.2).sub.4 2-pyridylsec-C.sub.4 H.sub.9 SO.sub.2 O(CH.sub.2).sub.2 4-pyridyln-C.sub.5 H.sub.11 SO.sub.2 OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5(CH.sub.3).sub.2 CH(CH.sub.2).sub.3 SO.sub.2 OCH(CH.sub.3)(CH.sub.2).sub.3 4-ClC.sub.6 H.sub.4HOCH.sub.2 CO OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5HOCH.sub.2 CH.sub.2 OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5HO(CH.sub.2).sub.2 CO OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5HO(CH.sub.2).sub.2 CH.sub.2 OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5CH.sub.3 CH(OH)CO CH(CH.sub.3)(CH.sub.2).sub.4 HCH.sub.3 CH(OH)CH.sub.2 C(CH.sub.3).sub.2 (CH.sub.2).sub.4 HHO(CH.sub.2).sub.3 CO C(CH.sub.3).sub.2 (CH.sub.2).sub.4 HHO(CH.sub.2).sub.3 CH.sub.2 C(CH.sub.3).sub.2 (CH.sub.2).sub.4 HHO(CH.sub.2).sub.4 CO OCH(CH.sub.3)CH(CH.sub.3)(CH.sub.2).sub.4 C.sub.6 H.sub.5HO(CH.sub.4)CH.sub.2 OCH(CH.sub.3 )CH(CH.sub.3)(CH.sub.2).sub.4 C.sub.6 H.sub.5CH.sub.3 CH.sub.2 CH(OH)CH.sub.2 CO (CH.sub.2).sub.4 O(CH.sub.2).sub.4 2-pyridylCH.sub.3 CH.sub.2 CH(OH)CH.sub.2 CH.sub.2 (CH.sub.2).sub.4 O(CH.sub.2).sub.4 2-pyridylCH.sub.3 (CH.sub.2).sub.2 CH(OH)CH.sub.2 CO (CH.sub.2).sub.4 O(CH.sub.2).sub.9 HHO(CH.sub.2).sub.6 CO (CH.sub.2).sub.9 O(CH.sub.2).sub.4 HHO(CH.sub.2).sub.6 CH.sub.2 (CH.sub.2).sub.9 O(CH.sub.2).sub.4 HCH.sub.3 (CH.sub.2).sub.4 CH(OH)CO OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5CH.sub.3 (CH.sub.2).sub.4 CH(OH)CH.sub.2 OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5CHO OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5CHO (CH.sub.2).sub.3 O(CH.sub.2).sub.3 HCH.sub.3 CO OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5CH.sub.3 CH.sub.2 CO (CH.sub.2).sub.4 O C.sub.6 H.sub.5(CH.sub.3).sub.2 CHCO (CH.sub.2).sub.3 O 4-ClC.sub.6 H.sub.4CH.sub.3 (CH.sub.2).sub.3 CO OC(CH.sub.3 ).sub.2 (CH.sub.2).sub.4 HHCCCO OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5HCCCH.sub.2 CO OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5CH.sub.3 CCCH.sub.2 CO OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5HCC(CH.sub.2).sub.4 CO C(CH.sub.3).sub.2 (CH.sub.2).sub.6 HCH.sub.3 (CH.sub.2).sub.3 CCCO C(CH.sub.3).sub.2 (CH.sub.2).sub.6 HCH.sub.3 CH.sub.2 CCCH.sub.2 CO OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5HCCCH.sub.2 OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5CHCCH.sub.2 (CH.sub.2).sub.2 O(CH.sub.2).sub.4 HHC CCH.sub.2 CH(CH.sub.3)(CH.sub.2).sub.3 O C.sub.6 H.sub.5CH.sub.3 CCCH.sub.2 (CH.sub.2).sub.4 O 4-pyridylHCC (CH.sub.2).sub.3 O 2-pyridylHCC OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5CH.sub.3 CH.sub.2 CCCH.sub.2 OCH(CH.sub.3)(CH.sub.2).sub.3 4-ClC.sub.6 H.sub.5CH.sub.3 CHCC(CH.sub.2).sub.2 C(CH.sub.3).sub.2 (CH.sub.2).sub.3 HCH.sub.3 (CH.sub.2).sub.2 CCCH.sub.2 C(CH.sub.3).sub.2 (CH.sub.2).sub.3 2-pyridyl______________________________________
EXAMPLE 30
N-n-Butyryl-2-[2-hydroxy-4-(5-phenyl-2-pentyloxy)phenyl]-4-piperidone
A. To a cooled solution of 25.8 g (50 mmol) N-n-butyryl-2-[benzyloxy-4-(5-phenyl-2-pentyloxy)phenyl]-4-piperidinol, 100 ml acetone, 6.0 g. (60 mmole) chromium trioxide, 15 ml water and 20 ml acetic acid is added dropwise 20 ml concentrated sulfuric acid at such a rate as to maintain the temperature at 5° C. The resulting mixture is stirred at 5°-20° C. for five hours, and then neutralized with ammonium hydroxide. The mixture is extracted with ethyl ether, the extracts washed with brine, dried (MgSO 4 ) and the solvent evaporated. The resulting crude material is purified by chromatography on silica gel to afford N-n-butyryl-2-[2-benzyloxy-4-(5-phenyl-2-pentyloxy)phenyl]-4-piperidone.
B. A mixture of 5 g of the benzyl ether obtained in Part A is dissolved in 100 ml ethanol and 100 ml ethyl acetate. To this is added 2 g of 10% palladium on carbon catalyst and the mixture is stirred under one atmosphere of hydrogen for 3 hours. The product is isolated and purified by the method of Example 4.
C. The remaining 4-piperidinols provided above are converted to the corresponding 4-piperidones of the formula below in like manner. ##STR22##
EXAMPLE 31
N-Propyl-2-[2-(4-N-piperidylbutyryloxy)-4-(1,1-dimethylheptyl)phenyl]-4-piperidinone Hydrochloride
To a solution of 0.9 g (2.5 mmole) N-propyl-2-[2-hydroxy-4-(1,1-dimethylheptyl)phenyl]-4-piperidinone in 25 ml methylene chloride is added 0.52 g (2.5 mole) 4-piperidylbutyric acid hydrochloride, 0.573 g (2.78 mmole) dicyclohexylcarbodiimide and the mixture is stirred at room temperature for six hours. After holding overnight at 0° C., the mixture is filtered, the filtrate evaporated and the residue triturated with ethyl ether to afford the desired hydrochloride salt.
Alternatively, the filtrate is extracted with dilute hydrochloric acid. The aqueous phase washed with ether, neutralized with potassium hydroxide solution and extracted with ether. Evaporation affords the free base of the title compound.
Repetition of this procedure, but employing the appropriate phenol of the formula below where R 1 is H, and the appropriate carboxylic acid in place of 4-piperidylbutric acid hydrochloride provides the following compounds in like manner ##STR23## where R 2 , R 3 , Z and W are as defined above and R 1 is as shown below.
R 1
COCH 2 CH 3
CO(CH 2 ) 2 CH 3
CO(CH 2 ) 3 CH 3
COCH 2 NH 2
CO(CH 2 ) 2 NH 2
CO(CH 2 ) 4 NH 2
CO(CH 2 )N(CH 3 ) 2
CO(CH 2 ) 2 NH(C 2 H 5 )
CO(CH 2 ) 4 NHCH 3
CONH 2
CON(C 2 H 5 ) 2
CON(C 4 H 9 ) 2
CO(CH 2 ) 3 NH(C 3 H 7 )
CO(CH 2 ) 2 N(C 4 H 9 ) 2
COCH 2 -piperidino
COCH 2 -pyrrolo
CO(CH 2 ) 2 -morpholino
CO(CH 2 ) 2 -N-butylpiperazino
CO(CH 2 ) 3 -pyrrolidino
CO-piperidino
CO-morpholino
CO-pyrrolo
CO--N-(methyl)piperazino
CO--C 6 H 5
COCH(CH 3 )(CH 2 ) 2 -piperidino
CHO
Basic esters are obtained as their hydrochloride salts. Careful neutralization with sodium hydroxide affords the free basic esters.
EXAMPLE 32
General Hydrochloride Acid Addition Salt Formation
Into an ethereal solution of the appropriate free base of formula (I), having one or more basic nitrogen containing groups, is passed a molar excess of anhydrous hydrogen chloride and the resulting precipitate is separated and recrystallized from an appropriate solvent, e.g. methanol-ether.
Similarly, the free bases of formula (I) are converted to their corresponding hydrobromide, sulfate, nitrate, phosphate, acetate, butyrate, citrate, malonate, maleate, fumarate, malate, glycolate, gluconate, lactate, salicylate, sulfosalicylate, succinate, pamoate and tartarate salts.
EXAMPLE 33
N-Butyryl-cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol, 100 mg, is intimately mixed and ground with 900 mg of starch. The mixture is then loaded into telescoping gelatin capsules such that each capsule contains 10 mg of drug and 90 mg of starch.
EXAMPLE 34
A tablet base is prepared by blending the ingredients listed below:
______________________________________Sucrose 80.3 partsTapioca starch 13.2 partsMagnesium stearate 6.5 parts______________________________________
N-Ethoxycarbonyl-cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol is blended into this base to provide tablets containing 0.1, 0.5, 1, 5, 10 and 25 mg of drug.
EXAMPLE 35
Suspensions of N-n-pentanoyl-cis-2-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-4-piperidinol hydrochloride are prepared by adding sufficient amounts of drug to 0.5% methylcellulose to provide suspensions having 0.05, 0.1, 0.5, 1, 5 and 10 mg of drug per ml.
|
2-[2-Hydroxy-4-(substituted)phenyl]piperidines and derivatives thereof of the formula ##STR1## or a pharmaceutically acceptable acid addition salt thereof, wherein R 1 is H, benzyl or certain acyl groups, R 2 is H, certain alkyl, alkenyl, alkynyl, hydroxyalkyl, acyl or alkylsulfonyl groups; R 3 is H 2 , O, ##STR2## and Z is (C 1 -C 13 )alkylene or -(alk 1 ) m -O-(alk 2 ) n - where each of (alk 1 ) and (alk 2 ) is (C 1 -C 13 )alkylene, provided that the number of carbon atoms in (alk 1 ) plus (alk 2 ) is not greater than 13; each of m and n is 0 or 1; and W is H, pyridyl or optionally substituted phenyl; their use as analgesic agents, intermediates therefor and processes for their preparation.
| 8
|
The present application claims priority under 35 USC section 119(e) to U.S. provisional application No. 60/081,310, filed Apr. 10, 1998, the complete disclosure of which is incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
The present invention relates to a process for alkylating hindered sulfonamides by Michael addition to propiolates and to novel intermediates prepared in said process. The products of the aforesaid reaction can be converted into matrix metalloproteinase inhibitors.
Inhibitors of matrix metalloproteinase (MMP) are known to be useful for the treatment of a condition selected from the group consisting of arthritis (including osteoarthritis and rheumatoid arthritis), inflammatory bowel disease, Crohn's disease, emphysema, acute respiratory distress syndrome, asthma, chronic obstructive pulmonary disease, Alzheimer's disease, organ transplant toxicity, cachexia, allergic reactions, allergic contact hypersensitivity, cancer, tissue ulceration, restenosis, periodontal disease, epidermolysis bullosa, osteoporosis, loosening of artificial joint implants, atherosclerosis (including atherosclerotic plaque rupture), aortic aneurysm (including abdominal aortic aneurysm and brain aortic aneurysm), congestive heart failure, myocardial infarction, stroke, cerebral ischemia, head trauma, spinal cord injury, neuro-degenerative disorders (acute and chronic), autoimmune disorders, Huntington's disease, Parkinson's disease, migraine, depression, peripheral neuropathy, pain, cerebral amyloid angiopathy, nootropic or cognition enhancement, amyotrophic lateral sclerosis, multiple sclerosis, ocular angiogenesis, corneal injury, macular degeneration, abnormal wound healing, burns, diabetes, tumor invasion, tumor growth, tumor metastasis, corneal scarring, scleritis, AIDS, sepsis, septic shock and other diseases characterized by inhibition of metalloproteinase or ADAM (including TNF-a) expression. In addition, the products which can be prepared from the compounds and processes of the present invention may be used in combination therapy with standard non-steroidal anti-inflammatory drugs (hereinafter NSAID'S), COX-2 inhibitors and analgesics for the treatment of arthritis, and in combination with cytotoxic drugs such as adriamycin, daunomycin, cis-platinum, etoposide, taxol, taxotere and alkaloids, such as vincristine, in the treatment of cancer.
The alkylsulfonamides that can be prepared by the methods of the present invention are described in the literature. PCT Publications WO 96/27583 and WO 98/07697, published Mar. 7, 1996 and Feb. 26, 1998, respectively, refer to arylsulfonyl hydroxamic acids, and structures referred to herein as formula V. The above references refer to methods of preparing sulfonamides using methods other than those described in the present invention. Each of the above referenced publications is hereby incorporated by reference in its entirety.
SUMMARY OF THE INVENTION
The present invention relates to a compound of the formula
wherein R 1 is (C 1 -C 6 )alkyl or optionally substituted benzyl;
R 2 and R 3 are independently (C 1 -C 6 )alkyl or R 2 and R 3 are taken together to form a three to seven membered cycloalkyl, a pyran-4-yl ring or a bicyclo ring of the formula
wherein the asterisk indicates the carbon atom common to R 2 and R 3 ;
Q is (C 1 -C 6 )alkyl, (C 6 -C 10 )aryl, (C 2 -C 9 )heteroaryl, (C 6 -C 10 )aryl(C 1 -C 6 )alkyl, (C 2 -C 9 )heteroaryl(C 1 -C 6 )alkyl, (C 6 -C 10 )aryloxy(C 1 -C 6 )alkyl, (C 6 -C 10 )aryloxy(C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy(C 2 -C 9 )heteroaryl, (C 6 -C 10 )aryl(C 6 -C 10 )aryl, (C 6 -C 10 )aryl(C 2 -C 9 )heteroaryl, (C 6 -C 10 )aryl(C 6 -C 10 )aryl(C 1 -C 6 )alkyl, (C 6 -C 10 )aryl(C 6 -C 10 )aryl(C 6 -C 10 )aryl, (C 6 -C 10 )aryl(C 6 -C 10 )aryl(C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryl(C 6 -C 10 )aryl, (C 2 -C 9 )heteroaryl(C 2 -C 9 )heteroaryl, (C 6 -C 10 )aryl(C 1 -C 6 )alkoxy(C 1 -C 6 )alkyl, (C 6 -C 10 )aryl(C 1 -C 6 )alkoxy(C 6 -C 10 )aryl, (C 6 -C 10 )aryl(C 1 -C 6 )alkoxy(C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryloxy(C 1 -C 6 )alkyl, (C 2 -C 9 )heteroaryloxy(C 6 -C 10 )aryl, (C 2 -C 9 )heteroaryloxy(C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryl(C 1 -C 6 )alkoxy(C 1 -C 6 )alkyl, (C 2 -C 9 )heteroaryl(C 1 -C 6 )alkoxy(C 6 -C 10 )aryl or (C 2 -C 9 )heteroaryl(C 1 -C 6 )alkoxy(C 2 -C 9 )heteroaryl;
wherein each (C 6 -C 10 )aryl or (C 2 -C 9 )heteroaryl moieties of said (C 6 -C 10 )aryl, (C 2 -C 9 )heteroaryl, (C 6 -C 10 )aryl(C 1 -C 6 )alkyl, (C 2 -C 9 )heteroaryl(C 1 -C 6 )alkyl, (C 6 -C 10 )aryloxy(C 1 -C 6 )alkyl, (C 6 -C 10 )aryloxy(C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy(C 2 -C 9 )heteroaryl, (C 6 -C 10 )aryl(C 6 -C 10 )aryl, (C 6 -C 10 )aryl(C 2 -C 9 )heteroaryl, (C 6 -C 10 )aryl(C 6 -C 10 )aryl(C 1 -C 6 )alkyl, (C 6 -C 10 )aryl(C 6 -C 10 )aryl(C 6 -C 10 )aryl, (C 6 -C 10 )aryl(C 6 -C 10 )aryl(C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryl(C 6 -C 10 )aryl, (C 2 -C 9 )heteroaryl(C 2 -C 9 )heteroaryl, (C 6 -C 10 )aryl(C 1 -C 6 )alkoxy(C 1 -C 6 )alkyl, (C 6 -C 10 )aryl(C 1 -C 6 )alkoxy(C 6 -C 10 )aryl, (C 6 -C 10 )aryl(C 1 -C 6 )alkoxy(C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryloxy(C 1 -C 6 )alkyl, (C 2 -C 9 )heteroaryloxy(C 6 -C 10 )aryl, (C 2 -C 9 )heteroaryloxy(C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryl(C 1 -C 6 )alkoxy(C 1 -C 6 )alkyl, (C 2 -C 9 )heteroaryl(C 1 -C 6 )alkoxy(C 6 -C 10 )aryl or (C 2 -C 9 )heteroaryl(C 1 -C 6 )alkoxy(C 2 -C 9 )heteroaryl is optionally substituted on any of the ring carbon atoms capable of forming an additional bond by one or more substituents per ring independently selected from fluoro, chloro, bromo, (C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, perfluoro(C 1 -C 3 )alkyl, perfluoro(C 1 -C 3 )alkoxy and (C 6 -C 10 )aryloxy;
and Y is hydrogen, (C 1 -C 6 )alkyl or a suitable protecting group.
Preferred compounds of formula IV are those wherein R 2 and R 3 are taken together to form a cyclobutyl, cyclopentyl, pyran-4-yl ring or a bicyclo ring of the formula
wherein the asterisk indicates the carbon atom common to R 2 and R 3 ;
and wherein Q is 4-(4-fluorophenoxy)phenyl.
The present invention also relates to a process for preparing a compound of the formula
wherein R 1 , R 2 , R 3 , Q and Y are as defined above;
comprising, reacting a compound of the formula
wherein R 1 is optionally substituted benzyl; and R 2 , R 3 , R 4 and Q are as defined above;
with a compound of the formula
wherein Y is (C 1 -C 6 )alkyl;
in the presence of a base, such as tetrabutylammonium fluoride, potassium carbonate, tertiary amines and cesium carbonate, preferably tetrabutylammonium fluoride, and a polar solvent, such as tetrahydrofuran, acetonitrile, tert-butanol, t-amyl alcohols and N,N-dimethylformamide, preferably tetrahydrofuran.
The present invention also relates to a process comprising reducing said compound of the formula
wherein R 1 , R 2 , R 3 Y and Q are as defined above;
with a reducing agent, such as palladium catalysts and a source of hydrogen, preferably hydrogen over palladium on carbon, in a solvent, such as alcohols or tetrahydrofuran, preferably ethanol, to form a compound of the formula
wherein R 5 is hydrogen; and
R 2 , R 3 , Y and Q are as defined above.
The present invention also relates to a process further comprising reacting said compound of formula III, wherein R 5 is hydrogen, with amines such as dicyclohexylamine to form the amine salts such as dicyclohexylammonium salt of the compound of formula III.
The term “protecting group” as a substituent for Y is as described in Greene and Wuts, Protective Groups in Organic Synthesis, (John Wiley & Sons, Inc., Wiley Interscience Second Edition, 1991).
The term “alkyl”, as used herein, unless otherwise indicated, includes saturated monovalent hydrocarbon radicals having straight, branched or cyclic moieties or combinations thereof.
The term “alkoxy”, as used herein, includes O-alkyl groups wherein “alkyl” is defined above.
The term “aryl”, as used herein, unless otherwise indicated, includes an organic radical derived from an aromatic hydrocarbon by removal of one hydrogen, such as phenyl or naphthyl.
The term “heteroaryl”, as used herein, unless otherwise indicated, includes an organic radical derived from an aromatic heterocyclic compound by removal of one hydrogen, such as pyridyl, furyl, pyroyl, thienyl, isothiazolyl, imidazolyl, benzimidazolyl, tetrazolyl, pyrazinyl, pyrimidyl, quinolyl, isoquinolyl, benzofuryl, isobenzofuryl, benzothienyl, pyrazolyl, indolyl, isoindolyl, purinyl, carbazolyl, isoxazolyl, thiazolyl, oxazolyl, benzthiazolyl or benzoxazolyl. Preferred heteroaryls include pyrdyl, furyl, thienyl, isothiazolyl, pyrazinyl, pyrimidyl, pyrazolyl, isoxazolyl, thiazolyl or oxazolyl. Most preferred heteroaryls include pyridyl, furyl or thienyl.
The term “acyl”, as used herein, unless otherwise indicated, includes a radical of the general formula R—(C═O)—wherein R is alkyl, alkoxy, aryl, arylalkyl or arylalkoxy and the terms “alkyl” or “aryl” are as defined above.
The term “acyloxy”, as used herein, includes O-acyl groups wherein “acyl” is defined above.
The squiggly line (i.e. “”) in formula IV indicates that the carboxy group can exist in either a cis or trans configuration.
The compounds of formulae I-V may have chiral centers and therefore exist in different diasteriomeric or enantiomeric forms. This invention relates to all optical isomers, tautomers and stereoisomers of the compounds of formula I-V and mixtures thereof.
Preferably, compounds of the formula I′ exist as the exo isomer of the formula
DETAILED DESCRIPTION
The following reaction Schemes illustrate the preparation of the compounds of the present invention. Unless otherwise indicated n, R 1 , R 2 , R 3 , Q and Z in the reaction Schemes and the discussion that follow are defined as above.
Scheme 1 refers to the preparation of matrix metalloproteinase inhibiting compounds of formula I.
Referring to Scheme 1, compounds of said formula I are prepared from compounds of formula II by reaction with an in situ formed silyated hydroxylamine followed by treatment with an acid. Specifically, in situ formed silyated hydroxylamine compounds are prepared by reaction of hydroxylamine hydrochloride or hydroxylamine sulfate, preferably hydroxylamine hydrochloride, with a ((C 1 -C 4 )alkyl) 3 silyl halide in the presence of a base to form O-trimethylsilylhydroxylamine, N,O-bistrimethylsilylhydroxylamine or combinations thereof. Suitable bases include pyridine, 2,6-lutidine or diisopropylethylamine, preferably pyridine. The reaction is performed at a temperature of about 0° to about 22° C. (i.e., room temperature) for about 1 to about 12 hours, preferably about 1 hour. Suitable acids include hydrochloric or sulfuric, preferably hydrochloric.
Compounds of said formula II, preferably not isolated, are prepared from compounds of formula III, wherein R 5 is hydrogen, by reaction with oxalyl chloride or thionyl chloride, preferably oxalyl chloride, and a catalyst, preferably about 2% of N,N-dimethylformamide, in an inert solvent such as methylene chloride or toluene. The reaction is performed at a temperature of about 0° to about 22° C. (i.e., room temperature) for about 1 to about 12 hours, preferably about 1 hour.
Compounds of the formula Ill, wherein R 5 is hydrogen, can be prepared from compounds of the formula IV, wherein R 1 is optionally substituted benzyl, by reduction in a polar solvent. Suitable reducing agents include palladium catalysts with a source of hydrogen, such as hydrogen over palladium, hydrogen over palladium on carbon or palladium hydroxide on carbon, preferably hydrogen over palladium on carbon. Suitable solvents include tetrahydrofuran, methanol, ethanol and isopropanol and mixtures thereof, preferably ethanol. The aforesaid reaction is performed at a temperature of about 22° C. (i.e., room temperature) for a period of I to 7 days, preferably about 2 days.
Compounds of the formula III, wherein R 5 is other than hydrogen, such as a protonated amine (such as protonated primary amine, secondary amine or tertiary amine), alkali metal or alkaline earth metal, can be prepared from compounds of the formula III, wherein R 5 is hydrogen, by treatment with an aqueous or alkanolic solution containing an acceptable cation (e.g., sodium, potassium, dicyclohexylamine, calcium and magnesium, preferably dicyclohexylamine), and then evaporating the resulting solution to dryness, preferably under reduced pressure or filtering the precipitate, preferably the dicyclohexylamine salt precipate.
Compounds of the formula IV, wherein R 1 is (C 1 -C 6 )alkyl or optionally substituted benzyl, can be prepared from compounds of the formula V, wherein R 1 is optionally substituted benzyl, by Michael addition to a propiolate ester in the presence of a base in a polar solvent. Suitable propiolates are of the formula H—C≡—C—CO 2 Y, wherein Y is (C 1 -C 6 )alkyl. Compounds of the formula H—C≡—C—CO 2 Y are commercially available or can be made by methods well known to those of ordinary skill in the art. Suitable bases include tetrabutylammonium fluoride, potassium carbonate, tertiary amines and cesium carbonate, preferably tetrabutylammonium fluoride. Suitable solvents include tetrahydrofuran, acetonitrile, tert-butanol, t-amyl alcohols and N,N-dimethylformamide, preferably tetrahydrofuran. The aforesaid reaction is performed at a temperature of about −10° C. to about 60° C., preferably ranging between 0° C. and about 22° C. (i.e., room temperature). The compounds of formula IV are obtained as mixtures of geometric isomers about the olefinic double bond (i.e. cis and trans isomers); separation of the isomers is not necessary.
Compounds of said formula I, wherein Y is (C 1 -C 6 )alkyl, can be saponified to the free acid (i.e. Y is hydrogen) using a base such as sodium hydroxide in a protic solvent such as ethanol, methanol or water or a mixture such as water and ethanol, water and toluene, or water and THF. The preferred solvent system is water and toluene. The reaction is conducted for a period of 30 minutes to 24 hours, preferably about 2 hours.
Compounds of the formula V, wherein R 1 is optionally substituted benzyl can be prepared according to methods known in the art. The alkylsulfonamides that can be prepared by the methods of the present invention and the starting materials of formula V are also described in the literature. PCT Publications WO 96/27583 and WO 98/07697, published Mar. 7, 1996 and Feb. 26, 1998, respectively, refer to arylsulfonyl hydroxamic acids. Each of the above referenced publications is hereby incorporated by reference in its entirety.
Compounds of the formula V wherein R 2 and R 3 are tetrahydropyran-4-yl or a bicyclo ring of the formula
wherein the asterisk indicates the carbon atom common to R 2 and R 3 can be prepared according to methods analogous to those of Examples 2 and 3.
The compounds of the formula I which are basic in nature are capable of forming a wide variety of different salts with various inorganic and organic acids. Although such salts must be pharmaceutically acceptable for administration to animals, it is often desirable in practice to initially isolate a compound of the formula I from the reaction mixture as a pharmaceutically unacceptable salt and then simply convert the latter back to the free base compound by treatment with an alkaline reagent, and subsequently convert the free base to a pharmaceutically acceptable acid addition salt. The acid addition salts of the base compounds of this invention are readily prepared by treating the base compound with a substantially equivalent amount of the chosen mineral or organic acid in an aqueous solvent medium or in a suitable organic solvent such as methanol or ethanol. Upon careful evaporation of the solvent, the desired solid salt is obtained.
The acids which are used to prepare the pharmaceutically acceptable acid addition salts of the base compounds of this invention are those which form non-toxic acid addition salts, i.e., salts containing pharmacologically acceptable anions, such as hydrochloride, hydrobromide, hydroiodide, nitrate, sulfate or bisulfate, phosphate or acid phosphate, acetate, lactate, citrate or acid citrate, tartrate or bitartrate, succinate, maleate, fumarate, gluconate, saccharate, benzoate, methanesulfonate and pamoate [ie, 1,1′-methylene-bis-(2-hydroxy-3-naphthoate)] salts.
Those compounds of the formula I which are also acidic in nature, are capable of forming base salts with various pharmacologically acceptable cations. Examples of such salts include the alkali metal or alkaline-earth metal salts and particularly, the sodium and potassium salts. These salts are all prepared by conventional techniques. The chemical bases which are used as reagents to prepare the pharmaceutically acceptable base salts of this invention are those which form non-toxic base salts with the herein described acidic compounds of formula I. These non-toxic base salts include those derived from such pharmacologically acceptable cations as sodium, potassium, calcium and magnesium, etc. These salts can easily be prepared by treating the corresponding acidic compounds with an aqueous solution containing the desired pharmacologically acceptable cations, and then evaporating the resulting solution to dryness, preferably under reduced pressure. Alternatively, they may also be prepared by mixing lower alkanolic solutions of the acidic compounds and the desired alkali metal alkoxide together, and then evaporating the resulting solution to dryness in the same manner as before. In either case, stoichiometric quantities of reagents are preferably employed in order to ensure completeness of reaction and maximum product yields.
The ability of the compounds of formula I or their pharmaceutically acceptable salts (hereinafter also referred to as the active compounds) to inhibit matrix metalloproteinases or ADAMs (such as inhibiting the production of tumor necrosis factor (TNF)) and, consequently, demonstrate their effectiveness for treating diseases characterized by matrix metalloproteinase or ADAM (such as the production of tumor necrosis factor) can be determined according to in vitro assay tests well known to those of ordinary skill in the art. One example of an assay recognized as demonstrating that the final products produced by the methods of the invention is the following Inhibition of Human Collagenase Assay.
BIOLOGICAL ASSAY
Inhibition of Human Collagenase (MMP-1)
Human recombinant collagenase is activated with trypsin using the following ratio: 10 μg trypsin per 100 μg of collagenase. The trypsin and collagenase are incubated at room temperature for 10 minutes then a five fold excess (50 μg/10 μg trypsin) of soybean trypsin inhibitor is added.
10 mM stock solutions of inhibitors are made up in dimethyl sulfoxide and then diluted using the following Scheme:
10 mM→120 μM→12 μM→1.2 μM→0.12 μM
Twenty-five microliters of each concentration is then added in triplicate to appropriate wells of a 96 well microfluor plate. The final concentration of inhibitor will be a 1:4 dilution after addition of enzyme and substrate. Positive controls (enzyme, no inhibitor) are set up in wells D1-D6 and blanks (no enzyme, no inhibitors) are set in wells D7-D12.
Collagenase is diluted to 400 ng/ml and 25 μl is then added to appropriate wells of the microfluor plate. Final concentration of collagenase in the assay is 100 ng/ml.
Substrate (DNP-Pro-Cha-Gly-Cys(Me)-His-Ala-Lys(NMA)-NH 2 ) is made as a 5 mM stock in dimethyl sulfoxide and then diluted to 20 mM in assay buffer. The assay is initiated by the addition of 50 μl substrate per well of the microfluor plate to give a final concentration of 10 μM.
Fluorescence readings (360 nM excitation, 460 nm emission) were taken at time 0 and then at 20 minute intervals. The assay is conducted at room temperature with a typical assay time of 3 hours.
Fluorescence vs time is then plotted for both the blank and collagenase containing samples (data from triplicate determinations is averaged). A time point that provides a good signal (the blank) and that is on a linear part of the curve (usually around 120 minutes) is chosen to determine IC 50 values. The zero time is used as a blank for each compound at each concentration and these values are subtracted from the 120 minute data. Data is plotted as inhibitor concentration vs % control (inhibitor fluorescence divided by fluorescence of collagenase alone×100). IC 50 's are determined from the concentration of inhibitor that gives a signal that is 50% of the control.
If IC 50 's are reported to be <0.03 μM then the inhibitors are assayed at concentrations of 0.3 μM, 0.03 μM, 0.03 μM and 0.003 μM.
The following Examples illustrate the preparation of the compounds of the present invention. Melting points are uncorrected. NMR data are reported in parts per million (6) and are referenced to the deuterium lock signal from the sample solvent (deuteriochloroform unless otherwise specified). Commercial reagents were utilized without further purification. THF refers to tetrahydrofuran. DMF refers to N,N-dimethylformamide. Chromatography refers to column chromatography performed using 32-63 mm silica gel and executed under nitrogen pressure (flash chromatography) conditions. Room or ambient temperature refers to 20-25° C. All non-aqueous reactions were run under a nitrogen atmosphere for convenience and to maximize yields. Concentration at reduced pressure means that a rotary evaporator was used.
EXAMPLE 1
3-[[4-(4-Fluoropohenoxy)benzenesulfonyl]-(1-Hydroxycarbamoylcyclopentyl)amino]propionic Acid
A) 1-[4-(4-Fluorophenoxy)benzenesulfonylamino]cyclopentanecarboxylic Acid Benzyl Ester
To a mixture of 12.41 g (0.032 mol) of 1-aminocyclopentanecarboxylic acid benzyl ester, toluene-4-sulfonic acid salt (can be prepared according to literature methods such as those described in U.S. Pat. No. 4,745,124), and 10.0 g (0.035 mol, 1.1 equivalents) of 4-(4-fluorophenoxy)benzenesulfonyl chloride (prepared according to Preparation 3) in 113 mL of toluene was added 11.0 mL (0.079 mol, 2.5 equivalents) of triethylamine. The resulting mixture was stirred at ambient temperature overnight, washed with 2N hydrochloric acid (2×100 mL) and brine (100 mL), dried over sodium sulfate, and concentrated to 30 mL. Hexane, 149 mL, was added drop-wise over three hours giving a solid precipitate which was granulated at 0° C. for one hour and filtered yielding 12.59 g (85%) of 1-[4-(4-fluorophenoxy)benzenesulfonylamino]cyclopentane-carboxylic acid benzyl ester.
1 H NMR (CDCl 3 ) δ 7.78-7.82 (m, 2H), 7.30-7.39 (m, 5H), 7.06-7.12 (m, 2H), 6.99-7.04 (m, 2H), 6.93-6.97 (m, 2H), 5.15 (s, 1H), 5.02 (s, 2H), 2.04-2.13 (m, 2H), 1.92-1.98 (m, 2H), 1.62-1.69 (m, 4H).
A 4.0 g sample was granulated in a mixture of 4 mL of ethyl acetate and 40 mL of hexanes overnight giving 3.72 g (93% recovery) of 1-[4-(4-fluorophenoxy)benzenesulfonyl-amino]-cyclopentanecarboxylic acid benzyl ester as light tan solids, mp 97.0-97.5° C.
B) 1-{(2-Ethoxycarbonylvinyl)-[4-(4-fluorophenoxy)benzenesulfonyl]-amino}cyclopentanecarboxylic Acid Benzyl Ester
A solution of 25.0 g (53.2 mmol) of 1-[4-(4-fluorophenoxy)benzenesulfonylamino]-cyclopentanecarboxylic acid benzyl ester and 10.8 mL (106 mmol, 2 equivalents) of ethyl propiolate in 200 mL of dry tetrahydrofuran at 1° C. was treated with 53.2 mL (53.2 mmol, 1 equivalent) of a solution of tetrabutylammonium fluoride in tetrahydrofuran (1M) over 45 minutes. The resulting solution was allowed to warm slowly to ambient temperature and stirred overnight. The tetrahydrofuran was displaced with toluene at reduced pressure, and the toluene solution was washed with water and brine, diluted to 600 mL with toluene, stirred with 90 g of silica gel for three hours, filtered, and concentrated to 25.14 g (83%) of 1{(2-ethoxycarbonylvinyl)-[4-(4-fluorophenoxy)benzenesulfonyl]amino}-cyclopentanecarboxylic acid benzyl ester as an orange oil. 1 H NMR (CDCl 3 ) indicated a 1.5:1 trans/cis ratio.
Trans δ 7.74-7.78 (m, 2H), 7.72 (d, J=14 Hz, 1H), 7.26-7.36 (m, 5H), 6.96-7.12 (m, 4H), 6.78-84 (m, 2H), 5.44 (d, J=14 Hz, 1H), 5.11 (s, 2H), 4.12 (q, J=7.1 Hz, 2H), 2.08-2.43 (m, 4H), 1.63-1.80 (m, 4H), 1.24 (t, J=7.1 Hz, 3H). Cis δ 7.68-7.72 (m, 2H), 7.26-7.36 (m, 5H), 6.96-7.12 (m, 4H), 6.86-6.91 (m, 2H), 6.47 (d, J=8.1 Hz, 1H), 5.90 (d, J=8.1 Hz, 1H), 5.11 (s, 2H), 3.93 (q, J=7.2 Hz, 2H), 2.08-2.43 (m, 4H), 1.63-1.80 (m, 4H), 1.17 (t, J=7.2 Hz, 3H).
C) 1-{(2-Ethoxycarbonylethyl)-[4-(4-fluorophenoxy)benzenesulfonyl-amino}-cyclopentanecarboxylic Acid
A solution of 2.50 g (4.4 mmol) of 1-{(2-ethoxycarbonylvinyl)-[4-(4-fluorophenoxy)benzenesulfonyl]amino}cyclopentanecarboxylic acid benzyl ester in 25 mL of ethanol was treated with 2.5 g of 50% water wet 10% palladium on carbon catalyst and shaken under 53 psi of hydrogen for 21 hours. The catalyst was removed by filtration and washed with ethanol (4×25 mL). The filtrate and washings were combined and concentrated under vacuum to 1.74 g (82%) of crude 1-{(2-ethoxycarbonylethyl)-[4-(4-fluorophenoxy)benzenesulfonyl]amino}cyclopentanecarboxylic acid as a viscous oil.
1 H NMR (CDCl 3 ) δ 7.78-7.82 (m, 2H), 6.94-7.09 (m, 6H), 4.09 (q, J=7.2 Hz, 2H), 3.56-3.60 (m, 2H), 2.75-2.79 (m, 2H), 2.33-2.39 (m, 2H), 1.93-2.03 (m, 2H), 1.69-1.76 (m, 2H), 1.56-1.63 (m, 2H), 1.22 (t, J=7.2 Hz, 3H).
D) 1-{(2-Ethoxycarbonylethyl)-[4-(4-fluorophenoxy)benzenesulfonyl]amino}-cyclopentanecarboxylic Acid, Dicyclohexylaminium Salt
A solution of 3.10 g (6.5 mmol) of crude 1-{(2-ethoxycarbonylethyl)-[4-(4-fluorophenoxy)benzenesulfonyl]amino}cyclopentanecarboxylic acid in 30 mL of ethanol was treated with 1.28 mL (6.5 mmol, 1 equivalent) of dicyclohexylamine at ambient temperature producing solids within five minutes. This mixture was stirred at ambient temperature overnight and then at 0° C. for five hours. White solids were isolated by filtration, washed with 10 mL of cold ethanol, and air dried giving 2.89 g (67%) of 1-{(2-ethoxycarbonylethyl)-[4-(4-fluorophenoxy)benzenesulfonyl]amino}cyclopentanecarboxylic acid, dicyclohexylaminium salt.
1 H NMR (CDCl 3 ) δ 7.86-7.91 (m, 2H), 6.99-7.09 (m, 4H), 6.90-6.94 (m, 2H), 5.3 (br s, 2H), 4.07 (q, J=7.1 Hz, 2H), 3.54-3.59 (m, 2H), 2.88-2.95 (m, 4H), 2.31-2.38 (m, 2H), 1.95-2.22 (m, 6H), 1.68-1.77 (m, 6H), 1.53-1.60 (m, 4H), 1.40-1.50 (m, 4H), 1.21 (t, J=7.1 Hz, 3H), 1.14-1.22 (m, 6H). Mp 164.5-165.9 ° C.
E) 1-{(2-Ethoxycarbonylethyl)-[4-(4-fluorophenoxy)benzenesulfonyl]amino}-cyclopentanecarboxylic Acid
A solution of 3.0 g (4.5 mmol) of 1-{(2-ethoxycarbonylethyl)-[4-(4-fluorophenoxy)benzenesulfonyl]amino}cyclopentanecarboxylic acid, dicyclohexylaminium salt in 30 mL of dichloromethane was treated with 30 mL of 2N hydrochloric acid at ambient temperature causing immediate precipitation of solids. This mixture was stirred at ambient temperature for three hours. The solids were filtered, the aqueous phase was extracted with dichloromethane, and the combined organic phases were washed with water, dried over sodium sulfate, and concentrated under vacuum to 2.2 g (100%) of 1-{(2-ethoxycarbonylethyl)-[4-(4-fluorophenoxy)benzenesulfonyl]amino}cyclopentanecarboxylic acid as a clear oil.
1 H NMR (DMSO-d 6 ) δ 12.68 (bs, 1H), 7.76-7.80 (m, 2H), 7.25-7.31 (m, 2H), 7.16-7.21 (m, 2H), 7.03-7.08 (m, 2H), 4.01 (q, J=7.1 Hz, 2H), 3.48-3.54 (m, 2H), 2.64-2.70 (m, 2H), 2.13-2.21 (m, 2H), 1.90-1.98 (m, 2H), 1.52-1.59 (m, 4H), 1.14 (t, J=7.1 Hz, 3H).
F) 3-{(1-Chlorocarbonylcyclopentyl)-[4-(4-fluorophenoxy)benzene-sulfonyl]amino}propionic Acid Ethyl Ester
A solution of 7.26 g (15.1 mmol) of 1-{(2-ethoxycarbonylethyl)-[4-(4-fluorophenoxy)benzenesulfonyl]amino}cyclopentanecarboxylic acid in 73 mL of dichloromethane was treated with 1.4 mL (17 mmol, 1.1 equivalents) of oxalyl chloride and 0.02 mL (0.3 mmol, 0.02 equivalents) of dimethylformamide at ambient temperature, causing some bubbling, and was stirred overnight. The resulting solution of 3-{(1-chlorocarbonylcyclopentyl)-[4-(4-fluorophenoxy)benzenesulfonyl]amino}propionic acid ethyl ester was used for the preparation of 3-[[4-(4-fluorophenoxy)benzenesulfonyl]-(1-hydroxycarbamoylcyclopentyl)amino]propionic acid ethyl ester without isolation.
A similarly prepared solution of 3-{(1-chlorocarbonylcyclopentyl)-[4-(4-fluorophenoxy)benzenesulfonyl]amino}propionic acid ethyl ester was concentrated under vacuum to an oil.
1 H NMR (CDCl 3 ) δ 7.84-7.87 (m, 2H), 6.97-7.12 (m, 6H), 4.10 (q, J=7.2 Hz, 2H), 3.55-3.59 (m, 2H), 2.68-2.72 (m, 2H), 2.47-2.53 (m, 2H), 1.95-2.02 (m, 2H), 1.71-1.76 (m, 4H), 1.24 (t, J=7.2 Hz, 3H).
G) 3-[[4-(4-Fluorophenoxy)benzenesulfonyl]-(1-hydroxycarbamoylcyclopentyl)amino]propionic Acid Ethyl Ester
A solution of 1.37 g (19.7 mmol, 1.3 equivalents) of hydroxylamine hydrochloride in 9.2 mL (114 mmol, 7.5 equivalents) of dry pyridine at 0° C. was treated with 5.8 mL (45 mmol, 3.0 equivalents) of trimethylsilyl chloride, causing white solids to precipitate. The mixture was allowed to warm to ambient temperature overnight. This mixture was then cooled to 0° C. and treated with a solution of 7.54 g (15.1 mmol) of 3-{(1-chlorocarbonylcyclopentyl)-[4-(4-fluorophenoxy)-benzenesulfonyl]amino}propionic acid ethyl ester in 73 mL of dichloromethane, prepared as described above, without isolation, causing an exotherm to about 8° C. This mixture was stirred at 0° C. for 30 minutes and at ambient temperature for about one hour. The reaction was then treated with 50 mL of 2N aqueous hydrochloric acid and was stirred at ambient temperature for one hour. The aqueous phase was extracted with dichloromethane and the combined organic phases were washed with 2N aqueous hydrochloric acid (2×50 mL) and water (50 mL). This solution of 3-[[4-(4-fluorophenoxy)benzenesulfonyl]-(1-hydroxycarbamoylcyclopentyl)amino]propionic acid ethyl ester in dichloromethane was used for the preparation of 3-[[4-(4-fluorophenoxy)benzenesulfonyl]-(1 -hydroxycarbamoylcyclopentyl)amino]propionic acid without isolation. An aliquot was concentrated to a foam.
1 H NMR (DMSO-d 6 ) δ 10.37 (s, 1H), 8.76 (s, 1H), 7.74-7.79 (m, 2H), 7.24-7.30 (m, 2H), 7.14-7.20 (m, 2H), 7.01-7.05 (m, 2H), 3.99 (q, J=7.1 Hz, 2H), 3.42-3.47 (m, 2H), 2.62-2.67 (m, 2H), 2.16-2.23 (m, 2H), 1.77-1.85 (m, 2H), 1.43-1.52 (m, 4H), 1.13 (t, J=7.1 Hz, 3H).
A similarly prepared solution was concentrated under vacuum to 6.71 g (89%) of 3-[[4-(4-fluorophenoxy)benzenesulfonyl]-(1-hydroxycarbamoylcyclopentyl)amino]propionic acid ethyl ester as a hard dry foam.
H) 3-[[4-(4-Fluorophenoxy)benzenesulfonyl]-(1-hydroxycarbamoylcyclopentyl)amino]propionic Acid
A solution of 7.48 g (15.1 mmol) of 3-[[4-(4-fluorophenoxy)benzenesulfonyl]-(1-hydroxycarbamoylcyclopentyl)amino]propionic acid ethyl ester in dichloromethane was concentrated by rotary evaporation with the addition of 75 mL of toluene. This solution was treated with 75 mL of water, cooled to 0° C., and treated with 6.05 g (151 mmol, 10 equivalents) of sodium hydroxide pellets over 10 minutes with vigorous stirring. This mixture was stirred for 15 minutes at 0° C. and warmed to ambient temperature over one hour. The aqueous phase was separated, diluted with 7.5 mL of tetrahydrofuran, cooled to 0° C., and treated with 33 mL of 6N aqueous hydrochloric acid over 20 minutes. This mixture was stirred with 75 mL of ethyl acetate at 0° C. to ambient temperature, and the ethyl acetate phase was separated and washed with water. The ethyl acetate solution was slowly treated with 150 mL of hexanes at ambient temperature causing solids to precipitate, and was stirred overnight. Filtration yielded 5.01 g of 3-[[4-(4-fluorophenoxy)benzenesulfonyl]-(1-hydroxycarbamoylcyclopentyl)amino]propionic acid as a white solid (71% yield from 1-{(2-ethoxycarbonylethyl)-[4-(4-fluorophenoxy)benzenesulfonyl]amino}cyclopentanecarboxylic acid).
1 H NMR (DMSO-d 6 ) δ 12.32 (s, 1H), 10.43 (s, 1H), 8.80 (s, 1H), 7.82 (d, J=8.6 Hz, 2H), 7.28-7.35 (m, 2H), 7.20-7.26 (m, 2H), 7.08 (d, J=8.9 Hz, 2H), 3.44-3.49 (m, 2H), 2.61-2.66 (m, 2H), 2.24-2.29 (m, 2H), 1.86-1.90 (m, 2H), 1.54-1.55 (m, 4H). mp 162.9-163.5° C. (dec).
EXAMPLE 2
3-[[4-(4-Fluoro-Phenoxy)-benzenesulfonyl]-(4-hydroxycarbamoyl-tetrahydropyran-4-yl)-amino]-propionic acid
A) 4-[N-(Diphenylmethylene)amino]tetrahydropyran-4-carboxylic acid benzyl ester
To a suspension of sodium hydride (6.56 grams. 0.164 mole) in ethylene glycol dimethyl ether (150 mL) at 0° C. is added a solution of the N-(diphenylmethylene)glycine benzyl ester (0.07398 mole) in ethylene glycol dimethyl ether (50 mL) dropwise via addition funnel. A solution of 2-bromoethyl ether (23.21 grams, 0.090 mole) in ethylene glycol dimethyl ether (50 mL) is then added, in 10 mL portions over approximately 5 minutes, to the ethylene glycol dimethyl ether solution. The ice bath is removed and the reaction is stirred at room temperature for 16 hours. The mixture is diluted with diethyl ether and washed with water. The aqueous layer is extracted with diethyl ether. The combined organic extracts are washed with brine, dried over magnesium sulfate, and concentrated to afford crude product. Chromatography on silica gel eluting first with 4 L of 5% ethyl acetate/hexane followed by 4 liters of 10% ethyl acetate/hexane provides 4-[N-(diphenylmethylene)amino]tetrahydropyran-4-carboxylic acid benzyl ester as a clear yellow oil.
B) 4-Aminotetrahydropyran-4-carboxylic acid benzyl ester
To a solution of 4-[N-(diphenylmethylene)amino]tetrahydropyran-4-carboxylic acid benzyl ester (0.047 mole) in diethyl ether (120 mL) is added 1M aqueous hydrochloric acid solution (100 mL). The mixture is stirred vigorously at room temperature for 16 hours. The layers are separated and the aqueous layer washed with diethyl ether. The aqueous layer is brought to pH 10 with dilute aqueous ammonium hydroxide solution and extracted with dichloromethane. The organic extract is dried over sodium sulfate and concentrated to give 4-aminotetrahydropyran-4-carboxylic acid benzyl ester.
C) 4-[4-(4-Fluorophenoxy)benzenesulfonylamino]tetrahydropyran-4-carboxylic acid benzyl ester
To a solution of 4-aminotetrahydropyran-4-carboxylic acid benzyl ester (0.0404 mole) in N,N-dimethylformamide (40 mL) is added triethylamine (5.94 mL, 0.043 mole). Solid 4-(4-fluorophenoxy)benzenesulfonyl chloride (12.165 grams, 0.0424 mole) is added to the above solution in portions. The resulting mixture is stirred at room temperature for 16 hours and then most of the solvent is removed by evaporation under vacuum. The residue was partitioned between saturated sodium bicarbonate solution and dichloromethane. The aqueous layer is separated and extracted with dichloromethane. The combined organic layers are washed with brine and dried over sodium sulfate. Evaporation of the solvent under vacuum provided crude 4-[4-(4-fluorophenoxy)benzenesulfonylamino]tetrahydropyran-4-carboxylic acid benzyl ester. Flash chromatography on silica gel eluting with 25% ethyl acetate/hexane followed by 50% ethyl acetate/hexane provided 4-[4-(4-fluorophenoxy)benzenesulfonylamino]tetrahydropyran-4-carboxylic acid benzyl ester.
D) 4-{(2-Ethoxycarbonyl-vinyl)-[4-(4-fluoro-phenoxy)-benzenesulfonyl]amino}-tetrahydro-pyran-4-carboxylic acid benzyl ester
A solution of (53.2 mmol) of the product of the previous step and 10.8 mL (106 mmol, 2 equivalents) of ethyl propiolate in 200 mL of dry tetrahydrofuran at 1° C. is treated with 53.2 mL (53.2 mmol, 1 equivalent) of a solution of tetrabutylammonium fluoride in tetrahydrofuran (1M) over 45 minutes. The resulting solution is allowed to warm slowly to ambient temperature and stirred overnight. The tetrahydrofuran is displaced with toluene at reduced pressure, and the toluene solution is washed with water and brine, diluted to 600 mL with toluene, stirred with 90 g of silica gel for three hours, filtered, and concentrated to the title compound.
E) 4-{(2-Ethoxycarbonyl-ethyl)-[4-(4-fluoro-phenoxy)-benzenesulfonyl]amino}-tetrahydro-pyran-4-carboxylic acid
A solution of (4.4 mmol) of the product of step D in 25 mL of ethanol is treated with 2.5 g of 50% water wet 10% palladium on carbon catalyst and shaken under 53 psi of hydrogen for 21 hours. The catalyst is removed by filtration and washed with ethanol (4×25 mL). The filtrate and washings are combined and concentrated under vacuum to crude product.
F) 3-{(4-Chlorocarbonyl-tetrahydro-pyran-4-yl)-[4-(4-fluoro-phenoxy)benzenesulfonyl]-amino}-propionic acid ethyl ester
A solution of (15.1 mmol) of the product from Step E in 73 mL of dichloromethane is treated with 1.4 mL (17 mmol, 1.1 equivalents) of oxalyl chloride and 0.02 mL (0.3 mmol, 0.02 equivalents) of dimethylformamide at ambient temperature, causing some bubbling, and is stirred overnight. The resulting solution of the title compound is used in step G without isolation.
G) 3-[[4-(4-Fluoro-phenoxy)-benzenesulfonyl]-hydroxycarbamoyltetrahydro-pyran-4-yl)-amino]-propionic acid ethyl ester
A solution of (19.7 mmol, 1.3 equivalents) of hydroxylamine hydrochloride in 9.2 mL (114 mmol, 7.5 equivalents) of dry pyridine at 0 ° C. is treated with 5.8 mL (45 mmol, 3.0 equivalents) of trimethylsilyl chloride, causing white solids to precipitate. The mixture is allowed to warm to ambient temperature overnight. This mixture is then cooled to 0° C. and treated with a solution of (15.1 mmol) of the product from Step F in 73 mL of dichloromethane causing an exotherm to about 8° C. This mixture is stirred at 0° C. for 30 minutes and at ambient temperature for about one hour. The reaction is then treated with 50 mL of 2N aqueous hydrochloric acid and was stirred at ambient temperature for one hour. The aqueous phase is extracted with dichloromethane and the combined organic phases are washed with 2N aqueous hydrochloric acid (2×50 mL) and water (50 mL). This solution of the title compound in dichloromethane is used in the next step.
(H) 3-[[4-(4-Fluoro-phenoxy)-benzenesulfonyl]-(4-hydroxycarbamoyltetrahydro-pyran-4-yl)-amino]-propionic acid
A solution of 15.1 mmoles of the product from Step G in dichloromethane is concentrated by rotary evaporation with the addition of 75 mL of toluene. This solution is treated with 75 mL of water, cooled to 0° C., and treated with 6.05 9 (151 mmol, 10 equivalents) of sodium hydroxide pellets over 10 minutes with vigorous stirring. This mixture is stirred for 15 minutes at 0° C. and warmed to ambient temperature over one hour. The aqueous phase is separated, diluted with 7.5 mL of tetrahydrofuran, cooled to 0° C., and treated with 33 mL of 6N aqueous hydrochloric acid over 20 minutes. This mixture is stirred with 75 mL of ethyl acetate at 0° C. to ambient temperature, and the ethyl acetate phase is separated and washed with water. The ethyl acetate solution was concentrated to yield the title compound.
EXAMPLE 3
3-[[4-(4-Fluoro-phenoxy)-benzenesulfonyl]-(3-hydroxycarbamoyl-8-oxabicyclo[3.2.1]oct-3-yl)-amino]-propionic Acid
A) 3-(Benzhydrylideneamino)-8-oxabicyclo[3.2.1]octane-3-carboxylic acid benzyl ester
To a suspension of sodium hydride (0.41 grams, 17.1 mmole) in N,N-dimethylformamide (50 mL) at 0° C. is added dropwise a solution of N-diphenylmethylene glycine benzyl ester (7.8 mmole) in N,N-dimethylformamide (50 mL). After stirring for 30 minutes at room temperature, a solution of cis-2,5-bis(hydroxymethyl)-tetrahydrofuran ditosylate (4.1 grams, 9.3 mmole)(prepared by literature methods such as those described in JOC, 47, 2429-2435 (1982)) in N,N-dimethylformamide (50 mL) is added dropwise. The reaction mixture is gradually heated to 100° C. in an oil bath and stirred at this temperature overnight. The solvent is evaporated under vacuum and the residue is taken up in water and extracted twice with diethyl ether. The combined organic extracts are washed with brine, dried over magnesium sulfate and concentrated to a crude product.
B) 3-Amino8-oxabicyclo[3.2.1]octane-3-carboxylic acid benzyl ester hydrochloride
A two-phase mixture of 3-(benzhydrylideneamino)-8-oxabicyclo[3.2.1]octane-3-carboxylic acid benzyl ester (3.9 mmole) in aqueous 1N hydrochloric acid solution (100 mL) and diethyl ether (100 mL) is stirred at room temperature overnight. The aqueous layer is concentrated to provide the title compound.
C) 3-exo-[4-(4-Fluorophenoxy)benzenesulfonylamino]-8-oxabicyclo[3.2.1]octane-3-carboxylic acid benzyl ester
A solution of 3-amino-8-oxabicyclo[3.2.1]octane-3-carboxylic acid benzyl ester hydrochloride (2.9 mmole), 4-(4-fluorophenoxy)benzenesulfonylchloride (923 mg, 3.2 mmole) and triethylamine (0.9 mL, 6.5 mmole) in N,N-dimethylformamide (45 mL) is stirred at room temperature overnight. The solvent is removed under vacuum and the residue is taken up in saturated aqueous sodium bicarbonate solution. After extracting twice with methylene chloride, the combined organic layers are washed with brine, dried over magnesium sulfate and concentrated to a brown oil. The title compound is isolated by chromatography on silica using 1% methanol in methylene chloride as eluant.
D) 3-{(2-Ethoxycarbonyl-vinyl)-[4-(4-fluoro-phenoxy)-benzenesulfonyl]-amino}-8-oxa-bicyclo[3.2.1]octane-3-carboxylic acid benzyl ester
A solution of (53.2 mmol) of the product of the previous step and 10.8 mL (106 mmol, 2 equivalents) of ethyl propiolate in 200 mL of dry tetrahydrofuran at 1° C. is treated with 53.2 mL (53.2 mmol, 1 equivalent) of a solution of tetrabutylammonium fluoride in tetrahydrofuran (1M) over 45 minutes. The resulting solution is allowed to warm slowly to ambient temperature and stirred overnight. The tetrahydrofuran is displaced with toluene at reduced pressure, and the toluene solution is washed with water and brine, diluted to 600 mL with toluene, stirred with 90 g of silica gel for three hours, filtered, and concentrated to the title compound.
E) 3-{(2-Ethoxycarbonyl-ethyl)-[4(4-fluoro-phenoxy)-benzenesulfonyl]-amino}-8-oxa- bicyclo[3.2.1]octane-3-carboxylic acid
A solution of (4.4 mmol) of the product of step D in 25 mL of ethanol is treated with 2.5 g of 50% water wet 10% palladium on carbon catalyst and shaken under 53 psi of hydrogen for 48 hours. The catalyst is removed by filtration and washed with ethanol (4×25 mL). The filtrate and washings are combined and concentrated under vacuum to crude product.
F) 3-{(3-Chlorocarbonyl-8-oxa-bicyclo[3.2.1]oct-3-yl)-[4-(4-fluoro-phenoxy)-benzene sulfonyl]-amino}-propionic acid ethyl ester
A solution of 15.1 mmoles of the product from Step E in 73 mL of dichloromethane is treated with 1.4 mL (17 mmol, 1.1 equivalents) of oxalyl chloride and 0.02 mL (0.3 mmol, 0.02 equivalents) of dimethylformamide at ambient temperature, causing some bubbling, and is stirred overnight. The resulting solution of the title compound is used in step G without isolation.
G) 3-[[4-(4-Fluoro-phenoxy)-benzenesulfonyl]-(3-hydroxycarbamoyl-8-oxa-bicyclo[3.2.1]oct-3-yl)-amino]-propionic acid ethyl ester
A solution of (19.7 mmol, 1.3 equivalents) of hydroxylamine hydrochloride in 9.2 mL (114 mmol, 7.5 equivalents) of dry pyridine at 0° C. is treated with 5.8 mL (45 mmol, 3.0 equivalents) of trimethylsilyl chloride, causing white solids to precipitate. The mixture is allowed to warm to ambient temperature overnight. This mixture is then cooled to 0° C. and treated with a solution of (15.1 mmol) of the product from Step F in 73 mL of dichloromethane causing an exotherm to about 8° C. This mixture is stirred at 0° C. for 30 minutes and at ambient temperature for about one hour. The reaction is then treated with 50 mL of 2N aqueous hydrochloric acid and was stirred at ambient temperature for one hour. The aqueous phase is extracted with dichloromethane and the combined organic phases are washed with 2N aqueous hydrochloric acid (2×50 mL) and water (50 mL). This solution of the title compound in dichloromethane is used in the next step.
(H) 3-[[4-(4-Fluoro-phenoxy)-benzenesulfonyl]-(3-hydroxycarbamoyl-8-oxa-bicyclo[3.2.1]oct-3-yl)-amino]-propionic acid
A solution of 15.1 mmoles of the product from Step G in dichloromethane is concentrated by rotary evaporation with the addition of 75 mL of toluene. This solution is treated with 75 mL of water, cooled to 0° C., and treated with 6.05 g (151 mmol, 10 equivalents) of sodium hydroxide pellets over 10 minutes with vigorous stirring. This mixture is stirred for 15 minutes at 0° C. and warmed to ambient temperature over one hour. The aqueous phase is separated, diluted with 7.5 mL of tetrahydrofuran, cooled to 0° C., and treated with 33 mL of 6N aqueous hydrochloric acid over 20 minutes. This mixture is stirred with 75 mL of ethyl acetate at 0° C. to ambient temperature, and the ethyl acetate phase is separated and washed with water. The ethyl acetate solution was concentrated to yield the title compound.
PREPARATION 1
4-(4-Fluorophenoxy)benzenesulfonic Acid 4-Fluorophenyl Ester
A solution of 14.68 g (0.131 mol, 2.0 equivalents) of potassium tert-butoxide in 27 mL of dry N-methylpyrrolidinone was treated with a solution of 15.39 g (0.137 mol, 2.1 equivalents) of 4-fluorophenol in 27 mL of dry N-methylpyrrolidinone at ambient temperature causing a mild exotherm to 45° C. A solution of 13.81 g (0.065 mol) of 4-chlorobenzenesulfonyl chloride in 27 mL of dry N-methylpyrrolidinone was slowly added to the dark reaction mixture causing a mild exotherm to 44° C. The resulting mixture was stirred at room temperature for one hour and then at 130° C. for 11 hours. The cooled reaction mixture was treated with 162 mL of water, seeded with a trace of 4-(4-fluorophenoxy)benzenesulfonic acid 4-fluorophenyl ester, and granulated at room temperature overnight. The resulting solids were filtered yielding 20.24 g (85%) of 4-(4-fluorophenoxy)benzenesulfonic acid 4-fluorophenyl ester.
1 H NMR (CDCl 3 ) δ 7.74 (dd, J=7.0, 2.0 Hz, 2H), 7.14-6.97 (m, 10H). mp 78-83° C.
PREPARATION 2
4-(4-Fluorophenoxy~benzenesulfonic Acid, Sodium Salt
To a slurry of 47.43 g (0.131 mol) of 4-(4-fluorophenoxy)benzenesulfonic acid 4-fluorophenyl ester in 475 mL of ethanol was added 13.09 g (0.327 mol, 2.5 equivalents) of sodium hydroxide pellets. This mixture was heated at reflux for three hours and stirred overnight at room temperature. The resulting solids were filtered yielding 37.16 g (98%) of 4-(4-fluorophenoxy)benzenesulfonic acid, sodium salt.
1 H NMR (CD 3 OD) δ 7.73-7.78 (m, 2H), 7.05-7.13 (m, 2H), 6.99-7.05 (m, 2H), 6.90-6.95 (m, 2H).
PREPARATION 3
4-(4-Fluorophenoxy)benzenesulfonyl Chloride
To a slurry of 15.0 g (0.052 mol) of 4-(4-fluorophenoxy)benzenesulfonic acids, sodium salt, in 150 mL of dry toluene was added 11.3 mL (0.155 mol, 3 equivalents) of thionyl chloride and 0.04 mL (0.5 mmol, 0.01 equivalents) of dimethylformamide. The resulting mixture was stirred at room temperature for 48 hours, filtered through diatomaceous earth, and concentrated under reduced pressure to 40 mL. This solution was used without further purification to prepare 1-[4-(4-fluorophenoxy)benzenesulfonylamino] cyclopentanecarboxylic acid benzyl ester.
A 5.0 mL portion of this solution was concentrated to 1.77 g of 4-(4-fluorophenoxy)benzenesulfonyl chloride as an oil, corresponding to a 96% yield.
1 H NMR (CDCl 3 ) δ 7.92-7.97 (m, 2H), 7.01-7.13 (m, 6H). A portion of similarly prepared oil was crystallized from hexane, mp 80° C.
|
The present invention relates to a process for alkylating hindered sulfonamides by Michael addition to propiolates, and to novel intermediates prepared in said process. The products of these reactions can be converted into pharmaceutical compounds useful in the treatment of disease states mediated by matrix metalloproteinase enzymes. Novel intermediates prepared according to the present invention include compounds of the formula
wherein R 1 is (C 1 -C 6 )alkyl or optionally substituted benzyl;
R 2 and R 3 are independently (C 1 -C 6 )alkyl or R 2 and R 3 are taken together to form a three to seven membered cycloalkyl, pyran-4-yl ring or a bicyclo ring of the formula
wherein the asterisk indicates the carbon atom common to R 2 and R 3 ; and group Q is as herein described.
| 2
|
FIELD OF THE INVENTION
This invention relates to an improved slotline antenna
BACKGROUND OF THE INVENTION
For creating broadband antennas with low production costs, conventionally Vivaldi-antennas are used. Vivaldi-antennas consist of a tapered slotline antenna on a circuit board. Regular Vivaldi-antennas though create an electrically short antenna with a dipole-mode of radiation at signal frequencies where the antenna width W is approximately shorter than half of the signal wave length (W<λ/2). At those frequencies, unwanted radio frequency currents flow on the outer shield of the feeding coaxial cable. Thus, the cable provides unbalanced feeding and becomes an antenna part, too. This deforms the radiation pattern towards a dipole-like radiation pattern. For example, the European Patent EP 1 425 818 B1 shows such a Vivaldi-antenna. Furthermore the electrically short antenna provides typically poor reflection coefficient at the feeding port.
Accordingly, the object of the invention is to create a broadband antenna with a highly directive radiation pattern and low reflection coefficient.
SUMMARY OF THE INVENTION
The object is solved by the features of the independent claims. The dependent claims contain further developments.
In a first aspect of the inventive antenna, the antenna comprises two antenna elements forming a planar slotline antenna. The antenna furthermore comprises absorber elements surrounding the antenna elements on two layers. The absorber elements are shaped to partially cover the antenna elements and partially not cover the antenna elements. Moreover, they are shaped to dampen at least a dipole-mode of the antenna elements and not to dampen a slotline-mode of the antenna elements. By use of the setup, a high directivity and a high bandwidth of the antenna can be achieved.
According to a second aspect of the present invention, the absorber elements are advantageously of identical shape on both layers or at least of nearly identical shape. This leads to a highly symmetrical radiation pattern of the antenna.
In a third advantageous aspect of the present invention, the antenna elements are tapered. The setup allows for an especially high bandwidth of the antenna, low reflection coefficient and a desired directivity.
In a fourth advantageous aspect of the present invention, the antenna elements form a Vivaldi-antenna. A high directivity and bandwidth can therefore be reached.
In a fifth advantageous aspect of the invention, the antenna elements are formed by a metallization layer on a circuit board. The absorber elements are shaped to cover outer sections of the antenna elements and not to cover inner sections of the antenna elements. Since for low frequencies inciting the undesired dipole-mode, the current flows in the outer sections of the antenna elements, at least the dipole-mode can be dampened by surrounding these outer sections of the antenna elements by the absorber elements. For high frequencies, at which the desired slotline-mode is emitted, the currents flow mainly in the inner sections of the antenna elements and therefore should not be dampened. Therefore, absorber elements are not arranged there.
In a sixth advantageous aspect of the invention, the antenna elements are formed by a metallization layer on a circuit board. The absorber elements are shaped to cover outer sections of the antenna elements. The circuit board and the absorber elements both extend beyond these outer sections of the antenna elements. This is done, since the electrical field created by the currents flowing in the outer sections of the antenna elements at low frequencies extends beyond the area covered by the antenna elements. By placing absorber elements supported by the circuit board in these areas beyond the outer sections of the antenna elements, this electrical field is dampened.
According to a seventh advantageous aspect, the antenna elements are also formed by a metallization layer on a circuit board. The absorber elements are located on the metallization layer side of the circuit board and on a non-metallization layer side of the circuit board. By dampening the electrical field not only on the metallization layer side of the circuit board but also on a non-metallization layer side of the circuit board, the directivity and the bandwidth of the antenna can be further increased.
According to an eighth advantageous aspect of the present invention, the antenna elements are also formed by a metallization layer on a circuit board. The metallization layer is largely covered by a protective coating. The protective coating though is interrupted in a feed line connection area. This feed line connection area is located at the narrowest point between the two antenna elements. By covering the majority of the surface area, the antenna is ideally protected. By leaving the feed line connection area uncovered, radio frequency influences are minimized in the especially sensitive area with lowest distance between the two antenna elements.
According to a ninth advantageous aspect, the antenna elements are also formed by a metallization layer on a circuit board. The antenna comprises a connector for connecting an external line. Moreover, it comprises a feed line connected to the connector and to the antenna elements for feeding a signal from the external line to the antenna elements. The feed line in this case may advantageously form an impedance transformer for transforming the impedance of a coaxial feed line to the antenna impedance. For example, a narrowing feed line can be used. This allows for an optimal power transfer if antenna impedance differs from line impedance.
According to a tenth advantageous aspect of the present invention, the antenna elements are also formed by a metallization layer on a circuit board. The antenna elements comprise radiating edges. The shape of the circuit board follows the shape of the radiating edges of the antenna elements in general and extends beyond the radiating edges slightly. The antenna elements are therefore ideally supported by the circuit board. Detrimental effects by unnecessary circuit board area are prevented which reduces dispersion in antenna. By cutting the circuit board in the slot between the antenna elements the ratio of the signal power propagating in the surrounding air to the signal power propagating in the circuit board is increased. Then the transmission line medium becomes more uniform and dispersion effect is reduced. This prevents directivity drop especially at the higher bound of frequency range.
According to an eleventh advantageous aspect of the invention, an antenna system comprises two previously described antennas. The two antennas are mounted perpendicularly, intersecting along a symmetry axis between their antenna elements. The two planar antenna elements form a three-dimensional antenna system. When using only one of the previously described antennas, a linear polarization of the emitted signal is achieved. By use of a here described antenna system, it is possible to achieve arbitrarily polarized electromagnetic emission or two orthogonal linear polarizations. Alternatively by adding a 90° phase shift between the signals of the two antennas, it is possible to reach a circular-polarized emitted signal.
According to a twelfth advantageous aspect, the antenna system comprises a base plate mounted perpendicularly to both antennas on a non-radiating side of the antennas and absorbers mounted on the base plate, advantageously extending in the direction towards a radiating side of the antenna. Undesired cross-effects between the two antennas and reflection from the base plate can therefore be prevented.
In an advantageous thirteenth aspect, an antenna comprises two antenna elements forming a planar slotline antenna. The antenna elements are formed by a metallization layer on a circuit board. The antenna elements in this case comprise radiating edges. The shape of the circuit board follows the shape of the radiating edges and extends beyond the radiating edges slightly. As described earlier, a high directivity can be achieved by reduction of signal dispersion.
In a fourteenth advantageous aspect of the present invention, a measurement chamber for measuring emissions of a wireless device comprises a container sealed against electromagnetic radiation and a previously described antenna or antenna system. The device under test is placed within the test chamber and can easily be measured. The test chamber can have a low size, since the inventive antenna and antenna system only require a small space.
The motivation for introducing the absorbers is to advantageously dampen all other modes except the slotline mode. At the frequencies where an antenna width W or an antenna length L are longer as λ/2, some parasitic electromagnetic modes might be excited along the metallic edges of the antenna. The absorbers shall dampen these modes as well. As a result broad bandwidth, high directivity and low reflection coefficient is maintained.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the subject invention will be better understood in connection with the Detailed Description in conjunction with the Drawings of, Exemplary embodiments of the invention are now further explained with respect to the drawings, in which
FIG. 1 shows a first embodiment of the inventive antenna in a front- and back-view with hidden absorbers;
FIG. 2 shows a second view of the first embodiment of the inventive antenna in a front- and back-view;
FIG. 3 shows a VSWR achievable by use of an inventive antenna;
FIG. 4 shows an absolute gain achievable by use of an inventive antenna without a cut;
FIG. 5 shows an achievable XPR by use of an inventive antenna;
FIG. 6 shows a second embodiment of the inventive antenna in a front- and back-view with hidden absorbers;
FIG. 7 shows an absolute gain achievable by use of an inventive antenna with a cut;
FIG. 8 shows a third embodiment of the inventive antenna;
FIG. 9 shows a fourth embodiment of the inventive antenna in an antenna system in a front- and back-view and
FIG. 10 shows an embodiment of the inventive measurement chamber.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First, we demonstrate the general construction and function of a first embodiment of the inventive antenna along FIG. 1-2 . Afterwards we show the achievable measurement results using an embodiment of the inventive antenna along FIG. 3 - FIG. 5 . By use of FIG. 6-9 additional embodiments of the inventive antenna are described in detail. Finally, along FIG. 10 , an embodiment of the inventive measuring chamber is described. Similar entities and reference numbers in different figures have been partially omitted.
First Embodiment
FIG. 1 shows a first embodiment of the inventive antenna 1 . In FIG. 1 , for reasons of clarity and comprehensibility, not all components of the antenna have been depicted. In FIG. 2 , a view of the antenna showing all components is depicted. On the left side of the FIG. 1 , a front-view of the antenna 1 is shown. On the right side, a back-view of the antenna 1 is shown.
The antenna 1 comprises a circuit board 10 and two antenna elements 12 , 13 formed in a metallization layer 11 on the front side of the circuit board 10 . The antenna elements 12 , 13 are not connected electrically. The antenna element 13 is directly connected to a connector 17 , while the antenna element 12 is connected to the connector 17 through a wire 19 and a feed line 18 . The connector 17 is for example a coaxial connector. The antenna element 13 in this case is connected to the shielding of the coaxial connector, while the antenna element 12 is connected to the center line of the coaxial connector 17 .
The antenna elements 12 , 13 are arranged symmetrically on the front-side of the circuit board 10 . The circuit board 10 extends outwardly from the symmetrical axis beyond the extent of the antenna elements 12 , 13 . Moreover, the antenna elements 12 , 13 comprise recesses 14 , 15 at their outer edges regarding the symmetry axis.
In FIG. 2 , the antenna 1 from FIG. 1 is shown including all relevant components. Identical elements have been partially omitted in the description of FIG. 2 . Absorber elements 20 , 21 , 22 and 23 are mounted on two layers surrounding the antenna elements 12 , 13 . The absorber elements 20 , 21 , 22 and 23 are mounted on the front-side and the back-side of the circuit board 10 . The absorber elements 20 - 23 are advantageously formed from a foam material having a dielectric constant ∈ r between 10 and 100.
The distance d 1 between the absorber elements 20 , 21 and 22 , 23 advantageously is between 20 mm and 100 mm, most advantageously about 60 mm. Moreover d 1 is in the range of 30% to 70% of the entire width of the antenna. Most advantageously, d 1 is 50% of the width of the entire antenna.
The entire width of the antenna W is between 50 mm and 200 mm, preferably between 80 mm and 140 mm, most advantageously about 120 mm.
The absorber elements 20 - 23 are mostly symmetrical regarding the circuit board 10 and regarding a symmetry axis of the antenna elements 12 , 13 .
The absorber elements 20 - 23 are arranged in an outer section 35 of the circuit board 10 above and below the antenna elements. The outer section 35 is outer in regard to the central symmetry axis of the antenna elements 12 , 13 . The outer absorber element areas 110 of the absorber elements 20 - 23 extend further outwards than the antenna elements 12 , 13 regarding the central symmetry axis.
An inner section 34 regarding the central symmetry axis of the antenna elements 12 , 13 is not covered by the absorber elements 20 - 23 . Moreover, the absorber elements 20 - 23 form recesses 33 regarding an emitting edge of the antenna elements 12 , 13 . Also, the absorber elements 20 - 23 form recesses 24 , 25 , 28 , 29 in the outer sections 35 . These recesses 24 , 25 , 28 , 29 can advantageously be used for mounting the antenna. Also, the absorber elements 20 - 23 form recesses 26 , 27 , 30 , 31 at a non-emitting side of the antenna 1 . These recesses 26 , 27 , 30 , 31 can also be used for mounting the antenna 1 .
The metallization layer 11 shown in FIG. 1 is largely covered by a protective coating. The protective coating is therefore placed on the circuit board 10 directly where no antenna elements 12 , 13 are formed and on the antenna elements 12 , 13 where they are formed. The protective coating is advantageously placed on the top and bottom of the circuit board. Near a feed line connection area 39 , a recess 32 within the protective coating is formed. This is done, so that the protective coating does not influence the antenna radio frequency behavior in the especially sensitive section of the antenna, where the antenna elements 12 , 13 have minimal distance. The recess 32 within the protective coating extends until the distance between the antenna elements 12 , 13 towards the emitting side of the antenna reaches d 2 . Advantageously, d 2 is between 2 mm and 8 mm, most advantageously 5 mm.
In FIG. 3 the performance of an example of an inventive antenna is shown. The VSWR (Voltage Standing Wave Ratio) of different antenna types is depicted over frequency. The curve 40 and the curve 41 show exemplary regular antennas. The curve 42 shows an exemplary embodiment of the inventive antenna. It can clearly be seen that the performance of the inventive antenna is most advantageous.
Moreover, in FIG. 4 the absolute gain of different antenna types over frequency is shown. The curve 50 shows the performance of an inventive antenna, while the curves 51 - 54 show the performance of regular broadband antennas. It can clearly be seen that the inventive antenna is very advantageous.
Moreover, in FIG. 5 , the cross-polarization of different antenna types is depicted. Curve 60 shows the cross-polarization XPR of an exemplary embodiment of the inventive antenna while the curve 61 and 62 show the cross-polarization of regular broadband antennas. Also here it can be seen that the inventive antenna is most advantageous.
Second Embodiment
In FIG. 6 , a second embodiment of the inventive antenna is shown. In this embodiment, the antenna 2 does not necessarily comprise absorber elements. The circuit board 70 of the antenna 2 here furthermore comprises a recess 72 at the emitting side of the antenna 2 . The shape of the circuit board 70 follows the shape of emitting edges 71 of the antenna elements. The circuit board 72 though extends beyond the shape of the antenna elements into the emitting direction of the antenna slightly. A current flowing in the antenna elements at the emitting edge of the antenna elements results in an electromagnetic field along the emitting edge of the antenna elements being present in the surround air and in the circuit board dielectric. These two media have different electrical permittivity creating dispersion effect. The cut 72 reduces the dispersion and increase radiation directivity.
Moreover, in FIG. 7 , the absolute gain 111 of an embodiment as shown in FIG. 6 is depicted. Gain does not drop above 12 GHz like it was shown in FIG. 4 for an antenna without the cut 72 .
Alternatively, the features of the embodiments shown in FIG. 1 and FIG. 2 and FIG. 6 can be combined. Then the absorber elements 20 - 23 of FIG. 2 are arranged on the circuit board 72 of FIG. 6 . In this combined embodiment a high directivity and a high bandwidth can be achieved.
Third Embodiment
In FIG. 8 , a third embodiment of an inventive antenna 83 is shown. The antenna 83 is part of an antenna system 3 which is comprised by the antenna 83 , a base plate 80 , on which the antenna 83 is mounted perpendicularly, an absorber base 81 mounted on the base plate 80 and a plurality of absorbers mounted on the absorber base 81 . The absorbers 82 extend from a non-emitting side of the antenna towards the emitting side of the antenna 83 and are mounted parallel to the antenna. The absorbers advantageously are shorter than the antenna 83 . The antenna 83 is an antenna according to one of the previously shown embodiments of the inventive antenna.
Fourth Embodiment
In FIG. 9 , an embodiment of the inventive antenna system 4 is shown. Two antennas 93 and 94 are arranged perpendicularly. They intersect at a central symmetry axis defined by the antenna elements. The antennas 93 , 94 are mounted on a base plate 90 , on which also an absorber base 91 and absorbers 92 are mounted. On the left side of FIG. 9 , the antennas 93 and 94 and the absorber base 91 and the absorbers 92 are depicted. For reasons of clarity, on the right side of FIG. 9 , the antennas 93 , 94 and the base plate 90 are shown on their own.
Fifth Embodiment
In FIG. 10 , finally an embodiment of the inventive measurement chamber 5 is depicted. The measurement chamber 5 comprises a container 101 , which is sealed against electromagnetic radiation and at least an antenna 100 or an antenna system according to one of the previous embodiments. The antenna 100 or the antenna system is mounted on an inner surface of the container 101 . The device under test 102 is placed within the container 101 . The inner surface of the container 101 is completely covered with absorbers. For reasons of clarity, only a part of these absorbers are depicted here.
The invention is not limited to the examples depicted here. The invention discussed above can be applied not only to sending antennas but also to receiving antennas. Also a use outside of measurement chambers, for example in base stations, etc. is possible. The characteristics of the exemplary embodiments can be used in any combination.
Having now described a few embodiments of the invention, and some modifications and variations thereto, it should be apparent to those skilled in the art that the foregoing is merely illustrative and not limiting, having been presented by the way of example only. Numerous modifications and other embodiments are within the scope of one of ordinary skill in the art and are contemplated as falling within the scope of the invention as limited only by the appended claims and equivalents thereto.
|
An inventive antenna comprises two antenna elements forming a planar slotline antenna. The antenna furthermore comprises absorber elements surrounding the antenna elements on two layers. The absorber elements are shaped to partially cover the antenna elements and partially not cover the antenna elements. Moreover, they are shaped to dampen at least a dipole-mode of the antenna elements and not to dampen a slotline-mode of the antenna elements.
| 7
|
FIELD OF THE INVENTION
[0001] The invention relates to the field of communication systems. More particularly, the present invention relates to orthogonal communication systems having channel frequency division multiplexing.
BACKGROUND OF THE INVENTION
[0002] Communication systems use various modulation and multiplexing techniques for communicating signals from a transmitter to a receiver. Multicarrier modulations, such as orthogonal frequency division multiplexing (OFDM), have been used due to advantages of improved bandwidth efficiency and data throughput over, for examples, the mobile radio channel. OFDM is an effective technique to mitigate the effects of delay spread introduced by the mobile radio channels. OFDM provides high spectral efficiency by adopting the orthogonal subcarriers and reduces the effects of intersymbol interference (ISI) by inserting the guard time between symbols to accommodate the delay spread caused by multipath.
[0003] Due to the advantages of improving bandwidth efficiency and data throughput over fading dispersive channels, OFDM has been used in many new digital wireless applications including digital video broadcasting, digital audio broadcasting, and wireless local area networks. The OFDM technique has also been proposed for a new third generation wireless systems. One of the major disadvantages of such a multicarrier modulated system is the performance sensitivity to frequency offsets. A frequency offset can result from a Doppler shift due to the mobile environment as well as from a carrier frequency synchronization error. Such a frequency offset causes a loss of the carrier orthogonality, and h nce, self-introduced intercarrier interference (ICI). ICI, due to frequency offsets, affects the performance of OFDM communication systems.
[0004] In an OFDM system, the input binary data stream is firstly mapped to a signal constellation of M-ary phase shifted keying modulation or M-ary quadrature amplitude modulation. Regardless of the modulation scheme used, the mapped symbols can be represented by a series of complex numbers in vector space. Then, N complex numbers are grouped together and in turn amplitude modulated onto N orthogonal subcarriers. These N modulated subcarriers are combined to form a composite signal called an OFDM symbol. The duration T OFDM for an OFDM symbol is N·T s where T s is the data symbol time duration. The mapping, grouping, amplitude modulation, and combining processes continues for every N data symbols of complex numbers. Each input M-ary data stream is communicated by frequency division across the frequency bandwidth of the communication channel. On the receiver side, OFDM symbols are frequency demodulated using the same N subcarriers. At the end of each OFDM symbol, the magnitude of a complex value associated with each of the N subcarriers will be extracted. These N complex numbers are placed in sequential order and the M-ary data is recovered based on the signal constellation mapping. It is well known that the discrete Fourier transforms (DFT) can be used to realize the orthogonal frequency modulation. Also, the forward fast Fourier transform (FFT) is an effective way to implement the DFTs.
[0005] Referring to FIGS. 1A and 1B, a conventional OFDM transmitter, shown as a module, and a conventional OFDM receiver, also shown as a module, form a conventional OFDM communication system. The transmitter includes an inverse FFT (IFFT) and the receiver includes an FFT. In the conventional OFDM transmitter, a serial-to-parallel operation and a mapping operation essentially perform the grouping of N consecutive data symbols into N parallel inputs to IFFT. The IFFT will take time to complete the inverse transform operation, which essentially puts N parallel inputs to N orthogonal subcarriers. After the IFFT operation, N symbols are serialized by a parallel-to-serial operation with an equal-time spacing between consecutive samples of the IFFT output sequence. The output sequence is transmitted using conventional digital-to-analog conversion and high power amplification, not shown. The reverse operations to the transmitter occur in the receiver. The existing forward and inverse transforms of the conventional OFDM system is given by a transmitter baseband IFFT equation and a receiver baseband FFT equation.
[0006] The IFFT employed at the transmitter is defined by the transmitter baseband IFFT equation.
x k = ∑ n = 0 N - 1 d n j 2 π N nk k = 0 , 1 , 2 , … , N - 1
[0007] In the transmitter baseband IFFT equation, d n is the sequence of input data symbols, k is the output symbol index, N is the number of subcarriers, x k is the output of the IFFT transmitter. After the IFFT transmitter output x k is communicated over an additive white Gaussian noise (AWGN) channel, the received signal is r k =x k +w k where w k is the channel AWGN. The FFT employed at the receiver is defined by the receiver baseband FFT equation.
d ^ k = 1 N ∑ n = 0 N - 1 r n - j 2 π N nk k = 0 , 1 , 2 , … , N - 1
[0008] In the receiver baseband FFT equation, {circumflex over (d)} k is the output of the FFT receiver as the estimated transmitter input data symbol, and N is the number of subcarriers. In order to maintain orthogonality without crosstalk among the subcarriers at the receiver, two conditions must be satisfied, that is, the demodulating carriers need to be exactly aligned with the transmitted carriers, and the receiver demodulation process takes place over a period of time exactly equal to the reciprocal of the subcarrier spacing Δf. If either of these conditions does not exist, the orthogonality is no longer perfectly maintained and the intercarrier interference (ICI), or, crosstalk, is self-generated. One of the major disadvantages of an OFDM system is the sensitivity of performance to a frequency offset. The frequency offset can result from a Doppler shift due to mobile environment as well as from a carrier frequency synchronization error. Such a frequency offset causes a loss of subcarrier orthogonality, and hence, self-introduced ICI. As a result, the desired signal is distorted and the bit-error-rate (BER) performance is degraded.
[0009] An OFDM signal is a composite signal of N component signals, modulated on N orthogonal subcarriers. The desired component signal should ideally be only on the desired subcarrier of interest. In the presence of frequency offset, the signal strength at any desired subcarrier will be reduced and the signal will leak into other undesired subcarriers, meaning that there exists ICI from a subcarrier to other subcarriers, at the output of the FFT receiver. Without losing generality, the desired component signal is on the subcarrier with an index zero for the FFT operation. Referring to all of the Figures, and particularly to FIG. 2, a weighting factor is defined as the square root of the percentage of the signal power, located on a particular subcarrier, that leaks to each of the other undesired subcarriers. When there is no frequency offset, the weighting factor should be 1.0 at the subcarrier index zero, and the weighting factor should be zero for all other indices. For weighting factors of a 16-point FFT with a frequency offset of 0.2·Δf, the weighting factor on the desired signal is less than 1 and those on other undesired sub-carriers are greater than 0. These non-zero weighting factors represent ICI. Practically, there is a limitation on the frequency offset that an OFDM receiver can tolerate. Such limitations for a 16-QAM OFDM system is 4% or less of Δf. Conventional systems have a 4% frequency offset limitation of the intercarrier frequency spacing when N=16.
[0010] The existing architecture of OFDM includes a transmitter, and using an inverse transform function, communicating with a receiver using a forward transform function. These paired transform functions are well known to have a limitation on the frequency offset that the receiver can tolerate within acceptable performance expectations. This performance limitation results from signal distortion due to the intercarrier interference when the frequency offset exists. These and other disadvantages are solved or reduced using the invention.
SUMMARY OF THE INVENTION
[0011] An object of the invention is to provide improved performance of an orthogonal frequency division multiplexed (OFDM) communications system.
[0012] Another object of the invention is to provide an orthogonal frequency division multiplexed (OFDM) communications system using a parallel architecture.
[0013] Yet another object of the invention is to provide an OFDM communications system using a parallel architecture with improved performance in the presence of frequency offsets.
[0014] Still another object of the invention is to provide an OFDM communications system using a parallel architecture with two parallel but inverse functioning transforms in the transmitter, and with two parallel inverse function transforms in the receivers for improved performance in the presence of relative frequency offsets and Doppler frequency offsets.
[0015] The present invention is directed to a parallel architecture for an orthogonal communication system having divisional multiplexing (DM) and have dual inverse transformation operations. In the preferred form, the divisional multiplexing is frequency division multiplexing, and hence, the present invention is directed to an OFDM communications system. The transmitter and receiver use inverse transforms that do not affect subcarrier orthogonality. The forward fast Fourier transform (FFT) and the inverse fast Fourier transform (IFFT) are used in the preferred form. The parallel architecture provides for the communication of a second multiplexed signal that is combined during reception for providing improved performance in the presence of frequency offsets.
[0016] An OFDM transmitter is equipped with a conventional inverse fast Fourier transform (IFFT) OFDM transmitter module connected in parallel to a forward fast Fourier transform (FFT) OFDM transmitter module, with both transmitter modules divisionally multiplexed together for providing two separate signals prior to transmission. The OFDM receiver is equipped with a conventional FFT OFDM receiver module connected in parallel to a parallel IFFT OFDM receiver module, with both receiver modules connected to a front end demultiplexer. That is, the parallel transmitter architecture includes a conventional IFFT transmitter module in parallel with a parallel FFT transmitter module, and the parallel receiver architecture includes a conventional FFT receiver module in parallel with a parallel IFFT receiver module. Hence, both the transmitter and receiver provide dual FFT and IFFT operations, along separate but parallel processing paths, differentiated by a transmitter back end multiplexer and a receiver front end demultiplexer. The parallel architecture contains the conventional OFDM operation and an additional parallel inverse OFDM operation. The conventional transmitter IFFT module operates in combination with the conventional receiver FFT module. The parallel transmitter FFT module operates in combination with the parallel receiver IFFT module. The use of a transmitter divisional multiplexer (DM) and a receiver divisional demultiplexer (DD) enable the two parallel processing paths to be processed together through a single transmitter and receiver.
[0017] The dual architecture provides additional signal diversity to the OFDM communication system. The parallel architecture provides improved performance for the OFDM system in the presence of relative frequency offsets and Doppler frequency offsets, and provides improved tracking capability for the receiver, while further providing backward compatibility with conventional OFDM systems. The combination of the two parallel transformation paths is used to provide improved system performance. This dual function effectively provides signal diversity.
[0018] The divisional multiplexing and divisional demultiplexing functions are preferably frequency division multiplexing, but can be code division multiplexing, or time division multiplexing, all of which respectively provide code diversity, frequency diversity, or time diversity. The receiver contains a divisional demultiplexer for demultiplexing the input signal to either the conventional FFT receiver module or the parallel IFFT receiver module. The divisional demultiplexer decomposes the divisional multiplexed input to the receiver for providing respective forward and inverse transformed received signals. The forward and inverse transformed received signals after respective FFT and IFFT operations are demodulated simultaneously and combined to form the final detected data symbol signal offering improved system performance.
[0019] In the presence of frequency offset, there exists intercarrier interference (ICI) from a subcarrier to other subcarriers at the output of the conventional FFT receiver module. As a result, the signal strength at any desired subcarrier will be reduced and the signal will leak into other undesired subcarriers. In the parallel architecture, the parallel IFFT receiver module generates an ICI signal that has the opposite polarity to the one generated by the conventional FFT receiver module. Therefore, after combining the two demodulated signals from two parallel paths, the majority part of the ICI signal is cancelled out with some residual ICI signal left. The parallel OFDM system provides significantly smaller weighting factors on undesired subcarriers while maintaining the same weighting factor on the desired subcarrier as that of the conventional OFDM system. As a result, the ICI is significantly reduced with improved performance.
[0020] Conventional OFDM communications systems can be upgraded to add the parallel OFDM FFT module in the transmitter and OFDM IFFT module in the receiver with backward compatibility. The backward compatibility is retained because the parallel structure contains the conventional architecture as a standing-alone alone operation with the additional parallel functions. These and other advantages will become more apparent from the following detailed description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1A is a block diagram of an orthogonal frequency division multiplexed transmitter.
[0022] [0022]FIG. 1B is a block diagram of an orthogonal frequency division multiplexed receiver.
[0023] [0023]FIG. 2 is a graph of orthogonal frequency division multiplexed weighting factors.
[0024] [0024]FIG. 3 is a graph of the signal to intercarrier interference ratio.
[0025] [0025]FIG. 4 is a graph of the bit error rate of orthogonal frequency division multiplexed systems.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] An embodiment of the invention is described with reference to the figures using reference designations as shown in the figures. Referring to FIG. 1A, an orthogonal frequency division multiplexing (OFDM) transmitter includes a conventional OFDM transmitter module in parallel to a parallel OFDM transmitter module. Serial input symbols are fed into a first serial-to-parallel converter for providing a first parallel symbols input to a first data-to-subcarrier mapper. The first data-to-subcarrier mapper provides first parallel subcarrier data to an N-point inverse fast Fourier transform (IFFT) providing parallel inverse transformed data that is serialized by a parallel-to-serial converter for providing a first serial transmitter output. Preferably, the parallel subcarrier data from the data-to-subcarrier mapper of the conventional OFDM transmitter module is clocked into an N-point fast Fourier transform (FFT) that provides parallel forward transformed data. It should be apparent that the parallel OFDM transmitter module may alternatively have a second serial-to-parallel converter and a second data mapper so as to receive the input symbols and provide a second parallel symbols input and second parallel subcarrier data to the FFT in the parallel OFDM transmitter module. The parallel forward transformed data from FFT in the parallel OFDM transmitter module is serialized by a second parallel-to-serial converter for providing a second s rial transmitter output. The first and second serial transmitter outputs are fed into a divisional multiplexer for combining the first and the second serial transmitter outputs as a divisional multiplexed transmitter composite output signal. In the preferred form, frequency division is used, but code and time divisional multiplexing could be used as well. The composite transmitter output signal is communicated over a channel, and is received by a receiver as a composite received input signal.
[0027] Referring to FIG. 1B, an OFDM receiver includes a conventional OFDM receiver module and a parallel OFDM receiver module. The divisional multiplexed transmitter composite output signal is communicated over the channel and is received as the composite received signal. The composite received signal is fed into a divisional demultiplexer in the OFDM receiver for demultiplexing the composite received signal into an inverse transformed received signal and a forward transformed received signal. The inverse transformed received signal-originates from the first serial transmitter output and the forward transformed received signal originates from the second serial transmitter output.
[0028] The inverse transformed received signal is communicated to the conventional OFDM receiver module and fed into a first serial-to-parallel converter for providing first parallel received inputs. In the conventional OFDM receiver module, the first parallel received inputs are fed into an N-point FFT for providing first parallel mapped signals. The first parallel mapped signals are fed into a first subcarrier-to-data mapper for providing first parallel demodulated signals that are in turn fed into a first parallel-to-serial converter for providing a first serial demodulated signal.
[0029] In the parallel OFDM receiver module, the forward transformed received signal is communicated to a second serial-to-parallel converter for providing second parallel received inputs. In the parallel OFDM receiver module, the second parallel received inputs are fed into an N-point IFFT for providing second parallel mapped signals. The second parallel mapped signals are fed into a second subcarrier-to-data mapper for providing second parallel demodulated signals that are in turn fed into a second parallel-to-serial converter for providing a second serial demodulated signal. Finally, the first and second demodulated signals are summed together by a summer for providing an average output signal. In this manner, two receiver output signals, independently processed and generated by parallel forward and inverse transformation processes, are averaged for providing an output signal, which is the estimate of the input symbol sequence into the transmitter.
[0030] The parallel OFDM system employs transform processes that can be described by equations. The transform processes include two conventional transforms and two additional transforms. The transmitter contains the conventional transmitter IFFT module that is described by the transmitter baseband IFFT equation, and the parallel transmitter FFT module, that is described by a transmitter baseband FFT equation.
x k ′ = ∑ n = 0 N - 1 d n - j 2 π N nk k = 0 , 1 , 2 , … , N - 1
[0031] In the transmitter baseband FFT equation, d n is the sequence of input data symbols, k is the FFT output symbol index, N is the number of subcarriers, and x {acute over (k)} is the output of the parallel transmitter FFT module. The receiver contains the conventional receiver FFT module and the parallel receiver IFFT module. After the parallel transmitter FFT output x {acute over (k)} is communicated over an additive white Gaussian noise (AWGN) channel, the parallel transmitter FFT output is then passed through the second serial-to-parallel converter. The second parallel received input to the parallel receiver IFFT module is r {acute over (k)} =x {acute over (k)} +w {acute over (k)} where w {acute over (k)} is the channel AWGN. The parallel receiver IFFT module is described by a receiver baseband IFFT equation.
d ^ k ′ = 1 N ∑ n = 0 N - 1 r n ′ j 2 π N nk k = 0 , 1 , 2 , … , N - 1
[0032] The outputs-from the conventional receiver FFT module and the parallel receiver IFFT module are summed by the summer to combine the receiver IFFT and FFT outputs as described in a receiver baseband combine equation.
d ^ avek = 1 2 ( d ^ k ′ + d ^ k ) k = 0 , 1 , 2 , … , N - 1
[0033] In the receiver baseband IFFT equation, {circumflex over (d)} {acute over (k)} is the output of the receiver IFFT module, N is the number of subcarriers. In the receiver baseband combine equation, {circumflex over (d)} avek is the average received signal providing improved performance.
[0034] When a frequency offset exists, the FFT operation alone in the receiver will generate intercarrier interference (ICI), which will interfere with the data on the desired subcarrier and in turn degrade the performance. The additional receiver IFFT in combination with the additional transmitter FFT provides a smaller ICI on undesired subcarriers while maintaining the same signal strength on the desired subcarrier as that of the existing OFDM system. Consequently, the additional transmitter FFT and additional receiver IFFT improves the signal to ICI ratio and effectively mitigates ICI.
[0035] The system includes a conventional OFDM operation with conventional transform processes and a parallel OFDM operation with an additional transform process. These transform processes are preferably the same FFT and IFFT transform processes, but in reversed order. Either a code division multiplexing, time division multiplexing or frequency division multiplexing can be applied to the multiplexer. The transmitter provides two baseband signals received and processed by the receiver. The parallel OFDM receiver module preferably contains the demultiplexer and a receiver IFFT. The demultiplexer demultiplexes the two mixed received signals inversely to the multiplexing of the multiplexer in the transmitter. The demultiplexer provides two separate parallel signals in the receiver. These two received signals are respectively forwardly and inversely transformed simultaneously and then averaged to obtain average output signal providing the final signal indicating the estimated input symbol sequence of the transmitter. The averaging of the receiver output signals improves the frequency offset limitations.
[0036] Referring to FIGS. 1A through 2, and more particularly to FIG. 2, the weighting factor for the system can be reduced on a particular subcarrier, that leaks to each of the other undesired subcarriers. The magnitudes of the weighting factors of the parallel OFDM system with a frequency offset of 0.2·Δf are indicated for a 16-point FFT. Without losing the generality, a desired signal can have a frequency index of zero. The desired signal power should ideally be completely on the subcarrier with a frequency index zero for the FFT operation. When there is no frequency offset, the weighting factor should be 1.0 at the frequency index zero, and the weighting factor should be zero for all other indices. For weighting factors of a 16-point FFT with a frequency offset of 0.2·Δf, the weighting factor on the desired signal is less than 1 and those on other undesired sub-carriers are greater than 0. These non-zero weighting factors represent ICI as a limitation on the frequency offset that an OFDM receiver can tolerate.
[0037] Referring to FIGS. 1A through 3, and more particularly to FIG. 3, the system provides significant advantage of signal to ICI power ratio over the conventional OFDM systems when frequency offset exists. FIG. 3 shows the signal to ICI power ratio (SICIR) as a function of frequency offset for N=16. The system has a SICIR advantage of about 7 dB improvement at a frequency offset of 0.04·Δf for N=16. Consequently, this parallel OFDM system improves the SICIR and effectively mitigates the ICI problem.
[0038] Referring to all of the Figures, and more particularly to FIG. 4, a performance comparison in an AWGN channel between the conventional and the new parallel OFDM systems for N=16 is depicted. Without increasing signal power, when each branch at the transmitter is at half of an original signal power, the system provides improved tracking capability. The new parallel architecture expands the 0.04·Δf frequency offset limitation of the conventional architecture to 0.06·Δf when N=16. This increase indicates that the relative speed as an effectively Doppler shift is allowed to increase 50% from the current limitation without losing communication. This improvement can also be directly applied to the coarse signaling detection and acquisition process for digital communications.
[0039] The parallel OFDM system is well suited for satellite and wireless communications such as cellular base stations and mobile communication systems. The present invention preferably uses frequency division, but can be expanded to code division and time division multiplexing systems. Those skilled in the art can make enhancements, improvements, and modifications to the invention, and these enhancements, improvements, and modifications may nonetheless fall within the spirit and scope of the following claims.
|
A parallel orthogonal frequency division multiplexed (OFDM) communications system includes a transmitter and receiver, the transmitter having a parallel fast Fourier transform (FFT) module operating in parallel to a conventional inverse fast Fourier transform (IFFT) module for providing respective orthogonal outputs received by the receiver. The receiver has a parallel IFFT module and a conventional FFT module for providing respective orthogonal outputs. The respective orthogonal outputs are combined to form a composite signal that provides improved insensitivity to relative frequency offsets and Doppler frequency offsets. The parallel FFT and IFFT modules in the OFDM communication system provides improved signal diversity and performance in the presence of relative frequency offsets and Doppler frequency offsets, and provides improved tracking capability for the receiver with backward compatibility.
| 7
|
CROSS REFERENCE TO RELATED APPLICATION
This application is based on U.S. Provisional Patent Application No. 61/980,022, filed Apr. 15, 2014, which is incorporated herein in its entirety.
FIELD OF THE INVENTION
Our invention relates to methods, systems, and marks for manufacturing paper products such as paper towels and bathroom tissue. In particular, our invention relates to a method of controlling a manufacturing line to convert a paper web into paper products and a converting line implementing this method. Our invention also relates to a mark for a paper web and a method of marking a paper web.
BACKGROUND OF THE INVENTION
In a typical paper manufacturing process, a paper web is created on a paper machine and wound onto a large roll called a parent roll. The paper web is then unwound from the parent roll and converted into consumer sized products on a converting line. In paper manufacturing, as in many manufacturing processes, efficient operations that maximize operational time are desired. Defects may occur, however, in the paper web as it is being manufactured on the paper machine. These defects may be significant enough to cause the paper web to break while, for example, the web is being unwound on the converting line. A web break reduces productivity in the converting line, because an operator must stop the converting line in order to re-thread the paper web. This process may take from about five minutes to about an hour. At typical converting speeds of about two thousand feet per minute, each web break reduces the amount of paper product produced by about ten thousand feet up to about one hundred twenty thousand feet. It is, therefore, desirable to accurately identify these web defects and take action on the converting line to prevent web breaks from occurring.
The inspection of a paper web while it is being created on a paper machine is commonly performed in the art. There are also many patents, such as U.S. Pat. No. 6,452,679, directed towards web inspection. Inspection of the paper web on the paper machine is commonly used to provide real-time feedback for the papermaking process. In this way, the paper machine can be adjusted to minimize the generation of defects or to adjust other parameters of the paper web, such as basis weight.
The defect information from the web inspection may also be used to repair or to remove the portions of the paper web having the defect, before these portions result in a web break on the converting line or a failure during operation. In U.S. Pat. No. 6,934,028, a paper web is inspected, and defects are classified and located relative to periodically placed fiduciary indicators. Using these fiduciary indicators, a portion of the web having a defect may be identified and removed. Similarly, in U.S. Pat. No. 7,297,969, a paper web is inspected, periodically marked, and wound on a reel. This patent discloses a mark sequence in which the spaces between the starting points of adjacent marks are used to encode a location along the length of the web. These marks may then be used to locate defects on the paper web that were identified during inspection. The paper web is placed on a repair machine and the reel is unwound. The marks are used to stop the unwinding at a defect location so that the defect may be repaired. While not using a repair machine, U.S. Pat. No. 6,725,123 likewise discloses using marks to stop a converting line, so that a defect may be repaired. U.S. Pat. No. 8,060,234 discloses a method and an apparatus similar to that discussed in U.S. Pat. No. 6,725,123. But, instead of using marks to subsequently identify a location on a paper web on a converting line, U.S. Pat. No. 8,060,234 discloses using an optical signature for one lane of the paper web. The optical signature is the small-scale and large-scale variability inherent in a paper web.
In another method known in the art, defects are identified during web inspection and located based on their position relative to one end of the paper web. The position of the paper web may be located as a function of the diameter of a parent roll. A laser may then be used to measure the diameter of the parent roll as it is unwound, in order to locate a defect on the paper web. While the laser may be very precise, small out-of-round conditions on the parent roll may have a large impact on the position of the paper web as measured by the laser. Accordingly, this method has a large uncertainty.
In another method, a web defect is marked with a physical tag, such as a tag disclosed in U.S. Pat. No. 5,415,123. This method is heavily reliant on operator skill and expertise, because it requires the operator to observe the tag and to take action to stop the converting line in a sufficient amount of time to prevent the defect from causing a web to break.
A series of patents, for example, U.S. Pat. No. 7,937,233; No. 8,175,739; and No. 8,238,646, discloses a system in which a paper web is inspected for defects and periodically marked with “fiducial marks.” This system then creates a defect map where defects identified during the inspection are mapped relative to the fiducial marks. These defect maps are then used to apply locating marks at the position of the defects. Because the paper web is cut into smaller sections, a converting plan can be created to more effectively utilize the paper by cutting around the defects. Further, the defect maps may be used to sort the paper web into different grades of paper.
Each of these methods treats the defects individually and establishes other individual action points to stop and to repair or to discard a portion of the paper web. There is thus a need for improved methods and systems for defect identification, marking, and converting line control.
SUMMARY OF THE INVENTION
According to one aspect, our invention relates to a system for producing a paper product. The system includes a paper machine for forming a paper web, an analysis tool, and a converting line for converting the paper web into a paper product. The paper web produced by the paper machine has a plurality of sections. The paper machine includes a web analysis unit to perform at least one of inspecting the paper web and identifying properties in the paper web. The paper machine also includes a marking unit to mark the paper web with a plurality of marks. At least one mark is assigned to each of the plurality of sections. The paper machine further includes a winder to wind the paper web into a parent roll. The winder is positioned after the web analysis unit and the marking unit. The analysis tool is configured to assign a paper rating to each section of the paper web based upon the identified properties in that section of the paper web. The converting line has a plurality of operating parameters. The converting line includes an unwind stand to unwind the paper web from the parent roll. The converting line also includes a mark reading unit that reads at least one of the plurality of marks on the paper web and produces a corresponding output from the mark that has been read. The converting line further includes a controller that receives the output from the mark reading unit and is configured to obtain the paper rating associated with the at least one mark read by the reading unit and to change at least one operational parameter of the converting line based upon the paper rating. The converting line yet further includes a finisher. The paper web is fed to the finisher and converted into a paper product.
According to another aspect, our invention relates to a method of producing a paper product. The method includes forming a paper web having a plurality of sections on a paper machine, and analyzing the paper web with a web analysis unit to perform at least one of inspecting the paper web and identifying properties in the paper web. The method also includes marking the paper web with a plurality of marks. At least one mark is marked at each of the plurality of sections. The method further includes winding the paper web with the winder to form a parent roll after the paper web has been inspected and marked. The method still further includes assigning a paper rating to each section of the paper web based upon the properties in that section of the paper web that are identified in the analyzing step. The method yet further includes unwinding a paper web from a parent roll on a converting line having a plurality of operational parameters. The method even still further includes reading at least one of the plurality of marks with a mark reading unit, obtaining the paper rating associated with the at least one mark read by the reading unit, and changing at least one operational parameter of the converting line based upon the paper rating. The method also includes converting the paper web into a paper product.
These and other aspects of our invention will become apparent from the following disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a papermaking machine configuration that can be used in conjunction with our invention.
FIG. 2 is a detailed top plan view of the papermaking machine configuration shown in FIG. 1 .
FIG. 3 is an exemplary defect database that can be used in conjunction with our invention.
FIG. 4 is a defect map of the defect database shown in FIG. 3 .
FIG. 5 shows an example of marking that can be used on a paper web in conjunction with our invention.
FIG. 6 shows how the marks of FIG. 5 may be applied to a paper web.
FIG. 7 shows examples of how the paper web may be subdivided.
FIG. 8 shows an example of how the paper web may be analyzed for defects in conjunction with our invention.
FIGS. 9A through 9C and 9F through 9K are flow charts of steps for assigning inputs for the converting line in accordance with a preferred embodiment of our invention, and FIGS. 9D, 9E, and 9L through 9N show the development of the scored database.
FIGS. 10A and 10B show a map of the scored database shown in FIG. 9N .
FIG. 11 is a system diagram of an embodiment of our invention.
FIGS. 12A and 12B are schematic diagrams of portions of converting line configurations that can be used in conjunction with our invention.
FIG. 13 shows a control screen for a converting line programmable logic controller that can be used in conjunction with our invention.
FIG. 14 is a graph showing an example of a preferred speed profile and a non-preferred speed profile for a converting line.
FIGS. 15A and 15B show an alternate control screen for a converting line programmable logic controller that can be used in conjunction with our invention.
FIG. 16 is a flow chart of an embodiment of our invention.
FIG. 17 is a detailed flow chart of process steps at a paper machine for the embodiment shown in FIG. 16 .
FIG. 18 is a detailed flow chart of process steps performed by an analysis tool for the embodiment shown in FIG. 16 .
FIG. 19 is a detailed flow chart of process steps at a converting line for the embodiment shown in FIG. 16 .
FIG. 20 is a flow chart of an alternate embodiment of our invention.
FIG. 21 is a detailed flow chart of process steps performed by an analysis tool for the embodiment shown in FIG. 20 .
FIG. 22 is a detailed flow chart of process steps at a converting line for the embodiment shown in FIG. 20 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Consumer paper products, such as paper towels, bathroom tissue, and the like, are made by first creating a paper web on a paper machine. This paper web is wound onto large rolls called parent rolls. The parent rolls are then moved to a converting line at which the paper web is unwound from the parent roll and converted into consumer paper products. Our invention relates to methods, systems, and marks for controlling the converting line.
The term “paper product,” as used herein, encompasses any product incorporating papermaking fibers having cellulose as a major constituent. This would include, for example, products marketed as paper towels, toilet paper, and facial tissues. Papermaking fibers include virgin pulps or recycle (secondary) cellulosic fibers, or fiber mixes comprising cellulosic fibers. Wood fibers include, for example, those obtained from deciduous and coniferous trees, including softwood fibers, such as northern and southern softwood kraft fibers, and hardwood fibers, such as eucalyptus , maple, birch, aspen, or the like. Examples of other fibers suitable for making the products of our invention include nonwood fibers, such as cotton fibers or cotton derivatives, abaca, kenaf, sabai grass, flax, esparto grass, straw, jute hemp, bagasse, milkweed floss fibers, and pineapple leaf fibers. Furnish refers to aqueous compositions including papermaking fibers, and, optionally, wet strength resins, debonders, and the like, for making paper products.
When describing our invention herein, the terms “machine direction” (MD) and “cross machine direction” (CD) will be used in accordance with their well-understood meaning in the art. That is, the MD of a fabric or other structure refers to the direction that the structure moves on a papermaking machine in a papermaking process, while CD refers to a direction crossing the MD of the structure. Similarly, when referencing paper products, the MD of the paper product refers to the direction on the product that the product moved on the papermaking machine in the papermaking process, and the CD of the product refers to the direction crossing the MD of the product.
When describing our invention herein, specific examples of operating conditions for the paper machine and converting line will be used. For example, various speeds will be used when describing paper production on the paper machine or converting on the converting line. Those skilled in the art will recognize that our invention is not limited to the specific examples of the operating conditions, including speed, that are disclosed herein.
Paper webs may be made on a paper machine implementing any one of a number of methods known in the art, such as conventional wet pressing and through-air drying. FIG. 1 is a schematic diagram showing an exemplary twin wire wet crepe machine layout that can readily be adapted to practice our invention. Those skilled in the art will recognize that other paper machines likewise may be readily adapted to practice our invention.
In the paper machine 100 shown in FIG. 1 , furnish issues from headbox 111 into nip 114 between inner wire 112 and outer wire 113 to form nascent web 101 . The nascent web 101 is carried on the inner wire 112 and transferred to felt 121 , at nip 122 . The nascent web 101 is then transferred from the felt 121 to Yankee cylinder 131 at nip 126 between suction pressure roll 123 and the Yankee cylinder 131 . In this paper machine 100 , felt 121 passes over idler roll 124 before passing around blind drilled roll 125 and though nip 127 between the blind drilled roll 125 and the Yankee cylinder 131 . The Yankee cylinder 131 is a heated cylinder that is used to dry the nascent web 101 . In addition, hot air from wet end hood 132 and dry end hood 133 is directed against the nascent web 101 to further dry the nascent web 101 as it is conveyed on the Yankee cylinder 131 . The dried nascent web 101 forms a paper web 102 . The paper web 102 is removed from the Yankee cylinder 131 with the help of doctor blade 134 . The paper web 102 is then wound around a reel 180 to form a parent roll 190 .
Some paper machines create a paper web 102 that is wider than can be used in a subsequent converting process. As a result, the paper web 102 may be split into two or more parent rolls 190 using a cutter 160 . The rolls may be designated with a letter such as an A roll or a B roll. The cutter 160 may be a circular blade with a continuous cutting surface. Those skilled in the art will recognize that any suitable cutter may be used including, for example, a water jet cutting system.
In this preferred embodiment, the paper web 102 is inspected for defects on the paper machine 100 . As shown in FIGS. 1 and 2 , the paper web 102 is inspected by web inspection units 141 , 142 , 143 after the paper web 102 leaves the Yankee cylinder 131 . The web inspection units are part of a web inspection system. Those skilled in the art will recognize that any suitable web inspection systems and units may be used including those made by ABB of Zurich, Switzerland; Metso of Helsinki, Finland; Papertec of North Vancouver, BC, Canada; Honeywell of Morristown, N.J.; and Event Capture Systems of Mint Hill, N.C. In the preferred embodiment, each web inspection unit 141 , 142 , 143 includes at least a digital high speed camera and a light source. The cameras of the preferred embodiment are set to take images at, for example, one hundred twenty frames per second and have a resolution of, for example, six hundred forty pixels by four hundred eighty pixels. The web inspection units 141 , 142 , 143 are positioned a distance above the paper web 102 to preferably have a field of view 150 between about seventy inches and about one hundred four inches wide, and more preferably, about one hundred two inches wide. An example of a suitable camera includes Prosilica GT1910 made by Allied Vision Technologies of Stadtroda, Germany. The web inspection units 141 , 142 , 143 are also preferably positioned so the entire width of the paper web 102 is inspected. Preferably, the field of view 150 for each web inspection unit 141 , 142 , 143 has a small amount of overlap of approximately two inches with the field of view 150 of the adjacent web inspection unit 141 , 142 , 143 . The resolution and distance from the paper web determine the size of an indication or a defect that can be detected. Increasing the resolution of the camera will enable smaller defects to be detected. Alternatively, placing the camera closer to the paper web enables smaller defects to be detected, but the field of view is also decreased and more cameras will be needed to image the entire width of the paper web 102 . The light source is preferably an array of light emitting diodes used to illuminate the paper web 102 . In the preferred embodiment, the light source is positioned coincident with the camera. Those skilled in the art will recognize that any suitable light source may be used, including high frequency florescent lighting or halogen lighting. The light source may also be positioned elsewhere on the paper machine 100 including below the paper web 102 . As those skilled in the art will recognize, the lighting requirements will depend upon the camera settings, including frame rate and aperture.
Any suitable web inspection system that is capable of analyzing the captured images to identify and to classify defects may be used. Further, any suitable method of identifying and classifying defects may be used, such as gray scale analysis or image comparison. In the preferred embodiment, defects are identified by using a gray scale method. The paper web 102 appears white to the camera, because the paper web 102 reflects the light from the light source. Defects, on the other hand, are non-reflective and appear dark to the camera. The opposite, where the paper web 102 appears dark to the camera and defects appear white, occurs when the lighting is positioned below the paper web. Defects may thus be identified as pixels in the images captured by web inspection units having a gray scale value darker than a predetermined threshold. Once identified, the dimensions and positions of individual defects may be determined. The defect analysis method discussed in U.S. Patent Appln. Pub. No. 2012/0147177 (the disclosure of which is incorporated by reference in its entirety) may be used to distinguish between true defects and false positives. Many different types of defects may be identified by the web inspection system. In the preferred embodiment, the web inspection units 141 , 142 , 143 identify holes, tears, wrinkles, chemical coating streaks, and the like.
When the defects are identified by the web inspection system, they are preferably recorded in a table or a database, such as the table shown in FIG. 3 . A “database,” as used herein, means a collection of data organized in such a way that a computer program may quickly select desired pieces of the data. An example is an electronic filing system. In the preferred embodiment, the time the defect is detected, the location of the defect, and defect specific information are recorded in a database. This database may be referred to as the defect database, and in the preferred embodiment, all data is established in the database with respect to a master time reference. As an example, the leading edge of the paper web 102 in the machine direction passes the web inspection units 141 , 142 , 143 at 09:34:01. The first web defect is identified at 09:41:10, which is recorded in the defect database. The first defect is located one thousand feet in the machine direction (MD) from the leading edge of the paper web 102 and ten inches from one of the edges of the paper web 102 in the cross-machine direction (CD). By grayscale analysis, the first web defect is identified as having both a length and a width of one half inch, resulting in an aspect ratio of length to width of one. Similarly, the second web defect is recorded at 10:10:00 and has an aspect ratio of 0.0625. Defects may be classified by the aspect ratio. In this case, the first web defect is considered to be a hole and the second web defect is considered to be a tear. This process is then repeated for the entire parent roll. The defects may also be represented graphically in a defect map such as the map shown in FIG. 4 . Here, the first web defect is shown with an open circle in the upper left of the paper web 102 . The second web defect is similarly shown with an open triangle.
The defect database may be stored in a non-transitory computer-readable medium in order to facilitate the analysis described below. A non-transitory computer readable medium, as used herein, comprises all computer-readable media except for a transitory, propagating signal. Examples of non-transitory computer readable media include, for example, a hard disk drive and/or a removable storage drive, representing a disk drive, a magnetic tape drive, an optical disk drive, etc. The non-transitory computer readable media may be connected to processors, programmable logic controllers for converting line control, the web inspection system using network connections that are common in the art, and other controllers and systems used in our invention. When the non-transitory computer readable media is connected to a network, it may be referred to as a file server.
Other paper web properties may be measured on the paper machine 100 , for example, moisture content and basis weight of the paper web. In this embodiment, as shown in FIG. 1 , a web property scanner 155 is positioned after the Yankee cylinder 131 and before web inspection units 141 , 142 , 143 . Any suitable web property scanner 155 known in the art may be used to measure web properties. An example of a suitable web property scanner 155 is an MXProLine scanner manufactured by Honeywell of Morristown, N.J., that is used to measure the moisture content with beta radiation and basis weight with gamma radiation. As these data are collected, the web property is recorded in a database along with the time that the property was obtained. This database may be the defect database or a separate database for web properties (e.g., web properties database). In addition, web properties may also be indirectly determined from other operating parameters of the paper machine 100 . Operating parameters such as pump speeds, fan speeds, and the like, may be correlated to web properties. By monitoring and recording these operating parameters, web properties can be calculated and recorded in the web properties database.
In order to effectively utilize the defect information generated during web inspection, the paper web 102 is marked at a set periodicity with mark 210 . As shown in FIGS. 1 and 2 , the paper web 102 is preferably marked after the web inspection units 141 , 142 , 143 and prior to being wound on the reel 180 . In the preferred embodiment, marking units 171 , 172 are positioned adjacent to the cutter 160 . This position allows for accurate and repeatable application of mark 210 . Cutting the paper web 102 requires that the paper web 102 be stable when it is cut, particularly, that the paper web 102 is taut and moved at a constant speed. Both of these conditions are well suited for accurate application of mark 210 . Further, the outside edges of the paper web 102 may move in the cross-machine (CD) direction when viewing a particular point on the paper machine 100 , because either the width of the paper web 102 changes or the paper web 102 as a whole shifts. By applying mark 210 near the cutter 160 , the mark 210 can be positioned at a set distance from an edge of the paper web 102 , making reading the mark 210 easier on the converting line and ensuring that the mark 210 is removed when the finished product is cut to length. The MD distance between the web inspection units 141 , 142 , 143 and the marking units 171 , 172 is also preferably minimized. As with the defects, the mark 210 is recorded in the defect database according to a master time reference. Preferably, the same time should correspond to the same MD location on the paper. If the web inspection units 141 , 142 , 143 and the marking units 171 , 172 are separated, however, a correction factor would need to be applied to one of the time references. This introduces a source of uncertainty.
Any suitable marking unit 171 , 172 may be used, such as COM-2112 manufactured by Ryeco Inc. of Marietta, Ga. Also, any suitable ink may be used to mark the web, including food grade ink or ink that is visible under ultraviolet light Ink that may be detected under ultraviolet light is advantageous in the event that the mark is not properly removed during the converting process. In this case, the mark is not visible to a consumer, even though the mark remains on the consumer product.
The mark of the preferred embodiment is a binary mark made of multiple discrete positions over a set distance of the paper web 102 . As shown in FIG. 5 , the mark includes N positions. Each position is either blank, indicating a value of zero, or contains ink, indicating a value of one. Ideally, the mark length 630 (see FIG. 6 ) is as small as possible and could be a bar code. Such a mark could be used to practice our invention, but the marking technology, especially for paper making used for tissue and towel, has not yet advanced to make such marks practical Ink marks have a tendency to spread on the paper web. Thus, it is difficult to precisely control the width of the ink mark as is necessary for a bar code. Additionally, at typical reel speeds of about three thousand five hundred feet per minute, the length of any mark will be limited by the rate of discharge from an ink head. We have thus found that the ink is preferably applied as a dash that is about one thirty-second of an inch in width and about three inches in length. At typical reel speeds, the marking unit 171 , 172 discharges ink for about two milliseconds to create a mark of three inches in length. Further, a dash provides a sufficient time for the mark to be detected and read on a converting line. (The converting line speeds may range from about one thousand three hundred feet per minute to about three thousand feet per minute.) A position is preferably less than about twenty inches in length, more preferably, less than about six inches in length, and, most preferably, about three inches in length. The start of each position is similarly preferably separated from adjacent positions by about twenty inches or less, more preferably, about six inches or less, and, most preferably, about three inches. Those skilled in the art will recognize, however, that other types of ink applications, including dots, may be used without deviating from the scope of our invention. The mark preferably contains between about sixteen positions and about sixty-eight positions, and, more preferably, about thirty-eight positions. The number of positions in a mark is a balance between providing enough positions or bits to convey the information contained in the mark and keeping the mark to a reasonable length. A mark as described above with thirty-eight positions will preferably have a mark length 630 , as shown in FIG. 6 , of about sixteen feet.
In the preferred embodiment, the first two positions (positions one and two in FIG. 5 ) each contains a dash. Together, the two dashes indicate the start of a mark. Similarly, the last two positions (positions N- 1 and N in FIG. 5 ) will contain a dash to indicate the end of the mark. In reading the mark, a mark reading unit (discussed below) can distinguish between marks when a predetermined amount of time has passed between successive detections of ink. This predetermined amount of time should be longer than the time it takes for the mark to pass by the reading unit.
The remaining thirty-four positions in the preferred embodiment are used to identify the parent roll and the lineal position of the mark on the parent roll. Positions three to five may be used to identify the particular paper machine and the mill from which the roll originated, positions six and seven may be used to identify whether the roll is an A roll or a B roll (as discussed above). Positions eight to twenty-four may be used to identify the specific roll. These positions may also be used to establish an inventory. In the present embodiment, the inventory numbers in positions eight to twenty-four are used on a rotating basis. A number is assigned to a parent roll when it is created. Once the parent roll is converted or otherwise used, the number may then be assigned to another parent roll. Taken together, positions three to twenty-four may be referred to as roll identification information or the parent roll identification number. The remaining positions, twenty-five to thirty-six may be used to convey a particular location with the paper web 102 and may be referred to as location information, linear footage, or MD footage, for example. When these thirty-eight positions are insufficient to convey this information in a single mark, additional positions may be added to the mark. As used hereafter, the foregoing will be referred to as the single mark embodiment where mark 610 and mark 620 shown in FIG. 7 are the same.
Alternatively, two marks can be used. One mark can be a roll identification mark 610 and a second mark can be a location mark 620 . Those skilled in the art will recognize that any number of marks may be used to convey the desired information from the paper machine to the converting line. As used hereafter, this type of marking configuration will be referred to as the multi-mark embodiment. In the roll identification mark 610 , for example, the positions may be used to identify the particular paper machine and the mill from which the roll originated, used to identify whether the roll is an A roll or a B roll (as discussed above), and used to establish an inventory. In the location mark 620 , the positions may be used to convey a particular location within the paper web 102 .
In the preferred embodiment shown in FIG. 6 , marks 610 and 620 are applied to the paper web 102 at a set periodicity. The marks are spaced such that the distance between the start of adjacent marks 631 is a predetermined distance. In the single mark embodiment, the distance between adjacent marks 631 is the distance of control on the converting line. This distance is thus set as a result of many factors including the speed of the converting line, the ability of the mark reading unit to distinguish between adjacent marks, a goal of minimizing the amount of product recycled, and the like. As will be discussed in more detail below, the distance between adjacent marks 631 may also determine the distance over which the paper web 102 is analyzed to develop converting line control inputs. Closer marks thus result in a finer analysis interval, and a more precise increment for control of the converting line. In addition, more frequent marks reduce the opportunity for error on the converting line. We have found that the distance between adjacent marks 631 is preferably between about two hundred fifty feet and about one thousand feet, and, more preferably, about four hundred feet. In the multi-mark embodiment, successive marks alternate between a roll identification mark 610 and a location mark 620 . When two marks are used, the distance between marks of the same type 632 is a predetermined distance. This distance 632 sets the distance of control on the converting line for the multi-mark embodiment. We have found that the distance between marks of the same type 632 is preferably between about three hundred feet and about one thousand feet, and, more preferably, about five hundred feet. We have found that, in the multi-mark embodiment, the distance between adjacent marks 631 is preferably half the distance between marks of the same type 632 . In either embodiment, the mark and the time that the mark is applied are recorded in the defect database when a mark 610 or 620 is applied to paper web 102 .
Once the defects have been identified and recorded in the defect database, they are then analyzed to develop inputs for converting line control. In the preferred embodiment, this analysis is performed using an analysis tool. Additional information beyond that recorded in the defect database may be useful in establishing converting line control inputs. A consolidated database is thus created by adding this additional information to the defect database. Those skilled in the art will recognize that this additional information includes commonly measured properties of the paper web, such as the moisture content of the paper web, the basis weight of the paper web, the tensile strength of the paper web, and the like. This additional information may include the information stored in the web properties database, discussed above. While the moisture content of the paper web and the basis weight of the paper web may be collected directly on the paper machine 100 (as discussed above), these data may also be collected offline and included in the analysis as an input into the consolidated database. In the following discussion, the moisture content and basis weight will be discussed in the context of collecting these data offline. This additional information may be entered into the consolidated database as a constant value for the entire parent roll or may vary depending upon the location in the parent roll. As with the defect database, if the paper web properties vary along the length of the paper web, the properties are entered using a master time reference. Additionally, other paper web problems, such as a paper web break, may not be automatically included in the defect database from the web inspection system. Locations of web breaks are then input into the consolidated database according to the time of occurrence. In addition, parent rolls 190 may be assigned a so-called “TAPPI Roll Number,” which is a number used to identify parent rolls 190 and assigned according to Technical Association of the Pulp and Paper Industry (TAPPI) Technical Information Paper (TIP) 1004-01. The TAPPI Roll Number may also be added to the consolidated database.
Once a consolidated database has been established, the analysis tool then analyzes the consolidated database to develop inputs for converting line control. The objective of the analysis is to generate an output for a specific portion of the web. This portion may be called a block. In the preferred embodiment, each block is associated with the mark containing the linear footage of the parent roll 190 (both marks 610 and 620 in the single mark embodiment and location mark 620 in the multi-mark embodiment). Those skilled in the art will recognize that the paper web 102 may be separated into blocks and associated with a location mark in a number of different ways. As shown in FIG. 7 , for example, block 711 may extend from the center of one roll identification mark 610 to the center of the next roll identification mark 610 . In this way, block 711 is centered about a location mark 620 . Alternatively, block 712 may extend from the beginning of location mark 620 to the beginning of the next location mark 620 . Blocks 711 , 712 may be further subdivided into segments 720 . As shown in FIG. 7 , each block 711 , 712 is subdivided into four equal segments 720 .
Inputs for converting line control are developed for each block 712 by determining the likelihood of converting line failure for each block 712 . Those skilled in the art will recognize that converting line failure refers to a number of different problems that could occur on a converting line. Such problems include the paper web breaking, the paper web wrapping on a roller, and the like. While some web defects and out of specification paper web properties are unlikely to cause converting line failure, these defects or properties may, nonetheless, be undesirable in a consumer product. Such defects or properties are often referred to as quality defects. Inputs for converting line control may also be developed for each block 712 to prevent these quality defects from being converted into consumer products. Any suitable inputs may be used, but we will discuss two approaches. The first approach, used in the preferred embodiment, is to use two criteria, an action score and a quality score, for converting line control. The first criterion is an action score and is established based on the likelihood of converting line failure. The action score may consist of three values: zero, one, or two. An action score of zero indicates a low likelihood of converting line failure. The converting line will not take any action for blocks 712 of the paper web with a score of zero. An action score of one indicates a high likelihood of converting failure with the most appropriate action being not converting that block 712 of the paper web. In this case, the converting line will be stopped to remove the block 712 with an action score of one and/or the converting line will splice to another parent roll 192 ( FIG. 12A ). An action score of two indicates a moderate likelihood of converting line failure. Here, the block 712 may be converted, but the converting line takes a mitigating action, such as slowing, reducing tension, and the like, to mitigate the risk of converting line failure.
The second criterion is a quality score and is established based on the need to reject a section of the paper web to prevent unacceptable quality defects. The quality score may consist of two values: zero or one. A quality score of zero indicates that there are no identified quality defects in block 712 of the paper web. A quality score of one indicates a quality defect that is unacceptable for delivery to consumers and that block 712 should be removed from further processing. For example, when the converting line is preparing rolled paper product (such as paper towels), a log 1080 ( FIG. 12A ) may be removed after it is formed and before it is further processed in the log saw 1094 ( FIG. 12A ).
The second, alternative approach of inputs for converting line control is a fault code and severity level. Fault codes may be, for example, a type of converting line failure or converting line problem, such as break, wrap, quality, and the like. Those skilled in the art will recognize that any number of suitable criteria may be used. The severity level may be a numerical value between, for example, one and ten, with ten being the most severe. A zero value for a severity level may indicate that a fault is unlikely.
The process of assigning the fault code and the severity level or the action score and the quality score will now be described. We have found that with either type of input (fault code and severity level or action score and quality score), a layered or multi-pass analysis approach is preferred. In this approach, the consolidated database is analyzed for one type of defect or defect grouping before moving on to the next defect type. A benefit of the layered or multi-pass analysis approach is that each layer or pass is independent of another. In this way, it is easy to modify the analysis for one particular defect type without the modification impacting the other defect passes. Similarly, it is easy to add or to delete different analysis passes without modifying the other passes. The analyses discussed below may be performed over any suitable analysis window 730 , which may include, for example, a single block 712 or multiple blocks 712 as shown in FIG. 8 . One having ordinary skill in the art will recognize, however, that our invention is not limited to the following methods of assigning inputs for converting line control. Rather, those skilled in the art will recognize that a number of different approaches may be taken to assign the inputs for converting line control without departing from the scope of our invention.
We will now describe the process for assigning an action score and a quality score with reference to FIGS. 9A to 9N and FIGS. 10A and 10B (with periodic reference to FIGS. 1 and 8 ). The process overview is shown in FIG. 9A . Each block 712 begins the analysis with a default action score and a quality score of zero. In step S 800 , a break analysis is performed for each block 712 in the parent roll 190 . If the analysis determines that a block 712 has a high likelihood of the paper web 102 breaking on the converting line, the action score will be set to one for that block 712 and the action footage will be set to the next mark starting footage (as will be discussed further below). For any blocks 712 in the parent roll 190 not having an action score set to one, a slow analysis is performed in step S 810 . Here, if the analysis determines that a block 712 has a moderate likelihood of the paper web 102 breaking on the converting line, the action score will be set to two and the action footage will be set to the next mark starting footage. The blocks 712 are then analyzed for quality defects in step S 820 . If any quality defects are identified, the quality score will be set to one. The analysis is then completed in step S 830 .
FIG. 9B shows the analyses performed as part of the break analysis S 800 . First, each block 712 is checked for any marked breaks from the paper machine 100 , in step S 840 . If a break has been marked for a block 712 , the action score is set to one for that block 712 and the action footage is set to the next mark starting footage. For the blocks that do not have an action score set to one, the break analysis then proceeds to the next step S 850 to check the sheet attributes. The process is then repeated for each of the remaining four analyses S 860 , S 870 , S 880 , and S 890 . Once all of these analyses has been performed, the break analysis S 800 is then completed in step S 831 . We will now describe each of these analyses in turn.
FIG. 9C is a detailed flow chart of the analysis for marked breaks S 840 . FIG. 9D is an example of a consolidated database before analysis, and FIG. 9E is the consolidated database after the marked breaks analysis S 840 has been performed. First, in step S 841 , the current block 712 is checked to identify if any break signals have been recorded. As shown in FIG. 9D , a break signal has been recorded for the fifth mark with a linear footage of two thousand one hundred seventy-five feet. For this break, the action score is set to one in step S 842 and the action footage is set to the next mark footage (in this case, mark six at two thousand four hundred feet) in step S 843 . Then, the analysis proceeds to step S 844 where it determined if this block 712 is the end of the roll. If so, the next analysis is started in step S 845 . If not, the process is repeated for the next block 712 . When no break signal is recorded, no change is made to the action score and action footage, and the analysis proceeds to step S 844 .
As discussed above, the linear footage is measured from the leading edge of the parent roll 190 . This edge, however, is the last portion to be converted on the converting line because converting begins at the end of the parent roll 190 . For this reason, each action analysis sets the action footage as the next mark footage and not the footage associated with the current block 712 . As shown in FIGS. 10A and 10B , for example, the paper web 102 will be converted from left to right. Although the block associated with the fifth mark contains a web break, the web break would have already caused a converting line failure if the action score of one and action footage of one thousand eight hundred feet was not processed until the fifth mark was read. As a result, the sixth mark, which has an action footage of two thousand four hundred feet, is set to indicate the upcoming web break and not action footage one thousand eight hundred feet, which is associated with the fifth mark.
FIG. 9F is a detailed flow chart of the check sheet attributes analysis S 850 . First, the sheet attribute data for the current block 712 is obtained in step S 851 . Sheet attribute data may also be referred to as web properties and includes any aspect of the web that is not visible to the naked eye. Specific examples include those properties discussed above, such as basis weight, moisture content, and MD tensile strength. Each attribute being analyzed for the likelihood of failure is compared to a threshold value in step S 852 . Typically, each attribute has a target mean and a variance of the attribute for the current block 712 can be calculated compared to that mean. If the variance exceeds a break limit, the action score will be set to one in step S 853 and the action footage set to the next mark footage in step S 854 . The analysis then proceeds to steps S 855 and S 856 , which are similar to steps S 844 and S 845 , respectively. If the variance is less than or equal to the break limit, no change to the action score will be made, and the analysis will proceed to steps S 855 and S 856 . Different types of paper product will be converted differently and respond to a converting line differently. Compare, for example, tissue product to towel product. Even within a type of product, there are different grades, for example, towel product produced for commercial use compared to towel product produced for consumer use. The break limit for each attribute is thus set differently for different grades of product. Additionally, converting lines used to convert the same product may have differences, and thus, the break limit for each attribute may be customized for each different asset.
FIG. 9G is a detailed flow chart of the check defect and sheet attributes analysis S 860 . Even though the individual variance of an attribute did not exceed the break limit, some variances when combined with a defect could lead to a high likelihood of converting line failure. Both sheet attribute data for the current block 712 and the defect data for the record being analyzed are obtained in step S 861 . As shown in FIG. 9L and as discussed above, each defect is recorded in the consolidated database as its own record. For example, a small hole is recorded as data table entry number two. Then, the attribute data is compared to a break limit in step S 862 , similar to the comparison performed in step S 852 , but for a lower break limit. If the variance exceeds the break limit, the defect data is compared against a break limit. In this example, it is the size of the defect that is evaluated, but those skilled in the art will recognize that other defect criteria may also be evaluated, including those discussed below in conjunction with steps S 870 , S 880 , and S 890 . If the size of the defect exceeds the break limit, then the action score is set to one in step S 864 and the footage is set to the next mark footage in step S 865 . The analysis then proceeds to steps S 866 and S 867 , which are similar to steps S 844 and S 845 , respectively, but before proceeding to the next block 712 , each defect within the current block is analyzed. If either of the break limits is not exceeded, no action score is set and the analysis proceeds to steps S 866 and S 867 .
FIG. 9H is a detailed flow chart of the check edge defect analysis S 870 . A defect on the edge of the paper web will generally have a greater likelihood of resulting in a converting line failure than the same defect located toward the center of the sheet. Thus, a defect record, for the current block 712 , having a position near the edge of the paper web is identified in step S 871 . In this embodiment, edge defects are those having a CD position located within the first five percent or the last five percent of the CD width (i.e., CD position is less than five percent or greater than ninety-five percent). Once the defects are identified, they are then compared to the break limit is step S 872 . If the size of the defect exceeds the break limit, then the action score is set to one in step S 873 and the footage is set to the next mark footage in step S 874 . The analysis then proceeds to steps S 875 and S 876 , which are similar to steps S 866 and S 867 , respectively. If the break limit is not exceeded, no action score is set and the analysis proceeds to steps S 875 and S 876 .
FIG. 9I is a detailed flow chart of the check single defect analysis S 880 . This analysis assesses the likelihood of converting line failure for a single defect. Here, a defect record for the current block 712 having a size greater than a limit is identified in step S 881 . The size is then compared to the break limit in S 882 . If the size exceeds the break limit, then the action score is set to one in step S 883 and the footage is set to the next mark footage in step S 884 . The analysis then proceeds to steps S 885 and S 886 , which are similar to steps S 866 and S 867 , respectively. If the break limit is not exceeded, no action score is set and the analysis proceeds to steps S 885 and S 886 .
FIG. 9J is a detailed flow chart of the check cluster defect analysis S 890 . This analysis assesses the likelihood of converting line failure of a combination or cluster of defects. Here, a defect record (current record) for the current block 712 is obtained in step S 891 . Then, the defect data for records located within a certain distance of the current record (for example, within plus or minus thirty feet in the MD direction) are obtained in step S 892 . The density of the positions of these defects is compared to a break limit in step S 893 . If the density exceeds the break limit, then the action score is set to one in step S 894 and the footage is set to the next mark footage in step S 895 . The analysis then proceeds to steps S 896 and S 897 , which are similar to steps S 866 and S 867 , respectively. If the break limit is not exceeded, no action score is set and the analysis proceeds to steps S 896 and S 897 .
Once the break analysis is completed, the slow analysis is performed in step S 810 . FIG. 9K shows the analyses performed as part of the slow analysis. Each of the analyses S 811 , S 812 , S 813 , S 814 , and S 815 is performed in a similar way as the corresponding break analysis, S 850 , S 860 , S 870 , S 880 , and S 890 , respectively. The limits for the slow analyses, however, are lower than the limits for the break analyses. The quality analyses S 820 are also performed in a like manner.
FIG. 9L shows an example of a consolidated database prior to performing break analysis S 800 . FIG. 9M shows the consolidated database after performing break analysis S 800 . The defect records in the first mark correspond to a cluster of defects. The defect record in the third mark corresponds to an edge defect. The defect record in the fourth mark corresponds to a large defect. The data table entry fourteen corresponds to a web break signal as discussed above with reference to FIGS. 9D and 9E . The sixth mark has a low basis weight, and the seventh mark has a combination of a low basis weight and a defect. As will be discussed further below, the action score and the footage for the next block with a non-zero action score is sent for each mark to the converting line controller. Once the action score and quality score have been assigned for each block 712 , the remaining marks are then updated to have the action score and action footage of block 712 with the next non-zero action score to result in the scored database. This database is shown in FIG. 9N . ( FIGS. 10A and 10B are graphical illustrations of this database, similar to that shown in FIG. 4 .)
We will now describe an alternative approach of inputs for converting line control using fault codes and severity levels, with reference back to FIG. 8 . Because the likelihood of failure in one segment may be influenced by an adjacent segment, the likelihood of failure is determined over an analysis window 730 . An analysis window 730 could be, for example, an individual block. In the preferred embodiment, the analysis window 730 encompasses multiple blocks 712 . In this example, an analysis is being performed to assign fault codes and severity levels for the block 712 corresponding to analysis centerline 740 . An additional advantage of an analysis window that encompasses multiple blocks is that some degree of smoothing can occur. As will be discussed further below, it is preferable to ramp down or to ramp up converting line parameters, instead of making sudden changes.
Then, for defects corresponding to one of the fault codes, a severity level may be established as a composite score from each of the analysis passes. For example, each block 712 of the consolidated database may be reviewed for a recorded web break that occurred on the paper machine 100 ( FIG. 1 ). This type of defect is associated with a break fault code and each of the blocks 712 having this defect would be assigned a fault code of break with a severity level of ten. Next, each block 712 of the consolidated database may be reviewed for tears. Each block 712 having a tear would be assigned the fault code break with a severity level corresponding to the length of the tear. At a next pass, each segment 720 may be reviewed to determine if the number of defects or total size exceeds a threshold value. Various threshold values could be used, each corresponding to a different severity level for break fault codes. The next pass could expand the analysis window 730 to encompass adjacent blocks 712 . Within the analysis window, a fault code of break could be assigned with a severity level when adjacent segments 720 contain a total number or total size of defects exceeding a threshold value. Again, various threshold values could be used, each corresponding to a different severity level for break fault codes. Once all of the analysis passes for defects to be assigned a break fault code are completed, a composite severity can be calculated when a block has been assigned two or more severity levels from the analysis passes.
The analysis process and severity level assignment may be modified by taking into account other web properties. For example, when a block 712 or, a segment 720 has a low basis weight, low tensile strength, or high moisture content, the severity level may be increased for that block 712 . The process may then be repeated for other fault codes, such as wrap and quality.
The foregoing methods and processes for assigning inputs for converting line control by the analysis tool 912 may be implemented on a computer. A system diagram showing how the analysis tool 912 is interconnected to the paper machine and the converting line is depicted in FIG. 11 . As discussed above (see FIGS. 1 and 2 ), the web inspection system, web marking unit 171 , 172 , and web property scanner 155 populate the defect database. The web inspection system may include web inspection units 141 , 142 , 143 connected to web inspection computer 902 . Likewise, the web marking unit 171 , 172 and the web property scanner 155 may also be connected to a web marking computer 904 and a web property computer 906 , respectively. These three computers 902 , 904 , 906 are configured to process the inspection, marking, and property data, and then transmit the data to a database server 910 to populate the defect database. Additional web information that is collected offline may be added to the defect database to create the consolidated database through an offline input personal computer (PC) 908 . The consolidated database may also be stored on the database server 910 . The analysis tool 912 then retrieves the consolidated database from the database server to create the inputs for the converting line. As depicted in FIG. 11 , the analysis tool 912 is its own computer, but alternatively, the analysis tool 912 may be implemented on the database server 910 . Once the analysis is completed, the scored database is transmitted to a roll server 914 and stored on the roll server 914 . The roll server 914 may also be implemented on the same server as the analysis tool 912 or database server 910 . Upon the start of converting, a master converting line computer 920 retrieves the scored database from the roll server 914 to use in the converting process, which will be discussed further below. In this regard, we will discuss that the converting line retrieves the scored database by identifying a marked edge of the paper web 102 .
The procedures depicted and discussed above with reference to the paper machine, offline input PC, database server, analysis tool, analysis tool, or any portion or function thereof, may be implemented by using hardware, software, or a combination of the two. Likewise, the procedures depicted and discussed below with reference to the converting line, or any portion or function thereof, may be implemented by using hardware, software, or a combination of the two. The implementation may be in one or more computers or other processing systems. While manipulations performed in these embodiments may have been referred to in terms commonly associated with mental operations performed by a human operator, no human operator is needed to perform any of the operations described herein. In other words, the operations may be completely implemented with machine operations. Useful machines for performing the operation of the embodiments presented herein include general purpose digital computers or similar devices.
Portions of the embodiments of the invention may be conveniently implemented by using a conventional general purpose computer, a specialized digital computer, and/or a microprocessor programmed according to the teachings of the present disclosure, as is apparent to those skilled in the computer art. Appropriate software coding may readily be prepared by skilled programmers based on the teachings of the present disclosure.
Some embodiments include a computer program product. The computer program product may be a non-transitory storage medium or media having instructions stored thereon or therein that can be used to control, or to cause, a computer to perform any of the procedures of the embodiments of the invention. As discussed above, the storage medium may include, without limitation, a floppy disk, a mini disk, an optical disc, a Blu-ray Disc, a DVD, a CD or CD-ROM, a micro drive, a magneto-optical disk, a ROM, a RAM, an EPROM, an EEPROM, a DRAM, a VRAM, a flash memory, a flash card, a magnetic card, an optical card, nanosystems, a molecular memory integrated circuit, a RAID, remote data storage/archive/warehousing, and/or any other type of device suitable for storing instructions and/or data.
Stored on any one of the non-transitory computer readable medium or media, some implementations include software for controlling both the hardware of the general and/or special computer or microprocessor, and for enabling the computer or microprocessor to interact with a human user or other mechanism utilizing the results of the embodiments of the invention. Such software may include, without limitation, device drivers, operating systems, and user applications. Ultimately, such computer readable media further includes software for performing aspects of the invention, as described above.
Included in the programming and/or software of the general and/or special purpose computer or microprocessor are software modules for implementing the procedures described above.
Next, we will describe a converting line and control of the converting line for a preferred embodiment of our invention, with reference to FIGS. 12A to 14B . Parent rolls 190 ( 191 , 192 in FIGS. 12A and 12B ) are converted to consumer sized rolls and other products at a converting line. Our invention may be adapted to work with any number of different converting lines known in the art. One of the simplest forms of converting lines is for a single-ply paper towel product. Here, a paper web is unwound from a parent roll 191 , 192 at an unwind stand 1010 and then rewound into a log 1080 at a rewinder 1076 . A log 1080 is the width of a parent roll, but has the diameter of the consumer sized product. Also, at the rewinder 1076 , the outermost end of paper web is glued by a tail gluer when the end is cut from the paper web feeding the rewinder. The log 1080 is subsequently cut into consumer length products using a log saw 1094 . Those skilled in the art will recognize that a converting line may encompass more operations than described above. For example, the paper web may be embossed by passing through a nip defined between, for example, an embossing roller 1072 and an anvil roller 1074 . Further, the paper web from two or more different parent rolls 191 , 192 may be combined prior to being wound into a log 1080 in order to form a multi-ply sheet. Other converting lines may not create rolls of consumer products, but instead, cut the web after embossing to form flat products such as napkins, facial tissue, and the like. These types of converting lines use a folder 1078 instead of a rewinder 1076 . In this application, we will use the term finisher to generically refer to a rewinder 1076 , a folder 1078 , and the like. Even among converting lines established to make the same product, the equipment may differ. For example, some unwind stands 1010 may hold a single parent roll 191 , 192 , but others may hold two parent rolls 191 , 192 and have the capability to switch between parent rolls 191 , 192 without stopping the converting line. Switching between parent rolls 191 , 192 may be accomplished through the use of a flying splice, as is known in the art, and will be discussed in more detail below. FIGS. 12A and 12B show schematic diagrams of an exemplary unwind stand 1010 having a flying splice.
FIG. 12A , thus, is a schematic diagram of an exemplary unwind stand 1010 and rewinder 1076 . Parent rolls 191 , 192 are placed on each of the roll mounts 1011 , 1012 . Each parent roll is driven by a motor 1013 , 1014 that is connected to the parent roll 191 , 192 through the use of drive belts 1013 , 1014 . The paper web 102 is being drawn from parent roll 191 and rewound in rewinder 1076 to create log 1080 . The paper web 102 is conveyed over a series of rollers 1041 , 1043 , 1045 , 1046 , and 1050 between parent roll 191 and rewinder 1076 . The depicted unwind stand 1010 is capable of performing a flying splice to switch from parent roll 191 to parent roll 192 . To perform a flying splice, parent roll 192 is brought up to the speed of parent roll 191 by motor 1014 . While the parent roll 192 is being brought up to speed, paper web 103 is being rewound on recovery roll 1022 . (Recovery roll 1021 is used in the same way as recovery roll 1022 when switching from parent roll 192 to parent roll 191 .) When splicing between parent rolls, press rollers 1031 , 1032 bring paper web 102 together with paper web 103 , and cutters 1033 , 1034 are used to sever the paper web 103 from the recovery roll 1022 and paper web 102 from the rewinder 1076 . Once the paper web 103 for log 1080 is being drawn from parent roll 192 , parent roll 191 may be replaced with another parent roll or a portion of the paper web 102 having a defect may be removed. In the converting line depicted in FIG. 12A , the paper web 102 is embossed as it travels through a nip formed between and embossing roller 1072 and an anvil roller 1074 . After being wound into a log 1080 , the log is transferred to an accumulator 1092 before being cut into consumer sized lengths by a log saw 1094 . The consumer size products are then packaged for distribution and sale by subsequent packaging equipment 1090 .
FIG. 12B is a schematic diagram of another exemplary converting line. This converting line is similar in operation to the converting line depicted in FIG. 12A , but includes a folder 1078 to produce folded consumer products such as napkins, tissues, and the like, instead of a rewinder 1076 .
Converting lines are conventionally classified into class one and class two converting lines. Class one converting lines typically operate at a speed of about two thousand feet per minute for bath tissue and about two thousand seven hundred feet per minute to about three thousand feet per minute for towel products. Class two converting lines typically operate in the range of about one thousand three hundred feet per minute to about one thousand seven hundred feet per minute for all products.
In the preferred embodiment, the converting line 1000 is controlled through the use of a programmable logic controller (PLC) 924 ( FIG. 11 ). In the discussion below, we will discuss the automated control of the converting line by referencing adjusting the converting line speed, splicing between parent rolls, and stopping the converting line. Those skilled in the art will recognize, however, that there are numerous parameters that can be controlled by the PLC 924 on the converting line, including tension between rollers and nip parameters, such as a gap between the rollers comprising the nip. Our invention may be readily adapted to control any number of these parameters, either individually or in concert with the other parameters.
In the embodiment shown in FIGS. 12A and 12B (with periodic reference to FIGS. 6, 7 and 11 ), a mark reading unit 1060 is positioned shortly after the location where the paper web 102 is unwound from parent roll 191 . The mark reading unit 1060 is positioned to inspect the edge of the parent roll 191 and to read any mark 610 , 620 that passes. In the preferred embodiment, the mark reading unit 1060 includes at least a digital high speed camera to read the mark and a light to illuminate the edge of the paper web 102 . Any suitable high speed camera may be used in the mark reading unit 1060 . Further, any suitable light source may be used, such as a light-emitting diode (LED), an incandescent light, and the like. When ink that is visible under ultraviolet light is used, an LED light source emitting light in the ultraviolet spectrum is preferred. The mark reading unit 1060 is preferably placed at a stable location on the unwind stand 1010 or rewinder 1076 . Suitable locations include, for example, flat surfaces (e.g., web run 1052 ) and rolls (e.g., roll 1050 ). In the preferred embodiment shown in FIGS. 12A and 12B , roll 1050 is a bowed roll. A bowed roll has an offset axis of rotation, which stretches the paper web 102 , 103 toward the ends of the roll. This roll may also be called a spreader roll, as it spreads the paper. As a result, the bowed roll 1050 helps to ensure that paper web 102 , 103 is taut and moving at a consistent speed as it moves under the mark reading unit 1060 . The mark reading unit 1060 is connected to a mark reading computer 922 , which performs the mark identification analysis.
When a parent roll 191 , 192 is loaded onto the unwind stand 1010 in the converting line 1000 , an operator may manually enter the roll identification numbers into the PLC 924 , which is then transmitted to the master converting line computer 920 . Alternatively, the mark reading unit 1060 and mark reading computer 922 may identify the parent roll 191 , 192 by reading a roll identification mark 610 . Preferably, a parent roll 191 , 192 is identified by reading the same roll identification number multiple times to ensure statistical confidence of the number read. Most preferably, the roll identification number is read twice from two sequential roll identification marks 610 . Once the parent roll 191 , 192 is identified, the parent roll identification number is transmitted to the master converting line computer 920 . In either case, the master converting line computer 920 then retrieves from the roll server 914 the scored database associated with the identified parent roll 191 , 192 . When the roll server 914 transmits the scored database, the database is “checked out” from the roll server 914 , and the scored database is “checked in” once the parent roll 191 , 192 has been converted.
As the parent roll 191 , 192 is unwound, the mark reading unit 1060 reads the mark 610 , 620 on the paper web 102 and passes the information to the PLC 924 . When roll identification information is read, the PLC 924 checks to ensure that the correct parent roll 191 , 192 is identified. When location information is read, the PLC 924 adjusts the converting line parameters based on the inputs for converting line control associated with that block 712 identified in the scored database.
We will now describe converting line control using the preferred embodiment of an action score and a quality score. In this approach, each time a location mark 620 is read, the master converting line computer 920 transmits to the PLC 924 : (1) the location information in linear feet associated with that mark (MD Footage), (2) the linear footage of the next block 712 of the paper web 102 that has a non-zero action score, (3) the action score of the next non-zero block 712 of the paper web 102 , and (4) the quality score for the block 712 associated with the mark just read. The PLC 924 continuously counts the linear footage of the paper web 102 being converted. This count is updated upon receipt of the location information associated with the mark just read. The PLC 924 then calculates the distance remaining to the next non-zero block 712 . The PLC 924 will also calculate, given the current operating parameters (for example, speed), the distance required to execute the action associated with the next non-zero block 712 . The PLC 924 includes several factors in this calculation, depending upon the next action and specific converting line. These factors include: deceleration rate for a splice, deceleration rate for stopping, deceleration rate to slow, target speed for slowing, and the like. The PLC 924 then compares the distance remaining to the next non-zero block 712 to the calculated distance required to execute the next action. If sufficient footage is still available, the PLC 924 will continue converting at the current operating parameters and repeat the calculation. The PLC 924 will initiate the next action when the current footage is within a buffer distance of the calculated footage for the next action. We have found that it is beneficial to include buffer footage to prevent unintended web breaks from occurring because the PLC 924 waited to initiate action until there is exactly the amount of footage required between the current location and the next action point.
FIG. 13 shows an exemplary operator control screen 1100 for the converting line PLC 924 that may be used with this implementation. The control screen 1100 may be implemented on any suitable device including, for example, a touch screen or an LED display that is operated by a mouse and a key board. The control screen includes a roll map 1110 . In this case, the roll map shows the first ply of a roll used in making a multi-ply paper product. The roll map includes a defect map 1112 . The defect map 1112 , like the defect map shown in FIG. 4 , above, contains graphical indications of defect positions. Each line in the defect map 1112 indicates a different block 712 ( FIG. 7 ). The action score associated with each block 712 is also identified on the defect map 1112 . While any suitable means of indication may be used, a colored box 1114 is along the side of each block is used in this embodiment. Here, an action score of zero is indicated by a green box 1114 and corresponds to normal operation of the converting line. An action score of one results in a stop or a splice command and is indicated by a red box 1114 . An action score of two slows the converting line and is indicated by a yellow box 1114 . A legend 1120 is provided to describe the graphical indications of defects and the converting line actions associated with the colored boxes 1114 . Also shown in the roll map 1110 is the MD footage 1116 associated with each block 712 and, as an operator aid, the diameter 1118 of the parent roll 190 .
The control screen 1100 also allows for manual action overrides in a section 1130 of the control screen. The operator may review the upcoming blocks 712 and manually override the action score for that block. The operator may select a particular block 712 and then choose from preset actions in a drop down menu 1132 . This section 1130 also includes a drop down menu 1134 for the operator to give a reason for his/her change. These reasons may subsequently be used to adjust the rules for assigning converting line control as discussed below. Once the operator has selected an action and a reason for the change,the operator then selects the apply button 1136 . When the apply button 1136 is selected, the PLC 924 the updates the scored database with the manually applied action. We have found that it is beneficial to assign an alternate score (e.g., a three, a four, or a five) for manually input actions. This improves subsequent analysis and feedback used in refining the rules used to assign the action scores and quality scores. A status section 1140 is also displayed on the control screen 1100 . This section 1140 gives an indication of the current footage, the footage at which the PLC will take the next action (action footage), and the next action.
We will now describe converting line control using the alternate converting line inputs of defect code and severity levels. When defect code and severity level are used, the PLC 924 adjusts the converting line parameters according to a predetermined set of rules. These rules are established for each converting line to prevent a converting line failure. For example, the PLC 924 may slow the converting line from about two thousand feet per minute to about one thousand five hundred feet per minute for a defect code for holes having a severity level of five, or slow the converting line to about one thousand two hundred feet per minute for holes having a severity level of seven. The actions taken by the PLC 924 to adjust parameters may vary by converting line. Using the example of a defect code for a web break, the PLC 924 on one converting line may execute a splice to switch between parent rolls, because the converting line has a flying splice capability, but the PLC 924 for a second converting line may stop the converting line for the same defect code.
In the preferred embodiment shown in FIGS. 12A and 12B , the mark reading unit 1060 is positioned downstream from the parent roll 191 being unwound. A particular block 712 ( FIG. 7 ) of the paper web 102 , therefore, has already traveled through a portion of the converting line 1000 before the location information associated with that block 712 is read. If that particular block has defects, they may cause a web break as the web passes one of the rollers 1041 , 1043 , 1045 , 1046 upstream of the mark reading unit 1060 . In this preferred embodiment, the PLC 924 , therefore, sets the operating parameters of the converting line 1000 based on the defect code and severity level for a predetermined number of blocks 712 after the block 712 associated with the mark just read.
The PLC 924 may also consider several of the upcoming blocks in determining how the converting line parameters are adjusted. As shown in FIG. 14 , blocks eight and fifteen may have defects requiring the converting line to slow to about one thousand five hundred feet per minute, and blocks eleven and twelve may have defects requiring the converting line to slow to about one thousand two hundred feet per minute. To avoid rapid and successive changes in operating speed (non-preferred profile in FIG. 14 ), the PLC 924 may begin slowing the converting line at block four to reach about one thousand five hundred feet per minute at block eight and about one thousand two hundred feet per minute at block eleven, and then gradually increase speed from block twelve to reach full speed of about two thousand feet per minute at block twenty (preferred profile in FIG. 14 ). Those skilled in the art will recognize that the assignment of operating parameters may be performed by the analysis tool and pushed to the converting line, instead of being performed at the converting line.
FIGS. 15A and 15B show an exemplary operator control screen 1200 for the converting line PLC 924 . FIG. 15A shows the left half of the control screen 1200 and FIG. 15B shows the right half. In this embodiment, the converting line is creating a two-ply paper product and uses two parent rolls, one for the first ply and the other for the second ply. As with control screen 1100 , the control screen 1200 may be implemented on any suitable device including, for example, a touch screen or an LED display that is operated by a mouse and a keyboard. The control screen 1200 has three major sections: operator controls 1210 , the first ply roll map and action registry 1220 , and the second ply roll map and action registry 1230 . Each roll map and action registry 1220 , 1230 contains a defect map 1221 , 1231 . The defect map, as with the defect map shown in FIG. 4 , above, contains graphical indications of defect positions. Each line in the defect map 1221 , 1231 indicates a different block 712 ( FIG. 7 ). Each action registry 1222 , 1232 contains two sub-registries. The first is an automatic action registry 1224 , 1234 . This registry contains the actions assigned to each block 712 by the PLC 1024 based upon the defect code and severity level. The second is a manual action registry 1223 , 1233 . The control screen 1200 allows an operator to review upcoming blocks 712 and to input manual actions in the manual action registry 1223 , 1233 . An operator may change input actions by selecting a block 712 and then choose one of the operator controls 1210 . An operator may specify a slower speed by inputting the speed into the slow speed set point 1212 and then pressing the slow button 1211 . Alternatively, the control screen may have only one slow speed preset. The operator may input a splice or a stop by pressing the splice button 1213 or stop button 1214 , respectively. The operator may clear the manually inputted action by pressing the clear action button 1215 . The PLC 924 will control the converting line by the actions in the automatic action registry 1224 , 1234 unless overridden by an action in the manual action registry 1223 , 1233 .
In the present embodiment, the PLC 924 takes the actions assigned to a block 712 that is a predetermined number of blocks 712 behind the mark read by the mark reading unit 1060 , as discussed above. On the control screen 1200 shown in Figures 15A and 15B , this is illustrated by mark read line 1241 and send action line 1243 . The operator may select a predetermined number of blocks by changing values assigned to the look ahead distance 1242 . In this embodiment, when a two-ply paper product is being created on the converting line 1000 , the speed for the converting line will be set for a particular segment by the slowest speed in the active action registry for either ply. When there is a splice, however, the action will be taken for only one parent roll.
We will now describe a preferred embodiment of our invention with reference to FIGS. 16 to 19 . In this preferred embodiment, the inputs assigned and used for converting line control are the action score and quality score. FIG. 16 is a flowchart showing an overall process flow of our invention. As described in the embodiments discussed above, our invention is implemented to a paper machine 100 , an analysis tool, and a converting line 1000 . Those skilled in the art will recognize that the analysis tool may be co-located at either the paper machine 100 or converting line 1000 or may be at a separate location. In our invention, a web is inspected at step S 1310 and the results of the inspection are used to identify defects in the web at step S 1320 . Also, at the paper machine 100 , the web is periodically marked and both the mark 210 and the time of marking is recorded in step S 1330 . In step S 1350 , other web properties 1340 , such as tensile strength and basis weight (discussed above), are used to aggregate the defects identified in step S 1320 over a particular time interval. Also, in this step S 1350 , inputs for converting line control (i.e., action score and quality score in this embodiment) are assigned to a mark 210 applied to the web in step S 1330 . On the converting line 1000 , the marks are read in step S 1360 . The action score, action footage, and quality score assigned to the read mark 210 are obtained in step S 1370 . In step S 1380 , the converting line parameters, such as converting line speed, are adjusted based upon the inputs obtained in step S 1370 .
Steps S 1310 , S 1320 , and S 1330 shown in FIG. 16 will now be described in more detail with reference to FIG. 17 . In step S 1410 , the web inspection system detects candidate defects. The web inspection system then determines whether the candidate defect is a true defect or a false defect using, for example, the method described in U.S. Patent Appln. Pub. No. 2012/0147177 (the disclosure of which is incorporated by reference in its entirety). For those defects that are true defects, the defect properties such as size and position are determined by the defect inspection system in step S 1430 . These defect properties for each true defect are then recorded in defect database 1400 . The web is also marked with a roll identification mark 610 at a set periodicity by a web marking unit 171 , 172 in step S 1450 . In step S 1460 , the roll identification mark 610 and the time the mark is made on the web is then recorded in defect database 1400 . Similarly, the web is marked with a location mark 620 in step S 1470 , and then, in step S 1480 , this mark 620 and time of marking is recorded in defect database 1300 . In the single mark embodiment, steps S 1470 and S 1480 may be omitted.
Step S 1350 shown in FIG. 16 will now be described in more detail with reference to FIG. 18 . In step S 1520 , the defect data from the defect database 1300 and other paper web properties such as paper web moisture content 1511 , paper web basis weight 1512 , paper web tensile strength 1513 , the paper machine parameters used to derive web properties 1514 , and TAPPI ID number 1514 are aggregated into a database and aligned in step S 1530 within the database according to the master timestamp to form a consolidated database 1502 . The consolidated database is then analyzed in step S 1530 according to a predetermined set of rules to assign the action scores and quality scores to each block of the parent roll. Step S 1530 may be executed using the process described above in reference to FIGS. 9A to 9M . Then, as described in reference to FIG. 9N , the action footage is assigned in step S 1540 to form the scored database 1504 . These rules may be adjusted periodically in step S 1550 based upon performance data 1680 from the converting line 1000 .
Steps S 1360 , S 1370 , and S 1380 shown in FIG. 16 will now be described in more detail with reference to FIG. 19 . A mark reading unit 1060 reads the mark 610 , 620 in step S 1610 . The action score, quality score, action footage, and current footage is the obtained for the mark read in step S 1620 from the scored database 1504 . The footage of the parent roll 190 is continually being calculated as the parent roll is consumed in the converting line 1000 . This is referred to as the rewinder footage and tracked in step S 1640 . But, the rewinder footage is updated based on the mark just read in step S 1630 using the current footage obtained in step S 1620 . As the rewinder footage is tracked in step S 1640 , the distance required to execute the next action based on the action score obtained in step S 1620 (“required distance”) is compared to the rewinder footage in step S 1650 . If the rewinder footage is less than or equal to the required distance, the converting line 1000 takes the action assigned to the action score in step S 1660 . If the rewinder footage is greater than the required distance, the converting line 1000 then check, if a new mark has been read by the mark reading unit 1060 in step S 1670 . If no new mark has been read, the process returns to step S 1640 , but if a new mark has been read the process returns to S 1620 .
Additionally, performance data can be collected to improve the assignment of action scores and quality scores. In this case, the specific location marks read are recorded in step S 1682 . In addition, converting line performance information is recorded in step S 1684 . This performance information may include operating parameters of the converting line, such as speed and when any unanticipated web failures occurred on the converting line or high speed video images of the web failures. This information may also include manual override action scores. The performance information and associated location marks 620 may be recorded as converting line performance data 1680 and used to adjust the rules to assign actions, or assign fault codes and severity levels (as discussed above).
We will now describe an alternate preferred embodiment of our invention with reference to FIGS. 20 to 22 . In this preferred embodiment, the inputs assigned and used for converting line control are the fault codes and severity levels. This embodiment is similar to the embodiment described above in reference to FIGS. 16 to 19 . We will focus our discussion of this alternate embodiment to the different features of this alternate embodiment, and we will use the same reference numerals to reference the same or similar features.
FIG. 20 is a flowchart showing an overall process flow of our invention, similar to that shown in FIG. 16 . In step S 1710 , other web properties 1340 are used to aggregate the defects identified in step S 1320 over a particular time interval. The defect code and severity level are also assigned in step S 1710 . On the converting line, the marks read in step S 1360 are used to obtain the fault codes and severity, in step S 1720 . In step S 1720 , the converting line parameters, such as converting line speed, are adjusted based upon the inputs obtained in step S 1730 .
Step S 1710 shown in FIG. 20 will now be described in more detail with reference to FIG. 21 . Step S 1520 is similar to that described above in reference to FIG. 18 . Here, however, the defects and web properties are aggregated and aligned into consolidated database 1800 . The consolidated database 1800 is then analyzed in step S 1810 according to a predetermined set of rules to assign inputs for converting line control to each block 712 ( FIG. 7 ) of the parent roll in the consolidated database 1800 . The predetermined set of rules may include those rules discussed above in conjunction with the process to assign fault codes and severity levels. These rules may be adjusted periodically in step S 1550 based upon performance data 1960 from the converting line 1000 .
Steps S 1360 , S 1720 , and S 1730 shown in FIG. 20 will now be described in more detail with reference to FIG. 22 . A mark reading unit 1060 reads both a roll identification mark 610 in step S 1910 and a location mark 620 in step S 1920 . In the single mark embodiment, only one mark is read in step S 1910 . In step S 1930 , the fault code and severity levels for upcoming blocks 712 are obtained from the consolidated database 1800 . Then, converting line actions are assigned in step S 1940 to each of the upcoming blocks 712 according to a predetermined set of rules for that particular converting line 100 . Steps S 1910 through S 1940 are repeated as successive marks are read on the paper web 102 , 103 . As each location mark is read, the actions to adjust converting line parameters that are associated with that mark are taken, in step S 1950 . As discussed above, the actions taken in step S 1950 may be the actions assigned to a block 712 a predetermined number of blocks from the mark read by the reading unit 1060 .
Performance data can also be collected in this embodiment to improve the assignment of fault codes and actions taken by the converting line 1000 . In this case, the specific location marks read are recorded in step S 1961 . In addition, converting line performance information is recorded in step S 1962 . This performance information may include operating parameters of the converting line, such as speed and when any unanticipated web failures occurred on the converting line or high speed video images of the web failures. The performance information and associated location marks 620 may be recorded as converting line performance data 1960 and used to adjust the rules to assign actions or assign fault codes and severity levels (as discussed above).
Although this invention has been described in certain specific exemplary embodiments, many additional modifications and variations would be apparent to those skilled in the art in light of this disclosure. It is, therefore, to be understood that this invention may be practiced otherwise than as specifically described. Thus, the exemplary embodiments of the invention should be considered in all respects to be illustrative and not restrictive, and the scope of the invention to be determined by any claims supportable by this application and the equivalents thereof, rather than by the foregoing description.
INDUSTRIAL APPLICABILITY
The invention can be used to produce desirable paper products, such as paper towels and bath tissue. Thus, the invention is applicable to the paper products industry.
|
A system for producing a paper product. The system includes a paper machine, an analysis tool, and a converting line. The paper machine forms a paper web having a plurality of sections, inspects the paper web to identify properties, and marks the paper web with a plurality of marks, at least one mark being assigned to each of the plurality of sections. The analysis tool assigns a paper rating to each section of the paper web based upon the identified properties in that section of the paper web. The converting line has a plurality of operational parameters and converts the paper web into the paper product. The converting line reads at least one of the plurality of marks on the paper web, obtains the paper rating associated with the mark read, and changes at least one operational parameter of the converting line based upon the paper rating.
| 3
|
BACKGROUND OF THE INVENTION
Perfected cutting device for a device for dispensing and simultaneous cutting of material rolled up in webs.
The object of the invention relates to the technical sector of means for dispensing lengths of material rolled up on reels. More particularly, but not exclusively, the invention relates to dispensers of paper, cotton wool and similar wiping materials.
FIELD OF THE INVENTION
The device is not limitative to the type according to which a roll of material in use is free rotating on a support and is applied with pressure directly on to a drum with a non-sliding surface so that by a simple manual pull on the web of material projecting from the device, a web is automatically dispensed and cut, the length of which is substanially equal to the drum diameter by means of a pinked cutting device associated with the drum and projecting outside the drum when it is rotated by pulling on the material, so as to penetrate into the material taut on either side of the cutting mechanism. After the cutting operation, the spinning drum goes back into its orginal position through the action of various additional components and a new web of material projects from the device.
Such a cutting device was particularly described in the French Pat. No. 2.332.215 and the certificate of addition No. 2.340.887 belonging to the applicant. The cutting device's driving means, the drum rotation and the moving control means, and stopping and control means were described in the previously mentioned patents and also in the European patent No. 0517713 and in the French Pat. Nos. 85.19447 and 85.02873 in the applicant's name. However, other means can be used. Nonetheless, it appeared important in order to fully understand the invention to be reminded beforehand, by way of a non-limitative example, the special features of the cutting device described in the previously mentioned patents, referring to FIGS. 1, 2 and 3 of drawings.
These diagramatically illustrate the movement of the cutting blade. The drum (1) of which the inside is hollow, is provided, allows for internal movement of the cutting blade (2) with respect to its rotation axis, through a roller (3) associated with the blade holder (4) cooperating with the contour of a fixed bearing (5) forming a cam around the latter. The bearing, by this cooperation, ensures a progressive dispensing movement of the blade (2), determined by the shape of the cam so as to have the same describing on the on the inside of the drum and simultaneously with the path of the latter and in the same direction, a 360° complete circle path from a retracted position up to a position near to the plane of tangency with respect to the paper web so that at the ending of the manual pull of the cutting blade across the drum slot, the blade projects in a crosswise direction in this web, with penetration in the paper web which is taut on both sides of the cutting blade.
The device of the type previously described is provided for the cutting off of lengths of material in webs of cotton wool and/or similar materials. This type of device is operated with a high rate of reliability and its commercial success confirms its technical performances.
However, on certain types of very thin wiping products the necessity appeared interesting to soften the pulling force of the cutting device during the paper cutting off operation. In fact, these very thin materials cause the paper to tear during the pulling operation with wet hands by the user.
The object according to the invention was therefore to improve the device's design in a non limitative manner in order to meet this requirement. Besides, the invention aims for a new cutting device whatever the additional means used for the drum stop control maybe.
After different tests and research carried out in relation to the rotation of the drum, a solution was found offering very performing unexpected results with regards to the cutting of very thin materials. This solution lies in a different arrangement of the cutting blade and cutting device in general according to an operating mode which is in opposition to the previous operation of this device as mentioned before, and of the prior art in general, the applicant has the knowledge of. This device is adaptable to single and double roll devices and generally to any device comprising a dispensing roll and at least a stand-by-roll.
SUMMARY OF THE INVENTION
According to a first feature, this devices comprises a hollow drum with a longitudinal slot on its external periphery, and taking a blade and blade holder hinged in opposition to a return means on the inside of the drum, the said blade projecting outside through the slot under the effect of rotation of the drum its during rotation whilst pulling on the material so as to penetrate into the material taut either side of the cutting device, the said blade being moved according to a path given through a follower roller joined with the blade holder and cooperating with mechanisms particularly including a fixed profiled cam arranged on a the side wall of the casing of the device arranged to take the said driving drum and one or several stand-by rolls, wherein the said device includes two independent blades arranged side by side according to an angle and each corresponding to half the length of the drum, the said blades fixed on blade holders, angularly oriented in the drum, are each associated toa follower roller respectively cooperating with a fixed cam of the same profile arranged on each side plate of the casing of the device, the said cams being angularly shifted to enable the progressive and successive projection of each blade and to define the two cutting zones of the web of material inside the device whereby obtaining only one clean cut of the said material perpendicular to its side edges.
Other specific objects and advantages will appear as the specification proceeds.
In order to clarify the object of the invention without limiting it, the invention is accompanied by the following drawings in which:
BRIEF DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 are schematic views illustrating the functioning of the cutting device such as described in the patent Nos. 2.332.215 and 2.340.887 of the applicant.
FIG. 3 schematic illustrates the blade used to cut the paper web, according to FIGS. 1 and 2.
FIG. 4 is a front view of the device with the new cutting device in its non-limitative implementation with one of the devices in operation by the applicant.
FIG. 5 is a side view taken on the line A--A of FIG. 4.
FIG. 6 is a side view taken on the line B--B of FIG. 4.
FIG. 7 is a partial view illustrating the positioning of one of the cutting blades in the drum, in sections taken on the line C--C of the FIG. 9.
FIG. 8 is a sectional view illustrating the drum taken in a semi-assembly state and arranged with the two cutting blades according to the invention.
FIG. 9 is a schematic view illustrating the position of one of the cutting blades at the time of the cut of the paper web.
FIGS. 10, 11, 12 and 13 are schematic views illustrating the different advancing phases of the cut of a very thin material web, with the device according to the invention.
The object of the invention will become more apparent from the following non-limitative detailed description with the accompanying drawings.
The cutting device according to the invention can be used with any type of dispensing devices for material rolled up in webs, single roll, double roll and more generally, with a dispensing roll and several reserve rolls.
DETAILED DESCRIPTION OF THE INVENTION
The cutting device according to the invention applies naturally but in a non-limitative manner to the different devices the features of which were described and defined particularly in the afore-mentioned patents. It stands to reason that the cutting device according to the invention can, by its principle and function, be used with other devices.
A non-limitative application of the cutting device to GRANGER devices is illustrated, to emphasise the new inventive concept.
Beforehand, the main elements of the GRANGER device shall be briefly recalled. The device comprises from a casing, a wall fixing base plate (6), free rotating support means, a driving drum (7) with respect to side plates (6.1) (6.2) of the said casing. The inside of the drum is designed to take a blade holder hinged on the drum's side wall including a follower roller (28, 29) on the outside, cooperating with a fixed cam (10) to allow the periodic moving of the pinked cutting blade outside the drum, when the web of material projecting from the device is pulled, thereby rotating the drum with a rough surface on which the roll (R1) of rolled up material is applied. The latter is held by a support stirrup (8) hinged on the base plate. A roll (11) can also be seen according to a device described in another application, with a belt (12) also associated with the drum so as to properly guide the material towards the lower opening and to avoid the user putting his fingers inside, near the cutting blade.
With reference to FIG. 4, the casing includes, at the same level as the drum positioning zone, the internal U-shaped clearances (6.3) on the side plates. The main means allowing the moving out of the blade, the means being arranged on one of the walls (6-1) of the casing shall be briefly recalled. With reference to FIGS. 4 and 6 as described in the previously-mentioned patents, the shock protector (13) is designed to successively take the plate support (14) of the cam (10), whilst the profiled cam (10) allows the guiding of the follower roller (28, 29) mounted on the blade holder, the ratchet pawl (16) with its return spring (17).
A fixed curvilinear ramp (15) of about 90 degrees is also illustrated, and on which the mobile stop (18) mounted on the drum is moved; the fixed stop arranged on the drum is referred to in (19). This ramp is arranged between the cam (10) and the ratchet pawl and its orientation is designed to allow the guiding and the support of the drum's mobile stop during its rotation. In (20) the non return stop of the shock protector is also illustrated and in (21) the guiding roll of the free end of the web of material. The mechanism's operation was described in the previously-mentioned prior patents which are to be referred to.
The cutting device integrated in the material driving includes, according to the invention, two independent blades (22-23) arranged side by side and each substantially corresponding to half the length of the drum. As per FIG. 4, the two blades are not placed in line but according to an angle α of about 150 to 179 degrees, preferably of about 170°. Thus the two blades are arranged substantially on a plane symmetric with respect to the transversal central line of the drum, and are thus mounted opposite. Their pinked sections however, are orientated on the same side. Each blade (22-23) is mounted on an L-shaped blade holder (24-25), hinged on its lower end on pins (32-33) positioned on support blocks (26) formed on the inside of the said drum; the support blocks of the same blade being shifted so as to give an angular orientation to the blades (FIGS. 7 and 4). Each blade holder (24-25) is arranged in the rest position corresponding to the withdrawal of the blade to the inside of the drum by a return spring (27) one end (27.1) of which is fixed to the drum wall. On the other hand, according to another embodiment of the invention, each blade or blade holder takes a roller (28-29) at its end, projecting from each side wall of the drum, the said roller being mounted in free rotation likely to act and cooperate with fixed cams arranged on the casing to take the drum and its additional mechanisms. So, it is apparent that each blade (22-23) has its own hinging movement whilst being similar to each other. In an advantageous manner, such a design is provided so that the drum's axis, the rotating axis of the rollers (28-29) and the hinge pin axis (32) situated towards the side of the drum of each blade holder are aligned substantially according to the line XX so as to limit the cutting forces. According to another particularly significant and complementary arrangement, the two afore-mentioned rollers (28-29) each cooperate with a fixed cam arranged on the device's casing. More precisely, by referring to figures of the drawings, a first fixed cam is that of (10) fixed on to the first side plate (6.1) of the casing of the side of the stopping and locking mechanism when the drum is in the position as illustrated in FIG. 6. A second fixed cam (30) is built up and fixed on the second side plate (6.2) of the casing opposite to the previous one. The two cams (10) and (30) have exactly the same peripheral profile so that when the follower rollers (28-29) associated to the blade holders (24-25) move around them along their external periphery, the paths of the two blades are exactly the same.
Nonetheless and according to an essential embodiment of the invention contributing to the proper operation of the cutting device in general, the two cams (10) and (30) have a different angular orientation of from around 80 to 100 degrees so that there is a continuity in the penetration of the two blades in to the web of material to be cut off. More specifically, as schematically shown in FIGS. 10 to 13, the angular shifting of the two cams (10-30) permits to obtain, firstly, the penetration into the wiping material by a blade (22) on a semi-width, then the other blade (23) on the second semi-width before the withdrawal of the first blade.
According to another interesting embodiment, the projection of teeth of each blade is progressive, in the sense that, as the drum rotates with the successive projection of blades, the teeth situated on the outside of the drum come out first, then the others move to the central part of the material. So, the depth of projection of the different teeth of each blade varies substantially, the projection being maximum for the tooth the nearest to the side end of the drum. On the other hand, the slot (31) formed on the drum through which the blades pass, is cut according to a V-shaped profile complementary to the profile and arrangements of blades. Therefore, there are two different cutting zones of the web of paper with respect to its dispensing roll and driving drum, one is situated substantially after the plane of contact of the roll of paper and the driving drum (ZCI, cutting zone 1) as illustrated in FIG. 10 and the other in the lower rear part of the driving drum illustrated by the reference (ZC2, cutting zone 2).
The cut is made along a continuous horizontal line of the web of material. On the other hand, according to FIGS. 10 to 13 it is schematically shown that the last tooth of the first blade situated the nearest to the centre of the drum starts a V-shaped cutting off operation corresponding to the profile of the tooth and the last tooth of the second blade situated nearest to the centre of the drum starts another V-shaped cutting off operation adjacent to the afore-mentioned, a minute web of paper ensuring the connection between them. Under the continuous pulling effect by the user on the web of material, the said connecting web is also torn finally separating the piece of paper pulled. The cutting of the material according to the previously-mentioned device is carried out by tearing the paper web with a progressive action. The fact that the sloping of the cutting blades in two planes, on the one hand, with respect to the longitudinal axis of the drum or its external generating line and on the other hand, the sloping of the teeth of each blade, into depth whilst moving towards the central part of the drum, combined with the cam profiles, allows a straight and clean cutting operation on the paper with no jagged edges perpendicularly to the sides of the web of paper, must be emphasised.
The result obtained, i.e. the quality of the cut and its cleanless requires particularly precise positioning of the different components of the cutting device. The fact that the first blade (22) penetrates into the material by a hinging movement given according to the arrow F1, contrary to the unrolling direction, F2 of the drum which enhances the tearing effect with less force must be highlighted. The second blade (23) penetrates in the same direction as the unrolling direction of the drum.
It is also necessary to point out that the sloping of the wide V-shaped opening for passage of blades outside the drum, avoiding the premature stopping of the roll of material at this stage, as the roll of material always has a point contact or a contact with a generating line with the driving drum. Comparatively to the prior art, the passage on a flat surface through the rectilinear slot of the drum on which the paper roll can be supported is no longer a hindrance.
Thus, according to the invention, the cutting of a paper web is carried out according to an original procedure. The cut is made in two stages, in two different cutting zones in situ in the device and thanks to special postioning of cutting blades and their respective teeth, the cutting line on the paper web is rectilinear and perpendicular to its edges.
Thanks to these different arrangments, the force of different return springs can be reduced and therefore their cost. Very thin wiping materials can be pulled with wet hands without the risk of unforeseen tearing.
|
Improved cutting device for an apparatus for the simultaneous dispensing and cutting of bands of wound material. This device is distinguished in that it comprises two independent blades located side by side at an angle, each of which corresponds to two half-lengths of the drum, whereby each of the blades is fixed to blade carriers oriented angularly in the drum and is associated with a follower roller which cooperates respectively with a fixed cam of the same profile located on each lateral wing of the housing of the apparatus, whereby said cams are offset angularly in order to permit the progressive and successive exiting of each blade and to define two cutting zones of the band of material in the apparatus while obtaining only a single clean cutting line of said material perpendicular to its lateral edges.
| 0
|
BACKGROUND OF THE INVENTION
This invention relates to control circuits for appliances such as dishwashers and washing machines which employ motors and solenoid actuated devices for performing various machine cycle operations such as water fill, water drain, dispensing of detergents and other additives, drying and the like. Conventionally, the approach has been to use a separate relay with each solenoid activated device and motor. The energization of the relays so employed is controlled by a mechanical or electromechanical timer or, more recently, by solid state logic controllers. In order to provide greater reliability and reduced cost, it is desirable to minimize the number of relays employed to provide the desired cycle functions.
It is accordingly an object of the present invention to provide a relay control circuit for an appliance which controls a predetermined number of functions, using a number of relays which is less than said predetermined number of functions.
It is a further object of the present invention to provide a relay control circuit for a washing appliance which uses four relays to control eight functions.
SUMMARY OF THE INVENTION
The present invention provides a relay control circuit for a washing appliance in which the number of functions controlled by the circuit exceeds the number of relays employed. In the preferred embodiment, eight dishwasher cycle functions are controlled using four relays. These cycle functions include fill, drain, circulate, circulate with heat, dispensing of wash and rinse aids, and dry. The reduction in relays is accomplished by interconnecting the contacts of the relays to provide a plurality of relay combinations. A particular function is associated with a particular relay combination such that the desired function is initiated by selecting the relay combination associated with that function. The cycle controller selects a particular relay combination by activating certain ralays and de-activating others. The relay combinations provided in the circuit of this invention allow sufficient flexibility to enable the controller to select transitional relay combinations between operative combinations to prevent the inadvertent initiation of a function which might otherwise occur as a result of a race condition in switching the relays.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a typical relay control system which is representative of the prior art.
FIG. 2 is a block diagram of a relay control circuit illustrating a preferred embodiment of the present invention.
FIG. 3 is a schematic diagram of the relay control circuit for the preferred embodiment of the present invention.
FIG. 4 is a logic truth table useful in understanding the operation of the preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a block diagram of a relay control circuit employed in an appliance such as a dishwasher or clothes washing machine is illustrated which is typical of the prior art. The relay drivers 11 are selectively triggered by a cycle controller 10 which may be a mechanical, electromechanical, or solid state timer or sequencer or a microprocessor. Operation of the relay portion of the circuit is the same regardless of the type of controller employed to coordinate the triggering of the relay drivers 11. The controller switches the desired relay driver into conduction at the desired time. The relay drivers 11 activate associated relays in relay network 13 which close power circuits for the solenoids, motors and heating elements typically found in appliances of the aforementioned type. Typically, one relay is provided for each of the desired system functions. For a dishwasher which provides a wash cycle, a rinse cycle, a drain cycle and a dry cycle, the following cycle functions are desirable; water fill control, water heating, water circulation, automatic dispensing of wash aid, automatic dispensing of rinse aid, draining and heated drying. Conventionally, a separate relay has been provided for each cycle function. The desired cycle progression determines the order in which the relays in network 13 are activated by the controller 10. In FIG. 1, network 13 includes seven relays, each one being uniquely associated with one of blocks 16-28 which represent means for performing the aforementioned cycle functions.
As shown in the block diagram of FIG. 2, the control circuit of the present invention reduces the seven relays of FIG. 1 to four relays to control eight functions. Although 15 relay contact pairs are employed, the reduction in relay coils in going from seven or eight relays to four relays results in a significant cost reduction. The preferred embodiment incorporates this circuit in an automatic dishwasher. This advantageous reduction in the number of relays employed results in part from a recognition of the fact that in a washing appliance such as a dishwasher, certain of the desired functions operate simultaneously. It should be recognized that the invention is equally applicable to a clothes washer for controlling a comparable number of functions although the particular functions employed in the clothes washer may differ somewhat.
A dishwasher incorporating the preferred embodiment of the control circuit of this invention provides at least the following operating cycles: a first wash cycle, a second wash cycle, a rinse cycle and a dry cycle. Other operating cycles or combinations of cycles will occur to those skilled in the art, which may be similarly implemented without departing from the present inventive concept. For example, the second wash cycle may be simply be omitted. The control system would then control seven, rather than eight, functions, the second wash aid dispensing function being deleted.
During the wash cycles, the following cycle functions are provided: a fill function typically performed by actuating a solenoid which opens a water valve, and deactuating the solenoid to close the valve when the water reaches a predetermined level or a predetermined time has elapsed; a water heating function performed by energizing a heating element at a relatively high power level with water present in the wash chamber; a water circulating function in which water is circulated in the wash chamber by dish spraying apparatus when the pump motor is energized; an automatic additive dispensing function in which a wash aid such as a liquid or dry detergent is dispensed into the wash chamber by energizing the wash aid dispensing mechanism at the desired time; and a draining function performed by energizing the pump motor and energizing a drain solenoid which actuates a means for diverting the path of the water being pumped to the drain for removal from the machine. The functional requirements for the rinse cycle are similar, substituting rinse aid dispensing for wash aid dispensing. The dry cycle requires that heat be provided to the wash chamber at a relatively low power level. In the illustrative embodiment, heat for the drying cycle is provided by energizing the same heating element used for heating the water but at a lower power level. However, a separate heating element of a lower power rating could be employed.
FIG. 3 is a schematic diagram of a portion of the system of FIG. 2 which illustrates the manner in which the contacts for the four relays of FIG. 2 are arranged in various combinations by interconnecting the contacts so that different ones of the various function performing means 16-28 are enabled by the selection of particular combinations of relays by the cycle controller (item 10, FIG. 2) to perform the required cycle functions. The relay coils and circuitry for activating the coils are not shown in order to avoid unduly complicating the circuit, it being understood that such circuitry is conventional and well known in the art.
Four relays R1-R4 have contacts designated K1-K4, respectively. The relays are of the double throw type, each having at least one set of contacts which are normally open (NO) and one set of contacts which are normally closed (NC). R1 is preferably a single pole relay having one set of normally open contacts K1(NO) and one set of normally closed contacts K1(NC); R2 is a double pole relay having two sets of normally open contacts K2(NO) and two sets of normally closed contacts K2(NC), and R3 and R4 are triple pole relays, each having three sets of normally open contacts K3(NO) and K4(NO), respectively, and three sets of normally closed contacts K3(NC) and K4(NC), respectively.
The circuit of FIG. 3 includes eight lines, designated L1-L8, which are arranged for parallel connection across a 120 volt AC power supply typical of power service available in the home. Line L1 includes second wash aid trip mechanism 22 connected in series with first normally open contacts K1(NO), designated K1(a), and K2(NO), designated K2(a). Line 12 includes a water valve solenoid 16 connected in series with first normally closed contacts K3(NC) and K2(NC), designated K3(b), and K2(b), respectively, and normally open contacts K1(a). Line L3 includes rinse aid trip mechanism 24 connected in series with first normally open contacts K3(NO), designated K3(a), normally closed contacts K2(b) and normally open contacts K1(a). Line L4 includes drain solenoid 26, connected in series with second normally closed contacts K3(NC), designated K3(d), second normally open contacts K2(NO), designated K2(c) and normally closed contacts K1(b). Line L5 includes first wash aid trip mechanism 21 connected in series with second normally open contacts K3(NO) and K2(NO) designated K3(c), and K2(c), respectively, and normally closed contacts K1(b). Line L6 includes heating element 32 connected in series with first and second normally open contacts K4(NO) designated K4(a) and K4(c), respectively, third normally open contacts K3(NO) designated K3(e) and a thermostatic switch 34. Line L7 includes heating element 32 in series with current limiting fuses 36 and 38, diode 40, first and second normally closed contacts K4(NC) designated K4(b) and K4(d), respectively, and normally open contacts K3(e). Line 8 includes pump motor 18 and vent closing mechanism 17 connected in parallel, the parallel combination being connected in series with third normally open contacts K4(NO) designated K4(e). Vent closing means 17 could as well be connected in series with pump motor 18.
The circuit of FIG. 3 includes means for providing heat at two energy levels, high heat for heating the water during wash and rinse cycles and low heat for drying the dishes during the dry cycle. The means for providing high heat comprises a conventional resistive heating element 32 arranged in the circuit for direct connection across the AC power supply. The means for providing low heat comprises heating element 32 arranged for connection across the power supply in serial connection with a unidirectional current device 40. Thus, resistive heating element 32 is energized at full power in the high heat mode and at half power in the low heat mode.
For operation in the high heat mode a relay combination in which relays R3 and R4 are activated is selected. In this mode heating element 32 is arranged for direct connection across the AC power via normally open contacts K3(e), K4(a) and K4(c) and thermostatic switch 34. The thermostat 34 is not essential to circuit operation but is provided to prevent overheating the wash chamber as might occur if the heating element were operated at full power in the absence of sufficient water. If thermostat 34 is omitted from the circuit, both normally open contacts 44(a) and normally closed contacts K4(b) and fuse 36 may be likewise omitted. Relay R4 may then be a double pole double throw relay. For operation in the low heat mode, a relay combination in which R3 is activated and R4 is not activated is selected. In this mode, heating element 32 is switched in series with diode 40 via normally closed contacts K4(d), for connection across the power supply via another set of normally closed contacts K4(b), normally open contacts K3(e) and current limiting fuses 36 and 38.
During the wash and rinse cycles pump motor 18 is energized to circulate water in the wash chamber of the appliance and during the drain cycle to remove water from the wash chamber. During those cycles in which pump motor 18 is operating, it is desirable to close the vent provided in the appliance for allowing air circulation during the drying cycle. Therefore, vent closing mechanism 17 which closes the vent and retains it in the closed position when actuated, is connected with pump motor 18 either in parallel (as shown in FIG. 3) or, alternatively, in series such that the vent closing mechanism is actuated when the pump motor is energized.
In addition to controlling eight cycle functions to provide the necessary operating cycles, a further requirement on the relay circuit of FIG. 3 is that when the relay combination in which each of the relays R1-R4 is inactivated is selected, none of the functions are operative; that is, each of the function performing means is placed in its non-operating state. This is accomplished in the circuit of FIG. 3 by arranging the interconnection of relay contacts such that when all four relays are inactivated lines L1-L8 are all open circuits, leaving all of the function performing means in their non-operative states.
FIG. 4 is a logic truth table in which the relay combinations for each function are defined in terms of the state of each relay in the combination. The left column of the table lists the functions. Each of the remaining four columns lists the state of one of relays R1-R4. A one state is a relay column indcates that that relay is activated, that is, its normally open contacts are closed and its normally closed contacts are open. A zero state indicates that the relay is not activated, that is, its normally closed contacts are closed and its normally open contacts are open. An X state represents a "don't care" condition in which the state of that relay has no effect on the corresponding function. Thus, each row represents as a four-bit code the combination of activated and non-activated relays associated with the function for that row which when selected enables that function to be performed.
Referring now to FIG. 3 and FIG. 4, the operation of the illustrative embodiment of the circuit of this invention will be described. For performance of the fill function the state of the relays is shown to be 100X. Selection of this relay combination enables water to be admitted to the wash chamber of the appliance by activaing relay R1 which closes normally open contacts K1(a) and not activating R2 and R3, thereby energizing water valve solenoid 16 on line L2 via normally open contacts K1(a) and normally closed contacts K2(b) and K3(b). The table of FIG. 4 indicates that for the fill function the state of relay 4 is inconsequential. However, it may be desirable to provide static fill, that is fill without circulation, during certain fill cycles, and to provide a dynamic fill, that is simultaneous fill and circulate, during other fill cycles. For a dynamic fill, the circulating pump is energized while water is entering the wash chamber; for a static fill the pump is not energized. In the circuit of FIG. 3, pump motor 18 is energized when relay R4 is activated. Thus, for a dynamic fill the state of the relays is 1001; for a static fill the state is 1000. The controller can provide a static fill or a dynamic fill as desired by properly selecting the state of relay R4. The drain function requires tha both drain solenoid 26 and pump motor 18 can be energized. This is accomplished by activating only relays R2 and R4, corresponding to relay combination 0101. Drain solenoid 26 is energized via normally closed contacts K1(b) and K3(d) and normally open contacts K2(c); and pump motor 18 is energized via normally closed contacts K4(e). The first wash aid dispensing function is accomplished by selecting the relay combination 011X, thereby energizing first wash aid dispenser mechanism 21, via normally closed contacts K1(b) and normally open contacts K2(c) and K3(c) by activating only R2 and R3. The state of relay R4 is irrelevant to this function. For the second wash aid dispensing function, second wash aid dispenser mechanism 22 is energized via normally open contacts K1(a) and K2(a), by activating relays R1 and R2 corresponding to relay combination 11XX. The state of relays R3 and R4 is irrelevant to this function. The rinse aid dispensing function is accomplished by energizing rinse aid dispensing mechanism 24 via normally open contacts K1(a) and K3(a) and normally closed contacts K2(b) by activating relays R1 and R3 corresponding to combination 101X. The state of relay R4 is irrelevant to this function. The circulate with heat function is performed when only R3 and R4 are activated, combination 0011. In this mode, heating element 32 is operated at full power, being coupled directly to the input power line via normally open contacts K3(e), K4(a) and K4(c) and thermostat 34. Pump motor 18 is energized via normally open contacts K4(e). For the circulate with no heat function, only relay R4 is activated (0001), energizing pump motor 18 via normally open contacts K4(e). Finally, for the drying function in the preferred embodiment, heating element 32 is energized at half power. This is accomplished in the circuit of FIG. 3 by connecting heating element 32 in series with diode 40 via contacts K4(d) and connecting this serial combination to the power supply via normally open contacts K3(e), normally closed contacts K4(b) and fuses 36 and 38, by activating only relay R3 (0010).
The above-described functions are performed in a dishwasher to provide the following sequences of steps during normal dishwasher operation: Fill, circulate with heat, drain; fill, dispense washing aid, circulate with heat, drain; fill, circulate with heat, drain; fill, dispense rinse aid, circulate, drain; dry.
In switching the relays from one step or function to the next in providing the above sequences, care must be taken to avoid a race condition in the relays which may initiate an undesired function resulting from the occurrence of an unintended intermediate state. For example, referring to the truth table of FIG. 4 it will be observed that the state of the relays for fill is (100X) and the state for circulate with heat is (0011). In switching from (100X) to (0011), if relay R3 were activated before relay R1 is de-activated, an intermediate state (101X) would exist at least briefly. This state, as seen in the truth table, trips the rinse aid dispensing mechanism.
In order to avoid race condition problems, the relay combinations are arranged so that there are sufficient states which can be interposed as transition states between operative states to avoid inadvertently initiating undesired functions. These transition states are either inoperative states, that is, states which do not initiate any functions, or operative states which initiate functions, the intermediate performance of which will not adversely affect system performance. Operative states which perform satisfactorily as transition states are those states which initiate functions which are compatible with the subsequent desired operative function. For example, state 0001 which initiates pump motor operation, is compatible with any of the functions except the dry function and the static fill function since motor operation does not adversely affect system operation. However, it is particularly important that dispensing of the wash and rinse aids does not occur inadvertently since the presence of wash aid during rinse or rinse aid during wash would seriously adversely affect system performance. Thus, states 011X or 11XX which dispense wash aid are incompatible with the rinse function; and, similarly, state 101X which dispenses rinse aid is incompatible with the wash function. The relay control circuit of the present invention provides sufficient flexibility in state selection so that the cycle controller can be arranged to select transition states intermediate certain operative states to prevent inadvertent initiation of unwanted functions when changing from one selected operative relay combination to another. A description of one embodiment in which the cycle controller selects certain transition states follows.
In the example situation involving the transition from fill to circulate with heat, transition state 0001 is employed to avoid the inadvertent tripping of the rinse aid dispenser. The controller switches the relays from state 100X to state 0001, and then to state 0011 in going from fill to circulate with heat. In this instance, and transition state initiates the circulate function between the fill and circulate with heat function. Obviously, this transition state is compatible with the next desired function, namely circulate with heat. This transition is completed by activating relay R3 to provide the heat function. In the transition from circulate with heat to drain and drain to fill, this same transition state is employed. This state is again compatible with the succeeding operative states because the pump motor which is energized in this state is to be energized in all of these functions. The transition from fill to dispense wash aid #1 involves the two transition states 0000 and 0100, both of which are inoperative states. Similarly, in the transition from dispense wash aid #2 to circulate with heat, two transition states are employed, 1111 and 0111. State 1111 merely actuates second wash aid dispensing mechanism, and state 0111 trips first wash aid dispensing mechanism. At this point in the cycle, these states are compatible. Since both the first and second wash aids have been dispensed earlier in the cycle, these steps do not introduce addtional additive into the wash chamber and thus do not adversely affect system performance. Finally, in the transition from drain to dry, inoperative transition state 0000 is employed.
Modifications and alterations of this invention will become apparent to those skilled in the art from the foregoing discussion, and it should be understood that this invention is not limited to the specific embodiment illustrated and described herein. It is intended to cover by the following claims all modifications coming within the spirit and scope thereof.
|
A relay control circuit for controlling the operation of various electrically actuated devices in a washing appliance such as a dishwasher is disclosed. The circuit employs four relays to provide eight operating functions, including filling, draining, dispensing of additives, water circulation, water circulation with heat, and drying.
| 3
|
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention pertains to an improved fibrous polyacrylonitrile mixture for use in the manufacture of friction products. The improved mixture is comprised of cut and refined polyacrylonitrile fibers in conjunction with an additive selected from the group consisting of:
(a) polyethylene glycol esters of pelargonic acid; or
(b) polyethylene glycol esters of enanthic, caprylic or capric acids; or
(c) blends of polyethylene glycol esters of enanthic, caprylic, pelargonic, or capric acids; or
(d) blends of polyethylene glycol esters of carboxylic acids derived from natural products containing at least 50% by weight of carboxylic acids containing less than 14 carbon atoms; or
(e) reaction products of ethylene oxide and carboxylic acid amides wherein at least 70% of the acids from which the amide is derived contain between 16 and 20 carbon atoms.
A decline in the use of asbestos in friction products has been occurring due to the resulting health hazards asbestos has created in both the workplace and the environment. Asbestos has provided uniquely favorable frictional characteristics and physical properties in brake and bearing products. Currently there is considerable research activity in an effort to find a suitable replacement for asbestos in friction product end uses. It is the object of the present invention to provide an asbestos substitute for the manufacture of friction products.
It has been found that of the synthetic fibers, acrylic fibers are favorably suited for use in friction products, as they do not melt as readily as nylon, polyester, polypropylene, etc. Furthermore, under appropriate conditions of heat and pressure, acrylic fibers are transformed into carbon fiber precursors and eventually into carbon fibers. These characteristics make acrylic fibers especially suited for use in friction products.
The manufacture of friction products (e.g. brake blocks) is carried out by placing a mixture into a first mold, and thereafter applying pressure to the mixture for a period of time in order to create a "preform". The preform is then removed from the first mold and placed into a second mold within which the preform is subjected to both heat and pressure. During the application of heat and pressure in the second mold, the preform is transformed into a friction product (e.g. a brake block).
In this manufacturing process, the preform must have a degree of integrity high enough so that it may be removed from the first mold and placed in the second mold without significant disintegration. All mixtures which are subjected to the preforming operation tend to "rebound" from the pressure exerted in the preforming operation. Theoretically, it is believed that the lower the degree of resilience, the better the quality of the preform. Too much resilience creates two detrimental consequences: (1) the degree of resilience is so high that the preform disintegrates upon the necessary handling required to remove the preform from the first mold and place it in the second mold; (2) the degree of resilience is so great that the preform expands by an amount so great that the preform will not fit into the second mold.
Although acrylic fibers have advantages (over many other synthetic fibers) in friction product applications, acrylic fibers having no liquid additives thereon have not been found to enable the production of satisfactory preforms. Furthermore, it has been found that in order to apply an operable amount of these liquid additives to the acrylic fibers, the fibers must be in a "wet gel" state. The structure of a wet gel is extremely "open" and absorbent (i.e. the polymer structure will hold large amounts of liquids, similar to a sponge) in comparison with a collapsed polymer structure. In addition, it has been found necessary to refine the wet gel fibers in order to create a fibrous pulp, rather than using continuous filaments, cut staple, or even comminuted fiber in the manufacture of friction products. Most preferably, the refining of the acrylic wet gel is performed in the liquid additive.
It has been found that liquid additives to the acrylic wet gel are taken up and thereafter held in amounts much greater than expected. For example, PEG - 400 monopelargonate has been applied to wet gel to a saturation point, after which the excess pelargonate was removed by centrifugation. The wet gel was then dried in a dryer, which caused the polymer structure to collapse. The resulting dried fiber was analyzed for PEG - 400 monopelargonate content, and it was found that the fiber contained over 50% (on weight of fiber) of PEG - 400 monopelargonate. This is extremely unusual as it was not believed previously that more than about 2% liquid (on weight of fiber) could be held by a dried acrylic fiber.
As described herein, the phrase "liquid additive" is intended to comprise not only additives which are themselves a liquid at room temperature and 1 atm. pressure, but also compounds which are liquefied, dispersed, or dissolved. It has been conceived that liquefied, dispersed, or dissolved additives within the group (a) through (e) above will be operable in enabling one to achieve the advantages of the present invention.
Furthermore, it has been unexpectedly found that certain liquid additives, when incorporated into the acrylic fiber in amounts greater than about 37% (on weight of fiber), dramatically decreased the resilience of the fiber as measured by a "white pellet test". This test is performed by placing a weighed 5 gram sample of dried, refined fiber having additive thereon into a press having a 1 inch (circular) cross-sectional area. The press is used to apply 5000 pounds of pressure to the 5 gram sample. The pressure was held for approximately 60 seconds. The thickness (i.e. height) of the pellet was measured while the pellet remained under pressure, this measurement being taken approximately 60 seconds after pressure was applied to the fiber. The fiber, having been pressed into a cylindrical "pellet" shape, remained in the press after pressure was removed, and the pellet was then removed from the press. The height of the pellet was then measured again approximately 5 minutes after removal of the pressure from the pellet. The percent rebound (i.e. resilience) was calculated as follows:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a portion of a process for making refined fiber/additive utilized in Examples 1 through 8.
FIG. 2 is a cross-sectional view of a 3-point breaking apparatus utilized in conjunction with the Instron testing machine which was used for measuring preform strength.
FIG. 3 is a schematic representation of a most preferred process for making the improved mixture of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Examples 1 through 8
The white pellet test was carried out on refined homopolymer (i.e. 100% polyacrylonitrile units) acrylic fiber wet gel having additives thereon and therein. The acrylic fiber, which was cut from acrylic wet gel tow, can be manufactured according to the following U.S. patents, which are hereby incorporated by reference:
(a) U.S. Pat. No. 2,847,405: polymerization
(b) U.S. Pat. No. 2,916,348: wet spinning with inorganic solvents
(c) U.S. Pat. No. 2,558,730: wet spinning with inorganic solvents
(d) U.S. Pat. No. 2,899,262: production of wet gel polyacrylonitrile tow
During manufacture of the wet gel, the extrudate was stretched approximately 10×. The acrylic wet gel was cut to a staple length of 0.375 inches. The denier per filament was 1.5.
The wet gel staple is then refined in water by the process shown in FIG. 1. The wet gel staple is placed into a tank (1) and is then dispersed in water. The dispersion (2) of wet gel staple and water is created by mixing 50 pounds of water with each pound of fiber (on a dry weight basis). One or more stirrers (3) are used to keep the wet gel staple dispersed in the water. A pump (4) is used to pump the dispersion (2) through a conduit (5) and directly into the first of a pair of refiners (6 and 7). The staple was then refined in the first refiner, after which the staple passed through the second refiner, where the staple was refined still further. The majority (by weight) of the wet gel which emerged from the second refiner had a length of between 1 millimeters and 4 millimeters. The average length of the refined product was between 1 and 2 millimeters. The refined gel was then dewatered by passing the refined gel into a centrifuge (8). The refined gel went into the centrifuge at a ratio of 50 lbs. water per pound of fiber (on a dry weight basis). The product emerged from the centrifuge at a ratio of 60 lbs. water per 40 lbs. fiber (on a dry weight basis). After centrifugation, the pulped wet gel (10) was collected in a container (9). Four pound aliquots (on a dry fiber basis) of pulped wet gel staple were placed into a Littleford model FM-130-D rotary mixer with chopper (not shown in FIG. 1). The Littleford mixer was obtained from Littleford Bros., Inc., 7451 Empire Drive, Florence, KY 41042. The plow speed was set to 155 rpm. The chopper speed was set to 3515 rpm. The chopper was comprised of a 6 inch diameter double starwheel, each wheel having 16 teeth, plus an 8 inch diameter double starwheel, each wheel having 4 arms. In this mixer the pulped wet gel staple was blended for two minutes in order to "open" the fiber. After the opening process, blending was continued while a liquid additive was pumped into the mixer and onto the pulped fiber. The liquid was pumped into the mixer over a period of six minutes. The additive was combined with fibrous pulp at a ratio of 1 part fiber (on a dry weight basis) to 0.538 parts additive. After the additive was combined with the pulped fiber, the additive and fiber pulp were blended for another 5 minutes. At this point the additive was thoroughly intermixed with the pulped fibrous gel. The gel pulp/additive mixture was next run through a dryer (for 12 minutes residence time). The environment within the dryer was maintained at 50° c wet bulb and 130° c dry bulb. The fiber emerging from the dryer was comprised of 0.5%-1.0% moisture. Here the wet gel polymer structure was "collapsed" by the addition of heat, which caused removal of water from the gel structure. The resulting product (i.e. a dried homopolymer acrylic staple fiber having approximately 54% percent additive on weight of fiber, i.e. owf) was removed from the dryer and was allowed to cool at room temperature.
The additive always comprised an effective amount of an antioxidant in order to prevent oxidation of the fiber in the drying operation. The antioxidant used was known as Irganox 1076™ which was applied with the application of the finish to the fiber, the antioxidant being applied at approximately 0.55%, on weight of dry fiber. Irganox 1076™ is actually octadecyl-3,5-di-tert-butyl-4-hydroxyhydrocinnamate. Irganox 1076™ is sold by Ciba Geigy Corp of Ardsley, N.Y., 10502.
The data reported for Examples 1-8 was obtained by preparing the fiber, pulp, additive, and pulp/fiber mixture as described above. The pulp/additive was then subjected to the "white pellet test" (as described above) and the expansion was calculated by the formula given above.
TABLE I______________________________________ Amt.Exam.- Additive Whiteple Used PelletNum- (owf), Expan-ber Additive Used % sion, %______________________________________1 PEG-400 Monopelargonate 54 11.22 POE (7) Coconut fatty acid 54 30.83 POE (9) Coconut fatty acid 54 24.74 POE (14) Coconut fatty acid 54 28.25 POE (15) Cocoamine 54 27.16 POA (8) Cetyl-stearyl Alcohol 54 26.57 POE (12) Stearic Monoethanolamide 54 17.28 POE (14) Monoisostearate 54 25.0______________________________________
As can be seen in the data in Table I, the additive used in Example 1, PEG-400 monopelargonate, yielded a superior (i.e. lower) white pellet expansion when compared to the remaining additives. The additive used in Example 7 (POE (12) Stearic monoethanolamide) was significantly better than the additives used in Examples 2-6 and 8, but the resilience produced by using the additive of Example 7 remained significantly greater than the resilience provided by the PEG-400 monopelargonate.
It has been found that the additives producing the lowest resiliency as measured by the white pellet test also yield preforms which have the greatest integrity. The pulped fiber/additive examples 1-8 were used to make preforms, as is described below.
Preforms were made by combining several ingredients with a pulp/additive sample. The ingredients used and the proportions used were proprietary. Resultsf tests performed on these propriety preforms are shown in Table II. Other nonproprietary ingredients and proportions are known to yield results at least as advantageous as the proprietary ingredients and proportions used to generate the data diven in Table II. These ingredients and proportions are as follows:
______________________________________Barytes 22.8%Resin 19.0%Graphite 4.3%Rubber Dust 5.0%Friction Particles 8.5%PMF 42.0%______________________________________
The "PMF" is pulverized mineral fiber, and can be obtained from Jim Walters Resources, Inc., P.O. Box 5327, Birmingham, Al., 35207. The preform was made by mixing 2 pounds of these ingredients together in an Eirich mixer model R02 (obtained from Eirich Machine Co. of Toronto, Canada). The ingredients were mixed for 10 minutes, the Eirich mixer having a stirrer which was rotating at a tip speed of 25.2 meters/second. After 10 minutes of mixing, 5% (by weight) of the fiber pulp/additive was added to the mixed ingredients in the Eirich mixer. The mixer was then allowed to mix all of this for an additional 5 minutes, again at a tip speed of 25.2 meters per second.
A 200 gram aliquot of pulped fiber with additive, furnace slag fibers, barytes, resin, etc. was removed from the Eirich mixer and placed in a preform mold having a length of 5.31 inches and a width of 1.50 inches. These ingredients and pulp were then placed under 1200 psi pressure for 15 seconds. After 15 seconds of pressure application, pressure was removed for 2 seconds, following which the pressure was reapplied for another 15 seconds. At the end of the second 15 second period of pressure application, the preform thickness was then measured while the preform was in the mold, under pressure. The product of this operation was a preform. The preform was removed from the preform mold and was allowed to stand for a period of about 30 minutes. The preform always increased in thickness somewhat after removal from the mold, but with most of the additives used in Table I, the preform expanded so much that subsequent handling of the preform became impractical. In general, if the preform's height expanded more than 30% after the preform was removed from the preforming mold, the preform's integrity was judged to be too poor for subsequent testing of the preform for strength characteristics. Table II indicates the results of test conducted on preforms made by the above procedure wherein the pulped fiber/additive sample used correlates with Table I.
TABLE II______________________________________ % Instron weight TestExam- acrylic of Pre-ple Amount pulp FormNum- Additive in (pounds tober Additive Used Used % preform break)______________________________________1 PEG-400 54 5 1.8 monopelargonate7 POE (12) Stearic 54 5 1.0 Monoethanolamide______________________________________
Preforms utilizing pulped acrylic fiber with the additives utilized in Examples 2-6 and 8 were not produced, as the unfavorable results of the white pellet test data found in Table I indicated that any corresponding preform made utilizing these examples would not have enough strength to even form a significant amount of measureable preform strength.
The testing of the preforms was carried out using an Instron testing machine (Model 1122, obtained from Instron Corporation, 3781 N.E. Expressway Access Road Drive, Atlanta, Ga. 30340). A special "three-point breaking apparatus" was constructed for use with the Instron, this apparatus being shown in FIG. 2. For testing of preform strength, the preform (11) was placed on two lower bars (12 and 13). The lower bars (12 and 13) each had a diameter of 1 inch, and were welded to a metal plate (14). The lower bars had parallel axes which were located a distance of 3.31 inches apart. Once the preform (11) was placed on the lower bars (12 and 13) which were mounted in the Instron, an upper bar (15) was lowered from a position above the preform. The upper bar (15) made contact with the preform and thereafter applied pressure to the preform until it broke. The Instron recorded the pounds of force required to break the preform. Table II reports these results. The upper bar (15) was positioned so that it was always equidistant from the lower bars (12 and 13). The diameter of the upper bar was approximately 1 inch. All three bars (12, 13, and 15) were made from steel.
As can be seen from Table II, the pelargonate additive provided a preform strength almost twice that of the POE (12) stearic monoethanolamide. Furthermore, no strength data was believed to be obtainable from the remaining 6 additives found in Table I.
The improved fibrous polyacrylonitrile reinforcing mixture as described in Examples 1-8 was based on a 1.5 denier per filament fiber which was cut and pulped. It has been conceived that 1.5 denier per filament is the most preferred denier per filament. However, the improved product has also been proven to be operable throughout the denier per filament range of 0.5 denier per filament to 20 denier per filament. However, it is preferred that the denier per filament is between 0.5 and 10, and it is more preferred that the denier per filament is between 0.7 and 5, and still more preferred that the denier per filament is between 1 and 2. It has been conceived that the wet gel tow may be cut into a uniform length which may range from 2 millimeters to 30 millimeters. A length of 10 millimeters is most preferred.
In examples 1-8, the improved fibrous polyacrylonitrile reinforcing mixture was comprised of only the most preferred type of acrylic fibers, i.e. homopolymer polyacrylonitrile fibers. Homopolymer polyacrylonitrile fibers are comprised of 100% polyacrylonitrile units. It has been conceived that any form of polyacrylonitrile fiber, i.e. copolymer, terpolymer, tetrapolymer will be operable in the present invention. However, it has been found that homopolymer polyacrylonitrile fibers are more easily fibrillated in the refining (i.e. pulping) process, and for this reason, among others, homopolymer polyacrylonitrile are most preferred.
PEG-400 monopelargonate is the most preferred additive for use in the present invention. It has been conceived, however, that either (1) a blend of caprylic acid and capric acid or (2) heptanoate will render resiliency low enough to provide the advantages of the present invention.
In Examples 1-8, approximately 54% (on a weight basis) of additive was held by the dried fiber. This was proven by extraction of additive from the dried fiber. Thus, every 1 pound of "dry" fiber in the pulped fiber/additive mixture contained an additional approximately 0.54 pounds of additive. It has been conceived that it is most preferred to incorporate at least 50% (owf, i.e. "weight of fiber") of additive onto the pulped fiber, and this most preferred amount is also the maximum amount of additive that the fiber will hold upon being dried. It has been conceived that the advantages of the present invention may be obtained if at least 37% (as based on weight of dry fiber) of additive is on the fiberous pulp. It is preferred that, on a weight of dry fiber basis, at least 43% of additive is on the fiber, and it is more preferred that this amount is at least 49%.
It has also been conceived that the cut and refined polyacrylonitrile product should have an average length of approximately 1 to 2 millimeters. It is known that the use of specific refiner blade clearance settings will produce an average length of approximately 1 to 2 millimeters, regardless of the length to which the wet gel staple is originally cut.
FIG. 3 illustrates a schematic of a most preferred process for production of the improved fibrous reinforcing mixture of the present invention. A polyacrylonitrile wet gel tow (16) was forwarded by a set of five feed rolls (17), and the tow was drawn into an aspirator (18) and was cut in a cutter (19). A tank (32) supplied a dilute additive solution (31) to the cut gel tow (20), the dilute additive solution (31) being supplied to a vortex bowl (21) via pipe 33. An antifoamant (34) was added to the vortex bowl (21) via pipe 35, simultaneously with the addition of the dilute additive solution (31) to the vortex bowl (21). The antifoamant (34) was manufactured by Dow Corning of Midland, Michigan, and was known as H-10. The antifoamant was added at a rate of 14 cc. per minute. The cut polyacrylonitrile gel two was (20) along with antifoamant (34) and solution 31 were supplied to the first refiner (6) at a ratio of fifty pounds of solution 31 for every one pound of fiber (on a dry weight basis). Fiber was supplied to the cutter at a rate of one pound of fiber (on a dry weight basis) per minute. The wet gel was refined in the refiners (6 and 7), after which excess liquid was removed from the pulped fiber/additive via centrifuge (8). The additive/refined gel (22) passed from the centrifuge (8) into a dryer (24), via a conveyor (23), the dryer removing substantially all of the water from the additive/refined gel (19), causing the gel structure to collapse.
In addition to the additive/wet gel mixture (22), the centrifuge (8) also emitted excess liquid (comprised of a very dilute additive solution, 25) through pipe 26, along with foam (not shown) which was created during the refining process. These emissions were fed into an effluent tank (36) via pipe 26. In the effluent tank (36), the liquid (25) was separated from the foam. The liquid was then pumped (via pump 37) to the dilute additive tank (32) via pipe 27. Since liquid 25 had a lower concentration of additive than the concentration necessary for application with the cut gel tow, the dilute additive tank (32) was supplied with very dilute solution of water and additive from effluent tank (36) along with a concentrated additive solution (28) from another tank (29). The concentrated additive solution (28) was supplied to the dilute additive tank (32) via pipe 30.
Examples 9-11
The most preferred process (described above) was carried out using a 1.5 denier per filament homopolymer polyacrylonitrile wet get tow having a total denier of 384,000. The gel tow (16) was forwarded (by five feed rolls, 17), drawn into an aspirator (18), cut into lengths of approximately 10 millimeters (in cutter 19), etc., as shown in FIG. 3. The three different additives utilized in these examples were as follows: Example 9: PEG-400 monopelargonate; Example 10: POE (9) Coconut fatty acid; Example 10: POE (12) stearic monoethanolamide. Results of white pellet test, preform handle ability, and preform strength were as follows:
TABLE III______________________________________ Pre-Exam- Amount form Resili- Preformple # Additive Han- ence StrengthNum- Applied dle- (White lbs tober Additives Species (owf) ability Pellet) break______________________________________ 9 PEG-400 54% Good 7.1% 2.8 monopelargonate10 POE (9) Coco- 56% Fair 9.7% -- nut fatty acid11 POE (12) Stearic 45% Fair 9.4% -- Monoethanola- mide______________________________________
In each of Examples 9-11, the additive solution in which the cut gel tow was refined (i.e. the composition of solution 31 as seen in FIG. 3) was made up of approximately 92% water, 8% additive, and 0.08% Irganox™ antioxidant. Furthermore, the additive solution also contained approximately 0.7% of H-10 TM antifoamant, obtained from Dow Corning, the antifoamant improving the drying operation. Preform strength tests were not carried out for Examples 10 and 11.
A comparison of white pellet resiliency of Example 1 versus Example 9, Example 3 versus Example 10, and Example 7 versus Example 11 indicates that the process of making the mixtures of Examples 1-8 was clearly inferior to the process of making the mixtures of Examples 9-11. The amount of improvement (i.e. decreased resilience) between these Examples was not expected. It has been conceived that it is the intimate connection between the wet gel and the additive during the refining process which causes the resulting lower resiliency found in the improved process. The preforms were also made in accordance with those shown in Table II and the accompanying description. A comparison of the preform strength of Example 9 with the preform strength from Example I (see Table II) indicate again that the most preferred process is capable of yielding a considerably stronger preform than the preform obtained by the process utilized in Example 1.
|
An improved fibrous polyacrylonitrile mixture for use in friction products enables the production of low resiliency preforms by mixing an additive with a polyacrylonitrile wet gel. The additive is incorporated into the fiber in extremely large amounts. The additive is a member selected from the group consisting of:
(a) polyethylene glycol esters of pelargonic acid; or
(b) polyethylene glycol esters of enanthic, caprylic or capric acids; or
(c) blends of polyethylene glycol esters of enanthic, caprylic, pelargonic, or capric acids; or
(d) blends of polyethylene glycol esters of carboxylic acids derived from natural products containing at least 50% by weight of carboxylic acids containing less than 14 carbon atoms; or
(e) reaction products of ethylene oxide and carboxylic acid amides wherein at least 70% of the acids from which the amide is derived contain between 16 and 20 carbon atoms.
| 3
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] Embodiments of the invention described herein pertain to the field of pest management and the monitoring of pest populations. More particularly, but not by way of limitation, one or more embodiments of the invention enable an easily disassembled navel orangeworm egg trap to facilitate cleaning, inspection, maintenance, reloading, and repair.
[0003] 2. Description of the Related Art
[0004] Navel orangeworm are the primary pest of pistachios and almonds and are a serious pest of walnuts. The larvae and pupae of navel orangeworm overwinter in old nuts left on the trees or on the ground after harvesting. The adults emerge in the spring, and the female adults lay their eggs on the nuts remaining on the trees or on twigs close to the old nuts. When the eggs hatch, the larvae of the navel orangeworm crawl to the inside of the nut and dig into the kernel of the nut. Navel orangeworm causes damage by feeding on nut kernels and increase processing costs.
[0005] Monitoring the population of navel orangeworm is a critical part of a pest management program. Accurate predictions of navel orangeworm populations are necessary for timing insecticide sprays to maximize the control of the larvae. Accurate timing is particularly important for modern insecticides which are effective for shorter periods of time.
[0006] The navel orangeworm egg trap is the primary tool nut growers use to monitor and control navel orangeworm populations. A conventional navel orangeworm egg trap typically is a narrow plastic vial with screened vents near the center of the vial. The vial is filled with an ovipositional bait attractant which draws the female navel orangeworm. Two end-caps attach to the ends of the plastic vial to seal the contents of the vial.
[0007] Orchard workers place the navel orangeworm egg traps on tree branches throughout an orchard. Volatile compounds from the ovipositional bait attractant escapes through the vents of the egg traps, which lures the female navel orangeworm to the egg traps. The female navel orangeworm lay their eggs on the grooved sections of the trap. Workers routinely examine the egg traps and count and record the number of eggs laid on each egg trap. Workers then remove the eggs from each egg trap and return the egg traps to the tree branches. The egg count information is analyzed over time to provide growers with an estimation of the total navel orangeworm population in the orchard. Alternatively, workers can monitor the development of the eggs laid on the trap. This population information enables growers to accurately manage pest control activities such as determining the time to apply insecticides.
[0008] One drawback of the commercially available traps is that they may be difficult to inspect, clean, and repair. Periodically, workers in the field are required to replace the attractant material and clean the navel orangeworm trap. Workers may remove the two end-caps from the trap, and then push the remaining attractant out of the trap. Inspection of the egg trap may be rendered difficult as the narrowness of the vial provides the workers with only an oblique view of the inner surfaces of the trap. Cleaning may be problematic as damage to the screens may result if workers attempt to aggressively clean the egg trap. Repair to the screens may also be difficult as workers are unable to directly access the inner surfaces of the trap. This inability to clearly see and directly access the inner surfaces of the vials may make inspection, cleaning, and repair problematic and time consuming.
[0009] For at least the limitations described above, there is a need for a navel orangeworm egg trap that easily disassembles for easy inspection, cleaning and repair.
BRIEF SUMMARY OF THE INVENTION
[0010] One or more embodiments of the invention enable an easily disassembled navel orangeworm egg trap. One or more embodiments of the invention enable orchard workers in the field to easily disassemble, clean, refill the ovipositional bait attractant, and reassemble navel orangeworm egg traps. In one or more embodiments of the invention, the navel orangeworm egg trap may have two half-tubular sections that have a half-circle cross section. The two half-tubular sections may attach to each other through the use of multiple pins and blind-holes. Ovipositional bait attractant material that lures female navel orangeworms to lay their eggs on the egg trap may be placed within the attached half-tubular sections. The half-tubular sections may have multiple vents that allow the volatile compounds of the bait attractant to be released into the surrounding air. The outer surfaces of the half-tubular sections may have grooves to replicate the topography of a splitting hull or nut shell that encourages the female navel orangeworm to lay her eggs on this surface. The top and bottom of the connected half-tubular sections are enclosed with two end-caps that seal the attractant material inside the trap. The top end-cap may be attached to a hanger that allows the navel orangeworm egg trap to be hung from a tree branch in an orchard. Egg traps may be examined periodically for the number of eggs laid on the grooved surfaces and the development stages of the eggs to determine the overall population and development stages of navel orangeworm in the orchard and to accurately time the application of insecticides.
[0011] In one or more sections of a chamber may be detachably coupled to form a chamber that holds an attractant but allows the volatile compounds of the attractant to permeate the environment where the trees are grown. These sections of the chamber may disassemble to expose the inner surfaces of the chamber for easy cleaning, inspection, and repair. In one or more embodiments of the invention, the outer surfaces of the chamber may have a surface topography on which female navel orangeworm may lay their eggs.
[0012] In one or more embodiments of the invention, a plurality of chamber sections may be detachably connected along a longitudinal axis to form a trap chamber. A multi-dimensional surface topography may be formed on some portion of the outer surface of at least one of these chamber sections. At least one vent may be fixedly coupled to at least one of the chamber sections which permits air to pass through the chamber section. The trap chamber may be configured to contain a bait attractant. The vent allows the volatile compounds from the bait attractant to escape from the trap chamber. In one or more embodiments of the invention, a hanger may be coupled to the trap chamber so that the trap chamber may be supported by a physical structure.
[0013] In one or more embodiments of the invention, orchard workers may periodically clean the navel orangeworm egg traps and place new attractant into the egg traps. A worker may remove the egg trap from the tree, and may disassemble the two end-caps from the chamber of the trap. The chamber may further disassemble into the two chamber sections. The worker may remove the attractant from the chamber sections and clean the exposed inner surfaces of the chamber sections with a brush. The worker may be able to inspect the vents, the screening materials, and the entire inner surface of the chamber sections.
[0014] In one or more embodiments of the invention, workers may be able to repair the egg traps. Workers may be able to replace the screening material, reattach the screening material, repair the means through which the chamber section are detachably coupled, and repair damage to the integrity of the egg trap.
[0015] In one or more embodiments of the invention, the chamber may have more than two chamber sections. In one or more embodiments of the invention, the chamber sections may be of any shape. In one or more embodiments of the invention, the chamber sections may be coupled to the other chamber sections with hinges that enable the chamber sections to disassemble and lay flat for easy cleaning and re-assembly.
[0016] In one or more embodiments of the invention, the multiple chamber sections may be formed out of a single piece of semi-flexible material. Workers may be able to open up the chambers by bending back one chamber section with respect to another. After cleaning and inspection, the workers may close the chamber sections back onto the adjacent chamber sections. In one or more embodiments of the invention, the chambers may be made of plastic or soft metals.
[0017] In one or more embodiments of the invention, the vents may be formed by a series of small holes or perforations in the chamber sections that are sufficiently small to prevent the solid attractant from escaping from the trap. The vents may be formed by holes upon which a meshed screening material is secured. The screening material may be made out of wire-mesh, polyester screening, or any other material that enables volatile compounds to escape to the surrounding environment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above and other aspects, features and advantages of the invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
[0019] FIG. 1 presents an exploded view of an embodiment of the invention.
[0020] FIG. 2 presents a view of an embodiment of the invention that is fully assembled.
[0021] FIG. 3 presents a view of an embodiment of the invention illustrating detachable chamber sections couple using a hinge.
[0022] FIG. 4 presents a view of an embodiment of the invention in which the chamber sections are formed out of a single piece of material.
[0023] FIG. 5 presents one or more embodiments of the invention that has a tongue and groove structure to detachably couple the chamber sections.
[0024] FIGS. 6A and 6B present one or more embodiments in which the chamber sections are marked with surface features.
DETAILED DESCRIPTION
[0025] An easily disassembled navel orangeworm egg trap will now be described. In the following exemplary description, numerous specific details are set forth in order to provide a more thorough understanding of embodiments of the invention. It will be apparent, however, to an artisan of ordinary skill, that the present invention may be practiced without incorporating all aspects of the specific details described herein. In other instances, specific features, quantities, or measurements well known to those of ordinary skill in the art have not been described in detail so as not to obscure the invention. Readers should note that, although examples of the invention are set forth herein, the claims, and the full scope of any equivalents, are what define the metes and bounds of the invention.
[0026] FIG. 1 presents an exploded view of an embodiment of the navel orangeworm egg trap apparatus, while FIG. 2 presents a view of one or more embodiments of the assembled egg trap. In one or more embodiments of the invention, an ovipositional bait attractant is placed within the inner volume of the chamber formed by first half tubular section 110 , second half tubular section 111 , top end-cap 160 , and bottom end-cap 161 . The ovipositional bait attractant may lure female navel orangeworm to lay their eggs on the egg trap. In one or more embodiments of the invention, a first half tubular section 110 may have a plurality of vents 130 and 133 . Second half tubular section 111 may have a plurality of vents 131 and 132 . In one or more embodiments of the invention, vents 130 , 131 , 132 , and 133 allow the volatile compounds of the attractant to permeate the air near where the trees are grown. Vents 130 , 131 , and 132 may be a series of openings that are sufficiently small to prevent the attractant from leaking out of the trap, or prevent an insect or animal from reaching or feeding on the attractant material. In one or more embodiments of the invention, a screened mesh may be secured behind or in front of the vent openings. The screening material may be made out of metal, fiber, plastic, wire, polyester screening, or any other material that enables volatile compounds to escape to the surrounding air.
[0027] The ovipositional bait attractant releases volatile odors which lure female navel orangeworms to lay their eggs on the trap hosts. Ovipositional bait attractant may consist of a meal in the form of chicken feed, ground corn, rolled oats, or ground nuts. Almond oils, almond extracts, glycerol, and other substances may be added to the meal to aid in the effectiveness of the ovipositional bait attractant.
[0028] Surface topographies 121 and 122 are formed on an outer surface of the first half tubular section 110 , and surface topographies 122 and 123 may be formed on an outer surface of the second half tubular section 111 . In one or more embodiments of the invention, the surface topographies 120 - 123 may simulate a surface where the navel orangeworm might preferably lay eggs. For example the surface topography may take the form of a crosshatch pattern or grooves that replicate a hull or shell split. In one or more embodiments of the invention, the grooves may be formed through an injection molding process, through a machining or milling process, through an etching process, through an engraving process, or through any process that results in a series of grooves on the surface. In one or more embodiments of the invention, the grooves may be nearly horizontal. In one or more embodiments of the invention, the grooves may be vertical. In one or more embodiments of the invention, one or more surfaces of the first half tubular section 110 and second half tubular section 111 and end-caps 160 and 161 may have crosshatch markings. In one or more embodiments of the invention, one or more of the end-caps 160 and 161 may have grooves or crosshatch marks on their surfaces. In one or more embodiments of the invention, the grooves or crosshatch marks are on a surface other than first half tubular section 110 and second half tubular section 111 .
[0029] In one or more embodiments of the invention, the first half tubular section 111 is detachably coupled along the length or longitudinal axis to second half tubular section 111 to form a chamber. In one or more embodiments of the invention, the detachable coupling of first half tubular section 110 and second half tubular section 111 may be through the use of pins 140 - 143 (shown) and blind-holes 150 - 153 (not shown) respectively, and pins 144 and 145 (shown) and pins 146 and 147 (not shown) with blind hole 154 (shown) and blind-holes 155 - 157 (not shown). First half tubular section 110 and second half tubular section 111 are detachably coupled as the blind holes 150 - 157 receive the pins 140 - 147 . The diameter of the blind holes 150 - 157 and the pins 140 - 147 may be such that first half tubular section 110 and second half tubular section 111 remains coupled for the ordinary use of the egg trap but may be decoupled for cleaning, inspection, and repair. In one or more embodiments of the invention, first half tubular section 110 and second half tubular section 111 may attach using a tongue-in-groove, hinges, mechanical fasteners, tape, elastic bands, or any other attachment means that provide a detachable coupling.
[0030] In one or more embodiments of the invention, and a bottom end-cap 161 may seal a bottom end of the said chamber formed by first half tubular section 110 coupled to second half tubular section 111 . In one or more embodiments of the invention, a bait attractant may be placed within the chamber formed by first half tubular section 110 , second half tubular section 111 , and bottom end-cap 161 . Top end-cap 160 may seal the top end of said chamber formed by first half tubular section 110 , second half tubular section 111 , and bottom end-cap 161 . The end-caps 160 and 161 may attach to the chamber formed by first half tubular section 110 and second half tubular section 111 through a compression fit, threads, tape, a mechanical fastener, an elastic band, or any other attachment method that provides for a detachable coupling.
[0031] In one or more embodiments of the invention, hanger 170 may be coupled to the top end-cap 160 which supports the chamber from a physical structure. Hanger 170 may be attached to end-cap 160 which enable the entire egg trap apparatus to be hung from tree branches or other physical structures. In one or more embodiments of the invention, the hanger may be made of plastic, metal, carbon fiber, cardboard, fiberglass, or any other durable material. In one or more embodiments of the invention, the hanger 170 and the top end-cap 160 may form a one-piece assembly. In one or more embodiments of the invention, hanger 170 and top end-cap may be formed through an injection molding process or through a machining or milling process.
[0032] In one or more embodiments of the invention, first half tubular section 110 and second half tubular section 111 and end-caps 160 and 161 may be formed in plastic, metal, carbon fiber, cardboard, fiberglass, or any other durable material. In one or more embodiments of the invention, first half tubular section 110 and second half tubular section 111 may be formed through the means of an injection molding process, a machining or milling process, or through an assembly process.
[0033] In one or more embodiments of the invention, first half tubular section 110 and second half tubular section 111 , and the end-caps 160 and 161 may be painted or covered with a material that has a dark and less-reflective color. In one or more embodiments of the invention, first half tubular section 110 and second half tubular section 1 , and the end-caps 160 and 161 may be formed out of a material with a dark and less-reflective material. Examples of a suitable dark color may include black, dark green, dark blue, dark brown, and dark indigo.
[0034] FIG. 3 is a view of one or more embodiments of the invention. In one or more embodiments of the invention, separate end-caps may be rendered unnecessary as chamber sections 310 and 311 are formed to include a top and bottom surface perpendicular to the length or longitudinal axis of the chamber sections 310 and 311 . In one or more embodiments of the invention, a bait attractant may be placed within the inner volume of chamber sections 310 and 311 . In one or more embodiments of the invention, chamber sections 310 and 311 may be formed by an injection molding process or by a machining and milling process. In one or more embodiments of the invention, hanger 370 may be coupled to chamber section 310 . In one or more embodiments of the invention, hanger 370 and chamber section 310 may be one piece. In one or more embodiments of the invention, the one-piece unit of hanger 370 and chamber section 310 may be formed by an injection molding process or by a machining and milling process.
[0035] In one or more embodiments of the invention, chamber sections 310 and 311 may be coupled together with a hinge 380 that runs along the length or longitudinal axis of the chamber sections 310 and 311 . The use of a hinge 380 may enable an orchard worker in the field to easily re-assemble the navel orangeworm egg trap as pins 340 - 343 and blind-holes 350 - 353 may be automatically aligned as the chamber section 310 folds over and on top of chamber section 311 . In one or more embodiments of the invention, the chamber may have more than 2 chamber sections, where each chamber section is coupled to the adjacent chamber section through the use of hinges.
[0036] In one or more embodiments of the invention, a second hinge forms another detachable coupling between chamber sections 310 and 311 and replaces the detachable coupling mechanism provided by the pins 340 - 343 and blind-holes 350 - 353 . In this configuration, a worker in the field may remove the pin from one of the hinges and opens up the chamber assembly about the other hinges. After cleaning and replacement of the attractant material, the worker may close the chamber sections together and replaces the pin in the hinge.
[0037] In one or more embodiments of the invention, vents 330 - 333 may be formed in the chamber sections 310 and 311 . In one or more embodiments of the invention, vents 330 - 333 may be in the form of a series of small holes or perforations that allow for ventilation but otherwise contains the attractant material. In one or more embodiments of the invention, the vents may also be larger holes with a screen mesh attached to the chamber sections 310 and 311 .
[0038] FIG. 4 is a view of an embodiment in which the chamber sections are formed out of a single piece. This approach potentially offers lower manufacturing costs. In one or more embodiments of the invention, chamber 410 may have an upper half-shell 411 and a lower half-shell 412 that is configured to couple detachably with each other. The inner surfaces of upper half-shell 411 and lower half-shell 412 may be configured to hold a bait attractant material, and chamber 410 is configured to release the volatile compounds of said attractant though vents 430 - 435 . Surface topographies 420 and 421 may be in the form of horizontal groove. Chamber 410 may be in the form of a cylinder that has a length that is parallel to the axis of the intersection of upper half-shell 411 and lower half-shell 412 . Chamber 410 is configured to disassemble along the length of the upper half-shell 411 and lower half-shell 412 .
[0039] In one or more embodiments of the invention, upper half-shell 411 and lower half-shell 412 may open up to expose the inner surfaces for cleaning, repair, and inspection. In one or more embodiments of the invention, the area where the upper chamber and the lower chamber meet effectively forms a hinge so that the upper and chambers automatically align when the chamber 410 is closed. In one or more embodiments of the invention, the upper and lower sections of chamber 410 may close through any means for detachably coupling the two sections including pins and blind-holes, tongue and grooves, hinges, tape, or mechanical fasteners for example.
[0040] In one or more embodiments, chamber 410 may be made out of a semi-flexible plastic such as polyethylene, polypropylene, nylon, flexible PVC, or out of rubber. Any type of flexible material is in keeping in spirit with the spirit of the invention. In one or more embodiments of the invention, chamber 410 may be formed through an injection molding process, through a stamping process, through a machining or milling process, or through a melting or fastening process.
[0041] In one or more embodiments of the invention, vents 430 - 435 may be formed to allow the volatile compounds of the bait attractant to escape to the surrounding environment. A plurality of grooves 420 and 421 may be formed on chamber 410 to encourage navel orangeworm to lay their eggs on these grooves. Hanger 470 is coupled to chamber 410 to enable chamber 410 to be hung from tree branches.
[0042] FIG. 5 presents one or more embodiments of the invention that may have a tongue 540 and groove 550 as the means for detachably coupling chamber section 510 to chamber section 511 . In one or more embodiments of the invention, a bait attractant may be placed within the inner volume of chamber section 510 and chamber section 511 . In one or more embodiments of the invention, the tongue 540 and groove 550 may be formed through an injection molding process, or through a milling or machining process. Chamber section 510 may rotate about hinge 580 so that the tongue 540 is automatically aligned with groove 550 . Vents 530 - 533 may allow the bait attractant to permeate the surrounding environment. Hanger 570 enables one or more embodiments of the invention to be hung from tree branches or other physical structures.
[0043] FIGS. 6A and 6B present one or more embodiments in which the chamber sections 610 and 610 may be marked with surface features 620 and 621 , and 622 and 623 respectively. FIG. 6A presents one or more embodiments in which the surfaces 620 - 623 may have grooves or ridges in a vertical or nearly vertical orientation. FIG. 6A presents one or more embodiments of the invention in which the outer surfaces of other the top and or bottom end-cap may be marked with a cross-hatch of grooves or ridges. FIG. 6B presents one or more embodiments of the invention in which the surfaces 620 - 623 are marked with a cross-hatch pattern of grooves or ridges. FIG. 6B presents an embodiment of the invention in which the top and or bottom end-cap 660 and 661 respectively are marked with a plurality of grooves or ridges. Any combination or orientation of grooves, ridges, cross-hatch patterns, or any other two dimensional surface topography that will simulate the splitting of a nutshell or is otherwise attractive to a female navel orangeworm is in keeping with the spirit of the invention. In one or more embodiments of the invention, the grooves may be formed through an injection molding process, through a machining or milling process, through an etching process, through an engraving process, or through any process that results in a series of grooves on the surface. Vents 630 - 632 allow the volatile compounds of the bait attractant to permeate the surrounding environment, which lures female orangeworms to lay their eggs on the surface topography. Hanger 670 enables one or more embodiments of the invention to be hung from a tree branch or other physical structure.
[0044] While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.
|
An easily disassembled navel orangeworm egg trap apparatus which facilitates easy cleaning, inspection, maintenance, reloading, and repair. One or more embodiments of the invention enable orchard workers in the field to easily disassemble a navel orangeworm egg trap for cleaning, inspection, and repair. In one or more embodiments of the invention, at least one chamber section that is detachably coupled along the length of the chamber section. The chamber disassembles along the length of the chamber sections, thus exposing the inner surfaces of the ovipositional bait attractant chamber. By offering an easily disassembled chamber that exposes the inner surface, navel orangeworm egg traps are easily cleaned and repaired in the field.
| 0
|
TECHNICAL FIELD
This invention relates to flow valves for control of fluids through a conduit and more particularly it relates to a fluid flow responsive device for automatically correcting an excessive flow condition through a conduit.
BACKGROUND ART
Flow regulation and safety valves of various sorts are known in the art for flow regulation of fluids such as gases and liquids. The following U.S. patents are representative of the state of this art.
______________________________________4,141,380 - Feb. 27, 1979 Lenk3,996,961 - Dec. 14, 1976 Siegwart3,973,410 - Aug. 10, 1976 Putman et al.3,965,928 - June 29, 1976 Siegwart3,841,350 - Oct. 15, 1974 Griensteidl et al.2,131,025 - Sept. 27, 1938 Danel______________________________________
This prior art, however, has a significant deficiency in that the valves when inserted into a fluid flow path greatly disturb the flow pattern causing significant turbulence and flow losses because they present a substantial cross section in the flow path or require special orifices or flow contortions in their operation.
It is therefore an object of this invention to provide improved flow regulation safety valve means operable in response to fluid flow without introducing significant losses or turbulence into the routine normal fluid flow path.
BRIEF DISCLOSURE OF THE INVENTION
This invention provides a safety flow valve to automtically shut off fluid gas or liquid flow through a conduit flow path when the flow rate increases beyond a predetermined threshold as might occur, for example, if a pipe were broken and leakage caused an increase in flow beyond normal expected maximum flow rates.
The valve mechanism for achieving this is not only simple and inexpensive but is substantially fool-proof and offers very little resistance or turbulence to normal flow rates through the conduit.
Thus, a substantially flat plate having eccentric off center pivot mounts is positioned parallel to the fluid flow path so that it can be turned by an appropriate turning moment into a position substantially normal to the flow path thereby deterring flow. The turning moment is supplied by fluid flow on a fluo-dynamic valve surface similar to an airplane wing lift surface when the flow rate exceeds a predetermined threshold such as may be established for example by counter rotational bias of a threshold spring setting.
Further objects, features and advantages of the invention will be found throughout the following description made with reference to the accompanying drawing.
DESCRIPTION OF THE DRAWINGS
In the drawing:
FIGS. 1 and 2 are respective broken away side and end views, partly in section of a fluid conduit pipe and the associated safety valve as provided in accordance with this invention;
FIG. 3 is a diagrammatic sketch of a water pipe or the like illustrating catastrophic failure conditions where the safety valve comes into play;
FIGS. 4A, 4B and 4C are diagrammatic sketches illustrating operation conditions affecting the safety valve in various pivot positions;
FIG. 5 is a diagrammatic sketch of a counterrotational biasing spring embodiment permitting selection of a variable predetermined flow threshold; and
FIG. 6 is an end view, partly in section of a further embodiment of the safety valve structure afforded by this invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Throughout the various views of the drawing, like reference characters refer to similar features to facilitate comparison. Primed reference characters indicate variations of basic elements.
As may be seen in FIGS. 1 and 2 a fluid conduit, in this embodiment cylindrical pipe 10, typically plastic or metallic, has flowing therein a fluid gas or liquid such as air or water in the general axial flow path represented by arrows 12.
The substantially flat valve plate member 14 is pivoted eccentrically on pivot pins 16, 18 to move between a normal flow rate position parallel to the axial direction of flow as shown in solid lines and a pipe closure position perpendicular to the axial direction of flow as shown by phantom lines 20 which thereby retards or stops flow out of pipe exit 21. An appropriate elastic sealing ring 22 may be used if a sealing relationship is desired upon operation of the safety valve into the retard position.
The operation of the safety valve member 14 is bistable in nature. Thus, it rests in either the axial or flow state parallel to flow or the flow retarding state perpendicular to the flow axis as shown by phantom lines 20. The transition from flow state to retarding state is automatic in response to the rate of flow within the conduit pipe 20. Thus, as seen from FIG. 3 if a water pipe 10 is accidental and catastrophically cut as at 25 to release the full capacity of flow at 27 then the rate of flow will increase enough to move safety valve 14 to the flow retardation state shown to prevent further loss of water from the pipe. By similar action air or gas flow is also protected.
The valve 14 effects this as a result of fluodynamic surface structure 30. This construction is similar to an airplane wing which passes the fluid flow over the plate (wing) with little resistance and turbulence as evidenced in FIG. 4A, but provides a lift or in the case of the valve a turning moment indicated by arrow 31.
By biasing means such as a counter-rotation threshold spring, the valve is held parallel to the flow at expected normal flow rates as in FIG. 4A. However, at flow rates exceeding this threshold the turning moment 31 is effective to overcome the bias and rotate valve 14 on its eccentric pivot axis 18 as shown in FIG. 4B.
When this occurs the upstream face of the plate valve member 14 confronts the flowing fluid and develops a further and substantial supplemental force increasing the turning moment. Because of the eccentric mount, a greater force will be exerted on the greater area of upstream plate surface 40 exposed below the pivot axis 18 as shown in FIG. 4B than will be exerted on the area of upstream plate surface 42 above the pivot axis 18. This causes a rapid snap action closure to the perpendicular to flow axis state shown in FIG. 4C where flow is stopped and the fluid 44 is restrained from flowing past valve plate 14.
The counterrotational bias force may be applied in the manner sketched by FIG. 5, wherein a screwdriver slot 50, as shown also in FIG. 1, may carry one end of a spiral bias spring 52 affixed at the other end 53 to the pipe 10. If the pin (which might be pivot pin 18) is frictionally held the screwdriver slot 50 can rotate the spiral spring body to increase or decrease bias and thus set the threshold level that need be overcome before the valve plate can be rotated by the fluid flow. A pointer 54 may be provided if desired with a calibrated dial 55.
While it is to be recognized that the above discussed embodiment operates in the spirit of the invention, it is also to be recognized that certain variations might be desirable in various operating conditions. Accordingly, reference to FIG. 6 shows several alternative features, including a rectangular shaped conduit pipe 10'.
The principle of operation remains similar as to the bistable states and the turning moments. However, it is sometimes permissible or desirable merely to retard excessive flow without full stoppage of flow as depicted in FIG. 4C. Thus, a margin 60 about plate 14' permits some fluid to flow past the valve plate 14 when in a flow retardation state perpendicular to the axis of flow. Also a spring loaded vent closure 62 can serve this purpose. Similarly it is clear that the plate 14 need not be disposed perpendicular to flow since it can be stopped short of a full 90° angle and yet otherwise retard the flow in the manner aforesaid. Stops such as the dimensions of the plate and piping then can intercept the valve plate short of the full 90° swing required to rest in a substantially normal position. Other such variations are feasible and sometimes desirable.
Having therefore set forth those features and embodiments representative of the invention, those features of novelty believed descriptive of the spirit and nature of the invention are set forth with particularity in the appended claims.
INDUSTRIAL APPLICATION
An automatic flow regulator responsive to gas or liquid fluid flow in a conduit above normal, as caused for example by catastrophic failure when the conduit bursts, serves to limit or stop the flow automatically. The flow regulator comprises an inexpensive and simple valve which under normal flow conditions does not significantly retard flow or introduce turbulence.
|
An automatic safety flow valve for fluid gas or liquid conveying conduits has a fluo-dynamically surface substantially flat plate eccentrically pivoted to turn in response to fluid flow rates above a normal threshold from a position substantially parallel to the flow path to a position retarding or stopping the flow.
| 8
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application 60/490357, filed Jul. 28, 2004.
BACKGROUND OF THE INVENTION
[0002] This invention relates to apparatus for conditioning or treating water that is believed to improve the quality of water used in supporting life.
SUMMARY OF THE INVENTION
[0003] Applicant believes that the crystalline structure of water is varied as it flows through the apparatus of the invention and thereby improves its life supporting and other qualities. The apparatus includes two fittings having bifurcated legs, for example Y-shaped fittings with a longitudinally elongated conductive metal rod extended therebetween and a pair of elongated vortexian spiral tubes symmetrically positioned around the rod with each tube having seven helical circular loops extending in fluid conducting relationship to the respective legs of the fittings. The tubes are mounted in overlaying relationship with the loops of each tube overlaying loops of the same size as those of the other tube and the loops of one tube being would in clockwise direction and those of the other tube in a counterclockwise direction. Advantageously the area encompassed by the loops of each tube in the direction from one fitting to the other is 1:1:2:3:5:8:13.
BRIEF DISCRIPTION OF DRAWINGS
[0004] FIG. 1 is a perspective view of the first embodiment of the invention;
[0005] FIG. 2 is an exploited view of the first embodiment of the invention;
[0006] FIG. 3 is a longitudinal, enlarged fragmentary view that is generally taken along the line and in the direction of the arrows 3 - 3 of FIG. 1 with the spacing of the loops from the rod being exaggerated;
[0007] FIG. 4 is a longitudinal enlarged fragmentary view that is generally taken along the line and in the direction of the arrows 4 - 4 of FIG. 1 with the spacing of the loops from the rod being exaggerated;
[0008] FIG. 5 is an enlarged cross sectional view of one of the Y-fittings of the first embodiment;
[0009] FIG. 6 is a transverse cross section view that is generally taken along the line and in the direction of the arrows 6 - 6 of FIG. 1 ; and
[0010] FIG. 7 is a fragmentary view of the second embodiment of the fittings and adjacent ends of the tubes that are connected thereto and the intermediate part of the rod connecting the fittings being broken away.
DETAILED DESCRIPTION OF THE INVENTION
[0011] The water treatment apparatus of the first embodiment of this invention includes a longitudinally elongated, solid rod 25 made of an electrically conductive metal, advantageously stainless steel. One end of the rod mounts a Y-fitting 28 and at the opposite end mounts a Y-fitting 44 . The fitting 28 includes a main leg 28 A that is fluidly connectable to a member 24 and bifurcated legs 28 B, 28 C that diverge in opposite directions at equal angles from the central axis of the main leg. The transverse cross sectional, fluid flow conducting area of leg 28 A is twice that of each of legs 28 B, 28 C. Similarly the fitting 44 includes a main leg 44 A that is fluidly connectable to a member 23 and bifurcated legs 44 B, 44 C with the cross sectional fluid flow conducting area of leg 44 A being twice that of each of legs 44 B, 44 C.
[0012] Fluidly connected to and extending between the legs 28 A, 44 A is an elongated, conductive metal tube X. The tube X in extending from leg 28 A to leg 44 A is bent to have several, substantial circular helix loops 30 , 32 , 34 , 37 , 39 , 40 , 42 that are coiled in a clockwise direction with the rod 25 extending through each of these loops. As viewed in plan view (the apparatus being supported on a horizontal surface with the rod being parallel to the surface), each of the loops includes a generally semicircular part designated with A as the last part of the reference number for each of the loops that extends below the rod and a second general semicircular part designated with the letter B as the last part of the reference number for each of the loops that extends above the rod. Desirably the ratio of the areas encompassed in the helical circular loops in a direction from loop 42 to loop 30 is 1:1:2:3:5:8:13.
[0013] Each of the semicircular parts of each of the loops 30 , 32 , 34 , 37 , 39 , 40 , 42 that in part includes the letter B as part of its reference number has one end fluidly connected to the one end of the respective semicircular part that in part includes the letter A. The tube X includes a first end portion 29 that has one end fluidly connected to fitting leg 28 B and the opposite (other) end fluidly connected to the other end of loop 30 A. The other end of loop portion 30 B is fluidly connected to the other end of loop portion 32 A by a generally linear tube portion 31 . Likewise, the generally linear tube portion 33 fluidly connects the other end of loop portion 32 B to the other end of loop portion 34 A, the generally linear tube portion 35 fluidly connects the other end of loop portion 34 B to the other end of loop portion 37 A, the generally linear tube portion 38 fluidly connects the other end of loop portion 37 B to the other end of loop portion 39 A, the generally linear tube portion 45 fluidly connects the other end of loop portion 39 B to the other end of loop portion 40 A and the generally linear tube portion 41 fluidly connects the other end of loop portion 40 B to the other end of loop portion 42 A. The other end of loop portion 42 B is fluidly connected to fitting leg 44 A by the opposite end portion 43 of the tube X.
[0014] Fluidly connected to and extending between the legs 28 C, 44 C is an elongated, metal tube Y. The tube Y in extending from leg 28 A to leg 44 A is bent to have several, substantial circular helix loops 52 , 54 , 57 , 59 , 72 , 74 , 77 that are coiled in a counterclockwise direction with the rod 25 extending through each of these loops. As viewed in plan view, each of the loops of tube Y includes a generally semicircular part designated with A as the last part of the reference number for each of the loops that extends below the rod and a second general semicircular part designated with the letter B as the last part of the reference number for each of the loops that extends above the rod. Desirably the ratio of the areas of the loops in a direction from loop 77 to loop 52 is 1:1:2:3:5:8:13.
[0015] Each of the semicircular parts of each of the loops 52 , 54 , 57 , 59 , 72 , 74 , 77 that in part includes the letter A as part of its reference number has one end fluidly connected to one end of the respective semicircular part that in part includes the letter B. The tube Y includes an end portion 51 that has one end fluidly connected to leg 28 C and an opposite end portion fluidly connected to other end of loop 52 A. The other end of the loop portion 52 B is fluidly connected to the other end of loop portion 54 A by a generally linear tube portion 53 . Likewise, the generally linear tube portion 55 fluidly connects the other end of loop portion 54 B to the other end of loop portion 57 A, the generally linear tube portion 58 fluidly connects the other end of loop portion 57 B to the other end of loop portion 59 A, the generally linear tube portion 71 fluidly connects the other end of loop portion 59 B to the other end of loop portion 72 A, the generally linear tube portion 73 fluidly connects the other end of loop portion 72 B to the other end of loop portion 74 B and the generally linear tube portion 75 fluidly connects the other end of loop portion 74 B to the other end of loop portion 77 A. The other end of loop portion 77 B is fluidly connected to fitting leg 44 C by the opposite end portion 50 of the tube Y.
[0016] The length of each of the tube linear section is about the same of the combined radii of the loops that it is connected to. For example, the length of the linear section 31 is advantageously substantially the same as the combination of the outer radii of the loops 30 and 32 while the length of the linear section 58 is advantageously substantially the same as the combination of the outer radii of the loops 57 and 59 . Through the provisions of the linear sections, the loops of each tube are connected in series between the fittings.
[0017] The tubes X and Y are of the same electrically conductive metal and may be made of stainless steel or copper and may or may not have their inner and outer surfaces coated with other conductive metals. The pair of tube X and Y are of the same size and shape other than one has its loops bent clockwise and the other has its loops bent counterclockwise whereby the linear sections of one tube are on the transverse opposite side of the rod 25 from the linear sections of the other tube. Thus, the tubes are mirror images of one another with the linear sections being on transverse opposite sides of the rod with the loops of one tube substantially overlaying the loops of the same size of the other tube. Further, the rod passes through the central portion of each of the pair of loops.
[0018] In use the apparatus of the first embodiment of this invention, water may be supplied from a source 24 to flow through the fitting 28 -and tubes X and Y to the fitting 44 and thence to the receptacle 23 , or alternately from a source 23 to flow through the fitting 44 and tubes X and Y to fitting 28 and thence to receptacle 24 . Thus, regardless whether the water flow is from member 24 to member 23 , or from member 23 to member 24 , equal volumes of water flow through each of tubes X and Y at the same rate of flow. The water flowing through the tubes may be distilled water.
[0019] It is to be understood that the water treatment apparatus may include more than seven loops in each tube. If more than seven loops are included, the additional loops connected between the fitting 28 and the loops 30 , 52 with each of the additional loops of each tube being in a ratio that the ones connected to loops 30 , 52 and the fitting 28 being the sum of the last two ratios in the series (8 plus 13) of the preceding two loops and the second added loops being the sum of the two preceding loops (13 plus 21) in the series and so on for each additional pair of loops connected between the loops 30 , 52 and the fitting 28 . With the addition of more loops, the rod 25 would be of greater lengths and there would additional linear sections extending between loops 30 , 52 and the additional loops and portions 29 , 51 , the tubes X and Y being of greater lengths.
[0020] Referring to FIG. 7 , the second embodiment is the same as the first embodiment except that the fittings 70 , 71 respectively have their bifurcated legs 70 B, 70 C and 71 B, 71 C extending at substantially right angles to their respective main leg 70 A, 71 A in diametrically opposite directions relative to the main legs. Further, the end portions 74 , 77 of the tubes E and F are fluidly connected to the legs 70 C, 70 B respectively and the opposite end portions 75 , 78 are connected to legs 71 C, 71 B, the tube end portion are of lengths which may be slight different and bent slightly different-from the end portions 51 , 29 , 50 , 43 of the first embodiment in view of the bifurcated legs 28 C, 28 B, 44 C, 44 B of the first embodiment extend outwardly of the fitting main legs 28 A, 44 A at a different angles than the bifurcated legs of the fittings 70 , 71 extend away from their main legs 70 A, 71 B. Additionally, the rod 73 which corresponds to rod 25 and mounts the fittings 70 , 71 may be slightly shorter than rod 25 in that the end portions 74 , 77 that are connected to the largest diameter loops extend more nearly directly toward one another than having to converge toward the respective fitting such as shown for the first embodiment. This is also applicable to the end portions 75 , 78 of the tubes of the second embodiment that are connected to the smallest diameter loops and to the bifurcated legs of the fitting 71 . Accordingly, even though the loops of the second embodiment are of the same size and shape as those of the first embodiment, the longitudinally adjacent surfaces of the fittings 70 , 71 are slightly more closely adjacent one another than the juncture of ends of the rod 25 to the fittings 28 , 44 . Other than for the above differences of the end portions of the tubes E, F, the tubes E, F include loops and linear portions (not shown) that are the same size and shape as the corresponding parts of Y, X. Even though not shown, the end portions 74 , 77 are fluidly connected to larger diameter loops that correspond to loops 30 , 52 and the tube end portions 75 , 78 are fluidly connected to the smaller diameter loops that correspond to loops 42 , 77 .
[0021] In use the apparatus of the second embodiment of this invention water or other liquid may be supplied from a source 24 to flow through the fitting 70 and tubes E and F to the fitting 70 and thence to the receptacle 23 , or alternately from a source 23 to flow through the fitting 71 and tubes E and F to fitting 70 and thence to receptacle 24 . Thus, regardless whether the water flow is from member 24 to member 23 , or from member 23 to member 24 of the second embodiment, equal volumes of water flow through each of tubes E and F at the same rate of flow. The water flowing through the tubes may be distilled water.
EAMPLE
[0022] In order to ascertain the effects on a liquid passed through the second embodiment of the invention, measurements were made to ascertain various parameters of spring water (sample A), a quantity of the spring water that was the same as that of sample A was pumped to pass from member 24 to flow first through the large loops and subsequently to member 23 (sample B) and a quantity of the spring water that was the same as sample A was similarly pumped to pass from member 23 to flow first through the small loops and subsequently to member 24 . The total length of each of the tube E, F was approximately 12 feet. As Samples B and C, the flow rate through the tubes was approximately 1.75 gallons/minute and the pump pressure was approximately 58 psi. The inner diameter of each tube was approximately an eighth of an inch.
Density Surface Tension SAMPLE pH (g/mL) Specific Gravity (dynes/cm) A 6.60 0.997 1.000 69.2 B 6.81 0.997 1.000 59.8 C 6.94 0.997 1.000 67.2
[0023] Each sample was analyzed in five replicates for apparent surface tension. The average of the three best values, a gravity constant of 980.8 cm/sec 2 , an R/r value for the platinum ring of 53.6 and the sample density reported above were used to determine the correction factor calculating the true surface tension.
[0024] With lower surface tensions, is absorbed more easily through plant and animal cellular walls. Basically with lower surface tensions, the water is wetter and the water is absorbed easier through the cellular walls. As a result there can be better hydration of the cells. It also enhances the cellular waste exchange.
[0025] With a somewhat increase in the alkalinity of the water, there is provided an increased benefit to living cells.
[0026] Although it is preferred that the tubes be of conductive metal, it is to be understood they could be made of other materials. Also, even though it is preferred the liquid flowing through the tubes is water, it could be other types of fluids.
|
The water treatment apparatus includes a first fitting having a first leg adapted for being connected to a supply of fluid and a second fitting having a first leg adapted for being connected to a container for the treated fluid, an elongated rod having a first end mounting the first fitting and a second end mounting the second fitting, each fitting having bifurcated legs, and a first and a second vortexian spiral tube respectively connecting the first bifurcated legs of the fittings and the second bifurcated legs of the fittings. Each tube includes a plurality of loops and a plurality of linear sections serially connecting adjacent loops to one another. Where each tube includes seven loops, advantageously the area encompassed by the loops of each tube in the direction from one fitting to the other is 1:1:2:3:5:8:13.
| 2
|
FIELD OF THE INVENTION
The present invention relates to gas compressors. More particularly, the present invention relates to an oilless compressor with a sealed, pressurizable crankcase and motor containment vessel, suitable for compression of precious or toxic gases or combustible gases, such as natural gas.
BACKGROUND OF THE INVENTION
Reciprocating piston compressors typically employ piston rings as seals to reduce gas leakage during compression of a gas. Typically the seal is not perfect and, during the upstroke of the piston, some of the gas leaks from the cylinder chamber past the piston rings and into the crankcase. In the case of air compressors the leakage or blow-by gas is typically vented to the surrounding atmosphere from a ventilated crankcase without a significant adverse effect. In the case of precious, toxic or combustible gases, external leaks from the compressor are undesirable, and leakage gas is preferably recaptured.
Some conventional crankcases are sealed so that blow-by gas which leaks into the crankcase is ducted back to the cylinder intake valves. If the compressor is operated with the suction intake at an elevated pressure (relative to ambient), then the crankcase must be a pressurized crankcase, designed to operate and remain gas-tight at elevated internal pressures typically equal to or slightly greater than the suction pressure.
In conventional compressors, the drive motor is typically separate from the crankcase. Typically, the drive shaft for the compressor protrudes from the crankcase and may be directly coupled to the drive motor, or driven via a belt power transmission. The shaft protruding from the crankcase employs rotating shaft seals to prevent leakage of the gas being compressed and the lubrication oil from the crankcase. The crankcase typically acts as an oil reservoir. The oil provides lubrication and cooling for the main shaft bearings and connecting rod bearings. In addition, the rotating shaft seal is typically cooled and lubricated by the lubricating oil in the crankcase. Such lubricated, rotating shaft seals have demonstrated reliability and longevity even at crankcase pressures of 600 psig. However, with oil lubricated compressors small amounts of oil tend to become entrained or carried in the compressed gas stream discharged from the compressor.
For some applications, it may not be acceptable to have any oil present in the compressed gas stream delivered from the compressor. Such applications include food and medical applications. Also, in fuel cell power plants it is important that reactant streams delivered to the fuel cell stacks are not contaminated with traces of oil, as such impurities can cause damage to system components, in particular to the membrane electrode assemblies in solid polymer fuel cell stacks. Also, oil traces can adversely affect reactant processing equipment, such as for example reformation and selective oxidation apparatus and purification modules, through which the compressed gas stream is directed en route to the fuel cell stack. Thus, compression of reactant streams, such as for example natural gas, oxygen and hydrogen, for eventual downstream delivery to a fuel cell stack, should be accomplished without introducing traces of oil into the streams.
oilless compressors are known in which there is no oil anywhere in the compressor apparatus. Polytetrafluoroethylene piston rings, cast iron cylinders and greased and sealed roller bearings are typically employed in such compressors. However, unlubricated or dry running rotating shaft seals which operate reliably under pressurization without leakage are not readily available.
It is therefore desirable to provide an oilless gas compressor with a pressurizable crankcase and motor containment vessel, in which the need for perimeter rotating shaft seals is obviated.
SUMMARY OF THE INVENTION
An oilless gas compressor comprises:
a motor containment vessel containing a motor for driving the compressor, the motor comprising a stator and a rotor;
a crankcase attached to the motor containment vessel, the crankcase and the motor containment vessel fluidly connected and together defining a sealed, pressurizable interior cavity;
a shaft disposed entirely in the interior cavity, the shaft rotatable by the motor;
a cylinder mounted upon the crankcase, the cylinder comprising a piston, the piston connected to the shaft for reciprocation of the piston within the cylinder, the cylinder further comprising a gas intake valve and a gas discharge valve;
a suction inlet port fluidly connected to the gas intake valve; and
a discharge outlet port fluidly connected to the gas discharge valve.
In operation, there are preferably no exterior openings, rotating shaft seals or other dynamic seals at the perimeter of the oilless gas compressor which, particularly under pressure, could create a fluid connection between the interior cavity and the surrounding atmosphere resulting in leakage.
Optionally, the motor may further comprise a motor housing encasing the stator and the rotor, with the motor containment vessel of the compressor enclosing the motor housing.
In preferred embodiments of an oilless gas compressor, the interior cavity is pressurizable to a pressure greater than 5 psig.
In operation, the suction inlet port of the oilless gas compressor may be fluidly connected to a natural gas supply, wherein the natural gas supply is preferably at a pressure greater than 5 psig.
In some embodiments of an oilless gas compressor, the suction inlet port may be formed in the motor containment vessel. In such embodiments, the incoming suction gas may be used to cool the compressor motor. For example, the suction inlet port may be fluidly connected to the cylinder intake valve via a passage, a portion of the passage extending through the motor, for cooling the motor with gas entering the compressor at the suction inlet port.
In other embodiments of an oilless gas compressor, the suction inlet port may be formed in the crankcase.
In still further embodiments of an oilless gas compressor, the suction inlet port may be formed in the cylinder, with the compressor further comprising a bypass conduit for placing the interior cavity in fluid communication with the cylinder.
Preferably, the oilless gas compressor comprises a plurality of cylinders, such as, for example, a pair of opposed cylinders aligned along a common axis or in some other configuration, or three cylinders.
For cooling of the oilless gas compressor, which is typically required, the compressor may further comprise an externally mounted fan, located outside the interior cavity. In preferred cooling configurations, the fan may be driven by the same motor and shaft that drives the compressor via a magnetic coupling, or the fan may be driven by a second motor disposed outside the interior cavity. In addition, or alternatively, the one or more cylinders may comprise a cooling jacket for liquid cooling by a circulated coolant fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of an oilless reciprocating piston compressor with a sealed, pressurizable crankcase fluidly connected to a motor, wherein the motor housing acts as a pressurizable motor containment vessel.
FIG. 2 is a sectional view of an oilless reciprocating piston compressor with a sealed, pressurizable crankcase fluidly connected to a pressurizable motor containment vessel, wherein the motor is cooled by the incoming suction gas.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an oilless reciprocating piston compressor 10 with a crankcase 20. A rotary electric motor 25 (such as, for example, a C-face motor) comprising a stator 21 and a rotor 23, is contained in a motor housing 30, which, in the illustrated embodiment, acts as a pressurizable containment vessel for the motor. One face 32 of motor housing 30 is mounted across an opening 22 in crankcase 20 by means of two cooperating flanges 24 and 34, on the crankcase 20 and motor housing 30, respectively. Flanges 24 and 34 are bolted together with a gasket or O-ring seal 26 interposed therebetween to form a static seal between crankcase 20 and motor housing 30. The rotor 23 is mounted on a motor shaft 40, which protrudes from motor housing 30 and extends into the crankcase 20. The shaft 40 is supported by three bearings 41, 42 and 43. In isolation, motor housing 30 is fluid-tight under pressure except around the front bearings 42 which surround motor shaft 40. The interior volume of the crankcase 20 and the motor housing 30 are thus fluidly connected to each other via region around the front motor shaft bearings 42, together forming an interior cavity 35. Shaft 40 is contained entirely within the interior cavity 35. Because there is a static seal, between the crankcase 20 and the motor housing 30, which circumscribes the motor shaft 40, and in operation there are no exterior openings or rotating shaft seals at the perimeter of the compressor, the interior cavity 35 is fluidly isolated from the surrounding atmosphere. The motor housing 30 thus becomes an extension of the pressure containment structure of the crankcase 20. The crankcase 20 and motor housing 30 are designed to be pressurizable to differential pressures (relative to the surrounding atmosphere) of at least 5 psig, and preferably at least 10 psig. In the embodiment illustrated in FIG. 1 the crankcase 20 is approximately 0.75 inch thick steel, and the motor housing 30 is approximately 0.25 inch thick steel.
Three cylinders 50 are mounted on crankcase 20 (only two are shown in FIG. 1; the third is mounted orthogonal to the two shown). Each cylinder houses a piston 60 which is connected to motor shaft 40 via an eccentric bearing and connecting rod 62 so that rotation of the motor shaft 40 causes reciprocation of the pistons 60 in cylinders 50. Cylinders 50 are non-lubricated, and polytetrafluoroethylene piston rings 61 are employed.
The gas supply line 68 is connected to a gas supply (not shown), and is branched for connection to the suction inlet 70 at the head of each cylinder 50. The gas enters the compressor 10 at suction inlets 70 and enters the cylinders via cylinder intake valves 72 which are open during the downstroke of the pistons 60. The gas is compressed in the cylinder 50 on the upstroke and exits the cylinder at discharge outlet port 75 via discharge valve 74. Preferably, from the discharge outlet ports 75 the gas is directed to a pulsation damper or cushion chamber (not shown) which damps out pressure variations to provide more uniform flow in the pressurized gas supply. The interior cavity 35 is fluidly connected to the gas supply line 68 via bypass line 71, so that blow-by gas is ducted back to the cylinder intake valves 72.
The electrical connections to the motor 25 in the interior cavity 35 are made via hermetic seal 90.
In the embodiment illustrated in FIG. 1, a fan is 80 is mounted on the exterior of the crankcase. In operation the fan, which is driven by a dedicated motor 85, directs cooling air over the crankcase 20 and cylinders 50. The cylinders typically include fins 58 to facilitate cooling.
In another variation, the cylinders 50 could be cooled using liquid cooling jackets through which a coolant is circulated. The motor 25 may be a high temperature motor which does not require active cooling, or it too may be cooled, for example, by using a fan, blower or a liquid cooling jacket. A cover which fits over the compressor may be employed to direct the cooling air around any of the cylinders, crankcase and motor, and to attenuate the sound.
FIG. 2 shows an oilless reciprocating piston compressor 110, which is similar to compressor 10 shown in FIG. 1. A bell-shaped pressurizable motor containment vessel 130 is connected to crankcase 120 by means of two cooperating flanges 124 and 134, on the crankcase 120 and motor containment vessel 130, respectively. Flanges 124 and 134 are bolted together with a gasket or O-ring seal 126 interposed therebetween to form a static seal. The crankcase 120 and motor containment vessel 130 cooperate to define an interior cavity 135 which, in operation, is fluidly isolated from the surrounding atmosphere. The motor containment vessel 130 thus becomes an extension of the pressure containment structure of the crankcase 120. The crankcase 120 and motor containment vessel 130 are designed to be pressurizable to differential pressures (relative to the surrounding atmosphere) of at least 5 psig, and preferably at least 10 psig. In the embodiment illustrated in FIG. 2, the crankcase 120 is approximately 0.75 inch thick steel, and the motor containment vessel 130 is approximately 0.25 inch thick steel. A rotary motor 125, comprising a stator 121 and rotor 123 in a ventilated motor housing 127, is contained in motor containment vessel 130. The rotor 123 is mounted on a motor shaft 140, which protrudes from motor housing 127 and extends into the crankcase 120. The shaft 140 is supported by three bearings 141, 142 and 143.
As in FIG. 1, three non-lubricated cylinders 150 are mounted on crankcase 120 (only two are shown in FIG. 2; the third is mounted orthogonal to the two shown), each housing a piston 160 which is connected to motor shaft 140, for reciprocation, via an eccentric bearing and connecting rod 162. Cylinders 150 are non-lubricated, and polytetrafluoroethylene piston rings 161 are employed.
Suction inlet 170 opens directly into the interior cavity 135. In operation, compressor suction inlet 170 is connected to a gas supply, such as a pressurized natural gas supply (not shown). In the embodiment illustrated in FIG. 2, the motor 125 is cooled by the incoming suction gas. Thus, the gas enters the compressor 110 at suction inlet 170 and is directed between the motor containment vessel 130 and the motor housing 127 then between the stator 121 and rotor 123 of motor 125, to cool the motor. The incoming gas is thus forced to pass though the interior of the housing 127. The gas is then directed into the crankcase section of the interior cavity 135, where it also cools the connecting rod 162 bearings. From the crankcase cavity the gas is directed via conduits such as lines 168 to cylinder intake valves 172 which are open during the downstroke of the pistons 160. The gas is compressed in the cylinder 150 on the upstroke and exits the cylinder at discharge outlet port 175 via discharge valve 174. Any gas which leaks past the pistons 160 on the compression stroke will be captured in the crankcase section of the interior cavity 135 and will be recirculated back to the cylinder intakes 172 via lines 168.
Again, the electrical connections to the motor 125 in the interior cavity 135 are made via hermetic seal 190.
Again, in the embodiment illustrated in FIG. 2, a cooling fan is 180 is mounted on the exterior of the crankcase, and is magnetically coupled to be driven by motor shaft 140 which also drives the compressor, without the need for a perimeter rotating shaft seal. No perimeter rotating shaft seal is required in the crankcase or motor containment vessel wall as the motor shaft 140 is fully enclosed within the interior cavity 135. A protruding section 128 of the crankcase 120 encloses an extension 146 of the motor shaft 140. An inner magnetic coupling sleeve 182 is fitted on the extension 146 of shaft 140, and an outer magnetic coupling sleeve 184 is fitted between the protruding crankcase section 128 and the hub 186 of the fan 180. In operation the fan directs cooling air over the crankcase 120 and cylinders 150. The cylinders typically include fins 158 to facilitate cooling.
In both of the illustrated embodiments, only static seals are employed to isolate the interior cavity of the oilless gas compressor from the surrounding atmosphere. No rotating shaft seals or other dynamic seals are employed at the perimeter of the compressor for this purpose, as they would be vulnerable to leakage, especially when a pressure differential is applied across the seal.
The oilless gas compressors illustrated in FIGS. 1 and 2 are suitable for the compression of natural gas without leakage, for example, to produce an oil-free compressed natural gas stream at a discharge pressure of approximately 100-115 psig when operated at an intake pressure of approximately 10 psig.
The present approach is applicable to many different reciprocating piston compressor designs. For example, the number and orientation of the cylinders is not important; the compressor may incorporate single- or double-acting reciprocating pistons; and, the compressor may be a single-stage compressor or a multi-stage compressor with intercooling. Further, this approach could be used with other types of oilless gas compressors including centrifugal, screw and scroll compressors, rotary compressors including rotary vane and rotary lobe compressors, and also with blowers.
While particular elements, embodiments and applications of the present invention have been shown and described, it will be understood, of course, that the invention is not limited thereto since modifications may be made by those skilled in the art, particularly in light of the foregoing teachings. It is therefore contemplated by the appended claims to cover such modifications as incorporate those features which come within the spirit and scope of the invention.
|
An oilless gas compressor includes a motor containment vessel containing a motor for driving the compressor and a crankcase attached to the motor containment vessel. The crankcase and the motor containment vessel are fluidly connected and together define a sealed, pressurizable interior cavity in which the rotatable motor shaft is disposed. The compressor further includes a cylinder mounted upon the crankcase, the cylinder having a piston disposed therein. The piston is connected to the shaft for reciprocation of the piston within the cylinder. The cylinder also includes a gas intake valve, fluidly connected to the compressor suction inlet port, and a gas discharge valve, fluidly connected to the compressor discharge outlet port. The oilless gas compressor, in which the need for perimeter rotating shaft seals is obviated, is suitable for compression of precious or toxic gases or flammable gases, such as natural gas.
| 5
|
BACKGROUND OF THE INVENTION
This invention relates to a method and means for laundering clothing contaminated with asbestos fibers and/or with lead, which decontaminates them, in an environmentally contained, controlled and safe facility.
The contamination of our living environment with asbestos and/or lead, is a serious but well known problem. The abatement, for instance, of the asbestos and lead from buildings of all types is a major undertaking costing billions of dollars every year.
During the asbestos and lead abatement process workers are required to wear protective clothing in addition to respirators equipped with HEPA (High Efficiency Particulate Absolute) Filter cartridges. This protective clothing has to be disposed of as contaminated material, additionally aggravating another serious problem, which is the creation of large quantities of contaminated solid waste which in turn increases the already heavy burden imposed on landfills nationwide in addition to the cost of replacing the contaminated clothing, which is very high indeed.
Recycling has become a very serious obligation of every American and it is becoming law in many instances. Recycling by laundering the clothing used in the asbestos and lead abatement projects could become a major contribution to the reduction of the solid waste problem, provided:
a. Safety procedures and means are included in the laundering process in order to protect the operator's health and to protect the surrounding atmosphere from contamination.
b. Methods and means are in place to prevent the clothing from getting re-contaminated within the work area of the laundry facility, after they have been laundered and before they leave the laundry facility.
c. Any quantity of the contaminants found on the laundered suits, after they exit the laundry facility, is insignificant or at most the maximum allowed by regulations.
d. No waste water will be disposed through the sewer system that is not in compliance with EPA regulations for maximum allowable content for the above mentioned contaminants.
It is therefore a principal object of the invention to provide a method and means for laundering asbestos and/or lead contaminated clothing which decontaminate them and which include safety procedures, controls and regular testings, as intrinsical parts of the decontamination process, implicating both, the protection of the laundry operator's health and the protection of the surrounding atmosphere from being contaminated with the listed contaminants from the laundry process.
A further object of the invention is to provide a method and means for laundering asbestos and/or lead contaminated clothing which decontaminate them and which include means combining microprocessor controlled washer technology with a Containment Area controlled environment, engineered with state of the art technology. The invention also provides methods and means for the constant differential pressure monitoring and recording, methods and means for constant air monitoring and testing by independent laboratory of both the Containment Area as a whole as well as the Operator's Breathing Area in particular. It also provides methods and means for testing the clothing, at regular intervals, by an independent laboratory for contaminant content, prior to and after laundering, all of which assures the laundered clothing does not get recontaminated within the laundry facility.
A further object of the invention is to provide a method and means for said laundry facility not to require a wall between its washer and dryer areas because of its washer equipment technology and because of its environmental control engineering, which directs the air flow in a manner that does not allow contaminated air to flow towards the dryer as proven by its monitoring and testing methods and means which becomes obvious to those trained in the art, in the description of the drawings and in the preferred embodiment.
A further object of the invention is to provide an improved method and means for laundering asbestos and/or lead contaminated clothing to decontaminate them. The method and means provide clean, decontaminated clothing, that can be safely worn. Said clothing leaves the laundry facility with an insignificant amount of the listed contaminants on it, if any, or at the most within the maximum allowed by regulation.
A further object of the invention is to provide an improved method and means for laundering asbestos and/or lead contaminated clothing with the purpose of decontaminating them including means for filtering the contaminated waste water down to a content/liter that is acceptable by EPA regulations for its disposal through the sewer system, further including means for reducing the contact between the hot, contaminated waste water and the Containment Area ambient air to an insignificant level.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of the floor plan of the overall facility, subject of this invention, which shows: the washers, the dryer, the filtration system, the settling tank, the holding tank, filter banks, pumps, pressure gauges, sensors, controls and piping. FIG. 1 also shows the clean air in-flow and its direction, indicated by arrows, up and towards the HEPA Air Filtration Machines. Also shown is the clean clothing, folding, repairing, counting, storage and office areas.
FIG. 2 is a sectional view of the settling tank, its piping, the washers, the dryer and its exhaust connection via flexible duct to one of the two HEPA Air Filtration Machines; the Air Filtration Machines set on a platform above the settling tank and their exhaust ducts connected to the outdoors.
SUMMARY OF THE INVENTION
An improved method and means for laundering clothing contaminated with asbestos fibers and/or lead residues, which decontaminate them, is described, wherein an environmentally controlled enclosure is created to define a washer/dryer/filtering area without the need for dividing walls between them. Vented rooms are provided to permit the operator to enter the washer/dryer/filtering area to perform the washing and drying procedures in such a manner so as to prevent the escape of contaminants from the enclosure and to the atmosphere and to ensure (in conjunction with the negative air engineering, the washer results repeatability, the method of handling the contaminated clothing before washing it, the monitoring and testing procedures and others explained hereinafter) that the washed clothes will not be contaminated during the drying procedures. At the same time it is also assured the operator's safety and that any of the above mentioned contaminants on the clothes, if any after laundering, will be at the most within the allowable safe level.
Means are also provided for the filtering and safe disposal of the contaminated wash water. A large clean room area is provided, separated from the washer/dryer/filtering area by walls and communicating with said area through the above mentioned vented rooms, this large clean room area is used for the purpose of sorting, repairing, folding and storing of the laundered clothing.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the numeral 8 designates the overall containment area and waste water filtration area and the numeral 2 designates the overall clean clothes, sorting, repairing, folding, storage and office area.
The Containment and Filtration Areas 8 include Outer Walls 1, 1a, 1h, 1j, 1k, 1b, 1c, 1d, 1e, 1f, 1g, and Overhead Door 9.
Area 8 includes Clean Room/Airlock 44, defined by Walls 1h, 1j, 1k and 1l and Shower Room 45, 46 defined by Walls 1a, 1l, 1m and 1n. Vented Solid Doors 3, 4 and 5 are provided in Walls 1j, 1l and 1n. Vents on Doors 3, 4 and 5 are positioned so that air, drawn in by Air Filtration HEPA (High Efficiency Particulate Absolute) Machines 36, may pass from the outside, through Clean Clothing Area 2, through Vent 55 and through Vents 3, 4 and 5 into the Clean Room/Airlock 44, the Shower Room 45, 46 and into the Laundering Area, as indicated by arrows 54. Clean, outside air is also drawn in through Vent 56 on Wall 1e. All vents are designed so as to prevent air from moving from the Shower Room 45, 46, through Clean Room/Airlock 44 and into the Clean Clothing Area 2. They have a flap over them on the negative pressure side. Arrows 54 indicate the direction of the flow of clean air into the containment, through the several self-closing flapped vents, throughout the Containment Area.
FIG. 1--Microprocessor controlled, programmable Washing Machines 12 are provided in Area 8 and they have Drain Lines 35 extending therefrom to Holding Tank 16. Sampling Outlet 19 is provided for testing the prefiltering waste water contamination level.
Electrical Control Panel 13 with indicators and alarms, controls all the electrical functions within the Containment Area, by means of microprocessor based programmable controller; manual override is available to the operator at all times, who can manually control the process in case of any malfunction.
Holding Tank 16 has an automatic Level Control 18 which turns on Pump 20 at a preset level. Waste water is pumped out of Holding Tank 16 via bottom Outlet 17 by Pump 20 through Pipe 21 and into a large Settling Tank 22 which has a top lid. A second, Automatic Level Control 18a turns on Pump 20, at a preset level, as a safety feature. When this Level Control 18a is activated, an alarm and a blinking red light turn on in Control Panel 13, alerting the operator.
At this point the separation of the heavy particulates, like dirt, sand, lint, etc., takes place, and a major portion of entrained contaminants settles down to the bottom of the tank.
After a predetermined period of time, measured by a timer in Control Panel 13, the contents of the closed top Tank 22 are pumped out automatically from a preset level from the bottom by the programmable controller in Control Panel 13, through Pipe 25 by Pump 24; the pumping pressure drop is read by differential Pressure Sensor/Transmitter 26, which transmits its reading to the programmable controller in Control Panel 13. The waste water is then routed automatically through one of three filter banks, A, B or C, which is selected by the programmable controller, who opens one bank and closes the next one by operating the electrically actuated Valves 27A, 27B or 27C, based upon a preset pressure differential at the programmable controller in Panel 13. Each Electrically actuated Valves 27A, 27B and 27C has a red and a green light. The green light is on when the valve is open, the red light is on when the valve is closed.
The Programmable Controller in Panel 13, will sound an alarm if all the valves are closed.
The loaded filters are removed from their housings and backwashed clean by Filter Backwashing Machine 33. Clean filters are installed at the time the loaded filters are removed for cleaning.
Each filter bank consists of 3 large filter cartridges, piped in series so as to force the waste water to go first through a five micron Filter 28, then through a one micron Filter 29 and finally through a second one micron Filter 29. The clean, filtered water now is well below the acceptable level for disposing the contaminated waste water through Drain Pipe 30 and into the sewer system.
Sampling Outlet 31 is provided for testing the filtered water downstream of the filtering banks. The Fiber Count, in MF/L (Million Fibers/Liter) is well below the EPA allowable level for disposal through the sewers, tested by the most accurate and reliable test available--the TEM (Transmission Electron Microscopy), done by accredited, AIHA Certified Laboratory (American Industrial Hygienist Association).
The larger Settling Tank 22, as well as, the smaller Holding Tank 16 and the filter housings have no large surface of contact between the contaminated water and the ambient air, only the normal venting for filling and pumping. This feature reduces the amount of contaminants that get entrained with the water vapors and which could then be carried out through the Containment Area.
At a preset period of time, the bottoms of Settling Tank 22 are pumped out through Outlet 38, the inside is pressure washed and the sludge is disposed of accordingly to EPA regulations.
The washing machines and tank are within a Dyke 52 in order to contain any remotely possible leak. Two Vacuum Cleaners 34, equipped with HEPA filters, are kept at all times within the Containment Area, one near Washing Machines 12, the other near Pumps 20 and 24.
All the functions of the Washing Machines 12 are controlled by a built in microprocessor, including cycles, duration of cycles, amount and temperatures of water, chemical feed from Metering Pumps 15 and Chemical Storage Containers 14, as well as other features, which ensure the repeatability of the washing results.
FIG. 1. The portion of all walls facing the inside of the Containment Area are finished with smooth, white marlite in order to reduce adherence of the above listed contaminants and to facilitate the wash down of Walls: 1, 1a, 1n, 1m, 1b, 1c, 1d, 1e, 1f and 1g.
Prior to the start of laundering, the floor in the work area is covered with one layer of 6 mil polyethylene sheeting. At the end of each day, this sheeting is HEPA vacuumed then rolled up and disposed of, as contaminated material. The pickup and delivery system requires that the contaminated clothing be picked up by trained personnel in a facility owned licensed enclosed truck. The clothing is picked up already inside two six-mil polyethylene marked bags. These bags have already been decontaminated on the outside surface, prior to leaving the pick up area. Once picked up, the bags are placed in sealed containers inside the enclosed truck. The box truck is lined with 6 mil polyethylene sheeting on the inside.
At the laundry, the truck is backed all the way into the Containment Area 8, through Overhead Door 9. At this point, the Air Filtration Machines (HEPA) 36 start automatically. The double bags are then transferred from the truck's sealed containers to the Containment Area Sealed Containers 10. By the described handling system, assurance is attained that no contaminants would be released to the atmosphere from pickup to delivery points.
FIG. 2. Dryer 32 has its Exhaust 39 directly connected, via Duct 40, to the Intake 41 of one of the two HEPA Air Filtration Machines 36. These HEPA Air Filtration Machines 36 are equipped with High Efficiency Particulate Absolute Filters (HEPA) rated and certified to be a minimum 99.97% efficient at 0.3 micron. In addition, these machines are equipped with two other non-HEPA prefilters, automatic controls, and loud sounding alarm and lights to warn the operator of the status of all the filters.
The outlet side of the HEPA Air Filtration Machines are connected by Duct 42 to the outdoors at Points 43 on Wall 1c. The two HEPA Air Filtration Machines 36 are on top of Platform 37 which stands above Settling Tank 22.
The air released to the atmosphere through Duct 42 is free of contaminants as proven by pre-established, scheduled air testings of samples taken through Sampling Outlets 53 and analyzed by AIHA Accredited Laboratories.
The suction of approximately 3600 CFM (cubic feet per minute) of air from the Containment Area 8 by HEPA Machines 36, creates a negative pressure inside said Containment Area 8, in relationship to the surrounding areas, beyond Walls 1, 1a, 1h, 1j, 1k, 1b, 1c, 1d, 1e, 1f, 1g and Overhead Door 19. The negative pressure within Containment Area 8 is maintained at minus 0.02 or less inches of water and it is documented by the use of differential pressure Documenter 47, which is an instrument used to monitor relative pressure differential. (A digital pressure manometer connected to a chart recorder for documentation and record keeping.) This instrument has both audible and visual alarms with highly visible readout; the alarm is to warn the operator of any possible failure in the negative pressure, inside the Containment Area.
HEPA Machines 36 turn on everytime Overhead Door 9 opens up and the delivery truck backs all the way into the Containment Area 8 or when the laundry process is taking place. Delivery never takes place when the laundry process is taking place.
HEPA Machines 36 change, a minimum of six times per hour, the entire volume of air in Area 8, by drawing-in fresh, clean air from the outside. This happens every time laundering is taking place.
The functioning of the HEPA Machines 36 and the negative pressure created in Containment Area 8 assure that air will always flow into the Containment Area from the clean surrounding areas and never in the opposite direction, further assuring that no contaiminants would be released to the atmosphere through the surrounding clean areas.
The vents on Vented Doors 3, 4 and 5 as well as Vent 55 on Wall 1b and Vent 56 on Wall 1e are permanent one-way, self-closing vents; that is with flaps on the negative pressure side of the air stream which flows from the surrounding clean areas into Containment Area 8 through said vents.
This vent system does not require that the operator open or close any vents.
Emergency Electrical Power Generator 57 is provided as a safety measure, in case of a failure in the electrical power supply. Should any electrical power failure occur, Emergency Generator 57, after a pre-established time delay, will automatically turn on, re-establishing all the functions within Containment Area 8, including the Air Filtration HEPA Machines.
All laundry which has been removed from Dryer 32 is placed into a sealed container and after all laundry is done and all decontamination procedures have taken place, the container is removed through the Shower Door 5, into Shower Room 45, 46, where the container is wet wiped. After showering, the operator moves the sealed, wet wiped container through Door 4 into the Clean Room 44, where he or she dresses in clean street clothes. Then he or she moves the container into Clean Area 2 through Door 3, for sorting, repairs, folding and storage.
The lint from Dryer 32 is removed everyday from the lint screen. At regular, preset periods of time, the lint from Dryer 32 is sampled and analyzed for asbestos fiber content, by AIHA Accredited Laboratory.
FIGS. 1 and 2. As claimed in this invention and as shown on FIG. 1 and 2, and as described in the description of the drawings and in the Preferred Embodiment, the Containment Area 8 does not require division by a solid wall or any other means, between washer and dryer area, because of the dramatic reduction in the amount of the listed contaminants released into the Containment Area 8, as proven by air monitoring of both the Containment Area itself, as well as, the Operator's Breathing Area, within the Containment Area in a TWA (Time Weighted Average) basis and as analyzed by an AIHA Accredited Laboratory.
The reduction in contaminants released into the Containment Area and the elimination of the need for a wall between the washers and the dryers thereof, are due to the following features of this invention:
1. Safe delivery procedures and means that ensure no contaminants are released into the Containment Area when dirty clothing bags are transferred into it.
2. Wetting of the clothing prior to pulling them out of their double bags.
3. Improved air filtration and flow control system in the Containment Area, which directs the air flow in a manner that does not allow contaminated air to flow towards the dryer, as well as the introduction of HEPA filters and other methods and means for constant monitoring of the air in the Containment Area, the Operator's Breathing Area air, the exhaust air and the negative pressure, which is introduced in the Containment Area, with respect to the surrounding areas.
4. The protection of the floors in the Containment Area by placing 6 mil polyethylene sheeting thereon.
5. The introduction of microprocessor controlled, programmable washers, which ensures repeatability of the results. Also the introduction of testings of the laundered clothing for residual contaminants, ensuring reliability in the laundering process and its results.
6. The introduction of a smooth wall finish, which substantially reduces adherence of contaminants to its surface and the washdown of all surfaces in the Containment Area after each day laundering is complete, reducing contamination possibility.
7. The utilization of enclosed waste water tank and filters, which reduces the contact of the hot, contaminated water with the Containment Area ambient air.
8. The reduction of possible human error in the closing and opening of vents by utilizing self closing flapped vents. These vents are strategically placed throughout the Containment Area in order to properly direct the flow of the clean air coming into the inside of the area: Vents 3, 4, 5, 55, 56 and Overhead Door 9 (when this door opens).
FIG. 1. Illustrates the overall layout of the facility, as herein before described.
FIG. 2. Illustrates a sectional view of the settling tank, the washers, the dryer and the HEPA Air Filtration Machines on a platform thereof. Steps 1 through 9 refer to FIGS. 1 and 2 and describe the methods.
STEP ONE
The operator has been previously thoroughly trained in the operation and the safety features of the facility. The operator turns on Red Warning Light 6, then enters Clean Room/Airlock 44, from Clean Room 2, through Vented Door 3. In Clean Room/Airlock 44, the operator changes his or her regular clothing and puts on protective coveralls, gloves, head covering, foot wear and OSHA approved respirator equipped with HEPA filters. The operator will also strap to his or her waist a personal air monitoring pump in order to monitor his or her breathing area air. The floor in Area 8 has been previously covered with a layer of 6 mil plastic.
STEP TWO
The operator proceeds through Vented Door 4, through Shower Room 45, 46, then through Vented Door 5 into Containment Area 8, where he or she proceeds to turn on both HEPA Air Filtration Machines 36, via Control Panel 13. At this point, if the filters in the Air Filtration Machines are loaded, meaning that they need replacing, or any other machine malfunction happens, a loud alarm will sound, red lights will go on at the machines and no laundering will take place until the cause for the malfunction is repaired.
STEP THREE
The operator now will turn on the high volume pump for the monitoring of the air in Area 8 and also will turn on his or her personal air monitoring pump at this time. These air samples are to be sent to an accredited laboratory for analysis, with a next day results turn around requested.
STEP FOUR
The operator picks up the double bagged dirty clothing, one bag at a time, from Sealed Containers 10 and reseals Container 10. The operator wets down the dirty clothes, by means of an airless spray gun and proceeds to load the Washing Machine 12.
At pre-established intervals the operator will take samples from the surface of a pre-established number of dirty clothing, prior to wetting them. This is done following an accepted, established procedure. The operator will also mark, with threads, the areas the samples were lifted from, then he or she will proceed to launder those clothing together with the rest. The sample will be tested by an accredited laboratory.
STEP FIVE
The operator turns on the Microprocessor Controlled, Programmable Machine 12 which proceeds, automatically, to launder the dirty clothing. The operator selects a program, which has been programmed in the machine and which is based upon the composition of the clothing itself, and only has to look up a chart and push in a numerical button indicated on the chart.
STEP SIX
The dirty waste water is automatically drained from Washing Machine 12 into Holding Tank 16 from where it is automatically pumped into Settling Tank 22 by Pump 20 and after a preset period of time it is pumped out of Settling Tank 22, by Pump 24, to the Filters 28, 29 and to the sewers through Drain Pipe 30, as previously described in detail.
On a pre-established schedule, the operator takes samples of the waste water, downstream from the filters and labels them, all accordingly with established procedures. The samples are to be immediately sent to an accredited laboratory for testing and a report.
STEP SEVEN
After laundering is complete, the operator removes the still wet clothes from Washers 12 and places them in Dryer 32 where they are dried.
STEP EIGHT
The dried clothing is then placed in a sealed, wheeled container and moved through Vented Door 5 into Shower Room 45, 46, where the operator wet wipes the wheeled container, then strips off the protective clothing and places them in a sealed container in the shower room. The operator then proceeds to take a shower and to wash clean the respirator. The respirator cartridges are disposed of at this point. The personal monitoring pump has been turned off and is also wet wiped.
On a pre-established schedule and procedure, samples are taken from the laundered clothing surface of the clothing tested in Step Four, in order to determine contaminated contents. The testings are to be made by an accredited laboratory.
STEP NINE
The operator then moves the wheeled container through Vented Door 4 into Clean Room/Air Lock 44 where he or she dresses in regular clothing and hangs up the respirator and the personal pump, then moves the wheeled container, through Vented Door 3, into Clean Room 2 for sorting, repairs, folding and storage.
Thus, it can be seen that a method and means are provided for laundering asbestos and/or lead contaminated clothing which decontaminate said clothing in a manner which ensures the safety and protects the health of the laundry operator and prevents asbestos and/or lead contamination to the atmosphere from the laundry.
Method and means are provided for laundering asbestos and/or lead contaminated clothing in an environmentally controlled, (air pressure, air flow pattern and volume, sealed in waste water) contained Laundry Area, without walls between washer and dryer areas, which does not recontaminate the clothing after laundering it and if any of the contaminants remain on the laundered clothes, the amount would be insignificant or at the most within the maximum allowed.
Method and means are also provided for:
A controlled environment enclosure defining a washer, dryer and waste water settling and filtering side without walls between them.
A clean room/air lock in communication with said washer/dryer filtering side and two solid doors with flapped vents-air inlets, one vented door communicating with the large clean room used for sorting, repairs, folding and storage of laundered clothing, the other vented door communicating with the shower room. The vents permit the air to flow only towards the shower room and beyond, but not the opposite direction.
A shower room which has a solid door with a flapped vent (air inlet) which door is communicating with the washer/dryer/filtering side. The flapped vent permits the air to flow only towards the washer, dryer area and not the opposite direction.
A one-way venting system (air inlets) with flaps, that allows the flow of air only in one direction, from the surrounding clean areas, as well as from the clean room used for sorting, repairs, folding and storage, through the clean room airlock, and through the shower room and into the washer/dryer/filtering side, which does not require the operator's attention. They are self closing air inlet flaps.
Two microprocessor controlled, programmable washers which ensure repeatability of the laundry parameters and one dryer in the washer/dryer/waste water settling and filtering side.
An asbestos and/or lead contaminated water filtering and disposal means associated with said programmable washers which operates automatically and which has failsafe features. Said filtering means, filter the waste water down to a contaminant content per liter which is acceptable for disposal through the sewer.
The installation of two state of the art Air Filtering Machines, equipped with HEPA filters for creating and maintaining a negative pressure within said washer/dryer/waste water settling and filtering area, through flapped vents on Walls 1b and 1e as well as through flapped vents on solid doors in the clean room/air lock and the shower room and through Overhead Door 9 when it opens for letting the enclosed/inside lined truck, back up all the way into the washer/dryer/filtering area.
A monitoring and alarm means to warn the operator of any failure in the level of negative pressure within the work area.
The utilization of a HEPA Air Filtering Machine for the direct filtering of the dryer exhaust air before it is exhausted to the surrounding atmosphere.
An emergency auxiliary generator, to ensure the functioning of the air filtration HEPA system as well as other elements of the process, with the purpose of protecting the health and safety of the laundry operator, as well as with the purpose of protecting the surrounding environment.
A series of alarms, warning audible and visible signals and redundant tank level control, also to ensure operator's safety and environmental protection.
Method and means to prove and ensure the health of the operator as well as the protection to the environment, by pre-established scheduled sampling of: the operator's breathing air area and the overall work area air, the air filtration HEPA machines exhaust air, the dryer exhaust air, the dryer lint, the contaminated clothing prior to and after laundering and the waste water after filtering it. The testing of all of the above samples shall be done only by independant AIHA Accredited Laboratory.
An overhead door between the outside and the washer/dryer/filtering side which opens up only when no laundering is taking place, to allow dirty clothing, in double bags, to be transferred from sealed containers in enclosed truck into sealable containers inside the washer/dryer/filtering area and only while the area is under negative pressure, which forces air flow only in one direction through overhead door and other clean areas and into the washer/dryer/filter area.
A clean room area used for sorting, counting, repairs, folding and storage of the laundered clothing said clean room communicating with the clean room/air lock through solid door with flapped vent, that allows the air to flow only from the clean room to the clean room/air lock and not the opposite direction.
Thus, it can be seen that the invention accomplishes all of the stated objectives.
|
This invention consists of a method and means for laundering clothing contaminated with asbestos fibers and/or with lead, herein called the contaminants. The method and means employed by this invention decontaminates the clothing in an environmentally contained, controlled and safe facility. The facility and the method described in association therewith permits contaminated clothing to be brought into the containment area, laundered and dried within the same contained, environmentally controlled, safe area. Clean clothing is then removed for further sorting, repairs, folding, counting and storing operations in another separated room of the facility. The facility and the method described in association therewith protect the health of the laundry operator and prevent the contaminants from being released into the atmosphere by the process itself. It also prevents contaminants from being carried from the interior of the facility by the person conducting the laundry operation. The method and means also prevent the release of the contaminants into the atmosphere at the time the contaminated clothing is delivered to the facility. The method and means also prevent the release of the contaminants by the laundered clothing themselves after they have been laundered. This is assured by the methods and means utilized to prevent recontaminating the clothing after it has been laundered. The method and means ensure the filtering of the laundry waste water to a level that is safe for its disposal through the sewer.
| 3
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Provisional Application Ser. No. 61/569,358, filed on Dec. 12, 2011. The contents of the prior application are incorporated herein by reference.
BACKGROUND
[0002] Compound A (6-chloro-3-amino-2-(2-hydroxypropyl)-1-azanaphthalene) is in early stage clinical trials for the treatment of macular degeneration.
[0000]
[0003] Although compound A can be readily prepared by those skilled in the art, more efficient synthetic routes are necessary for the production on a commercial scale. A highly efficient route to compound A is disclosed herein.
SUMMARY
[0004] This invention relates to a process for the preparation of 6-chloro-3-amino-2-ethoxycarbonyl-1-azanaphthalene, which comprises treating 6-chloro-3-pyridylium-2-ethoxycarbonyl-1-azanaphthanlene bromide with morpholine at about 80° C. This process may further comprise treating ethyl pyridyliumpyruvate halide with 2-amino-5-chloro-benzaldehyde and pyridine at 80° C. under an inert atmosphere to yield 6-chloro-3-pyridylium-2-ethoxycarbonyl-1-azanapthalene halide mentioned above.
[0005] This invention also relates to a process for the preparation of 6-chloro-3-amino-2-(2-hydroxypropyl)-1-azanapthalene, which comprises the process for making 6-chloro-3-amino-2-ethoxycarbonyl-1-azanaphthalene described above, followed by treating the product thereof with methylmagnesium chloride.
[0006] In addition, this invention relates to a process for the preparation of 2-amino-5-chloro-benzalehyde, which comprises treating 5-chloro-2-nitrobenzaldehyde with hydrogen and 3% sulfided platinum.
DETAILED DESCRIPTION OF THE INVENTION
[0007] The overall synthetic route to Compound A is shown in scheme 1 below.
[0000]
EXAMPLE 1
Preparation of A-1
[0008] To a 2 L round bottom flask was charged ethanol (220 mL), and pyridine (31 g, 392 mmol) and the resulting solution stirred at a moderate rate of agitation under nitrogen. To this solution was added ethyl bromopyruvate (76.6 g, 354 mmol) in a slow, steady stream. The reaction mixture was allowed to stir at 65±5° C. for 2 hours.
EXAMPLE 2
Preparation of A-2
[0009] Upon completion of the 2 hour stir time in example 1, the reaction mixture was slowly cooled to 18-22° C. The flask was vacuum-purged three times at which time 2-amino-5-chloro-benzaldehyde (ACB) (50.0 g, 321 mmol) was added directly to the reaction flask as a solid using a long plastic funnel. Pyridine (64.0 g, 809 mmol) was added followed by an EtOH rinse (10 mL) and the reaction mixture was heated at 80±3° C. under nitrogen for about 16 hours (overnight) at which time HPLC analysis indicated that the reaction was effectively complete.
EXAMPLE 3
Preparation of A-3
[0010] The reaction mixture from example 2 was cooled to about 70° C. and morpholine (76.0 g, 873 mmol)) was added to the 2 L reaction flask using an addition funnel. The reaction mixture was heated at 80±2° C. for about 2.5 hours at which time the reaction was considered complete by HPLC analysis (area % of A-3 stops increasing). The reaction mixture was cooled to 10-15° C. for the quench, work up, and isolation.
EXAMPLE 4
Isolation of A-3
[0011] To the 2 L reaction flask was charged water (600 g) using the addition funnel over 30-60 minutes, keeping the temperature below 15° C. by adjusting the rate of addition and using a cooling bath. The reaction mixture was stirred for an additional 45 minutes at 10-15° C. then the crude A-3 isolated by filtration using a Buchner funnel. The cake was washed with water (100 mL×4) each time allowing the water to percolate through the cake before applying a vacuum. The cake was air dried to provide crude A-3 as a nearly dry brown solid. The cake was returned to the 2 L reaction flask and heptane (350 mL) and EtOH (170 mL) were added and the mixture heated to 70±3° C. for 30-60 minutes. The slurry was cooled to 0-5° C. and isolated by filtration under vacuum. The A-3 was dried in a vacuum drying oven under vacuum and 35±3° C. overnight (16-18 hours) to provide A-3 as a dark green solid.
EXAMPLE 5
Preparation of Compound A
[0012] To a 2 L round bottom flask was charged methylmagnesium chloride (200 mL of 3.0 M solution in THF, 600 mmol). The solution was cooled to 0-5° C. using an ice bath.
[0013] A 500 mL flask (magnetic stirring) was charged with 22.8 grams A-3 from example 4 and THF (365 mL), stirred to dissolve then transferred to an addition funnel on the 2 L Reaction Flask. The A-3 solution was added drop-wise to the reaction flask over 5.75 hours, keeping the temperature of the reaction flask between 0-5° C. throughout the addition. At the end of the addition the contents of the flask were stirred for an additional 15 minutes at 0-5° C. then the cooling bath was removed and the reaction was allowed to stir overnight at ambient temperature.
[0014] The flask was cooled in an ice bath and the reaction mixture was carefully quenched by adding EtOH (39.5 g, 857 mmol) drop-wise to the reaction mixture, keeping the temperature of the reaction mixture below 15° C. during the course of the addition. An aqueous solution of NH 4 Cl (84.7 g NH 4 Cl in 415 mL water) was then carefully added and the mixture stirred under moderate agitation for about 30 minutes then transferred to a separatory funnel to allow the layers to separate. Solids were present in the aqueous phase so HOAc (12.5 g) was added and the contents swirled gently to obtain a nearly homogeneous lower aqueous phase. The lower aqueous layer was transferred back to the 2 L reaction flask and stirred under moderate agitation with 2-methylTHF (50 mL) for about 15 minutes. The original upper organic layer was reduced in volume to approximately 40 mL using a rotary evaporator at ≦40° C. and vacuum as needed. The phases in the separatory funnel were separated and the upper 2-MeTHF phase combined with the product residue, transferred to a 500 mL flask and vacuum distilled to an approximate volume of 25 mL. To this residue was added 2-MeTHF (50 mL) and distilled to an approximate volume of 50 mL. The crude compound A solution was diluted with 2-MeTHF (125 mL), cooled to 5-10° C. and 2M H 2 SO 4 (aq) (250 mL) was slowly added and the mixture stirred for 30 minutes as the temperature was allowed to return to ambient. Heptane (40 mL) was charged and the reaction mixture stirred for an additional 15 minutes then transferred to a separatory funnel and the layers were allowed to separate. The lower aqueous product layer was extracted with additional heptane (35 mL) then the lower aqueous phase was transferred to a 1 L reaction flask equipped with a mechanical stirrer and the mixture was cooled to 5-10° C. The combined organic layers were discarded. A solution of 25% NaOH(aq) was prepared (NaOH, 47 g, water, 200 mL) and slowly added to the 1 L reaction flask to bring the pH to a range of 6.5-8.5.
[0015] EtOAc (250 mL) was added and the mixture was stirred overnight. The mixture was transferred to a separatory funnel and the lower phase discarded. The upper organic layer was washed with brine (25 mL) then the upper organic product layer was reduced in volume on a rotary evaporator to obtain a obtain the crude compound A as a dark oil that solidified within a few minutes. The crude compound A was dissolved in EtOAc (20 mL) and filtered through a plug of silica gel (23 g) eluting with 3/1 heptane/EtOAc until all compound A was eluted (approximately 420 mL required) to remove most of the dark color of compound A. The solvent was removed in vacuo to provide 14.7 g of compound A as a tan solid. Compound A was taken up in EtOAc (25 mL) and eluted through a column of silica gel (72 g) using a mobile phase gradient of 7/1 heptane/EtOAc to 3/1heptane/EtOAc (1400 mL total) . The solvent fractions containing compound A were stripped, compound A diluted with EtOAc (120 mL) and stirred in a flask with Darco G-60 decolorizing carbon (4.0 g) for about 1 hour. The mixture was filtered through celite using a firtted funnel, rinsing the cake with EtOAc (3×15 mL). The combined filtrates were stripped on a rotary evaporator and compound A dissolved in heptane (160 mL)/EtOAc(16 mL) at 76° C. The homogeneous solution was slowly cooled to 0-5° C., held for 2 hours then compound A was isolated by filtration. After drying in a vacuum oven for 5 hours at 35° C. under best vacuum, compound A was obtained as a white solid.
[0000] HPLC purity: 100% (AUC)
HPLC (using standard conditions):
A-2: 7.2 minutes
A-3: 11.6 minutes
EXAMPLE 6
Preparation of ACB
[0016]
[0017] After a N 2 atmosphere had been established and a slight stream of N 2 was flowing through the vessel, platinum, sulfided, 5 wt % on carbon, reduced, dry (9.04 g, 3.0 wt % vs the nitro substrate) was added to a 5 L heavy walled pressure vessel equipped with a large magnetic stir-bar and a thermocouple. MeOH (1.50 L), 5-chloro-2-nitrobenzaldehyde (302.1 g, 1.63 mol), further MeOH (1.50 L) and Na 2 CO 3 (2.42 g, 22.8 mmol, 0.014 equiv) were added. The flask was sealed and stirring was initiated at 450 rpm. The solution was evacuated and repressurized with N 2 (35 psi), 2×. The flask was evacuated and repressurized with H 2 to 35 psi. The temperature of the solution reached 30° C. w/in 20 min. The solution was then cooled with a water bath. Ice was added to the water bath to maintain a temperature below 35° C. Every 2 h, the reaction was monitored by evacuating and repressurizing with N 2 (5 psi), 2× prior to opening. The progress of the reaction could be followed by TLC: 5-Chloro-2-nitrobenzaldehyde (Rf=0.60, CH 2 Cl 2 , UV) and the intermediates (Rf=0.51, CH 2 Cl 2 , UV and Rf=0.14, CH 2 Cl 2 , UV) were consumed to give ACB (Rf=0.43, CH 2 Cl 2 , UV). At 5 h, the reaction had gone to 98% completion (GC),and was considered complete. To a 3 L medium fritted funnel was added celite (ca. 80 g). This was settled with MeOH (ca. 200 mL) and pulled dry with vacuum. The reduced solution was transferred via cannula into the funnel while gentle vacuum was used to pull the solution through the celite plug. This was chased with MeOH (150 mL 4×). The solution was transferred to a 5 L three-necked round-bottom flask. At 30° C. on a rotavap, solvent (ca. 2 L) was removed under reduced pressure. An N 2 blanket was applied. The solution was transferred to a 5 L four-necked round-bottomed flask equipped with mechanical stirring and an addition funnel. Water (2.5 L) was added dropwise into the vigorously stirring solution over 4 h. The slurry was filtered with a minimal amount of vacuum. The collected solid was washed with water (1.5 L 2×), iPA (160 mL) then hexanes (450 mL 2×). The collected solid (a canary yellow, granular solid) was transferred to a 150×75 recrystallizing dish. The solid was then dried under reduced pressure (26-28 in Hg) at 40° C. overnight in a vacuum-oven. ACB (>99A % by HPLC) was stored under a N 2 atmosphere at 5° C.
OTHER EMBODIMENTS
[0018] While the invention has been described in conjunction with the detailed description thereof, the foregoing description is intended to illustrate and not limit the scope of the invention, which is defined by the scope of the appended claims. Other aspects, advantages, and modifications are within the scope of the following claims. It will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
|
This invention relates to a process for the preparation of 6-chloro-3-amino-2-(2-hydroxypropyl)-1-azanapthalene. It comprises treating 6-chloro-3-pyridylium-2-ethoxycarbonyl-1-azanaphthanlene bromide with morpholine at about 80° C., followed by treating the product thereof with methylmagnesium chloride.
| 2
|
FIELD OF THE INVENTION
[0001] The invention relates to an electric power tool, in particular a handheld electric power tool, for operating with alternating current, having an electric motor, an electronic control device and an electric power switch for actuating the electric motor.
BACKGROUND
[0002] Electric power tools of this kind are known. The electric motor of electric power tools of this kind is typically supplied with a generally single-phase AC mains voltage by phase gating control. This is done in the manner of phase gating control by the electric power switch being “triggered”, that is to say switched to the on state, by application of a control potential or control current (triggering pulse) by the electronic control device, so that a motor current can flow as a result of the voltage applied to the electric motor. One problem which frequently arises is that of so-called “faulty triggering”, that is to say that the power switch has not been switched to the on state or has returned to the off state, for example because the triggering moment did not occur after, but rather shortly before, a zero crossing of the motor current, and therefore the power switch was deactivated, that is to say switched to the off state, again by the following current zero crossing.
[0003] In order to ensure reliable operation and rotation of the electric motor, which is a universal motor in particular, it is necessary to ensure that the power switch is duly switched to the on state in accordance with prespecified powers as intended at the correct time during a half-wave of the AC voltage, and also remains in the on state.
[0004] To this end, it is feasible, for example, for triggering to be monitored by measuring the voltage across the power switch. It would also be feasible for the motor current to be measured; however, a low-resistance measurement resistor which, for its part, would in turn require an amplifier arrangement for the measurement signal, would have to be used for this purpose. Both these measures are complex and costly to implement in respect of hardware. Outputting several triggering pulses one after the other at a predefined time interval would result in the unnecessary consumption of triggering current in the case in which the power switch is duly in the on state. In addition, a power supply part forming the several triggering pulses would have to be of correspondingly complex design.
[0005] The present invention is based on the object of providing an electric power tool of the type described in the introductory part in which reliable actuation of the electric motor as intended and as required is ensured in an economical manner.
[0006] According to the invention, this object is achieved by an electric power tool of said type in that the electronic control device comprises a bias voltage output and a detection input which are connected to one another and to that side of the circuit breaker which faces the electric motor via a voltage divider which has a summation point, and the control device is further designed such that the potential across the detection input after respective triggering of the power switch is monitored, and, on the basis of this, a check is made as to whether the power switch is on, and that it is triggered again if the power switch was not on or had returned to the off state during monitoring, and that this check and possibly renewed triggering of the power switch is repeated within a half-wave of the AC voltage.
[0007] Monitoring triggering of the power switch in this way using a circuit arrangement having two resistors in conjunction with a bias voltage output and a detection input of the electronic control device, which typically comprises a microcontroller, is associated with an extremely low level of possible costs of implementation in respect of hardware. In addition, the requirements made of programming of the electronic control device which is required for this purpose are relatively low. All that is necessary following a triggering pulse is that preferably continuous, that is to say not only intermittent, monitoring of the potential across the detection input of the control device be carried out. To this end, a signal is available at the voltage divider and therefore at the detection input immediately after triggering of the power switch, said signal, in this way, allowing basically immediate assessment of the state of the power switch (on or off).
[0008] Therefore, according to the invention, a check as to whether the power switch has been triggered as intended and also continuously remains in the on state is made by the control device immediately after triggering of the power switch. If this is not the case, this is detected by virtue of a change in signal at the detection input of the control device and the further control measures can be executed, specifically renewed triggering of the power switch as required. The potential across the detection input is again monitored immediately after this and a check is made as to whether this further triggering of the power switch leads to continuous “success” or whether the power switch returns to the off state again, and therefore still further triggering is initiated.
[0009] The power switch is advantageously a triac. The invention can also be advantageously used in multi-phase systems.
[0010] The check and, if required, triggering of the power switch are carried out at most ten times, in particular at most eight times, in particular at most six times, and further particularly at most five times, within a half-wave according to one embodiment of the invention. It has proven advantageous for the number of checks and, if required, triggering operations of the power switch to be performed at most x times, where x=T half-wave /T triggering sequence . In this case, T triggering sequence denotes the time interval between two triggering operations which is predefined in the control arrangement.
[0011] If it is established during the check that the power switch is off, it may prove advantageous for post-triggering to be performed immediately, that is to say as rapidly as possible, as soon as the check of the signal at the detection input has shown that the power switch is off. This may be the case, in particular, when the power switch is initially triggered in the middle of a half-wave.
[0012] However, it may also prove advantageous, in a development of the invention, for the electronic control device to be designed such that post-triggering takes place only after a predefined time interval, so that the triggering sequence or T tiggering sequence lasts for 5 to 500 μs, in particular 100 to 500 μs, in particular 150 to 400 μs and preferably 200 to 300 μs. This may be the case, in particular, when the power switch is initially triggered at the beginning of a half-wave, for example when the current zero crossing has not yet taken place (in this case, immediate post-triggering would not lead to the desired result since the following current zero crossing would re-open the power switch).
[0013] The triggering period of the power switch lasts for preferably 5 to 40 μs, in particular 15 to 30 μs.
[0014] The electronic control device advantageously comprises a synchronization input in order to detect the zero crossing of the respective half-wave. This is intended to prevent the power switch from being triggered too early, that is to say, for example, during a time interval when the actual motor current is “lagging”, that is to say is still ahead of the respective current zero crossing, on account of inductive loads of the electric motor. In such a case, the power switch could be switched to the on state by triggering, but (as already mentioned above) it would immediately return to the off state again at the subsequent zero crossing of the motor current. Preferably exact triggering of the power switch in relation to the half-wave of the relevant phase also proves advantageous in order to actuate the electric motor as required.
[0015] The electronic control device is further advantageously designed such that the bias voltage output is operated with a negative control voltage (low), in particular of −5 volts, during a positive half-wave, and with a comparatively higher potential, in particular zero volt, (high) during a negative half-wave.
[0016] The present invention also relates to a method for operating an electric power tool having the features of claim 10 .
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Further features, details and advantages of the invention can be found in the appended patent claims and in the illustration in the drawing and the following description of a preferred embodiment of the invention. In the drawing:
[0018] FIG. 1 shows a schematic illustration of power supply and actuation in an electric power tool according to the invention;
[0019] FIG. 2 shows a flowchart for the actuation of the electric power tool according to the invention; and
[0020] FIG. 3 shows an illustration of the current/voltage parameters during operation of the electric power tool according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] FIG. 1 illustrates the supply of electrical power to an electric motor 2 in an electric power tool according to the invention. A phase L of an electrical AC mains voltage and the neutral conductor N are illustrated. One electrical connection of a winding of the electric motor 2 is connected to the phase L, and the other is connected to the neutral conductor N with the interposition of a power switch 4 . An electronic control device which is denoted overall by reference symbol 6 and has a microcontroller 8 is also illustrated. The electronic control device 6 or the microcontroller 8 is supplied with an operating voltage of −5 V directly by the one phase L (operating voltage input 10 ). A synchronization input 12 is also provided, and therefore the electronic control device 6 can always be synchronized with respect to a zero crossing of the voltage of the relevant phase L, that is to say the time of control processes in relation to the zero crossing of the voltage of the phase L of the mains voltage can be temporally defined. The power switch 4 , which is preferably in the form of a triac, is actuated by means of a control output 14 from the microcontroller 8 of the electronic control device 6 by a control pulse (triggering pulse) being applied to the power switch 4 in order to switch the power switch 4 to the on state, and therefore the present voltage of the phase L is applied to the electric motor 2 and consequently a motor current flows through the windings of the electric motor. The time of the triggering pulse is selected by the electronic control device 6 to be within a half-wave of the AC voltage, depending on the power requirement. The shorter the time interval between the triggering pulse and the preceding zero crossing of the AC mains voltage, the greater the time integral with respect to electrical power which is supplied to the electric motor 2 . However, this is true only if the power switch 4 continuously remains in the on state, that is to say is closed, by virtue of the triggering pulse during the relevant half-wave.
[0022] The control device 6 or the microcontroller 8 further comprises a bias voltage output 16 and a detection input 18 which are connected to one another and to a connection 28 of the electric motor 2 via a summation point 20 of a voltage divider 26 which comprises two resistors 22 and 24 . Said connection is between the electric motor 2 and the power switch 4 , and therefore a potential of the power switch 4 relative to the neutral conductor N can ultimately be tapped off as a result. In this way, according to the invention, a signal is applied to the detection input 18 , it being possible to monitor said signal following triggering of the power switch 4 and it being possible for said signal to be used to check the “switching state” of the power switch 4 by virtue of the electronic control device 6 .
[0023] If, immediately after a triggering pulse is emitted (via the control output 14 from the electronic control device 6 ), it is established by monitoring the potential across the detection input that the power switch 4 is off or has returned to the off state, a renewed triggering pulse is transmitted to the power switch 4 by the electronic control device 6 . This check and possible re-triggering of the power switch 4 during a relevant half-wave of the AC mains voltage can be carried out several times, specifically in accordance with a first embodiment in such a way that post-triggering is performed as rapidly as possible, that is to say virtually immediately, if it is established that the power switch is off, or in accordance with a second embodiment in such a way that a triggering sequence of, in particular, 50 to 500 μs is realized in order to be able to use the available periods of the respective half-wave in as optimum a manner as possible to supply power to the electric motor 2 . However, the supply can also advantageously be restricted to a specific number of cycles.
[0024] FIGS. 2 and 3 show, using a flowchart and a voltage and current profile, the operation of the electric power tool according to the invention.
[0025] FIG. 3 shows, at the top, one oscillation period of a phase of the AC mains voltage (denoted by mains sine wave). A triggering pulse during the positive and subsequent negative half-wave of the AC voltage of in each case I G , where I G is advantageously between 1-50 mA, in particular approximately 25 mA, is illustrated beneath said oscillation period with a corresponding orientation in relation to the profile of the voltage of the phase. The bias voltage which is applied to the voltage divider 26 via the bias voltage output 16 of the control device 6 is illustrated beneath said triggering pulse. Said bias voltage is, in the case illustrated by way of example, −5 V (potential low) during the positive half-wave of the AC mains voltage and 0 V (potential high) during the subsequent negative half-wave of the AC mains voltage (only by way of example).
[0026] The motor current flowing through a winding of the electric motor 2 is illustrated in the row beneath the bias voltage. It can be seen that, during the course of phase gating control, the motor current flows only after the power switch 4 is triggered, that is to say only when the power switch 4 is switched to the on state, until the subsequent zero crossing of the AC mains voltage (or even somewhat longer on account of inductive effects). The motor voltage, that is to say the motor voltage which is dropped across the two connections of the winding of the electric motor 2 in question, is illustrated beneath the motor current. If the power switch 4 is on and a motor current is flowing, the illustrated motor voltage is dropped across the terminals of the electric motor 2 .
[0027] In the same way, the voltage which is dropped across the power switch 4 is illustrated beneath the motor voltage. Finally, the voltage which is applied to the detection input via the summation point 20 of the voltage divider 26 is illustrated in the lowermost row of FIG. 3 , said voltage being monitored for control purposes and being used to check whether the power switch 4 is on. In the event of successful triggering of the power switch during the positive half-wave, a low potential (in particular approximately −5 V) is applied to the detection input, specifically until the next zero crossing of the AC mains voltage, but only if the power switch remains in the on state until this time! During the negative half-wave, the voltage across the detection input continuously falls from high potential (in particular 0 V) to low potential (−5 V), until the power switch is switched to the on state as a result of a triggering pulse. The detection input then jumps to high potential, it being possible for this, for its part, to be evaluated by the control device 6 as a test parameter for correct conduction of the power switch 4 . Therefore, FIG. 3 shows correct operation of the electric power tool, in the case of which the power switch 4 is ideally closed, as intended, with each triggering pulse, and therefore power is supplied to the electric motor 2 .
[0028] Operation of the electric power tool according to the invention and the method according to the invention are also shown with reference to the flowchart according to FIG. 2 . The routine is such that the electronic control device determines a triggering time for the power switch 4 in accordance with the current power requirement during a half-wave of the AC mains voltage in accordance with programmed prespecifications. In order to correctly position this specific time in relation to the half-wave in question of the phase in question, the time of the zero crossing of the AC mains voltage of this phase is monitored using the synchronization input 12 . As soon as the zero crossing is established, a check is made as to whether the zero crossing is a positive zero crossing or a negative zero crossing (a positive zero crossing means the start of the positive half-wave). The flowchart then continues with one or the other path. When there is a positive zero crossing, that is to say at the start of the positive half-wave, the right-hand path of the flowchart is applicable. The potential “low”, that is to say, for example, −5 V, is applied to the bias voltage output. The triggering timer is started and, when the triggering timer is run down (above triggering time) for the first time during the half-wave in question in accordance with the prespecification by the control device, a triggering pulse is transmitted to the power switch 4 via the control output 14 . The potential across the summation point 20 is then monitored via the detection input 18 . If the potential produced is “low” and is produced at the detection input 18 in this form, the power switch 4 is on, that is to say closed, and the mains voltage is applied to the electric motor 2 in accordance with its profile.
[0029] If, however, the potential “low” is not produced at the detection input 18 , but rather the potential “high” is produced, this is an indication that the power switch 4 has returned to the off state. Immediate post-triggering and renewed monitoring and evaluation of the potential across the detection input 18 then take place. This is carried out cyclically, with the number of cycles within one half-wave expediently being limited, reference being made to this in the introductory part.
[0030] A corresponding profile for the negative half-wave can be found in the path of the flowchart which is illustrated on the left-hand side in FIG. 2 .
[0031] During operation of the electric power tool according to the invention or when executing the method according to the invention, the electric motor can be actuated in an operationally reliable manner with the least possible expenditure on hardware, with a number of triggering pulses which is as low as possible being required, and this being the case only when a preceding triggering operation proves to be a faulty triggering operation or the power switch returns to the off state for other reasons. Further post-triggering is only performed after this, specifically substantially immediately after a faulty switching state of the power switch is established.
|
The invention relates to an electrical power tool, particularly an electric hand power tool, for operating with alternating current, having an electric motor, and electronic control device, and an electrical power switch for actuating the electric motor, wherein the electronic control device comprises a bias voltage output and a detection input, connected to each other by means of a voltage divider comprising a summation point and to the side of the power switch facing the electric motor, and the control device is further designed such that the potential at the detection input is monitored after actuating the power switch and used for checking whether the power switch is conducting, and that it is actuated again if the power switch was not conducting or returned to the non-conducting state during the monitoring, and that said checking and any renewed actuation of the power switch is repeated within a half-wave of the alternating voltage.
| 7
|
FIELD OF THE INVENTION
[0001] This invention relates to pipe fittings, specifically instrument tees used for mounting instruments in closed piping systems.
BACKGROUND OF THE INVENTION
[0002] Instrument tees are well known in the art for providing a mounting platform in pipelines for instruments such as thermocouples, pressure transducers, pH meters, flowmeters, and the like. As a practical matter, however, standard instruments come in many sizes and connections, and sometimes the instrument connection may be larger than the pipe or tubing line into which the instrument is mounted. This may be particularly true of small-scale processes prevalent in the pharmaceutical and biotech industries. Instrument tees used in such situations frequently resemble the “bucket-type” instrument tee 10 illustrated in FIGS. 1 and 2 .
[0003] Instrument tee 10 , shown in plan view in FIG. 1 , comprises a body member 12 having an inlet 16 and an outlet 18 for providing a flow path through the body, and a concave surface that forms a cup 14 in fluid communication with the flow path for providing fluid access to the instrument. Cup 14 has a central axis L Inlet 16 and outlet 18 (and the resulting flow path) are aligned in a straight line L that intersects with central axis I. It should be noted that the term “fluid” as used herein refers to any process material that is of a sufficiently flowable nature that makes it appropriate for processing within a pipeline in which the instrument tee is mounted. Such a fluid may include but is not limited to a liquid, a gas, a liquid/gas mixture (such as a vapor with entrained condensate), a liquid/solid mixture (such as a dispersion or slurry), and a gas/solid mixture (for example, fluidized particles in a pneumatic conveying operation).
[0004] In many pharmaceutical or biotech processes, it is important to be able to periodically drain the system completely, often because the fluid within the piping is highly valuable and sought to be recovered or because it is necessary to completely clean the piping between batches to avoid cross-contamination. Although instrument tee 10 is capable of draining completely when the tee is mounted in a pipeline with central axis I aligned vertically, the piping configuration may not always permit a vertical installation. FIG. 2 , a cross-section of tee 10 shown in FIG. 1 , illustrates what happens inside instrument tee 10 , when the tee has been installed in a position that is rolled along axis L so that central axis/is at a sufficiently large angle relative to vertical V. Because of the geometric configuration of region 22 pooling of material 24 occurs. The pooled material may be a liquid, such as process liquid or condensate, or a solid, such as particulate or biological material settled out of a slurry or left behind by a fluidizing gas.
[0005] In addition to the loss of product and potential contamination from batch to batch that such pooling may cause, the pooled material may also be prone to formation of living contaminants such as bacteria, mold, and the like, in some systems. Also, in liquid/solid or gas/solid systems, region 22 may be prone to build-up of sediment that is difficult to clean or remove, even upon opening the tee and removing the instrument to get access to cup 14 for a thorough cleaning. For any of these reasons, pooling may be unacceptable in many types of installations, and therefore design of piping systems and fittings to prevent pooling is desirable.
[0006] It is also important for the proper operation of an instrument tee, that the instrument tee becomes sufficiently filled and completely refreshed with process fluid so that the fluid reaches an interface with the instrument to allow the instrument to get a true reading of the process conditions. In a piping system that has been drained of any process liquid, for example, air (or other blanketing gas, referred to generally herein as “air”) typically fills the piping, unless the system has been put under vacuum. It is important in many cases to avoid the formation of air pockets when filling or re-filling a piping system with process liquid. Furthermore, in other types of systems and even once a liquid system is filled, it is important to avoid stagnant pockets of fluid which may form in the cup above the flow path, depending upon the fluid dynamics of the system.
[0007] Thus, for example, instrument tee 10 may be prone to development of an air pocket or stagnant region above minimum fluid line F as shown in FIG. 2 . It should be understood that the “minimum fluid line” may not just denote a liquid/gas interface, but can also denote the interface between a moving region and a stagnant region. If the probe or other sensing interface of the instrument mounted in the mounting tee does not extend down below line F and an air pocket or other stagnant region is present above line F, this is likely to adversely affect the readings provided by the instrument. In other cases, the mere presence of air in the system may pose unacceptable risks to the purity of the process materials. Accordingly, it is also desirable to design piping systems and fittings to avoid formation of air pockets or otherwise stagnant regions.
SUMMARY OF THE INVENTION
[0008] One aspect of the invention comprises a tee for mounting an instrument in a pipe system, the tee comprising a body member having at least one inlet and one outlet for providing a flow path through the body, and a concave surface that forms a cup in fluid communication with the flow path for providing fluid access to the instrument, at least one of the inlet or the outlet positioned offset relative to a central axis of the cup. In one embodiment, the inlet and the outlet may be coaxial with one another along a flow path axis, and in another embodiment the outlet may be vertically offset from the inlet, such as to provide an operating fluid level in the cup that is co-planar or higher than a level of fluid required for instrument/fluid contact.
[0009] In one embodiment, the body member has a first planar side perpendicular to the inlet, the inlet comprising a first hole in the first planar side and a first conduit attached to the first planar side in communication with the first hole. A second planar side may be opposite the first planar side and perpendicular to the outlet, the outlet comprising a second hole in the second planar side and a second conduit attached to the second planar side in communication with the second hole. For example, the body member may comprise a length of cylindrical bar stock having material removed to form the first planar side, the second planar side, the cup, the first hole, and the second hole, and in which the first conduit and second conduit are welded to the first planar side and second planar side, respectively.
[0010] Still another aspect of the invention comprises a tee for mounting an instrument in a pipe system, the tee comprising a body member having at least one inlet and one outlet for providing a flow path through the body, and a concave surface that forms a cup in fluid communication with said flow path for providing fluid access to the instrument, wherein the inlet is vertically offset from the outlet. In one embodiment, the inlet is positioned tangential to a relatively lower cross-section of the cup, and the outlet is positioned tangential to a relatively higher cross-section of the cup.
[0011] Another aspect of the invention comprises a piping system comprising one or more instrument tees of the type described above, in which at least one of the inlet or the outlet is positioned offset relative to a central axis of the cup, and/or wherein the outlet of the instrument tee is vertically offset relative to the inlet. Particularly, at least one instrument tee in the piping system may be mounted in a rolled position such that the central axis of the cup is aligned in a range of 0 to 90 degrees from vertical.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a plan view illustration of an instrument tee of the prior art.
[0013] FIG. 2 depicts a cross-section of the instrument tee of FIG. 1 , taken along line A-A.
[0014] FIG. 3 is an isometric view of a body member or an exemplary instrument tee embodiment of the present invention.
[0015] FIG. 4 is a top view of the body member depicted in FIG. 3 .
[0016] FIG. 5 is a cross-sectional view of the body member depicted in FIG. 4 , taken across line A-A.
[0017] FIG. 6 is a cross-sectional view of the body member depicted in FIG. 4 , taken across line B-B.
[0018] FIG. 7 is an isometric view of an exemplary instrument tee of the present invention, showing the body member with attached inlet and outlet conduit.
[0019] FIG. 8 an isometric view of an exemplary instrument tee of the present invention and an attached instrument installed in surrounding process piping.
[0020] FIG. 9 is partial cross section of the instrument tee of FIG. 8 , taken across line A-A.
[0021] FIG. 10 is a longitudinal section of the instrument tee of FIG. 9 , taken across line B-B.
[0022] FIG. 11 is a side view of another exemplary instrument tee embodiment of the present invention.
[0023] FIG. 12 is a top view of the instrument tee of FIG. 11 .
DETAILED DESCRIPTION OF THE INVENTION
[0024] The invention will next be described with respect to exemplary embodiments shown in the figures. FIGS. 3-6 illustrate an exemplary instrument tee body member 30 of the present invention, and FIG. 7 illustrates the body member with attached inlet 32 and outlet 34 . As shown in FIG. 3 , body member 30 comprises a cup 36 having a central axis I, but inlet hole 38 and outlet hole 40 cut in body member 30 are mounted so that axis L, along which the holes are coaxially centered, is offset from central axis I rather than intersecting it. In the embodiment shown in FIGS. 3-7 , central axis I lies long a plane P that is perpendicular to longitudinal axis L on which the inlet and outlet are coaxially positioned.
[0025] As best shown in FIG. 5 , cup 36 has a cylindrical upper section 42 having a circular cross-section and also has a conical bottom section 44 . Inlet hole 38 and outlet hole 40 are offset from central axis I a sufficient distance so as to be tangential to the circular cross-section of the cylindrical portion of the cup. This tangential location eliminates entirely any potential for pooling for a mounting configuration of the tee that is rolled along axis L at an angle α to vertical V in the range of 0 to 90 degrees. As used herein, “tangential” means that, for example, at least the projected circumference of hole 40 aligns tangentially with the circumference of cup as shown in FIG. 5 . It should be understood, however, that hole 40 may be aligned so that a portion of the projected circumference of the hole extends radially outward (to the left in FIG. 5 ) relative to the circumference of the cup, the wall thickness of body member 30 permitting.
[0026] As shown in FIGS. 3-7 , body member 30 may be constructed from bar stock that is drilled out to form cup 36 and that is milled to form planar sides 46 and 48 . The planar sides allow the attachment of inlet conduit 32 and outlet conduit 34 , typically by welding, without having to make a specialized, “fishmouthed” cut of the end of the conduit for attachment to a cylindrical external wall of the body member. Because of the desirability of forming planar sides for attachment of the inlet and outlet conduit, a larger diameter bar stock is typically used to make the offset instrument tee of the present invention than for an instrument tee of the prior art having the same cup diameter D, because the offset location of the inlet and outlet require the planar side to be wider and therefore the thickness of material cut at the center line to be deeper.
[0027] FIGS. 8-10 depict an exemplary pipe installation including exemplary instrument tee 50 of the present invention. As shown in FIG. 9 , the installation of tee 50 is rolled at an angle β to vertical V in a range of 0 to 90 degrees, specifically at an angle of approximately 75 degrees. There is no preferred angle, however, as the angle will be set by the need to avoid interference with surrounding structure in the piping layout. As shown in FIG. 9 , even at the extreme angle of roll, inlet hole 52 is at the lowest vertical point in the cup, so no pooling can occur.
[0028] Although shown with a flanged instrument connection fitting 54 for mounting the instrument using a union clamp, such as a Sanitary TRI-CLAMP® fitting, manufactured by Tri-Clover of Kenosha, Wis., the instrument connection fitting may comprise any design known in the art. By way of example, such fittings may include, but are not limited to: “John Perry” Fittings, Bevel Seat Fittings, DC Fittings, H-Line Fittings, HDI Fittings, IPS Schedule 5 Fittings, and SWAGELOK® TS Fittings. Similarly, although shown with flanged ends 56 on the inlet and outlet in FIGS. 8 and 10 , the inlet, outlet, and instrument connection ends are not limited to any particular configuration and may comprise any other type of end fitting, including stub ends for a welded connection.
[0029] Although the instrument tee may typically comprise stainless steel, which is a preferred material of construction generally for fittings used in pharmaceutical and biotech applications, the instrument tee of the present invention is not limited to use in any particular industry or to construction of any particular materials. Accordingly, the instrument tee may comprise stainless steel, carbon steel, copper, PVC, CPVC, or specialized alloys, such as but not limited to Hastalloy, titanium, and the like.
[0030] Referring now to FIGS. 11 and 12 , there is shown another instrument tee embodiment 60 that provides not only the ability to drain at mounting angles rolled from vertical, but also is designed to minimize air pockets or other stagnant regions in the cup. Because outlet 64 is vertically offset from inlet 62 , the fluid line F is significantly higher in the cup as compared to embodiments where the inlet and outlet are both positioned at the bottom of the cup. Preferably, the placement of outlet 64 is such that fluid line F is at least as high as the level needed for instrument/fluid interface for the instrument intended for installation within the tee. As shown In FIG. 12 , tangent T 1 along which outlet 64 is positioned is parallel to and on the opposite side of cup 66 from tangent T 2 , along which inlet 62 is positioned. Mounting the outlet in this position maximizes the height of fluid line F for a particular vertical height H of the outlet relative to the inlet when the tee is installed in a rolled configuration.
[0031] Although depicted in FIG. 12 (and in each of the figures herein) with the inlet having an effective diameter d 1 that is equal to the effective outlet diameter d 2 and smaller than the effective cup diameter D, other relationships among the effective diameters may be present. For example, effective diameter d 1 may not equal effective diameter d 2 . Also, although depicted with tubular conduit and a cylindrical cup, the conduit and/or cup may have a non-round cross section. Accordingly, the term “effective” diameter is used herein, meaning the actual diameter for a round cross section and an equivalent diameter for a non-round cross section.
[0032] Also, although depicted with a single inlet and a single outlet, the invention is not limited to any particular number of inlets or outlets. What is key, is that at least one of the inlets or outlets is mounted in an offset position relative to the center line of the cup, is vertically offset from another of the inlets or outlets, or a combination thereof.
[0033] It should be understood that although the discussed herein with respect to a configuration in which the outlet is vertically higher than the inlet, the vertical relationships may be reversed so that the inlet is vertically higher than the outlet. In fact as used herein throughout the application, the terms inlet and outlet may be interchanged and are used solely for distinguishing one side from the other. Similarly, although discussed herein with respect to inlets and/or outlets positioned tangentially relative to the circular cross-section of the cup, any position of the inlet or outlet offset from a line that intersects the central axis of the cup may be provided and may have advantages over the prior art. Also, although illustrated in embodiments with both the inlet and outlet offset from the central axis of the cup, embodiments may be provided with only one offset and the other centered. Finally, although illustrated with respect to a cup having a cylindrical cross section and a conical bottom, the cup may be cylindrical throughout its entire depth, or may comprise one or more portions having cross-sections of other geometric shapes. Similarly, although described in terms of an embodiment milled from cylindrical bar stock, instrument tees of the present invention may be manufactured in any way desired, and may further have a body member that originates from a shape that is not cylindrical in cross-section, such as for example, a square block which does not require additional milling to create planar sides.
[0034] While preferred embodiments of the invention have been shown and described herein, it will be understood that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the spirit of the invention. Accordingly, it is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention.
|
A tee for mounting an instrument in a pipe system, the tee comprising a body member having at least one inlet and one outlet for providing a flow path through the body, and a concave surface that forms a cup in fluid communication with the flow path for providing fluid access to the instrument, wherein (a) at least one of the inlet or the outlet is positioned offset relative to a central axis of the cup, (b) the inlet is vertically offset from the outlet, or (c) a combination of (a) and (b). Piping systems having such tees, particularly with at least one tee mounted in a rolled position such that the central axis of the cup is aligned at an angle in a range of 0 to 90 degrees from vertical, are also disclosed.
| 5
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an embroidery machine and, more particularly, to an embroidery machine incorporating a stitch pattern selecting system and capable of stitching an embroidery in a desired size.
2. Description of the Related
As shown in FIG. 2, a known embroidery machine has a bed 1, a post 2 standing in the right-hand end of the bed 1, an arm 3 laterally extending from the upper end of the post 2 over the bed 1, and a sewing head 4 attached to the extremity of the arm 3. The arm 3 is provided with a needle bar driving mechanism, not shown, for vertically reciprocating a needle bar 5 holding a needle 6 on its lower end, a needle bar swinging mechanism, not shown, for swinging the needle bar 5 in a direction perpendicular to a feed direction in which a workpiece is fed, a thread take-up lever driving mechanism, not shown, for vertically swinging a thread take-up lever 5 in synchronism with the vertical reciprocation of the needle bar 5, and the associated parts. A main motor 14 drives the needle bar driving mechanism, and a stepping motor 15 drives the thread take-up lever driving mechanism.
A liquid crystal display 10 is put on the front surface of the arm 3 to display symbols representing various pattern elements and stitching functions of the embroidery machine M. Touch keys 11 serving also as transparent electrodes are arranged on the front surface of the liquid crystal display 10 at positions corresponding to the symbols. The touch key 11 corresponding to a symbol representing a desired pattern element is depressed to select the desired pattern element. The start/stop key (hereinafter, referred to as "S/S key") 12 of a start/stop switch (hereinafter, referred to as "S/S switch") for starting and stopping a stitching operation is disposed on the sewing head 4.
An embroidery unit 30 is mounted on the left-hand portion of the bed 1. The embroidery unit 30 is provided with an embroidery table 31 capable of moving along a Y-axis parallel to the feed direction in which a workpiece is fed and along an X-axis perpendicular to the Y-axis. An embroidery frame, not shown, for detachably holding a workpiece is mounted detachably on the embroidery table 31. A first stepping motor 32 for driving the embroidery table 31 to move along the X-axis and a second stepping motor 33 for driving the embroidery table 31 to move along the Y-axis are disposed within the main frame 32 of the embroidery unit 30. The stepping motors 32 and 33 and the needle bar 5 are driven according to driving signals provided by the embroidery machine M to stitch a desired stitch pattern on the workpiece held on the embroidery frame.
Referring to FIG. 3, showing the configuration of an embroidery machine, switches operated by the touch keys 11 and the S/S switch operated by the S/S key 12 are connected to a CPU 23. The main motor 14, the stepping motor 18 for driving the needle bar for swing motion, a display controller (LCDC) 20 for controlling the liquid crystal display (LCD) 10, and the first stepping motor 32 and second stepping motor 33 of the embroidery unit 30 are controlled by the CPU 23. Data including embroidery data to be displayed on the liquid crystal display 10 is stored in a ROM 24. A RAM 25 stores embroidery data temporarily.
When the embroidery machine M is connected to a power source, a pattern element selection picture as shown in FIG. 7(a) is displayed on the liquid crystal display 10. If necessary, a page up key 40 or a page down key 41 is operated to display a picture including desired pattern elements. A touch key corresponding to a desired pattern element displayed on the liquid crystal display 10 is depressed to select the desired pattern element. A cancel key 43 is depressed to cancel the selected pattern element. Thus, a desired stitch pattern consisting of pattern elements can be selected.
When thus selecting a desired stitch pattern, the CPU 23 determines if the desired stitch pattern can be formed within a predetermined available area. The CPU 23 selects the desired stitch pattern when the desired stitch pattern can be formed within the predetermined available area or gives an error signal to the liquid crystal display 10 when the desired stitch pattern cannot be formed within the predetermined available area. A stitching scale can be selected by operating a scale key 42. A middle scale mode in which the desired stitch pattern is stitched on a middle scale is selected (FIG. 7(b)) when the scale key 42 in a state shown in FIG. 7(a) is depressed, and a small scale mode in which the desired stitch pattern is stitched on a small scale is selected (FIG. 7(c)) when the scale key 42 in a state shown in FIG. 7(b) is depressed. The CPU 23 gives an error signal to the liquid crystal display 10 to inhibit the selection of the scale if the desired stitch pattern cannot be formed on the selected scale in the available area.
For example, when selecting a stitch pattern "AB" as shown in FIG. 8, touch keys 46 and 47 respectively corresponding to the pattern elements "A" and "B" are depressed successively. The selected scale changes sequentially in order of "small"→"large"→"middle"→"small" every time the scale key 42 is depressed.
For example, suppose that a stitch pattern "ABCD" and the small scale mode have been selected, and it is desired to change the small scale mode for the middle scale mode. Then, the CPU 12 tries first to select the large scale mode. However, since the stitch pattern "ABCD" cannot be formed in the large scale within the predetermined available area, the CPU 12 sends an error signal to the liquid crystal display 10. Therefore, when the middle scale mode is desired, the operator must cancel the character "D," depress the scale key 42 twice to change the scale from "small" via "large" to "middle," and add the character "D" again to "ABC" to select the stitch pattern "ABCD," which is a troublesome and inefficient operation.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an embroidery machine having a stitch pattern selecting system capable of directly changing a selected scale for a desired scale to omit the repetition of a pattern element selecting operation for selecting a desired pattern element after selecting a desired scale so that a desired stitch pattern and a desired scale can be readily and efficiently selected by a simple stitch pattern selecting procedure.
To achieve this object, the present invention provides a stitch pattern selecting system for selecting a desired stitch pattern in an embroidery machine including: a stitching device for forming a stitch pattern in a predetermined available area, including a needle, a needle driving mechanism for vertically reciprocating the needle and a rotary hook assembly; an embroidery frame for detachably holding a workpiece; an embroidery frame moving device for moving the embroidery frame in directions along an X-axis and a Y-axis; an embroidery frame controller for controlling the embroidery frame moving device; a stitch pattern selecting device for selecting a stitch pattern having a predetermined area; and a scale changer for changing the scale on which to stitch the stitch pattern selected by the stitch pattern selecting device. The stitch pattern selecting device includes a calculating device for calculating the sizes of the selected stitch pattern on all the scales; a decision device for deciding if the calculated sizes of the selected stitch pattern are not greater than a predetermined available area; and a controller for specifying the available scales.
The stitch pattern selecting device selects a desired stitch pattern, the calculating device calculates the sizes of the selected stitch pattern on all the scales, the decision device decides if the calculated sizes are not greater than the predetermined available area, and the controller specifies the available scales. Accordingly, the components of the selected stitch pattern need not be recombined after determining a desired scale, so that a series of stitch pattern selecting operations can be efficiently and easily carried out.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become more apparent from the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a block diagram of an embroidery machine incorporating a stitch pattern selecting system according to the present invention;
FIG. 2 is a front view of the embroidery machine of FIG. 1;
FIG. 3 is a block diagram of a control system for controlling the embroidery machine of FIG. 1;
FIGS. 4A, 4B, 5A, 5B and 6 are flow charts of a control program to be executed by a stitch pattern selecting system incorporated into the embroidery machine of FIG. 1; and
FIGS. 7(a)-(c), and 8 to 12 are pictorial views explaining a method of selecting a desired stitch pattern.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
An embroidery machine incorporating a stitch pattern selecting system embodying the present invention is substantially the same in mechanical configuration as known embroidery machines, and hence only a stitch pattern selecting procedure of the stitch pattern selecting system will be described with reference to FIGS. 4 to 12, and the description of the mechanical configuration of the embroidery machine will be omitted.
Upon the connection of an embroidery machine M to a power source, a CPU 23 reads a predetermined control program from a ROM 24 and carries out the control program. Referring to FIGS. 4A and 4B, an initial pattern element selection picture for a large scale pattern mode as shown in FIG. 7(a) is displayed in step S1. A query is made in step S2 to see if a scale key 46 is depressed. If the response in step S2 is affirmative, a second pattern element selection picture for a middle scale pattern mode as shown in FIG. 7(b) is displayed. If the response in step S2 is negative, the initial pattern element selection picture for the large scale pattern mode remains unchanged. If the response to a query in step S4 is negative, the control program returns to step S2. Then, if the scale key 42 is depressed, i.e., if the response to a query in step S2 is affirmative, a third pattern element selection picture for a small scale pattern mode as shown in FIG. 7(c) is displayed in step S3.
When a pattern element "A" is selected by depressing a touch key 46 corresponding to a symbol A, the response in step S4 is affirmative. The CPU 32 reads the size of the pattern element "A" on a small scale from the ROM 24 and makes a query in step S6 to see if the pattern element "A" on the small scale is greater than a predetermined available area. If the response in step S6 is negative, the pattern element "A" is displayed on a display 10 in step S7. Then, the size of the pattern element "A" on a middle scale is calculated in step S8, and a query is made in step S9 to see if the size of the pattern element "A" on the middle scale is greater than the predetermined available area. If the response in step S9 is negative, the size of the pattern element "A" on a large scale is calculated in step S10, and a query is made in step S11 to see if the size of the pattern element "A" on the large scale is greater than the predetermined available area. If the response in step S11 is negative, "Small/Middle/Large" is indicated on the scale key 42 in step S12.
In this state, the large scale for the large scale pattern mode is selected in step S16 when the scale key 42 indicating "Small/Middle/Large" as shown in FIG. 7(C) is depressed, the response in step S13 is affirmative, the response in step S14 is negative, and the response in step S15 is negative. If the scale key 42 as shown in FIG. 7(A) is depressed, the middle scale for the middle scale pattern mode is selected in step S24, in which the response in step S14 is affirmative. If the scale key 42 as shown in FIG. 7(B) is depressed, the small scale for the small pattern mode is selected in step S25, in which the response in step S14 is negative, and the response in step S15 is affirmative.
Then, the control program advances through exit and entry connector A to step S26 (FIG. 4B). If neither a cancel key 43 nor an S/S key 12 is depressed and no pattern element is selected, the responses in steps S26 and S27 are negative and the control program goes to step S31. Since the pattern element "A" can be formed on the large scale, i.e., the response in step S31 is affirmative, the control program goes to an exit connector D, and step S13 is executed to see if the scale key 42 indicating "Large/Middle/Small" is depressed. When the response in step S13 is negative, the control program goes through the exit and entry connector A to step S26. When the S/S key 12 is depressed, i.e., when the response in step S27 is affirmative, the pattern element "A" is stitched in step S29, and the control program is ended. When a second pattern element "B" on the small scale is selected, and a third pattern element "C" is selected after the selection of the second pattern element "B", the response in step S28 is affirmative, the foregoing steps for selecting the pattern element "A" are executed, and a pattern element selection picture shown in FIG. 9 is displayed.
When a fourth pattern element "D" is selected in addition to a pattern "ABC", and the size of a pattern "ABCD" on the large scale calculated in step S10 is greater than the predetermined available area, the response in step S11 is affirmative. Then, the indication "Large/Middle/Small" on the scale key 42 is changed to "Middle/Small" as indicated at 50 in FIG. 10. When the scale key 42 indicating "Middle/Small" is depressed, the response in step S20 is affirmative, and the small scale pattern mode changes to the middle scale pattern mode in step S22 (the response in step S21 is negative). If the current mode is the middle scale pattern mode, the middle scale pattern mode changes to the small scale pattern mode in step S23 (the response in step S21 is affirmative).
Then, the control program goes through the exit and entry connector A to step S26. If the responses in steps S26 and S27 are negative and no pattern element is selected (the response in step S28 is negative), the control program goes to step S31. When the pattern "ABCD" cannot be formed in a size on the large scale and can be formed in a size on the middle scale, i.e., the response in step S31 is negative, and the response in step S32 is affirmative, the control program returns to step S20, where a query is made to see if the scale key 42 indicating "Middle/Small" is depressed. When the response in step S20 is negative, the control program goes through the exit and entry connector A to step S26. When the cancel key 43 is depressed, the pattern element "D" is canceled in step S30, and the sizes of the pattern "ABC" on all the scales are calculated in step S5. If the pattern "ABC" can be formed in a size on the large scale, the pattern element selection picture of FIG. 9 is displayed.
If a fifth pattern element "F" is selected with the small scale selected, i.e., when the response in step S28 is affirmative, the same steps as those executed when the first pattern element "A" is selected are executed.
When a sixth pattern element "F" is selected, the size of a pattern "ABCDEF" on the middle scale is calculated in step S8, and a query is made in step S9 to see if the size of the pattern "ABCDEF" on the middle scale is greater than the predetermined available area, i.e., when the response in step S9 is affirmative, and the pattern "ABCDEF" on the small scale can be formed in the predetermined available area, an indication "Small" as indicated at 51 is indicated on the scale key 42 as shown in FIG. 11. The size is not changed whether the key 42 indicating "Small" is depressed, i.e., the response in step S18 is affirmative, or whether the same is not depressed, i.e., the response in step S18 is negative. Then, the control program goes through the exit and entry connector A to step S26. When the responses in steps S26 and S27 are negative and no further pattern element is selected (the response in step S28 is negative), the control program goes through steps S31 and S32 and entry connector F to step S18, because the pattern "ABCDEF" cannot be formed on the large scale or the middle scale.
When the fourth pattern element "D" is selected by repeating the foregoing steps after selecting the pattern "ABC" on the large scale as shown in FIG. 12, the size of the pattern "ABCD" on the large scale is calculated in step S5, and a query is made in step S6 to see if the size of the pattern "ABCD" on the large scale is greater than the predetermined available area. If the response in step S6 is affirmative, a query is made in step S33 to see if it is true that "Small" is indicated on the scale key 42 and the small scale is selectable. If the response in step S33 is negative, a query is made in step S34 to see if it is true that "Middle/Small" is indicated on the scale key 42 and the middle scale is selectable. If the response in step S34 is negative, the size of the pattern "ABCD" on the middle scale is calculated in step S35, and a query is made in step S36 to see if the pattern "ABCD" on the middle scale is not greater than the predetermined available area. When the response in step S36 is negative, the middle scale is selected and the pattern "ABCD" of a size on the middle scale is displayed in step S37, and "Middle/Small" is indicated on the scale key 42 in step S38. When the response in step S36 is affirmative, i.e., when the size of the pattern "ABCD" on the middle scale is greater than the predetermined available area, the size of the pattern "ABCD" on the small scale is calculated in step S39, and a query is made in step S40 to see if the size of the pattern "ABCD" on the small scale is greater than the predetermined available area. When the response in step S40 is negative, the small scale is selected, and the pattern "ABCD" of a size on the small scale is displayed in step S41, and "Small" is indicated on the scale key 42.
If the pattern "ABCD" of a size on the small scale is greater than the predetermined available area, i.e., if the response in step S40 is affirmative, a size error message is displayed on the display 10 in step S43, and the control program goes through the exit and entry connector A to step S26. When the sixth pattern element "F" is selected after a pattern "ABCDE" and the middle scale have been selected to select a pattern "ABCDEF," and when the size of the pattern "ABCDEF" on the middle scale is greater than the predetermined available area, i.e., the response in step S6 is affirmative, the control program goes through exit and entry connector B to step S33. Since the middle scale is available in this state, i.e., the response in step S33 is negative, and the response in step S34 is affirmative, the size of the pattern "ABCDEF" on the small scale is calculated in step S39, and a query is made in step S40 to see if the size of the pattern "ABCDEF" on the small scale is greater than the predetermined available area. When the response in step S40 is negative, the small scale is selected, the pattern "ABCDEF" on the small scale is displayed on the display 10 in step S41, and "Small" is indicated on the scale key 42 in step S42. If the size of the pattern "ABCDEF" on the small scale is greater than the predetermined available area, a size error message is displayed on the display 10 in step S43, and the control program goes through the exit and entry connector A to step S26.
When a pattern element "H" is selected after a pattern "ABCDEFG" and the small scale have been selected, and when the size of the pattern "ABCDEFGH" on the small scale is greater than the predetermined available area, i.e., the response in step S6 is affirmative, the control program goes through the exit and entry connector B to step S33. However, since the size of the pattern "ABCDEFGH" on the small scale is greater than the predetermined available area and "small" is indicated on the scale key 42, a size error message is displayed on the display 10 in step S43, and the control program goes through the exit and entry connector A to step S26.
The embroidery machine in this embodiment uses three scales, namely, the large scale, the middle scale and the small scale, however, the embroidery machine may use any suitable number of scales.
Although the invention has been described in its preferred form with a certain degree of particularity, obviously many changes and variations are possible therein. It is therefore to be understood that the present invention may be practiced otherwise than as specifically described herein without departing from the scope and spirit thereof.
|
An embroidery machine incorporates a stitch pattern selecting system capable of selecting a possible scale for a selected pattern on which the selected pattern is to be stitched to omit the repetition of pattern selection after determining a scale in order that a series of pattern selecting operations can be carried out easily and efficiently. When selecting a pattern and a scale on which the pattern is to be stitched, a CPU calculates the sizes of the selected pattern on all the scales and compares the sizes of the selected pattern with a predetermined available area for embroidering. The CPU specifies the available scales.
| 3
|
DESCRIPTION
1. Technical Field
This invention relates to a hydraulic control circuit and more particularly to a circuit having preselected actuation delays when the rotational direction of the motor is changed.
2. Background Art
Many earthmoving machines have mechanisms driven by a hydraulic motor which receives pressurized fluid from a hydraulic pump. One example of such mechanism is an elevating scraper in which the elevating mechanism is hydraulically driven by a hydraulic motor. The elevating mechanism is driven in a first direction by directing pressurized fluid from the pump to one side of the motor and a second direction by directing pressurized fluid from the pump to the other side of the motor. Such elevating mechanism is generally quite heavy and generates substantial amounts of inertia energy once it is in motion. If the direction of the drive motor is reversed while the elevating mechanism is in motion, high shock loads are imparted to the entire machine. To prevent the generation of such shock loads some elevating scrapers have a mechanical latch which physically stops the control lever associated with controlling the drive motor at the neutral position. The mechanical latch must then be manually moved by the operator before the control lever can be put in a position to drive the motor in the opposite direction. Stopping the control lever momentarily in the neutral position allows the elevating mechanism to coast to a stop so that by the time the control lever is moved to the other operating position the inertia energy has decayed. One of the problems with such mechanical latch is that it requires several hand movements by the operator to change the driving direction of the elevating mechanism. Such hand movements require the operator to expend additional energy each time he changes the drive direction of the elevating mechanism.
The present invention is directed to overcoming one or more of the problems as set forth above.
SUMMARY OF THE INVENTION
In one aspect of the present invention a pilot control circuit is provided for controlling a hydraulic system including a reversible hydraulic motor, a variable displacement pump connected to the motor and having a pilot operated displacement control, and a reversing valve disposed between the pump and the motor and being movable between forward and reverse drive positions. The pilot control circuit includes a source of pressurized pilot fluid, a control valve connected to the source of pressurized pilot fluid and being movable between a first position to output a first regulated pressure pilot signal and a second position to output a second regulated pressure pilot signal, and a means for communicating the first or second pilot signal to the displacement control of the pump. A delay means is provided for delaying the communication of the first or second signal to the displacement control for a predetermined period of time after the control valve is moved between the first and second positions.
BRIEF DESCRIPTION OF THE DRAWINGS
The sole figure is a schematic illustration of an embodiment of the present invention.
BEST MODE FOR CARRYING OUT THE INVENTION
A hydraulic control system 10 is provided for operating a reversible hydraulic motor 11 which can be utilized to drive an elevating mechanism (not shown) of an elevating scraper. The hydraulic system 10 includes a variable displacement hydraulic pump 12 and a source of pressurized pilot fluid such as a pump 13 connected to a pilot fluid supply line 14. The pump 12 includes a movable swash plate 15 and a displacement control 16 adapted to control the angle or position of the swash plate 15 and thereby regulate the volumetric output of the pump. The displacement control 16 is of the type in which the swash plate 15 is moved toward the maximum displacement position in response to receiving a pressurized pilot signal. The pump 12 is preferably of the type in which the swash plate is forcibly retained at a zero displacement position in the absence of the pilot signal. A signal line 17 is connected to the displacement control.
A pilot operated reversing valve 18 is connected to the variable displacement pump 12 through a supply conduit 19 and to the hydraulic motor 11 through a pair of motor conduits 21,22. The reversing valve 18 is movable between a first position at which the supply conduit 19 is communicated with the motor conduit 21 and the motor conduit 22 is communicated with a tank 23 and a second position at which the supply conduit 19 is in communication with the motor conduit 22 and the motor conduit 21 is in communication with the tank 23. A pilot line 24 is connected to the reversing valve 18. The reversing valve 18 is resiliently biased to the first position and is urged to the second position when a pilot signal is present in the pilot line 24.
A pilot control circuit 25 is operatively connected to the system 10 and includes a manually actuated control valve 26 having a pair of pilot outlet ports 27,28 and being connected to the pilot supply line 14. The control valve has an operator controlled handle 29 operatively connected thereto and is shown at a neutral position at which the pilot supply line 14 is blocked from both of the outlet ports. The handle 29 is movable in a clockwise direction to a first operating or reverse drive position at which a regulated pressure pilot signal is outputted through the outlet port 28, or in a counterclockwise direction to a second operating or first speed forward drive position at which a regulated pressure pilot signal is outputted through the outlet port 27 at a predetermined pressure level, or a third operating or second speed forward drive position at which the regulated pressure pilot signal outputted through the outlet port 27 is increased to a second predetermined level. A detent mechanism 30 is provided to retain the control handle in the selected operating position.
A means 31 is provided for communicating the first or second pilot signals to the displacement controller 16. The communicating means 31 includes the pilot line 17, a pair of signal passages 32,33 connected to the outlet ports 27,28, a shuttle valve 34 having a pair of inlet ports 36,37 connected to the signal passages 32,33 and an outlet port 38 connected to the pilot line 17. The shuttle valve 34 constitutes a valve means for selectively communicating one of the first or second signal passages to the pilot line 17.
A delay means 41 is provided for delaying the communication of the first or second pilot signals to the displacement controller 16 for a predetermined period of time after the control valve 26 is moved between the forward and reverse drive positions. The delay means 41 includes a pair of pilot operated delay valves 42,43 disposed within the signal passages 32,33, respectively, a pilot passage 44 connecting the signal passage 33 to the delay valve 42 through a check valve 46 and an orifice 47, and a pilot passage 48 connecting the signal passage 32 to the delay valve 43 through a check valve 49 and an orifice 51.
The delay valve 42 includes a spool 52 slidably disposed in a bore 53 and defining a chamber 54 in communication with the pilot passage 44. The spool 52 has an annular groove 56 which establishes communication through the signal passage 32 when the spool is at the position shown. The spool is biased to the position shown by a spring 57 and is moved leftward to a position blocking communication through the signal passage 32 when pressurized pilot fluid is directed into the chamber. The chamber 54 acts as both an actuating chamber and an accumulator means 55 for storing a preselected volume of pressurized fluid.
The delay valve 43 also includes a spool 58 slidably disposed in a bore 59 and defining a chamber 61 in communication with the pilot passage 48. The spool 58 has a pair of axially spaced annular grooves 62,63 with the groove 62 establishing communication through the signal passage 33 when the spool is at the position shown. The spool 58 is biased to the position shown by a spring 64 and is moved leftward to a position blocking communication through the signal passage 33 when pressurized pilot fluid is directed into the chamber. The chamber 61 acts as both an actuating chamber and an accumulator means 65 for storing a preselected volume of pressurized fluid. The groove 63 communicates the signal passage 33 between the delay valve 43 and the shuttle valve 34 with a drain line 66 when the spool 58 is at the leftward position.
Alternatively, the accumulator means 55,65 can include a pair of separate accumulators connected to the pilot passages 32,33.
A pilot operated valve 67 is connected to the pilot supply line 14, the pilot line 24, and to the drain line 66. The valve 67 is movable between a first position at which the pilot line 24 is communicated with the drain line 66 and blocked from the supply pilot line 14, and a second position at which the pilot line 24 is in communication with the pilot supply line 14. The valve 67 is resiliently urged to the first position. The valve 67 is connected to the signal passage 33 between the delay valve 43 and the shuttle valve 34 and is moved to the second position when pressurized fluid is directed through the pilot line 33 to the displacement control.
A vent passage 69 communicates the outlet port 38 with the drain line 66 through an orifice 70 to prevent fluid from being trapped in the displacement controller 16.
In the present embodiment the components enclosed within the phantom line indicated at 68 are contained within the same body.
INDUSTRIAL APPLICABILITY
The delay means 41 is effective only when the control handle 29 is being shifted between the forward and reverse positions with no intermediate stop at the neutral position. For example, when the control handle is at the position shown the pilot passages 44 and 48 and thus the chambers 54,61 are communicated with the tank 23 through the respective orifices 47,51 and through the control valve 26 to the tank 23. Thus, the pilot operated valves 42,43 and 67 would be in the position shown. If the control handle 29 is thus shifted to a forward position from the neutral position, a pilot signal is outputted through the outlet port 27, the signal passage 32, the pilot operated valve 42, the shuttle valve 36, and the pilot line 17 to the displacement control 16. The pilot signal entering the displacement control 16 causes the swash plate 15 to move to a predetermined position to direct pressurized fluid through the conduit 19, the reversing valve 18, and the conduit 21 to the motor 11 to drive it in the forward direction. The pressurized pilot signal in the signal passage 32 also passes through the pilot passage 48 and the check valve 49 and into the chamber 61 of the valve 43. Initially, the pilot signal entering the chamber 61 moves the spool 58 rightwardly against the bias of the spring 64 to the position at which fluid flow through the pilot line 33 is blocked. The pilot signal continues to enter the chamber 61 causing further rightward movement of the spool until it reaches a position at which the end of the pilot operated valve 67 is communicated with the tank. The chamber 61 holds a predetermined volume of the pilot signal and thus acts as an accumulator. The chamber 61 will remain filled with fluid and the pilot operated valve 43 will remain in the extreme rightward position as long as the control handle 29 is maintained at the forward drive position.
If the control handle 29 is moved from the forward drive position directly to the reverse drive position without stopping at the neutral position a pilot signal is immediately outputted through the outlet port 28 and into the signal passage 33. However, the pilot operated valve 43 remains in the blocking position until the pressurized fluid in the chamber 61 of the valve 43 has bled through the orifice 51, the signal passage 32 and the control valve 26. The volume of the chamber 61 and the size of the orifice 51 are selected so that the spool 58 of the valve 43 does not reach the position for establishing communication through the signal passage 33 for a predetermined period of time to permit the pump to destroke to the zero displacement position and the inertia forces in the elevating mechanism decay such that the motor 11 comes to a stop. At the end of the predetermined period of time, the spool 58 of the valve 43 reaches the position at which the pilot signal in the signal passage 33 passes therethrough and through the shuttle valve 34 and the pilot line 17 to the displacement controller 16. The pilot signal passing through the valve 43 is also simultaneously directed to the pilot operated valve 67 to shift it to the position at which pressurized fluid in the pilot supply line 14 passes through the pilot line 24 to shift the valve 18 to its other position for reversing fluid flow through the hydraulic motor 11.
At the same time that the pressurized fluid was being bled from the chamber 61 the pressurized pilot signal in the signal passage 33 passes through the check valve 46 and into the pilot passage 44. The pilot signal in the pilot passage 44 initially enters the chamber 54 of the valve 42 to shift the spool 52 leftwardly to its blocking position and then fills the chamber 54 with a predetermined volume of pressurized fluid. Thus, when the handle 29 is subsequently moved from the reverse drive position back to the forward position the actuation of the hydraulic system would not occur until the volume of fluid stored in the chamber 54 has bled through the orifice 47 similar to that previously described.
In view of the foregoing, it is readily apparent that the structure of the present invention provides an improved pilot control circuit for controlling operation of a hydraulic system in which the changing of the rotational direction of the motor is automatically delayed for a predetermined period of time when the control handle is moved between the forward and reverse drive positions. This is accomplished by providing a pilot operated valve in each of the pilot signal passages with each valve having a chamber connected to the opposite signal passage. The chambers are sized to store pressurized pilot fluid when the associated pilot operated valve is in the blocking position. The stored fluid in the chamber maintains the pilot operated valve in the blocking position until such fluid is bled through an orifice. The volumetric capacity of the chambers and the size of the orifice are sized so that the inertia forces acting on the hydraulic motor have dissipated before the pilot operated valve is shifted to the open position.
Other aspects, objects and advantages of this invention can be obtained from a study of the drawings, the disclosure and the appended claims.
|
Reversible hydraulic motors driven by fluid from variable displacement pumps are useful in driving various mechanisms of earthmoving machines. The subject pilot control circuit includes a pilot operated valve in each of a pair of signal passages which communicate a pilot signal from a control valve to a pump displacement control. The pilot operated valve in one of the signal passages is shifted to a position blocking fluid flow therethrough by the pilot signal in the other signal passage. An accumulator means stores a portion of the pilot signal from the other signal passage and causes the pilot operated valve in the one signal passage to remain in the blocking position for a predetermined time after the pilot signal is vented from the other signal passage.
| 4
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to a funnel system for directing the flow of material such as liquids or granular solids from a first container to a second container. More specifically, the present invention relates to a funnel system which holds material from a first container and may prevent the flow of the material to the second container.
[0003] 2. Description of the Related Art
[0004] When cooking, it is often necessary to measure materials or pour materials from one container to another container. Although several methods exist to perform these tasks, none are ideal. One such method would be to first pour the material from the first container into a measuring cup to ensure the proper amount of material and to then pour the material from the measuring cup into a second container. Even if the measuring cup has a spout, it is difficult to ensure that all of the material flows into the second container without spilling. This is especially true if the second container has a narrow opening. A second method further improves the first method by employing a funnel which is inserted into the second container. Instead of pouring the material directly from the measuring cup, the material may be poured from the measuring cup to the funnel thus ensuring that none of the material spills. However, this method requires the purchase, storage, and cleaning of two separate pieces of equipment.
SUMMARY OF THE INVENTION
[0005] A funnel system may include a first hollow frusto-conical device having an intake port and an exit port, wherein a diameter of the exit port may be smaller than a diameter of the intake port The funnel system may further include a second hollow frusto-conical device having an intake port and an exit port, wherein a diameter of the exit port may be smaller than a diameter of the intake port, and wherein the second device may be adapted for mating with the first device for forming a passage from the second device through the first device, wherein the exit ports may be partially eclipsed so that when the second device rotates with respect to the first device the passage throttles between a substantially open position and a substantially closed position.
[0006] A method for introducing and dispensing a material may include providing a first hollow frusto-conical device having an intake port and an exit port, wherein a diameter of the exit port may be smaller than a diameter of the intake port. The method may further include providing a second hollow frusto-conical device having an intake port and an exit port, wherein a diameter of the exit port may be smaller than a diameter of the intake port, and wherein the second device may be adapted for mating with the first device for forming a passage from the second device through the first device, wherein the exit ports are partially eclipsed so that when the second device rotates with respect to the first device the passage throttles between a substantially open position and a substantially closed position. The method may further include rotating the second hollow frusto-conical device relative to the first hollow frusto-conical device for throttling the passage to the substantially closed position. The method may further include introducing the material into the intake port of the second hollow frusto-conical device. The method may further include rotating the second hollow frusto-conical device relative to the first hollow frusto-conical device for throttling the passage to the substantially open position. The method may further include dispensing the material from the exit port of the first hollow frusto-conical device.
[0007] A funnel system may include a first funnel, including an intake port and an exit port, wherein a diameter of the exit port may be smaller than a diameter of the intake port. The funnel system may further include a second funnel adapted to mate with and operably rotate with respect to the first funnel, including an intake port and an exit port, wherein a diameter of the exit port may be smaller than a diameter of the intake port. The funnel system may further include a passage through the exit ports. The funnel system may further include a first occluding member disposed within the exit port of the first funnel, wherein the first occluding member partially eclipses the exit port of the first funnel. The funnel system may further include a second occluding member disposed within the exit port of the second funnel, wherein the second occluding member partially eclipses the exit port of the second funnel, and wherein when the second funnel rotates with respect to the first funnel the passage throttles between a substantially open position and a substantially closed position.
DESCRIPTION OF THE DRAWINGS
[0008] Various embodiments of the present invention are illustrated in the following drawings, which are meant to be exemplary only and are not limiting on the scope of the present invention, and in which
[0009] FIG. 1 is a side view drawing of a funnel system in accordance with one embodiment of the present invention;
[0010] FIG. 2 is a side view drawing of a funnel system with an optional tube attachment in accordance with one embodiment of the present invention;
[0011] FIG. 3 is a side view drawing of the funnel system of FIG. 2 , rotated 90 degrees from FIG. 2 ;
[0012] FIG. 4 a is a top view drawing of a first frusto-conical device in accordance with the funnel system of FIG. 1 and FIG. 2 ;
[0013] FIG. 4 b is a top view drawing of a second frusto-conical device in accordance with the funnel system of FIG. 1 and FIG. 2 ; and
[0014] FIG. 5 is an isometric view drawing of the funnel system of FIG. 2 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] In the following description, various aspects of the present invention will be described. For purposes of explanation, specific configurations and details are set forth in order to provide a thorough understanding of the present invention. However, it will also be apparent to one skilled in the art that the present invention may be practiced without the specific details presented herein. Furthermore, well known features may be omitted or simplified in order not to obscure the present invention.
[0016] A side view drawing of an embodiment of funnel system 100 is shown in FIG. 1 . Other views are shown in FIGS. 2-5 . The funnel system 100 is generally constructed of two separable devices, for example, a first hollow frusto-conical device 110 and a second hollow frusto-conical device 130 . The first hollow frusto-conical device 110 is comprised of side walls 122 which taper from an intake port 112 and which lead to an exit port 114 . The diameter of the exit port 114 is smaller than the diameter of the intake port 112 . The first hollow frusto-conical device 110 may also have a depending cylindrical member 116 which may lead from the exit port 114 . The second hollow frusto-conical device 130 is comprised of side walls 142 which taper from an intake port 132 and which lead to an exit port 134 . The diameter of the exit port 134 is smaller than the diameter of the intake port 132 .
[0017] The second hollow frusto-conical device 130 is adapted for mating with hollow frusto-conical device 110 . In a preferred embodiment of the invention, the side walls 142 of the second hollow frusto-conical device 130 conform to the inner dimensions of the side walls 122 of the first hollow frusto-conical device 110 . In this embodiment, the second hollow frusto-conical device 130 fits within first hollow frusto-conical device 110 so that the exit port 134 of the second device 130 sits within the exit port 114 of the first device 110 . When the two devices are mated, a passage 160 is created through exit port 134 and exit port 114 . The mating between the two devices allows the second hollow frusto-conical device 130 to rotate with respect to the first hollow frusto-conical device 110 . In a preferred embodiment of the present invention, when mated, the intake port 132 of the second device may extend beyond the intake port 112 of the first device in a direction distal to the exit ports of both devices. In another embodiment of the present invention, the intake port 132 of the second device may not extend beyond the intake port 112 of the first device.
[0018] A locking mechanism 170 shown in FIG. 1 may be used to lock the two hollow frusto-conical devices 110 and 130 in a mated position so that the two devices cannot be separated. However, even in embodiments of the invention that may include a locking mechanism 170 , the second hollow frusto-conical device 130 is free to rotate with respect to the first hollow frusto-conical device 110 . An unlocking mechanism (which may be incorporated into locking mechanism 170 ) may also be used when a locking mechanism is employed to unlock the two devices from the mated position and allow their separation.
[0019] The exit ports 114 and 134 of the first and second devices further include occluding members 118 and 138 respectively. The occluding members 118 and 138 may be formed integral to their respective exit ports or may alternately be removable. The exit ports 114 and 134 are preferably partially eclipsed by occluding members 118 and 138 , respectively. An embodiment of the occluding members is shown in FIGS. 4 a - 4 b . When the second hollow frusto-conical device 130 is made to rotate with respect to the first hollow frusto-conical device 110 , the occluding member 138 also rotates with respect to occluding member 118 . During this rotation, the occluding members 118 and 138 are made to cause the passage 160 created between exit ports 114 and 134 to throttle between a substantially open and a substantially closed position. In a preferred embodiment of the present invention, the occluding members 118 and 138 may each be formed as a semi-circular disk. In other embodiments, the occluding members 118 and 138 may be formed into alternate shapes which partially eclipse the exit ports 114 and 134 as is well known to those skilled in the art. In another embodiment, only one occluding member may be used which expands and contracts, or which opens and closes when the two hollow frusto-conical devices are rotated relative to each other. In this way, they may cause the passage 160 to throttle between a substantially open and a substantially closed position.
[0020] The second hollow frusto-conical device 130 may further include one or more measuring scale(s) 136 . An embodiment of the measuring scale 136 is shown in FIG. 4 b . The measuring scale 136 may be for example a volumetric scale useful for determining the quantity of material within the funnel system. The measuring scale(s) 136 may be a liquid scale with labels such as teaspoons, tablespoons, ounces, cups, pints, quarts, milliliters, liters, or the like. The measuring scale(s) 136 may alternately or additionally be a solid (or dry) scale with labels such as ounces, pounds, grams, kilograms, or the like in which the scale is based on the density of a particular solid (or dry) material to be measured.
[0021] The second hollow frusto-conical device 130 may also include a handle 140 . The handle 140 may be used to ease rotating the second hollow frusto-conical device 130 with respect to the first hollow frusto-conical device 110 . The handle 140 may also be used for transporting the funnel system 100 . The handle 140 may be either solid or may have a through-hole which may be used to hang the funnel system 100 on a hook. The through-hole may also be sized for the finger or fingers of a user. The second hollow frusto-conical device 130 may also have a spout 144 shown in FIG. 3 that may be used for pouring materials from the funnel system 100 .
[0022] In some embodiments of the present invention, the funnel system 100 may also include an hollow exit port attachment 150 adapted for mating with exit port 114 of the first hollow frusto-conical device 110 . An embodiment of the hollow exit port attachment 150 is shown in FIG. 2 . The hollow exit port attachment 150 may be comprised of an intake port 152 , an exit port 154 , and a depending cylindrical member 156 attached to exit port 154 . In some embodiments of the present invention, a locking mechanism (not shown but similar to locking mechanism 170 ) may be used to lock hollow exit port attachment 150 and first hollow frusto-conical device 110 in a mated position so that the two cannot be separated. An unlocking mechanism (which may be incorporated into the locking mechanism) may also be used when a locking mechanism is employed to unlock the hollow exit port attachment 150 from the first hollow frusto-conical device 110 and allow their separation. In some embodiments of the present invention, the depending cylindrical member 156 may be narrower than the exit port 114 of the first frusto-conical device 110 in order to allow the funnel system 100 to be used with containers having a narrower opening. In other embodiments of the present invention, the depending cylindrical member 156 may be wider than the exit port 114 of the first frusto-conical device 110 in order to allow the funnel system 100 to be used with containers having a wider opening.
[0023] The first frusto-conical device 110 , the second frusto-conical device 130 , and the hollow exit port attachment 150 can be made from a wide variety of materials such as-glass, plastic, ABS, stainless steel, or the like. Further, not all of the components of funnel system 100 need be made from the same materials. For example, the second frusto-conical device 130 may be made of glass and the first frusto-conical device 110 may be made of plastic. Clear materials may be preferred in order to view the volume of the material within the funnel system with measuring scale(s) 136 .
[0024] The funnel system 100 may be used both to measure a volume of material from a first container and to dispense the material into a second container. In such an embodiment, the first hollow frusto-conical device 110 is first rotated with respect to the second hollow frusto-conical device 130 . During this rotation, the passage 160 created between exit ports 114 and 134 is preferably throttled into the substantially closed position. Once the passage 160 is substantially closed, a material such as a liquid or a granular solid, may be introduced into the intake port 132 of the second hollow frusto-conical device 130 . Since the passage 160 is substantially closed, the material will remain within the funnel system 100 . The material may then be measured using measuring scale(s) 136 . Material may then be removed or added to the funnel system 100 based upon whether too much or too little material has been introduced into the funnel system 100 . Once the desired measure of material is within the funnel system 100 , the exit port 114 of first hollow frusto-conical device 110 may be aligned with the opening of a second container. Optional depending cylindrical member 116 or optional hollow exit port attachment 150 may be used to aid in the alignment of the funnel system 100 if the material contained therein is to be discharged into a container. Once aligned, the first hollow frusto-conical device 110 is rotated with respect to the second hollow frusto-conical device 130 . This rotation may be in the same direction as the first rotation or in a different direction. During this second rotation, the passage 160 created between exit ports 114 and 134 is throttled from the substantially closed position to a substantially open position. As the passage 160 is opened, the material within the funnel system is discharged therefrom. For example, it may be introduced into a container by way of the exit port 114 of the first hollow frusto-conical device 110 .
[0025] Various devices (not shown) which alter the material as it is introduced into the second container may be incorporated into the funnel system. Such devices may be a permanent part of the funnel system 100 or may be optionally attached or interchangeably exchanged. The physical location of these devices will depend upon the device, but they may be incorporated in or attached to exit port 114 or 134 , occluding member 118 or 138 , hollow cylindrical depending member 116 , hollow exit port attachment 150 or other members of the funnel system 100 . An exemplary embodiment of such a device is an aerator which introduces air into a material as it exits the funnel system 100 . Such a device may be useful for wines or other beverages. Another exemplary embodiment of an additional device may be a strainer which only allows material of a certain dimension to pass through the funnel system 100 . Such a device may be useful for creating a sieve or for removing sediment from a liquid. Another exemplary embodiment of such a device is a sifter which may be useful for both aerating a material and allowing material of only a certain dimension to pass through the funnel system 100 . Other devices which act upon the material as it exits the funnel system 100 are also possible. Alternately, devices may be employed which act upon the material while still within the funnel system 100 . Such devices may include mixers or separators.
[0026] Although particular embodiments are shown and described herein, further modifications of the present invention will occur to persons skilled in the art. All such modifications are deemed to be within the scope and spirit of the present invention as defined by the appended claims.
|
A funnel system and method for introducing and dispensing a material are presented. In this funnel system two frusto-conical devices having intake ports which have a larger diameter than the diameter of their exit ports may be mated. When mated, a passage exists through the devices' exit ports. Both frusto-conical devices may have partially eclipsed exit ports such that when one device rotates with respect to the other, the passage throttles between a substantially open and a substantially closed position. In this method the devices may be rotated such that the passage may be in the substantially closed position and a material may then be introduced into the second device's intake port. To dispense the material, the devices may be rotated such that the passage may be in a substantially open position whereupon the material may be dispensed from the first device's exit port.
| 1
|
BACKGROUND OF THE INVENTION
The invention is based on a vehicle brake system for reducing drive slip. An apparatus for reducing possible drive slip in the wheels has already been proposed, in German Pat. No. 18 06 671, for use in a vehicle having an internal combustion engine, a differential transmission and wheels which are driven by the differential transmission and with which wheel brakes are associated, and having at least one pressure reservoir as well as brake pressure control valves which have positions for buildup, maintenance and reduction of brake pressure. This apparatus includes means for measuring the angular velocities of the driven and the non-driven wheels; means for determining the magnitude of drive slip that occurs; and control switches which, if the magnitude of the drive slip exceeds a preselected upper switching threshold, moves the brake pressure control valve or valves of the slipping wheel or wheels into the positions for brake pressure buildup. If the slip value falls below this upper switching threshold, the brake pressure control valves are moved into their brake pressure maintenance position, and if the value falls below a second value, lower switching threshold, these valves are moved into the position for reducing brake pressure. This apparatus very quickly reduces drive slip to very low values. However, on road surfaces where the grip or traction varies, and especially while accelerating during startup using a friction clutch, this drastic reduction in drive slip can have the disadvantage that if the traction between the wheels and the road surface should increase suddenly, the vehicle engine will be braked down below its minimum rpm and will therefore stall. The engine will then have to be restarted and the vehicle started up and accelerated once again, yet the end result may be no different from before.
OBJECT AND SUMMARY OF THE INVENTION
The invention has the advantage over the prior art that the increase in brake pressure has already ended before the angular velocity of the slipping wheel or wheels drops disadvantageously. The goal, accordingly, is to attain brake pressures such that braking moments effected by such pressures are substantially identical in magnitude to the excesses in drive moment that cause the drive slip. These brake pressures are initially kept constant, thereby bringing about either a smooth termination of drive slip or gentle transitions to possible regulating cycles which may ensue, as the case may be.
The exemplary embodiment of the invention is preferred whenever the vehicle brake system, because of its structural features, experiences very rapid pressure increases in its brake cylinders. Despite unavoidable delays in moving the brake pressure control valves into their pressure maintenance positions, the control criterion selected avoids disadvantageously severe braking of the slipping wheels. As a result, the ending times of brake pressure increases substantially coinciding with the instants at which the maximum angular wheel velocities occur during the slippage phases.
The exemplary embodiment is preferred whenever the vehicle brake system typically undergoes relatively slow brake pressure increases.
The exemplary embodiment is also preferred whenever the brake pressure increases are not overly rapid, and it has the advantage that the ending times of the brake pressure rises substantially coincide with the instants at which the slip velocities attain their maximum value. A further development of the invention has the advantage that are further applicable to vehicle brake systems by means of which brake pressure increases required for emergency braking can be generated quickly, in an advantageous manner. The characteristics define an exemplary embodiment which is attainable without using expensive throttles and bypass valves. The pulse train generator, for instance, can be embodied by a digital computer already built into the vehicle brake system for other purposes, which performs control functions and can therefore be programmed additionally to emit the desired pulse trains.
The invention will be better understood and further objects and advantages thereof will become more apparent from the ensuing detailed description of preferred embodiments taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a vehicle brake system;
FIG. 2 is a diagram showing the course over time of angular wheel velocities, slip and brake pressure for the brake system according to FIG. 1; and
FIG. 3 is a diagram showing a second course of angular wheel velocity, slip and brake pressure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The apparatus 2 for reducing drive slip is intended for a vehicle 3 having, for example, a front wheel axle 4 having wheels 5, 6, wheel brakes individually associated with these wheels but not shown, and wheel brake cylinders 7, 8 associated with the front wheel brakes. A rear wheel axle 9, rear wheels 10, 11 and wheel brakes associated with the rear wheels, but not shown, and wheel brake cylinders 12, 13 associated with the rear wheel brakes are included on the vehicle. The apparatus 2 has an electrical control unit 14, such as shown in U.S. Pat. No. 3,606,492 and British Pat. No. 1,483,258, which receives signals from rate of rotation sensors 15, 16, 17 and 18 positioned relative to the wheels for sensing the rate of wheel rotation having electric lines 19, 20, 21, 22 leading to the control unit 14 by which signals are directed to the electrical control unit. Electromagnets 25 and 27 controllable by means of signals from the control unit 14 via electric lines 23, 24 are intended for actuating brake pressure control valves 27, 28 which are connected to fluid pressure lines that control flow of brake fluid to the wheel brake cylinders 12 and 13, respectively, via lines 29, 30. A reversing electromagnetic controlled valve 33 which is controllable by an electromagnet 39 via an electric line 40 controls the brake fluid from pump 31 to the valves 27 and 28. The brake pressure control valves 27, 28 are embodied by way of example in the manner of anti-wheel lock or anti-skid valves in the form of well known 3/3-way valves, with one basic position for building up brake pressure, another position for maintaining brake pressure and a third position for decreasing brake pressure depending on the electrical current applied to the electromagnet. The brake pressure control valves 27, 28 are supplied with a pressure medium by a pump 31 via a line 32, the reversing valve 33 and lines 34, 35, 36. This pressure medium may be a fluid such as a well known brake fluid (liquid) or air. A pressure container 37 is connected via a tap line 38 to the line 32 in order to apply a uniform pressure to the line 32. The reversing valve is embodied as a well known 3/2-way valve and for its actuation it has an electromagnet 39, which is controlled by the control unit 14 via the electric line 40 for the evantuality that drive slip may appear at one or both of the wheels 10, 11. In that case, the reversing valve 33 then connects the line 32 with the line 34 within the reversing valve. In its basic position, this reversing valve 33 connects the line 34 with a line 41, which is supplied with brake pressure from a main brake cylinder 42 or some other pressure transducer, which is actuatable by means of an operating brake pedal 43.
The vehicle 3 is driven by an internal combustion engine 44 which acts upon the wheels 10 and 11, for instance via a friction clutch 45, a mechanical manual transmission 46, a universal joint-drive shaft 47 and a differential gear 48. With the engine running and the transmission 46 shifted into first gear, the vehicle 3 is set into motion by slowly engaging the friction clutch 45. The wheels 10 and 11 are made to rotate, and the vehicle 3 is accelerated. As long as the torque transmitted via the friction clutch 45 remains sufficiently slight, no notable slip occurs between the wheels 10 and 11 and the road surface located beneath them. As a result, signals from the sensors 17 and 18 for the wheel rotation will indicate angular wheel velocities which differ virtually not at all from those indicated by the sensors 15 and 16, which detect the rotational angle of the non-driven wheels 5 and 6. In this case, the control unit 14 remains inactive because the signals from sensors 15, 16 and 17, 18 are balanced. However, if the output of the engine 44 increases, causing the wheel 10, for example, to begin to slip relative to the road surface, then the control unit 14 is informed via the rotational wheel sensor 17 that the angular velocity of the wheel 10 is increasing. Means not shown are incorporated into the control unit 14 in a known manner for ascertaining signal differences due to slip variables, which can be derived from various signal trains of the wheel rotational angle sensors 15, 16 and 17. These means are embodied such that when a preselected switching threshold S is exceeded, a signal representing the sensor differences is emitted from the control unit 14 to electromagnet 39 via line 40 which excites the electromagnet 39. Electromagnet 39 operates control valve 33 such that pressure from the pressure container 37 reaches the wheel brake cylinder 12 via the pressure control valve 27. At the same time, the other brake pressure control valve 28 is moved out of its basic position into the position for brake pressure maintenance. As a result, the pressure in the wheel brake cylinder 12 begins to increase, which exerts an increasing braking moment upon the wheel 10. No pressure increase takes place in the wheel brake cylinder 13. The diagram in FIG. 2 illustrates the example of the increase of the angular wheel velocity W of the wheel 10 when slip beings to occur, as well as the brake pressure increase P a which begins after the switching threshold S, which is above the angular wheel velocity W ref of the wheels 5, 6, is exceeded. The effect of this increasing pressure P a is finally that the course of the angular wheel acceleration W'1, which caused the increase in angular velocity represented by the curve W1, begins to flatten out. A differentiating device 49 such as a one-channel trigger incorporated into the control unit 14 and associated with the wheel rotational angle sensor 17 is then switched on, when the threshold S is exceeded. A further pressure increase P a in the wheel brake cylinder 12 finally causes the rotational wheel angle acceleration W'1 to increase no further and instead to make a transition to a branching curve W'2. At the instant of the transition of the rising branch W'1 of the curve W' to the falling branch W'2, the differentiating device 49 sends a signal to the control unit 14, whereupon the control unit 14, via the electrical line 23, directs the brake pressure control valve 27 into the position for brake pressure maintenance. Because of the unavoidable delays arising from elements following the differentiating device 49 inside the control unit 14 but not shown in the drawing, and because of switching delays in the brake pressure control valve 27, the brake pressure initially increases still further during a time period T v . After that, the brake pressure remains substantially constant, as represented by the line P2 in FIG. 2. The effect is that the angular wheel velocity W of the wheel does not increase further and finally drops, as indicated by way of example by the branch curve W2.
In the same manner, in the event of slip occurring between the wheel 11 and the road surface, a further differentiating device 50, which is associated with the rotational wheel angle sensor 18, effects control of the valves 27, 28 and 33 via the control unit 14 and the lines 24 and 40. It is also possible that slip may occur at both wheels 10 and 11 simultaneously, causing the threshold S to be exceeded. Then, influence is exerted upon both wheel brake cylinders 12, 13 in order to reduce the angular velocity of the wheels.
In the illustrated exemplary embodiment, the wheel brake cylinders 12 and 13 are simultaneously components of a service brake system which includes the brake master cylinder 42. To effect service braking, which is initiated by means of the service brake pedal 43, the brake pressure control valves 27 and 28 are located in their positions for brake pressure buildup. The basic position for these valves 27 and 28 is therefore preferably the position for brake pressure buildup. As already noted, the brake pressure control valves 27, 28 may be embodied as anti-skid valves, and accordingly they may also be used as anti-skid means, that is, as means for preventing wheel locking. In that case, the wheel brake cylinders 7 and 8 are connected with the brake master cylinder 42 or brake pressure transducer via lines 51, 52, further anti-skid valves 53, 54 and lines 55, 56 and via a brake pressure line 57.
In the illustrated exemplary embodiment, the vehicle 3 is designed with rear wheel drive. Naturally it is equally possible for the vehicle instead to be embodied with front wheel drive or four wheel drive.
The portion of the above-mentioned time period T v resulting from elements inside the control unit 14 can for example be designed to be selectable, so that the increase in brake pressure that continues to take place from the time the differentiating device 49 or 50 responds until P2 is attained will terminate the drive slip gently. If the control unit 14 is designed with the use of a programmed computer, for instance, then the advantageous delay in the control signals can be accomplished by program by means of this computer. The differentiating devices 49, 50 can also be embodied by computers programmed for this purpose.
A second exemplary embodiment, which is not shown, differs from that shown in FIG. 1 primarily in that means not shown are disposed within the vehicle brake system which have the effect of slower brake pressure increases P a . The speed of the brake pressure increase in the second exemplary embodiment may for instance be half that of the first exemplary embodiment. This can be attained by using throttles and bypass valves bypassing them, of the type known from anti-skid brake systems. The bypass valves enable more rapid pressure increases for emergency braking. The engineering expense is less if the brake pressure P a , as shown in FIG. 3, is generated in stages. To this end, the computer of the control unit 14 is additionally programmed as a pulse train generator, so as to switch brake pressure control valve 27 or 28 over repeatedly for brief periods, such as to bring about brake pressure increases of the kind shown.
Because of the slower increase in brake pressure, the differentiating device 49 or 50 can be embodied such that it differentiates the angular wheel velocity, and if the maximum thereof is exceeded it then interrupts the brake pressure increase P. The consequence is a gentle decrease of drive slip. Alternatively, the differentiating devices 49, 50 may be embodied such that in the event of decreasing rotational wheel angle accelerations they emit signals to triggers, not shown. The triggers terminate the brake pressure increases P a whenever the rotational wheel angle accelerations have dropped sufficiently or disappeared. These triggers may likewise be realized by appropriate programming of the computer. The switching range SB of the triggers is shown in FIG. 3.
The foregoing relates to preferred exemplary embodiments of the invention, it being understood that other variants and embodiments thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims.
|
A vehicle having wheels driven via a differential transmission, non-driven wheels and wheel brakes individually associated with the wheels and having wheel brake cylinders has an apparatus for reducing drive slip between the driven wheels and a road surface located beneath these wheels. The apparatus includes a control unit, which is connected to angular velocity wheel sensors for rotational wheel angle associated with the wheels and has at least one differentiating device, which emits control signals whenever drive slip exceeds a preselected switching threshold. By using the control unit, brake pressure control valves of the slipping wheels are controlled such that brake pressure in their wheel brakes builds up (P2). The pressure buildup is terminated as soon as the differentiating device ascertains that a drop of the angular wheel accelerations have dropped below a maximum value. Subsequently the brake pressure initially remains substantially constant. This has the advantage of avoiding the danger of abruptly choking off an internal combustion engine in the vehicle when the vehicle is being started up on a road surface having greatly varying traction.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of the PCT International Application No. PCT/FR2007/050656 filed Jan. 16, 2007, which is based on the French Application No. 0600526 filed Jan. 20, 2006.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is provided for the analysis of the wavefront of a light beam.
Such a type of analysis makes it possible to test optical elements, to qualify optical devices, as well as to steer deformable optical components as used in active or adaptive optics. It also allows for the study of non directly measurable physical phenomena, such as variations of optical index within turbulent media that can be encountered when crossing the terrestrial atmosphere, as well as in a blower vein. It is also used for testing the planarity of electronic components, for example matrix focal planes, as well as for shaping power laser beams.
2. Description of Related Art
The type of analysis of a wavefront according to the invention is based on the use of a diffraction grating positioned on the path of the beam to be analyzed.
For a better understanding of the following, such a grating is defined as being an optical system introducing periodic variations of phase, intensity or phase and intensity. Any diffraction grating is thus characterized by the multiplication of two functions: the one, referred to as phase function, represents the periodical variations of phase introduced by the grating and the other one, referred to as intensity function, represents the periodical variations of intensity introduced by the grating.
The French patent application No. 2,712,978 (which corresponds with U.S. Pat. No. 5,606,417) discloses the mode of construction and definition of a two-dimensional grating. A set of points regularly arranged, according to two directions constitutes a planar meshing. Such points define an elementary mesh. The elementary mesh is the smallest surface allowing for a non-lacunary paving of the plane to be reached according to both directions defining the latter. The polygon of the elementary mesh is the minimal surface polygon having the sides thereof supported by the mediatrices of the segments connecting any point of the set with its nearest neighbors. A two-dimensional grating is the free repetition of an elementary pattern arranged according to a planar meshing. A planar meshing can define elementary meshes, being either hexagonal or rectangular (square meshes being only a special case for the latter).
When a diffraction grating is being illuminated with a light beam, referred to as an incident beam, light beams being diffracted by the grating, also called emerging beams, can be described using two equivalent approaches.
The first approach consists in considering emerging beams as replicas of the incident beam. These are called sub-beams, each corresponding to one diffraction order of the grating. Amongst such sub-beams, two categories are to be distinguished. First of all, there are classified sub-beams, referred to as main beams corresponding to the diffracted orders being used according to the invention. The other orders, being not useful for analysis, are called secondary sub-beams. The grating will be thus defined so as to favour the emergence of the main sub-beams and to minimize the presence of the secondary sub-beams.
The second approach consists in considering emerging beams as beams being diffracted by each mesh of the grating. These are called secondary beams.
When an intensity function is introduced by a grating, each secondary beam results from a mesh of the intensity grating called sub-pupil.
In the aforementioned French patent application No. 2,712,978, a three-wave lateral shearing interferometer implements a two-dimensional phase and/or intensity grating and a spatial filtering system. According to the approach through decomposition into sub-beams, the grating optically subdivides the incident beam to be analyzed into a plurality of sub-beams in a conjugated plane of the defect. A system for spatial filtering the sub-beams is intended to select three main sub-beams used for analysis. A particular optical processing of the three sub-beams obtained in this way makes it possible to observe an interferogram made of a hexagonal meshing of light spots having a contrast being invariant, whatever the selected observation plane is. This interferogram is sensitive to gradients of the wavefront and this with a continuous adjustment possibility for dynamics and sensitivity. The observation distance is there defined as the distance separating the selected observation plane from the so-called zero sensitivity plane, this latter being a conjugated plane conjugated with the plane of the grating located downstream the spatial filtering. Such a type of interferometer has the advantage of displaying important metrological qualities because of the frequency purity of the generated interferogram. Moreover, the measurement error can be estimated from the measurement itself. Finally, such an interferometer can operate with polychromatic light, provided the path difference of the defect to be detected does not depend on the wavelength.
On the other hand, it is complex to be implemented, because of the insertion of the spatial filtering system for selecting the main sub-beams between the grating and the observation plane of the interference fringe system. Moreover, the spatial filtering system brings limitations for measuring strongly disturbed light beams or light beams with a very large spectrum width.
The French patent application No. 2,795,175 (which corresponds to U.S. Pat. No. 6,577,403) discloses an interferometer of a four-wave lateral shear type being a development of the interferometer with a three-wave lateral shearing as being described hereinabove. The grating at the basis of such an interferometer optically subdivides, in a conjugated plane of the defect, the incident beam to be analyzed into four main sub-beams, useful for analysis. As secondary sub-beams are minor with a low amplitude, removing them by a spatial filtering system is not necessary. The interferogram comprises a rectangular meshing of light spots, the contrast of which is invariant, whatever the selected observation plane is. Like the interferometer of a three-wave lateral shearing type, such an interferometer can operate with polychromatic light and offers a continuously set sensitivity and dynamics by a simple translation of the observation plane with respect to the so-called zero sensitivity plane. Moreover, as opposed to the three-wave lateral shearing interferometer, the absence of a spatial filtering system offers a better implementing ease and makes it possible to measure strongly disturbed light beams or light beams with a very large spectrum width. Estimating the error is also possible by means of such an interferometer, however, it will be less robust in the case of the measurement of high dynamics defect. In addition, the sampling geometry of wavefronts to be analyzed in the four-wave lateral shearing type interferometer is less optimal than that achieved with a three-wave lateral shearing type interferometer.
Thus, it seems highly desirable to provide an interferometer combining, on the one hand, the implementing simplicity and the operating capacity, from highly disturbed low intensity light sources or light sources having a very large spectrum width of the four-wave lateral shearing type interferometer and, on the other hand, the possibility to estimate the measurement error robustly and the optimum sampling geometry of the wavefronts to be analyzed of the three-wave lateral shearing type interferometer.
OBJECT OF THE INVENTION
The object of the present invention is to provide a development in this respect.
SUMMARY OF THE INVENTION
The invention can be considered in the form of a method or a system.
The provided method is of the type wherein:
(a) a diffraction grating with two-dimensional meshing is arranged and carries out the multiplication of:
(1) an intensity function which defines a hexagonal meshing of sub-pupils transmitting the light from the beam to be analyzed into a plurality of secondary beams arranged in a hexagonal meshing, by
(2) a phase function, inside or in the vicinity of a first plane perpendicular to the light beam to be analyzed and optically conjugated to the analysis plane of the wavefront, resulting in a diffraction of the beam into different emerging beams, and
(b) an image formed by the interference of the emerging beams is created and observed in a plane located at a chosen distance from the first plane, said image having deformations linked to the gradients of the wavefront to be analyzed.
According to one aspect of the invention, the phase function in (2) introduces a phase shift of a value close to 2π/3 (modulo 2π) between two adjacent secondary beams.
Thereby, the diffraction grating performing the multiplication of both functions thus defined diffracts a hexagonal meshing of secondary beams which propagate and interfere with each other so as to generate, in any observation plane parallel to the grating plane, an image in the form of a hexagonal meshing of light spots, the contrast of which is substantially independent from the wavelength as well as the observation distance.
In the approach consisting in considering the emerging beams as replicas of the incident beam, the phase function diffracts plural sub-beams including the three main sub-beams and secondary sub-beams. The multiplication by an intensity function makes it possible to minimize the energy being diffracted in the secondary sub-beams so that there essentially remain only the three main sub-beams, useful for the analysis.
The hexagonal meshing of light spots can be observed in the grating plane, i.e. the zero sensitivity plane. The meshing is advantageously observed from a plane located at an observation distance selected by the user as a function of the gradients of the wavefront to be analyzed and the desired dynamics.
Such a method operates with a polychromatic light and, while adjusting the observation distance, makes it possible, through a continuous setting of the sensitivity and dynamics of the system, to measure highly disturbed light beams.
Thus, the user has available a continuous setting flexibility in dynamics for the three-wave lateral shearing type interferometer without the implementing constraints linked to the insertion of the spatial filtering system.
The invention also provides systems likely to allow for implementing the proposed method. Such a system is of the type including:
(a) an input optics for optically conjugating a reference plane with a plane wherein the wavefront is analyzed,
(b) a diffraction grating comprising an intensity grating with a hexagonal elementary mesh and a phase grating with a hexagonal elementary mesh, and arranged in said reference plane, perpendicularly to the light beam, resulting in a diffraction of the beam in different emerging beams referred to as secondary beams, and
(c) means for observing the image formed by the interference of the emerging beams, said image having deformations linked to the gradients of the analyzed wavefront.
According to the invention, the system is characterized in that the grating of (b) includes:
the intensity grating having a hexagonal elementary mesh with a surface S where there is arranged an elementary intensity pattern with a surface S, and
the phase grating having a hexagonal elementary mesh with a surface equal to three times the surface S, where there is arranged an elementary phase pattern having a surface equal to three times the surface S,
all six apexes of a phase mesh matching with the apexes located at one of the ends of the six small diagonals of three adjacent intensity meshes, the other end of said small diagonals being located at the common apex of said three adjacent intensity meshes,
the elementary intensity pattern being such that it introduces a variation of intensity from a secondary beam crossing the elementary intensity pattern between a maximum value of 100% at the centre of the elementary pattern of surface S and a minimum value of 0% on the apexes of the pattern, and
the elementary phase pattern being such that it introduces a phase shift close to 2 π/3 (modulo 2π) between two secondary beams crossing two adjacent elementary intensity patterns.
A preferred intensity two-dimensional grating according to the invention has a hexagonal elementary intensity pattern the transmission surface of which is close to 66% of the elementary intensity mesh surface.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of the invention will be apparent from the following particular description and the appended drawings, wherein:
FIG. 1A is a theoretical optical diagram of a system for implementing the invention for checking optical components;
FIG. 1B is a theoretical optical diagram of a system for implementing the invention for measuring turbulent media such as the terrestrial atmosphere being crossed by a beam from a polychromatic source such a star;
FIG. 2A illustrates a two-dimensional grating GI with a hexagonal meshing with a surface S;
FIG. 2B illustrates a two-dimensional grating GP with a hexagonal meshing with a surface 3 S;
FIG. 2C illustrates the relative positioning of elementary intensity meshes MEI and elementary phase meshes MEP according to the invention;
FIG. 3A illustrates a first example of an elementary pattern of an intensity grating useful in the invention;
FIG. 3B illustrates a second example of an elementary pattern of an intensity grating useful in the invention;
FIG. 4A illustrates an example of a phase grating with a hexagonal meshing useful in the invention
FIG. 4B indicates the relative position of the elementary phase mesh and the corresponding phase pattern;
FIG. 5A illustrates a first example of a diffraction grating GR 1 according to the invention;
FIG. 5B illustrates a second example of a diffraction grating GR 2 according to the invention.
DETAILED DESCRIPTION
FIGS. 1A and 1B show two examples of systems for implementing the invention.
On FIG. 1A , a source S o of polychromatic light is located at the focus of a collimating lens O 1 . The parallel light beam coming from the lens O 1 illuminates a sample to be tested, which is diagrammatically represented as a plate LA with parallel faces, arranged in the plane P D , and having a planarity defect D 1 . The sample can be any other optical system (a lens or a mirror, in particular, a telescope mirror), or even simply a region in a gas medium being disturbed by a flow, for example.
In the case of an application in the astronomy field, a system for implementing the invention is illustrated on FIG. 1B . A planar wave from a very distant source, such a star, for example crosses a turbulent medium whose index variations are represented by sinuous lines.
An input arrangement performs the optical adaptation necessary for implementing the method according to the invention.
Such an adaptation is preferably achieved by an afocal system consisting in two lenses O 2 and O 4 , with a field lens O 3 at an intermediary position. Such an afocal system has the function of, on the one hand, matching the diameter of the beam analyzed in the plane P D , to the dimensions of the two-dimensional grating arranged in a plane P C , and, on the other hand, conjugating the plane P D where the defect to be analyzed optically with the plane P C .
Other means achieving such an optical conjugation between such two planes can also be suitable.
A diffraction grating GR adapted for achieving the combination of intensity and phase functions is arranged in the analysis plane P C . Materially, such a grating can be constructed as for example those on FIG. 5A or 5 B. It is the particular combination of functions that characterizes the grating of the invention rather than a particular embodiment.
In the example of the embodiment shown, the diffraction grating GR is made up of a two-dimensional intensity grating GI and a two-dimensional phase grating GP.
The intensity grating GI implements an intensity function FI which defines a hexagonal meshing of sub-pupils transmitting the light from the beam to be analyzed into a plurality of secondary beams.
The phase grating GP implements a phase function FP which introduces an mean phase shift between two adjacent secondary beams close to 2π/3 (modulo 2π).
The order in which the two functions are effected in the plane is of no importance.
According to the invention, the interferogram is made up of a hexagonal meshing of spots.
The plane P C is a zero sensitivity plane. The observation is effected in a plane P S located at a chosen observation distance d from the plane P C .
The dynamics and the sensitivity of the system vary with the observation distance. Thus if d is zero, the observation plane P S is coincident with the analysis plane P C in which the grating is located and the sensitivity is zero.
Generally, an additional means of observing the plane P S , comprising, for example, a lens, which optically conjugates the plane PS and a more accessible working plane, can be used.
FIGS. 2A and 2B show elementary meshes of the two-dimensional gratings, the patterns being represented serving as an illustration. The patterns of the invention are shown in FIGS. 3A , 3 B, 4 A, and 4 B.
FIG. 2A shows a two-dimensional intensity grating GI having a hexagonal meshing characterized by a hexagonal elementary mesh with a surface S. FIG. 2B shows a two-dimensional phase grating GP having a hexagonal meshing characterized by a hexagonal elementary mesh with a surface 3 S. The meshing, shown as broken lines, is not necessarily visible in the final grating. In each mesh of GI, a pattern MOI introducing intensity variations into the incident light beam is shown. In each mesh of GP, a pattern MOP introducing phase variations into the incident light beam is shown.
FIG. 2C shows the relative positioning of elementary meshes of both gratings. This positioning is essential for a good operation of the invention. The surface of the elementary phase mesh MEP is equal to three times the surface of the elementary intensity mesh MEI. In order to facilitate the description of the relative positioning of hexagonal elementary meshes, a large diagonal of a hexagon is defined as linking two opposite apexes and a small diagonal is defined as linking two non adjacent and non opposed apexes. The phase mesh MEP is centred on the common apex of three adjacent intensity meshes MEI. The apexes of a phase mesh MEP match with the apexes located at one of the ends of the six small diagonals of three adjacent intensity meshes MEI. The other end of said small diagonals is located at the common apex of said three adjacent intensity meshes, i.e. at the centre of the phase mesh MEP.
FIGS. 3A and 3B show examples of elementary patterns for the GI two-dimensional intensity grating on FIG. 2A allowing for performing the intensity function according to the method of the invention.
FIG. 3A illustrates an elementary pattern MOI of a grating GI with a hexagonal meshing MEI of surface S having a continuously variable opacity. The lightest areas A 1 at the centre of the pattern are those where the transparency is highest, and the dark areas A 2 in the periphery are characterized by a higher opacity. The area of the sub-pupil can be defined here as the area where the transmission is higher than 33% of the maximum value of the grating transmission. A means for characterizing this grating comprises defining the transmission profiles over a period T along the directions of a small diagonal Pd and a median Me, and the period T′ along the direction of a large diagonal Gd of the intensity mesh. The corresponding values are indicated in the appended table at the end of the description. The intensity grating GI obtained from such an elementary pattern is the ideal intensity grating. It makes it possible producing an interferometer with metrological qualities equivalent to those obtained with the spatial filtering as described in FR 2 712 978 but with a much simpler implementation.
FIG. 3B illustrates an elementary pattern MOI of a Ronchi type grating GI having a hexagonal meshing MEI with a surface S. The dotted areas A 3 have a zero transmission and the light areas A 4 are transparent. The elementary pattern MOI comprises a central transparent hexagonal area A 5 whose apexes are located at the middle of the sides of the hexagon of the elementary intensity mesh, and six opaque peripheral isosceles triangles I. The apexes of each isosceles triangle are the centers of two adjacent sides and the common apex for said two sides. Thus, the maximum transmission surface of the sub-pupil is close to 67% of the surface of the elementary mesh. The light yield is thus substantially improved in comparison with intensity masks with rectangular or hexagonal meshes, more particularly those shown on FIG. 8 of French patent 2 712 978. This embodiment less expensive than the previous one is particularly valuable for common applications, more particularly with polychromatic light.
The elementary intensity patterns are such that they introduce an intensity variation of the secondary beam crossing them lying between a maximum value of 100% at the centre of the hexagonal pattern with a surface S and a minimum value of 0% on the apexes of said pattern.
FIG. 4A shows a perspective view of one example of a two-dimensional phase grating GP which offers a simple means of implementing the phase function according to the method of the invention. FIG. 4B shows the same grating GP, observed along an axis perpendicular to the plane of the grating, onto which the elementary meshing with a surface 3 S is represented in black broken lines. The grating GP of the checkerboard type has stepped periodic thickness variations so that the thickness difference e between two adjacent steps satisfies the equation:
e =λ/( n− 1)×( k+ ⅓)
where
λ is the mean operating wavelength,
n is the refractive index of the material when the phase grating is used in transmission mode, and
k is an integer.
On FIG. 4B , there can be seen that the pattern MOP of the hexagonal checkerboard type in the phase grating GP overlaps the meshing of the intensity grating. The various levels of the checkerboard in the grating GP in this figure shown by the dotted areas A 6 and the slanted-line areas A 7 only illustrate thickness variations of the various steps of the grating, in no means the transmission variations between the steps. This grating is transparent in transmission mode.
An advantageous means of implementing the two-dimensional gratings GI and GP is to use the masking and photolithography etching techniques widely used in the semiconductor industry; GI can thus be implemented by depositing a metallic mask onto a substrate wafer and GP by etching a substrate wafer. With these techniques it is possible to make using a two-dimensional phase and intensity grating which combines both FI and FP functions of GI and GP, respectively, from a single substrate wafer.
In addition, the recent developments in the field of photolithography allow for contemplating coding in grey levels of the intensity function. Such various levels of grey can be obtained coding various thicknesses of metallic mask or drilling the latter with small openings of a size lower than the analysis mean wavelength.
Other methods of implementing both functions FI and FP by gratings GI and GP can be contemplated, for example on the principle of registering interferograms on photosensitive plates so as to thereby achieve the production of holographic gratings. Similarly, the description of this invention has been provided within the scope of gratings operating in transmission mode. The one skilled in the art will be able to apply this invention to gratings operating in reflection mode.
The overlap of gratings GI and GP allows for producing two-dimensional gratings GR. FIG. 5A shows a grating GR 1 obtained by overlapping the intensity grating having the pattern in FIG. 3A and the phase grating in FIG. 4A . FIG. 5B shows a grating GR 2 obtained by overlapping the intensity grating having the pattern in FIG. 3B and the phase grating in FIG. 4B . For an appropriate understanding of FIG. 5A , there should be considered the effect linked to the various grey levels A 8 of the GP grating checkerboards overlapping on that linked to the grating GI. For FIG. 5B , understanding is easier, dotted triangles A 9 showing the opaque parts of the grating GI, the white hexagons and the stripped and cross-hatched hexagons A 10 and A 11 , respectively, representing the various thicknesses of the GP grating steps.
Combining the gratings GI and GP allows for generating a meshing of light spots whose contrast is substantially independent of the observation distance d and the wavelength used. Because of the sudden intensity variations introduced by the intensity grating GI of the Ronchi type whose elementary pattern are shown in FIG. 3B , contrast fluctuations occur during the propagation which cause high-frequency local deformations of the light spots. Those unwanted deformations remain small compared to the sinusoidal intensity modulation observed in the two directions and do not disturb the analysis of the wavefront. A means for reducing such small fluctuations due to the residual energy diffracted in the secondary sub-beams comprises coding the intensity function using an intensity grating, the transmission of which is continuously variable between 100% at the centre of the mesh with a surface S and 0% on the edges, according to an apodization surface of the Hanning window type commonly encountered in digital signal processing.
In French patent application No. 2,682,761, a technique is proposed for acquiring and analyzing interference images obtained in order to reach gradients of the wavefront by means of a UT processing unit UT. Those techniques are directly applicable to the meshing of light spots obtained according to the present invention.
APPENDIX
Table of transmission index values
Abscissa
Large diagonal
Small diagonal
Median
over a
index
index
index
period
Gd
Pd
Me
1
0.000
0.000
0.327
2
0.069
0.052
0.334
3
0.147
0.091
0.352
4
0.230
0.131
0.378
5
0.314
0.171
0.411
6
0.399
0.210
0.448
7
0.483
0.249
0.488
8
0.564
0.286
0.530
9
0.642
0.323
0.573
10
0.714
0.358
0.616
11
0.781
0.391
0.658
12
0.840
0.423
0.699
13
0.891
0.454
0.739
14
0.933
0.482
0.776
15
0.965
0.509
0.811
16
0.987
0.533
0.844
17
0.998
0.556
0.875
18
1,000
0.576
0.902
19
0.988
0.593
0.926
20
0.967
0.609
0.947
21
0.935
0.622
0.965
22
0.893
0.632
0.979
23
0.843
0.640
0.990
24
0.784
0.645
0.997
25
0.718
0.647
1.000
26
0.646
0.647
1.000
27
0.568
0.645
0.996
28
0.487
0.639
0.989
29
0.403
0.631
0.978
30
0.318
0.621
0.964
31
0.234
0.608
0.946
32
0.151
0.592
0.924
33
0.073
0.574
0.900
34
0.000
0.554
0.873
35
0.079
0.532
0.842
36
0.141
0.507
0.809
37
0.197
0.480
0.774
38
0.244
0.452
0.736
39
0.282
0.421
0.696
40
0.310
0.389
0.655
41
0.327
0.355
0.613
42
0.334
0.320
0.570
43
0.330
0.284
0.527
44
0.315
0.246
0.485
45
0.290
0.208
0.445
46
0.254
0.168
0.408
47
0.209
0.129
0.376
48
0.156
0.088
0.350
49
0.086
0.049
0.334
50
0.000
0.000
0.327
|
A method and a system for analyzing the wavefront of a light beam, wherein a diffraction grating is arranged in a plane perpendicular to the light beam to be analyzed and optically conjugated to the analysis plane. Different emerging beams of the grating interfere to generate an image having deformations linked to the gradients of the wavefront to be analyzed.
The method is characterized in that the grating carries out the multiplication of an intensity function which is implemented by a two-dimensional grating with hexagonal meshing of surface S transmitting the light of the beam to be analyzed into plural emerging beams arranged in a hexagonal meshing, by an phase function which is implemented by a two-dimensional grating with hexagonal meshing of surface 3 S which introduces a phase shift close to 2π/3 (modulo 2π) between two adjacent secondary beams.
| 6
|
REFERENCE TO PATENTS, APPLICATIONS AND PUBLICATIONS PERTINENT TO THE INVENTION
(1) Japanese Patent Provisional Publication No. 52,111/74 dated May 21, 1974.
The contents of the above-mentioned prior document will be described later under the heading of the "BACKGROUND OF THE INVENTION".
FIELD OF THE INVENTION
The present invention relates to a method for recovering useful metals from a dust discharged from a metal refining metallurgical furnace, which permits efficient recovery of such useful metals as zinc, lead and other metals from a dust containing principally ferric oxide (Fe 2 O 3 ), zinc oxide (ZnO) and lead oxide (PbO) discharged from the metal refining metallurgical furnace.
BACKGROUND OF THE INVENTION
For example, when manufacturing steel from steel scrap including scrap of galvanized steel sheets in a steelmaking electric furnace, the amount of dust produced during refining ranges from 13 to 17 kg per ton of molten steel, thus giving a huge annual production. This dust has a chemical composition as shown in the following Table 1.
TABLE 1______________________________________(wt. %)T.Fe Zn Pb Cd C Cl F Na K______________________________________20 10 1 0.1 0.5 2 0.3 1 0.5to 40to 30 to 6 to 0.5 to 1.5 to 5 to 1.0 to 4 to 3.0______________________________________
As shown in Table 1, the dust contains, in addition to iron, such useful metals as zinc, lead and other metals in the form of oxides in large quantities, and this dust has often been rejected as waste. However, to reject the dust with the above-mentioned chemical composition is very uneconomical from the point of view of effectively utilizing resources. Furthermore, since the aforementioned useful metals are toxic substances on the other hand, rejection of the dust having the above-mentioned chemical composition is a serious problems in environment control.
For these reasons, studies have been carried out actively in various circles concerned to find a method for recovering such useful metals as zinc, lead and other metals from a dust containing principally ferric oxide, zinc oxide and lead oxide, and as a result, the reducing volatilization process by rotary kiln has been industrialized as a relatively easy method.
With regard to the conventional reducing volatilization proces by rotary kiln as described above, the following proposal is made:
(1) A method for treating a dust discharged from a steelmaking furnace, disclosed in Japanese Patent Provisional publication No. 52,111/74 dated May 21, 1974, which comprises:
Charging a dust discharged from a steelmaking furnace, together with a solid carbonaceous reducing agent, into a rotary kiln, evaporating by reduction zinc oxide and lead oxide contained in the dust by heating the dust in the rotary kiln to separate zinc and lead from the dust; discharging from the rotary kiln, zinc and lead thus separated from the dust, together with exhaust gases produced in the rotary kiln, and recovering zinc and lead; carrying out a primary treatment comprising recovering iron powder through magnetic separation of clinker containing reduced iron after recovery of zinc and lead; then, carrying out a secondary treatment comprising charging again non-magnetic substances produced during said primary treatment into the rotary kiln and recovering zinc and lead remaining in said non-magnetic substances; recovering non-magnetic substances, principally comprising carbon produced during said secondary treatment; and then, using said non-magnetic substances thus recovered as a reducing agent (hereinafter referred to as the "prior art").
However, the aforementioned prior art involves the following problems.
(1) Recovery efficiency of useful metals from the dust is low.
(2) As a result of the low recovery efficiency of useful metals from the dust, a solid carbonaceous reducing agent is required in an amount of from 25 to 30 wt. % of the dust, and industrial treatment of the dust in a large quantity requires a large-capacity rotary kiln.
(3) Therefore, high running and installation costs are required for recovering useful metals from the dust.
Under such circumstances, there is a strong demand for the development of a method for efficiently recovering such useful metals as zinc, lead and other metals from a dust containing principally ferric oxide, zinc oxide and lead oxide discharged from a metal refining metallurgical furnace, which method requires only low running and installation costs. However, such a method is not as yet proposed.
SUMMARY OF THE INVENTION
A principal object of the present invention is therefore to provide a method for efficiently recovering such useful metals as zinc, lead and other metals from a dust containing principally ferric oxide, zinc oxide and lead oxide discharged from a metal refining metallurgical furnace, which method requires only low running and installation costs.
In accordance with one of the features of the present invention, there is provided: in a method for recovering useful metals from a dust discharged from a metal refining metallurgical furnace, which comprises:
charging into a rotary kiln from the entry thereof a dust principally containing ferric oxide (Fe 2 O 3 ), zinc oxide (ZnO) and lead oxide (PbO), discharged from a metal refining metallurgical furnace, together with a granular carbonaceous reducing agent; moving said dust and said reducing agent toward the exit of said rotary kiln; the interior of said rotary kiln comprising a reducing atmosphere zone accounting for a major portion including the entry section and an oxidizing atmosphere zone including the exit section, the temperature of said oxidizing atmosphere zone being increased by at least one burner horizontally installed toward the interior of said rotary kiln at said exit section; evaporating by reduction zinc oxide and lead oxide in said dust by means of said reducing agent in said reducing atmosphere zone in said rotary kiln to separate zinc and lead from said dust; and, discharging zinc and lead thus separated from said rotary kiln, together with exhaust gases produced in said rotary kiln, and recovering zinc and lead;
the improvement characterized in that:
Said granular carbonaceous reducing agent is charged in the total amount of an amount necessary for reducing ferric oxide (Fe 2 O 3 ) contained in said dust into ferrous oxide (FeO), an amount necessary for reducing zinc oxide and lead oxide contained in said dust, and an amount necessary as a heat source for said respective reductions;
thereby, reducing ferric oxide (Fe 2 O 3 ) contained in said dust into ferrous oxide (FeO) in said reducing atmosphere zone; reoxidizing ferrous oxide (FeO) into tri-iron tetroxide (Fe 3 O 4 ) and ferric oxide (Fe 2 O 3 ) in said oxidizing atmosphere zone; and, increasing the temperature of the portion of said reducing atmosphere zonenear said oxidizing atmosphere zone through combustion of said reducing agent as the heat source in said oxidizing atmosphere zone, thereby accelerating said reduction of zinc oxide and lead oxide in said portion of the reducing atmosphere zone near said oxidising atmosphere zone.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic descriptive view illustrating an embodiment of the method of the present invention;
FIG. 2 is a graph illustrating the temperature distribution in the rotary kiln in the method of the present invention; and,
FIG. 3 is a schematic cross-sectional view illustrating a portion near the exit of the rotary kiln used in the method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
From the above-mentioned point of view, we carried out extensive studies with a view to developing a method for efficiently recovering such useful metals as zinc, lead and other metals from a dust containing principally ferric oxide, zinc oxide and lead oxide discharged from a metal refining metallurgical furnace, which method requires only low running and installation costs. The granular carbonaceous reducing agent to be charged into a rotary kiln in the conventional method is used in an amount equal to the total amount of the amount necessary for reducing zinc oxide, lead oxide and other metal oxides contained in the dust, the amount necessary to reducing ferric oxide contained in the dust into metallic iron (Fe), and the amount necessary as a heat source for the reduction process, and as a result, the amount of charged granular carbonaceous reducing agent reaches such a high level as from 25 to 30 wt. % of the dust, thus bringing about increase in the running costs and decrease in the dust treating efficiency.
We continued further studies, giving attention to this point, on the effective amount of charged granular carbonaceous reducing agent, and the temperature in the rotary kiln for efficiently reducing zinc oxide, lead oxide and other metal oxides contained in the dust. As a result, it was found possible to efficiently reduce zinc oxide, lead oxide and other metal oxides contained in the dust and to recover useful metals thus reduced by using the granular carbonaceous reducing agent for reducing ferric oxide contained in the dust in the amount necessary for reducing the ferric oxide into ferrous oxide, reoxidizing the ferrous oxide into tri-iron tetroxide and ferric oxide in the oxidizing atmosphere zone at the exit of the rotary kiln, and rapidly increasing the temperature at the portion near the exit of the rotary kiln with the use of reoxidizing heat thus produced.
The present invention was made on the basis of the above-mentioned finding, and the method for recovering useful metals from a dust discharged from a metal refining metallurgical furnace is as follows:
in a method for recovering useful metals from a dust discharged from a metal refining metallurgical furance, which comprises:
charging into a rotary kiln from the entry thereof a dust principally containing ferric oxide (Fe 2 O 3 ), zinc oxide (ZnO) and lead oxide (PbO), discharged from a metal refining metallurgical furnace, together with a granular carbonaceous reducing agent; moving said dust and said reducing agent toward the exit of said rotary kiln; the interior of said rotary kiln comprising a reducing atmosphere zone accounting for a major portion including the entry section and an oxidizing atmosphere zone including the exit section, the temperature of said oxidizing atmosphere zone being increased by at least one burner horizontally installed toward the interior of said rotary kiln at said exit section; evaporating by reduction zinc oxide and lead oxide in said dust by means of said reducing agent in said reducing atmosphere zone in said rotary kiln to separate zinc and lead from said dust; and discharging zinc and lead thus separated from said rotary kiln, together with exhaust gases produced in said rotary kiln, and recovering zinc and lead;
the improvement characterized in that:
Said granular carbonaceous reducing agent is charged into said rotary kiln in the total amount of an amount necessary for reducing ferric oxide (Fe 2 O 3 ) contained in said dust into ferrous oxide (FeO), an amount necessary for reducing zinc oxide and lead oxide contained in said dust, and an amount necessary as a heat source for said respective reductions;
thereby, reducing ferric oxide (Fe 2 O 3 ) contained in said dust into ferrous oxide (FeO) in said reducing atmosphere zone; reoxidizing ferrous oxide (FeO) into tri-iron tetroxide (Fe 3 O 4 ) and ferric oxide (Fe 2 O 3 ) in said oxidizing atmosphere zone; and, increasing the temperature of the portion of said reducing atmosphere zone near said oxidizing atmosphere zone through combustion of said reducing agent as the heat source in said oxidizing atmosphere zone, thereby accelerating said reduction of zinc oxide and lead oxide in said portion of the reducing atmosphere zone near said oxidizing atmosphere zone.
Now, the method of the present invention is described with reference to the drawings.
FIG. 1 is a schematic descriptive view illustrating an embodiment of the method of the present invention. In FIG. 1, 1 is a rotary kiln having a dust charging entry 1a at an end thereof and a clinker discharging exit 1b at the other end thereof; 2 is an entry hood installed adjacent to the entry 1a of the rotary kiln 1; 3 is an exit hood installed adjacent to the exit 1b of the rotary kiln 1; 4 is a dust charging chute provided in the entry hood 2; 5 is a burner, provided horizontally movably toward the interior of the rotary kiln 1 in the exit 1b section, for increasing the temperature of the exit 1b section in the rotary kiln 1; 6 is a duct, connected to the entry hood 2, for discharging exhaust gases produced in the rotary kiln 1; 7 is a chamber for recovering coarse granular dust contained in the exhaust gases; 8 is a cyclone for separating and recovering fine dust contained in the exhaust gases; 9 is a bag filter type dust collector for separating and recovering fine dust not separated and not recovered by the chamber 7 and the cyclone 8; 10 is a fan; 11 is a chimney; 12 is a transfer mechanism such as a pan conveyor for transporting dust collected respectively at the entry hood 2, the chamber 7, the cyclone 8, and the bag filter type dust collector 9; 13 is a pit for containing and taking out the dust transported by the transfer mechanism 12; 14 is a chute installed in the exit hood 3 for discharging clinker; and, 15 is a rotary cooler for cooling the clinker.
The interior of the rotary kiln 1 comprises a reducing atmosphere zone taking a major portion of the interior of the rotary kiln 1 including the entry 1a section, and an oxidizing atmosphere zone including the exit 1b section. In order to make the portion near the exit 1b of the rotary kiln 1 an oxidizing atmosphere zone, it suffices to cause air in an appropriate amount to come into the rotary kiln 1 through the exit 1b by adjusting the pressure in the rotary kiln 1 through opening of a pressure adjusting damper (not shown) installed in the fan 10.
Dust to be treated is charged, together with a granular carbonaceous reducing agent, into the rotary kiln 1 from the entry 1a through the chute 4 installed in the entry hood 2, and then, moved through the interior of the rotary kiln 1 in the direction as indicated by the arrow 16 in accordance with the rotation of the rotary kiln 1 toward the exit 1b. Dust to be charged into the rotary kiln 1 should preferably be granulated in advance into particles with a size of from 4 to 20 mm diameter by a granulating machine and dried into dust pellets having a prescribed strength. The granular carbonaceous reducing agent to be charged into the rotary kiln 1 to reduce the dust comprises coke and highly reactive coal with a high volatile matter content at a prescribed ratio. The granular carbonaceous reducing agent is charged into the rotary kiln 1 in an amount equal to the total amount of the amount necessary for reducing ferric oxide (Fe 2 O 3 ) contained in the dust into ferrous oxide (FeO), the amount necessary for reducing zinc oxide, lead oxide and other metal oxides contained in the dust, and the amount necessary as a heat source for the above-mentioned reduction. The aforementioned amount necessary as the heat source for the reduction should preferably be up to substantially the total amount of the amount necessary for reducing ferric oxide (Fe 2 O 3 ) into ferrous oxide (FeO), and the amount necessary for reducing zinc oxide, lead oxide and other metal oxides.
FIG. 2 is a graph illustrating the temperature distribution of atmosphere in a rotary kiln 1 having, for example, a length of 24 m. In FIG. 2, the portion "a" indicates a reducing atmosphere zone, and the portion "b", an oxidizing atmosphere zone. The abscissa represents the distance from the entry 1a of the rotary kiln 1, and the ordinate, the temperature of atmosphere in the rotary kiln 1. T 1 , T 2 , T 3 , T 4 and T 5 marked along the abscissa are temperature measuring positions.
In the present invention, the temperature of atmosphere in the rotary kiln 1 is kept, as shown by the solid curve in FIG. 2, at a temperature of up to about 700° C. for the reducing atmosphere zone which covers about one third of the total length of the rotary kiln 1 from the entry 1a of the rotary kiln 1 to the point A, and at a temperature within the range of from about 700 to about 900° C. for the reducing atmosphere zone which covers about two thirds of the total length of the rotary kiln 1 from the point A to the point B. And, the temperature of atmosphere in the rotary kiln 1 is rapidly increased to a temperature of at least from about 900 to about 1,200° C. for the portion from the point B up to the point C in the oxidizing atmosphere zone near the exit 1b.
The dust is charged into the rotary kiln 1 having the above-mentioned temperature of atmosphere from the entry 1a thereof together with the granular carbonaceous reducing agent and moved toward the exit 1b thereof. In the reducing atmosphere zone of up to the above-mentioned point A, ferric oxide (Fe 2 O 3 ) contained in the dust is reduced to tri-iron tetroxide (Fe 3 O 4 ), and in the reducing atmosphere zone of from the point A to the point B, the aforementioned tri-iron tetroxide (Fe 3 O 4 ) is reduced to ferrous oxide (FeO). Then, in the reducing atmosphere zone of from the point B to the aforementioned point C, where the temperature is increased rapidly, zinc oxide (ZnO), lead oxide (PbO) and other metal oxides are actively reduced and evaporated. Zinc, lead and other metals thus separated from the dust are reoxidized by oxygen present in the interior of the rotary kiln 1 again into zinc oxide, lead oxide and other metal oxides. These metal oxides including zinc oxide and lead oxide are discharged, together with exhaust gases produced in the rotary kiln 1 and flowing in the arrow 17 direction, from the entry 1a of the rotary kiln 1.
The exhaust gases containing zinc oxide, lead oxide and other metal oxides discharged from the entry 1a of the rotary kiln 1 are directed, through a duct 6 installed in the entry hood 2, sequentially from the chamber 7 to the cyclone 8 and the bag filter type dust collector 9, and after recovery of zinc oxide, lead oxide and other metal oxides by the above-mentioned chamber 7, the cyclone 8 and the bag filter type dust collector 9, discharged to open air from the chimney 11. Zinc oxide, lead oxide and other metal oxides thus recovered are transported to outside, after being gathered in the pit 13 by a transfer mechanism 12 such as a pan conveyor.
On the other hand, ferrous oxide (FeO) in the dust reduced in the course of up to the above-mentioned point B is reoxidized into tri-iron tetroxide (Fe 3 O 4 ) and ferric oxide (Fe 2 O 3 ) in the oxidizing atmosphere zone, thus discharged in the form of a clinker containing iron oxides, together with other residues in the dust, from the exit 1b into the exit hood 3, and then, after being cooled to a prescribed temperature in the rotary cooler 15, transported to outside.
In FIG. 2, the dotted curve represents an example of the distribution of the temperature of atmosphere in the rotary kiln 1 under the conventional reducing volatilization process. As is evident from the comparison with this conventional distribution, the temperature of atmosphere in the rotary kiln 1 in the present invention is kept at a relatively low temperature of up to 900° C. in the reducing atmosphere zone covering about two thirds of the total length of the rotary kiln 1 from the entry 1a of the rotary kiln 1 to the point B, and rapidly increased to a temperature of at least about 1,200° C. in the course of from the above-mentioned point B to the point C in the oxidizing atmosphere zone near the exit 1b. Therefore, zinc oxide, lead oxide and other metal oxides contained in the dust are not reduced in the reducing atmosphere zone with a relatively low temperature extending to the above-mentioned point B, but are reduced at a very high efficiency in the reducing atmosphere zone of from the point B to the point C, where the temperature increases rapidly.
Concrete means to achieve the above-mentioned temperature distribution of atmosphere in the rotary kiln 1 in the present invention are described later. The temperature in the oxidizing atmosphere zone near the exit 1b of the rotary kiln 1 increases to over 1,200° C. since ferrous oxide is reoxidized into tri-iron tetroxide and ferric oxide, and the reducing agent as the heat source is burnt. This increases the temperature in the portion of the reducing atmosphere zone near the oxidizing atmosphere zone, thus accelerating reduction of zinc oxide, lead oxide and other metal oxides in the portion of the reducing atmosphere zone near the oxidizing atmosphere zone.
It is possible to efficiently recover such useful metals as zinc, lead and other metals from the dust with the use of a smaller quantity of granular carbonaceous reducing agent and a shorter length rotary kiln 1 than those ever used in the conventional method, by keeping the temperature of atmosphere in the rotary kiln 1 to a temperature of up to 900° C. for the reducing atmosphere zone taking about two thirds of the total length of the rotary kiln 1, and rapidly increasing the temperature of atmosphere to above 1,200° C. in the remaining zone taking about one third thereof, as described above. Furthermore, by achieving a high temperature of at least 1,200° C. near the exit 1b of the rotary kiln 1, scaffolding, if it occurs on the inner wall near the exit 1b, immediately becomes semi-molten and melts down. Such scaffolding therefore never grows larger.
FIG. 3 is a schematic cross-sectional view illustrating the portion of the rotary kiln 1 near the exit 1b thereof. As shown in FIG. 3, by making the burner 5, which is horizontally installed toward the interior of the rotary kiln 1 in the exit 1b section of the rotary kiln 1 for increasing the temperature of the oxidizing atmosphere zone, in a horizontally movable position as shown by the dotted line, it is possible to control the position of the point C which represents the highest temperature in the oxidizing atmosphere zone shown in FIG. 1. When abnormal scaffolding occurs near the exit 1b, it is possible to melt such scaffolding and remove it by shifting the burner 5 so that the tip of the burner 5 is located at the position of the scaffolding.
In order to achieve the above-mentioned distribution of the temperature of atmosphere in the rotary kiln 1, the temperature is measured in the longitudinal direction of the rotary kiln 1 by temperature-measuring probes installed at prescribed positions T 1 , T 2 , T 3 , T 4 and T 5 , and the temperature in the rotary kiln 1 is controlled on the basis of the difference between the value of temperature thus measured and the predetermined standard value of temperature for the individual prescribed positions. An example of the means for controlling the temperature is described below.
(1) Control based on pressure in the rotary kiln:
The amount of air coming through the exit 1b into the rotary kiln 1 is controlled by adjusting the pressure in the rotary kiln 1 by means of the opening of the pressure adjusting damper (not shown) installed in the fan 10, and thus, the reoxidation of ferrous oxide in the oxidizing atmosphere zone and the combustion of the granular carbonaceous reducing agent as the heat source are controlled. More specifically, the temperature in the rotary kiln 1 is increased by reducing the pressure in the rotary kiln 1, and is decreased by increasing the pressure in the rotary kiln 1.
(2) Control by burner:
The temperature in the oxidizing atmosphere zone and the position of the maximum temperature in the oxidizing atmosphere zone are controlled by controlling the amount of fuel oil and air ejected from the burner 5 installed in the exit hood 3 of the rotary kiln 1 into the rotary kiln 1, and by changing the position of the tip of the burner 5 in the rotary kiln 1 by moving the burner 5 horizontally.
(3) Control of the amount of supply of granular carbonaceous reducing agent:
This practice comprises controlling the amount of the granular carbonaceous reducing agent prepared by blending at a prescribed ratio of coke and highly reactive coal with a high volatile matter content to be charged into the rotary kiln 1 together with the dust. More particularly, the temperature in the rotary kiln 1 is increased by increasing the amount of charged granular carbonaceous reducing agent, and is decreased by reducing the amounts of charged granular carbonaceous reducing agent.
(4) Control of blending ratio of coke and coal in the granular carbonaceous reducing agent:
This practice comprises controlling the blending ratio of coke and highly reactive coal with a high voltatile matter content in the granular carbonaceous reducing agent charged into the rotary kiln 1 together with the dust. The temperature in the rotary kiln 1 is increased by increasing the above-mentioned blending ratio of coal, and is descreased by reducing the above-mentioned blending ratio of coal. Thus, by using coke and coal in a prescribed ratio as the granular carbonaceous reducing agent, it is possible to properly control the temperature in the rotary kiln 1, and thus to effectively reduce the dust.
Now, the present invention is described in more detail by means of an example.
EXAMPLE
Pellets having a strength of about 15 kg were prepared by granulating a steelmaking electric furnace dust having the chemical composition shown in Table 2 into particles of a size of about 10 mm diameter by a granulator, and drying these particles at a temperature of 200° F. for about 20 minute.
TABLE 2__________________________________________________________________________(wt. %)Fe.sub.2 O.sub.3 ZnO PbO CdO SiO.sub.2 CaO Al.sub.2 O.sub.3 MnO NaO F Cl Na K C__________________________________________________________________________43.3 17.5 3.0 0.04 4.5 3.2 2.6 2.3 1.3 0.7 4.0 2.2 1.6 1.0__________________________________________________________________________
As the granular carbonaceous reducing agent, a coke and a coal having the properties as shown in Table 3 were employed.
TABLE 3______________________________________ Volatile Fixed ParticleAsh matter carbon Calorific sizecontent content content value diameter(wt. %) (wt. %) (wt. %) (Kcal/kg) (mm)______________________________________Coke 11.23 3.16 85.61 7,200 4 to 10Coal 13.88 44.65 41.47 6,550 up to 15______________________________________
The dust in the form of the above-mentioned pellets and the granular carbonaceous reducing agent were charged into a rotary kiln 1 having a length of 24 m and a shell inside diameter of 3.2 m as shown in FIG. 1 from the entry 1a thereof. The dust was charged in an amount of 5,608 Kg/H ands the granular carbonaceous reducing agent, in an amount of 656 kg/H. In the above granular carbonaceous reducing agent, 425 kg/H of coke (75.8 kg per ton of dust) and 231 kg/H of coal (41.2 kg per ton of dust) were employed.
From a burner 5 installed in the exit 1b section of the rotary kiln 1 movably horizontally toward the interior of the rotary kiln 1, kerosene in an amount of 36 kg per ton of dust was blown together with air into the rotary kiln 1 and burnt. The temperature in the rotary kiln 1 was detected by means of temperature-measuring probes at the positions T 1 , T 2 , T 3 , T 4 and T 5 as shown in FIG. 2, and was controlled so as to achieve the temperature profile as shown in FIG. 2 by the method described above.
As a result, ferric oxide contained in the dust was reduced into ferous oxide in the portion with a relatively low temperature ranging from the entry 1a of the rotary kiln 1 to the point B located at about two third of the total length of the rotary kiln 1. Then, in the portion from the above-mentioned point B to the point C in the oxidizing atmosphere zone near the exit 1b where the temperature increases rapidly, zinc oxide, lead oxide and other metal oxides were reduced, evaporated and separated from the dust. Zinc, lead and other metals thus separated from the dust were discharged from the rotary kiln 1 together with exhaust gases produced in the rotary kiln 1, and recovered by the chamber 7, the cyclone 8 and the bag filter type dust collector 9.
In the oxidizing atmosphere zone, on the other hand, ferrous oxide was reoxidized into tri-iron tetroxide and ferric oxide, and after increasing the temperature of the portion of the reducing atmosphere zone near the oxidizing atmosphere zone by high-temperature oxidation heat produced during this reoxidation, discharged from the exit 1b in the form of a clinker containing iron oxides, together with other residues. The amount of the recovered dust containing zinc oxide, lead oxide and other metal oxides was 1,480 kg/H, and the amount of the clinker was 3,650 kg/H. Table 4 shows the chemical composition of the recovered dust containing zinc oxide, lead oxide and other metal oxides, and Table 5 gives the chemical composition of the discharged clinker.
TABLE 4______________________________________(wt. %)FeO Fe.sub.2 O.sub.3 ZnO PbO CdO F Cl Na K C______________________________________0.08 3.98 51.7 9.1 0.14 0.6 12.0 1.0 0.2 0.9______________________________________
TABLE 5__________________________________________________________________________(wt. %)FeO Fe.sub.2 O.sub.3 ZnO PbO SiO.sub.2 CaO Al.sub.2 O.sub.3 MnO MgO F Cl Na K C S P Cu__________________________________________________________________________32.5 32.7 2.5 0.5 8.6 4.9 3.4 5.1 2.5 0.7 0.8 2.0 0.2 0.9 0.6 0.17 0.12__________________________________________________________________________
The amount of solid carbon in the granular carbonaceous reducing agent used in the example and the consumption of this solid carbon for the individual reduction reactions and as the heat source were as follows:
(1) Amount of solid carbon in the granular carbonaceous reducing agent:
a. Coke:
Amount of charge: 425 kg/H
Amount of solid carbon: 425 kg/H=85.61=363.8 kg/H where, the percentage of 85.61% in the equation represents the solid carbon content in coke.
b. Coal:
Amount of charge: 231 kg/H
Amount of solid carbon: 231 kg/H×41.47%=95.8 kg/H where, the percentage of 41.47% in the equation represents the solid carbon content in coal.
c. Total amount of solid carbon: 459.6 kg/H
(2) Consumption of solid carbon:
a. Amount consumed for reduction of ferric oxide: 80.1 kg/H
b. Amount consumed for reduction of zinc oxide: 140.6 kg/H
c. Amount consumed for reduction of lead oxide: 7.8 kg/H
d. Amount consumed for reduction of cadmium oxide: 0.2 kg/H
e. Amount consumed as heat source: 230.9 kg/H
Table 6 shows the consumption of the granular carbonaceous reducing agent per ton of dust and the amount of treated dust per day per m 3 of the effective volume of the rotary kiln in the method of the present invention and the conventional method.
TABLE 6______________________________________ Consumption of granular carbonaceous reducing Amount of agent (kg/t) treated dust Coke Coal Total (t/day · m.sup.3)______________________________________Method of the 75.8 41.2 117.0 0.518inventionConventional 250 to -- 250 to 0.400method 300 300______________________________________
According to the method of the present invention, as described above, it is possible to efficiently recover such useful metals as zinc, lead and other metals from a dust produced during refining in a metal refining metallurgical furnace, with the use of a granular carbonaceous reducing agent in an amount of under a half of that in the conventional method. Furthermore, since the amount of treated dust per day per m 3 of rotary kiln is improved to extent of about 1.3 times as large as that in the conventional method, the rotary kiln may be of a smaller capacity, requiring lower running and installation costs than those in the conventional method, thus providing industrially useful effects.
|
In a method for recovering zinc and lead from a dust containing ferric oxide, zinc oxide and lead oxide discharged from a metal refining metallurgical furnace, the dust is charged into the entry of a rotary kiln together with a granular carbonaceous reducing agent. The atmosphere of the interior of the kiln comprises a reducing atmosphere zone accounting for a major portion of the interior including the entry section of the kiln and an oxidizing atmosphere zone accounting for a minor portion of the interior including at least a part of the exit section of the kiln. The temperature of the interior of the kiln is increased by the combustion of a fuel from at least one burner installed at the exit section of the kiln directed toward the interior of the kiln. The dust is reduced in the reducing atmosphere zone to vaporized zinc and lead, and also to reduce the ferric oxide into ferrous oxide. The resultant zinc and lead are reoxidized in the oxidizing atmosphere zone, and discharged from the kiln, together with exhaust gases produced in the kiln to recover zinc and lead. The method includes the characterizing step of reoxidizing the ferrous oxide into the ferric oxide in the oxidizing atmosphere zone. The characterizing step has an effect enabling saving an amount of the reducing agent used as the fuel which corresponds to the amount necessary to generating the heat corresponding to that obtained by the reoxidation heat of the ferrous oxide.
| 8
|
BACKGROUND OF THE INVENTION
The invention relates to a change-speed transmission for motor vehicles, farm and industrial tractors in particular, featuring a drive clutch, a gear-shift transmission unit, a range-shift transmission unit with one or several forward speeds and a reverse speed, and an additional intermediate drive.
DESCRIPTION OF THE PRIOR ART
A change-speed transmission known having gear-shift, intermediate drive, and range selection transmission units is known by the International Harvester Company mbH published German patent specification, DAS No. 1,530,901, filed on Aug. 11, 1964, and published on Feb. 5, 1970, with Otto A. Bohner and Helmut Scholz named as co-inventors. On this known change-speed transmission the intermediate transmission can -- by means of a friction contact clutch -- be engaged optionally in the power flow together with the range shift transmission which is also engageable via a friction contact clutch whereby the power output-shaft can be driven directly either by the engaged intermediate drive or the engaged range-shift transmission. Although this known change-speed transmission already has a comparatively large number of speeds, practical application proved that a further increase in the number of speed stages would be desirable. To achieve such an extension of the change-speed transmission by several speed ratios at economically justifiable cost, it is essential to change as little as possible the arrangement of the change-speed transmission in view of its basic design.
The invention is based on the realization that an increase of the gear stages can be achieved by simple means if the friction clutch pack of the original intermediate drive is replaced by an epicyclic gearing unit, whereby said unit will render possible the desired increase in gear ratios.
SUMMARY OF THE INVENTION
Therefore, the invention is based on the objective of providing for motor vehicles, farm and industrial tractors in particular, a suitable change-speed transmission in range-type design of the initially mentioned kind which -- due to an increase in gear stages to be achieved at structurally negligible expenditure -- distinguishes itself by an even larger range of gear ratios. According to the invention this problem is solved by adding to the intermediate drive gear unit a sun-and planet gear, the planetary ring gear of which can be externally by three separate power sources. The intermediate drive unit which according to the invention is designed as sun and planetary gearing can be installed as a complete unit in the place of the friction clutch pack in the original intermediate drive unit provided on the known DAS No. 1,530,901 change-speed transmission. In the manner of the unit existing design of the known transmission can be adhered to, particularly modification in the mutual arrangement of the individual shafts of the transmission units. Thus a considerable simplification in manufacturing the change-speed transmission is achieved, since it can be built without any considerable modification of the production machine tools. By driving the planetary ring gear externally, a multitude of transmission ratios can be realized. In principle it is of no consequence to the invention at which location the intermediate gear unit is placed in the overall transmission. However, in an appropriate design the planetary drive is located between the gear-shift transmission unit and range-shift transmission unit. With such an arrangement the sun pinion of the planetary gear is preferably driven by the countershaft of the gear-shift transmission unit, and the planet gear carrier is in drive connection with the countershaft of the range-shift transmission unit.
As regards this invention, it is of utmost importance that the planetary gear ring is driven by the final drive shaft of the range-shift transmission unit. For this purpose a sliding pinion is provided which is movably supported on the final drive shaft and has to be forced into engagement with external gearing providing on the circumference of the planetary gear ring. By shifting the sliding pinion to a second position it can also be meshed with the main drive shaft of the gear-shift transmission unit, so that -- on the one hand -- the inner gear ring can be driven by the final drive shaft of the range shift transmission unit while -- on the other hand -- it can be driven by the main drive shaft of the gear-shift transmission unit.
Furthermore, the gear ring of the planetary drive can be driven by an auxiliary or second power shaft which is independently driven, irrespective by the vehicle engine of the vehicle traveling or not. For this purpose a sliding ratchet wheel is provided on the auxiliary shaft whereby the ratchet wheel can be glared to the external gearing on the planetary gear ring. By this drive additional speed ratios also be achieved.
Furthermore, the planetary gear ring can be braked. For this purpose a band brake is provided which acts upon the outer circumference of the planetary gear ring.
Furthermore, a drive connection is also provided between the gear ring and the countershaft of the range-shift transmission unit which can be disconnected planetary obtain additional speed ratios. This is effected by providing a dog clutch between a splined hub section of the gear ring and the countershaft of the range-shift transmission unit.
BRIEF DESCRIPTION OF THE DRAWING
A preferred embodiment of the invention is displayed in the drawing and is described in detail in which.
FIG. 1 shows a schematic representation of a change-speed range selector with an intermediate drive unit incorporating a planetary gear drive; and
FIG. 2 shows an enlarged cross section through the planetary gear drive.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows that the illustrated change-speed transmission has a gear box or housing 1, divided by separating walls 2 into several -- in this case 5 -- chambers 3, 11, 25, 32 and 50 in which the transmission units (explained in detail later on) of the change-speed range selector several transmission are accommodated. On a crankshaft 4 extending into the front face of the transmission housing 1 and driven by a drive engine (not shown) a first dry-type clutch 5 and a separate second dry-type clutch 6 are arranged. Both dry-type clutches 5, 6 can be combined into a single clutch pack unit. Clutch 6 is connected to constant mesh gears 7, 17a which drive an auxiliary shaft or secondary power shaft 8 supported laterally in the transmission housing 1. Parallel to the auxiliary shaft 8 there is a main drive shaft 9 of the gear-shift transmission unit 11 connected to clutch 5. The four speeds of the gear shift transmission unit 11 are as follows: first speed gear ratio: gears 12 and 13; second speed gear ratio: gears 14 and 15; third speed gear ratio: gears 16 and 17; and fourth speed gear ratio: gears 18 and 19. Between the driven gear wheels 13 and 15, a first gear-shifting mechanism 21 is arranged, and between the drive gear wheels 16 and 18 a second gear-shifting mechanism 22 is provided. By means of said gear-shifting mechanisms the selected speed gear ratio can be engaged to the power flow.
Parallel to the main drive shaft 9 a main or first countershaft 23 is arranged. On the main or first countershaft 23 a sun gear 24 is arranged which is included in the intermediate drive transmission unit 25. Planetary gear wheels 26 mesh with the sun gear 24 and are carried by the planet gear carrier 27. Carrier 27 is splined onto a second countershaft 33 which is part of the range selector transmission unit 32. The planetary gear ring 28 has internal gear teeth 51 meshing with the planetary gears 26. A hub section 29 of the planetary gear ring 28 is provided with dog clutch means 31 which can be put in drive connection with the second main countershaft 33 belonging to the range-shift transmission 32. The range-shift transmission unit 32 has the gear wheels 34 and 35 for a field speed ratio range, the gear wheels 36 and 37 for a road speed ratio range, and the gears wheels 38, 39, and 41 for a reverse speed ratio range. The gear wheels 35, 36, and 38 are a cluster of sliding gears movably supported on a power output shaft or bevel pinion shaft 42 which extends parallel to the countershaft 33 of the range-shift transmission unit 32 and coplanar with the main drive shaft 9. By the selection of the vehicle operator either the field range, the road range, or the reverse range of the range shifting transmission 32 can then be engaged to the transmission power flow. In a known manner a final drive 43, not described in detail, is driven by the bevel tubular gear means shaft 42.
On the bevel pinion shaft 42 a sliding pinion 44 is arranged in an axially movable manner. The sliding tubular gear means has a pinion which 44 can be engaged to the external gear ring portion 45 provided on the outer circumference of the planetary gear ring 28, so that the planetary gear ring 28 can be driven in a rotating manner. Furthermore, as shown in FIG. 2 the sliding pinion 44 of the tubular gear means has an internal spline portion 52 which can be thrown into a force-locking engagement with a mating splined portion 53 on the main drive shaft 9. Finally, the sliding pinion 44 can be moved to a neutral position where there is no drive connection, with either the external gearing 45 of the gear ring 28 or with the main drive shaft 9. To brake the planetary gear ring 28 a band brake 46 acts upon the periphery of the gear ring 28.
Ultimately, the planetary gear ring 28 can also be driven by a ratchet wheel 47 arranged on the auxiliary power shaft 8. Actuating elements not shown in detail are used to actuate the dog clutch 31, the band brake 46, the sliding pinion 44, and the ratchet wheel 47.
As shown in FIG. 2, the hub portion 29 of the gear ring 28 is supported on the rear countershaft 33 by means of a first antifriction bearing 48, while a web portion 54 is supported on the carrier 27 by means of a second antifriction bearing 49.
The operating characteristics of the change-speed transmission according to this invention will now be explained. Supposing the dog-clutch 31 and the band brake 46 are released and the sliding pinion 44 has been moved axially along the bevel pinion shaft 42 to the right so that it can rotate on the bevel pinion shaft 42 on bearing 55 and internal spline 52 is in force-locking engagement with the external spline 52 on main drive shaft 9. In this position the left side of the gear teeth 56 on the sliding pinion 44 still remain engaged with the external gearing 45 of the gear ring 28. Thus the gear ring 28, by way of the sliding pinion 44, is driven in a rotating manner by the main drive shaft 9. Simultaneously, by way of one of the engaged sets of speed ratio gears 12-13, 14-15, 16-17, or 18-19, the sun gear 24 is driven, and together with it the planetary wheels 26 and the carrier 27. Due to the simultaneous external and internal driving of the gear ring 28 a differential speed of rotations develops at the carrier 27 which is transferred to the countershaft 33 of the range-shift transmission unit 32. In the range-shift transmission unit 32 either the field range gear sets 34-35 or the road range gear sets 36-37 can be engaged. By the mode of operation described above a total of eight different transmission ratios can be obtained.
The second possible mode of driving the gear ring 28 is achieved by moving the sliding pinion 44 slightly to the left, while the dog clutch 31 and the band brake 46 are released. Then the sliding pinion 44, via its internal spline-type gearing 52 is in a force-locking engagement with the splined end 57 on the bevel pinion shaft 42. As before the external gearing 45 on the gear ring 28 remains in a force-locking engagement with the external gearing 45 but now on the right side of the gearing. The sun gear 24 of the intermediate drive 25 is again driven in a rotating manner and at a corresponding speed by a gear set ratio selected from the gear-shift transmission train 11. Simultaneously the planetary wheels 26 and the carrier 27 are driven, and together with them also the countershaft 33 of the range-shift transmission unit 32. Either by way of the field range gear ratio sets 34-35 or via the road range gear ratio sets 36-37 the power flow can be transferred to the bevel pinion shaft 42 from where it is transferred to the external glaring 45 on the gear ring 28 via the sliding pinion 44. Since this way the gear ring 28 is driven, too, a differential speed of rotations develops in the intermediate drive 25 from where it is transferred via the range-shift transmission 32 to the bevel pinion shaft 42 and to the final reduction drive 43. Through the four selectable gear set ratio of the gear-shift transmission train 11 and the two ranges of the range-shift transmission 32 in this case, too, a total of eight forward speeds is obtained.
The third possible mode of driving the gear ring 28 is achieved by way of the ratchet wheel 47 which is arranged on the auxiliary counter shaft 8 and can be shifted. For this purpose the sliding pinion 44 is moved to the exterme teeth 56 on the sliding pinion 44 no longer mesh with the teeth on the external gearing 45 of the gear ring 28. There is, of course, a locking mechanism (not shown in detail) provided between the sliding pinion 44 and the ratchet wheel 47 to prevent accidental or careless simultaneous engaging of the sliding pinion 44 and the ratchet wheel 47. The sun gear 24, the planetary gears 26 and the carrier 27 as before are driven by one of the selected gears of the gear-shift transmission train 11 simultaneously with the ring gear 28 being driven externally by the ratchet wheel 47. By simultaneous driving of the gear ring 28 via the ratchet wheel 47, yet another differential speed of rotations is produced which is transferred from the carrier 27 to the countershaft 33 of the range-shift transmission 32. In the range-shift transmission 32, again either the field range or the road range can be engaged, so that in this case, too, a total of eight forward speeds is obtained.
A fourth possible mode of increasing the number of transmission ratios can be realized by braking the gear ring 28 by means of the band brake 46. As before the dog clutch 31 remains disengaged and the sliding pinion 44 remains in the extreme leftward or neutral position so that it does not exercise any drive effect. When the inner gear ring 28 is braked, the power is transferred via one of the selected gears of the gear-shift transmission train 11, to the sun gear 24 which drives the planetary gear wheels 26 and the carrier 27, from where the power flow is transferred to the countershaft 33 of the range-shift transmission unit 32, were again either the field range or the road range can be selected. With this particular mode of drive a total of eight different forward speed transmission ratios is produced, too.
Finally, there is a fifth possible mode of driving the gear ring 28 in a rotating manner. In this case the band brake 46 is released, and the sliding pinion 44 and the ratchet wheel 47 remain in their disengaged position. However, the dog clutch 31 is shifted to the right into an engaged position with the spline teeth 58 in the hub 29 of the ring gear 28, so that the gear ring 28 and the countershaft 33 of the range-shift transmission 32 are row splined together to the countershaft 33. Now the intermediate drive transmission unit 25 acts as clutch, between the change-speed transmision unit 11 and the range-shift transmission unit 32. Thus the power flow is transferred from the countershaft 23 to the countershaft 33 via the sun gear 24, the carrier 27, and the gear ring 28, and the dog clutch 31. By this possibility of selecting four speeds from the gear-shift transmission train 11 and of selecting by way of the range-shift transmission 32 either the field or the road range, in this case, too, a total of eight forward gear speeds can be produced.
By means of the arrangement described in this invention a change-speed transmission has been developed on which by installation of a planetary drive in place of the known clutch in the intermediate drive a total of 40 forward speeds instead of the original 12 forward speeds is produced. The arrangement also does not alter the change-speed transmission unit or the and range-shift transmission unit.
Such a design offers the advantage of facilitating the selective installation of either a conventional intermediate drive or the planetary drive described in this invention in the change-speed transmission without necessitating any major changes on the change-speed transmission itself. The result is a considerable simplification in manufacturing said change-speed transmission as well as the possibility of an extremely advantageous universal application. The change-speed transmission featured in this invention is most suitable for farm tractor application, where a comparatively large number of gear speeds is a necessity.
|
A multi-speed gear transmission in which the available speed ratios are increased by the addition of planetary gearing in an intermediate drive transmission unit which is between a change speed transmission unit and a range and direction of travel transmission unit. The planetary ring gear is provided with an external gear ring portion which is selectively driven by either a primary power shaft or by an auxiliary power shaft or by the power output shaft, and also can be braked and connected directly to the output shaft to provide the additional speed ratios.
| 5
|
The present application claims priority under 35 U.S.C. § 119(e) to provisional application 60/059,732, filed Sep. 23, 1997, the entirety of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus and method for improving the economics of hydrocarbon production from a producing well. In particular, the present invention relates to an apparatus and method for selectively lifting produced fluid, including produced hydrocarbons and a portion of produced water, to the ground surface and for injecting the remaining produced water, subsurface, in a subterranean well.
2. Related Art
Conventional hydrocarbon production wells have been constructed in subterranean strata that yield both hydrocarbons, such as oil and gas, and an undesired amount of water. These wells are usually lined with heavy steel pipe called "casing" which is cemented in place so that fluids cannot escape or flow along the space between the casing and the well bore wall. In some wells, large amounts of water are produced along with the hydrocarbons from the onset of production. Alternatively, in other wells, relatively large amounts of water can be produced later during the life of the well.
The production of excess water to the ground surface results in associated costs in both the energy to lift, or "produce," as well as the subsequent handling of the excess produced water after it has arrived at the surface. Moreover, the produced water must be disposed of after it has been brought to the ground surface. Surface handling of excess water, in addition, creates risks of environmental pollution from such incidents as broken lines, spills, overflow of tanks, and other occurrences. Further, the facilities, lines, and wells required to handle excess water disturb the environment by virtue of their construction and presence. Accordingly, many oil production fields and wells often rapidly become uneconomic to produce hydrocarbons because of excessive water production.
Various apparatuses and methods have been proposed to overcome the problems associated with excess water production and the aforementioned problems associated with lifting, or producing, this water to the ground surface. Several approaches have been used to produce excess water to the ground surface or to avoid producing the excess water to the ground surface by shutting off the water at the entry into the wellbore. Among these means are: installing larger pumps to pump the water to the ground surface; shutting off the water by injecting gels or resins into the formation; and installing mechanical means in the well to interrupt the flow of water into the wellbore. These approaches, however, have not recognized that effective removal of water from oil or gas wells can be accomplished by transferring the accumulated water subsurface to a water-absorbing injection formation.
An evolving approach to the problem of excess water production is to take advantage of the downhole gravity segregation of produced hydrocarbons and produced water in the wellbore. The excess produced water is then conveyed into an injection formation of the subterranean strata while, for example, the oil and a small portion of the produced water that has not fully segregated from the oil are produced, or "lifted," to the ground surface. Such an approach has generally been referred to as an "in-situ" injection method. The conveyance downhole of produced water, without having lifted a majority or all of it to the ground surface, can substantially improve lease revenues or reduce lease operating expenses and investments, thereby extending the economic life of entire fields.
Devices or systems that lift and/or flow hydrocarbons and a portion of the water to the ground surface, while simultaneously injecting the water which has been separated downhole may be referred to by those persons having ordinary skill in the art as "Dual Injection and Lifting Systems (DIALS)," or alternatively, as "Downhole Oil Water Separation (DOWS)."
Generally, such methods have required the availability of a suitable injection formation, either below or above the production zone, with sufficient permeability to permit injection of the excess water into the injection formation. In addition, these in-situ methods have generally employed pumps of the same type (e.g., dual rod pumps). These pump combinations have generally been powered by the same prime mover or drive, such as a conventional pump drive located at the ground surface.
Conventional coupled systems which have been driven by the same prime mover have presented numerous problems with regard to production flexibility in order to accommodate changing reservoir conditions. This is so because it has not been feasible or simple enough to individually control the amount of fluids being lifted to the ground surface and the amount of water being injected by the coupled pumps. For example, the output of the lifting pump in a coupled system, such as a dual-rod pump, may not be variably reduced during production and the output of the injection pump may not be variably increased during production. Such flexibility is needed, for instance, when the well volume remains constant during production but the percentage of oil production decreases with time.
One example of a conventional production apparatus of the coupled in-situ type is a Dual Action Pumping System ("DAPS") that produces oil and a portion of the water from a casing/tubing annulus on the upstroke of the pump, injects water on the downstroke, and uses the gravity segregation of the oil and water within the annulus. Such an apparatus is shown in U.S. Pat. No. 5,497,832, also assigned to the assignee of the present application, the entirety of which is incorporated herein by reference.
Tests of this technology in a number of different wells have shown that gravity segregation of oil and water enable a dual-ported, dual-plunger rod pump to selectively lift produced fluids, including produced hydrocarbons and a portion of produced water, while separating and injecting the remaining produced water into an injection zone within the subterranean strata.
The DAPS apparatus, however, does not solve all of the problems associated with excess water production or changing water production within the subterranean reservoir. Very often, the use of two pumps of the same type (e.g., dual rod pumps) may limit the ability of the pumping system to minimize the amount of water lifted to the ground surface. For example, a system, such as DAPS, using a 1.75" diameter rod pump and a 1.5" diameter rod pump will generally lift approximately 18% of the total produced fluids to the ground surface even though the well produces only approximately 5% oil. Further, in coupled systems (i.e., pumps sharing the same prime mover), as noted above, the ability of the systems to adjust to changing water cut production is limited. For example, the various parts of the pump assemblies of coupled systems cannot economically be changed frequently enough to meet changing reservoir conditions.
In a further example of the conventional in-situ approach, coupled rod pumps are used for separating and producing oil from water in a well, while simultaneously injecting the water into the producing formation or into an injection formation below the producing formation. Such an apparatus is shown in U.S. Pat. No. 5,697,448. The apparatus employs three spaced packers (upper, middle, and lower). An oil pump is located between the upper and middle packers, and a water pump is located between the middle and lower packers. Produced oil and water are accumulated between the upper and middle packers. The oil is delivered through an opening into the oil pump and fills a cylinder associated with the oil pump. Produced water is allowed to drain through additional passages into the water pump cylinder where it accumulates for injection. Selective pumping of the oil on the upstroke of the pump and the water on the downstroke of the pump is effected by a set of check valves associated with both the oil and water pumps. Such an apparatus, however, is not an optimal solution to the problems associated with changing water and oil production presented by conventional coupled systems. For example, the apparatus does not provide the flexibility needed to vary the percentage of total reservoir output that is lifted or brought to the ground surface without substantial modifications to the system.
In another example of an in-situ type apparatus, a formation injection tool, mounted to a bottom-hole tubing pump, carries out underground separation and down-bore in-situ transport and injection of the undesired fluids into an injection formation in the production well. Such an apparatus is shown in U.S. Pat. No. 5,425,416. As with the apparatus shown in U.S. Pat. No. 5,697,448, this system does not provide the flexibility needed to quickly and inexpensively change the proportion of fluids lifted to the ground surface as conditions within the subterranean producing strata change.
Moreover, conventional systems such as those described above have failed to provide a simple and effective method for handling high viscosity oils or solids, such as sand, which are present in many production wells. In addition, many wells have become inoperative due to the inability of conventional systems to handle crude oil and gas mixtures or shear sensitive fluids. Conventional wells generally have also not been able to compensate for changes in pressure, such as those that may be caused by gas bubbles.
Thus, there is a need in the art for an apparatus and method that substantially obviates one or more of the limitations and disadvantages of conventional pumping systems. Particularly, there is a need for a system for lifting produced oil and a portion of the produced water to the ground surface, while injecting the remainder of the produced water into an injection formation. There is a particular need for uncoupled systems which have the flexibility to vary the proportions of fluids lifted to the ground surface to the amount of water injected subsurface within the subterranean strata. There is also a need for such systems to be able to handle a variety of conditions within the producing reservoir.
SUMMARY OF THE INVENTION
The present invention solves the problems with, and overcomes the disadvantages of, conventional coupled systems for lifting produced hydrocarbons and a portion of the produced water to the ground surface following gravity segregation, and for injecting, without lifting to the ground surface, the remaining produced water into an injection zone.
The present invention relates to an apparatus for selectively lifting produced fluids, including produced hydrocarbons and a portion of produced water, to a ground surface and injecting, without lifting to the ground surface, the remaining produced water below the ground surface. The apparatus includes a casing having two spaced intervals. The casing extends from the ground surface downwardly such that a first of the two spaced intervals communicates with a producing zone and a second of the two spaced intervals communicates with an injection zone.
The apparatus further includes an electrical submersible progressive cavity pump and an electrical submersible pump disposed in the casing. A packer is also included. The packer is disposed within the casing between the first of the two spaced intervals and the second of the two spaced intervals. The casing and the packer are configured to permit the produced fluids to collect above the packer whereby the produced hydrocarbons and produced water segregate by gravity.
The apparatus also includes a first inlet for permitting the segregated produced hydrocarbons and portion of the produced water to enter one of the electrical submersible progressive cavity pump and the electrical submersible pump. A second inlet is included for permitting the segregated produced water to enter the other of the electrical submersible progressive cavity pump and the electrical submersible pump.
In a further aspect of the invention, a downhole oil and water separation system is provided for conducting produced fluids, including produced hydrocarbons and a portion of produced water, to a ground surface and injecting, without conducting to the ground surface, the remaining produced water below the ground surface. The system includes a casing having two spaced intervals. The casing extends from the ground surface downwardly such that a first of the two spaced intervals communicates with a producing zone and a second of the two spaced intervals communicates with an injection zone.
The system further includes an electrical submersible progressive cavity pump and an electrical submersible pump disposed in the casing. The electrical submersible progressive cavity pump is not drivingly coupled to the electrical submersible pump. A packer is disposed within the casing between the first of the two spaced intervals and the second of the two spaced intervals. The casing and the packer are configured to permit the produced fluids to collect above the packer whereby the produced hydrocarbons and produced water segregate by gravity.
In one aspect of the system, a first inlet permits segregated produced hydrocarbons and portion of the produced water to enter the electrical submersible progressive cavity pump, and a second inlet permits the segregated produced water to enter the electrical submersible pump.
In an alternate aspect of the system, the first inlet permits segregated produced hydrocarbons and portion of the produced water to enter the electrical submersible pump, and the second inlet permits the segregated produced water to enter the electrical submersible progressive cavity pump.
In another aspect, the present invention relates to a method for selectively lifting fluids, including produced hydrocarbons and a portion of produced water from a subterranean well, to a ground surface and injecting, without lifting to the ground surface, the remaining produced water, subsurface, the subterranean well traversing a producing zone and an injection zone.
The method includes allowing produced water and produced hydrocarbons to collect and to segregate above a packer disposed in a casing in the subterranean well. In addition, the method includes controlling one of an electrical submersible progressive cavity pump and electrical submersible pump to lift the segregated produced hydrocarbons and a small portion of the produced water to the ground surface. The method also includes independently controlling the other of the electrical submersible progressive cavity pump and electrical submersible pump to inject the segregated produced water into the injection zone.
Features and Advantages
The present invention represents a different approach to the aforementioned problems of conventional systems. The present invention represents an improvement over such systems, and is particularly suitable for use in loosely consolidated formations where solids production can be a problem, or where gas and condensate production accompanies the crude oil production. The present invention also utilizes smaller surface profiles and weight-bearing requirements which may be important in such applications as offshore platforms.
The present invention also provides for uncoupled pump systems which are separately and independently controlled by, and driven by, individual drive units, or separately driven and independently controlled by the same drive unit. As such, the present invention provides a simple, expedient, and flexible method for controlling the amount of hydrocarbons and water lifted to the ground surface, while at the same time injecting excess produced water into an injection zone. The present invention provides such flexibility while retaining the advantages of electrical submersible progressive cavity pumps and electrical submersible pumps.
The present invention also is advantageous over purely rod-driven lift systems because it can handle larger volumes of produced fluids. Moreover, the rates for lifting hydrocarbons to the ground surface and for injecting water into a disposal zone may be separately and independently varied and controlled.
The present invention may also be used in oil-producing wells to reduce lease costs that are directly associated with the volume of the total produced fluids from a producing well lifted to and handled at the ground surface. A reduction in the volume of produced fluids lifted to and handled at the ground surface results in a lowering of the horsepower required to operate the well since only produced hydrocarbons and a small fraction of produced water are actually lifted to the ground surface. Similarly, water injection costs, water treatment costs, spill containment costs, water transportation costs, and environmental cleanup costs may be substantially reduced by use of the present invention.
The present invention may also increase revenues from oil-producing wells. Use of dual injection and lifting systems such as the present invention, as opposed to use of conventional lift systems (which produce all fluids to surface) can increase production rates of producing wells. This increases operating revenues which can lead to an extended economic life of the well. Moreover, wells which previously were not operating due to high water volumes may be returned to production.
The present invention may also reduce investment costs for surface equipment. Moreover, separation equipment, treating equipment, and filtration equipment may be eliminated or reduced in size.
The present invention may also reduce exposure of the environment to damage from oil-producing operations. Potential environmental damages may be lessened by minimizing the amount of water produced to, and handled at, the surface. As known in the art, such surface water must then be reinjected into the subterranean strata through separate wellbores, or "injection wells." The very act of constructing facilities or drilling injection wells disturb the natural environment.
The present invention also provides a simple and effective method for handling high viscosity oils or solids, such as sand, which are present in many production wells. In addition, many wells which have become inoperative due to the inability of conventional systems to handle crude oil and gas mixtures or shear sensitive fluids may be returned to production. The present invention also allows compensation for changes in pressure, such as those that may be caused by gas bubbles.
Additional features and advantages of the invention will be set forth in the description that follows, and in part will be apparent from the description, or may be learned in practice of the invention. These descriptions and drawings are intended as illustrative of the invention, and not as limitative thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the features, advantages, and principles of the invention.
FIG. 1 is a schematic side-elevation sectional view of an exemplary embodiment of the present invention;
FIG. 2 is a schematic side-elevation sectional view of a second exemplary embodiment of the present invention;
FIG. 3 is a schematic side-elevation sectional view of a third embodiment of the present invention shown with an injection zone overlying a producing zone in the subterranean reservoir; and
FIG. 4 is a schematic side-elevational view illustrating an exemplary electrical submersible progressive cavity pump suitable for use in the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. The exemplary embodiments of this invention are shown in some detail, although it will be apparent to those skilled in the relevant art that some features which are not relevant to the invention may not be shown for the sake of clarity.
Referring first to FIG. 1, there is illustrated, in a schematic side-elevation sectional view, an exemplary embodiment of the present invention and is represented generally by reference numeral 5. A casing 11 is shown extending from a ground surface 14 downwardly within a subterranean well through a hydrocarbon and water producing zone 12 and then to a water injection zone 19. It should be understood by one of ordinary skill in the art that injection zone 19 may alternatively be referred to as a disposal zone. It is preferable to have a long distance or an isolation zone 18 between producing zone 12 and injection zone 19.
As shown in FIG. 1, casing 11 has a producing interval, shown generally at 15, separated from an injection interval, shown generally at 17. Producing interval 15 is located adjacent to and in fluid flow communication with producing zone 12. In a similar manner, injection interval 17 is located adjacent to and in fluid flow communication with disposal, or injection zone 19. Producing interval 15 may preferably be for example, but is not limited to, perforations 15a with or without gravel packs in casing 11 as shown in FIG. 1. Alternatively, producing interval 15 may be, but is not limited to, a slotted liner with or without gravel packs, wire-wrapped screens with or without gravel packs, or pre-packed wire-wrapped screens. Likewise, injection interval 17 may preferably be, but is not limited to, perforations 17a with or without gravel packs in casing 11 as shown in FIG. 1. As an alternative, injection interval 17 may be a slotted liner with or without gravel packs, wire-wrapped screens with or without gravel packs, or pre-packed wire-wrapped screens. As a further alternative, instead of using injection interval 17, the excess water may be injected directly into an open hole (not shown) within the subterranean strata. Preferably, however, injection interval 17 will be perforations 17a.
It should be readily apparent to one skilled in the art that casing 11 may be provided with multiple producing intervals 15 and injection intervals 17 in communication with producing zone 12 and injection zone 19, respectively. Moreover, injection zone 19 can be the same formation as producing zone 12 provided that producing interval 15 and injection interval 17 are not communicating actively (i.e., fluid flow is isolated between producing interval 15 and injection interval 17). It should be understood by those of skill in the art, however, that fluids produced into casing 11 through producing interval 15 and water injected through injection interval 17 may influence the flow parameters of each other.
Casing 11 surrounds a tubing 24 which extends from ground surface 14 downwardly within casing 11. Tubing 24 preferably includes three tubing sections, 24a, 24b, and 24c. It should be apparent to one of ordinary skill in the art that tubing 24 may include any number of tubing sections depending, of course, upon the particular configuration of the well.
A first pump 10 is disposed at an end of first tubing section 24a which extends from ground surface 14 downwardly within casing 11. Tubing section 24b extends between and is coupled to first pump 10 and a second pump 20. Second pump 20 is preferably disposed below first pump 10 in casing 11 on tubing 24, or more particularly, on second tubing section 24b. Tubing section 24c is coupled to second pump 20 and extends downwardly within casing 11 below a packer 16 disposed in casing 11.
First pump 10 and second pump 20 are shown in the embodiment of FIG. 1 uncoupled relative to each other. Particularly, first pump 10 is not drivingly coupled to second pump 20. First pump 10 and second pump 20 are preferably controlled by individual drives as will be described in more detail below. This configuration allows the individual pump rates to be separately controlled to respond to changing reservoir conditions. Moreover, individual rates of lift and injection can be separately controlled to optimize overall field performance.
In the embodiment shown in FIG. 1, first pump 10 is an electrical submersible progressive cavity pump (ESPCP) and second pump 20 is an electrical submersible pump (ESP). An electrical submersible centrifugal pump is particularly preferred. In an alternate embodiment of the present invention, first pump 10 is an ESP and second pump 20 is an ESPCP.
As noted above, packer 16 is disposed within casing 11, preferably between producing interval 15 and injection interval 17. Casing 11 and packer 16 are configured to permit produced hydrocarbons and produced water to collect above packer 16. By "produced hydrocarbons" is meant crude oil, gas, gas condensate, and various combinations thereof. Particularly, tubing 24, casing 11, and packer 16, together define casing/tubing annulus 26 that extends upward to ground surface 14. Hydrocarbons, such as oil or gas, and water flow or are "produced," into casing 11 through producing interval 15. The hydrocarbons and water segregate by gravity within casing/tubing annulus 26 forming a hydrocarbon/water interface 28. Gravity segregation, as used herein, is intended to describe the preservation of the isolation between produced hydrocarbons and water, as opposed to separation which indicates that a mixture is mechanically divided into separate fluids. Thus, the produced hydrocarbons and water are allowed to collect in annulus 26 above packer 16 and to segregate by gravity to form segregated produced water 23 below hydrocarbon/water interface 28 and segregated produced hydrocarbons and a small proportion or portion of produced water 25 above hydrocarbon/water interface 28.
A first, or upper inlet 30 is preferably disposed in tubing 24, or more particularly, in an upper end of tubing section 24b, below first pump 10. First inlet 30 is disposed in a region of casing 11, or more particularly, in a region of casing/tubing annulus 26, where segregated hydrocarbons and only a small proportion or portion of water are expected to be present and preferably, adjacent hydrocarbon/water interface 28. As shown in the exemplary embodiment in FIG. 1, first inlet 30 may be sets of perforations 30a in tubing 24. Alternatively, first inlet 30 may be a port or multiple ports or other suitable mechanisms for conducting fluid flow. Preferably, however, first inlet 30 will be sets of perforations 30a. First inlet 30 is configured to permit produced hydrocarbons and any portion of water that has not segregated from the hydrocarbons 25 to enter first pump 10. The operation of first inlet 30 will be described in more detail below.
A second, or lower inlet 13 is shown disposed in tubing 24, or more particularly, in a lower end of tubing section 24b, above second pump 20. Second inlet 13 is preferably disposed in a region of casing 11, or more particularly, in a region of casing/tubing annulus 26, where primarily only the heavier segregated produced water is present (i.e., inlet 13 is in fluid-flow communication primarily with segregated produced water 23). As shown in FIG. 1, second inlet 13 may be sets of perforations 13a in tubing 24 or second tubing section 24b. Second inlet 13 is configured to permit the segregated produced water from producing zone 12 to enter second pump 20 and to be injected into disposal zone 19 as will be discussed in more detail below. It may also be desirable, although not required, to dispose a tubing plug 38 in tubing 24, or more particularly second tubing section 24b, between first pump 10 and second pump 20, in order to maintain separation of the segregated produced hydrocarbons and a portion of the produced water 25 and the segregated produced water 23 within second tubing section 24b.
A first variable speed drive 36 may be disposed at ground surface 14 to provide power to and control the pump rate of first pump 10. First pump 10 is preferably coupled to first variable speed drive 36 by a first electrical line or cable 34. Similarly, a second variable speed drive 40 may be disposed at ground surface 14 to provide power to and control the pump rate of second pump 20. Second pump 20 is preferably coupled to second variable speed drive 40 by a second electrical line or cable 37.
Reference will now be made to the operation of the first exemplary embodiment shown in FIG. 1. In operation, produced fluids (hydrocarbons and water) are produced from producing zone 12 via intervals 15 into casing 11 above packer 16 forming a column of produced hydrocarbons and water within casing/tubing annulus 26. The lighter produced fluids (mostly hydrocarbons 25) rise to the top of the column while the heavier fluids (mostly water 23) settle to the bottom of the column.
Segregated hydrocarbons and a small portion of water 25 then flow, or are "pulled," through first inlet 30 and into tubing 24 below first pump 10. First pump 10 then pumps the segregated hydrocarbons and a small portion of water 25 (as will be described in more detail with reference to FIG. 4) through tubing 24 to ground surface 14 where it is collected in a well-known manner. It is preferred that, during production, hydrocarbon/water interface 28 is maintained adjacent first inlet 30 in order to provide stabilized pumping conditions. In order to meet the capacity of first pump 10 and to ensure that hydrocarbon/water interface 28 is maintained adjacent first inlet 30, an upper portion of segregated produced water 23 (in addition to produced hydrocarbons and portion of produced water 25) may be "pulled" by first pump 10 through first inlet 30 and pumped to ground surface 14.
Simultaneously, segregated produced water 23 that has settled at the bottom of the casing/tubing annulus 26 flows through second inlet 13 and into second pump 20. The segregated water is then pumped, or injected, through the end of tubing section 24c and into casing 11 below packer 16 and thereafter into injection zone 19.
It should be understood by one skilled in the art that first pump 10 and second pump 20 may include sensors (not shown) for flow rate, pressure, and temperature measurement or other types of control information which is transmitted to variable speed drives, 36 and 40. Thus, first pump 10 and second pump 20 are individually and independently controllable to provide maximum flexibility in selecting pump output to optimize reservoir performance and to allow conformance to changing reservoir conditions. Moreover, because first pump 10 and second pump 20 are separately controlled (i.e., first pump 10 is controlled by first variable speed drive 36 and second pump 20 is controlled by second variable speed drive 40), their respective pump output may be separately and independently varied to correspond to the changing reservoir conditions during production.
The entire combination of first pump 10 and second pump 20 may typically be about 30 feet to several hundred feet in length. Moreover, the distance from producing intervals 15 to packer 16, percentage of water cut and injection rate, and designed production rate can all be variables in deciding whether it is desirable to place second pump 20 just above packer 16 or higher in the well.
Reference will now be made to FIG. 2, wherein a second embodiment of the present invention is shown employing a single submersible electric motor 32 to separately provide power to and control first pump 10 and second pump 20. Like reference numerals will be used where appropriate to describe similar elements to those of the embodiment shown in FIG. 1.
In FIG. 2, motor 32 is shown disposed in casing 11, and more particularly, in tubing section 24b between first pump 10 and second pump 20. Preferably, motor 32 will be axially aligned with first pump 10 and second pump 20. Motor 32 includes an upper drive shaft 42 coupled to first pump 10 through a gearbox 32a. Additionally, a lower drive shaft 44 is coupled between motor 32 and second pump 20.
Variable speed drive 36 is disposed at ground surface 14 to provide power to motor 32 and to control the output of motor 32 (e.g., speed of rotation). Motor 32 is preferably coupled to variable speed drive 36 by electrical line or cable 34. The remaining elements shown in FIG. 2 have been described above with reference to FIG. 1, and for the sake of brevity are herein incorporated by reference.
Reference will now be made to the operation of the second exemplary embodiment shown in FIG. 2. In operation, produced fluids (hydrocarbons and water) are produced from producing zone 12 via intervals 15 into casing 11 above packer 16 forming a column of produced hydrocarbons and water within casing/tubing annulus 26. The lighter produced fluids (mostly hydrocarbons) rise to the top of the column while the heavier fluids (mostly water) settle to the bottom of the column.
Segregated hydrocarbons and a small portion of water 25 then flow through first inlet 30 and into tubing 24 below first pump 10. First pump 10, driven by motor 32 via gearbox 32a, pumps the segregated hydrocarbons and small portion of water 25 through tubing 24 to the ground surface 14 where it is collected in a well-known manner.
Simultaneously, segregated produced water 23 which has settled at the bottom of casing/tubing annulus 26 flows through second inlet 13 and into second pump 20. The segregated water is then pumped, or injected through the end of tubing section 24c and into casing 11 below packer 16 and thereafter into injection zone 19.
Reference will now be made to FIG. 3, wherein a second embodiment of the present invention is shown in which third tubing section 24c is coupled to second pump 20 for injecting produced water into disposal zone 19 which is located above producing zone 12. In this embodiment, second pump 20 is preferably disposed at the end of tubing 24, or more particularly, at the end of second tubing section 24b.
As can be seen in FIG. 3, third tubing section 24c extends up casing/tubing annulus 26 and through a passage 16a in packer 16. A second packer 27 is disposed in casing 11 preferably above injection zone 19. Packer 16 and second packer 27 are configured to isolate injection zone 19 within casing 11 from both producing zone 12 and, for example, an isolated aquifer 40. Second inlet 13 is shown disposed on a lower end of second pump 20 such that segregated produced water 23 passing through second pump 20 may be used for cooling purposes.
Tubing plug 38 may be disposed in tubing 24, or more particularly in second tubing section 24b, between first pump 10 and second pump 20 in order to isolate segregated hydrocarbons and portion of produced water 25 from segregated produced water 23 within tubing 24.
During operation of the system shown in FIG. 3, first pump 10 lifts segregated produced hydrocarbons and a portion of produced water 25 to ground surface 14 in the manner described above. At the same time, second pump 20 pumps segregated produced water 23 that enters second pump 20 through second inlet 13 through third tubing section 24c and thereafter into disposal zone 19 via injection interval 17.
Reference will now be made to FIG. 4, which is provided to illustrate a schematic partial view of an exemplary electrical submersible progressive cavity pump (ESPCP) suitable for use with the present invention, represented generally as reference numeral 7. An exemplary electrical submersible progressive cavity pump suitable for use with the present invention is shown in U.S. Pat. No. 3,677,665, the entirety of which is incorporated herein by reference. When used with the present invention, ESPCP 7 is preferably coupled to tubing 24 as described above, however, ESPCP 7 may also be disposed within tubing 24.
The ESPCP preferably comprises a helically shaped rotor 26 and a stator 22. Rotor 26, which is the ESPCP's only moving part, is usually in the shape of a single external helix with a round cross section. Rotor 26 is normally plated with a hardened surface coating for abrasion resistance in the presence of sand, formation residue chips, or the like. Stator 22 is generally formed of a very firm, but elastomeric compound (such as synthetic rubber) and usually has a double internal helix. Its external shape is generally cylindrical and therefore provides a surface which may be bonded to a pump body. Rotor 26 is suspended in stator 22 and may be powered (i.e., rotated) by an electrical submersible motor 48 via a gear reduction drive 46 which is used preferably as a conventional speed reducer. A flex shaft 42 and a seal section 44 are coupled together and located between rotor 26 and gear reduction drive 46.
In operation, as internal helical pump rotor 26 is turned by motor 48, a series of cavities are formed between the helices of rotor 26 and stator 22 beginning at the intake end and progressing, with the rotary motion, to the output end. The progressive cavities cause fluid to be pumped from the input end to the output end. If rotor 26 is chosen to have a right hand pitch helix, then a vertical pump placed in a well will input fluid into its lower end 29 and output fluid from its upper end 31 with right hand rotation. Conversely, if rotor 26 is chosen to have a left hand pitch helix, then a vertical pump placed in a well will input fluid from its upper end 31 and output the fluid from its lower end 29.
The ESPCP is highly efficient when compared to other oil field pumps in common usage. For example, a typical electrical-powered submersible centrifugal pump is from about 25% to 45% efficient. A hydraulic jet pump usually runs from about 15% to 30% efficient. Sucker rod powered mechanical pumps generally run from about 45% to 50% efficient. Conversely, ESPCP's usually run from about 70% to 95% efficient. The ESPCP can also handle solids or very heavy crude oil where more delicate electric pump impellers, electric motors or gearboxes on sucker rod pumping units fail. While a hydraulic jet pump can efficiently operate in high solids environment, its operating efficiency is only about one third of the ESPCP. ESPCP's that are commercially available can operate at production rates of up to 5,200 barrels of fluid per day from shallow wells. ESPCP's are capable of operating at depths up to about 5,000 feet, with fluid density from 6 to 45 American Petroleum Institute (API) degrees gravity, at temperatures up to 300° F./150° C. and in salty, sandy and high viscosity fluids. However, at such depths the volume of fluid produced would be less than producing from shallow wells.
As described above, the present invention provides a simple method and apparatus for providing flexibility and reliability in lifting produced hydrocarbons and only a portion of the produced water to the ground surface while simultaneously injecting excess produced water subsurface. It should be apparent that the present invention may be used to increase efficiency and production, to lower production, injection, and equipment costs, and to extend the overall commercial life of hydrocarbon producing fields.
Moreover, the present invention significantly reduces the disturbance to and impact on the natural environment while improving the economics of hydrocarbon recovery. The apparatus and method of the present invention reduces the amount of land disturbance, such as less earthwork, erosion, and spills. In addition, the present invention reduces the amount of surface facilities required such as tanks, separators, and surface handling equipment. With less and/or smaller surface equipment, there would be fewer leaking valves and connections as well as reduced chemical handling, storage, and use. Through use of the present invention, fewer single-use injection wells and associated facilities, pumps, and injection lines are needed. The present invention can also reduce the need for produced water trucking or transportation. Further, because less water is lifted to the ground surface, the evaporation and exposure of water-soluble hydrocarbons to the atmosphere is minimized. In reservoirs wherein the excess water has a moderate to high hydrogen sulfide content, exposure of the hydrogen sulfide to the surrounding environment may also be minimized or eliminated. Moreover, with less equipment at the ground surface, noise or other air pollution from such equipment may be minimized. Waterfloods or pressure maintenance projects could utilize less fresh water. Fewer spills from corrosion, overflowing tanks, or other equipment failures are other benefits. Further, there is less need for isolated wastewater disposal sites and fewer wellbores penetrating aquifers. Smaller offshore platforms are possible as well.
The present invention can also result in less electrical power and associated costs which allows for more efficient recovery of natural hydrocarbon resources and extended life for marginal wells and fields. The present invention could also provide pressure maintenance or waterflooding as a byproduct of production.
Conclusion
While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.
|
The present invention relates to an apparatus and method for selectively lifting produced fluids, including produced hydrocarbons and a portion of produced water, to a ground surface while injecting the remaining produced water into an injection zone subsurface in a subterranean well. The invention preferably utilizes an electrical submersible progressive cavity pump (ESPCP) in conjunction with an electrical submersible pump (ESP) in order to carry out the dual injection and lifting steps. Further, this apparatus and method make it possible to produce hydrocarbons from oil wells in a manner that poses less risk and disturbance to the environment.
| 4
|
TECHNICAL FIELD
[0001] This present disclosure relates generally to an elastomeric bearing assembly for rotorcraft.
DESCRIPTION OF RELATED ART
[0002] Typically, the centrifugal force motions and the feathering motions experienced by the blade of a rotorcraft are managed by discrete bearings mounted within separate components. These separate components are generally heavy and complex. Hence, there is a need for an improved device for managing both the centrifugal force and feathering motions in a rotorcraft.
DESCRIPTION OF THE DRAWINGS
[0003] The novel features believed characteristic of the system and method of the present disclosure are set forth in the appended claims. However, the system and method itself, as well as a preferred mode of use, and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings, wherein:
[0004] FIG. 1 is a perspective view of a rotorcraft, according to an example embodiment;
[0005] FIG. 2 is a perspective section view of a rotor system of a rotorcraft, according to an example embodiment;
[0006] FIG. 3 is a perspective view of an elastomeric bearing assembly, according to an example embodiment;
[0007] FIG. 4 is a side section view of an elastomeric bearing assembly, according to an example embodiment;
[0008] FIG. 5 is a perspective view of a spindle, according to an example embodiment;
[0009] FIG. 6 is a perspective section view of an inboard side of a housing of an elastomeric bearing assembly, according to an example embodiment;
[0010] FIG. 7 is a perspective section view of an outboard side of a housing of an elastomeric bearing assembly, according to an example embodiment;
[0011] FIG. 8 is a perspective section view of an elastomeric bearing assembly, according to an example embodiment;
[0012] FIG. 9 is a partially exploded perspective view of an elastomeric bearing assembly, according to an example embodiment; and
[0013] FIG. 10 is a partially exploded perspective view of an elastomeric bearing assembly, according to an example embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] Illustrative embodiments of the system and method of the present disclosure are described below. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
[0015] In the specification, reference may be made to the spatial relationships between various components and to the spatial orientation of various aspects of components as the devices are depicted in the attached drawings. However, as will be recognized by those skilled in the art after a complete reading of the present disclosure, the devices, members, apparatuses, etc. described herein may be positioned in any desired orientation. Thus, the use of terms such as “above,” “below,” “upper,” “lower,” or other like terms to describe a spatial relationship between various components or to describe the spatial orientation of aspects of such components should be understood to describe a relative relationship between the components or a spatial orientation of aspects of such components, respectively, as the device described herein may be oriented in any desired direction.
[0016] FIG. 1 shows a rotorcraft 100 according to one example embodiment. Rotorcraft 100 features one or more rotor systems 110 , a fuselage 130 , and a wing 140 . Rotor system 110 can include blades 120 , a control system, and a pitch horn 160 for selectively controlling the pitch of each blade 120 in order to control direction, thrust, and lift of rotorcraft 100 . In the example of FIG. 1 , rotorcraft 100 represents a tiltrotor aircraft, and rotor system 110 features rotatable nacelles. In this example, the position of the nacelles operate rotorcraft 100 in both helicopter and airplane modes. Fuselage 130 represents the main body of rotorcraft 100 and can be coupled to one or more rotor systems 110 (e.g., via wing 140 ) such that rotor system 110 can provide thrust to move fuselage 130 through the air. Wing 140 can also generate lift during forward flight.
[0017] Referring now to FIG. 2 , a propulsion system provides torque to a rotor mast (not shown). Yoke 150 is coupled to the rotor mast such that rotation of the rotor mast causes yoke 150 and rotor blade 120 to rotate about the rotor mast axis 340 of rotation. Each yoke 150 further includes at least one elastomeric bearing assembly 200 for receiving and coupling to each rotor blade 120 . Elastomeric bearing assembly 200 can be configured to treat and react a plurality of dynamic forces, such as centrifugal force 310 and torsional force 320 , that act on blade 120 .
[0018] Referring now to FIGS. 3 through 7 , elastomeric bearing assembly 200 may include a spindle 260 , a housing 230 , a shear bearing 270 , a centrifugal force bearing 210 , a cone set 240 , and a cap 250 . Outboard portion 264 of spindle 260 can pass through the center of shear bearing 270 , housing 230 , centrifugal force bearing 210 , and cap 250 . Centrifugal force bearing 210 can be vulcanized to the outboard end of housing 230 and held in place by cone set 240 , which can be two separate pieces that form a cone shape, and cap 250 .
[0019] Spindle 260 can be fabricated out of any suitable material. For example, spindle 260 can be forged, cast, or machined out of a suitable material such as stainless steel or titanium. The inboard portion 262 of spindle 260 can be attached to yoke 150 by four bolts and the outboard portion 264 of spindle 260 can be rigidly coupled to cap 250 . In another example embodiment, spindle 260 and yoke 150 can be one piece where the spindle is an outer portion of yoke 150 .
[0020] Housing 230 can be fabricated out of any suitable material. For example, housing 230 can be forged, cast, or machined out of a suitable material such as stainless steel or titanium. On the inboard end of housing 230 , a first cavity with interior wall portion 237 can accommodate shear bearing 270 . The first cavity can have substantially the same diameter as the exterior diameter of shear bearing 270 . As best seen in FIGS. 6 and 7 , wall 233 may provide support for the first cavity and can also have an exterior wall portion 234 that can be of a similar shape as shear bearing 270 . Wall 233 can be of a suitable thickness, depending on the size of shear bearing 270 . For example, if the diameter of shear bearing 270 is 5.5 inches, a suitable thickness of wall 233 may be 0.5 inches. On the outboard end of housing 230 , a second cavity with interior wall portion 235 can accommodate outboard portion 264 of spindle 260 passing through housing 230 .
[0021] On the sides of housing 230 , two cavities 232 that are perpendicular to spindle 260 , but parallel to each other, can accommodate bushings 220 and blade bolts configured to couple a flat portion of blade 120 to housing 230 . Cavity 232 can be outboard of spindle bearing 270 but inboard of centrifugal force bearing 210 .
[0022] In one embodiment, shear bearing 270 is a cylindrical elastomeric bearing which has multiple cylindrical layers that are laminated or vulcanized together. In another embodiment, shear bearing 270 may have conical or spherical layers that are laminated or vulcanized together. Shear bearing 270 can include alternating elastomeric layers 271 and rigid layers 272 . Elastomeric layers 271 may be made of an elastic material such as rubber, and rigid layers 272 may be made of a rigid material such as steel. However, embodiments are not limited to any particular materials, and elastomeric layers 271 and rigid layers 272 may be made of any elastic and rigid materials, respectively.
[0023] Shear bearing 270 can be vulcanized or adhered to both the outboard portion 264 of spindle 260 and wall portion 237 of housing 230 . Shear bearing 270 can be configured such that housing 230 is allowed to rotate clockwise and counterclockwise about a center axis 330 that runs along the length of each blade 120 and spindle 260 . For example, shear bearing 270 reacts to torsional force 320 by elastically deforming the cylindrical elastomeric layers between each rigid layer. As mentioned, pitch horn 160 can selectively control the pitch of blade 120 . Therefore, as pitch horn 160 rotates blade 120 , torsional force 320 is transferred from blade 120 to housing 230 , from housing 230 to shear bearing 270 . Accordingly, since spindle 260 is not rotatable, torsional force 320 is in relation to spindle 260 .
[0024] In one embodiment, centrifugal force bearing 210 is a cylindrical elastomeric bearing which has multiple substantially planar layers that are laminated or vulcanized together. In another embodiment, centrifugal force bearing 210 may have conical or spherical layers that are laminated or vulcanized together. The planar layers may run perpendicularly in relation to the length of spindle 260 . Centrifugal force bearing 210 can include alternating elastomeric layers 211 and rigid layers 212 . Elastomeric layers 211 may be made of an elastic material such as rubber, and rigid layers 212 may be made of a rigid material such as steel. However, embodiments are not limited to any particular materials, and elastomeric layers and rigid layers may be made of any elastic and rigid materials, respectively.
[0025] Centrifugal force bearing 210 can be vulcanized or adhered to surface 236 of housing 230 . Centrifugal force bearing 210 can be configured to counteract centrifugal forces acting on blade 120 as blade 120 spins around yoke 150 . For example, centrifugal forces acting on blade 120 are transferred from blade 120 to housing 230 , housing 230 then exerts a compression force to centrifugal force bearing 210 . Centrifugal force bearing 210 reacts and counteracts the compression force by compressing the elastomeric layers between each rigid layer.
[0026] In one example embodiment, centrifugal force bearing 210 may not be cylindrical. Those skilled in the art will understand that centrifugal force bearing 210 may be deviated from being cylindrical. For example, centrifugal force bearing 210 may be cube shaped.
[0027] In one example embodiment, housing 230 includes a plurality of apertures 510 running parallel to spindle 260 , as seen in FIG. 8 . These apertures can serve several purposes. For example, apertures 510 may make it easier to remove shear bearing 270 from the assembly. Specialized tooling can be made to fit within apertures 510 and pull shear bearing 270 away from housing 230 . Another purpose of apertures 510 is to allow air to flow into apertures 510 in order to cool the elements of elastomeric bearing assembly 200 . During operation, centrifugal force bearing 210 and shear bearing 270 can be repeatedly compressed or twisted due to the compression and torsional forces acting on them. These forces can produce excess heat that can be reduced by apertures 510 .
[0028] In one example embodiment, shear bearing 270 may include a race 275 , as seen in FIGS. 9 and 10 . Race 275 can be made out of any suitable metal, such as stainless steel. The outermost layer of shear bearing 270 can be vulcanized or adhered to race 275 . Shear bearing 270 with race 275 can be wet installed, bonded, or thermally fit into housing 230 . One of the advantages of this embodiment is that shear bearing 270 can be easily removed from housing 230 and replaced with a lower risk of damaging the centrifugal force bearing 210 .
[0029] In yet another example embodiment, shear bearing 270 may include additional anti-rotation features when shear bearing 270 is bonded to race 275 instead of housing 230 . As seen in FIG. 9 , race 275 may include holes 276 , and housing 230 may include holes 236 that may run transversely in relation to shear bearing 270 . Holes 236 and 276 may accommodate locked set screws 280 that run through housing 230 and race 275 . In another example embodiment, race 275 and housing 230 may include holes 296 that run parallel to race 275 , as seen in FIG. 10 . Holes 296 can accommodate pinned plates 290 that are secured to housing 230 by screws 295 .
[0030] One advantage of elastomeric bearing assembly 200 is that both shear bearing 270 and centrifugal force bearing 210 are located in the same assembly. Having both of these bearings in the same assembly makes the assembly more compact and lightweight. Additionally, the design of elastomeric bearing assembly 200 can allow the assembly to be closer to the center of gravity of the rotor system, which can reduce the forces acting on elastomeric bearing assembly 200 and blade 120 .
[0031] Another advantage of elastomeric bearing assembly 200 is that cavities 232 , which accommodate bushings 220 and the blade bolts, are located close to center axis 330 , and close to each other. A person of skill in the art would recognize that a flat portion 122 of blade 120 is the optimal position for the blade bolts to couple elastomeric bearing assembly 200 to blade 120 . Hence, locating the blade bolts closer to center axis 330 and each other would reduce the width of the flat portion 122 of blade 120 . The reduction of the width of flat portion 122 of blade 120 may reduce manufacturing complexity and cost.
[0032] For example, if cavities 232 were to exceed a specific width apart, the spar of blade 120 may become equally wide at that location; therefore, the final blade structure may not be dynamically acceptable for certain applications, such as tiltrotor aircraft. A person of skill in the art would recognize that the blades of tiltrotor aircraft are especially sensitive to structural dynamic tuning.
[0033] The particular embodiments disclosed above are illustrative only, as the system may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Modifications, additions, or omissions may be made to the apparatuses described herein without departing from the scope of the invention. The components of the system may be integrated or separated. Moreover, the operations of the system may be performed by more, fewer, or other components.
[0034] Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the application. Accordingly, the protection sought herein is as set forth in the claims below.
[0035] To aid the Patent Office, and any readers of any patent issued on this application in interpreting the claims appended hereto, applicants wish to note that they do not intend any of the appended claims to invoke paragraph 6 of 35 U.S.C. § 112 as it exists on the date of filing hereof unless the words “means for” or “step for” are explicitly used in the particular claim.
|
In some embodiments, a rotorcraft may include a yoke, a blade, a spindle associated with the yoke, and an elastomeric bearing assembly. The center length of the spindle may define a center axis that passes through a center of the elastomeric bearing assembly. The elastomeric bearing assembly may contain a housing coupled to the blade and disposed around the center axis that is configured to rotate in relation to the center axis. The elastomeric bearing assembly may contain an elastomeric shear bearing that has an interior portion coupled to the spindle and an exterior portion coupled to the housing. The elastomeric bearing assembly may contain an elastomeric centrifugal force bearing pressed against the housing. The shear bearing may be configured to counteract a torsional force, and the centrifugal force bearing may be configured to counteract a compression force.
| 1
|
This application is a national stage of International Application No.: PCT/DE2010/000337, which was filed on Mar. 25, 2010, and which claims priority to German Patent Application Nos.: DE 10 2009 016 996.2, which was filed in Germany on Apr. 8, 2009; and to DE 10 2009 017 729.9, which was filed in Germany on Apr. 11, 2009, and which are both herein incorporated by reference.
The invention relates to an apparatus for compacting a fiber web according to the precharacterizing part of claim 1 .
From EP-A-0-859 076, there is known an apparatus for compacting the fibers of a fiber web of natural and/or synthetic fibers of any type, wherein a belt/drum-type compaction of the fiber web is performed. Said apparatus comprises the following features and respectively is designed as indicated hereunder:
a first endless belt supporting the fiber web, said belt being guided and trained in a tensioned state between two rollers, a permeable needling drum having the endless belt wrapped around it, a second endless belt, assigned to said first endless belt and also guided and in a tensioned state between two rollers, wherein the working strand of said second endless belt which is opposite to the working strand of the first endless belt is arranged to revolve in a driven manner in the same direction as that of the first endless belt, the two working strands of the two endless belts are, with respect to their longitudinal extension, conically directed to each other at the feed site in such a manner that the fiber web (the initial fiber web, the pile) arranged on the working strand of the first endless belt is increasingly compacted between the advancing endless belts, the two endless belts are pressed, by two rollers, against the needling drum for wrapping them more strongly around the drum, between said two rollers, a nozzle bar is facing toward the fiber web for wetting the fiber web.
The apparatus of the above type has the advantage that the initial fiber web, i.e. the fiber web advancing voluminously, will be compacted between the two endless belts in a slowly increasing manner and with uniform pressure from above and below, while not being subjected to shearing stress, and will be wetted at the needling drum only when being tightly held between the two endless belts.
This known apparatus is distinguished particularly by an intensive wetting generated directly on the drum. Further, after the second endless belt has been led away, there can be directly performed, on the drum, a needling process with the aid of a second nozzle bar which now is oriented directly towards the fiber web arranged on the drum. This arrangement, however, is very complex and too expensive for some products.
Known from EP 1 126 064 B1 is a device wherein the compacting and the first netting of the nonwoven are simplified. This known device provides a belt-to-belt compacting and comprises the following features and respectively is designed as indicated hereunder:
a first endless belt supporting the fiber web, said belt being guided and trained in a tensioned state between two rollers, a second endless belt, also guided in a tensioned state between at least two rollers, wherein the working strand of said second endless belt which is opposite to the working strand of the first endless belt is arranged to revolve in a driven manner in the same direction as that of the first endless belt, the two working strands of the two endless belts are, with respect to their longitudinal extension, conically directed to each other at the feed site in such a manner that the fiber web arranged on the working strand of the first endless belt is increasingly compacted between the advancing endless belts, in a region not supported by a guide roller, a first nozzle bar is arranged, which is assigned to the two endless belts revolving with each other and is provided with a suctioning function for wetting the fiber web.
The known apparatus are able to accomplish a slow compressing of the fiber web consisting of loose, not rigidly interconnected fibers, and the wetting process in the pressed state. Since the fiber web is compressed and wetted in this state, it will happen that, after the wetting and after detachment from the fiber web which is to be needled further on, single fibers still remain attached to the compressing endless belt (the compacting belt), which fibers will contaminate the belt and ultimately hinder a permanent optimal treatment of the subsequent fiber web.
To avoid the above described disadvantage, the belt-drum compacting according to WO 2004/046444 A1 provides that the nozzle bar arranged between the rollers guiding the compacting belt is oriented in such a manner that the water jets will impinge onto the fiber web only behind the compression region when seen in the transport direction of the fiber web.
Such an orientation of the nozzle bar will achieve an invariably effective wetting of the pressed fiber web wherein, however, the fiber web will be detached from the pressing endless belt by the water jets. At the same time, the compacting belt will be rinsed to be free of adhering fibers, and these fibers will be returned to the fiber strand. However, the described approach is possible only in a belt-drum compacting process.
From WO 2008/107549 A2, there is known a device for treatment of a non-woven wherein the web of fibers and filaments arranged on a revolving transport belt will be transferred onto the lower side of a second transport belt by application of water jets from below through the transport belt. The two transport belts have a distance larger than the thickness of the nonwoven web. By different speeds of the transport belts, the weight per surface unit of the nonwoven web can be influenced. However, by means of the two transport belts moving at different speeds, no compacting of the nonwoven web is effected. Compacting can be performed only by a further belt system, which causes considerable constructional expenditure.
DE 10 2005 055 939 B3 discloses a nozzle bar for generating fluid jets serving for compacting a fiber web. The nozzle strip comprises an exchangeable nozzle strip comprising the exit openings for the fluid. The exit openings can be arranged parallel to each other in a row, but also in two or more rows. The mutual distance and the diameter of the exit openings are dictated by the intended use. The fluid used can be pressurized water but, generally also overheated vapor.
It is an object of the present invention to improve an apparatus, known from EP 1 126 064 B1, which is provided for compacting a material web made of fibers and/or filaments, comprising a first revolving endless belt which carries the material web and is tensioned around guide rollers, and a second endless belt which is tensioned around guide rollers and revolves in the direction opposite to the first belt at the same speed, wherein the first and second endless belts, forming a conical compacting region in a first region in the conveying direction of the material web, run at an angle toward each other, whereby the material web located between the belts is increasingly pressed, wherein, subsequent to the first region, a first nozzle beam is disposed for a first fluid application onto the material web still located between the two endless belts, wherein the two belts in this region of the first fluid application are in each case guided to run in a tensioned manner in a straight direction.
According to the invention, it is provided, in a first embodiment, that, in the region of the first fluid application, the two belts are not guided in parallel extension relative to each other. The two belts, the transport belt carrying the material web consisting of fibers and/or filaments, as well as the compacting belt generating the pressing effect, extend at an acute angle relative away from each other when viewed in the transport direction of the web. Preferably, the guidance of the belts is adjustable in correspondence to the type of fibers or filaments or other conditions. Thus, it can be provided that the fluid application is performed in a region in which the web is hardly held in a pressed state anymore. Particularly, it is possible that the first fluid application is performed by means of two serially arranged, mutually parallel rows of exit openings for the fluid. It can be provided in this arrangement that, in the nozzle bar, a nozzle strip comprising the openings has two rows of exit openings, or that two nozzle bars are arranged behind each other. The latter arrangement makes it possible to perform the fluid application with different pressure values.
In an arrangement for first fluid application onto the material web arranged in a pressed state between the transport and compacting belts, which is performed by two nozzle bars, it can be provided that the two belts are guided in such a manner that the material web is still held in a pressed state during the application by the fluid jets of the first nozzle bar, but is hardly or not at all pressed anymore during the application of the fluid jets of the second nozzle bar. In case of a slight pressing process by the compacting belt or a pressing process not performed anymore, the fibers adhering in the screen tissue of the compacting belt will be driven back into the material web by the fluid jets of the second nozzle bar and, from there, be integrated into the composite structure.
The same inventive idea is realized in a second embodiment which provides the following: In the region of the first fluid application, the two belts are guided parallel to each other in a first section and are guided non-parallel to each other in a subsequent second section. A first fluid application is to be understood herein as the treatment of the fiber web by fluid jets of a single nozzle bar or a plurality of nozzle bars arranged closely behind each other.
By way of modification of the above, the following is provided:
In a second section, the two belts are tensioned such that they extend away from each other at an acute angle. The two belts are together wrapped around a guide roller and extend in parallel to each other, while holding the material web in a pressed state, toward a further common guide roller. The non-parallel guidance of the two belts is adjustable in the second section. One guide roller of one of the belts is settable so that the angle of the directions in which the belts run apart from each other can be changed. The first fluid application is performed by means of a plurality of nozzle bars arranged closely behind each other with respect to the total path of the material web within the entire system, said nozzle bars being arranged in the first and/or the second section. In the first section, a first nozzle bar is arranged, and in the second section, a second nozzle bar is arranged.
According to this alternative embodiment of the invention, it is provided that the two belts in the second section are tensioned to extend away from each other at an acute angle. In the first section, the two belts are guided parallel to each other, which can be performed in that the two belts are together deflected by a first guide roller and, subsequently, by means of a further guide roller, the compacting belt is guided away from the web-carrying transport belt at an acute angle. In this section, the compacting belt will run in the direction of a further guide roller which preferably is adjustably supported to allow for adjustment of the angle at which the transport and compacting bands extend away from each other.
Further, it can be provided that, for forming the first section, the two belts which are respectively guided around two guide rollers, extend parallel to each other in the thus formed section.
In this arrangement, said common wrap-around movement around the two guide rollers can be performed in the same direction or alternately. Also in these arrangements, it is provided that, starting from the second guide roller, the compacting belt is guided at an acute angle away from the transport belt carrying the web. In this second section, the compacting band runs in the direction of a second guide roller which preferably is adjustably supported to allow for adjustment of the angle at which the transport and compacting bands extend away from each other.
According to one embodiment of the invention, a respective nozzle bar is arranged in the first and in the second section alike. Thus, in this first section, there is performed a first application, a wetting, of the fiber web held in a pressed state between the two parallel belts. In the second section, a further nozzle bar is arranged so that the wetted nonwoven will now be once more treated and compacted through the structure of the compacting belt wherein, in this second section, the compacting belt extends away from the nonwoven-carrying transport belt at an acute angle.
In case of a slight or ceased pressing performed by the compacting belt in the second section, fibers adhering in the screen tissue of the compacting belt will be driven back into the material web by the fluid jets of the second nozzle bar and, from there, be integrated into the composite structure.
In this arrangement, it can be provided that the fluid application in the two successive sections is performed with different pressure values and also different hole spacings and hole diameters.
Exemplary embodiments of the invention will be explained hereunder with reference to the drawings. In this context, the term “fiber web” is to designate a non-compacted pile of fibers and/or filaments which is delivered by a pile producer in non-compacted form (material web prior to first compacting, fluid application). The term “nonwoven” is used for the material web after the latter has undergone a first compacting.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an apparatus for compacting a fiber web according to an exemplary embodiment;
FIG. 2 illustrates an enlarged view of a transport belt;
FIG. 3 illustrates a further enlarged view of the transport belt;
FIG. 4 illustrates an angle adjustment between the transport belt and a compacting belt;
FIG. 5 illustrates the apparatus for compacting a fiber web according to another exemplary embodiment;
FIG. 6 illustrates the apparatus for compacting a fiber web according to another exemplary embodiment;
FIG. 7 illustrates the apparatus for compacting a fiber web according to another exemplary embodiment;
FIG. 8 illustrates the apparatus for compacting a fiber web according to another exemplary embodiment;
FIG. 9 illustrates the apparatus for compacting a fiber web according to another exemplary embodiment;
FIG. 10 illustrates an enlarged view of the apparatus for compacting a fiber web according to FIG. 9 ;
FIG. 11 illustrates the apparatus for compacting a fiber web according to another exemplary embodiment;
DETAILED DESCRIPTION
A transport belt 1 formed as an endless screen belt (first endless belt) is held in a tensioned state around guide rollers U,U 1 and will rotate in clockwise sense as indicated by the arrow ( FIG. 1 ). A further—compacting—belt 2 formed as an endless screen belt (second belt) is held in a tensioned state around guide rollers U 2 ,U 2 -J and will rotate in anticlockwise sense as indicated by the arrow. Said compacting belt 2 runs at the same speed as said transport belt 1 and thus, in the region of its working strand, in synchronism with the working strand of transport belt 1 carrying the fiber web F. Said guide rollers U,U 1 ,U 2 ,U 2 -J are arranged for rotation in machine frame portions, not shown.
On transport belt 1 , there is supplied a non-compacted fiber web F (pile) e.g. from a carding machine, not shown, and will run on the transport belt in the direction of guide roller U. By the guide roller U 1 shown on the lefthand side in FIG. 1 , the guide roller U and a guide roller U 2 , the transport belt 1 and the compacting belt 2 form a conically converging compacting region for the fiber web F. Since both the transport belt 1 and the compacting belt 2 are deflected around guide roller U, the fiber web F will be subjected to the strongest pressing force in this common wrap-around region.
Following guide roller U, transport belt 1 and compacting belt 2 will extend away from each other at an acute angle while tensioned in straight directions. The compacting belt 2 runs in the direction of guide roller U 2 -J, and the transport belt 1 runs in the direction of a further guide roller, not shown in FIG. 1 .
In this region, following guide roller U, a first nozzle bar D is arranged above the fiber web covered by compacting belt 2 . Said nozzle bar cooperates with a suction device A arranged below the transport belt 1 carrying the fiber web and, by the fluid jets W directed onto the fiber web, will effect a first slight compacting of the structure. When water jets are discharged by the nozzle bar D, the fiber web F will be wetted in this region. The fiber web F has now been compacted into a slightly consolidated nonwoven (initial nonwoven) V and will leave the region of compacting belt 2 at a site below guide roller U 2 -J. There follow further devices, not shown, for fluid application, further compacting and/or structuring of the nonwoven.
FIG. 2 is an enlarged view of the region between the common guide roller U and the guide roller U 2 -J cooperating with compacting belt 2 . The transport belt 1 and the compacting belt 2 cooperating therewith are wrapped around the common guide roller U at an angle α. In this region, the fiber web is subjected to the strongest pressing effect. After guide roller U, the transport belt 1 and the compacting belt 2 extend away from each other at an acute angle β. The guide roller U 2 -J directing the compacting belt K away from the direction of transport belt 1 is arranged in the machine frame, not shown, in a height-adjustable manner (dual arrow) so that the angle β can be adjusted within a range marked by the interrupted line.
FIG. 3 is a further enlarged view of the arrangement according to FIG. 2 in the region between the guide roller U and the height-adjustable guide roller U 2 -J. The angle β set by adjusting the guide roller U 2 -J, which angle is included between the transport belt 1 , carrying the nonwoven V, and the compacting belt 2 , is such that the fluid jets W passing through the compacting belt 2 will impinge onto the surface of the nonwoven V only after the compacting belt 2 is not in contact with the nonwoven V anymore. The final point of the contact between the compacting belt 2 and the nonwoven V is marked by K.
FIG. 4 shows a situation in which the angle β between the transport belt 1 carrying the nonwoven V and the compacting belt 2 is adjusted such that the fluid jets W passing through the compacting belt 2 will impinge onto the surface of the nonwoven V at the site K, i.e. at that site where the compacting belt 2 loses its contact with nonwoven V. The guide roller U is not shown in FIG. 4 .
Thus, by adjustment of guide roller U 2 -J, it is possible to set the angle β between the transport belt 1 carrying the nonwoven V and the compacting belt 2 , i.e. the path between the point K from which the compacting belt 2 is not in contact with the nonwoven V anymore, and the passage of the fluid jets W through the compacting belt 2 .
Further, it is also possible to set an angle β such that the fluid jets W passing through the compacting belt 2 will impinge onto the nonwoven V when the compacting belt 2 is still in contact with nonwoven V. Also in this case, the transport belt 1 and the compacting belt 2 do not extend parallel to each other; the angle β is only flatter than in the situations according to FIG. 3 or 4 .
In the embodiment according to FIG. 5 , it is provided that, in the region between the common guide roller U and the adjustable guide roller U 2 -J, two nozzle bars D 1 ,D 2 are arranged above compacting belt 2 , with suction devices A 1 ,A 2 being arranged below transport belt 1 . By means of the fluid jets W 1 of the first nozzle bar D 1 , the nonwoven is first treated, wetted, and by means of the fluid jets W 2 of the second nozzle bar D 2 , passing through the compacting belt 2 after the compacting belt 2 has no contact to the nonwoven V anymore, adhering fibers will be detached out of from the compacting belt 2 and returned to the nonwoven V.
FIG. 6 shows an embodiment of the invention wherein, in contrast to the version shown in FIG. 1 , none of the guide rollers U 2 deflecting the compacting belt 2 is adjustable. The adjustment of an angle between the compacting belt 2 and the transport belt 1 carrying the nonwoven, in the region of the first application of fluid jets W, is performed by a guide roller U 1 -J supporting the transport belt 1 , which guide roller is adjustable in the direction marked by the double arrow.
Said alternative embodiment of the invention and the corresponding variants will now be explained with reference to FIGS. 7-11 .
A transport belt 1 formed as an endless screen belt (first endless belt) is held in a tensioned state around guide rollers U,U 1 and will rotate in clockwise sense as indicated by the arrow ( FIG. 7 ). A further—compacting—belt 2 formed as an endless screen belt (second belt) is held in a tensioned state around guide rollers U 2 ,U 2 P,U 2 -J and will rotate in anticlockwise sense as indicated by the arrow. Said compacting belt 2 runs at the same speed as said transport belt 1 and thus, in the region of its working strand, in synchronism with the working strand of transport belt 1 carrying the fiber web F. Said guide rollers U,U 1 ,U 2 ,U 2 -P,U 2 -J are arranged for rotation in machine frame portions, not shown.
On transport belt 1 , there is supplied a non-compacted fiber web F (pile) e.g. from a carding machine, not shown, and will run on the transport belt in the direction of guide roller U. By the guide roller U 1 shown on the lefthand side in FIG. 1 , the guide roller U and a guide roller U 2 , the transport belt 1 and the compacting belt 2 form a conically converging compacting region for the fiber web F. Since both the transport belt 1 and the compacting belt 2 are deflected around guide roller U, the fiber web F will be pressed in this common wrap-around region.
In a first section AB 1 , the transport belt 1 and the compacting belt 2 run parallel while holding the nonwoven between them in a pressed state.
After guide roller U 2 -P, in second section AB 2 , the transport belt 1 and the compacting belt 2 extend away from each other at an acute angle β while tensioned in straight directions. The compacting belt 2 runs in the direction of the adjustable guide roller U 2 -J, and the transport belt 1 runs in the direction of a further guide roller. The adjustability of guide roller U 2 -J is visualized by the double arrow.
In said first section AB 1 , after guide roller U, a first nozzle bar D 1 is arranged above the fiber web covered by compacting belt 2 . Said nozzle bar cooperates with a suction device A 1 arranged below the transport belt 1 carrying the fiber web and, by the fluid jets W 1 directed onto the fiber web, will effect a slight compacting of the structure. When water jets are discharged by the nozzle bar D 1 , the fiber web will be wetted in this region. The fiber web F has now been compacted into a slightly consolidated non-woven (initial nonwoven) V and, past guide roller UP-P, will reach the second section AB 2 in which the transport belt 1 and the compacting belt 2 extend away from each other at an acute angle β while being tensioned in a linear direction. In the second section AB 2 , a second nozzle bar D 2 is arranged above the compacting belt 2 . Below the transport belt 1 carrying the nonwoven V, a suction device 2 is arranged. Herein, the treatment of the nonwoven V is performed by the fluid jets W 2 which will pass through the structure (screen belt) of compacting belt 2 , then will reach the surface of the nonwoven V and the will pass through the structure of the transport belt 1 . The nozzle bars D 1 and D 2 are arranged closely behind each other with respect to the total path of the fiber web F within the entire system and together will effect a first application of fluid onto the material web as provided according to the sense of the invention.
FIG. 8 shows an embodiment of the invention wherein the transport belt 1 and the compacting belt 2 will first run around a common guide roller U and then, redirected into the reverse direction, around a guide roller U 2 -P. In the first section AB 1 , the two belts 1 , 2 run parallel while holding the intermediate fiber sheet in a pressed state. This is followed by an application with fluid jets W 1 of a first nozzle bar D 1 , with a suction device A 1 arranged below the transport belt. Following the guide roller U 2 -P, in the second section AB 2 , the transport belt 1 and the compacting belt 2 extend away from each other at an acute angle β while tensioned in a linear direction. The compacting belt 2 runs in the direction of the adjustable guide roller U 2 -J, the transport belt 1 in the direction of a further guide roller, not shown in FIG. 2 .
In the embodiment according to FIG. 9 , the transport belt 1 and the compacting belt 2 each extend in the same direction while being deflected around two guide rollers U, U 1 -P. In this first section AB 1 , a first nozzle bar D 1 with suction device A 1 is arranged. Following the guide roller U 1 -P, in the second section AB 2 , the transport belt 1 and the compacting belt 2 extend away from each other at an acute angle β while tensioned in a linear direction. Arranged in this second section AB 2 is a second nozzle bar D 2 with suction device A 2 for continuing the first fluid application onto the nonwoven V. Here, the treatment of the nonwoven V is performed by fluid jets W 2 passing through the structure (screen belt) of the compacting belt 2 , reaching the surface of nonwoven V and finally passing through the structure of transport belt 1 .
Thus, by adjustment of guide roller U 2 -J, the angle β between the transport belt 1 , carrying the nonwoven V, and the compacting belt 2 can be adjusted, i.e. the distance between the point K from which the compacting belt 2 has no contact with the nonwoven V anymore, and the passage of fluid jets W 2 through the compacting belt 2 ( FIG. 10 ).
FIG. 10 is an enlarged view of the arrangement according to FIG. 9 in the second section AB 2 between the guide roller U 1 -P and the height-adjustable guide roller U 2 -J. The angle β, set by the adjustability of guide roller U 2 -J, which angle is between the transport belt 1 , carrying the nonwoven V, and the compacting belt 2 , is such that the fluid jets W 2 passing through the compacting belt 2 will impinge onto the surface of the nonwoven V only after the compacting belt 2 is not in contact with the nonwoven V anymore. The final point of the contact between the compacting belt 2 and the nonwoven V is marked by K.
FIG. 11 shows a situation in which the angle β between the transport belt 1 , carrying the nonwoven V, and the compacting belt 2 is adjusted such that the fluid jets W 2 passing through the compacting belt 2 will impinge onto the surface of the nonwoven V at the site K, i.e. at that site where the compacting belt 2 loses its contact with nonwoven V.
Further, it is also possible to set an angle β in the second section AB 2 such that the fluid jets W 2 passing through the compacting belt 2 will impinge onto the nonwoven V when the compacting belt 2 is still in contact with nonwoven V. Also in this case, the transport belt 1 and the compacting belt 2 do not extend parallel to each other; the angle β is only flatter than in the situations according to FIG. 10 or 11 .
LIST OF REFERENCE NUMERALS
1 transport belt, first endless belt
2 compacting belt, second endless belt
F fiber web, pile, filament web
V nonwoven, fiber web, pile, filament web after pressing, after first fluid application
U guide roller—transport belt 1 , compacting belt 2
U 1 guide roller—transport belt
U 2 guide roller—compacting belt
U 1 -J guide roller—transport belt, adjustable
U 2 -J guide roller—compacting belt, adjustable
U 1 -P guide roller—transport belt
U 2 -P guide roller—compacting belt
D nozzle bar
D 1 first nozzle bar
D 2 second nozzle bar
A suction device
A 1 first suction device
A 2 second suction device
W fluid jet
W 1 fluid jet—first nozzle bar D 1
W 2 fluid jet—second nozzle bar D 2
AB 1 first section (transport and compacting belts parallel)
AB 2 second section (transport and compacting belts at an acute angle)
α wrap-around angle—transport belt 1 , compacting belt 2
β angle between transport belt 1 and compacting belt 2
|
The invention relates to an apparatus for compacting a material web made of fibers and/or filaments, comprising a first revolving endless belt which carries the material web and is tensioned around guide rollers, and a second endless belt which is tensioned around guide rollers and revolves counter to the first belt at the same speed, wherein the first and second endless belts form a conical compacting region in a first region in the conveying direction of the material web and run at an angle with respect to each other, whereby the material web located between the belts is increasingly pressed, wherein subsequent to the first region a first nozzle beam is disposed for a first fluid application onto the material web still located between the two endless belts, wherein the two belts in this region of the first fluid application are in each case guided to run in a tensioned manner in a straight direction. According to the invention, the following is provided: the two belts ( 1,2 ) are guided in the region of the first fluid application (D,W,A) such that they do not run parallel to each other, or: the two belts ( 1,2 ) are guided in the region of the first fluid application (D,W,A) such that they run parallel to each other in a first section (AB 1 ) and not parallel to each other in a subsequent second section (AB 2 ).
| 3
|
CROSS-REFERENCE To RELATED APPLICATIONS
[0001] This application is a divisional of and claims the benefit of non-provisional application Ser. No. 10/760,168, filed Jan. 16, 2004, which is a continuation in part of and claims the benefit of non-provisional application Ser. No. 10/462,461, filed on Jun. 16, 2003, now U.S. Pat. No. 6,926,160, which is a continuation of and claims the benefit of non-provisional application Ser. No. 10/331,826, filed on Dec. 30, 2002, now U.S. Pat. No. 6,811,043.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Generally, the invention relates to a workroom storage system for organizing the tools and supplies found in workrooms, especially garages. More specifically, the invention relates to a space-efficient workroom storage system providing both wall mounted storage and cabinet storage, with a combination of slotwall panels, slot tracks, cabinets removably mounted to the slotwall panel and/or slot tracks, and a workbench in combination with mobile storage cabinets that are stowable beneath the workbench.
[0004] 2. Description of the Related Art
[0005] There has long been a need for organized storage in workrooms, whether the workroom is a dedicated workshop, a garage, or any other room, since workrooms by their very nature tend to house many types of tools and equipment, along with general supplies and supplies for the tools and equipment. Past solutions to providing organized storage in workrooms were based on the operator selecting unrelated organization systems and combining them as operator saw fit, without an integrated system. The organization systems often reflected a hodgepodge of non-integrated solutions, such as fixed wall cabinets, pegboards, and workbenches with internal storage, which collectively did not provide a space-efficient solution. That is, the resulting combination of components comprising the operator-selected organization system, often consumed more space in the workroom than what was necessary, which limited the amount of storage and/or work area in the workroom. Therefore, there is still a need for a space-efficient, integrated workroom organization system that helps the operator maximize both the storage of tools and supplies and the useful area of the workroom.
SUMMARY OF THE INVENTION
[0006] The invention provides a unique solution to the need for space-efficient, organized storage for a workroom via a workroom organization system comprising at least one slot track. The slot track has a plurality of slots with at least one undercut sidewall with adjoining slots forming a slat having edges defined by the slots. The slots further have a bottom wall generally parallel to and spaced inwardly from the face of the at least one slat. The organization system includes one or more removable mounting brackets having a support portion for attaching a device to the bracket. The mounting brackets include a first “J” shaped hook on one edge of the support portion opening in a first direction to hook over an edge of a slat into the undercut sidewall. The mounting brackets include a second “J” shaped hook on an opposite edge of the support portion opening in the first direction to hook over an edge of the adjoining slot into the undercut sidewall.
[0007] Another aspect of the invention provides a unique solution to the need for space-efficient, organized storage for a workroom via a workroom organization system comprising at least one slotwall panel and at least one slot track. The slotwall panel has a plurality of slots with at least one undercut sidewall forming a plurality of slats having edges defined by the slots. The slots in the slotwall panel have a bottom wall generally parallel to and spaced inwardly from the face of the slats. The slot track has two slots with at least one undercut sidewall forming a slat having edges defined by the slots. The slots in the slot track have a bottom wall generally parallel to and spaced inwardly from the face of the slat. The organization system includes one or more removable mounting brackets usable on the slotwall panel and on the slot track. The mounting brackets include a support portion for attaching a device to the mounting bracket and a first “J” shaped hook on one edge of the support portion opening in a first direction to hook over an edge of a slat into the undercut sidewall. The mounting brackets also include a second “J” shaped hook on an opposite edge of the support portion opening in the first direction to hook over an edge of the adjoining slot into the undercut sidewall.
[0008] Another aspect of the invention provides a unique solution to the need for space-efficient, organized storage for a workroom via a workroom organization system comprising one or more slot tracks in combination with a wall-mounted cabinet and a floor supported workbench with at least one nesting mobile storage cabinet. The organization system provides for space-efficient, organized storage of workroom items, such as tools and supplies used in a workroom. The slot tracks are mountable on a wall of the workroom and have at least two slots defining at least one slat. The organization system further includes one or more removable mounting brackets having a first “J” shaped hook on one edge opening in a first direction to hook over an edge of the at least one slat. The mounting brackets include a second “J” shaped hook opening in the first direction to hook over an edge of a slot adjoining the slat engaging the first “J” shaped hook. The wall-mounted storage cabinets have at least one mounting bracket to engage at least one slot track. The workbench has a work surface and multiple legs extending from the work surface to support the work surface above a floor and defines a workbench recess beneath the work surface. A mobile storage cabinet having a top surface located at a height such that the at least one mobile storage cabinet can be received within the workbench recess with the top surface underlying the work surface. The mobile storage cabinet has wheels extending from the mobile storage cabinet to support the mobile storage cabinet on the floor to ease the movement of the mobile storage cabinet into and out of the workbench recess.
[0009] The workroom organization system enables a user to mount workroom items on mounting brackets mounted on the plurality of slot tracks and to arrange the at least one wall-mounted storage cabinet, workbench and at least one mobile storage cabinet within the workroom in a manner most space-efficient for a particular workroom. The workroom organization system permits the easy relocation of the workroom items and rearrangement of the at least one wall-mounted storage cabinet, workbench, and at least one mobile storage cabinet as needed over time as the quantity and mix of workroom items changes.
[0010] Another aspect of the invention provides a unique solution to the need for space-efficient, organized storage for a workroom via a workroom organization system comprising one or more slotwall panels and one or more slot tracks in combination with other elements of the organization system. The organization system further includes one or more wall-mounted cabinets and a floor supported workbench with at least one nesting mobile storage cabinet for space-efficient, organized storage of workroom items, such as tools and supplies used in a workroom. Slotwall panels are mountable on a wall of the workroom and have multiple slots defining a plurality of slats. Slot tracks are mountable on a wall of the workroom and have two slots defining a slat. The organization system includes a plurality of removable mounting brackets having a first “J” shaped hook on one edge opening in a first direction to hook over an edge of a slat on a slotwall panel or a slot track. The mounting brackets also include a second “J” shaped hook opening in the first direction to hook over an edge of a slot adjoining the slat engaging the first “J” shaped hook. The wall-mounted storage cabinets have at least one mounting bracket having a “J” shaped hook to hook over the edge of a slat on a slotwall panel or a slot track. The workbench includes a work surface and multiple legs extending from the work surface to support the work surface above a floor and defines a workbench recess beneath the work surface. The organization system includes at least one mobile storage cabinet having a top surface located at a height such that the at least one mobile storage cabinet can be received within the workbench recess with the top surface underlying the work surface. The mobile storage cabinet has wheels extending from the mobile storage cabinet to support the mobile storage cabinet on the floor to ease the movement of the mobile storage cabinet into and out of the workbench recess.
[0011] The workroom organization system enables a user to mount workroom items on removable mounting brackets on slotwall panels or slot tracks and arrange one or more wall-mounted storage cabinets, workbench and at least one mobile storage cabinet within the workroom in a manner most space-efficient for a particular workroom. The organization system permits the easy relocation of the workroom items and rearrangement of the wall-mounted storage cabinet, workbench, and at least one mobile storage cabinet as needed over time as the quantity and mix of workroom items changes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In the drawings:
[0013] FIG. 1 is a partial perspective view of the slotwall storage system suitable for use in a space-efficient workroom storage system according to the invention, and illustrating a mounting device and hanger bracket mounted on a slotwall panel.
[0014] FIG. 2 is an enlarged perspective view of a portion of the slotwall panel with a hanger bracket mounted on the slotwall panel in an unloaded position.
[0015] FIG. 3 is an enlarged perspective view of a portion of the slotwall panel with a hanger bracket mounted on the slotwall panel in a loaded position.
[0016] FIG. 4 is an end view of a slotwall panel showing the spacing of the generally “T” shaped slots.
[0017] FIG. 4A is an enlarged end view of a portion of a slotwall panel showing the configuration of a generally “T” shaped slot.
[0018] FIG. 4B is an enlarged end view of a portion of a slotwall panel showing the configuration of a connecting rib on the edge of a slotwall panel.
[0019] FIG. 4C is an enlarged end view of a portion of a slotwall panel showing the configuration of a connecting groove on the edge of a slotwall panel.
[0020] FIG. 4D is an enlarged end view of a portion of a slotwall panel showing the location of a connecting rib on the edge of a slotwall panel.
[0021] FIG. 4E is an enlarged end view of a portion of a slotwall panel showing the location of a connecting groove on the edge of a slotwall panel.
[0022] FIG. 5 is an end view of a hanger bracket showing the configuration of the generally “J” shaped hooks.
[0023] FIG. 6A is a top view of a hanger bracket showing the configuration of the spring arm and the generally “J” shaped hook adjacent the spring arm.
[0024] FIG. 6B is an end view of an enlarged end view of a portion of a hanger bracket showing the spring arm configuration.
[0025] FIG. 7 is a partial front perspective view of a cabinet having plural cabinet brackets mounted on a slotwall panel.
[0026] FIG. 8 is a perspective view of a cabinet bracket showing two generally “J” shaped hooks and the configuration of the cabinet bracket.
[0027] FIG. 8A is a partial front view of a cabinet bracket showing mounting holes.
[0028] FIG. 9 is a schematic side view of an unloaded cabinet bracket mounted on a slotwall panel.
[0029] FIG. 10 is a schematic side view of a loaded cabinet bracket mounted on a slotwall panel.
[0030] FIG. 11 is a partial rear perspective view showing a cabinet bracket mounted on a cabinet.
[0031] FIG. 11A is an end view showing a wall cabinet mounted on a slotwall panel.
[0032] FIG. 12 is a rear elevation view of a cabinet showing mounting holes for cabinet brackets.
[0033] FIG. 13 is a perspective view of a multiple hook device mounted on a slotwall panel wall with plural hanger brackets and examples of tools carried on a multiple hook device.
[0034] FIG. 14 is a partial perspective view of a shelf mounted on a slotwall panel with a cabinet bracket.
[0035] FIG. 15 is a front view of another embodiment of slotwall panel having ruler markings in the generally “T” shaped slots.
[0036] FIG. 16 is a front view of another embodiment of a slotwall panel having a different arrangement of ruler markings in the generally “T” shaped slots.
[0037] FIG. 17 is a partial perspective view of another embodiment of a slotwall panel.
[0038] FIG. 18 is a partial end view of another embodiment of a slotwall panel having the connecting rib and connecting groove in a different position on the edge of the slotwall panel.
[0039] FIG. 18A is a partial end view of another embodiment of a slotwall panel having the connecting rib and connecting groove in a different position on the edge of the slotwall panel.
[0040] FIG. 19 is a front perspective view of the modular workbench system providing space-efficient storage and work surface for the workroom organization system of the invention.
[0041] FIG. 20 is a front perspective view of the modular workbench system with one module moved out from under the workbench and positioned as an auxiliary work surface.
[0042] FIG. 21 is an exploded rear perspective view of the modular workbench.
[0043] FIG. 22 is a schematic rear perspective view showing a power strip mounted on the modular workbench top.
[0044] FIG. 22A is a schematic front view of the power strip.
[0045] FIG. 22B is a schematic perspective view of a T-bracket for mounting a power strip to a modular workbench top.
[0046] FIG. 23 is a partial sectional view of a workbench leg showing the leveling mechanism.
[0047] FIG. 24 is a front perspective view of a drawer module.
[0048] FIG. 25 is a front perspective view of a drawer module without the optional wood work surface.
[0049] FIG. 26 is a front perspective view of a cabinet module.
[0050] FIG. 27 is a front perspective view of a refrigerator module.
[0051] FIG. 28 is a perspective view of a slot track suitable for use in a space-efficient workroom storage system according to the invention.
[0052] FIG. 29 is a partial perspective view of a slot track of FIG. 28 with a hanger bracket mounted on the slot track.
[0053] FIG. 30 is an end view of a slot track of FIG. 28 showing the spacing of the generally “T” shaped slots.
[0054] FIG. 31 is an enlarged partial end view of a slot track of FIG. 30 showing the configuration of the edge of a slot track.
[0055] FIG. 32 is a partial end view of another embodiment of a slot track suitable for use in a space-efficient workroom storage system according to the invention configured to be the finishing the edge of a slotwall panel and positioned on a slotwall panel.
[0056] FIG. 33 is a perspective view of a space-efficient workroom storage system having plural slot tracks positioned on a wall supporting wall cabinets and tool hanger brackets for a modular workbench system.
[0057] FIG. 34 is a perspective view of a space-efficient workroom storage system having plural slot tracks and slotwall panels mounted on a wall supporting wall cabinets and tool hanger brackets for a modular workbench system.
DESCRIPTION OF THE INVENTION
[0058] In accordance with the present invention a slotwall and slot track storage system incorporating a slotwall panel 10 having a plurality of generally “T” shaped slots 11 forming a plurality of generally “T” shaped slats 12 and/or a slot track 210 having a plurality of generally “T” shaped slots 211 forming at least one generally “T” shaped slat 212 are provided with a hanger bracket for mounting a device on the slotwall panel or slot track. The slotwall panel and/or slot track can be formed of extruded polyvinyl chloride material. Co-pending patent application Ser. No. 10/747,421, discloses one such material, which patent application is incorporated by reference. The slotwall and/or slot track storage system according to the present invention can be used in a residential garage to provide storage for outdoor tools and equipment. A variety of storage options can be provided as will be described below. The slotwall and/or slot track storage system can also be used in a workroom or workshop, or in commercial and industrial locations. The slotwall and/or slot track storage system can be used in conjunction with a Modular Workbench System as disclosed in U.S. Pat. No. 6,926,376, which is incorporated by reference, and the disclosure of which is copied into this application as FIGS. 19-27 and the corresponding description. Slotwall panels 10 with suitable hanger brackets can be used alone or in combination with slot tracks 210 , and slot tracks 210 with suitable hanger brackets can be used alone or in combination with slotwall panels 10 and/or in combination with a Modular Workbench System mentioned above to form a flexible, space-efficient workroom storage system.
[0059] Referring to FIG. 1 , a slotwall panel 10 is shown. It should be understood that the slotwall panel 10 shown in FIG. 1 is only a portion of the panel that can extend longitudinally for any desired length. Typically, slotwall panels can be extruded in 8 feet long lengths to facilitate handling and installation. However, it should be understood that panels longer or shorter that 8 feet can fabricated and used. Further, a single panel can be used or an entire wall can be covered with panels as shown in FIG. 13 . One embodiment of a hanger bracket 20 is shown mounted on the panel 10 and is shown with one example of a hook device 40 attached to the hanger bracket 20 . Other well known and available hooks and hanging devices can be attached to one or more hanger brackets 20 as will be understood by one skilled in the art. While a few examples of types of hook and other storage devices that can be attached to one or more hanger brackets are disclosed in this application, one skilled in the art will understand that there are many available hooks and storage devices available on the market that could be used with the brackets and slotwall panels according to this invention.
[0060] Mounting of hanger bracket 20 to a slotwall panel 10 can be understood by referring to FIG. 2 and FIG. 3 . In FIG. 2 and FIG. 3 a device 40 has been omitted from hanger bracket 20 to more clearly show hanger bracket 20 on the slotwall panel 10 . Those skilled in the art will understand that in use a hook device or other storage device would be attached to hanger bracket 20 . Hanger bracket 20 includes a central support portion 21 , a generally “J” shaped hook 22 extending from one edge of support portion 21 , and a generally “J” shaped hook 23 extending from an opposite edge of support portion 21 . Generally “J” shaped hook 22 includes a first leg 24 extending generally perpendicular from the edge of support portion 21 and a second leg 25 extending from the distal end of first leg 24 generally parallel to support portion 21 . Generally “J” shaped hook 23 has a first leg 26 extending generally perpendicular from the edge of support portion 21 and a second leg 27 extending from the distal end of first leg 26 generally parallel to support portion 21 in the same direction as leg 25 . Thus, hanger bracket 20 has two downward opening “J” shaped hooks on opposite edges of support portion 21 . Hanger bracket 20 also has a spring arm 28 extending from the edge of support portion 21 that divides generally “J” shaped hook 22 into two portions. Spring arm 28 extends in an opposite direction from leg 25 . Referring to FIG. 2 and FIG. 3 generally “J” shaped hook 22 hooks over an edge 13 of a generally “T” shaped slat 12 . Generally “J” shaped hook 23 hooks behind the lower adjacent half slat 16 in undercut 14 . Spring arm 28 is positioned behind the upper adjacent slat 12 in undercut 14 .
[0061] As shown in FIG. 2 , leg 27 bears against the underside of the lower adjacent half slat 16 in undercut 14 biased against the underside of the slat by the spring arm 28 . The force of spring arm 28 holds support portion 21 out of contact with the face of slat 12 . Thus, hanger bracket 20 transfers the load on a device 40 through hanger bracket 20 to slotwall panel 10 by contact of leg 24 on edge 13 of slat 12 , the contact of leg 25 against the inside edge of slat 12 and the force of spring arm 28 against the inside of the upper adjacent slat 12 in undercut 14 . Leg 26 of “J” shaped hook 23 does not normally contact edge 13 of lower adjacent slat 12 . Referring to FIG. 3 , when a load is placed on device 40 that generates a moment sufficient to overcome the bias of spring arm 28 , hanger bracket 20 pivots on “J” shaped hook 22 so that leg 27 engages the bottom wall 15 of “T” shaped slot 11 . When hanger bracket 20 is loaded, hanger bracket 20 transfers the load on a device 40 through hanger bracket 20 to slotwall panel 10 by contact of leg 24 on edge 13 of slat 12 , the contact of leg 25 against the inside edge of slat 12 , the force of spring arm 28 against the inside of upper adjacent slat 12 in undercut 14 and by contact of leg 27 against bottom wall 15 of generally “T” shaped slot 11 . The length of leg 26 holds hanger bracket 20 spaced from the face of slat 12 when hanger bracket 20 is loaded by items carried on device 40 so that leg 27 rests against the bottom wall 15 of slot 11 . In the event hanger bracket 20 is overloaded by items placed on device 40 , the pressure on leg 24 may be sufficient to deform the edge 13 of slat 12 allowing hanger bracket 20 to move down until leg 26 engages edge 13 of lower adjacent slat 12 . In an overload condition, the load is spread over two adjacent slats 12 by generally “J” shaped hooks 22 and 23 in addition to the load spread by spring arm 28 to upper adjacent slat 12 and leg 27 to the bottom wall 15 . Thus, hanger bracket 20 is locked in position on slotwall panel 10 by friction due to spring arm 28 whether loaded or unloaded. Accordingly, hanger bracket 20 and its attached device, whether loaded or unloaded, can not inadvertently be knocked off or dislodged from a slotwall panel 10 .
[0062] Hanger bracket 20 , together with any attached device such as device 40 , can be mounted to a slotwall panel 10 by inserting spring arm 28 into the undercut 14 in a slot 11 far enough under the upper adjacent slat 12 for leg 25 to clear edge 13 of slat 12 . Hanger bracket 20 can then be pivoted down against the moment of spring arm 28 until leg 27 clears the lower adjacent slat edge 13 . Hanger bracket 20 can then be slid down over slat 12 until leg 25 rests on edge 13 with leg 27 bearing against the underside of the lower adjacent slat 12 in undercut 14 . As mentioned above, hanger bracket 20 will be held in place by friction resulting from the moment of spring arm 28 bearing against the inside surface of the upper adjacent slat 12 .
[0063] Turning to FIG. 4 , a slotwall panel 10 can include four generally “T” shaped slots 11 that form three generally “T” shaped slats 12 and two half slats 16 , one on each edge of panel 10 . One edge of slotwall panel 10 can include a projecting connecting rib 17 and the other edge can include a mating connecting groove 18 . As shown in FIG. 1 , rib 17 and connecting groove 18 connect adjacent panels and, when so joined, the half width slats 16 of the adjacent panels form a full width slat.
[0064] As shown in FIG. 1 and FIG. 4 , the bottom wall 15 of the generally “T” shaped slots 11 includes a longitudinal alignment groove 19 in the center of bottom wall 15 . Alignment groove 19 can facilitate mounting of slotwall panels on a wall. Alignment groove 19 can provide a locating function to allow screws or other mounting devices to be aligned along slotwall panel sections. In a wall installation, screws 29 (see FIG. 13 ) can be driven through the slotwall panel along groove 19 into studs supporting the wall to mount the slotwall panel or panels to the wall as is well known to those skilled in the art. Mounting of plural slotwall panels is facilitated by connecting rib 17 and connecting groove 18 since another slotwall panel can be placed on a slotwall panel already attached to a wall and the slotwall panel will remain in place until fastened to the wall by screws or other suitable fasteners. Normally slotwall panels 10 can be mounted to a wall with connecting rib 17 directed up and connecting groove 18 directed down over rib 17 of an adjacent panel 10 if an adjacent panel is already mounted. Those skilled in the art will recognize that slotwall panels 10 can be mounted to a wall in the opposite direction if so desired, i.e. with rib 17 directed down and connecting groove 18 directed up. Applicants have found that locating the joint between adjacent slotwall panels in the center of a slat provides a stronger slotwall structure since torsional loads are minimal in the center of a slat as compared to joint locations in a slot or at an edge of a slat.
[0065] Referring to FIG. 4 through FIG. 4E , the dimensions of one embodiment of a slotwall panel 10 can be as provided in the following table. It should be understood that the following dimensions are approximate and that slotwall panels having different dimensions can be provided in accordance with the invention as desired.
Description Reference Dimension (mm) Width of slotwall panel 10 w 305 Center to center of “T” shaped slots 11 a 76.2 Width of “T” shaped slot opening b 17 Center of slot to end of undercut 14 c 18.5 Depth of undercut 14 d 5 Thickness of slat 12 e 7 Length of rib 17 f 5 Depth of groove 18 g 10 Center of slot 11 to edge of panel 10 h 38.1 Width of rib 17 j 5.75 Width of groove 18 k 6 Rib 17 to face of panel 10 m 9 Groove 18 to face of panel 10 n 9
[0066] Referring to FIG. 2 , FIG. 5 and FIG. 6A , the dimensions of one embodiment of a hanger bracket 20 adapted for use with a slotwall panel as shown in FIG. 4 through FIG. 4E can be as provided in the following table. It will be appreciated by those skilled in the art that the following dimensions are approximate and that a hanger bracket having different dimensions can be provided in accordance with the invention as desired for use with slotwall panels having different dimensions.
Description Reference Dimension (mm) Distance from “J” hook 22 to “J” hook 23 A 75.2 Inside length of leg 24 B 8.5 Inside length of leg 25 C 6 Outside length of leg 26 D 12.1 Offset of spring arm 28 from face of E 6.6 bracket Distance to top of spring arm 28 from leg F 19 24 Overall length of bracket 20 G 99 Overall width of bracket 20 H 80 Width of spring arm 28 J 26 Width of leg 24 K 26
[0067] Hanger bracket 20 can be formed of metal such as steel. When hanger bracket 20 is formed with steel, hanger bracket 20 can be stamped from sheet steel. When hanger brackets 20 are formed of steel, raised surfaces or bosses 44 as shown in FIG. 5 can be stamped in support portion 21 to provide attachment points for hook devices to be welded to the hanger bracket. After a hook device is attached to hanger bracket 20 , the hanger bracket can be finished as desired such as by painting the entire hanger bracket and hook.
[0068] Referring to FIG. 6B , spring arm 28 can extend up from first leg 24 at an acute angle of approximately 65°. As also shown in FIG. 6B the distal end 28 ′ of spring arm 28 can be bent to extend generally parallel to support portion 21 and leg 25 . Referring to the embodiment shown in FIG. 4 through FIG. 4E , FIG. 5 and FIG. 6B the function of spring arm 28 can be seen. The thickness e of a generally “T” shaped slat can be 7.0 mm and the offset E of spring arm 28 can be 6.6 mm. When a hanger bracket 20 is installed on a slotwall panel 10 with spring arm 28 positioned behind an adjacent generally “T” shaped slat in undercut 14 and generally “J” shaped hook 22 is hooked over an edge 13 of a generally “T” shaped slat, interference of the distal end of the spring arm 28 with the inside of the adjacent “T” shaped slat will tend to rotate hanger bracket 20 away from the face of slotwall panel 10 . When generally “J” shaped hook 22 is hooked over and engages an edge 13 of a generally “T” shaped slat 12 , hook 23 will be positioned adjacent edge 13 of a lower adjacent generally “T” shaped slat 12 . Leg 27 will be positioned behind the lower adjacent generally “T” shaped slat 12 in undercut 14 . The moment produced by spring arm 28 pressing against the inside of upper adjacent “T” shaped slat 12 will drive leg 27 into contact with the inner surface of lower adjacent generally “T” shaped slat 12 thus friction locking hanger bracket 20 in place. When a device such as a hook device 40 is attached to support portion and a load is placed on the hook device, the downward force on the hook device will drive hanger bracket 20 toward slotwall panel 10 until leg 27 engages the bottom wall 15 of the generally “T” shaped slot 11 . The outside length D of leg 26 can be 12.1 mm and can be slightly greater than the width d of undercut 14 which can be 5.0 mm plus the thickness e of slat 12 which can be 7.0 mm. Thus, hanger bracket 20 can be held out of contact with the face of slat 12 over which it is installed, whether loaded or unloaded. The distance A from the inside of first leg 24 of “J” shaped hook 22 to the inside of first let 26 of “J” shaped hook 23 can be 75.2 mm compared to the center to center spacing a of slots and slats which can be 76.2 mm. When hanger bracket 20 is installed on a generally “T” shaped slat 12 with leg 24 of “J” shaped hook 22 engaging an edge 13 , leg 26 of “J” shaped hook 23 will not engage edge 13 of adjacent slat 12 . Thus, hanger bracket 20 can pivot between the position shown in FIG. 2 to the position shown in FIG. 3 as a load is applied to hanger bracket 20 by an attached hook device such as 40 .
[0069] Referring to FIG. 7 , FIG. 8 and FIG. 8A , a cabinet 50 is shown mounted on a slotwall panel 10 . Cabinet 50 can be provided with another embodiment of hanger brackets mounted to one wall of cabinet 50 . Cabinet brackets 30 can extend generally the full width of cabinet 50 . Alternately, cabinet brackets 30 can extend less than the full width of cabinet 50 and multiple cabinet brackets 30 can be installed across the width of cabinet 50 . Cabinet bracket 30 can include a support portion 31 for mounting the cabinet bracket 30 to a cabinet 50 . A generally “J” shaped hook 32 can be provided on one edge of support portion 31 . Another generally “J” shaped hook 33 can be provided on an opposite edge of support portion 31 . Generally “J” shaped hook 32 can include a first leg 34 extending generally perpendicular to support portion 31 and a second leg 35 extending from the distal end of first leg 34 generally parallel to support portion 31 . Generally “J” shaped hook 33 can include a first leg 36 extending generally perpendicular to support portion 31 and a second leg 37 extending from the distal end of first leg 36 generally parallel to support 31 and in the same direction as second leg 35 . Cabinet brackets 30 can be dimensioned so that a cabinet bracket can be mounted to a slotwall panel without tipping the cabinet bracket 30 . In order to mount a cabinet bracket without tipping the cabinet bracket 30 , the length of second legs 35 and 37 should be less than width b the opening of “T” slots 11 in FIG. 4B . Similarly, the spacing of generally “J” shaped hooks 32 and 33 should correspond to center to center dimension a of the generally “T” shaped slots in FIG. 4 .
[0070] Referring to FIG. 8 , the dimensions of one embodiment of a cabinet hanger bracket 30 adapted for use with a slotwall panel as shown in FIG. 4 through FIG. 4F can be as provided in the following table. It will be appreciated by those skilled in the art that the following dimensions are approximate and that cabinet brackets having different dimensions can be provided in accordance with the invention as desired for use with slotwall panels having different dimensions.
Description Reference Dimension (mm) Distance from “J” hook 32 to “J” hook 33 A′ 75.2 Inside length of leg 34 and 36 B′ 8.5 Inside length of leg 35 and 37 C′ 6
[0071] Cabinet brackets 30 can be formed of metal. Cabinet bracket 30 as shown in FIG. 8 can be formed of extruded aluminum cut to lengths corresponding to the width of the cabinet or device to which the particular cabinet bracket will be attached.
[0072] As with the case of hanger bracket 20 , cabinet bracket 30 can have a dimension A′ from the inside of generally “J” shaped hook 32 to the inside of generally “J” shaped hook 33 that is slightly less than the center to center dimension a of the slotwall panel in FIG. 4 . When dimension A′ is slightly less than the center to center dimension a of slotwall panel, the load on cabinet bracket 30 produced by cabinet 50 will be on generally “J” shaped hook 32 and first leg 34 engaging edge 13 of generally “T” shaped slat 12 . Because generally “J” shaped hook 32 engages an edge 13 of a generally “T” shaped slat 12 before generally “J” shaped hook 33 , cabinet bracket 30 is held parallel to slotwall panel 10 and does not tip out at the top.
[0073] Referring to FIG. 9 and FIG. 10 , the operation of cabinet brackets 30 can be seen. As the load on cabinet bracket 30 is increased by the load placed in cabinet 50 , the edge 13 of slat 12 under generally “J” shaped hook 32 deforms allowing generally “J” shaped hook 33 to engage edge 13 of adjacent slat 12 thus increasing support for the cabinet bracket. Thus, cabinet brackets 30 initially transfer the load of cabinet 50 through generally “J” shaped hook 32 to the slotwall panel 10 by engagement of leg 34 with edge 13 of a generally “T” shaped slat 12 . Generally “J” shaped hook 33 only engages the lower adjacent generally “T” shaped slat 12 when the load in cabinet 50 is sufficient to deform edge 13 of slat 12 on which leg 34 is resting.
[0074] Referring again to FIG. 8A , FIG. 11 , FIG. 11A and FIG. 12 a plurality of square holes 39 can be provided in cabinet bracket 30 for mounting cabinet bracket 30 to cabinet 50 . Cabinet 50 can be provided with a plurality of mounting holes 51 adjacent the top of cabinet 50 for a top cabinet bracket spaced to correspond to the spacing of mounting holes 39 in cabinet bracket 30 . Mounting holes 51 can be round to permit mounting of a top cabinet bracket 30 in a fixed position adjacent the top of cabinet 50 . One or more additional rows of mounting holes 52 can be provided below mounting holes 51 to allow mounting of one or more lower cabinet brackets 30 . Mounting holes 52 can be vertically elongated slots to permit vertical adjustment of the lower cabinet brackets to insure that each cabinet bracket upper generally “J” shaped hook 32 engages a slat edge 13 .
[0075] In order to install a cabinet 50 on a slotwall panel, a top cabinet bracket can be attached to cabinet 50 utilizing a plurality of mounting bolts 55 inserted with the head in cabinet bracket 30 and the threaded portion projecting through mounting holes 51 into cabinet 50 . Mounting bolts can be a carriage bolt or similar fastening device that can be tightened without access to the head. Suitable fasteners, not shown, can be threaded on mounting bolts 55 and tightened to secure top cabinet bracket 30 to cabinet 50 . Next, one or more lower cabinet brackets can be attached to cabinet 50 utilizing a plurality of mounting bolts 55 inserted with the head in cabinet bracket 30 and the threaded portion projecting through vertical slot mounting holes 52 into cabinet 50 . Suitable fasteners, not shown can be threaded on mounting bolts 55 and left loose to permit adjustment of the position of the one or more cabinet brackets 30 on cabinet 50 relative to the slotwall panel 10 . Cabinet 50 can then be mounted on slotwall panels that have mounted or attached to a wall structure. The top cabinet bracket 30 is first hooked on a selected slotwall panel slat 12 with leg 34 engaging a slat edge 13 . Next, the lower cabinet bracket or brackets 30 are vertically adjusted so that each generally “J” shaped hook 32 engages a slotwall panel slat 12 with leg 34 engaging a slat edge 13 . After the one or more lower cabinet brackets 30 are all positioned hooked over a slotwall panel slat 12 with leg 34 engaging a slat edge 13 the fasteners can be tightened securing the one or more cabinet brackets to the cabinet 50 . As mentioned above, the vertically elongated mounting holes provide sufficient vertical adjustment to allow multiple cabinet brackets to be employed for mounting a cabinet to a plurality of slotwall panels 10 with each cabinet bracket transferring load from the cabinet 50 to the slotwall panel to spread the load in cabinet 50 across multiple slotwall panels 10 and slats 12 .
[0076] Referring to FIG. 13 , hanger brackets 20 can be combined to support plural mounting hooks 40 ′. FIG. 13 also illustrates yard tools carried on the mounting hooks on a slotwall storage system occupying a section of a wall. As shown in FIG. 13 , slotwall panels 10 can be fastened to a wall using a plurality of fasteners such as screws 29 . In the embodiment shown in FIG. 13 a plurality of screws 29 are fastened through the slotwall panels 10 in each slot 11 spaced apart by the distance between underlying studs or wall support structures. Those skilled in the art will understand that fasteners 29 can be used in alternate generally “T” shaped slots 11 , or other patterns as desired depending on the anticipated loading on the slotwall panels 10 . Likewise, fasteners 29 could be driven into alternate studs or wall supports. The specific mounting hooks shown and the yard tools carried are only examples to show how the slotwall storage system can be used. Those skilled in the art will understand that many other hooks or storage devices could be attached to one or more hanger brackets to store any desired objects. In the embodiment of FIG. 13 , two hanger brackets can be connected with a pair of connecting rods 41 to which three mounting hooks 40 ′ are attached. The connecting rods can be welded to hanger brackets 20 and mounting hooks 40 ′ can be welded to connecting rods 41 . The combined mounting hook device can be mounted on a slotwall panel 10 in the same manner as a single hanger bracket as described above. Those skilled in the art will recognize that the combined mounting hook device shown in the embodiment of FIG. 13 is only one possible arrangement of multiple mounting hooks and that more or less than three mounting hooks could be attached to two or more connected hanger brackets.
[0077] Referring to FIG. 14 , a cabinet bracket 30 can be attached to a shelf 42 to support shelf 42 on slotwall panels 10 . In the embodiment shown in FIG. 14 , a cabinet bracket 30 can be attached to shelf 42 using threaded fasteners as used in connection with the cabinet as described above, or permanently attached to shelf 42 by welding. Shelf 42 can be mounted on slotwall panel 10 by inserting “J” shaped hooks 32 and 33 into adjoining slots 11 and sliding shelf 42 and cabinet bracket 30 down over adjoining slat edges 13 .
[0078] As one of skill in the art should recognize, hanger brackets 20 can be combined to support a basket (not shown) on slotwall panels 10 . In the embodiment two hanger brackets 20 can be attached to a basket by welding or by any other known connection means. The basket can be mounted on a slotwall panel in the same manner as a single hanger bracket as described above in detail.
[0079] Referring to FIG. 15 and FIG. 16 , another embodiment of a slotwall panel 10 ′ is shown. In the embodiment of FIG. 15 and FIG. 16 repeating ruler markings 45 and 46 can be provided on the bottom wall 15 of generally “T” shaped slot 11 ′ on either side of groove 19 ′. Ruler markings 45 can be repeating 1-16 inch marks while ruler markings 46 can be repeating 1-24 inch marks. Repeating ruler markings can facilitate mounting of slotwall panels on conventional stud wall construction. Once a stud is located for a mounting screw 29 , adjacent screws can be inserted at the same number in the repeating sequence as the first screw since most stud walls are built on 16 inch or 24 inch centers. The provision of the repeating markings eliminates the need to measure and mark the location of subsequent studs for mounting screws once the first mounting screw 29 is driven into a stud. As shown in FIG. 16 , the repeating markings can be provided in alternate generally “T” shaped slots 11 ′. Those skilled in the art will recognize that other patterns of repeating markings could be used such as in one generally “T” shaped slot per slotwall panel 10 ′.
[0080] Referring to FIG. 17 another embodiment of slotwall panel is shown. The slotwall panel 10 ″ can be fabricated of metal such as extruded aluminum. The slotwall panel 10 ″ of the embodiment shown in FIG. 17 can have dimensions a″, b″ and d″ corresponding to the same dimensions in slotwall panel 10 as shown in FIG. 4 . The slotwall panel 10 ″ can support hanger brackets 20 and cabinet brackets 30 in the same manner as described above even though the thickness e″ of slat 12 ″ is less than the thickness e of slat 12 . As shown in FIG. 17 , a groove 49 can be provided in the center of slat 12 ″. The provision of a slat groove 49 will make the appearance of slats 12 ″ the same as a joint between adjoining slotwall panels 10 ″ where adjoining half slats 16 ″ meet. Those skilled in the art will recognize that a groove 49 can be provided in slat 12 of the embodiment of the slotwall panel 10 shown in FIG. 4 - FIG. 4E to provide the same function as in the embodiment of FIG. 17 .
[0081] Referring to FIG. 18 and FIG. 18A , other embodiments of the slotwall panel are shown. In FIG. 18 slotwall panel 10 ′″ can have a connecting rib 17 ′ and connecting groove 18 ′ that are offset toward half slat 16 ′″ instead of offset toward the opposite surface of the slotwall panel as in the embodiment shown in FIG. 4 - FIG. 4E . In FIG. 18A , slotwall panel 10 ″″ can have a connecting rib 17 ″ and connecting groove 18 ″ that are centered in slotwall panel 10 ″″. Those skilled in the art will understand that the connecting rib and connecting groove can have a configuration other than as shown in FIG. 4 - FIG. 4E and FIG. 18 and FIG. 18A . Such other rib and connecting groove configurations could include semicircular, triangular, trapezoidal or other shapes. The rib and connecting groove configuration could also be interlocking with one panel hooking into and interlocking with an adjacent panel.
[0082] The material used to form slotwall panels 10 can be extruded foamed CPVC/PVC material as disclosed in co-pending patent application Ser. No. 10/747,421 mentioned above. Alternately, slotwall panels can be extruded of foamed PVC material as is known in the art. Slotwall panels can also be formed of wood panels by removing material to form the generally “T” shaped slots which in turn form the generally “T” shaped slats. Particleboard material could be used to form the slotwall panels instead of wood or extruded foamed PVC material. Particleboard slotwall panels could be formed by removing material to form generally “T” shaped slots. Alternately, particleboard slotwall panels could be formed by attaching generally “T” shaped slats to a particleboard. Plywood slotwall panels could be formed by removing material to form generally “T” shaped slots or by attaching generally “T” shaped slats as in the case of particleboard.
[0083] FIGS. 19-27 illustrate a modular workbench storage system according to the invention that provides a heavy duty workbench and storage space for one or more modules that can dock underneath the workbench to minimize the area of the consumed in the room and thereby maximize the useful area of the workroom. When combined with the slotwall storage system and wall-mounted storage cabinet previously described, the workbench storage system provides the operator of a workroom with a highly flexible and very space-efficient storage system.
[0084] Referring to FIG. 19 , a modular workbench system according to the invention is shown. Workbench 110 can include a leg assembly 111 at each end of the workbench and a top 130 . Top 130 can be laminated hard wood or other sturdy, durable material as is well known in the art. In the embodiment shown in FIG. 19 , top 130 can be 1¾ inches thick laminated hard wood maple strips that run lengthwise in top 130 to provide a strong heavy-duty work surface. The workbench 110 shown in FIG. 19 can be 8 feet long, 38 inches high and 25 inches deep to provide ample work surface and storage area for up to three modules. Those skilled in the art will understand that the length of the workbench can be longer or shorter as desired to provide space for docking two modules or more than the three modules as shown in the embodiment of FIG. 19 . For example, the workbench could be made 6 feet long and provide storage space for two modules. Likewise the height and width of the workbench can be adjusted as desired. The modules can include a drawer module 140 , a storage cabinet module 150 and a refrigerator module 160 . Refrigerator module 160 can be a low ambient temperature refrigerator as disclosed in U.S. Pat. No. 7,191,827 incorporated by reference. Those skilled in the art will understand that other modules can be provided as desired. In addition, less than three modules can be provided for use with workbench 110 and more than one of a particular module can be used with workbench 110 as desired by the user.
[0085] The modules can be provided with heavy duty casters, as described in detail below, to facilitate movement for docking underneath the workbench 110 , rearrangement of the modules underneath the workbench, or to facilitate positioning away from the workbench for cleaning under the workbench or for use as a mobile work surface. Referring FIG. 20 , one of the modules, storage cabinet module 150 , is shown withdrawn from under the workbench for use as a mobile work surface. While storage cabinet module 150 is shown withdrawn those skilled in the art will recognize that any or all of the modules can be so withdrawn for use as a mobile work surface or positioned elsewhere as a remote storage module.
[0086] Referring to FIG. 21 , the workbench 110 is shown with top 130 removed and spaced from the leg assemblies 111 and stringer 115 . Each leg assembly 111 can include two legs 112 , a bottom spacer 113 and a top plate 114 . Leg assembly 111 can be fabricated of metal such as steel, and welded together. Each of the legs 112 and bottom spacer 113 can be square tubes that can be approximately 3 inches square. Top plate 114 can be wider than legs 112 to provide a mounting flange on each side of leg assembly 112 . Each top plate 114 can have a plurality of elongated mounting holes 126 provided in two rows on either side of legs 112 . As shown in FIG. 21 , there can be 8 elongated mounting holes 126 in top plate 114 , four being adjacent each leg 112 . As those skilled in the art will understand, less than 8 elongated mounting holes 126 can be provided in top plate 114 , and plate 114 could be substantially the same width as legs 112 with elongated holes 126 positioned between legs 112 . Mounting holes 126 can be eliminated altogether and stringer 115 can be used to attach workbench top 130 to the leg and stringer assembly 128 as described below. If mounting holes 126 are eliminated from plates 114 , some alternate fastener can be used in the vicinity of the front leg 112 of each leg assembly 111 to prevent top 130 from lifting off the leg assemblies during use as will be understood by those skilled in the art.
[0087] Leg assemblies 111 can be connected with stringer 115 that can be a metal plate extending from one rear leg to the opposite rear leg. Stringer 115 can include a vertical plate 116 that can be attached to legs 112 to form a leg and stringer assembly 128 including a pair of leg assemblies 111 and a stringer 115 . Stringer 115 can also include a mounting flange 117 that can be formed on the top edge of stringer 115 . In the embodiment of FIG. 19 vertical plate 116 can be 6 inches wide and mounting flange 117 can be 1 inch wide. Stringer 115 can be attached to leg assemblies 111 with a plurality of mounting bolts 118 and washers 118 ′ to the rear surface of rear legs 112 as is well known to those skilled in the art. While flat washers 118 ′ are shown, those skilled in the art will understand that lock washers could be used instead of, or in addition to flat washers 118 ′. Mounting bolts 118 can be threadably attached to legs 112 by weld nuts 124 attached to rear legs 112 . Stringer 115 can have a plurality of vents 127 formed in vertical plate 116 to prevent build up of heat under workbench 110 as discussed in more detail below. Vent 127 can comprise a plurality of vertical slots 129 adjacent the upper edge of vertical plate 116 . In the embodiment shown in FIG. 19 , there can be 3 vents spaced across stringer 115 each having a plurality of slots 129 . In the embodiment shown in FIG. 19 and FIG. 21 there can be 25 slots 129 in each vent 127 and the slots 129 can be 2 inches long and ¼ inch wide with alternate slots 129 offset by ½ inch. While stringer 115 is shown in this embodiment as a separate component from leg assemblies 111 to facilitate shipping, it will be appreciated by those skilled in the art that the stringer 115 could be permanently attached to leg assemblies 111 as by welding. Stringer 115 can be fabricated of metal such as steel. Leg assemblies 111 and stringer 115 can be finished as desired such as by painting. Those skilled in the art will recognize that the dimensions of the stringer and vents can be adjusted as desired.
[0088] Referring to FIG. 21 and FIG. 23 , each leg 112 can have a bottom wall 120 that can be welded into the bottom end of leg 112 . Bottom wall 120 can have a threaded fastener such as a tee nut 121 welded in the center of bottom wall 120 . A leveling foot 119 can be provided for each leg 112 that can include a threaded portion 122 fastened to foot 119 and adapted to be threaded into tee nut 121 in bottom wall 120 . The top portion 122 ′ of threaded portion 122 can be provided without threads to prevent threaded portion 122 from backing all the way out of tee nut 121 such as when workbench 110 is being moved across the floor. Providing the top portion 122 ′ without threads can also facilitate assembly, in that one corner of the workbench can be lifted and a leveling foot 119 inserted into tee nut 121 without having to start the threads on threaded portion 122 upon insertion of threaded portion 122 into tee nut 121 . Leveling foot 119 can have a pad 123 on the bottom surface to provide a non-slip surface on leveling foot 119 . Pad 123 can be nylon or rubber or other material as will is well known to those skilled in the art. Those skilled in the art will understand that another form of leveling mechanism for some or all of the legs 112 could be provided as desired, or that a leveling mechanism could be omitted.
[0089] Elongated mounting holes 126 in top plate 114 and mounting holes 125 in mounting flange 117 can receive a plurality of fasteners 131 for attaching top 130 to the leg and stringer assembly 128 . Fasteners 131 can be lag screws and pilot holes (not shown) can be pre-drilled in top 130 to facilitate locating and attaching top 130 to leg and stringer assembly 128 . Mounting holes 126 are elongated in the plane of leg assembly 111 to allow for expansion and contraction of top 130 over the range of humidity conditions likely to be encountered in a non-climate controlled environment such as a basement, a garage or other outdoor work area. Thus, elongated mounting holes 126 are positioned to allow the width of the laminated hard wood maple top to expand and contract with changes in humidity. Mounting holes 125 in mounting flange 117 can be circular since laminated hard wood maple top 130 is unlikely to expand and contract along the direction of the laminated wood strips. In addition, use of round mounting holes 125 in mounting flange 117 can provide a sturdy workbench since the leg and stringer assembly can not shift under top 130 as the fasteners 131 can lock top 130 to the leg and stringer assembly 128 . Those skilled in the art will understand that if top 130 is formed of strips of hard wood that run from front to back instead of side to side that mounting holes 126 could be round and mounting holes 125 elongated along the length of stringer 115 to allow for expansion and contraction in that direction.
[0090] Referring to FIG. 22 , FIG. 22A and FIG. 22B , a schematic power strip 170 is shown mounted to a workbench top 130 . A plurality of T-brackets 133 can be provided to lock power strip 170 in position on workbench 110 . Each T-bracket 133 can be attached to the rear edge 132 of top 130 by fasteners such as conventional lag screws, not shown. T-bracket 133 can include a mounting portion 134 having a mounting hole 135 through which a mounting screw can be driven into rear edge 132 of top 130 . Above mounting portion 134 there is an enlarged support portion 136 that can overlie rear panels 176 and 178 to hold power strip firmly on workbench top 130 . Rear panels 176 and 178 can have slots 171 formed in the lower end of the rear panels to slide down over mounting portions 134 of T-brackets 133 . Mounting portion 134 is thicker than support portion 136 by offset 137 which provides sufficient space for rear panels 176 and 178 of power strip sections 172 and 174 to be slid down between the rear edge 132 of workbench top 130 and support portions 136 . The slots 171 in rear panels 176 and 178 can be dimensioned to snuggly fit over mounting portions 134 to hold the power strip 170 in place when installed on a workbench top 130 . Those skilled in the art will recognize that power strip sections 172 and 174 could be mounted to workbench top 130 in other ways than as disclosed in FIG. 22 - FIG. 22B .
[0091] Power strip 170 can be provided in two sections 172 and 174 that extend approximately the full width of top 130 . While the embodiment of FIG. 22 and FIG. 22A shows has power strip 170 in two sections, those skilled in the art will recognize that the power strip could be provided in a single piece, and that power strip 170 could extend less than the full width of top 130 . Power strip sections 172 and 174 can be joined by a connecting plate 173 attached to the rear panels 176 and 178 of power strip sections 172 and 174 . A suitable electrical connector can be provided to electrically connect power strip sections 172 and 174 at the respective ends of power strip sections 172 and 174 , not shown, and covered by connecting plate 173 . A suitable power cord 175 can be provided at the rear panel 176 of section 172 to connect the power strip 170 to a power source, not shown. A suitable strain relief can be provided to mount power cord 175 to rear panel 176 as is well known to those skilled in the art. Power cord 175 can be provided in any desired length to readily connect power strip 170 to a power source. In the embodiment shown in FIG. 22 , power cord 175 can be twenty feet long. A plurality of electrical outlets 184 can be provided on the front panels 180 and 182 of power strip sections 172 and 174 . Electrical outlets 185 can be provided on rear panels 176 and 178 to provide a power source for a refrigerator module 160 , a light fixture for workbench 110 , not shown, or other electrically operated device that is not used on the workbench top 130 . The electrical outlets 184 , 185 , can be commercially available panel outlets consisting of a terminal block and a cover that can be snapped into cutouts in the front and rear panels. In addition, a ground fault circuit interrupter (GFCI) outlet 186 can be provided on front panel 180 through which the other outlets 184 and 185 can be connected. GFCI outlet 186 can be provided with an on/off switch 187 and test and reset buttons as is well known in the art. After electrical outlets 184 , 185 and GFCI outlet 186 are installed in the front and rear panels, the outlets can be connected by electrical wire to a power cord 175 as is well known to those skilled in the art. While a GFCI outlet is shown in the embodiment of FIG. 22 and FIG. 22A , GFCI outlet 187 could be replaced with an on/off switch, an overload protector or a surge protector or any combination thereof as is well known to those skilled in the art.
[0092] The power strip housing including front panels 180 and 182 and rear panels 176 and 178 can be can be formed of metal and painted as other metal parts of the modular workbench 110 , although those skilled in the art will understand that a plastic housing could be used. After installation of the electrical outlets and connecting the electrical outlets and power cord, the power strip housing can be assembled using threaded fasteners as is well known to those skilled in the art.
[0093] Referring to FIG. 24 and FIG. 25 , a drawer module 140 is shown. Drawer module 140 can have a plurality of drawers 141 each mounted on tracks for easy access as are well known to those skilled in the art. The face of each drawer 141 can have an ornamental treadplate pattern surface that is the subject of co-pending design patent application Ser. No. 29/173,442. Drawer module 140 can have a cabinet 142 having a raised top edge 143 that forms a work surface 144 and also can form a frame for an optional hardwood work surface 145 that can be sized to fit tightly inside raised top edge 143 . Drawer module 140 can have a pair of fixed casters 147 mounted at the front of module 140 that are aligned with the sides of cabinet 142 to facilitate rolling drawer module 140 under and out from underneath workbench 110 . Drawer module 140 can also have a pair of swivel casters 148 mounted at the rear of drawer module 140 to facilitate movement of drawer module 140 to any desired location. Casters 147 and 148 are large heavy-duty casters to provide a sturdy, stable module that can be used as a portable work surface. Casters 147 and 148 are also sized so that the height of drawer module 140 with casters installed is approximately the same height as the other modules (even though the cabinet height of other modules may differ) and so that drawer module 140 fits easily under workbench 110 . Drawer module 140 can have side handles 146 in the side walls of cabinet 142 to facilitate moving drawer module 140 . Side handles 146 allow a user to grasp both sides of cabinet 142 to position drawer module 140 as desired on casters 147 and 148 . Drawer module 140 can also have a bumper 149 on the lower sidewalls of cabinet 142 that wraps around the front and rear corners of cabinet 142 . Bumper 149 prevents adjoining modules from striking one another when being moved into and out of docking underneath workbench 110 , or from striking other objects and damaging or scratching the cabinet walls. Bumper 149 can be fabricated of vinyl, other plastic material, or a mixture of plastic and rubber material, or other suitable bumper material as is well known to those skilled in the art. Bumper 149 can be attached to drawer module 140 using screws or other suitable fasteners. Fixed casters 147 can be locking casters as shown in the embodiment of FIG. 24 and FIG. 25 to facilitate use as a mobile work surface or to maintain drawer module 140 in position under workbench 110 .
[0094] Referring to FIG. 26 , a storage cabinet module 150 is shown. Storage cabinet module 150 can have a pair of doors 151 hinged to the front edge of cabinet 152 . Doors 151 can have an ornamental treadplate pattern surface that is the subject of co-pending design patent application Ser. No. 29/173,444. Storage cabinet module 150 can have a cabinet 152 having a raised top edge 153 that forms a work surface, not shown covered by hard wood work surface 155 , and also can form a frame for an optional hardwood work surface 155 that can be sized to fit tightly inside raised top edge 153 . Storage cabinet module 150 can have a pair of fixed casters 157 mounted at the front of storage cabinet module 150 that are aligned with the sides of cabinet 152 to facilitate rolling storage cabinet module 150 under and out from underneath workbench 110 . Storage cabinet module 150 can also have a pair of swivel casters 158 mounted at the rear of storage cabinet module 150 to facilitate movement of storage cabinet module 150 to any desired location. Casters 157 and 158 are large heavy-duty casters to provide a sturdy stable module that can be used as a portable work surface. Casters 157 and 158 are also sized so that the height of storage cabinet module 150 with casters installed is approximately the same height as the other modules (even though the cabinet height of other modules may differ) and so that module 150 fits easily under workbench 110 . Storage cabinet module 150 can have side handles 156 in the side walls of cabinet 152 to facilitate moving storage cabinet module 150 . Side handles 156 allow a user to grasp both sides of cabinet 152 to position storage cabinet module 150 as desired on casters 157 and 158 . Storage cabinet module 150 can also have a bumper 159 on the lower sidewalls of cabinet 152 that wraps around the front and rear corners of cabinet 152 . Bumper 159 prevents adjoining modules from striking one another when being moved into and out of docking underneath workbench 110 , or from striking other objects and damaging or scratching the cabinet walls. Bumper 159 can be fabricated of vinyl, other plastic material, or a mixture of plastic and rubber material, or other suitable bumper material as is well known to those skilled in the art. Bumper 159 can be mounted to module 150 using screws or other fasteners as desired. Fixed casters 157 can be locking casters as shown in the embodiment of FIG. 26 to facilitate use as a mobile work surface or to maintain storage cabinet module 150 in position under workbench 110 .
[0095] Referring to FIG. 27 , a refrigerator module 160 is shown. As mentioned above, refrigerator module 160 can be a low ambient temperature refrigerator as disclosed in U.S. Pat. No. 7,191,827, which is incorporated by reference. Refrigerator module 160 can have a cabinet 162 having a hinged door 161 mounted on the front of cabinet 162 . Door 161 can have an ornamental treadplate pattern surface that is the subject matter of co-pending design patent application Ser. No. 29/173,543. Refrigerator module 160 can have a top tray 163 and a bottom tray 164 that are attached to the top and bottom of cabinet 162 . Top tray 163 can form a work surface 164 and also a frame for an option hardwood work surface, not shown, that can be sized to fit tightly inside top tray 163 . Top tray 163 can have a vent, not shown, in the rear edge of tray 163 to facilitate cooling of a condenser, not shown, mounted on the rear wall of cabinet 162 as disclosed in the above identified U.S. Pat. No. 7,191,827, and incorporated by reference. The optional hardwood work surface can be sized to assure that the vent is not covered when a hardwood work surface is installed. Top tray 163 and bottom tray 164 can extend beyond the rear surface of cabinet 162 to protect the static condenser. Refrigerator module 160 can have a pair of fixed casters 167 mounted at the front of refrigerator module 160 that are aligned with the sides of cabinet 162 to facilitate rolling refrigerator module 160 under and out from underneath workbench 110 . Refrigerator module 160 can also have a pair of swivel casters 168 mounted at the rear of refrigerator module 160 to facilitate movement of refrigerator module 160 to any desired location. Casters 167 and 168 are heavy-duty casters to provide a sturdy stable module that can be used as a portable work surface. Casters 167 and 168 are also sized so that the height of refrigerator module 160 with casters installed is approximately the same height as the other modules (even though the cabinet height of other modules may differ) and so that refrigerator module 160 fits easily under workbench 110 . Module 160 can also have a bumper 169 on the lower sidewalls of cabinet 162 . Bumper 169 prevents adjoining modules from striking one another when being moved into and out of docking underneath workbench 110 , or from striking other objects and damaging or scratching the cabinet walls. Bumper 169 can be fabricated of vinyl, other plastic material, or a mixture of plastic and rubber material, or other suitable bumper material as is well known to those skilled in the art. Bumper 169 can be mounted to module 160 using screws or other fasteners as desired. Fixed casters 167 can be locking casters as shown in the embodiment of FIG. 27 to facilitate use as a mobile work surface or to maintain refrigerator module 160 in position under workbench 110 .
[0096] Each of modules 140 , 150 and 160 can be sized and provided with casters such that each of the modules fits easily under workbench 110 . In the embodiment shown in FIG. 19 , there can be approximately 1 and ½ inches clearance between the top of the modules with an optional hardwood work surface in place and the underneath side of top 130 . While the modules disclosed in the embodiment of FIG. 19 , FIG. 24 , FIG. 25 , FIG. 26 and FIG. 27 are approximately the same height when provided with casters as discussed above, those skilled in the art will recognize that the height of modules, with casters installed, could be substantially identical, or could be designed to differ in height as desired. The clearance space between the tops of modules 140 , 150 and 160 coupled with vents 127 in stringer 115 provides adequate ventilation under workbench 110 when a refrigerator module 160 is in use and the condenser (not shown) is releasing heat under workbench 110 . Those skilled in the art will recognize that vents 127 and/or the clearance space above modules 140 , 150 and 160 can be changed as desired to provide more or less ventilation under workbench 110 . Vents 127 can be located on stringer 115 to be centered with respect to each module, in embodiment of FIG. 19 and FIG. 21 three modules. Those skilled in the art will understand that if workbench 110 is modified to provide for docking of two or more that three modules the number of vents 127 in stringer 115 can be modified to correspond to the number of modules that can be docked under workbench 110 .
[0097] In accordance with the present invention a slot track storage system can incorporate a slot track 210 having a plurality of generally “T” shaped slots 211 forming at least one generally “T” shaped slats 212 that can be provided with a hanger bracket for mounting a device on the slot track. A variety of storage options can be provided as described above in conjunction with slotwall panels. Referring to FIG. 28 , a slot track 210 is shown. It should be understood that the slot track 210 shown in FIG. 28 can extend longitudinally for any desired length. Typically, slot tracks can be extruded in 8 feet long lengths to facilitate handling and installation. However, it should be understood that slot tracks longer or shorter that 8 feet can be fabricated and used. Further, a single slot track can be used or multiple slot tracks can be mounted on one or more walls as shown in FIG. 33 and FIG. 34 . While the slot tracks 210 shown in FIG. 28 through FIG. 32 include two slots 211 forming a slat 212 , those skilled in the art will recognize that more than two slots 211 forming more than one slat 212 can be provided if desired. Slot track 210 can include upper and lower slots 211 having undercuts 214 in the sidewalls of the slots 211 and a bottom wall 218 . Undercuts 214 form edges 213 in the slots 211 . On the sides of slots 211 opposite slat 212 the edges 216 of slot track 210 extend away from the slots 211 and then taper toward the rear surface 209 of the slot track 210 .
[0098] Slot tracks 210 can be mounted on a wall in a manner similar to slotwall panels 10 . In a wall installation, screws (not shown) can be driven through the bottom wall 218 of slot track 210 along groove 219 into studs supporting the wall to mount the slot track or tracks 210 to the wall as is well known to those skilled in the art. Mounting screws (not shown) can be driven in one or both slots 211 through groove 219 every 16 or 24 inches into studs supporting the wall. Those skilled in the art will recognize that the spacing of mounting screws can be modified to align with studs supporting the wall on which the slot track(s) is mounted. Similarly, those skilled in the art will recognize that slot tracks 210 can be mounted to a concrete or concrete block wall using screws (not shown) and suitable anchors well known in the art.
[0099] Turning to FIG. 29 , one embodiment of a hanger bracket 20 is shown mounted on the panel 210 and is shown with one example of a hook device 40 attached to the hanger bracket 20 . Another embodiment of a hook device 40 ′ is shown in FIG. 13 . Other well known and available hooks and hanging devices can be attached to one or more hanger brackets 20 as will be understood by one skilled in the art. While a few examples of types of hook and other storage devices that can be attached to one or more hanger brackets are disclosed in this application, one skilled in the art will understand that there are many available hooks and storage devices available on the market that could be used with the brackets and slot tracks according to this invention.
[0100] Mounting of hanger bracket 20 to a slot track 210 can be understood by referring to FIG. 29 . The slot track 210 as shown in FIG. 28 through FIG. 32 can include the same slot and slat geometry as a slotwall panel 10 as described conjunction in FIG. 1 through FIG. 4 , and can be used in conjunction with the same hanger brackets 20 that can be used with slotwall panels 10 . Referring to FIG. 29 generally “J” shaped hook 22 hooks over an edge 213 of a generally “T” shaped slat 212 . Generally “J” shaped hook 23 hooks behind lower edge 216 in undercut 214 . Spring arm 28 is positioned behind upper edge 216 in undercut 214 . Hanger bracket 20 interacts with slot track 210 in the same way as with a slotwall panel 10 as described above in connection with FIG. 1 through FIG. 4 . Thus, hanger bracket 20 is locked in position on slot track 210 by friction due to spring arm 28 whether loaded or unloaded. Accordingly, hanger bracket 20 and its attached device, whether loaded or unloaded, can not inadvertently be knocked off or dislodged from a slot track 210 .
[0101] Hanger bracket 20 , together with any attached device such as device 40 , can be mounted to a slot track 210 by inserting spring arm 28 into the undercut 214 in a slot 211 far enough under the upper edge 216 for leg 25 to clear edge 213 of slat 212 . Hanger bracket 20 can then be pivoted down against the moment of spring arm 28 until leg 27 clears the edge 213 of lower edge 216 . Hanger bracket 20 can then be slid down over slat 212 until leg 25 rests on edge 213 with leg 27 bearing against the underside of the lower edge 216 in undercut 214 . Thus, hanger bracket 20 can mount on slot track 210 the same as hanger bracket 20 mounts on a slotwall panel 10 , see FIG. 2 . As mentioned above, hanger bracket 20 will be held in place by friction resulting from the moment of spring arm 28 bearing against the inside surface of the upper edge 216 in undercut 214 . For convenience in describing attaching of a bracket 20 to a slot track 210 , edges 216 have been described as upper and lower edges 216 . Slot track 210 as shown in the embodiment of FIG. 28 through FIG. 32 can be symmetrical so that “upper” and “lower” has no significance other than a reference to understand the description since slot tracks 210 can be mounted on a wall with either edge “up”.
[0102] Referring to FIG. 30 and FIG. 31 , the dimensions of one embodiment of a slot track 210 can be as provided in the following table. It should be understood that the following dimensions are approximate and that slotwall panels having different dimensions can be provided in accordance with the invention as desired.
Description Reference Dimension (mm) Width of slot track 210 w′ 165 Center to center of “T” shaped slots 211 a′ 76.2 Width of “T” shaped slot opening b′ 17 Center of slot to end of undercut 214 c′ 18.5 Depth of undercut 214 d′ 5 Thickness of slat 212 e′ 7 Center of slot 211 to edge of slot track 210 h′ 44.5
[0103] Hanger brackets 20 as described above in FIG. 2 , FIG. 5 and FIG. 6A including the dimensions of the embodiment of a hanger bracket 20 described in conjunction with those figures can be used with a slot track as shown in FIG. 28 through FIG. 32 . It will be appreciated by those skilled in the art that the dimensions referenced above are approximate and that a hanger bracket having different dimensions can be provided in accordance with the invention as desired for use with slot tracks having different dimensions.
[0104] Turning to FIG. 32 , another embodiment of slot track 310 is mounted on an edge of a slotwall panel 10 . When slotwall panels 10 are used to cover less than a full wall of a workroom, the upper or lower edge of a slotwall panel 10 can present a connecting rib 17 or a connecting groove 18 on the exposed edge(s) of the slotwall panel(s) 10 . In order to provide a finished edge, a slot track 310 having a half slat 316 ′ on one edge can be provided. Slot track 310 can include a connecting groove 318 on one edge adjacent half slat 316 ′ in order to mate with the connecting rib 17 of a slotwall panel 10 . The dimensions of the half slat 316 ′ and connecting groove 318 can be the same as the corresponding components of a slotwall panel 10 described above. While slot track 310 is shown with a connecting groove 318 on one edge, those skilled in the art will appreciate that slot track 310 can be provided with a connecting rib, not shown, on one edge in lieu of connecting groove 318 in order for the slot track 310 to mate with an exposed connecting groove 18 . Should a connecting rib, not shown, be provided it can have the same dimensions as the connecting rib 17 included in slotwall panels 10 . Those skilled in the art will understand that slot tracks 310 having a connecting rib and other slot tracks having a connecting groove can be provided for use with slotwall panels having both edges exposed to form a finished storage system.
[0105] FIG. 33 illustrates a modular workbench storage system 110 in combination with a slot track storage system in a workroom. The modular workbench storage system 110 can include a heavy duty workbench and storage space for one or more modules that can dock underneath the workbench to minimize the area of the consumed in the room and thereby maximize the useful area of the workroom all as described above in connection with FIG. 19 through FIG. 27 . When combined with the slot track storage system and wall-mounted storage cabinet previously described, the workbench storage system provides the operator of a workroom with a highly flexible and very space-efficient storage system. In the embodiment shown in FIG. 33 , a plurality of slot tracks 210 are shown mounted on a wall of the workroom. Some of the slot tracks 210 have one or more hangers 40 installed on the slot tracks. Three wall cabinets 50 are shown mounted on a pair of slot tracks 210 mounted on the workroom wall over the workbench system 110 . Slot tracks 210 can be mounted on the workroom wall spaced so that wall cabinets can be mounted in the same manner as wall cabinets are mounted on slotwall panels as described above in connection with FIG. 7 through FIG. 12 . Wire form shelves 42 ′ having brackets 20 can be mounted on the workroom wall for storing items off the floor of the workroom.
[0106] FIG. 34 illustrates another embodiment of workroom having a modular workbench storage system 110 in combination with a slotwall and slot track storage system in a workroom. The workroom in this embodiment has a plurality of slot tracks 210 mounted on a wall of the workroom, and also has a plurality of slotwall panels 10 covering a portion of one section of a wall of the workroom. A pair of the slot tracks 210 ′ and 210 ″ are shown mounted to align with slots in a slotwall panel 10 . In addition, a slot track 310 is shown positioned at the top of series of slotwall panels to provide a finished top edge. When one or more slot tracks 210 are mounted adjacent one or more slotwall panels with slots in the slot tracks aligned with slots in the slotwall panel, devices such as a wall cabinet 50 can be installed partially on a slotwall panel and partially on a slot track. Slot tracks 210 can be dimensioned so that they can be mounted on a wall spaced apart an even number of slot track widths apart with the slots 211 lined up with slots 11 of a slotwall panel 10 . Then, if desired, additional slot tracks 210 can be added between slot tracks already mounted on a wall, in each case with slots 211 aligned with the slots 11 of a slotwall panel 10 . Those skilled in the art will also recognize that one or more slot tracks 210 can be mounted at any convenient height on a wall of a workroom to support hanger brackets for storing tools and equipment in the workroom, or for supporting shelves, baskets or other storage devices.
[0107] While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation, and the scope of the appended claims should be construed as broadly as the prior art will permit.
|
A space-efficient workroom organization system comprising a slotwall panel and/or slot track storage system with at least one repositionable slotwall or slot track mounted storage cabinet, and a workbench system comprising a workbench having a work surface and defining a storage recess beneath the work surface, with at least one mobile storage cabinet.
| 0
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention concerns an apparatus for selecting and feeding weft yarns to an insertion device of a weaving machine, in which at least one weft feeder is displaceable between a rest position and a feed position by means of an eccentric drive having its own drive motor.
2. Description of Related Art
An apparatus which selects and feeds weft yarns to an insertion device of a weaving machine, and which has at least one weft feeder for feeding a weft and guided in its longitudinal direction, is shown in European published patent application EP 0 362 089 A1. In this apparatus, the rod- or needle-shaped feeders are supported in longitudinally displaceable manner in two longitudinal guides and are acted upon by rockers having a first end which is stationary and a second end which engages the feeders between longitudinal guides. The rockers are moved by actuation rods, first ends of which engage a central portion of the rockers and the other ends of which are connected to an eccentric drive which includes a drive motor, in particular a stepping motor. The excursion of the eccentric drives is transformed by the rockers, as a result of which the feeders move over a distance between their rest and feed positions which is about twice the excursion.
In another apparatus, disclosed in European published patent application EP 0 478 986 A1, displaceable yarn feeders are affixed to a toothed belt on alternating sides from the rest to the feed position. The toothed belt runs around a reversing wheel and around a drive wheel which has been actuated by an electric motor into a reciprocating motion.
Other apparatus for selecting and feeding wefts to an insertion device of a weaving machine are described in U.S. Pat. Nos. 4,964,443 and 4,781,226. In the apparatus described in the two U.S. patents, the feeders are actuated from the central machine drive by the intermediary of transmission means.
SUMMARY OF THE INVENTION
It is a principal objective of the invention to provide an apparatus of the type described above, in which at least one weft feeder guided in its longitudinal direction is displaceable by means of an eccentric drive between a rest position and a feed position, and in which the feeder can operate at higher rates than prior feeders.
This objective is achieved by a feeder which is directly connected to the eccentric driving having an excursion corresponding at least to the distance between the rest and feed positions of the feeder, and by providing an improved guide for the feeder.
The apparatus of the invention offers the advantage that only comparatively slight masses need be moved to displace the feeder(s) between the rest and feed positions, resulting in higher operational rates for the feeder(s) and, consequently, high weaving rates. Another advantage is that the feeder(s) can be displaced in arbitrary sequence and at arbitrary times independently of the other machine parts.
In this simple design, a guide rotatable about an axis parallel to a shaft of the associated eccentric drive is provided for each feeder. As a result, compensation between the reciprocating feeder motion(s) and the transverse, deviating motions of the eccentric drive can be achieved, without necessitating an increase in the masses to be moved.
In an especially advantageous embodiment of the invention, each feeder together with a drive motor, its eccentric drive and its guide forms a module. This simplifies matching of the number of yarn feeders to the requirements of a specific fabric. Moreover, the module may be exchanged as a unit in case of defect.
In a further preferred embodiment of the invention, the feeders are mounted in a common plane. Especially advantageously, in this embodiment, the modules of neighboring feeders are mounted in mirror-symmetrical manner relative to the common feeder plane. As a result, a plurality of feeders can be arranged very compactly.
To reduce the stresses on wefts when they are being inserted, the drive motor is preferably connected to a control unit containing means for stopping the drive motor in a position intermediate between the rest and the feed position. This intermediate position is selected in such a manner that the weft is deflected as little as possible by the feeder when being inserted.
Further features and advantages of the invention are elucidated in the description below of the illustrative embodiments shown in the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevated schematic view of an apparatus constructed in accordance with the principles of a preferred embodiment of the invention.
FIG. 2 is an elevation of the apparatus of FIG. 1 taken in the direction of arrow F2.
FIGS. 3 and 4 are elevations corresponding to that of FIG. 1 but showing feeder positions other than that shown in FIG. 1.
FIG. 5 is a partly sectional view similar to that of FIG. 2 but showing a mirror-symmetrical arrangement of modules according to a further preferred embodiment of the invention.
FIG. 6 is a sectional view taken along line VI--VI of FIG. 5.
FIG. 7 shows the detail F7 of FIG. 6 on an enlarged scale.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 through 4 show a single module 1 of an apparatus for selecting and feeding wefts which includes a plurality of identical modules 1. Each module 1 contains a yarn feeder 3, one end of which includes an eye 21 for guiding a weft 30.
Each module 1 also contains a drive motor 4 for the yarn feeder 3. The drive motor 4 is directly connected through an eccentric drive 6 to the yarn guide 3, which is in the form of a round bar or needle 11. A crank 9 parallel to the yarn feeder 3 is irrotationally mounted to the shaft 5 of the drive motor 4, the shaft running transversely to the longitudinal axis of the yarn feeder. The crank 9 includes a crank pin 10 which supports the end of the yarn feeder 3 that is opposite the eye 21. The rod or needle 11 of the yarn feeder 3 passes through a longitudinal borehole 13 of a guide 12. This guide 12 is mounted as close as possible to the end of the yarn feeder 3 which includes the eye 21 and further is rotatable about a pin 14 parallel to the shaft 5.
Each module 1 includes a support plate 16. The drive motor 4 is affixed to a back side of the plate 16 by a suitable affixing means such as screws 22. In the area of the eccentric drive 6, plate 16 includes a clearance 17. The yarn feeder 3 and its guide 12 are located on that side of the plate 16 which is opposite the drive motor 4. By its pin 14, the guide 12 passes through the plate 16 and is secured in place on the opposite side by a securing element such as a clip 23. As shown by FIGS. 1, 3 and 4, the base surface of the plate 16 is trapezoidal, tapering from the area of the drive motor 4 toward the area of the guide 12.
The masses of the parts to be moved by the drive motor 4, namely of the crank 9 and of the yarn feeder 3 and the guide 12 are comparatively slight, as a result of which only commensurately low inertias need be overcome to move the yarn feeder 3. Consequently, higher operational rates and/or the use of relatively low-power drive motors 4 are made possible.
The maximum angle of the motor-shaft rotation is bounded by stops 25, 26. In the illustrated embodiment, the stops are made up of projections 25, 26 of the clearance 17, which limit the maximum angle of rotation of the crank 9 and hence also of the shaft 5 of the drive motor 4. The projections 25, 26 are arranged in such a way that for the rest and feed positions, shown in FIGS. 1 and 3, respectively, the crank 9 and the rod of the yarn feeder 3 are aligned, i.e., the shaft 5 and the crank pin 10 are in a plane passing through the axis of the rod or needle 11.
In a variation of the above-described embodiment, adjustable stops are provided, for example in the form of adjusting screws mounted on the plate 16 and limiting the angle of rotation of the crank 9.
The drive motors 4 of the particular modules 1 are hooked up to an electronic control unit 20 for determining when and how, i.e., at what speed, the yarn feeders 3 are moved from the rest position (FIG. 1) toward the feed position (FIG. 3) and, where called for, also to an intermediate position (FIG. 4). The control unit 20 is able to move the yarn feeder 3 at any time and regardless of the positions of other machine parts such as a reed-batten drive, harness drive, or other drives, into the desired position. As a result, the displacement of the yarn feeder 3 can be selected, for instance, in relation to the kind of weft, or the weft insertion may be cancelled, or the yarn feeder 3 may be moved during beat-up or weaving-machine shutdown into an arbitrary position.
In a preferred embodiment of the invention, the drive motors 4 are stepping motors fed by the control unit 20 with a pulse sequence or a number of pulses suited for the desired motion. This pulse sequence may be selected in such a manner that, for the rest position, the crank 9 is forced against the stop 25 and, for the feed position, against the stop 26, as a result of which two stable positions are provided for the yarn feeder 3. Preferably, however, the pulse sequence is such that the crank 9 does not rest against the stop 25 or 26 when in its end positions. This feature can be achieved by appropriately selecting the number of steps through which the drive motor is actuated. The yarn feeder 3 can be kept in an adjustable rest or feed position by applying a so-called latching current to the drive motor 4. This latching current is selected to be in such a direction that positioning of the yarn feeder 3 remains unaffected by weaving-machine vibrations or by forces applied to it by the wefts. When the crank 9 and the rod or needle 11 of the yarn feeder 3 are at least approximately aligned in the rest and/or feed positions, forces applied by a weft 30 on the yarn feeder 3 are not transmitted to the crank 9, and therefore only a relatively low retaining current is required.
Because the eccentric drive 6 provides only a relatively small component of motion in the longitudinal direction of the yarn feeder 3 at the beginning of its displacement out of the rest position, i.e., in the direction of the arrow P1 of FIG. 1, and also out of the feed position, i.e., in the direction of the arrow Q in FIG. 3, the start of the motion of feeder 3 is comparatively smooth, as a result of which the wefts 30 are not stressed and the danger of rupturing them is reduced. To enhance this effect, the control unit 20 may feed the pulse sequence in variable frequencies to the drive motor 4, so that drive motor 4 always starts smoothly.
When the yarn feeder 3 is in its rest position, then after a given time or illustratively after a specified number of beat-ups of the batten, the crank 9 may be made to rest against the stop 25, as a result of which a reference position of the motor shaft 5 is set for the control unit 20. However, such a reference position also can be implemented using a detector such as a proximity switch.
In another preferred embodiment of the invention, the shaft 5 of the drive motor 4 is fitted with an angle sensor connected to the control unit 20. In that case, the control unit 20 is able to actuate the drive motor 4, which need not be a stepping motor, until the pre-determined angular position is reached. Also, the drive motor 4 may be actuated at such a variable angular speed that startup always takes place at a low speed. For that purpose, the control unit 20 may feed the drive motor 4 with a variable-frequency current.
In the rest position (FIG. 1), the yarn feeder 3 deflects a weft extending between a stationary yarn feeder, for example a stationary eye 33, and a shed 34 such that it is located outside the range of displacement of an insertion device 31, in particular a gripper 32, in the manner schematically indicated in FIG. 1. In the feed position (FIG. 3), the yarn feeder 3 has been displaced such that the weft 30 now runs within a zone where it is seized by the insertion device 31, for instance the gripper 32. Once the weft 30 has been seized by the insertion device 31, the yarn feeder 3 can be returned to its rest position.
In one design shown in FIG. 4, however, the yarn feeder 3 is moved into an intermediate position during weft insertion. In the intermediate position, the weft 30 in the vicinity of the eye 21 of the yarn feeder 3 is deflected as little as possible, decreasing friction in the vicinity of the eye 21 and hence also the danger of weft rupture. Moreover, the yarn feeder 3 may also be shifted with a constant motion in such a way that the friction in the eye 21 is minimized, by enabling the yarn feeder 3 to change its position. Again, this constant shifting can be implemented by suitably designing the control unit 20. The provision for movement into the intermediate position also is advantageous in the situation where, during the next weft insertion, the same weft needs to be reinserted. In that case, the yarn feed 3 need only cover a shortened path to its feed position.
In case of weft rupture, the weft feeder 3 appropriately is moved into a position in which threading of the weft is easy. For that purpose, a switch 48 is associated with each module 1 and is connected to the control unit 20. By actuating the switch 48, a signal is fed to the control unit 20 which then moves the associated yarn feeder 3 into the threading position by appropriately rotating the drive motor 4. In the case where drive motor 4 is a stepping motor, the control unit 20 supplies a corresponding latching current for the threading position. By actuating the switch 48 of the active yarn feeder 3 again, the feeder is returned to its initial position.
As mentioned above, the preferred apparatus for selecting and feeding wefts includes a plurality of modules such as shown in FIGS. 5 through 7. For clarity, only five modules 1A through 1E are shown, although those skilled in the art will appreciate that, in practice, the number of modules may be substantially higher. Each particular module 1A through 1E is designed as in the above described embodiments, i.e., each module includes a drive motor 4A through 4E, and an eccentric drive for a yarn feeder 3A through 3E which is always guided by a rod or needle 11A through 11 in a guide 12A through 12E. These components are affixed to plates 16A through 16E in the manner already discussed in relation to FIGS. 1 through 4. The yarn feeders 3A through 3E are located in a common plane. In order to mount the individual yarn feeders 3A through 3E as tightly through 4E, and an eccentric drive for a yarn feeder 3A through 3E which is always guided by a rod or needle 11A through 11E in a guide 12A through 12E. These components are affixed to plates 16A through 16E in the manner already discussed in relation to FIGS. 1 through 4. The yarn feeders 3A through 3E are located in a common plane. In order to mount the individual yarn feeders 3A through 3E as tightly against each other as possible, the modules 1A through 1E are arrayed in mirror-symmetrical manner relative to the common plane of the yarn feeders 3A through 3E in two rows 40, 41, and are mutually offset. The common plane may be flat, but it also may be spatially curved (convex). The plates 16A through 16E are mounted between two holding plates 42, 43 to which they are also affixed by screws 46. The plates 42, 43 are connected to each other by crossbars 44 (FIG. 6). The plate 43 is affixed by screws 47 to the machine frame 45.
In this preferred embodiment, as shown in FIG. 7, the yarn feeders 3A through 3E move along an arcuate path 27 between their rest and feed positions. To assure that the yarn feeders 3A through 3E do not hamper one another in spite of their tight sequence, the arcuate displacements 27 of all yarn feeders 3A through 3E are made to be mutually parallel. For that purpose, the direction of rotation of the drive motors 4C, 4E mounted on one side is opposite the direction of rotation of the drive motors 4a, 4B, 4D mounted on the other side. Accordingly, the clearances 17A, 17B, 17D also are mirror-symmetrical with the opposite clearances 17C, 17E. Advantageously, the same plates 16 may be used, with just the arrangement of the drive motors 4 and of the longitudinal guides 12 being interchanged on the base surfaces of the plates 16.
The individual modules 1A through 1C affixed to the plates 42, 43 can be arrayed so as to be in various relative positions. Furthermore, the plates 42, 43 can be aligned in relation to the machine frame 45 and be mounted in a commonly aligned position with respect to the frame. Because the apparatus is made up of a plurality of individual modules, it may be rapidly and simply enlarged or made smaller as called for by adding or removing modules 1. If defective, a particular module can easily be exchanged as a unit. Also, because the drive motors 4 are mounted on the outside even for the mutually opposite design of FIG. 5, they are directly accessible and therefore can also be easily exchanged if defective.
As shown by FIGS. 6 and 7, the yarn feeders 3A through 3E when in the feed position are adjacent to one another, and the individual modules can be aligned such that all yarn feeders 3A through 3E assume feed positions essentially located on the same axis or even in the same point.
The motion of the yarn feeders 3 being independent of the motions of other weaving-machine drives, the advantage follows that, for instance in case of yarn rupture, the particular yarn feeder 3 can be moved again into the feed position without the need to synchronize this motion with other machine drives, i.e., without having to move other machine drives forward or back. Even more advantageously, the movable parts are light, and accordingly high frequencies and therefore high weaving-machine speeds are feasible.
Another advantage obtained by the suitable control of the drive motors 4 as described above is that it is possible to change the rest positions of the yarn feeders 3 without mechanical adjustments. A corresponding adjustment can be implemented by the control unit 20 which is for example provided with an input unit.
The illustrated embodiments provide yarn eyes 21 for the yarn feeders 3. In another embodiment, the yarn feeders 3 are fitted with yarn clamps such as are known in the art.
In a variational embodiment, the guides 12 of the yarn feeders 3 are held by elastic rubber supports, as a result of which the pin 14 is eliminated. In another variation, the yarn feeders 3 are elastically supported in the transverse direction.
Furthermore, it is possible to displace the yarn feeders 3 rectilinearly between the rest and feed positions by using other means to compensate the transverse displacement of the eccentric drive in relation to the reciprocating motion of the yarn feeders 3. Illustratively, this can be implemented by forming the yarn feeders 3 each of two parts joined by a link of which the axis of rotation is parallel to the motor shaft 5.
Having thus described preferred embodiments of the invention and variations and modifications thereof in sufficient detail to enable those skilled in the art to make and use the invention based on the above description and accompanying drawings, it is nevertheless intended that the invention not be limited by the description or illustrations, but rather that it be defined solely by the appended claims.
|
In an apparatus for selecting and feeding wefts to an insertion device of a weaving machine, the feeders are directly connected to eccentric drives which have an excursion corresponding at least to the paths covered by the feeders between their rest and feed positions, and each feeder is associated with a guide and arranged to compensate for transverse displacements of the eccentric drives which deviate from the reciprocating motions of the feeders. The feeders have an excursion corresponding to at least the distance between the rest and feed positions of the feeder, with each feeder together with a drive motor, the eccentric drive, and the guide forming a module to simplify matching of yarn feeders to the requirements of a specific fabric and exchange of units in case of a defect. Advantageously, the modules of neighboring feeders may be mounted in mirror-symmetric manner relative to a common plane in which all of the feeders are mounted. The drive motor is preferably connected to a control unit arranged to control the drive motor to position the feeder at a position intermediate between the rest and the feed positions and selected in such a manner that the weft is deflected as little as possible by the feeder when being inserted.
| 3
|
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] The present invention contains subject matter related to Japanese Patent Application JP 2006-247178 filed in the Japanese Patent Office on Sep. 12, 2006, the entire contents of which being incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an apparatus that switches and outputs input video signals on a plurality of channels. Particularly, the present invention relates to the apparatus to which various types of video signals are input.
[0004] 2. Description of the Related Art
[0005] Video switchers (video switching apparatuses) are used for producing video contents. Video signals on a plurality of channels are input to a video switcher that switches and outputs those video signals and performs processing (e.g., effects such as wiping, and keying) on video at switching.
[0006] Although a video switcher is installed and used in a television broadcasting station, there is also a portable video switcher (for example, refer to Sony Corporation “Live Content Producer AWS-G500” issued in November 2005). A portable video switcher includes a processing unit configured to perform switching and processing on video content, an operation unit configured to perform various operations, and a display unit configured to display input video or the like, which are integrally formed. Such portable video switcher can be carried to, for example, a place where an event or the like is held and the carried portable video switcher is used to produce such video contents as introducing an activity of the event or the like.
[0007] Typically, video cameras of different models and a personal computer may be used to output video signals in respective places. Accordingly, a portable video switcher may need to have a configuration for composite, S-Video, DV (Digital Video), RGB and other video signals input to respective video cameras and personal computers that are used in such places.
[0008] For example, the video switcher described in the above Non-patent Reference (hereinafter, referred to as “related-art video switcher”) includes a plurality of slots for mounting video signal input modules in order to satisfy such requirement. Three kinds of modules (a) through (C) are prepared as the input modules capable of being mounted to those slots.
[0009] (a) SD module for any one of composite signal, S-Video signal and DV signal inputs;
[0010] (b) PC module for RGB signal input; and
[0011] (c) SDI module for SDI signal (serial/digital video signal based on SMPTE259M standard) input
[0012] Further, the related-art video switcher includes a function of collectively storing data indicating setup content carried out by a user so that later the stored data can be read and used (moreover, such data is stored on a compact memory card so that the data can also be used by another video switcher). The setup content data stored by such function includes settings for the type of input module mounted to each slot and the type of video signal input thereto.
[0013] However, the type of video signal input to the video switcher depends on a video camera and personal computer used as described above. Accordingly, if the past input setup with the function is used, there may be a number of cases in which another type of input module is mounted at present to the slot. Further, in the case where another video switcher uses the input setup, there may be a number of cases in which a different type of input module from the present input setup is mounted from the beginning.
[0014] In a video switcher of related art, in the case where an input module of a type different from the past input setup is mounted at present, processing of changing the input setup is manually performed.
[0015] FIG. 1 is a table showing the content of input setup change processing. Each cell of the uppermost row shows a type of input signal in the past input setup data, which has been read. Each cell of the left end column shows a type of input module mounted at present. Other cells show the content of input setup to be changed.
[0016] As shown in FIG. 1 , cells highlighted with thick lines indicate that RGB and SDI signals (i.e., video signals to be input to the other modules than the SD module) are used in the past input setup, which are changed into input setup for the composite signal if the input module mounted at present is the SD module. Processing performed in the SD module is different depending on the type of input video signals. Composite signal and S-Video signal are converted into a digital component signal through luminance/color-difference separation processing and analogue/digital conversion processing. On the other hand, DV signal is converted into a digital component signal using a DV codec, and in addition, the luminance/color-difference separation processing also differs between the composite signal and S-Video signal. Accordingly, processing on the composite signal is performed in the SD module as a default (initial setting).
SUMMARY OF THE INVENTION
[0017] However, after the input setup is changed to that for the composite signal as shown with the thick lines in FIG. 1 , S-Video signal and DV signal are still input to the SD module depending on the model of the video camera used at present. In such case, S-Video signal and DV signal may not be processed in the SD module since the input setup is composite signal. As a result, pictures of the S-Video signal and DV signal may not be displayed on a display unit. Further, S-Video signal and DV signal may not be switched and output from the video switcher.
[0018] FIGS. 2A and 2B are diagrams showing an example of the above-described state. As shown in FIG. 2A , an SDI module and a PC module are mounted to Slots A, B, respectively. Input setup data is stored while pictures of video signals output from the Slots A, B are displayed in respective areas 52 , 53 in part of a screen of a display unit 51 . As shown in FIG. 2B , the input setup data is read after the input modules mounted to the slots A, B are changed to SD modules respectively. Alternatively, another video switcher having SD modules respectively mounted to Slots A, B reads the input setup. In such a case, composite signal and S-Video signal are here input to the respective SD modules mounted to the slots A, B.
[0019] Since the type of input video signal corresponds to composite signal after the input setup change processing shown in FIG. 1 , the input composite signal can be processed in the SD module mounted to Slot A. On the other hand, the input S-Video signal may not be processed in the SD module mounted to Slot B since the type of the input video signal does not correspond to the composite signal after the input setup change processing shown in FIG. 1 . As a result, a picture of a video signal output from Slot A is displayed in the area 52 of the display unit 51 but a picture of a video signal output from Slot B is not displayed in the area 53 of the display unit 51 as shown in FIG. 2B .
[0020] In order to display the picture of the video signal output from Slot B and to switch and output the video signal from Slot B under such state, it may have been necessary in the past to change the input setup of Slot B to the setup of S-Video signal by manually operating the operation unit. In such case, a user first checks that S-Video signal is input to the SD module mounted to Slot B based on a connection state of the SD module and video camera, or the like, and manually operates the operation unit. Therefore, such confirmation work or the like may be cumbersome for the user.
[0021] It is desirable to reduce cumbersome work when changing an input setup in response to a video signal input at present into a video switching apparatus including an input module such as an SD module in the above-described video switcher of related art in which content of processing varies depending on the type of the input video signal.
[0022] A video switching apparatus according to an embodiment of the present invention has a plurality of slots for mounting an input module for video signal input. One of a first input module and a second input module can be mounted to the slots. The first input module is capable of inputting any one of a plurality of predetermined types of video signals and performs processing, content of which varies depending on the type of input video signal. The second input module is capable of inputting only predetermined one type of video signal. The video switching apparatus switches and outputs video signals of a plurality of channels input to the input modules mounted to the plurality of slots. The video switching apparatus includes an input setup data memory processor, a detector and an input setup changer. The input setup data memory processor stores input setup data indicating a type of input module mounted to each of the slots and a type of video signal input thereto in a memory unit. The detector reads the input setup data from the memory unit and detects a slot having an input module mounted at present the type of which is not matched with the type of module indicated in the read input setup data. The input setup changer determines the type of video signal input to the first input module and causes the first input module to execute processing corresponding to the determined type of video signal upon detecting that the input module mounted at present to the slot is the first input module by the detector.
[0023] A video input setting method according to an embodiment of the present invention is a video signal input setting method for a video switching apparatus which has a plurality of slots for mounting an input module for video signal input. One of a first input module and a second input module can be mounted to the slots. The first input module is capable of inputting any one of a plurality of predetermined types of video signals and performs processing, content of which varies depending on the type of input video signal. The second input module is capable of inputting only predetermined one type of video signal. The video switching apparatus switches and outputs video signals of a plurality of channels input to the input modules mounted to the plurality of slots. The video signal input setting method includes the steps of:
[0024] storing input setup data indicating a type of input module mounted to each of the slots and a type of video signal input thereto by a controller provided in the video switching apparatus in a memory unit;
[0025] reading by the controller the input setup data from the memory unit and detecting a slot having an input module mounted at present the type of which is not matched with the type of module indicated by the read input setup data; and
[0026] determining by the controller the type of video signal input to the first input module and causing the first input module to execute processing corresponding to the determined type of video signal upon detecting that the input module mounted at present to the slot is the first input module by the detector.
[0027] According to the above-described embodiments of the present invention, it is possible to store the past input setup data and later use the stored data, similarly to the video switcher of related art which is described above. Further, in the case where an input module different from the input module indicated in the past input setup data is mounted at present and the mounted input module is the input module, processing of which varies depending on the type of input video signal, the type of video signal input to the input module is automatically determined so that the processing corresponding to the determined type is automatically performed. Therefore, the input setup is automatically changed corresponding to the type of input video signal at present without checking the type thereof and without manually executing a change operation.
[0028] A video switching apparatus according to another embodiment of the present invention has a plurality of slots for mounting an input module for video signal input. One of a first input module and a second input module can be mounted to the slots. The first input module is capable of inputting any one of a plurality of predetermined types of video signals and performs processing, content of which varies depending on the type of input video signal. The second input module is capable of inputting only predetermined one type of video signal. The video switching apparatus switches and outputs video signals of a plurality of channels input to the input modules mounted to the plurality of slots. The video switching apparatus includes an input setup data memory processor, a detector and an information display processor. The input setup data memory processor stores input setup data indicating a type of input module mounted to each of the slots and a type of video signal input thereto in a memory unit. The detector reads the input setup data from the memory unit and detects a slot having an input module mounted at present the type of which is not matched with the type of the module indicated in the read input setup data. The information display processor determines the type of video signal input to the first input module and causes information indicating the determined type of video signal to be displayed on a screen of a display unit upon detecting that the input module mounted at present to the slot is the first input module by the detector.
[0029] A video input setting method according to another embodiment of the present invention is a video signal input setting method for a video switching apparatus which has a plurality of slots for mounting an input module for video signal input. One of a first input module and a second input module can be mounted to the slots. The first input module is capable of inputting any one of a plurality of predetermined types of video signals and performs processing, content of which varies depending on the type of input video signal. The second input module is capable of inputting only predetermined one type of video signal. The video switching apparatus switches and outputs video signals of a plurality of channels input to the input modules mounted to the plurality of slots. The video signal input setting method includes the steps of:
[0030] storing input setup data indicating a type of input module mounted to each of the slots and a type of video signal input thereto in a memory unit by a controller provided in the video switching apparatus;
[0031] reading by the controller the input setup data from the memory unit and detecting a slot having an input module mounted at present the type of which is not matched with the type of the module indicated in the read input setup data; and
[0032] determining by the controller the type of video signal input to the first input module and causing information indicating the determined type of video signal to be displayed on a screen of a display unit upon detecting that the input module mounted at present in the slot is the first input module by the detector.
[0033] According to the above-described embodiments of the present invention, it is possible to store the past input setup data and later use the stored data, similarly to the video switcher of related art which is described above. Further, in the case where an input module different from the input module indicated in the past input setup data is mounted at present and the mounted input module is the input module, processing of which varies depending on the type of input video signal, the type of video signal input to the input module is automatically determined so that the information indicating the determined type is displayed. As a result, the user can confirm readily and instantaneously the type of the present input video signal by viewing the display and perform the operation of changing the input setup.
[0034] According to the video switching apparatus and the input setting of the embodiments, it is possible to use past input setup data when mounting the input module, processing of which varies depending on the type of input video signal. Further, the input setup is automatically changed corresponding to the type of the present input video signal without checking the type of input video signal at present and without manually executing a change operation.
[0035] According to the video switching apparatus and the input setting method of the other embodiments, it is possible to use past input setup data when monitoring the input module, processing of which varies depending on the type of input video signal. Further, the user can confirm readily and instantaneously the type of input video signal at present and perform the operation of changing the input setup.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 is a table showing content of input setup change processing in a video switcher according to related art.
[0037] FIGS. 2A and 2B are diagrams showing an example in which an input video is not displayed on the video switcher according to related art.
[0038] FIG. 3 is a diagram showing the whole appearance of a video switcher to which an embodiment of the present invention is applied.
[0039] FIG. 4 is a diagram showing slots at the rear of the video switcher shown in FIG. 3 and appearances of input modules mounted to those slots.
[0040] FIG. 5 is a diagram showing display areas for thumbnail pictures of input video signals on a screen of a liquid crystal display shown in FIG. 3 .
[0041] FIG. 6 is a block diagram showing a configuration of the video switcher shown in FIG. 3 and input modules shown in FIG. 4 .
[0042] FIG. 7 is a flow chart illustrating input setup change processing performed by a main CPU indicated in FIG. 6 .
[0043] FIGS. 8A to 8C are diagrams showing an example in which an input setup is changed by the processing indicated in FIG. 7 .
[0044] FIG. 9 is a flow chart illustrating the input setup change processing performed by the main CPU shown in FIG. 6 .
[0045] FIGS. 10A to 10C are diagrams showing examples in which an input setup is changed by the processing indicated in FIG. 9 .
[0046] FIG. 11 is a flow chart illustrating another example of input setup change processing.
[0047] FIG. 12 is a diagram showing an example of an input setup change recommendation screen based on the processing of FIG. 11 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0048] Hereinafter, embodiments of the present invention are specifically explained referring to the accompanied drawings. Those embodiments are applied to a portable video switcher. FIG. 3 is a perspective view of the whole appearance of a portable video switcher to which an embodiment of the present invention is applied. A video switcher 1 according to the embodiment has a shape somewhat larger than a notebook type personal computer. The video switcher 1 is brought to a place where an event or the like is held, for example, and is used to produce video content introducing such event by inputting video signals from a video camera and a personal computer.
[0049] The video switcher 1 includes an operation unit 2 configured to perform various operations such as setup, storage and retrieval of setup content, change of setup, selection of input video, switching of video, selection of effects, selection of an output mode of video and the like at a position where a keyboard is provided in a notebook type personal computer. Further, the video switcher 1 includes a liquid crystal display 3 similarly to a notebook type personal computer.
[0050] Three slots for mounting an input module for video signal input are provided at the rear of the video switcher 1 . FIG. 4 is a diagram showing those slots with input modules. Any one of three types of input modules, which are an SD module 4 , a PC module 5 and an SDI module 6 , can be mounted to the three slots of Slot 1 , Slot 2 and Slot 3 , respectively.
[0051] The SD module 4 has terminals 4 a , 4 b , terminals 4 c , 4 d to respectively input two channels of composite signals and S-Video signals, and terminals 4 e , 4 f to input and output two channels of DV signals, to which two channels of any one of those three types of video signals can be input.
[0052] The PC module 5 has terminals 5 a , 5 b to input two channels of RGB signals. The SDI module 6 has terminals 6 a , 6 b to input two channels of SDI signals (serial/digital video signal based on SMPTE259M) and a terminal 6 c to output one channel of SDI signal.
[0053] The operation unit 2 shown in FIG. 3 performs an input setup of mounting input modules from among the SD module 4 , PC module 5 and SDI module 6 to Slot 1 , Slot 2 and Slot 3 respectively, and selecting the type of video signal input thereto, as the above-described content of setup and setup change.
[0054] Thumbnail pictures of video signals of total six channels, which are input to the input modules mounted to Slot 1 through Slot 3 shown in FIG. 4 , are respectively displayed on a part of the screen of the liquid crystal display 3 shown in FIG. 3 . FIG. 5 is a diagram showing display areas for the thumbnail pictures. Each of six areas A 1 through A 6 A displays a thumbnail picture of the input video signal on one channel.
[0055] It should be noted that there are other areas on the screen of the liquid display 3 than the area where such thumbnail pictures are displayed. Specifically, there is an area for displaying a picture of the video signal selected by the operation of the operation unit 2 as the video signal before switching (PGM signal) and the video signal after switching (NEXT signal) among the input video signals. Further, there is an area for displaying a menu for the operation. However, illustrations thereof are omitted since such areas are not directly related to embodiments of the present invention.
[0056] FIG. 6 is a block diagram showing a configuration of relevant portions of the video switcher 1 with configurations of the SD module 4 , PC module 5 and SDI module 6 shown in FIG. 4 and a connection relation between the input modules mounted to Slot 1 through Slot 3 and the video switcher 1 .
[0057] The SD module 4 includes a block 4 - 1 configured to process composite signal, S-Video signal, or DV signal input from the terminal 4 a , 4 c or 4 e and a block 4 - 2 configured to process composite signal, S-Video signal or DV signal input from the terminal 4 b , 4 d or 4 f . Also, the PC module 5 includes a block 5 - 1 configured to process RGB signal input from the terminal 5 a and a block 5 - 2 configured to process RGB signal input from the terminal 5 b . Further, the SDI module 6 includes a block 6 - 1 configured to process SDI signal input from the terminal 6 a and a block 6 - 2 configured to process SDI signal input from the terminal 6 b . Since the two blocks in the respective input modules have internal configurations similar to each other, the configuration of one of the two blocks is shown as a representative.
[0058] Composite signal input from the terminal 4 a to the SD module 4 and S-Video signal input from the terminal 4 c to the SD module 4 are supplied to an A/D converter 10 . The A/D converter 10 converts the input video signal into a digital component signal (D1 signal) through synchronization detection processing, luminance/color-difference separation processing and analogue/digital conversion processing and supplies the converted D1 signal to a frame synchronizer and resizer 11 .
[0059] The DV signal input from the terminal 4 e to the SD module 4 is sent to a DV codec 12 . The DV codec 12 converts the input DV signal into a D1 signal through synchronization detection processing and decoding processing and supplies the converted D1 signal to the frame synchronizer and resizer 11 .
[0060] The frame synchronizer and resizer 11 synchronizes the D1 signals received from the A/D converter 10 and the DV codec 12 with a reference synchronization signal in the video switcher 1 . Subsequently, the frame synchronizer and resizer 11 converts a picture size of the signal into 1,280×1,024 pixels (SVGA) that is a unified picture size in processing performed in the video switcher 1 .
[0061] The D1 signal having the picture size converted by the frame synchronizer and resizer 11 is supplied from the frame synchronizer and resizer 11 to a cross point unit 21 in the video switcher 1 and is also supplied from the frame synchronizer and resizer 11 to a picture converter 30 in the video switcher 1 through a local CPU 13 .
[0062] Composite signal, S-Video signal or DV signal input from the terminal 4 b , 4 d or 4 f to the SD module 4 is also converted into a D1 signal of 1,280×1,020 pixels in the same manner and is supplied to the cross point unit 21 and the picture converter 30 in the video switcher 1 .
[0063] The content of processing in the SD module 4 varies depending on the type of input video signal. Specifically, input composite signal or S-Video signal is converted into D1 signal in the A/D converted 10 . On the other hand, input DV signal is converted into D1 signal in the DV codec 12 . Moreover, the luminance/color difference separation processing in the A/D converter 10 is also different between composite signal and S-Video signal. The processing to be performed in the SD module 4 is determined in accordance with a type of video signal by a main CPU 31 included in the video switcher 1 depending on a slot among Slot 1 through Slot 3 to which the SD module 4 is mounted, as later described.
[0064] Analogue RGB signal input from the terminal 5 a to the PC module 5 is converted into a digital RGB signal of 1,280×1,024 pixels by an A/D converter 14 and a frame synchronizer and resizer 15 , and the converted digital RGB signal is supplied from the frame synchronizer and resizer 15 to the cross point unit 21 in the video switcher 1 . Further, the converted digital RGB signal is also supplied from the frame synchronizer and resizer 15 to the picture converter 30 in the video switcher 1 through a local CPU 16 .
[0065] The analogue RGB signal input from the terminal 5 b to the PC module 5 is also converted into a digital RGB signal of 1,280×1,024 pixels in the same manner and is supplied to the cross point unit 21 and the picture converter 30 in the video switcher 1 .
[0066] The processing to be performed in the PC module 5 is also determined in accordance with a type of video signal by a main CPU 31 included in the video switcher 1 depending on a slot among Slot 1 through Slot 3 to which the PC module 5 is mounted.
[0067] SDI signal input from the terminal 6 a to the SDI module 6 is converted into D1 signal by a S/P (Serial/Parallel) converter 17 . Subsequently, the resultant signal is converted into a signal having the picture size of 1,280×1,024 pixels by a frame synchronizer and resizer 18 , and is supplied to the cross point unit 21 in the video switcher 1 from the frame synchronizer and resizer 18 . Further, the signal is supplied from the frame synchronizer and resizer 18 to the picture converter 30 in the video switcher 1 through a local CPU 19 .
[0068] SDI signal input from the terminal 6 b to the SDI module 6 is also converted into the D1 signal of 1,280×1,024 pixels in the same manner and is supplied to the cross point unit 21 and the picture converter 30 in the video switcher 1 .
[0069] The processing to be performed in the SDI module 6 is also determined in accordance with a type of video signal by a main CPU 31 included in the video switcher 1 depending on a slot to which the SDI module 6 is mounted among Slot 1 through Slot 3 .
[0070] The cross point unit 21 in the video switcher 1 receives the digital video signals of 1,280×1,024 pixels of maximum six channels input from Slot 1 through Slot 3 . The cross point unit 21 selects a video signal of one channel as the video signal before switching (PGM input), video signal after switching (NEXT input), and signal for keying, respectively. The cross point unit selects those signals by the control of the main CPU 31 based on the operation of selecting input video performed at the operation unit 2 ( FIG. 3 ), and sends the selected video signals to a switcher/effects unit 22 .
[0071] The switcher/effects unit 22 performs video switching and video processing (effects such as wipe, and keying) by the control of the main CPU 31 based on the video switching operation and effect selection operation using the operation unit 2 .
[0072] The video signal (PGM output) formed through the switching and processing performed at the switcher/effects unit 22 is converted into D1 signal or digital RGB signal at a resizer 23 . Further, the resultant signal is converted into composite signal or S-Video signal or analogue RGB signal at D/A converters 24 and 25 both by the control of the main CPU 31 based on the video output mode selection operation performed at the operation unit 2 . Subsequently, the converted signals are output from video output terminals 26 through 28 of the video switcher 1 . In addition, PGM output from the switcher/effects unit 22 and D1 signal from the resizer 23 are also returned to the DV codec 12 in the SD module 4 and the P/S converter 20 in the SDI module 6 through a selector 29 by the control of the main CPU 31 in response to the video output mode selection operation. As a result, returned signals are output as D1 signal and SDI signal from the terminals 4 e and 4 f of the SD module 4 and the terminal 6 c of the SDI module 6 , respectively.
[0073] The picture converter 30 compresses a digital video signal of 1,280×1,024 pixels of maximum six channels input from Slot 1 through Slot 3 into the video signal for thumbnail display and supplies the compressed video signal to the main CPU 31 .
[0074] The main CPU 31 causes the thumbnail picture of each channel to be displayed in each of the areas A 1 through A 6 of the liquid crystal display 3 using the compressed video signal as shown in FIG. 5 . Further, the main CPU causes the thumbnail pictures of the selected channels as the PGM input and NEXT input to be displayed in other areas of the liquid crystal display 3 .
[0075] It should be noted that the video switcher 1 further includes a slot for mounting a recording device such as a compact memory card, although not illustrated in the figure.
[0076] Next, input setup processing performed in the video switcher 1 is explained. As described above, the operation unit 2 is capable of performing not only the setup of the video switcher 1 but also the storage and retrieval of the setup content. Specifically, according to such function, data showing the content of setup performed by the user is collectively stored in a memory in the main CPU 31 and the stored data is later read and used. Further, the data may be stored in a compact memory card so that another video switcher can use the data. The main CPU 31 controls each unit included in the video switcher 1 and an input module mounted to each of Slot 1 through Slot 3 based on the setup content data retrieved.
[0077] The content of setup performed with the above-described function includes such input setup as follows. Specifically, the input setup includes determining: the type of input module mounted to each of Slot 1 through Slot 3 ; the types of video signals respectively input to the two blocks of each input module; and areas for the thumbnail pictures of the video signals of six channels output from Slot 1 through Slot 3 respectively displayed in the areas A 1 through A 6 (as shown in FIG. 5 ) of the liquid crystal display 3 .
[0078] It should be noted that first blocks (block 4 - 1 in the SD module 4 , block 5 - 1 in the PC module 5 , and block 6 - 1 in the SDI module 6 ) in the respective input modules mounted to Slot 1 , Slot 2 and Slot 3 are hereinafter referred to as “Slot 1 - 1 ”, “Slot 2 - 1 ” and “Slot 3 - 1 ”. Further, second blocks (block 4 - 2 in the SD module 4 , block 5 - 2 in the PC module 5 , and block 6 - 2 in the SDI module 6 ) in the respective input modules mounted are referred to as “Slot 1 - 2 ”, “Slot 2 - 2 ” and “Slot 3 - 2 ”. When referring to respective blocks in this manner, the above-described input setup is expressed as follows. Specifically, the input setup includes determining: the type of input module mounted to each slot of Slot 1 through Slot 3 ; the types of video signals respectively input to Slots 1 - 1 , 1 - 2 , 2 - 1 , 2 - 2 , 3 - 1 and 3 - 2 ; and areas for the thumbnail pictures of the video signals output from the Slots 1 - 1 , 1 - 2 , 2 - 1 , 2 - 2 , 3 - 1 and 3 - 2 respectively displayed in the areas A 1 through A 6 (as shown in FIG. 5 ) of the liquid crystal display 3 .
[0079] However, if input setup of the past is used with such function, there may be a number of cases in which the input modules mounted to Slot 1 through Slot 3 have been changed to other types of input modules depending on a video camera and personal computer being used, since the type of input video signal to the video switcher 1 is dependent on the video camera and personal computer used at present. In addition, when another video switcher uses the input setup, there are a number of cases in which an input module having input setup originally different from the input setup is mounted.
[0080] Therefore, the main CPU 31 executes input setup change processing as shown in FIG. 7 and input setup change processing as shown in FIG. 9 , on the input setup retrieved by the above-described function.
[0081] According to input setup change processing indicated in FIG. 7 , input setup data is read (step S 1 ). Subsequently, the type of input module mounted at present to each of Slot 1 through Slot 3 is detected based on identification information of each type of input module that is stored in the respective local CPU 13 , 16 and 19 (as shown in FIG. 6 ) in the SD module 4 , PC module 5 and SDI module 6 (step S 2 ).
[0082] Subsequently, it is determined for each of Slot 1 through Slot 3 whether the type of input module indicated in the read input setup data corresponds to the type of the input module mounted at present (step S 3 ).
[0083] If there is a slot to which is mounted an input module different from a module indicated in input setup data, it is determined whether the input module mounted at present to the slot is a PC module 5 or SDI module 6 (step S 4 ). If the result is NO (the input module mounted at present is an SD module 4 ), a synchronization detection result is obtained at the A/D converter 10 or DV codec 12 in the respective blocks of 4 - 1 and 4 - 2 in the SD module 4 (shown in FIG. 6 ) through the local CPU 13 . Subsequently, it is determined based on the synchronization detection result which type of video signal is input to the respective blocks of 4 - 1 and 4 - 2 in the SD module 4 among composite signal, S-Video signal and DV signal (step S 5 ).
[0084] Subsequently, the input setup is changed so that the processing corresponding to the determined type of video signal is performed at respective blocks in the input module of the slot (step S 6 ), and the processing is ended.
[0085] If the result is YES at step S 4 , video signals input to the PC module 5 and SDI module 6 are RGB signal and SDI signal respectively. Therefore, input setup is changed so that the input module of the slot in the case of the PC module 5 performs processing corresponding to RGB signal (step S 7 ). Similarly, input setup is changed so that the input module of the slot in the case of the SDI module 6 performs processing corresponding to SDI signal (step S 7 ), and the processing is ended.
[0086] In the case where the result is YES at step S 3 , processing is ended without changing input setup since the input module mounted to each of Slot 1 through Slot 3 can process the input video signal without any change.
[0087] FIGS. 8A , 8 B and 8 C are diagrams showing an example in which input setup is changed through the input setup change processing indicated in FIG. 7 . In this example, the PC module 5 is mounted to Slot 1 as shown in FIG. 8A and the input setup is stored in a state of a picture of the video signal from Slot 1 being displayed in the area A 1 (as shown in FIG. 5 ) of the liquid crystal display 3 . Further, as shown in FIG. 8B , the input setup is read after the input module mounted to Slot 1 is exchanged with the SD module 4 , or the input setup is read by another video switcher having the SD module 4 mounted to Slot 1 . In such a case, S-Video signal is input to the block 4 - 1 of the SD module 4 . In the figures, Slot 1 - 1 indicates a portion corresponding to the first block of the input module mounted to Slot 1 as described above. FIGS. 8A and 8B illustrate the same states as those of slot B shown in FIGS. 2A and 2B .
[0088] Here, the processing in FIG. 7 is performed from step S 3 to steps S 4 and S 5 . The video signal input to the block 4 - 1 of the SD module 4 is automatically determined as S-Video signal at step S 5 . Afterward, the input setup is automatically changed at step S 6 so that the processing corresponding to S-Video signal is performed at the block 4 - 1 of the SD module 4 . More specifically, input setup is automatically changed corresponding to the type of video signal input at present. Accordingly, there is no need for the user to confirm from the state of connection between the SD module 4 and video camera or the like that S-Video signal is input to the block 4 - 1 of the SD module 4 mounted to the slot of Slot 1 . Further, there is no need to manually change the input setup of Slot 1 - 1 to S-Video signal by operating the operation unit 2 .
[0089] Accordingly, since the type of input video signal matches S-Video signal obtained through the input setup change processing shown in FIG. 7 , input S-Video signal can be processed in the block 4 - 1 of the SD module 4 . As a result, as shown in FIG. 8C , a thumbnail picture of S-Video signal output from Slot 1 - 1 is displayed in the area A 1 of the liquid crystal display 3 and the S-Video signal can be switched and output.
[0090] As described above, the video switcher 1 can use the past input setup and can automatically change input setup through the input setup change processing indicated in FIG. 7 corresponding to the type of video signal input at present.
[0091] In the input setup change processing indicated in FIG. 9 , the same processing (steps S 11 through S 13 ) as that of steps S 1 through S 3 of the input setup change processing indicated in FIG. 7 is performed. Subsequently, if it is determined that there is a slot to which is mounted an input module different from a module indicated in input setup data, loop processing of steps S 14 through S 19 is performed on each slot in the numerical order of the above-described Slots 1 - 1 , 1 - 2 , 2 - 1 , 2 - 2 , 3 - 1 and 3 - 2 .
[0092] The processing performed on each slot in the loop processing is as follows. First, it is searched based on the above-described identification information on each type of input module whether the same type of input module as the input module, which has been mounted to the slot according to the input setup data read at step S 11 , is mounted to another slot at present (step S 15 ).
[0093] If the same type of input module is found, it is determined whether the type of input module indicated in the input setup data read at step S 11 is the type of input module mounted at present to the above-described “another slot” to which the same type of input module is mounted (step S 16 ). In the case where the result is NO, it is determined whether the input setup is already changed at subsequent step S 18 with respect to the above-described “another slot” (step S 17 ).
[0094] If the result is NO, input setup is changed so that the video signal output from the above-described “another slot” is alternatively displayed in an area where a picture of the video signal, which is output from the slot and determined to be different at step S 13 according to the input setup data read at step S 11 , has been displayed in the areas A 1 through A 6 (as shown in FIG. 5 ) of the liquid crystal display 3 (step S 18 ).
[0095] The processing is ended after completing the loop processing. The processing is ended without further processing: in the case where the result is YES at step S 13 ; in the case where the result is NO at step S 15 ; and in the case where the result is YES at step S 16 or step S 17 .
[0096] FIGS. 10A , 10 B and 10 C are diagrams showing an example in which input setup is changed through the input setup change processing indicated in FIG. 9 . As shown in FIG. 10A , an SDI module 6 , PC module 5 and SD module 4 are respectively mounted to Slot 1 , Slot 2 and Slot 3 , and composite signals are input to Slots 3 - 1 and 3 - 2 respectively; and thumbnail pictures of video signals output from the Slots 1 - 1 , 1 - 2 , 2 - 1 , 2 - 2 , 3 - 1 and 3 - 2 are displayed in the areas A 1 , A 5 , A 6 , A 2 , A 3 and A 4 of the liquid crystal display 3 , respectively. Such a state is stored as an input setup. Further, as shown in FIG. 10B , the above-described input setup is read after the input modules mounted to Slot 1 , Slot 2 and Slot 3 are respectively changed to the PC module 5 , SD module 4 , and SDI module 6 . Alternatively, the input setup is read by another video switcher having the PC module 5 , SD module 4 , and SDI module 6 respectively mounted to Slot 1 , Slot 2 and Slot 3 . In this state, composite signals are respectively input to the blocks 4 - 1 and 4 - 2 of the SD module 4 .
[0097] In the state shown in FIG. 10B , the thumbnail pictures are displayed respectively in the areas of A 1 through A 6 by the above-described input setup change processing indicated in FIG. 7 . However, correspondence between thumbnail pictures of video signals and displayed areas, shown in FIG. 10B , becomes different from that shown in FIG. 10A .
[0098] In such a case, the processing goes from step S 13 to the loop processing of steps S 14 through S 19 in the processing indicated in FIG. 9 . As a result, as shown in FIG. 10C , the correspondence between the video signals and the areas A 1 through A 6 is changed by the loop processing so that the correspondence becomes the same as that shown in FIG. 10A .
[0099] Accordingly, the correspondence between the thumbnail pictures of video signals displayed and areas is automatically maintained to be constant.
[0100] Next, another example of the input setup change processing performed by the main CPU 31 will be explained with reference to FIG. 11 . According to the input setup change processing indicated in FIG. 11 , the same processing (steps S 21 through S 25 ) as steps S 1 through S 5 of the input setup change processing indicated in FIG. 7 is first performed. After the result is YES at step S 24 and after the processing of step S 25 is performed, processing (steps S 26 and S 27 ) equivalent to that of steps S 15 and S 16 in the input setup change processing indicated in FIG. 9 is performed on the slot determined to be a slot having an input module different from the module indicated in input setup data at step S 23 .
[0101] Further, based on the processing performed at steps S 26 and S 27 and a result of the type of video signal determined at step S 25 , such an input setup change recommendation screen as exemplarily shown in FIG. 12 is displayed on the liquid crystal display 3 (step S 28 ). Then, the process is ended.
[0102] As shown in FIG. 12 , numerals 1 through 6 shown in vertical direction at the left end of the input setup change recommendation screen indicates the areas A 1 through A 6 (shown in FIG. 5 ) on the liquid crystal display 3 . The input setup change recommendation screen recommends the change of the input setup to maintain the correspondence between the types of video signals and the respective areas A 1 through A 6 of the liquid crystal display 3 to be constant as exemplarily shown in FIGS. 10A to 10C based on the result of the processing at steps S 26 and S 27 . Further, recommendation for changing the input setup into the determined type of video signal is displayed with respect to the slot, the type of video signal of which is determined at step S 25 . FIG. 12 shows a state in which a thumbnail picture of video signal output from Slot 1 - 2 is displayed in the area A 1 and the recommendation for changing the input setup of Slot 1 - 2 into DV signal is displayed.
[0103] Referring to the displayed input setup change recommendation screen as shown in FIG. 12 , the user can confirm easily and instantaneously which thumbnail picture of a video signal output from a slot should be displayed in which area in order to constantly maintain the correspondence between the types of video signals and the areas A 1 through A 6 . Hence, the user can perform the operation of changing the input setup using the operation unit 2 so that the thumbnail picture of the video signal output from Slot 1 - 2 is displayed in the area A 1 . In addition, the user can confirm easily and instantaneously from the above display that DV signal is input to the block 4 - 2 of the SD module 4 mounted to Slot 1 without confirmation based on the connection state between the SD module 4 and the video camera, or the like, and the operation of changing the input setup of Slot 1 - 2 into DV signal can be performed using the operation unit 2 .
[0104] If the user changes the input setup as recommended in the display shown in FIG. 12 , Slot 1 - 2 is excluded from the slots to which the recommendation is displayed in the input setup change recommendation screen with respect to the areas A 2 through A 5 other than the area A 1 . Such case is equivalent to the case in which the result is YES at step S 17 indicated in FIG. 9 .
[0105] It should be noted that the recommendation screen is displayed in the input setup change processing indicated in FIG. 11 upon executing both the determination of the type of video signal by the input setup change processing of FIG. 7 and the search of an alternative slot by the input setup change processing of FIG. 9 . However, embodiments of the present invention are not limited thereto, and the determination of the type of video signal by the input setup change processing of FIG. 7 alone may be performed such that the recommendation for changing the input setup to the determined type of video signal is displayed.
[0106] Further, in the above-described examples, embodiments of the present invention are applied to a video switcher to which is mounted an SD module capable of inputting any one of video signals among composite signal, S-Video signal and DV signal. However, embodiments of the present invention can be applied to any video switching apparatuses to which is mounted an input module performing processing which is different depending on the type of input video signal.
[0107] It should be understood by those skilled in the art that various modifications, combinations, sub-combinations and alterations may occur depending on design requirements and other factors insofar as they are within the scope of the appended claims or the equivalents thereof.
|
A video switching apparatus has a plurality of slots each for mounting any of a first input module capable of inputting any one of a plurality of predetermined types of video signals and performing processing, content of which varies depending on the type of input video signal and a second input module capable of inputting only predetermined one type of video signal. The video switching apparatus switches and outputs video signals of a plurality of channels input to the input modules mounted to the plurality of slots. The video switching apparatus includes an input setup data memory processor, a detector, and an input setup changer.
| 6
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to laser based systems and methods. More specifically, the present invention relates to eyesafe ladar transmitters.
[0003] 2. Description of the Related Art
[0004] Current applications require highly accurate laser transmitters for high resolution ranging (one-dimensional profiling) and/or laser illumination for two-dimensional and three-dimensional sensing applications. For example, one-dimensional profiling allows for the target returns to be matched against a database to identify the target type. For two and three-dimensional sensing applications, a tight, highly accurate sensing pulse is transmitted and used to illuminate features of a target. The tight pulses reflect off of various surfaces of the target differently and reflect return pulses which are processed with sophisticated signal processing algorithms to yield more complete images of the target. Two-dimensional and three-dimensional imaging allows for a display of the target return data or an image of the target based on data from a stored database.
[0005] One of the main problems with multi-sensor eyesafe ladar systems is the prohibitively high cost of the transmitter component. Current approaches to eyesafe ladar transmitter design involve Optical Parametric Oscillator (OPO) shifting of the Nd:YAG laser to 1.5 micron.
[0006] For the above-noted sophisticated vibration sensing applications and other applications, separate laser transmitters have been required. Unfortunately, the use of multiple transmitters adds significantly to the cost and weight of deployment and would be impractical for many significant applications. That is, using separate transmitters for each sensor function necessitates complex beam-combining optics or requires multiple transmit apertures. In either case, the size and weight (and cost) are significantly increased. Producing both Q-switched and coherent mode-locked modes in a single Nd:YAG OPO would be complex and costly.
[0007] No approaches are known to exist for combining both high pulse energy Q-switched and coherent mode-locked functions in the same transmitter. Hence, there is a need in the art for a simple, accurate, low cost, efficient laser transmitter suitable for use in remote, long range, vibration sensing applications which may be implemented in a single laser transmitter capable of performing single point ranging, one-dimensional profiling and/or laser illumination for two-dimensional and three-dimensional sensing applications.
SUMMARY OF THE INVENTION
[0008] The need in the art is addressed by the multifunctional laser of the present invention. In a particular embodiment, the present teachings are implemented in a multifunctional laser which, in a first operational mode, outputs a mode-locked beam and, in a second operational mode, outputs a Q switched illumination beam. The inventive laser includes a resonant cavity; a gain medium disposed with the cavity; a first arrangement in communication with the medium for causing a Q-switched signal to be transmitted from the cavity; a second arrangement in communication with the medium for causing a mode-locked signal to be transmitted from the cavity; and a mechanism for switching between the first arrangement and the second arrangement.
[0009] In the illustrative embodiment, the switching mechanism consists of a 90 degree rotator, a beam block, and a polarizer. The first arrangement may be implemented with a Q switch. The second arrangement may be implemented with a quantum well absorber or an acoustic crystal.
[0010] Unlike the single mode laser transmitters that typify the prior art, the mode-locking mechanism of the present invention causes the laser to output energy at all modes within the gain profile in phase with one another. The result is a series of tight clean pulses which may be used for range resolved vibration and one-dimensional (high resolution ranging) applications.
[0011] Hence, in accordance with the present teachings, a single transmitter is provided which enables both functions using only a small mechanical switching mechanism to move one optic and a beam block. Both Q-switched and mode-locked beams emit from the same aperture with the same polarization, thus allowing common beam steering and shaping optics to be shared for both functions (e.g., only a single telescope).
[0012] In the illustrative embodiment, the laser is an erbium or erbium, ytterbium-doped, fiber pumped laser and the mode-locking mechanism is a passive quantum well absorber crystal or an active acoustic crystal mounted in the laser cavity. The high pulse energy, Q-switched mode can be used for 3D range imaging, and the coherent mode-locked mode can be used for RRV sensing and 1D target profiling. The invention allows for a single transmitter aperture with a common polarization, which means that the ladar beam-steering and telescope optics are shared between the multi-functions, thus reducing size, weight, and cost of the multi-sensor ladar system.
BRIEF DESCRIPTION OF THE DRAWING
[0013] [0013]FIG. 1 a is a diagram of the optical configuration of the transmitter of the illustrative embodiment configured to provide a Q switched output.
[0014] [0014]FIG. 1 b is a diagram illustrative of the output of the transmitter of the illustrative embodiment in the Q switched configuration.
[0015] [0015]FIG. 2 a is a diagram of the optical configuration of the transmitter of the illustrative embodiment configured to provide a mode-locked output.
[0016] [0016]FIG. 2 b depicts a mode-locked pulse train.
[0017] [0017]FIG. 3 is a diagram which illustrates the modes that exist within a laser cavity.
[0018] [0018]FIG. 4 is a diagram that illustrates the output of a typical laser with modes at random phase.
[0019] [0019]FIG. 5 is a simplified diagram of a typical laser cavity with a gain medium and a loss modulator disposed therein.
[0020] [0020]FIG. 6 is a diagram which illustrates the output of a typical laser with modes in phase.
[0021] [0021]FIG. 7 is a diagram of the modes in a laser cavity having a mode selection element therein.
DESCRIPTION OF THE INVENTION
[0022] Illustrative embodiments and exemplary applications will now be described with reference to the accompanying drawings to disclose the advantageous teachings of the present invention.
[0023] While the present invention is described herein with reference to illustrative embodiments for particular applications, it should be understood that the invention is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications, and embodiments within the scope thereof and additional fields in which the present invention would be of significant utility.
[0024] [0024]FIG. 1 a is a diagram of the optical configuration of the transmitter of the illustrative embodiment configured to provide a Q-switched output. The multifunctional transmitter 10 includes a gain medium 100 disposed in a optical cavity provided by a partially reflective output coupler 110 and a high reflectivity mirror 120 . In the illustrative embodiment, the gain medium 100 is an erbium crystal pumped via optical fibers (not shown). Those skilled in the art will appreciate that the invention is not limited to an erbium crystal gain medium. Erbium, ytterbium-doped, crystal, YVO 4 , or glass host or other suitable medium could be used without departing from the scope of the present teachings.
[0025] In the Q-switch mode, vertically polarized (s-polarized) energy from the gain medium is highly reflected by a polarizer 140 to a Q switch 150 disposed in the cavity in front of the high reflector 120 . The beam block 187 prevents lasing in the alternate resonator path that is used in the modelocked mode of operation.
[0026] The optics which are used in the Q-switched function alone, such as the passive or active Q-switch element and the rear (HR, high reflector) mirror of the Q-switched resonator, are accessed only via the s-polarized beam path.
[0027] [0027]FIG. 1 b is a diagram illustrative of the output of the transmitter of the illustrative embodiment in the Q switched configuration. In an illustrative embodiment, in the Q-switched configuration, the transmitter delivers high energy pulses of ˜10 nanosecond duration. This transmitter configuration would be used in 3-D and 2-D imaging to illuminate a remote target with a single high-energy pulse.
[0028] [0028]FIG. 2 a is a diagram of the optical configuration of the transmitter of the illustrative embodiment configured to provide a mode-locked output. In the mode-locked configuration, the rotator 130 is activated by mechanical switch. As a consequence, the vertically polarized output of the gain medium 100 is rotated to a horizontal polarization state by the rotator 130 . The rotator 130 is fabricated of an optically active material (e.g. quartz) which, when inserted in the beam path, causes the light polarization to be rotated by 90 degrees. This is a standard, readily available, commercial component which is not particularly alignment sensitive, so it can be mechanically inserted. The function of this component is to keep the polarization of both Q-switched and mode-locked modes of operation within the same plane. This is critical in a ladar system where the beam-steering optics possess polarization-sensitive coatings. It is also critical for polarization sensitive laser crystals such as Erbium-doped YVO 4 . The horizontally polarized energy passes through the polarizer 140 and is reflected by first and second fold mirrors 160 and 170 through a mode-locker 180 to a second high reflector 190 .
[0029] The mode-locked resonator path is ‘p-polarized’ (relative to the polarizer) which is highly transmitted by the polarizer. The optics that serve the mode-locked laser alone are accessed only via the p-polarized beam path. This architecture allows that the resonator lengths and the highly reflective mirrors to be optimized for each function individually, while the output aperture remains common. For example, the mode-locked resonator will have a considerably longer path length than that of the Q-switched resonator.
[0030] As is well known in the art, the outcoupler 110 and the high-reflector 190 of FIG. 2 a provide a resonant cavity in which there are multiple resonant modes or frequencies. The frequencies are uniformly spaced at c/2l, where ‘c’ is the speed of light and ‘l’ is the length of the cavity. These modes are called Fabry-Perot laser modes and are depicted in FIGS. 2 b and 3 .
[0031] [0031]FIG. 2 b depicts a mode-locked pulse train. In the illustrative embodiment, in the mode-locked configuration, a continuous train of coherent mode-locked pulses (sub-nanosecond durations) is emitted at average output powers on the order of 3 watts. This enables Range Resolved Vibration (RRV) measurements and 1-D profiling target identification.
[0032] [0032]FIG. 3 is a diagram which illustrates the modes that exist within a laser cavity relative to a laser gain line. When a gain medium is added to the cavity, a gain profile is provided as depicted in FIG. 3. With a gain medium inside the cavity, there will be a region in which there is optimal gain, i.e., each resonant mode under the gain line can lase. Energy at the laser modes within the gain profile lase and will be output by the outcoupler in random phases as depicted in FIG. 4.
[0033] [0033]FIG. 4 is a diagram which illustrates the output of a typical laser with modes at random phase.
[0034] [0034]FIG. 5 is a simplified diagram of a typical laser cavity with a gain medium and a loss modulator disposed therein.
[0035] [0035]FIG. 6 is a diagram which illustrates the output of a typical laser with modes in phase. Note that in FIG. 4, with the phases of the modes being random, the sine peaks do not line up for narrow pulses. However, the addition of a loss modulator to the cavity as depicted in FIG. 5 has the effect of lining up the modes such that the modes are in phase as depicted in FIG. 6. That is, the loss modulator excites all the modes under the gain line of the laser and keeps them in phase. The laser is said to be ‘mode-locked’ in that the modes under the gain line exist and are lined up in phase. This contrasts with the typical conventional single mode laser transmitter used for vibration sensing. Single mode laser transmitters generally employ a mode selection element, Etalon or seeded mode, to isolate a single mode and suppress the other modes under the gain line. This is depicted in FIG. 7.
[0036] [0036]FIG. 7 is a diagram of the modes in a laser cavity having a mode selection element therein. Unfortunately, as mentioned above, the isolation of a single mode and the suppression of the other modes in a cavity is difficult and adds significantly to the cost and complexity of the system.
[0037] However, as illustrated in FIG. 2 a, in accordance with the present teachings, instead of isolating a single mode and suppressing the other modes in the cavity, the mode-locking element 180 is added to excite the modes so that the modes line up in phase. The mode-locking element or loss modulator 180 can be: 1) a passive modelocker, i.e., a crystal that is normally opaque to light (does not let the light through) until it reaches a certain intensity threshold (e.g., a passive multiple quantum well absorber crystal such as gallium arsenide) or 2) an active mode-locker with an acoustic crystal which may be purchased from IntraAction Corp in Bellwood, Ill., or Brimrose Corp in Baltimore Md.
[0038] A beam blocker 182 is inserted in the mode-locked resonator in the Q-switched mode, in order to prevent parasitic mode-locked lasing, for the case that a passive mode-locker element is employed. The beam blocker 182 may not be necessary with an active mode-locker, since the mode-locker could simply be turned off. When in the mode-locked mode, a beam block in the Q-switched resonator path will probably not be needed since the laser threshold for Q-switched, high energy pulses will be significantly higher than that for a mode-locked train of pulses. The polarizer in this design may be any of several available low loss polarizers (e.g. thin film polarizer) at the laser wavelength within the eye safe band.
[0039] Thus, the present invention has been described herein with reference to a particular embodiment for a particular application. Those having ordinary skill in the art and access to the present teachings will recognize additional modifications, applications and embodiments within the scope thereof.
[0040] It is therefore intended by the appended claims to cover any and all such applications, modifications and embodiments within the scope of the present invention.
[0041] Accordingly,
|
A multifunctional laser ( 10 ) which, in a first operational mode, outputs a mode-locked beam for vibration sensing applications and, in a second operational mode, outputs a Q switched illumination beam for imaging applications. The inventive laser ( 10 ) includes a resonant cavity ( 110, 120, 190 ); a gain medium ( 100 ) disposed with the cavity; a first arrangement ( 150 ) in communication with the medium for causing a Q-switched signal to be transmitted from the cavity; a second arrangement ( 180 ) in communication with the medium for causing a mode-locked signal to be transmitted from the cavity; and a mechanism ( 130, 140 ) for switching between the first arrangement and the second arrangement.
| 7
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the correction of heat imbalances of a building resulting from the effects of incident solar radiation, and more particularly, this invention relates to a system and method for entrapping the heat component of incident solar radiation and either distributing it to other portions of the building or returning it to the atmosphere.
2. Description of the Prior Art
Wall units, particularly windows, exposed to incident solar radiation are known to present difficulties in the heating and air conditioning of buildings. These difficulties vary with the seasons, with the weather, and with the spatial orientation of the wall unit or window in question. For instance, in both hot and cold weather the heat from incident solar radiation causes imbalances, sometimes quite severe, in the air conditioning and heating of the building, which either requires separate units or separate control of a master unit. Even so, a uniform temperature can not be achieved over the entire gradation of solar energy heating effects on the building without excessive expense.
During the summer, the solar radiation incident on building walls and windows causes a heat gain in the adjacent interior areas, thus increasing the burden on the cooling system of the building. During the winter, the heat gain from such incident solar radiation can relieve some of the burden on the heating system of the building, but on clear days the walls and windows exposed to incident solar radiation allow substantial amounts of excess heat energy to enter the adjacent areas, while other areas in the same building (not adjacent to wall units exposed to incident solar radiation) receive insufficient heat energy. The disproportionate heat gain from this source places undue burdens on the heating, ventilating and air conditioning system of the building, for it requires that such system supply cooling to the former areas at the same time that it supplies heating to the latter areas.
At least one system (that illustrated in U.S. Pat. No. 3,590,913 -- Tschudin) attempts to deal with the ultimate problem of air conditioning the interior areas by constructing wall units of parallel glass panels separated by a cavity through which a light-transmitting heating or cooling medium can be circulated. This system is inordinately expensive and inefficient because: (1) it allows the ambient outside environment to withdraw from (or add to) the heating (or cooling) medium as much or more heat energy than the adjacent indoor environment is able to withdraw (or add); and (2) it fails to utilize the incident energy which otherwise would result in the undesirable heat gain.
Some wall units, particularly windows, are designed with outside surfaces which reflect incident solar radiation to reduce the heat gain in the adjacent interior areas. These wall units are inefficient in that the incident solar radiation is reflected back to the ambient atmosphere and not utilized. This is particularly wasteful in the winter months when the mid-day sun, being low in the sky, causes more than average amounts of incident radiation to strike the vertical walls exposed to the south and west, while at the same time the winter temperatures cause greater than average heat loss from all walls, particularly those exposed to the north and east.
It is possible to avoid this inefficiency by constructing the wall unit or window in such a way that the reflective surface can be removed when conditions dictate that the solar radiation be allowed to enter and add heat to the adjacent interior area. An arrangement described by Nicholas Fuschillo in an article entitled "Semi-Transparent Solar Collection Window System", Solar Energy, Vol. 17, pp. 159-165 (1975), avoids this manual operation by erecting a second, transparent panel outside of the reflective surface and providing valves to allow venting the heat from the area between the panels either to the outside (during hot weather) or to the adjacent interior area (during cold weather). Neither of these types of systems, however, deals with the problems of differential heating of interior areas adjacent to wall units or windows exposed to incident solar radiation and interior areas adjacent to wall units or windows not exposed to incident solar radiation.
SUMMARY OF THE INVENTION
The differential heating problems encountered in heating or air conditioning a building are considerably alleviated by the invention disclosed herein. In the present invention a window or other wall unit is composed of two spaced parallel panels forming a cavity or chamber therebetween. The exterior panel (adjacent to the ambient atmosphere) is designed to transmit solar heat radiation. The exterior surface of the exterior panel (adjacent to the ambient atmosphere) may, but need not, be specially treated. The interior surface of the exterior panel (adjacent to the chamber) is treated in a manner to absorb solar heat radiation.
The interior panel (adjacent to the interior building area) is designed not to transmit solar heat radiation. The exterior surface of the interior panel (adjacent to the chamber) is treated in a manner to reflect solar heat radiation, or to absorb such radiation, or to partially reflect and partially absorb such radiation. The interior surface of the interior panel (adjacent to the interior building area) may, but need not, be specially treated.
Solar heat radiation incident on the window or other wall unit is blocked from entering the adjacent interior area of the building and is absorbed by the surfaces of the panels, which surfaces form the vertical side boundaries of the chamber. Since the radiant energy is absorbed by such surfaces, their temperature rises and the heat is transferred by conduction to the air occupying the chamber, thus increasing its temperature as well.
The chamber is sealed, but provision is made for free air to selectively enter the chamber from the adjacent interior building area. Further provision is made to selectively withdraw the heated air entrapped in the chamber and to transport it elsewhere, where its increased heat energy content may be utilized or transferred to the atmosphere, depending upon the season. Because the heated air is constantly being withdrawn, the temperature of the surfaces of the panels forming the chamber rise only moderately. This reduces the amount of heat transmitted through the interior panel by conduction and further increases the efficiency of the system for reducing the cooling burden on the adjacent interior areas.
One way to provide for such free air to enter and heated air to be withdrawn from the cavity is to seal the side edges of the chamber, provide free air access to the bottom of the chamber and withdraw the heated air from the top of the chamber to the existing ductwork of the building ventilating system. Modern building design already provides for the ceiling ventilation system to withdraw air from those building areas where the number of lights, people, or other factors create excess heat and to utilize the heat in such air for the purposes of preheating incoming fresh air, heating water for the restroom facilities and for other purposes. Since current building design already provides for utilization of excess heat generated by lights, people, machinery, etc., the full potential of the present invention readily can be realized by connecting the chamber through a short duct to the existing heated air exhaust system, which is already equipped to utilize heat energy such as that obtained by the invention from the incident solar radiation.
By use of the present invention, it is possible to prevent excess heat build-up or reduce the cooling burden on interior areas adjacent to walls exposed to incident solar heat radiation by intercepting and entrapping that radiation before it enters such interior areas. The entrapped heat energy in such incident solar heat radiation may then be discarded or made available for use in heating those areas of the building receiving insufficient solar heat radiation or for use in other ways. Further, the present invention is accomplished in a manner compatible with current wall and window architectural design and with current heating, ventilating, and air conditioning design. Hence, the present invention reduces the cooling burden on those areas of the building receiving excess incident solar heat, reduces the heating burden on those areas of the building receiving insufficient incident solar heat, and achieves both these results with only minor additions to the building's system of ventilating duct work.
Although the present invention is of a general nature relating to wall units, it is of particular utility when utilized in a wall unit transparent or semi-transparent to electromagnetic waves in the visible spectrum and designed to function as a window. The preferred embodiment disclosed herein will be described as a window unit, but the invention is not restricted to use in the window format.
These and other objects, advantages and features of this invention will hereinafter appear, and for purposes of illustration, but not of limitation, exemplary embodiments of the subject invention are shown in the appended drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a cross-sectional view of a wall unit constructed in accordance with the present invention.
FIG. 2 is a vertical cross-sectional view of the wall unit of FIG. 1 utilized as a window unit in a building.
FIG. 3 is a schematic plan view of the present invention utilized in conjunction with a heating, ventilating and cooling system of a building or buildings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 a wall unit 11 is illustrated. Wall unit 11 includes two panels 13 and 15 positioned substantially parallel to one another. While the panels 13 and 15 may be any appropriate wall panels, for this preferred embodiment they will be referred to as panes of glass utilized to provide a window unit for a building.
Panes 13 and 15 are secured in the substantially parallel position by a supporting structure C. Supporting structure C is any appropriate type of mounting arrangement, such as a window frame which encloses the edges of the area between window panes 13 and 15 to form a chamber 17. The window unit 11 thus constructed is utilized as part or all of the exterior wall of a building to separate the outside ambient atmosphere A from an adjacent interior area B.
The exterior wall panel 15 is designed to transmit solar radiation, which includes solar heat radiation (primarily electromagentic radiation in the infra-red spectrum), such as glass when a pane of a window unit. The exterior surface 19 of window pane 15 need not be specially treated. However, to increase the relative efficiency of the insulating properties of the invention (while suffering a decrease in the relative efficiency of the heat energy collecting properties of the invention), surface 19 could be designed to reflect solar heat radiation, for example, by the application of a thin film of chromium, gold, copper, alloy or other suitable metal. The interior surface 21 of pane 15 is designed to absorb solar heat radiation, for example, by the application of a thin film 22 (shown in exaggerated form for purposes of illustration) of a dark metallic oxide, such as chromic oxide (Cr 2 O 3 ) or cuprous oxide (Cu 2 O).
The interior wall panel 13 is designed not to transmit solar heat radiation. For example, it might be constructed of metal, wood or plastic. If the wall unit is to function as a window, wall panel 13 would be a pane of glass. The exterior surface 23 of window pane 13 is designed to reflect, to absorb or partially to reflect and partially to absorb solar heat radiation, for example, by the application of a thin film 24 (shown in exaggerated form for purposes of illustration) using materials as described in the preceeding paragraph. The interior surface 25 of window pane 13 need not be specially treated. To increase the relative efficiency of the invention as an insulator, surface 25 may be designed to reflect heat radiation, for example, by the application of thin films such as described in the preceeding paragraph.
If the wall unit 11 is to function as a window, panels 13 and 15, surfaces 19, 21, 23 and 25 and films 22 and 24 must be designed to transmit at least some electromagnetic radiation in the visible spectrum. The use of glass panes for panels 13 and 15 and the use of films of metals and metal oxides as described above in thicknesses of a few hundred angstroms will permit transmission of substantial portions of the incident visible light. The materials to be utilized in such films may be varied or used in differing combinations to achieve desirable architectual effects by passing more or less visible light of various colors.
When solar heat radiation is incident on window unit 11 so constructed, it passes through pane 15 and film 22. Much of the heat radiation is absorbed by film 22, but some passes through chamber 17 and is incident on surface 23. Some of the heat radiation incident on surface 23, is absorbed by film 24, some is reflected, and some small amount is transmitted through film 24 and surface 23 into pane 13.
This small amount of heat radiation will pass through window pane 13 and into the adjacent interior area B. If panel 13 is constructed of wood, metal, plastic or a similar material not transparent to heat radiation, this small amount of heat radiation will be absorbed by panel 13 and some even smaller amount will be transmitted by conduction into the adjacent interior area B.
The heat radiation reflected from film 24 on surface 23 passes back through chamber 17 and impinges upon surface 21. Most of this heat radiation is absorbed by film 22, but some small amount passes on out through window pane 15 and is lost in the ambient atmosphere.
The radiant energy absorbed by films 22 and 24 on surfaces 21 and 23 increases the temperature at such surfaces and the heat is transmitted to the air in chamber 17 by conduction. Passages 27 are provided in supporting structure C so that unheated air from the outside atmosphere A or the adjacent interior area B may be drawn into chamber 17 and so that the heated air in chamber 17 may be withdrawn and discarded or its increased heat energy content utilized elsewhere.
Withdrawing the heated air from chamber 17 tends to cool the surfaces 21 and 23 and hence decreases the rate at which heat is conducted from film 24 on surface 23 through pane 13 and into the adjacent interior area B. Hence, it further increases the efficiency of the invention by insulating the adjacent interior area B from excess heat build-up resulting from the incident solar energy.
FIG. 2 shows a typical installation of window unit 11 in a building. Supporting structure C is located in an exterior wall G of the building between a floor D and a floor E of the building. As described in connection with FIG. 1, the window unit 11 separates the outside ambient atmosphere A from the adjacent interior area B.
A duct 29 is provided to insert unheated air into chamber 17 from near the floor D of adjacent interior area B. A duct 31 is provided to withdraw the heated air from chamber 17 and transport it through the building ductwork 33 between the top of a ceiling F and the bottom of the floor E above the adjacent interior area B.
Arrows 35, 37 and 39 represent solar energy striking window pane 15. Arrow 35 represents solar heat energy incident on pane 15 which is transmitted through pane 15, absorbed by film 22 on surface 21, and the conducted into the air in chamber 17. Arrow 37 represents solar heat energy incident on pane 15 which is transmitted through pane 15, surface 21, film 22 and chamber 17; absorbed by film 24 on surface 23 and then conducted into the air in chamber 17. Arrow 39 represents solar heat energy incident on pane 15 which is transmitted through pane 15, film 22 on surface 21, and chamber 17; reflected by film 24 on surface 23; transmitted back through chamber 17; absorbed by film 22 on surface 21; and then conducted into the air in chamber 17. Of course, in practice a certain amount of solar heat radiation will pass through window pane 13 into the adjacent area B, as a result of the necessity of insuring that as much of the solar visual light radiation be transmitted to the area B. However, by proper choice of the films 22 and 24, visual light transmission may be maximized and heat radiation minimized.
Unheated air entering chamber 17 from the adjacent interior area B through duct 29 is heated in chamber 17 and transported through ducts 31 and 33 to another area where its increased heat energy may be used in space heating, water heating, or in other manners. If it is just desired to discard this heat energy, another duct, shown schematically at 41, may be provided to appropriately vent the heated air to atmosphere A. Of course, the duct 33 would have to be closed when the heated air is passed to duct 41, and vice versa, so appropriate control panels are schematically illustrated at 43 and 45.
FIG. 3 is a schematic plan of a typical utilization of the present invention in a building heating, ventilating, and cooling system of conventional design. Spaces 45 and 47 are different areas of a building (or of different buildings). A heating and cooling unit 49 supplies conditioned air (heated or cooled) through duct 51 to area 45. A similar heating and cooling unit 53 supplies conditioned air through duct 55 to area 47.
A ceiling light fixture 57 is shown in area 45. A window unit 11 constructed in accordance with the present invention is installed in an exterior wall of each of the areas 45 and 47. A fan 59 extracts heated air from light fixture 57 through duct 61. Duct 61 has been extended and connected to the window unit 11 of the present invention to withdraw heated air from the chamber 17 therein.
A similar ceiling light fixture 63 is provided in area 47. A fan 65 extracts heated air from light fixture 63 through a duct 67. Duct 67 has been extended and connected to the window unit 11 of the present invention in area 47 to withdraw heated air from the chamber 17 therein.
A duct 69 is provided to permit fan 65 to exhaust heated air to the outside, and a similar duct 71, through which fan 59 may exhaust heated air to the outside, is provided. A duct 73, through which unit 49 may draw fresh air from the outside, extends from unit 49. A similar duct 75 extends from unit 53 to draw fresh air from the outside.
A series of dampers are schematically shown at 77, 79, 81, 83, 85, 87, 89 and 91. These dampers are utilized to control the flow of air through the various ducts of the system. Additional dampers may be employed (e.g., in the extension of ducts 61 and 67) if required.
During the typical summer months, the heat gain from the lights and exterior walls places a burden on the cooling capacities of units 49 and 53. Dampers 81 and 89 are then closed and dampers 83 and 91 are opened, so that the fans 59 and 65 may extract the heated air from light fixtures 57 and 63 and exhaust it outside through ducts 69 and 71, where its heat is dissipated in the atmosphere, or where its heat energy may be extracted from some useful purpose. Since ducts 61 and 67 have been extended and connected to window units 11, the heat energy which window units 11 prevented from entering areas 45 and 47 is also exhausted (or utilized elsewhere) and the cooling burden on units 49 and 53 is further reduced.
In the typical winter months when the sun, lying low in the sky, shines most strongly on the vertical walls with southern exposures and not at all on the vertical walls with northern exposures, without the present invention there would be a disproportionate solar heat gain in an area having a southern exposure over that in an area having a northern exposure. If the atmosphere is clear, this can even lead to a situation where one unit (e.g., 49) supplies cooled air to area 45, while another unit (e.g., 53) supplies heated air to area 47.
With the present invention, this waste of energy resources is easily eliminated as follows. Dampers 83, 85 and 91 are closed. Dampers 79, 81 and 89 are opened. Assuming that area 45 has a southern exposure and area 47 has a northern exposure, the heat trapped by window unit 11 in area 45, with its southern exposure, is prevented from overheating area 45 and the heated air in that unit 11 is forced by fan 59 to join the heated air from fixtures 57 and 63. This heated air enters unit 53, where it is used to preheat the cold, fresh air from duct 75 before unit 53 heats such air and sends it through duct 55 to heat the cool interior area 47.
It should be understood that various modifications, changes and variations may be made in the arrangements, operations and details of construction of the elements disclosed herein without departing from the spirit and scope of this invention.
|
A more even distribution of heat in a building is achieved by preventing incident solar radiation from unequally heating the building. The heat component of incident solar radiation is entrapped and conveyed to other portions of the building requiring heat. In warm weather the entrapped heat may be vented to the atmosphere. One form of the invention involves the use of two spaced panes of glass for a window, with the heat component of the incident solar radiation being entrapped in the chamber between the panes and then conveyed either to other parts of the building or to the atmosphere.
| 8
|
FIELD OF THE INVENTION
[0001] The present invention relates to a method of making a lifter bar and more particularly to a method as defined in the preamble of independent claim 1 .The present invention also relates to a refurbished lifter bar as defined in the preamble of independent claim 12 . The present invention also relates to a mould for producing a refurbished lifter bar as defined in the preamble of independent claim 15 .
BACKGROUND OF THE INVENTION
[0002] Grinding mills are used to process hard solid material such that the solid material is crushed into smaller pieces. The grinding mills comprise a rotatable drum having a cylindrical wall and the interior of the drum is used for processing the solid material. The interior wall of the drum is equipped with lifter bars and as the drum rotates the lifter bars lift up the solid material along the inside wall of the drum to a point where gravity causes the solid material to fall down inside the drum and by falling down the solid material is crushed.
[0003] The lifter bars' function is to assist in lifting the solid material being processed up the side of the drum as it rotates. The lifter bars are typically made of rubber or elastomer so during time the lifter bars become worn and they have to be replaced by new ones. The lifter bars become worn from the wearing surface and especially from the leading face of the lifter bar, the leading face being the upstream side of the lifter bar which is at least partially facing the predetermined direction. The extent of the leading face of the lifter bar depends on the form of the lifter bar but it is the part of the lifter bar which contacts the solid material when the solid material is lifted up to the point from which it falls down. When the leading face of the lifting bar wears over time because of the continuous impact of the solid material the lifting effect becomes less and the efficiency of the grinding mill diminishes. The lifter bars may have to be replaced with new ones about every six months.
[0004] The following discussion of the prior art is intended to present the invention in an appropriate technical context and allow its significance to be properly appreciated. Unless clearly indicated to the contrary, however, reference to any prior art in the specification should not be construed as an admission that such art is widely known or forms part of the common knowledge in the field.
[0005] US 2012/0181364 A1 discloses a mill liner assembly to be mounted on a shell of a grinding mill. The mill liner assembly includes shell plates and lifter bars having a mounting portion. The publication discloses a problem that while the lifter bars and shell plates become worn they have to be replaced quickly and separately and for this purpose a new way of mounting of said assembly is developed.
[0006] One of the disadvantages associated with the above arrangement is that when the lifter bars become worn they have to be replaced with new ones and the old lifter bars are waste that has to be disposed. The replacement of lifter bars with new ones is a necessary but expensive part of maintenance of a grinding mill and the disposal of the worn lifter bars add costs on top of that. There is also an environmental aspect relating to the used lifter bars because over time the amount of waste material becomes quite considerable.
BRIEF DESCRIPTION OF THE INVENTION
[0007] An object of the present invention is thus to provide a method for producing a lifter bar so as to alleviate the above disadvantages, that is to save in costs and in waste material. The objects of the invention are achieved by a method of producing a lifter bar and a refurbished lifter bar which both are characterized by what is stated in the independent claims. The object of the invention is also achieved by a mould for producing a refurbished lifter bar. The preferred embodiments of the invention are disclosed in the dependent claims.
[0008] The invention is based on the idea of reusing the existing lifter bars and refurbishing them so as to minimize the waste material that is caused by the wear and tear of the lifter bars over time. Another aspect of the invention is that a lifter bar having a form that is not preferable to a certain grinding mill or a certain grinding process can be change with the method according to the invention.
[0009] A method of making a lifter bar which is used in a grinding mill according to the invention comprises the following steps: providing a mould having an interior space that conforms at least partially to a predetermined form of the lifter bar used in a grinding mill, joining the mould and a base member of the lifter bar together to form a cavity defined by the base member and the interior space and filling the cavity with polymer and allowing the polymer to attach to the base member to construct a lifter bar having the predetermined form. The lifter bar for use in a grinding mill and/or the lifter bar that is that is already used in a grinding mill have a predetermined form and comprise a base member.
[0010] So the base member may be a worn lifter bar or a part of the worn lifter bar or a lifter bar having a different form than the predetermined form such that a new wearing surface is moulded to the lifter bar to form a predetermined form to the lifter bar. So that the invention relates to a method of refurbishing a worn lifter bar which said lifter bar is being used in a grinding mill. The method comprises the step of providing a mould for moulding a new wearing surface to the lifter bar, arranging the mould and the lifter bar together such that an empty space between the lifter bar and the mould is formed, i.e. a cavity is formed by the mould and the lifter bar comprising a base member, said empty space conforming to a worn-away portion of an unused lifter bar. The method also comprises a step of filling the empty space in the mould, i.e. the interior space of the mould with a polymer such that the polymer is attached to the lifter bar to form a bond with the lifter bar for forming a refurbished lifter bar having a new wearing surface. In other words an embodiment of invention is the method of providing a refurbished lifter bar for use in a grinding mill comprising the steps of providing a mould for moulding the refurbished lifter bar which the mould having a cavity conforming to at least a portion of an unused lifter bar and filling the cavity of the mould with a polymer to form a refurbished lifter bar having a new wearing surface. A lifter bar to be refurbished has a first form, which the first form is either a form that results from the lifter bar being worn or a form that is a different form from what is wanted or preferred when being used in a grinding mill. So the method according to the invention is providing a mould for moulding a second form to the lifter bar, the second form being the predetermined form of the lifter bar. The mould can be arranged such that the mould and the lifter bar are arranged together such that at least part of the lifter bar is inside the mould and an empty space, i.e. a cavity, is formed between the lifter bar and the mould. After the step of arranging the mould and the lifter bar together a step of filling the empty space in the mould with polymer is performed. The empty space is filled with polymer such that polymer is attached to the lifter bar for forming a lifter bar having the second form, i.e. the predetermined form.
[0011] Another embodiment of the invention is that the base member may be a rail or a profile, preferably in aluminium, that connects the lifter bar to the grinding mill, especially to the cylindrical wall of the grinding mill, and the predetermined form of the lifter bar is moulded in connection with the base member such that a lifter bar having a predetermined form is achieved.
[0012] The method of making or refurbishing a lifter bar may further comprise an additional step of heat treating the moulded lifter bar, i.e. the lifter bar comprising a used lifter bar having a worn wearing surface attached with a moulded new wearing surface or the lifter bar comprising a base member such that the lifter bar is not worn but has another shape than the predetermined form and is attached with the moulded part to construct the lifter bar having the predetermined form. The mould for moulding a new wearing surface to the used lifter bar having a worn wearing surface is preferably made according to the unused lifter bar so that the new wearing surface of the refurbished lifter bar will be similar to an original one. The mould can be made of sheet metal because of the size of the new wearing surface that is moulded. This sheet metal made mould is less expensive compared to the casting moulds of complete lifter bars because the casting mould of complete lifter bars have to be made heavier and more robust. The at least part of the outer surface of the lifter bar is preferably prepared such that the contact surface for attaching a new wearing surface is accomplished by roughening at least part of the surface of the lifter bar and/or by treating the at least part of the surface of the lifter bar with some chemical. The mould is preferably attached to the used lifter bar such that at least part of the used lifter bar and especially the part of the used lifter bar having a worn wearing surface is arranged inside the mould. The mould can be attached to the used lifter bar for example by screws. When the mould is attached to the used lifter bar polymer is fed to fill the empty space in the mould such that said polymer adheres to the contact surface of the used lifter bar which is roughened and/or chemically treated or in some other way prepared to form a suitable contact area such that the moulded polymer and the wearing surface of the used lifter bar form a tight connection.
[0013] The step of filling the cavity with polymer and allowing it to attach to the lifter bar forms a refurbished lifter bar having a new wearing surface. The new wearing surface forms together with the base member the lifter bar having the predetermined form.
[0014] The step of treating at least part of an outer surface of the base member, i.e. a worn lifter bar or a part of the worn lifter bar or a lifter bar having a different form than the predetermined form or a rail or a profile, makes a contact surface to the base member for attaching the polymer to the lifter bar comprising the base member. The step of treating at least part of the outer surface of the base member comprises at least one of the following steps: drying the outer surface, heating the outer surface, roughening the outer surface and/or treating the outer surface with chemical. This way the outer surface of the base member may have more adhesive capacity the polymer to attach it.
[0015] The method may further comprise a step of applying a heat treatment to the lifter bar having the predetermined form. In other words the lifter bar having the predetermined form after moulding is further heat treated to improve the properties accomplished by the moulding. The polymer is preferably polyurethane and it may comprise additives, such as metal particles, ceramics or carbide.
[0016] The step of providing a mould comprises a step of forming the mould from sheet metal using an unused lifter bar as a model for the mould so that the predetermined form of the lifter bar is achieved. The step of providing a mould may also comprise a step of attaching a separate reinforced surface or separate reinforced surfaces inside the mould such that the reinforced surface is to be arranged to the surface of the lifter bar having the predetermined form. In other words the reinforced surface or surfaces are arranged inside the mould such that when the polymer is fed to the mould the reinforced surface or surfaces remain in contact with the mould such that in the moulded lifter bar having the predetermined form the reinforced surface or surfaces are on the surface of the lifter bar.
[0017] A refurbished lifter bar according to the invention comprises a lifter bar having a worn wearing surface and a new wearing surface that is attached to the worn lifter bar through moulding. The new wearing surface comprises polymer such as polyurethane. In other words the refurbished lifter bar to be used in a grinding mill comprises a worn lifter bar and a new wearing surface, said worn lifter bar and said new wearing surface being attached to each other by moulding. The refurbished lifter bar comprises a contact surface through which the worn lifter bar and the new wearing surface are bonded together to form a refurbished lifter bar. The refurbished lifter bar is moulded such that a predetermined form of the lifter bar is achieved through moulding with a mould having the predetermined form, the predetermined form being a form of an the lifter bar before it is used, in other words before it has worn.
[0018] The invention also relates to a mould for producing a refurbished lifter bar for use in a grinding mill, said mould comprising a plurality of walls for connecting the mould to a worn lifter bar and for defining a cavity in co-operation with an abraded surface of the worn lifter bar, said cavity conforming to a worn-away portion of an unused lifter bar, and an opening for admitting a polymer into said cavity. So the plurality of walls connect the mould to a base member of the lifter bar, said base member of the lifter bar being either a worn lifter bar or a part of the worn lifter bar or even a lifter bar having a different form than the predetermined form such that a new wearing surface is moulded to the lifter bar to form a predetermined form to the lifter bar. The base member may also just be a rail or a profile which connects the lifter bar to the wall of the grinding mill. The plurality of walls of the mould defines an interior space and further together with the base member of the lifter bar a cavity. The interior space conforms at least partially to a predetermined form of the refurbished lifter bar, and an opening for feeding polymer into said interior space. The mould is preferably made of sheet metal.
[0019] An advantage of the method and the refurbished lifter bar of the invention is that the need of new material for a new lifter bar is minimized because about half of the needed material can be taken from the used lifter bar and a profile for connecting the lifter bar to the grinding mill may already be arranged on the bottom of the used lifter bar which can be reused as well.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] In the following the invention will be described in greater detail by means of preferred embodiments with reference to the accompanying drawings, in which
[0021] FIG. 1 shows a longitudinal cross-section of a grinding mill;
[0022] FIG. 2 is a view in cross-section of the grinding mill shown in FIG. 1 taken at line A-A;
[0023] FIG. 3 shows a typical wear profile of a lifter bar;
[0024] FIG. 4 shows a mould for moulding a new wearing surface to a worn lifter bar together with said worn lifter bar;
[0025] FIG. 5 shows the mould and the worn lifter bar as shown in FIG. 4 such that the mould is filled with polymer; and
[0026] FIG. 6 shows a mould with a reinforced surface together with the worn lifter bar.
DETAILED DESCRIPTION OF THE INVENTION
[0027] FIG. 1 shows a longitudinal cross-section of a grinding mill 2 having an inner cylindrical wall which comprises lifter bars 1 a , 1 b , 1 c attached to the cylindrical wall. Shell plates, wear plates or similar elements are preferably attached to the shell of the grinding mill in between said lifter bars 1 a , 1 b , 1 c such that the lifter bars 1 a , 1 b , 1 c and shell plates together protect the inner surface of the grinding mill 2 and wear is subjected to them. The grinding mill 2 rotates about its central axis in the direction indicated by arrow B in FIG. 2 .
[0028] FIG. 2 shows a view in cross-section of the grinding mill 2 shown in FIG. 1 taken at line A-A. The grinding mill 2 rotates in the direction indicated by arrow B. The lifter bars 1 a , 1 b , 1 c are arranged such that they are around the cylindrical wall of the grinding mill 2 . Lifter bar 1 a , 1 b , 1 c comprises a rail, a profile or an insert element on the bottom of the lifter bar 1 a , 1 b , 1 c . The lifter bar 1 a , 1 b , 1 c is secured to the shell of the grinding mill 2 with fasteners such as bolts extending from the outer surface of the grinding mill 2 to the bottom of the lifter bar 1 a , 1 b , 1 c securing the lifter bar 1 a , 1 b , 1 c to the interior wall of the grinding mill 2 . The rail, the profile or the insert element alone can be a base member of the lifter bar such that a predetermined form of the lifter bar 1 a , 1 b , 1 c is moulded over it or the rail, the profile or the insert element can form a part of the base member such that a worn lifter bar 1 b , a part of the worn lifter bar 1 b or a lifter bar 1 a having a different form than the predetermined form forms another part of the base member. The lifter bars 1 a , 1 b , 1 c are typically made of rubber or elastomer and attached to the inner wall of the grinding mill 2 by bolt connection. Over time the upper and/or side surface of the lifter bar 1 a , 1 b , 1 c wears and the wearing surface becomes uneven and the solid material is not lifted upwards inside the grinding mill 2 as effectively as with the new lifter bars 1 a , 1 c.
[0029] FIG. 3 shows a typical wear profile of a worn lifter bar 1 b . The outer surface 5 of the lifter bar 1 a , 1 b , 1 c and especially the upper surface of the lifter bar 1 a , 1 b , 1 c wears over time because of the impacts of the solid material that it carries and/or lifts upwards in the grinding mill 2 . The upper surface comprises at least part of the top surface of the lifter bar as well as at least part of the side surface of the lifter bar which is toward the moving direction of the grinding mill 2 . The outer surface 5 that wears over time is called wearing surface. As the wearing surface wears the lifting effect becomes less and the grinding mill 2 becomes ineffective and the lifter bar 1 a , 1 b , 1 c has to be changed and replaced by a new lifter bar.
[0030] FIG. 4 shows a mould 3 for moulding a new wearing surface 8 to a worn lifter bar 1 b and said worn lifter bar 1 b . The mould 3 is preferably made of sheet metal by bowing such that a new unused lifter bar 1 a is used as a model for the mould. The mould 3 can be made according to new dimensions without having an existing lifter bar 1 a as a model. The mould comprises plurality of walls for connecting the mould 3 to the base member of the lifter bar 1 a , 1 b , which said plurality of walls define an interior space 4 a . The mould also comprises an opening (not shown in figure) for feeding polymer into said interior space 4 a . When the lifter bar 1 a has been in use for example six months the wearing surface of the lifter bar 1 a has worn such that the lifter bar 1 a , 1 b , 1 c has to be changed for a new one. The new lifter bar 1 a can then be made by using the mould 3 for moulding a new wearing surface to the used lifter bar 1 b . The aluminium profile or rail of the used lifter bar 1 b from which the lifter bar is attached to the shell of the grinding mill 2 can be used again as well as the bottom part of the worn lifter bar 1 b and only a new wearing surface 8 is moulded. The worn lifter bar 1 b is first treated such that the new wearing surface 8 to be moulded will form a bond with the worn lifter bar 1 b . The worn wearing surface is preferably heat treated such there isn't any moisture in the worn wearing surface of the worn lifter bar 1 b . The worn wearing surface may also be roughened and/or chemically treated so that the chemical bond between the worn wearing surface and the new wearing surface 8 will be created. This bond is created in the contact surface 6 between the worn lifter bar 1 b and the new wearing surface 8 . The mould 3 is then preferably attached in a conventional way to the used worn lifter bar 1 b such that at least part of the used lifter bar 1 b is inside the mould 3 and such that the mould 3 and the base member of the lifter bar form a cavity 4 b for the new wearing surface 8 to be moulded. The interior space 4 a conforms at least partially to a predetermined form of the refurbished lifter bar 1 c . Next step is to fill the cavity 4 b in the mould 3 with polymer such as polyurethane to form a new wearing surface 8 to the lifter bar 1 b . This is shown in FIG. 5 . Polymer can comprise ceramics and/or carbides and/or other additives to change the properties of the polymer. The polymer can also comprise metal particles. When the polymer is hardened the lifter bar having a new wearing surface 8 may be heat treated.
[0031] FIG. 6 shows a mould 3 with a reinforced surface 7 for moulding a new wearing surface 4 to a worn lifter bar 1 and said worn lifter bar 1 . The mould 3 can additionally comprise a reinforced surface 7 to be moulded on the wearing surface 5 of the lifter bar 1 . The reinforced surface 7 is for example metal piece or some other element that stays in shape longer and doesn't wear that easily. The reinforced surface 7 may be attached to the mould 3 with a screw connection such that after the polymer is hardened and the mould 3 and the screw connection is be separated from it, the reinforced surface 7 is on the surface of the new wearing surface 4 . The reinforced surface 7 may comprise fin or fins which protrude from the reinforced surface 7 inside to the wearing surface 4 .
[0032] The mould for producing a refurbished lifter bar for use in a grinding mill as shown in FIGS. 4 to 6 comprise a plurality of walls for connecting the mould to a worn lifter bar and for defining a cavity in co-operation with an abraded surface of the worn lifter bar, said cavity conforming to a worn-away portion of an unused lifter bar, and an opening (not shown in the figures) for admitting a polymer into said cavity.
[0033] It will be obvious to a person skilled in the art that, as the technology advances, the inventive concept can be implemented in various ways. The invention and its embodiments are not limited to the examples described above but may vary within the scope of the claims.
|
The invention relates to a method of making a lifter bar ( 1 a, 1 c ) for use in a grinding mill ( 2 ), to a refurbished lifter bar ( 1 b ) and to a mould ( 3 ) for producing the refurbished lifter bar ( 1 c ). The lifter bar ( 1 a, 1 c ) has a predetermined form and comprises a base member. The method comprises the steps of providing a mould ( 3 ) having an interior space ( 4 a ) that conforms at least partially to the predetermined form; joining the mould ( 3 ) and the base member together to form a cavity ( 4 b ) defined by the base member and the interior space ( 4 a ); and filling the cavity ( 4 b ) with polymer and allowing the polymer to attach to the base member to construct a lifter bar ( 1 a ) having the predetermined form.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATIONS: This application claims the benefit of Provisional Patent Application Ser. No. 60/428373 filed Nov. 22, 2000.
FEDERALLY SPONSORED RESEARCH
[0001] Not Applicable
SEQUENCE LISTING
[0002] Not Applicable
BACKGROUND
[0003] 1. Field of Invention
[0004] This invention advances previous flexural pivot designs by simplifying the manufacture, assembly, and integration into a device.
[0005] 2. Description of Prior Art
[0006] A typical pivot consists of a combination of bearings which provide both radial and axial stiffness, while allowing a low resistance to rotation about an axis. Radial and thrust journal bearings can accomplish this with simple components, but the continual or intermittent sliding contact generates significant resistance to rotation, and material wear limits the service life. Radial and thrust roller bearings can provide the axial and radial stiffness under heavy loads, but require precision roller elements, raceway structures, and lubrication methods. A pre-loaded set of two ball bearings can provide axial and radial stiffness for light loads, but again require precision balls, raceway structures, and lubrication.
[0007] Journal, ball, and roller bearings allow a simple co-axial configuration of the fixed and rotational portions. A shaft is attached to the inner diameter of the bearings and the outer diameter of the bearings are attached to a sleeve or housing. The shaft can rotate or the sleeve can rotate. With a rotating sleeve, the shaft can be fixed at one end (cantilevered) or both ends (doubly-supported). Fixing the shaft at both ends (doubly-supported) offers a significantly more rigid structure over a cantilevered attachment, and is required in many applications. The co-axial placement of the shaft and sleeve allow a straight-forward centering of the rotational mass between the axial spacing of the bearings. The centering of the rotational mass between the radial bearing elements is usually desired to uniformly distribute radial loads.
[0008] However, journal, ball, and roller bearings have several disadvantages. They require oil or grease lubrication and the associated oil replenishment or grease seals for ensuring a long service life in harsh environments. Lubricants can migrate, decompose, or give off gasses over their working life, and degrade the performance of the bearing. Migration or off-gassing of lubricants may also contaminate surrounding parts of the device in which the bearing is mounted. These contaminants can cause failure of sensitive components such as those found on satellites or inside magnetic data storage drives. In satellites, the vacuum of space will draw-out chemical compounds from the lubricants, which can foul sensors. In magnetic data storage drives, off-gassed chemical compounds can foul critical air bearing surfaces which are designed to operate at air gaps of less than a millionth of an inch. Journal, ball, and roller bearings are also sensitive to contamination; if particles are introduced between the moving surfaces, an increased force is required to roll over the particle. Hard particles will damage the bearing surfaces and hasten bearing wear. Given the sliding wear or rolling resistance, these bearings exhibit a hysteresis-effect; frictional forces oppose motion in both rotational directions. Additionally, the properties of lubricants vary with temperature; at low temperatures an increased force is required to displace lubricants. Further, lubricants are typically non-conductive, which electrically isolates the rotational portion from the fixed portion, allowing a generally un-desirable voltage potential to develop between the two portions.
[0009] Advantages of Flexural Pivots:
[0010] For applications requiring rotational motion within a limited angular range, +/−30 degrees for example, Lucas produces and markets a line of flexural pivots as described in U.S. Pat. No. 3,811,665. FIG. 1 depicts a Lucas flexural pivot 10 . A pair of flexures 13 are attached to the inner diameter of a stationary member 11 . The flexures are also attached to the inner diameter of a rotational member 12 .
[0011] Flexural pivots such as the Lucas pivot provide many advantages over journal bearings, ball, or roller bearings. They require neither lubrication nor the associated seals and oil replenishment systems. Without the temperature-sensitive greases or oils, their performance varies little over a wide range of temperatures. They are not sensitive to contaminants. If fabricated out of metal components, the Lucas flexural pivot can provide a continuous, low-resistance electrical path to eliminate voltage potentials between the moving and stationary portions of the pivot. With no rolling or sliding interactions, the life of a flexural pivot can be many times that of a journal, ball, or roller bearing pivot. With no friction forces to oppose rotational motion regardless of rotational direction, there is no hysteresis-effect exhibited by a flexural pivot.
[0012] Further, the flexural members of a flexural pivot provide a restoring force to the pivot, such that it will return to a repeatable angular position when external forces are removed. This is beneficial during assembly to control the relative positioning of the stationary and rotate-able portions. It is also beneficial to the application, when it is desired for the rotate-able portion to return to a pre-determined rotational location.
[0013] While the Lucas flexural pivot solved many problems, the design limited its applications. The rotating and fixed housings are both tubular forms, which allow for limited attachment methods. Attachment is necessarily made on the outer diameter of both the fixed and rotating housings, which are the same size and closely spaced along the axis of the pivot. Hence, the mating parts must be closely placed along the axis of the pivot, but not at the same axial location. The simplest of the Lucas pivots offers two separate tubular forms, one fixed and one rotational. The fixed portion is held at one end and the rotational portion is at the other end of the pivot axis. The fixed portion cannot be held at both ends of the pivot's axis. Hence, the rotational portion must be cantilevered. This cantilevered attachment offers significantly lower stiffness than a doubly-attached shaft, as journal, ball, and roller bearing pivots allow.
[0014] Further, the rotating and fixed housings of the Lucas pivot are complex forms, generally requiring wire electron-discharge machining, are well as conventional lathe and milling machine operations. Assembly of the flexures into the inner diameters of these tubular housings is difficult, especially for small pivots and small tubular diameters.
[0015] Objects and Advantages:
[0016] The current invention simplifies the fabrication of flexural pivot components, uncomplicates the assembly, improves upon methods of attachment, and allows scaling to smaller sizes. These features allow integration of this flexural pivot into a wider range of applications. These applications can now take advantage of the benefits of flexural pivots in applications where journal, ball, or roller bearing pivots have been the only choice.
SUMMARY OF INVENTION
[0017] The present invention offers a simplified flexural pivot construction and allows improved attachment methods for the fixed and rotational portions. A set of flexural members are preloaded in opposite directions to provide a stable rotational axis. These flexural members can be formed as a unitary set, as compared to the two independent flexures of the Lucas pivot. Affixing features on the stationary and rotate-able portions are simplified to external surfaces, as compared to complex internal features of the tubular forms in the Lucas pivot. Assembly is thereby simplified to external operations, as compared to the intermeshing components assembled into the tubular forms for the Lucas pivot. Fabrication of the stationary and rotate-able members can be simple metal stampings, as compared to the milled and electron-discharge machining required of the Lucas pivot components.
[0018] Integration into an application is greatly simplified. Since the stationary and rotational portions are placed on either side of the rotational axis, the rotational load can be centered between the flexural elements, along the axis of rotation. The stationary portion can be affixed at both ends (doubly-supported), providing maximum mechanical stiffness. Further, with simple attachment features, the rotate-able and stationary portions can easily be integrated into other components of the application. The stationary member can easily be integrated into the application chassis. The rotate-able portion can easily be integrated into the rotational component of the application.
[0019] All of these simplifications are accomplished, while maintaining the advantages of a flexural pivot: the absence of a hysteresis-effect, lubrication requirement, tolerance to contaminants, stable performance over temperature, continuous low-electrical resistance, long life, and a restorative force to maintain a zero-load angular position.
BRIEF DESCRIPTION OF DRAWINGS:
[0020] [0020]FIG. 1 is an isometric view of the prior art Lucas flexural pivot.
[0021] [0021]FIG. 2 is an isometric view of the current invention with a mounting flange parallel to the axis of rotation.
[0022] [0022]FIG. 3 shows a top or axial view of the current invention, showing centers of curvature.
[0023] [0023]FIG. 4 shows the current invention, but from the opposite viewing direction as FIG. 2.
[0024] [0024]FIG. 5 is an isometric view of an alternate configuration of the current invention with a mounting flange perpendicular to the axis of rotation.
[0025] [0025]FIG. 6 shows the alternate configuration, but from the opposite viewing direction as FIG. 5.
REFERENCE NUMERALS
[0026] [0026] 10 Lucas pivot (prior art)
[0027] [0027] 11 Stationary member (prior art)
[0028] [0028] 12 Rotational member (prior art)
[0029] [0029] 13 Flexures (prior art)
[0030] [0030] 100 Stationary post
[0031] [0031] 101 Backside stationary post surface
[0032] [0032] 102 Frontside stationary post surface
[0033] [0033] 103 Spot welds
[0034] [0034] 104 Mounting holes
[0035] [0035] 200 Flexure system
[0036] [0036] 201 Upper backside flexure
[0037] [0037] 202 Upper frontside flexure
[0038] [0038] 203 Lower frontside flexure
[0039] [0039] 204 Lower backside flexure
[0040] [0040] 300 Movable post
[0041] [0041] 301 Movable post surface
[0042] [0042] 303 Spot welds
[0043] [0043] 304 Mounting holes
[0044] [0044] 400 Axis of rotation
[0045] [0045] 401 Angular direction (clock-wise)
[0046] [0046] 402 Angular direction (counter clock-wise)
[0047] [0047] 403 Axial direction
[0048] [0048] 405 Lateral direction
[0049] [0049] 406 Roll direction
[0050] [0050] 407 Pitch direction
[0051] [0051] 411 Approximate backside center of curvature
[0052] [0052] 412 Approximate frontside center of curvature
[0053] [0053] 500 Movable post
[0054] [0054] 504 Axial mounting holes
DETAILED DESCRIPTION
[0055] Description—Preferred Embodiment:
[0056] The preferred embodiment of the current invention is depicted in FIG. 2. A flexure system 200 is comprised of an upper backside flexure 201 , a upper frontside flexure 202 , a lower frontside flexure 203 , and a lower backside flexure 204 . The flexure system 200 is affixed between a stationary post 100 and a movable post 300 . The stationary post 100 has two surfaces onto which the flexure system 200 is affixed: a backside stationary post surface 101 and a frontside stationary post surface 102 . The upper backside flexure 201 and the lower backside flexure 204 are affixed tangent to the backside post surface 101 . The upper frontside flexure 202 and the lower frontside flexure 203 are affixed tangent to the frontside stationary post surface 102 . The movable post 300 has a movable post surface 301 for affixing the flexure system 200 . The flexure system 200 is affixed tangent to the movable post surface 301 .
[0057] Before assembly, the flexure system 200 is flat. During assembly, the upper backside flexure 201 and lower backside flexure 204 are preloaded against the backside stationary post surface 101 . This preload causes the backside flexures 201 and 204 to deform and assume a shape with variable curvature. As shown in FIG. 3, the approximate backside center of curvature 411 of backside flexures 201 and 204 is spaced away from the stationary post 100 , in a direction normal to the backside stationary post surface 101 . Similarly, during assembly, the upper frontside flexure 202 and lower frontside flexure 203 are preloaded against the frontside stationary post surface 102 . The preload causes the frontside flexures 202 and 203 to deform and assume a shape with variable curvature. The approximate frontside center of curvature 412 of frontside flexures 202 and 203 is spaced away from the stationary post 100 , in a direction normal to the frontside stationary post surface 102 . After affixing, the preload force of the backside flexures 201 and 204 will equal in magnitude the preload force of the frontside flexures 202 and 203 . The preload forces are in opposite directions and hence, provide a stable resting position of the movable post 300 . Preload forces are chosen to ensure no yielding during the assembly, full limit rotation of the movable post 300 , or during static and dynamic loading.
[0058] As shown in FIG. 2, spot welds 103 , produced by such methods as resistance, laser, or ultrasonic, are the preferred method of affixing the flexure system 200 to the stationary post 100 . Spot welds 303 are the preferred method of affixing the flexure system 200 to the movable post 300 . Alternatively, adhesives, such as epoxies, glues, contact cement, and pressure-sensitive-adhesive, or mechanical fasteners, such as screws and spring-clips, could be used to affix the flexure system 200 to the stationary post 100 or to the movable mount 300 .
[0059] [0059]FIG. 2 depicts threaded mounting holes 104 , which are located at both ends of the stationary post 100 , allowing either doubly-supported attachment of the stationary post 100 for highest mechanical stiffness or cantilever attachment of the stationary post 100 for the simplest attachment. The movable post 300 has mounting holes 304 , aligned with the lateral direction 405 , which allow the attachment of the device to be rotated. FIG. 5 and FIG. 6 depict an alternate configuration of the movable post 500 with axial mounting holes 504 .
[0060] Preferably the flexure system 200 is fabricated out of a high tensile strength spring steel alloy which will exhibit a fatigue-limit stress, allowing a nearly infinite flexural cycle life. A steel stationary post 100 and steel movable post 300 can allow assembly with the preferred spot welds 103 and 303 .
[0061] Operation—Preferred Embodiment:
[0062] As shown in FIG. 3, the movable post 300 will rotate about an axis of rotation 400 , which is approximately parallel to the backside flexure center of curvature 411 and the frontside flexure center of curvature 412 . The axis of rotation 400 lies approximately on a line drawn between the backside flexure center of curvature 411 and the frontside flexure center of curvature 412 .
[0063] Rotation of the movable post 300 about the axis of rotation 400 in an angular direction 401 (clockwise from above) will generally reduce the radius of curvature of the backside flexures 201 and 204 , while increasing the radius of curvature of the frontside flexures 202 and 203 . Similarly, rotation of the movable post 300 about the axis 400 in a direction 402 (counter-clockwise from above) will generally increase the radius of curvature of the backside flexures 201 and 204 , while reducing the radius of curvature of the frontside flexures 202 and 203 . During rotation in either direction 401 or 402 , the axis of rotation 400 will move slightly.
[0064] As seen in FIG. 2, the tangency of the system of flexures 200 at the affixing movable post surface 301 provides a high mechanical stiffness in a longitudinal direction 404 , the axial direction 403 and the pitch direction 407 . The placement of the center of curvatures 411 and 412 on either side of the flexural system 200 provides a moderate mechanical stiffness in the lateral direction 405 . The spacing of the flexural system along the axial direction 400 provides a moderate stiffness in the roll direction 406 .
[0065] Description—Additional Embodiment:
[0066] While the preferred embodiment demonstrates one design of the current invention, many variations exist which may be chosen to optimize integration into different applications. For instance, the stationary post 100 of the preferred embodiment could be allowed to rotate, while the movable mount 300 could be fixed.
[0067] The backside flexures 201 and 204 could be located at the same positions along the axial direction as the frontside flexures 202 and 203 . This may necessitate that the flexure system is comprised of two parts, the backside flexures 201 and 204 could be combined into a single backside flexure and the frontside flexures 202 and 203 could be combined into a single frontside flexure. The backside flexures 201 and 204 could alternatively be affixed to a different surface of the movable post 300 , perhaps on the surface opposite the movable post surface 301 . As a further variation, a single part comprised of frontside flexures 202 and 203 could be affixed to a single part comprised of backside flexures 201 and 204 , which in-turn is affixed to the movable post surface 301 .
[0068] The number of backside flexures and frontside flexures is a design variable. A single backside flexure and single frontside flexure can be used for the simplest design. Multiple backside flexures and frontside flexures may be employed to meet certain design requirements. Multiple backside flexures and frontside flexures allows the rotate-able structure to be interleaved between flexures.
[0069] Backside flexure stiffness may be matched to the frontside flexure stiffness to provide a balanced mechanical rotational stiffness. Or the backside flexure stiffness may be unequal to frontside flexure stiffness to allow different restoring forces in the clockwise and counter-clockwise rotational directions.
[0070] The flexures of the preferred embodiment are shown as rectangular forms, but different geometries could be devised for optimizing mechanical stiffnesses, load stresses, pivot life, or variation of the axis of rotation 400 .
[0071] Given the simple features required on the stationary post 100 , it could be integrated into the chassis of the application, instead of fabricated as a separate part. Similarly, the movable post 300 could be integrated into the rotate-able component of the application, eliminating attachment features and attachment parts.
[0072] With the appropriate fabrication technology, two or more of three parts of the current invention, the flexure system 200 , stationary post 100 , and movable post 300 , could be fabricated as a single part. For example, all three parts could be molded in a plastic resin simultaneously.
[0073] Alternate materials can be used in the construction of the flexure system 200 , stationary post 100 , and movable post 300 . Many ferrous and non-ferrous alloys could be used for typical high-strength constructions. Plastic resins could be employed for simplified fabrication. Ceramics or semi-conductors could be used for MEMS (Micro Electro-Mechanical Systems) applications, where devices are fabricated and assembled using semiconductor processes.
[0074] Conclusion:
[0075] The present invention simplifies the construction of a flexural pivot. The simple shapes of the stationary and rotational members simplify the fabrication of these components. The flexures can be made from flat raw materials. The attachment of the flexures is made on flat or simply-curved, external features of the stationary and rotational members. With this simple construction, the present invention allows flexural pivots to be scaled to fit into extremely small devices. Further, the simplified methods of attachment to the stationary and rotational members allows integration of these components into other parts of a device.
|
An improved flexural pivot design simplifies the structure, fabrication, assembly, and integration into a device. A set of flexures 200 is affixed to two surfaces of a stationary member 100 and a single surface of a rotational member 300 . The set of flexures follow opposing centers of curvature 411 and 412 to provide a stable center of rotation 400 and allow repeatable limited-angle rotational motion.
| 5
|
BACKGROUND OF THE INVENTION
[0001] (1) Field of the Invention
[0002] The present invention generally relates to free weight exercise equipment, and in particular to an improved self-spotting bench press.
[0003] (2) Description of the Prior Art
[0004] The use of barbells, i.e., free weights, for conditioning and enhancement of the body's musculature is widely practiced by a variety of people. Often, these people prefer to weight lift in the privacy of their home, and when they feel like weight lifting.
[0005] Most often weight training is executed with a spotter, i.e., someone who can assist the lifter when they become fatigued or are having difficulty or are about to drop the weight. Style, communication, consistency and reaction time are all factors that vary when being spotted. These factors are major deterrents to using a human spotter. However, to weight lift without a spotter may be dangerous to the weight lifter. There is a significant danger of serious injury due to fatigue or improper technique unless a spotter is present to grab the barbell to prevent the barbell from dropping on the weight lifter. This danger exists in situations from private to professional weight lifting.
[0006] The danger of crushing ones chest performing the bench press exercise is a great concern. U.S. Pat. No. 6,746,379 to Brawner (2004) shows a device that lifts the weight from the lifters chest using multiple hydraulic cylinders. While this device removes the weight it does so at considerable cost since multiple cylinders and the hydraulic components to support them are required. U.S. Pat. No. 5,989,164 to Kullman et al (1999) shows a device that lifts the weight from the lifter's chest. While this device removes the weight from the lifter's chest, it utilizes cables attached to the lifting weight that increase setup time and can cause increased or decreased resistance due to contact with the barbell. U.S. Pat. No. 6,926,648 to Capizzo (2005) shows a device that also lifts the weight from the lifter's chest using a motor. This device lacks the ability to adjust the amount of assist, and rate of lift to each lifter's preference. U.S. Pat. No. 6,632,159 to Slattery (2003) describes a spotting machine that requires power to operate an electric motor that limits the machine to an area supplied with a power source.
[0000] All the machines heretofore known suffer from one or more of the following disadvantages:
[0007] a. Using multiple hydraulic cylinders. The lifting functionality of U.S. Pat. No. 6,746,379 to Brawner (2004) can be achieved without the use of multiple cylinders.
[0008] b. When using multiple hydraulic cylinders connected to the same pressure supply the cylinders don't always ascend at the same rate.
[0009] c. Exercisers regularly lean weight plates against the uprights of the exercise bench. Prior art using upright mounted hydraulic cylinders risk cylinder damage and hydraulic leaks due to this tendency.
[0010] d. Require lifting mechanism adjustment such that the lifting range of the mechanism is consistent with the lifting range of the exerciser.
[0011] e. Not being adjustable to suit each individual lifter's spotting preference, such as whether the spotting mechanism should assist the lifter by removing a fraction of the weight, remove all the weight, or not be used at all, and rate at which the spotting mechanism lifts the weight.
[0012] f. Not enabling the lifter to continue repetitions while being assisted by the spotting device and still having the ability to lock the spotting device preventing the weight from falling on or crushing the lifter.
[0013] g. Requiring electrical power.
[0014] h. Using barbell attachments such as cables that impede motion.
[0015] i. Using a greater quantity of material and being significantly larger and therefore heavier than traditional bench presses. This is more costly and discourages their use in private homes.
[0016] j. Not enabling the lifter to use the device with a human spotter.
SUMMARY OF THE INVENTION
[0017] The present invention relates to a safety device for supporting a weight bar (barbell) above an exerciser, and to an apparatus comprised of the safety device in combination with free-weight exercise equipment (such as, but not limited to a bench press or squat rack).
[0018] Generally, the apparatus is comprised of first and second placed elongated uprights positionable on opposite sides of the head or upper end of the weightlifting bench, or of the squatting area. Note that the weightlifting bench position within the plane of the uprights is the position from which the squat exercise is performed should the apparatus not be fitted with a bench. Each of the uprights includes a slotted, elongated outer housing, an elongated slide bar that is longitudinally aligned within the housing, and a sleeve slideable on the slide bar between raised and lowered positions. The slideable sleeve and slide bar can be replaced by a shuttle type slide that does not require a slide bar/ball bushing slide. Such a shuttle type slide would have wheels and traverse up and down the upright using the upright as a track. Affixed to the slideable assembly of each upright is a cable of sufficient strength and flexibility to convey hydraulic cylinder force to the slide assembly. In other words, a first cable is included for the first upright and a second cable is included for the second upright. For the purposes of this disclosure, the term cable includes straps, cords and wires.
[0019] Conventional pulley wheels located at each end of the uprights are for directing the cables in a plane parallel with the uprights and then in the direction of the hydraulic cylinder push-rod. This pulley and cable arrangement allows the conversion and relocation of linear push-rod movement into linear slide assembly movement in each upright. A horizontal barbell support arm is attached to the sleeve and extends outwardly from the housing through the first slot in the direction of the bench or perpendicular to the vertical plane that passes through the barbell. The support arms are parallel and lie in a horizontal plane above the bench or squatting position, with the arm intersecting the path of the barbell when it is lifted.
[0020] A single hydraulic cylinder is positioned between the first and second uprights. The hydraulic cylinder is of conventional design and is comprised of a tubular section with a hydraulic fluid inlet at one end. At the other end a push-rod having inner and outer ends projects outwardly from the cylinder. The inner end of the push-rod is connected to a piston within the cylinder. When hydraulic fluid enters the interior of the tubular section, the push-rod extends outwardly from the cylinder. The outer end of the push-rod includes a pulley wheel with axle of sufficient strength and size to accommodate the cables having their first ends attached to the slideable assembly. The second ends of the cables are attached to the distal end of the cylinder. However, the cable second ends could be fastened to other locations and achieve the same result of providing an anchor point for each cable. An idler pulley is mounted to the distal end of the cylinder. The idler pulley is free to rotate within a plane parallel to the extendable push-rod such that the cable originating from the upright in the direction that the cylinder push-rod extends can be redirected. From their anchor point on the distal side of the cylinder, each cable will extend in the direction of, and around the pulley wheel on the extendable push-rod, then extend back in the direction of, and parallel to the cylinder. At this point, the first cable will round the pulley wheel on the distal end of the cylinder and be directed toward the pulley wheel at the lower end of the first upright in the direction that the cylinder push-rod extends. The second cable will extend past the cylinder and be directed toward the pulley wheel at the lower end of the second upright. Preferably, the tubular section of the hydraulic cylinder is attached at each end to a cross member adjoining the first and second uprights. Thus, as the push-rod is extended under pressure of hydraulic fluid, the slideable sleeves and attached support arms are urged to move in an upward direction.
[0021] The combination of cables and pulleys with the single hydraulic cylinder and push-rod provides a unique mechanical advantage over the prior art. For example, the number and arrangement of pulleys can be selected to provide a fixed ratio of travel between the barbell supports and the stroke length of the push-rod. The preferred embodiment uses a cable and pulley arrangement that yields a two-inch travel for every inch of push-rod stroke. This allows for a shorter and less expensive hydraulic cylinder to be used as the system's actuator. Other travel ratios such as 3:1 could be selected. In fact, dependent upon the number and arrangement of pulleys used as well as their diameter, a practical travel ratio of push-rod travel to barbell support travel can be implemented from about 1:10 to 10:1.
[0022] Hydraulic fluid is stored in an accumulator of conventional design. Basically, the accumulator or “gas-oil” tank is comprised of a pressure housing containing an air inlet above the hydraulic fluid level, and a hydraulic outlet beneath the hydraulic fluid level. Valves along the hydraulic fluid outlet stream and air inlet control the flow of hydraulic fluid and air respectively. Hydraulic fluid is stored under pressure within the accumulator due to the compressed air also in the accumulator. When the hydraulic fluid valve is opened, fluid flows from the accumulator to the hydraulic cylinder. The accumulator can be pre-charged with gases other than air could be used in place of air. For example, nitrogen gas would provide extended system life due to its inertness. Moreover, the accumulator can include a gas pressure relief valve and a connection above the hydraulic fluid level that allows the accumulator tank to be pressurized or charged with gas. There is also a hydraulic line connection below the lowest fluid level of the tank.
[0023] The apparatus may include a user support bench, which is preferably of sufficient length to support the user's head and torso. When combined with the safety device, the head of the bench can be raised and lowered. For example, a vertically adjustable bench support bar may extend from the frame of the bench, with the head of the bench being supported on the support bar. An additional horizontal mounting bar may be used to attach the uprights to each other. The uprights may also include barbell rests attachable at various locations along the upright housings.
[0024] When combined with the safety device, the apparatus may further include a sufficiently vacant area between the uprights for giving the user space or weight lifting area to perform squat exercises. This space is also available for placing detached seats, benches, or other exercise enabling supports. An additional horizontal mounting bar may be used to attach the uprights to each other in such a way that it does not interfere with the squat exercise, or placement and use of exercise enabling devices. The uprights may also include barbell rests attachable at various locations along the upright housings.
[0025] The apparatus may further include the incorporation of the upright supports into a cage that prevents the lifting weight from moving outside the area above the lifting arms. When combined with the safety device, the lifting arms may extend into the lifting cage with sufficient depth and movement to support the squat exercise or any other bar based exercises performed within the cage.
[0026] In order to control the position of the support arms, the apparatus includes a controller or actuator accessible by the user when reclined on the bench or standing between the uprights. This actuator, which may be foot or hand operated, is used to open the hydraulic valve, thereby causing hydraulic fluid to enter the hydraulic cylinder. As a result, the push-rod of the hydraulic cylinder is extended, raising the support arms and lifting the barbell away from the user. The valve may be partially opened to release a limited volume of fluid to slowly raise the barbell, or fully opened to raise the barbell quickly. If the actuator is hand operated, it is preferred that it be a trigger type actuator. This trigger is important because anyone doing squats on the bench is required to stand between the uprights, thereby making foot operation of the actuator impractical.
OBJECTS AND ADVANTAGES
[0000] Accordingly, several object and advantages of the present invention are:
[0027] a. To provide a new and novel safety device or apparatus for an individual engaged in the activity of weight lifting.
[0028] b. To provide a new and novel device that acts instead of a spotter (eliminates need for spotter).
[0029] c. To provide a device that enables the lifter to easily adjust the rate at which the device assists (raises the weight from) the lifter.
[0030] d. To provide a device that enables the lifter to easily adjust the amount of assistance provided by the machine.
[0031] e. To provide a device easily set up that can either assist in lifting the weight or lift the weight in its entirety.
[0032] f. To provide a device that when actuated, enables the lifter to continue performing repetitions while being assisted.
[0033] g. To provide a device that when actuated by the lifter, does not allow any downward movement of the weight.
[0034] h. To provide a device that does not require electrical power.
[0035] i. To provide a device that can be used with a traditional human spotter.
[0036] j. To provide a device with a shape, weight and size similar to traditional manual machines.
[0037] k. To provide a device that enables the user to exercise with the seat in incline, flat, and decline positions.
[0038] l. To provide a device that enables the user to perform a squatting or ‘box squat’ exercise.
[0039] m. To provide a device with improved lifting arm motion and a less complex design than prior art offering the same functionality.
[0040] Further objects and advantages of the present invention will become apparent from a consideration of the drawings and ensuing description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] FIG. 1 Self Spotting Safety Bench Press Composite
[0042] FIG. 2 Inner Front Side of Upright
[0043] FIG. 3 Upright Internal Attachments
[0044] FIG. 4 Adjustable Weight Rest
[0045] FIG. 5 Adjustable Weight Rest
[0046] FIG. 6 Hydraulic & Pneumatic Power System with Transmission
LIST OF REFERENCE NUMERALS
[0000]
1 . Upright
2 . Lifting Arm
3 . Slide Bar
4 . Slide
5 . Slide Bearing
6 . Cross Bar
7 . Seat
8 . Accumulator
9 . Hydraulic Cylinder
10 . Actuator
11 . Hydraulic cylinder fluid supply line.
12 . Adjustable Hydraulic Fluid Flow Valve
13 . One way hydraulic flow valve (to cylinder)
14 . One way flow valve (to accumulator)
15 . Actuator Cables
16 . Adjustable Weight Rest
17 . Pulley 1 (End of cylinder piston shaft)
18 . Pulley 2 (Near cylinder)
19 . Pulley 3 (At base of uprights)
20 . Pulley 4 ) (at top of Uprights)
21 . Weight Rest Support Holes
22 . Lifting Arm Slot
23 . Cap
24 . Centering Plate
25 . Floor Plate
26 . Barbell
27 . Cable
28 . Valve
29 . Upright Support
30 . Seat frame (Adjustable)
31 . Weight Rest Mounting Pins
[0078] When reference numerals identify multiples of similar parts those parts will be labeled with the coinciding number followed by a letter. For example there are two Uprights, 1 a and 1 b.
DETAILED DESCRIPTION OF THE INVENTION
[0079] In the following description, terms such as horizontal, upright, vertical, above, below, beneath, and the like, are used solely for the purpose of clarity in illustrating the invention, and should not be taken as words of limitation. The drawings are for the purpose of illustrating the invention and are not intended to be to scale.
[0080] FIG. 1 shows a composite drawing of the device. There are two uprights ( 1 a , 1 b ) parallel to each other and tilted slightly away from the longer side of the seat ( 7 ). Two adjustable weight rests ( 16 a , 16 b ) are located on the inner side of each upright. Protruding from the front of each upright ( 1 a , 1 b ) is a lifting arm ( 2 a , 2 b ) that extends perpendicular to gravity, and in the direction of the seat ( 7 ) and adjustable seat frame ( 30 ). Each upright ( 1 a , 1 b ) has a support ( 29 a , 29 b ) and is connected to the other via a cross bar ( 6 ). Mounted to the cross bar ( 6 ) is an accumulator ( 8 ) (see FIG. 6 ) and a hydraulic cylinder ( 9 ) (see FIG. 6 ). Attached to the center of the cross bar ( 6 ) is the upper end of the adjustable seat ( 7 ) frame. Attached close to the floor at the foot end of the seat ( 7 ) is an actuator ( 10 ).
[0081] FIG. 2 focuses on upright ( 1 b ). The inner side and front side of upright ( 1 b ) contains weight rest support holes ( 21 ) extending partially down the upright. The front of the upright ( 1 b ) to the right of the holes contains a lifting arm slot ( 22 ). Contained within the upright are centering holes for holding the slide bar ( 3 b ) (please see FIGS. 3 and 6 ).
[0082] FIG. 3 shows the parts an upright ( 1 b ) contains without the upright itself included. The slide bar ( 3 b ) nearly extends the full length of the upright ( 1 b ) and is held in place by centering plates ( 24 b ). Mounted on the slide bar ( 3 b ) is the slide ( 4 b ) that contains bearings ( 5 ) at either end. Attached to the slide ( 4 b ) is a cable ( 27 b ) and lifting arm ( 2 b ). An upright base Pulley ( 19 b ) and top pulley ( 20 b ) are located at the extents of the upright ( 1 b ). The upright cap ( 23 b ) and floor plate ( 25 b ) are at opposing ends of the upright.
[0083] FIGS. 4 and 5 show the adjustable weight rest ( 16 b ). This piece is “u” shaped to partially wrap around an upright ( 1 b ). It contains two mounting pins ( 31 ). The first pin is located on the backside of the front plate containing the barbell support extension. The second pin is located on the side plate to extend into the inner weight rest support holes ( 21 ). Pin location coincides with the weight rest support holes ( 21 ). Pin location allows the front pin to slide into the rest support hole ( 21 ) when the adjustable weight rest ( 16 b ) is rotated clockwise ninety degrees. Once the first pin is seated in the support hole, rotation of the adjustable weight rest ( 16 b ) ninety degrees counter clock wise (with the front pin within the support hole ( 21 ) being the axis of rotation) seats the inner pin in the inner rest support hole ( 21 ).
[0084] FIG. 6 shows the Hydraulic and Pneumatic system that powers the self-spotting bench along with the cable ( 27 ) and pulley ( 17 , 18 , 19 , 20 ) system for transmitting the power to the lifting arms ( 2 a , 2 b ). The accumulator ( 8 ) is connected to a hydraulic line ( 11 ) that exits the accumulator ( 8 ) and leads to three valves; one way valve to cylinder ( 13 ), one way valve to accumulator ( 14 ), and the flow rate valve ( 12 ). The hydraulic line then leads to the hydraulic cylinder ( 9 ). One end of the cable ( 27 a , 27 b ) is attached to the hydraulic cylinder, it then rounds the hydraulic cylinder piston shaft pulley ( 17 ) then proceeds toward the cylinder pulley ( 18 ). At the cylinder pulley ( 18 ) cables ( 27 a , 27 b ) separate to serve each of the uprights ( 1 a , 1 b ). One cable ( 27 a ) proceeds towards the bottom of its respective upright ( 1 a ) and one cable ( 27 b ) rounds the cylinder pulley ( 18 ) then proceeds toward its respective upright ( 1 b ). The cables ( 27 a , 27 b ) then round the upright base pulley ( 19 a , 19 b ), round upright top pulley ( 20 a , 20 b ), then connect with the slide ( 4 a , 4 b ).
Operation
[0085] FIG. 1 shows the barbell ( 26 ) free weight starting point held on the adjustable weight rest ( 16 ). The distance of the weight from the seat ( 7 ) (and therefore the lifter) can be adjusted by rotating each adjustable weight rest ( 16 ) ninety degrees away from the upright ( 1 a , 1 b ) using the front pin as a pivot point. After being rotated the adjustable weight rest ( 16 ) can be separated from the upright ( 1 ) by moving it perpendicular to the upright in the direction the lifting arm ( 2 ) extends. The adjustable weight rest ( 16 ) can be reattached in other locations performing the reverse of these instructions in any other weight rest support hole ( 21 ).
[0086] Once the barbell is held on the adjustable weight rest ( 16 a , 16 b ) the lifter can now set the one-way flow valve (to accumulator) ( 14 ) to be active. This will allow the lifting arms ( 2 a , 2 b ) to only move downward. The lifter has two options as to how to depress the lifting arms ( 2 a , 2 b ). The first option is to get in the exercising position, remove the barbell ( 26 ) from the adjustable weight rests allowing the weight to lower and depress the lifting arms ( 2 a , 2 b ), and then start repetitions from the lowest point the bar traveled. The second option is to depress each lifting arm ( 2 a , 2 b ) by hand to a point where it will not interfere with the exercise until released.
[0087] If the lifter desires an increased or decreased assisting force exerted on the barbell by the lifting arms, an air adjustment can be made to the accumulator by adding air using a conventional air compressor or releasing air through the accumulator tank valve ( 28 ). If the rate at which the lifting arm ascends is too slow or fast the adjustable hydraulic fluid flow valve ( 12 ) can also be manipulated to suit user preference.
[0088] Repetitions are started once the lifting arms are depressed and the equipment is adjusted to suit lifter's preferences. When the lifter needs a “spot” the one way flow valve (to accumulator) is released. The compressed air in the accumulator ( 8 ) acts as a spring and forces hydraulic fluid through the hydraulic cylinder fluid supply line ( 11 ) and into the hydraulic cylinder ( 9 ). The cylinder shaft then extends pulling the cable ( 27 ) and causing the attached lifting arm to also rise. The lifting arms contact the barbell and assist (spot) the lifter. The opposite of this action occurs when the lifting arms are being depressed (i.e. the hydraulic fluid in the hydraulic cylinders ( 11 a , 11 b ) is forced back into the accumulator where potential energy is stored in the form of compressed air.).
[0089] Once the one-way flow valve (to accumulator) ( 14 ) is released, the lifting arms ( 2 ) will be permitted to move up and down while still asserting an assisting force on the barbell ( 26 ). This allows the lifter to continue by performing assisted repetitions when he/she could no longer lift the original weight unassisted. Should the upward force desired by the lifter exceed the weight of the barbell the entire weight will be lifted by the machine, not permitting assisted repetitions.
[0090] When the lifter is no longer able to perform the assisted repetitions (or whenever else the lifter desires) the one way flow valve (to cylinder) ( 13 ) can be engaged. This will only allow hydraulic fluid to flow toward the cylinder ( 9 ) thus allowing the lifting arms to raise but not be lowered. This will allow the lifter to lift the barbell with assistance, and then prevent the barbell ( 26 ) from falling on the lifter when failure occurs.
[0091] The manipulation of the one way flow valves ( 13 , 14 ) mentioned above is accomplished by use of an actuator ( 10 ) the exerciser manipulates with his/her lower leg or foot. The actuator ( 10 ) is connected to the hydraulic valves via actuator cables ( 15 ) and pulley transmission system. When the actuator ( 10 ) is kicked once in the direction of the accumulator ( 8 ) the one way valve to the accumulator ( 14 ) will be released. When kicked a second time the one way valve to the cylinder ( 13 ) will be engaged. The system can then be reset by either kicking the actuator ( 10 ) a third time or manually resetting the one way flow valves ( 13 , 14 ).
[0092] Due to the stress the exerciser is experiencing during failure the exercisers leg or foot is likely to contact the actuator with significant force. The actuator therefore has a limited range of motion and does not transfer all of this energy to the valves. For the same reason the actuator is constructed with suitable smooth surface area as to not injure the exerciser when kicked. The design of the actuator ( 10 ) shown in FIG. 1 is not intended to limit the scope of this invention. A lanyard that attaches to the exerciser's leg or foot, or a switch that is mounted on the barbell is also feasible.
[0093] Thus the reader will see that the self-spotting safety bench press of this invention provides a dependable spotting machine that increases user safety with a minimum of components. The spotting speed and force exerted is fully adjustable to suit user preferences, as is weight rest position, and seat position. This machine has two spotting modes. The first mode allows the lifter to continue repetitions (up and down) assisted by the machine. The second mode only allows upward movement, preventing the weight from falling on the lifter. Furthermore this machine requires no electrical power and is of a weight and size similar to traditional non-spotting bench presses. These attributes make this machine likely to be used in private and public gyms alike.
[0094] While the above description contains many specifics, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of one preferred embodiment thereof. Many other variations are possible. For example, the uprights described above do not have to be tilted away from the seat extension of the bench. Still another example is that the spotting device used with this machine is not to be limited to use with only one type of seat. A seat adjustable to various incline, decline and flat positions and seats in fixed positions are all types that can be used with this device.
[0095] Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents.
|
A self-spotting safety bench press is composed of an adjustable bench and uprights located on either side of the bench adjacent the lifters upper body. Lifting arms extend from the uprights into the barbell's pathway and have the ability to slide up and down to contact the barbell and decrease the weight exerted on the exerciser. A single hydraulic cylinder in conjunction with a pulley system provides force to each lifting arm, which is depressed below the barbell's path before use. When assistance is needed, the exerciser releases a hydraulic restrictor valve causing the arms to ascend removing a user-determined amount of weight from the barbell. If the total amount of weight is not chosen to be removed the user can continue performing repetitions with machine assistance. A second restrictor valve allows only upward movement should the exerciser fail. A third flow restrictor valve adjusts the rate of arm travel. An air charged hydraulic accumulator provides the hydraulic pressure to the cylinder.
| 0
|
BACKGROUND OF INVENTION
The subject matter of the present invention relates generally to fuel vent apparatus for venting gaseous fuel vapors from a fuel tank, and in particular to such a vent apparatus which also includes an improved gravity operated valve to prevent liquid fuel spillage from the tank. The fuel vent apparatus of the present invention is especially useful on the fuel tanks of trucks and other vehicles operated by liquid fuel such as gasoline, diesel fuel and the like. However, it is also useful on fuel tanks for outboard motor boats, lawn mowers, chain saws and gasoline cans to prevent fuel spillage and fires when such fuel tanks are accidentally overturned.
Previously, it has been proposed to provide a fuel tank with a fuel filler cap having a gravity operated valve which closes a vent passage in such cap when the tank overturns, as on an outboard motor for a boat discussed in U.S. Pat. No. 1,683,338 of Evinrude, granted Sept. 4, 1928. In addition, it is also known to provide such a filler cap with pressure relief valves to prevent excessive positive pressure in addition to such gravity operated valves on the fuel tank of a motor vehicle, as shown in U.S. Pat. No. 3,757,987 of Marshall, granted Sept. 11, 1973, and U.S. Pat. No. 3,918,606 of Keller, granted Nov. 11, 1975. However, the gravity operated valves employed in such patents all employ a valve control means having a spherical weight which is positioned below the movable valve member and rolls up a guide to urge such valve member into a closed position when the tank overturns. This has the disadvantage that tipping of the gas tank through a much greater angle is required before the gravity operated valves of such prior art apparatus close completely. As a result, these valves are slow acting and do not eliminate spillage under certain conditions.
In the fuel vent apparatus of the present invention, the gravity operated valve is controlled by a plumb weight supported above the movable valve member. This plumb weight control means is much more sensitive in that it closes such valve with very little movement of the tank through an angle of about 30°. Thus, in one embodiment when the axis of the vent body moves from its normal vertical position through an angle greater than 28° in any direction, the gravity operated valve closes to prevent fuel spillage from the tank.
In addition, the present fuel vent apparatus also includes a gas pressure check valve in a second path in parallel with the path through the gravity operated valve. This check valve prevents a vacuum from being created within the fuel tank when the fuel therein is used up, which would otherwise tend to hold the gravity operated valve closed. The check valve opens when a negative pressure is created in the fuel tank and immediately closes as soon as the pressure within the tank is equalized to atmospheric pressure and thereafter becomes slightly positive, preventing spillage when the tank has been tipped on its side. Excess positive pressure within the tank in its tipped position is relieved by the conventional pressure relief valves used on filler caps.
SUMMARY OF THE INVENTION
It is therefore one object of the present invention to provide an improved fuel tank vent apparatus having a gravity operated valve of greater sensitivity which is automatically closed when the fuel tank tips at greater than a predetermined angle to prevent leakage of liquid fuel through the vent passageway.
Another object of the present invention is to provide such a fuel tank vent apparatus of simple, trouble-free operation and of economical construction.
A further object of the invention is to provide such a fuel tank vent apparatus in which the gravity actuated valve is operated by a control weight pivotally supported above the valve and connected to a movable valve member.
An additional object of the invention is to provide such a fuel tank vent apparatus in which the control weight is hung as a plumb weight above the valve member and connected to such valve member for closing the valve in response to tipping movement of the fuel tank and vent apparatus.
Still another object of the invention is to provide such an improved fuel tank vent apparatus which also includes a pressure check valve for preventing a negative pressure from being created within the fuel tank and tending to hold the gravity operated valve closed.
A still further object of the invention is to provide such a fuel tank vent apparatus in which the pressure check valve is in a second fluid path which is in parallel with the fluid path closed by the gravity valve between the fuel tank chamber and the vent passageway.
DRAWINGS
Other objects and advantages of the present invention will be apparent from the following detailed description of certain preferred embodiments thereof and from the attached drawings, of which:
FIG. 1 is a side elevation view of a truck employing the fuel tank vent apparatus of the present invention;
FIG. 2 is an enlarged vertical section view of one embodiment of the vent apparatus taken along line 2--2 of FIG. 1 with the gravity valve open;
FIG. 3 is a vertical section view similar to FIG. 2 but showing the vent apparatus tipped and the gravity valve closed;
FIG. 4 is a plan view of the top of FIG. 3 taken along line 4--4 of FIG. 3 with a portion of the cap removed for clarity;
FIG. 5 is an enlarged vertical section view of a second embodiment of the vent apparatus with the gravity valve open;
FIG. 6 is a vertical section view similar to FIG. 5 but showing the vent apparatus tipped and the gravity valve closed;
FIG. 7 is a horizontal section view taken along line 7--7 of FIG. 6;
FIG. 8 is an enlarged partial vertical section view of a third embodiment of the vent apparatus of the invention; and
FIG. 9 is a horizontal section view taken along line 9--9 of FIG. 8.
DESCRIPTION OF PREFERRED EMBODIMENTS
As shown in FIG. 1, a truck 10 or other wheeled vehicle such as an automobile, lawn mower, etc. having a fuel tank 12 filled with liquid fuel such as gasoline, fuel oil, etc. is provided with the fuel tank vent apparatus 14 of the present invention. In addition, the fuel tank is also provided with a separate fuel filler apparatus including a fuel cap 15 which may be provided with a pressure relief valve, as shown in my earlier U.S. Pat. No. 3,918,606 of R. D. Keller, granted Nov. 11, 1975. However, the fuel vent apparatus may also serve as the fuel filler apparatus.
The fuel tank vent apparatus 14 of one embodiment is shown in FIG. 2 and includes a vent body 16 of metal such as aluminum which defines a vent passage including a cylindrical upper passage portion 18 and a cylindrical lower passage portion 20 of smaller diameter, joined by an intermediate passage portion 22 of a tapered conical shape. The bottom of the lower passage portion 20 is also joined to a bottom passage portion 24 in the form of another circular cylinder of smaller diameter than such lower portion. The lower end of the bottom passage portion 24 terminates at the bottom surface of the vent body 16 and provides the inlet opening 26 of the vent passage.
A gravity operated valve 27 including a movable valve plate member 28 is provided at the inlet opening 26 of the vent passage. Such valve is positioned in a first fluid path provided from such vent passage to the interior of the fuel tank through four connecting passages 30. The connecting passages 30 are drilled into the bottom end of the vent body 16 and extend in communication with an annular groove 32 provided in the outer surface of such vent body surrounding the bottom portion 24 of the vent passage. Thus, the first fluid path extends from the tank through groove 32, passages 30 and inlet opening 26 to the vent passage. The gravity operated valve 27 when operated moves the valve member 28 upward into engagement with the bottom end of the vent body closing connecting passages 32 and the inlet opening 26 of the vent passage. This closes the first fluid path between the vent passage and the interior of the fuel tank. As a result, no liquid fuel can leak through such first path and such vent passage out of the fuel tank.
The valve 27 is controlled by a gravity operated control means including a weight 34 which is pivotally supported above the valve 27 by hanging it on a support chain 36 whose upper end is secured to a hanger plate 38 extending across the top of the vent body 16. The weight 34 is fastened to the chain 36 in any suitable manner such as by crimping, to position such weight within the upper vent passage portion 18. Such weight is of a frusto-conical shape and may be of any suitable heavy material such as brass, lead or other metal which is not corroded by the fuel. Similarly, the chain 36 which is formed of interconnected beads, is made of a suitable non-corrosive metal such as stainless steel. As a result, the weight 34 hangs freely on the chain and acts as a plumb weight which is maintained in a substantially vertical position. The weight 34 is connected to the movable valve member 28 by a connecting chain 40 which may be a portion of the same chain forming the support chain 36. Thus, the weight is provided with a central passage 42 through which the chain 36, 40 extends. The top end of the chain is secured into a notch 44 provided in the center of the hanger member 38 and the bottom end of such chain is secured within a tubular stem portion 46 extending upward from the center of the valve plate member 28. The stem portion 46 is secured to the bottom end of the chain 40 by crimping such stem at 48.
A second fluid path is provided from the inlet end 26 of the vent passage to the interior of the fuel tank through two openings 50 in the opposite sides of the stem 46 of the valve member 28 and through an axial passageway including portions 52 and 54 in the bottom end of a ball cage member 56 of aluminum attached to the bottom of the vent body 16. A pressure check valve 57 is formed by such ball cage and a nylon sphere 58 is provided as a check ball within the enlarged passage portion 54 of the second fluid path. The check ball is held in such passage by an inward crimped flange 60 at the bottom of such passage. This ball operates as a pressure sensitive check valve and is caused to move down into the position shown in FIG. 2 to open the check valve when there is a negative pressure within the fuel tank relative to atmospheric pressure. The ball is caused to move upward into the position shown in FIG. 3 to close the valve when there is a positive pressure within the fuel tank relative to atmospheric pressure outside the tank. The check valve has a valve seat surface 62 provided by a conical intermediate portion of the passage between the two circular cylindrical passage portions 52 and 54 which are of different diameters, the upper passage 52 being approximately one-half the diameter of the lower passage 54. An external flange 63 is provided on the lower end of the valve body 16 which snaps into a corresponding groove in the interior of the ball cage 56 to attach such cage to the valve body.
The vent body 16 is threadedly attached to a vent tube 64 of the fuel tank by external threads 66 provided on the outer surface of such vent body surrounding the upper passage portion 18. However, for tanks with a smaller vent tube a second set of threads 68 is provided on the outer surface of the vent body surrounding the lower passage 20. The upper end of the vent passageway in the vent body 16 is provided with a plurality of vent outlets 70 formed by spaces between such vent body and a vent cap 72. The upper end of the vent body 16 is provided with four slots 74 spaced 90° apart which provide the primary vent outlets 70. However, three holes 76 are drilled through the sides of the vent body 16 at equally spaced positions above the top of the vent tube 64 to provide secondary vent outlets. The hanger member 38 is positioned within two diagonal slots 74 to center it and prevent turning. The vent cap 72 is provided with four inward crimped locking projections 78 which extend into the slots 74 and slide beneath outwardly projecting flanges 80 at the top of the vent body when the cap is rotated one-quarter turn to lock the cap onto the vent body.
The longitudinal axis 82 of the vent body 16 normally extends substantially vertical, as shown in FIG. 2. In this position the gravity operated valve 27 is open since the valve member 28 is spaced away from the inlet end 26 of the vent passage. When the truck tips, such as when driving into a ditch or rolling over, the axis 82 of the vent body will be displaced from the vertical line 84 by an angle greater than a predetermined angle of, for example, 28° which is sufficient to operate the gravity valve. When this happens, the weight 34 moves relative to the valve body 16 toward the side of the upper passage portion 18 sufficiently to pull the valve member 28 into engagement with the lower end of the vent body, thereby closing the vent passage and the first fluid path through connecting passages 30. This closed position is shown in FIG. 3.
Normally there is a slight positive pressure within the fuel tank which closes the check valve 57 by causing the check ball 58 to be urged upwardly into contact with the valve seat 62, as shown in FIG. 3. Under some conditions, however, a vacuum or negative pressure may be created in the fuel tank, such as when the fuel has been pumped out of the tank to the motor. Such a vacuum would be transmitted through passages 30 and tend to hold the valve member 28 up in the closed position shown in FIG. 2. This can be quite troublesome, especially if the gravity operated valve 27 closes momentarily when a truck rounds a corner and tips sufficiently to actuate such gravity operated valve. Thus, if the vacuum in the tank holds the valve member 28 closed, than the vacuum increases until no fuel flows into the engine. This problem is averted by check valve 57 because under conditions of negative pressure, the check ball 58 is urged downwardly into the position shown in FIG. 2, thereby opening the second path to the atmosphere through the hollow stem 46 of the valve member including openings 50 and passages 52 and 54. As a result, the negative pressure is relieved and the internal pressure within the tank is equalized to the atmospheric pressure outside the tank. Once this happens the valve member 28 falls down to the open position shown in FIG. 2. Then the pressure within the tank slowly builds up to a slight positive level again, thereby closing the check valve 57.
Another embodiment of the vent apparatus of the present invention is shown in FIGS. 5, 6 and 7. This vent apparatus 14' is similar to the vent apparatus 14 of FIGS. 2 and 3 so only the differences will be described with respect to this latter embodiment and the same numbers have been used on like parts. The main difference in the second embodiment is that the support member 36' for the weight 34' is a rigid link in the form of a metal rod of brass having spherical balls 86 provided at the opposite ends thereof. The upper ball is pivotally mounted in a nylon socket member 88 attached to the vent cap 72 by a snap fit within an opening 90 provided in the center of such cap. The bottom ball of the support link 36' is pivotally mounted in a second nylon socket member 92 which is fixedly attached on internal flange 93 within opening 42 extending through the weight 34'. As a result, such weight is hung from the cap 72 above the gravity actuated valve 27' and is free to pivot about balls 86 to raise valve member 28' and close such valve.
The socket member 92 is provided with a second socket which is engaged by the upper ball 94 of the connecting link 40' which is also in the form of a solid metal rod of brass or similar non-corrosive material. The lower ball 94 of the connecting rod 40' is secured within a third nylon socket member 96 attached to the movable valve member 28'. This third socket member is held by an enlarged head 97 within the hollow stem 46' of the valve member 28'. A valve cage member 56' of aluminum or other suitable metal is fastened to the lower end of the valve body 16 by flange 63 and surrounds the movable valve member 28'. A plurality of apertures 98 are provided in the bottom of the valve cage 56' in the spaced between four leg portions 99 of such cage. The apertures 98 are in communication with the inlet end 26 of the vent passage to enable gases to be vented from the fuel tank through such vent passage to the exterior of the tank through outlets 44. The leg portions 99 are each provided with flange 100 projecting inward toward the center of the bottom of the valve cage 56'. The flanges 100 retain the valve member 28' within the cage in the event socket 96 becomes disconnected from the connecting rod 40'.
In the second embodiment of the vent apparatus, when the truck turns over or there is any other tipping of the fuel tank to cause the longitudinal axis 82 of the vent body 86 to be displaced by an angle greater than 35° with respect to the vertical line 84, the plumb weight 34 is moved sufficiently to the side of passage portion 18 to close the valve. Thus, in the closed position the weight pulls the link 40' and moves the valve member 28' up into contact with the lower edge of inlet 26 of the vent passage. It should be noted that in this embodiment the intermediate passage portion 22' of the vent passage is provided with a greater length and conical taper in order to accommodate the rigid connecting link 40'.
The check valve 57 including ball 58 of FIG. 2 has been eliminated from the embodiment of FIG. 5. However, in this embodiment when a vacuum is produced within the fuel tank, such vacuum tends to move the valve member 28 down into the open position of FIG. 5 and does not tend to hold such valve member in the closed position of FIG. 6 as it does in the earlier embodiment. Thus, the same problem does not exist in the embodiment of FIG. 5. However, when positive pressure is produced within the fuel tank, it does tend to hold the valve closed so this is a problem. This can be overcome by providing a pressure relief valve in the filler cap. For low pressures, the weight of the weight 34' would be sufficient to reopen the valve 27'. At greater positive pressures the pressure relief valve opens to reduce such pressure and enable the valve 27' to reopen.
A third embodiment of the vent apparatus of the present invention is shown in FIGS. 8 and 9. This third embodiment is similar to that of FIGS. 2 and 4, so that only the differences will be described and the same numbers will be used for like parts. The movable valve member 28" employs a conical end portion 102 rather than the flat valve plate. When the gravity operated valve 27" is tipped into the closed position so that axis 82 is displaced about 30° from the vertical, the conical end 102 is raised by chain 40 and urges three spherical valve closure members or balls 104 upward into engagement with valve seats 106 in the three connecting passages 30', closing the first path. Passages 30' slant at an angle of about 45° to 55° with respect to the vent passage axis 82. However, the pressure check valve 57 may be opened by negative gas pressure within the fuel tank urging check ball 58 downward to provide a second path to the vent passageway 24 through the hollow stem 76 and holes 50. This enables valve members 28" and 106 to fall downward to reopen the gravity valve 27" when the fuel vent axis 82 returns to a vertical position. Thus check valve 57 prevents such gravity valve from sticking closed by operating in a similar manner to the embodiment of FIG. 2.
It will be obvious to those having ordinary skill in the art that many changes may be made in the above-described preferred embodiments of the present invention without departing from the spirit of the invention. For example, other types of hanger support means can be employed instead of bead chains or ball and socket links, such as, e.g., a nylon cord. Also, the cord could be provided as two pieces, one of which is attached between the top of the weight 34 and the hanger 38 and another of which attached between the bottom of such weight and the valve member 28. Therefore, the scope of the present invention should only be determined by the following claims.
|
A fuel tank vent apparatus is described with an improved gravity actuated valve for preventing liquid fuel spillage. A weight pivotally supported above the valve acts as a plumb weight for operating a movable valve member connected thereto to close the valve when the vent apparatus is tipped. In the one embodiment the plumb weight is hung on a chain that is also connected to the valve member. The fuel vent apparatus is especially useful on the fuel tank of an automobile or truck in that it enables gaseous fuel vapor to be vented from the tank through a passageway, thereby preventing pressure buildup within the tank while also employing in such passageway the gravity operated valve which is closed when the truck turns over or tips at an angle greater than a predetermined angle to prevent the leakage of liquid fuel through such vent. In one embodiment, the fuel vent apparatus also includes a gas pressure check valve for preventing the internal pressure within the tank from falling below the outside atmospheric pressure, which tends to hold the gravity valve closed and would otherwise prevent proper venting. In another embodiment the chain supporting the weight and connecting such weight to the valve member is replaced by link rods attached by ball and socket connections.
| 5
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a raised floor made up of modular slabs mounted on vertical supports which are separated from each other and which rest on the ground.
2. Discussion of Background and Relevant Information
Raised floors known today are constituted of modular, usually square, slabs which are attached to one another in a horizontal plane and whose tops rest on horizontal supporting plates made up of the upper horizontal heads of vertical supports separated from each other. Each of these supports comprises a lower base fixed to the ground and a vertical bonding element, of fixed or adjustable length, between the lower base fixed to the ground and the upper support head of the slabs.
Up to the present time, slab tops have usually been placed quite simply on the upper support head of each support, their position on said head being determined by upwardly projecting elements held by the upper head of the support. These projecting elements are generally constituted of splinters which, in the case of square or rectangular slabs, are placed at regular intervals at right angles to each other around the vertical support axis, on which said axis the tops of four adjacent slabs merge. The splinters are inserted loosely in demarcated intervals between the lower parts of the slab edges in such a way that the assembly of the adjacent slabs on the support is relatively loose and the resulting floor is therefore not perfectly stabilized.
Another type of known raised floor assembly consists of supports whose heads possess slots into which the edges of the modular slabs are fitted, but the assembly of the adjacent slabs on the support obtained according to this process is also relatively loose, because a certain amount of play needs to be maintained for the purpose of fitting the edges of the slabs into the slots of the supports in order to facilitate assembly and to compensate for any expansion of the slabs. A known example of such an assembly is given in the context of U.S. Pat. No. 5,052,157 filed under the name of DUCROUX et al; another example is constituted by the floor described in German Patent Publication No. 2,107,898 filed under the name of CENTRAL FLOORING LTD. in which the support heads possess a protuberance against which the truncated tops of the slabs rest. Although the amount of play may be reduced in such an assembly, it cannot be completely eliminated for fear of raising the slabs in the event of expansion.
SUMMARY OF THE INVENTION
This invention aims to remedy the disadvantages described above by providing a slab assembly device ensuring a firm hold on these slabs once they are fixed on the upper heads of their supports. For this purpose, the raised floor, whose surface consists exclusively of modular slabs 1 in the shape of a regular polygon, presenting along their sides vertical edges 6 perpendicular to the plate 7 forming the base surface of said slabs 1, sustained at their tops by vertical supports 2 resting on the ground, is characterized in that the upper head 5 of the vertical supports 2 is fitted with radial slots 4 which are usually rectangular and which terminate in the periphery of said upper head 5, the width of said radial slots 4 being so determined as to cause a tightening through vertical fitting into a radial slot 4 of the vertical edges 6, facing each other, said vertical edges 6 belonging to two adjacent slabs 1.
BRIEF DESCRIPTION OF THE DRAWINGS
Non-limitative examples of various embodiments of the invention will now be described with reference to the accompanying drawings in which:
FIG. 1 is a perspective view of the assembly device according to the invention ensuring the maintenance of the square or rectangular slabs on a common support designed to hold four slabs.
FIG. 2 is a vertical section view along line II--II of FIG. 1.
FIG. 3 is a plan view of a square-shaped floor slab.
FIG. 4 is a side-face view of the slab in FIG. 3 as seen from the left of this figure.
FIG. 5 is a perspective view of a variant embodiment of the square or rectangular slab assembly device.
FIG. 6 is a vertical section view along line VI--VI of FIG. 5.
FIG. 7 is a side-face view of a slab according to a variant embodiment of the raised floor.
FIG. 8 is a plan view of a square-shaped slab of the floor according to a variant embodiment of the raised floor.
FIG. 9 is a side-face view of the slab in FIG. 8 as seen from the left of this figure.
FIG. 10 represents a view similar to that of FIG. 9 according to another variant of the slab.
FIGS. 11 and 12 are plan views of a floor of a square-shaped slab of the floor presenting the two possible forms of dividing the bosses on the slab edges.
FIG. 11a shows a portion of FIG. 11 in greater detail.
FIG. 13 is a plan view of a raised floor according to a variant of the invention in which the slabs are in the shape of an equilateral triangle.
FIG. 14 is a plan view of a floor slab made of sheet metal cut and folded into the form of an equilateral triangle.
FIG. 15 is a side-face view of the slab in FIG. 14 as seen from the left of the figure.
FIG. 16 is a larger-scale, partially cross-sectional, plan view of the zone in which six adjacent triangular slabs are attached to a common support.
FIG. 17 is a partial vertical section view along line XVII--XVII of FIG. 16.
FIG. 18 is a bottom view of the six adjoining slabs represented in FIG. 16.
FIG. 19 is a bottom view of an end slab made of sheet metal cut and folded into the shape of an isosceles trapezium.
FIG. 20 is a side-face view of the end slab represented in FIG. 19.
FIGS. 21, 22, 23, 24, 25 and 26 are front and axial section half-views of various embodiments of fixed-height triangular slab supports.
FIG. 27 is an overhead view of the variant embodiment of the support presented in FIG. 26.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The assembly device represented in FIGS. 1 to 3 is designed to ensure the maintenance of horizontal modular slabs 1, square or rectangular, of a raised floor on vertical supports 2 resting on the ground on which the raised floor is to be mounted. These vertical supports 2 are separated from each other by a distance corresponding to the dimensions of the modular slabs 1. Each vertical support 2, of fixed or adjustable height, comprises, on its lower part, a ground support base, not represented in the drawing, and, on its upper end, a horizontal support head 5 on which the tops of modular slabs 1 rest. In FIG. 1, only two slabs are partially represented, but it is clear that each vertical support 2 serves to support four square or rectangular slabs 1. These four slabs 1 are attached to each other, that is to say that their vertical edges 6 are fixed against each other, and the tops of the four adjacent slabs are merged together, as seen from a plan view in point O through which the vertical axis zz' of the support 2 passes.
According to the invention, the width of the rectangular slots 4, fitted on the upper head 5 of vertical supports 2 and terminating in its periphery, is so determined as to cause a tightening of vertical edges 6, facing each other, when said vertical edges 6, belonging to two adjacent slabs 1 are fitted vertically into a radial slot 4.
FIGS. 3 and 4 represent a variant of square-shaped modular slabs according to which the edge 6 of said slab spreads horizontally over a length which is less than that of a side of the slab, being centered on the middle of the side.
FIGS. 5 and 6 represent a slab assembly device according to another variant. In FIGS. 5 and 6, each edge 6 of a square or rectangular-shaped slab 1 is formed by a lateral rim, folded at right angles towards the bottom of the upper plate or plate portion 7 of slab 1. This edge 6 extends over a part of the length of the side of the slab, terminates at a distance from the top O of the slab and is extended towards this top for a short distance by a vertical joining edge of lesser height constituting a locking element of the slab 1 on the upper horizontal head 5 of a vertical support 2. For this purpose, the head 5 possesses four rectangular radial slots 4, terminating in the periphery of the circular or polygonal head 5, converging towards the center O and distributed regularly at right angles to each other around the vertical axis zz' of the support 2. Each locking slot 4 is rectangular in shape and its width e is equal, in the case of edges without bosses, to twice the thickness of a joining edge 3 of reduced height. The radial depths, and according to axis zz' of each slot 4, are sufficient to receive the whole of the joining edge 3, thereby allowing the corner of the slab 1 to rest on the central part of head 5 without there being contact between the vertical slices 8 of the parts 3 of the edges 6 ensuring the joining of slabs 1 and the vertical bottom 9 of the slots 4.
As may be seen from a study of FIG. 6, the adjacent slabs 1 are firmly secured on the head 5 of the support 2 by their joining edges 6 which are inserted tightly in their locking slots 4 and are held close to each other due to the fact that the thickness e of each slot 4 is equal to twice the thickness of the edges 6.
FIG. 7 is a side-face view of the slabs represented in FIGS. 5 and 6.
FIGS. 8, 9 and 10 illustrate a variant embodiment of the slabs according to the invention in which the end 3 of the edge 6 ensuring the fastening of each slab 1 in a radial slot 4 is made up of an elastic strip 10 which is obtained by means of a vertical cut 11 or horizontal cut 12 in the edge 6. In these same figures, a boss 13, shown in greater detail in FIG. 11a, is represented on half of the elastic strips, this boss corresponding to another embodiment of the slabs. According to this variant, one elastic strip in two is fitted with a boss 13 according to the distribution illustrated in FIGS. 11 and 12. These figures represent, in the case of square slabs, the two possible distributions of the bosses allowing the assembly of the slabs according to the invention. It is obvious that the shape of the slabs is not limitative and that the same results would be achieved with triangular or hexagonal slabs. The purpose of the elastic strips 10 is to make it possible to fix the slabs on the supports, this fixture presenting a certain elasticity, due to the strips, whilst at the same time maintaining a tight assembly of said strips 10 in the slots 4 provided on the heads 5 of the supports. Moreover, the addition of a boss on one of the two strips facing towards the interior of a slot 4 makes it possible to create a certain play between the surfaces 7 of the corresponding adjacent slabs. This illustrates how elastic strips fitted with bosses preserve play between the surfaces of the slabs which may therefore expand, for example as the result of heat, without this expansion causing the slabs to rise, even if the expansion of one or more slabs is greater than the play between the same slabs, the elasticity of the assembly allowing a relative movement of the slabs with regard to their support in the horizontal plane without causing upheaval phenomena. In addition, the slabs 1 will firmly fit onto their support 2 by means of the tight assembly of the strips in the slots 4. The result is a floor on which the two kinds of play have been disassociated. The play concerning the slots is eliminated thereby allowing a firm assembly of the edges 6 of the slabs 1 in the radial slots 4. The play between the base plates 7 of the slabs 1 is preserved and even accentuated by the elasticity of the bonding between the slabs and their supports, thus making it possible to offset all the problems of expansion. Obviously, the play between the base surfaces 7 of the adjacent slabs 1 obtained by adding a boss on the elastic strips 10 could equally well be achieved with another device, for example through folding the strips 10, but in this case, a regular distribution of the play between the base surfaces 7 would be harder to achieve than with bosses.
FIG. 13 shows a raised floor according to the invention consisting of a set of horizontal modular slabs 1, which are attached to each other and are of the same size and the same equilateral triangle shape. The tops of the individual slabs 1 are merged in points O constituting the nodes of a mesh network with triangular meshes formed by the set of slabs 1.
Each node O of the network constitutes the common top of six triangular slabs 1 distributed regularly around a vertical axis passing through the node O and constituting at the same time a regular hexagon. A subjacent support 2 is associated to each node O, which said subjacent support will be described in detail below. The support may consist of an independent element, for example such as one of the element 16, 21, 25, 29, or 31 illustrated in FIGS. 21 to 27. At its lower end, the support 2 rests on the ground on which the raised floor is mounted. From the preceding description it may therefore be seen that each triangular slab 1 rests on the floor at the three points O formed by the three tops of the equilateral triangle constituted by said slab.
The triangular-shaped modular slabs 1 are only used if the length L of the surface to be covered by the raised floor is equal to a multiple of the height h of each triangular slab 1.
However, as may be required in exceptional circumstances, provision is made, again according to the invention, to complete the assembly of the raised floor, in the neighborhood of the walls, by means of supplementary end slabs 14 , each in the form of an isosceles trapezium corresponding to three attached standard main triangular slabs 1. In other words, the small base of each end slab 14 is equal in length to the side of the triangular slab 1, the length of its large base is equal to twice the length of the side of a triangular slab 1, and the height of an end trapezoid slab 14 is equal to the height h of a triangular slab 1. The median area of the large base of each end slab 14 is arranged so as to be capable of receiving a standard support or a standard jack, as will be seen below.
The end slabs 14 ensure good floor stability along the walls, once adjusting cuts have been made. FIG. 14 shows various scenarios explaining this necessity.
The section carried out in the direction of arrow a reveals that the triangular main slabs 1 give satisfactory results, that is to say an adequate support along length a1. Lengths a2 and a3 show three other adjustment possibilities by means of end slabs 14 which are truncated in order to obtain improved results.
The section carried out in the direction of arrow b shows that the small surfaces x of the triangular slabs 1, remaining after cutting and indicated by section lining, are inadequate and unequal to the task of providing satisfactory support along length b1. In contrast, end slabs 14 are used along length b2, and the parts remaining after cutting, represented in section lining, have a sufficient surface to provide a satisfactory support.
The section carried out in the direction of arrow c shows that satisfactory stability is obtained, along length c1, using the end slabs 14, but in this case triangular slabs 1 could also have been used.
The section carried out in the direction of arrow d reveals that satisfactory stability along length d1 is obtained using cut end slabs 14, whereas the triangular slabs 1 would involve small cuts x which would be impossible to fix.
In the angles, the sectional intersections--in directions a and c, on the one hand, and in directions b and d, on the other hand--are made using end slabs 14.
FIGS. 14, 15, 16, 17 and 18 represent the triangular-shaped slabs corresponding to the variant of the invention under consideration. The characteristics are the same as for modular slabs of any regular polygonal shape. The subjacent support 2 comprises an upper support face 5 in which six converging radial slots are bored, these slots being distributed at regular intervals and at an angle of 60° to each other, on a circle of center O where the tops of six adjacent triangular slabs 1 are merged, as shown in FIG. 16. If the support face 5 is circular, it may be seen that each corner of a triangular slab 1 rests on a sector at an angle of 60° of the circular support face 5. Parts 3 of edges 6, folded downwards, are inserted in the converging radial slots 4. As the width e of each slot 4 is chosen equal to twice the thickness of the parts 3 of the edges 6, said edges 6 of two adjacent triangular slabs 1 are packed and blocked against each other in the same slot 4, as may be seen from a study of FIGS. 17 and 18, thereby ensuring a firm fixture of the slabs 1 on the support 2. The converging forms of the slots 4 provide the horizontal hold of the slabs 1, while the three-point support for each slab 1 gives perfect stability, thus eliminating any risk of vertical movement which might lead to disassembly, but at the same time ensuring easy, fast and effortless dismantling. Moreover, each support 2 is particularly stable since it is simultaneously retained by six adjacent triangular slabs 1.
With a view to making the representation as clear as possible, in FIGS. 14, 15, 16, 17 and 18 the edges 6 are shown in their simplest form, that is to say without height reduction at their extremities, without strips and without bosses. It is clear that all these different variants may be applied to triangular-shaped slabs. In particular, in the presence of bosses 13 on the elastic strips 10, the width of the radial slots 4 will be equal to twice the thickness of the strips 10 plus once the thickness of the boss 13.
The view from below represented in FIG. 18 gives a good illustration of the way in which the edges 6 of triangular slabs 1 are attached to each other, thereby establishing the continuity of the floor. However, due to the fact that there is a separation plane between two adjacent slabs 1, the floor displays good acoustic performance since the separation planes between the slabs break horizontal sound transmission, particularly in the case of the variant in which parts 3 of edges 6 are in the shape of elastic strips fitted with bosses, because in this case the base plates 7 of the slabs are separated from each other by a play corresponding to the thickness of the boss. Moreover, given that the triangular slabs 1 are small in size, they mitigate the membrane effect obtained with larger surfaces.
FIGS. 19 and 20 represent an arrangement of a trapezoid end slab 14. This end slab may also, like the triangular slab 1, be made up of sheet metal cut and folded so as to form a trapezoid base plate 35 which presents, on its sides, rims folded at right angles in the same direction and culminating at a same distance from the tops of the base plate 35. The two inclined sides and the small base of the trapezoid slab 35 each comprise two distinct edges 15 which are obtained by creating a recess 34 centered on the edge of the large base. This recess 34 between the two edges 15 of the large base is needed to attach the end slab 14 to the subjacent supports.
With reference to FIGS. 21 to 27, a description will now be given of various non limitative embodiments of the floor supports. These supports, which are constituted by independent elements designed to receive, according to a preferred variant of the considered invention, on their upper faces, the triangular slabs 1 and the trapezoid end slabs 14 and to keep them assembled, determine the height of the plenum obtained, that is to say, of the empty space under the floor which is equal to their own height. Each support comprises a horizontal upper face 5 in which are formed the six converging radial slots 4 distributed, at an angle of 60° in relation to each other, around the center O of the upper face 5.
The support 16 represented in FIG. 21, is made in a single steel piece, in a general upwardly converging tapered shape, terminated at its lower part by an external flange 17 constituting a support base on the ground. The upper face of the upper horizontal wall 18 of the support 16 constitutes in itself the planar support and fastening face 5 of the slabs. The radial slots 4 are bored both in the upper wall 18 and in the upper part of the tapered lateral wall.
In the variant represented in FIG. 22, the support 16 comprises a full upper wall 20 onto which is fastened, for example by welding, an added circular plate 19 in which the radial slots 4 are formed.
In the variant represented in FIG. 23, the support 21 is made up of three parts, assembled together by welding or otherwise, namely a lower horizontal base 22, an upper horizontal head 23 in which the radial slots 4 are bored in order to fasten the slabs, and an intermediate vertical body 24 stretching between the base 22 and the head 23, all these elements being preferably fabricated in steel.
In the variant represented in FIG. 24, the support 25 comprises a lower block 26, of tapered shape and possibly made of matter which is inert to fire such as resin, plastic matter, plaster, cement, anhydrites, calcium silicate, conglomerate wood, etc. An upper circular steel plate 27 is fixed on the upper face of block 26, in which said plate 27 are cut the radial slots 4 which lie above corresponding radial grooves 28 formed on the upper part of block 26.
In the variant represented in FIG. 25, the support 29 is made up of a molded block, with a grooved structure, and fabricated of light alloy, plastic material, compressed wood, resin, etc. The support 29, of a general taper shape, possesses in its upper horizontal wall six molded radial grooves 30 placed at an angle of 60° in relation to each other as described in the previous embodiments.
FIGS. 26 and 27 show a variant in which the support 31 is made up of a hexagonal shape in molded material hollowed out by six radial slots 32 and equipped with six reinforcement grooves 33 shifted by 30° compared to the radial slots, these reinforcement slots 33 making it possible both to increase the ground support surface and the slab support surface.
|
A raised floor having an upper surface in the form of regular polygon-shaped modular slabs, each having a substantially horizontal plate portion and downwardly extending side edges. The plate portion of each slab is supported on the top of substantially vertical ground-engaging supports. Around the periphery of a top member of each vertical support are a plurality of radial slots for receiving pairs of confronting side edges of adjacent slabs for securing the slabs to the supports.
| 4
|
BACKGROUND OF THE INVENTION
1. Field of the Art
The present invention relates generally to a bush assemblage which is disposed between two members in a vibration system for resiliently connecting the two members so as to damp vibrations in the system, and more particularly to such bush assemblage, especially for the pivotal connection of a suspension member in an automotive vehicle, of generally cylindrical shape which comprises an inner sleeve, an outer sleeve, and a cylindrical resilient member interposed between the inner and outer sleeves.
2. Related Art Statement
A bush assemblage used for a pivotal connection in a vehicle suspension, for example, a bush assemblage, such as a control arm bush mounted in a connecting portion between a control arm and a member of a car body side or car chassis side, is generally constructed of a couple of concentrically placed metal sleeves, i.e., an inner metal sleeve and an outer metal sleeve, with a cylindrical resilient or elastic member of rubber material interposed therebetween. Such bush assemblages are aimed to, owing to the spring characteristics of the resilient member, absorb or damp mainly vibrations in their radial direction, i.e., perpendicular direction to the axis thereof. However, the use of a relatively hard rubber material as the resilient member in such bush assemblages causes the assemblages to demonstrate relatively hard or stiff circumferential spring characteristics, i.e. spring characteristics in their circumferential direction or the direction of twisting about their axis.
Some proposals have been made so far to mitigate that undesirable circumferential spring characteristic or twisting spring action, by means of interposing a sliding member or friction-reducing means between the inner metal sleeve and the resilient member, for example: U.S. Pat. No. 3,331,642, and Japanese Utility Model Application laid open in 1984 under Publication No. 59-153736. In such proposed bush assemblages, the friction resistance between the inner metal sleeve and the resilient member is decreased due to interposing of the sliding member, and relative rotation between the sleeve and the resilient member is made considerably smooth around the axis, irrespective of the extent of radial rigidity. It allows reduction of the rigidity around the axis, while maintaining the radial rigidity of the bush assemblage.
3. Problems Solved by the Invention
In such a bush assemblage provided with the sliding member, there still remain some problems.
Possible ingress of particles (such as dirt and sand grains) and mud water between the sliding member and the inner sleeve may cause some cracks or scratches and consequently cause rusting on the sliding surface of the sleeve which is usually made of metallic material. It in turn deteriorates the sliding action itself therebetween, thereby possibly resulting in degradation of the originally aimed reduction effect of the twisting spring action by the sliding member.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide a bush assemblage which has improved sliding action in its circumferential direction.
According to the present invention, there is provided a bush assemblage having an inner sleeve, an outer sleeve disposed around the inner sleeve in co-axial and radially-spaced relation with each other, a rigid sleeve member disposed between the inner and outer sleeves, a cylindrical resilient member interposed between the outer sleeve and the rigid sleeve member, and a cylindrical sliding member interposed between the inner sleeve and the rigid sleeve member, comprising: a retainer member located at at least one of axial ends of the inner sleeve to extend radially outwardly; and a sealing means for sealing between at least the retainer and the rigid sleeve member, the sealing means including a rubber member which is disposed on one of the retainer member and an axial end of the rigid sleeve member corresponding to the above-identified at least one axial end of the inner sleeve and which abuts against the other.
In the above assemblage, the rubber member, disposed between the retainer member and the corresponding axial end of the rigid sleeve member, prevents dirt, sand grain, mud water, etc., from ingressing thereinto, so as to ensure advantageous relative rotation between the sliding member and the rigid sleeve member and/or between the sliding member and the inner sleeve. That is, the rubber member permits the sliding member to realize the originally expected effects of mitigating the twisting spring action of the resilient member.
Being interposed between the rigid sleeve member of relatively high rigidity and the inner sleeve and protected by the two members, the sliding member is therefore effectively protected against deformation, cracking, etc., caused by the vibrational load or the like. That leads to elongation of life of the bush assemblage as well as maintenance of the effects of the sliding member, e.g. satisfactory reduction of rotation resistance of the bush assemblage.
In accordance with one embodiment of the invention, the rigid sleeve member has an outer flange extending radially outwardly from one of axial ends thereof situated on the side of the retainer member, and the rubber member is disposed on an axially external surface of the outer flange and abuts against the retained member.
According to another embodiment of the invention, the resilient member is secured, both to the inner surface of the outer sleeve and to the outer surface of the rigid sleeve member, through vulcanization on the spot between the outer sleeve and the rigid sleeve member, so as to make an integral body consisting of the outer sleeve, the resilient member and the rigid sleeve member.
In a further embodiment of the invention, the sliding member is made of an oil-containing plastic material.
According to a yet further embodiment, the retainer member is located at each of the axial ends of the inner sleeve, and the sealing means is provided so as to correspond to each of the retainer members.
According to another aspect of the invention, there is provided a bush assemblage having an inner sleeve, an outer sleeve disposed around the inner sleeve in co-axial and radially-spaced relation with each other, a rigid sleeve member disposed between the inner and outer sleeves, and a cylindrical resilient member interposed between the outer sleeve and the rigid sleeve member, comprising: a retainer member located at at least one of axial ends of the inner sleeve to extend radially outwardly; a sealing means for attaining sealing at least between the retainer member and the rigid sleeve member, the sealing means including a rubber which is disposed on one of the retainer member and an axial end of the rigid sleeve member corresponding to the above-identified at least one axial end of the inner sleeve and which abuts against the other; and a cylindrical sliding member interposed between the inner sleeve and the rigid sleeve member, and consisting of a pair of separate cylindrical parts while an annular space of a predetermined size is defined by the pair of cylindrical parts, the inner sleeve and the rigid sleeve member, one of the separate cylindrical parts being situated on the side of the retainer member having an outer flange which extends radially outwardly from one of axial ends thereof situated on the side of the retainer member.
The aforementioned annular space of predetermined size which is confined by the inner sleeve, the rigid sleeve member and both non-flanged ends of the cylindrical parts of the sliding member, can function as an oil reservoir for lubricating oil which has been smeared on the surfaces of the cylindrical parts, etc. The lubricating oil of the reservoir (the annular space) is progressively supplied to the surfaces of the inner sleeve, the sliding member, etc., by means of repeated rotations of those members. The annular hollow space greatly contributes, along with the the sealing rubber member, to enhancement of the effects of the sliding member on the rotation-resistance reduction. The annular space also contributes, along with the inner sleeve and the rigid sleeve member, to protection of the sliding member by decreasing wearing of the sliding surfaces. As a result, life of the bush assemblage is elongated. The size of the annular space is defined large enough to work effectively as a reservoir as set forth above.
According to a further aspect of the invention, there is provided a bush assemblage having an inner sleeve, and an outer sleeve disposed around the inner sleeve in co-axial and radially-spaced relation with each other, a cylindrical resilient member disposed between the outer and the inner sleeves and adjacent to the outer sleeve, and a cylindrical sliding member disposed between the inner sleeve and the cylindrical resilient member and adjacent to the inner sleeve, comparising: a rigid sleeve member interposed between the resilient member and the sliding member, and having an outer flange which extends radially outwardly form at least one of axial ends thereof and a first cylindrical portion which extends axially inwardly from the circumferential edge of the outer flange; a retainer member located at one of axial ends of the inner sleeve corresponding to the above-mentioned at least one axial end of the rigid sleeve member, and having a second cylindrical portion which extends axially inwardly from the circumferential edge thereof while surrounding the first cylindrical portion of the rigid sleeve member at a predetermined distance away therefrom; and a sealing rubber member for sealing between the first cylindrical portion of the rigid sleeve member and the second cylindrical portion of the retainer member, the sealing rubber member being disposed on one of the outer surface of the first cylindrical portion and the inner surface of the second cylindrical portion, and abutting against the other.
According to a yet further aspect of the invention, there is provided a bush assemblage having an inner sleeve, an outer sleeve disposed around the inner sleeve in co-axial and radially-spaced relation with each other, a cylindrical resilient member disposed between the outer and inner sleeves and adjacent to the outer sleeve, and a cylindrical sliding member interposed between the inner sleeve and the resilient member and adjacent to the inner sleeve, comprising: a rigid sleeve member interposed between the resilient member and the sliding member, and having an outer flange extending radially outwardly from at least one of axial ends thereof and a cylindrical portion extending axially outwardly from the circumferential edge of the outer flange; a retainer member located at one of axial ends of the inner sleeve corresponding to the above-identified at least one axial end of the rigid sleeve member; and a sealing means for sealing between at least the rigid sleeve member and the retainer member, the sealing means including a rubber member which is disposed on the inner surface of the cylindrical portion of the rigid sleeve member and which abuts against the circumferential surface of the retainer member.
In the bush assemblages according to the last two aspects of invention, both the sealing rubber member and the sealing means do not suffer from a radial-directional load which acts between the inner sleeve and the outer sleeve, whereby wearing of the sealing means or sealing rubber member is reduced to a minimum. This in turn prolongs the durability of such sealing means and sealing rubber member and maintains their sealing effect semi-permanently. Another merit resides in that no relative position change in the radial direction can take place between the rigid sleeve member and the retainer member, and it ensures constant sealing, irrespective of load change in the radial direction. The sliding member of such bush assemblage is interposed between the rigid sleeve member of comparatively high rigidity and the inner sleeve, and is thereby well protected by the two, so it is not susceptible to deformation and/or cracking due to vibration load from outside, whereby effective reduction of the rotation resistance and life elongation of the device are achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the present invention will be better understood from reading the following detailed description of preferred embodiments of the invention, when considered in conjunction with the accompanying drawings, in which:
FIG. 1 is an elevational view in longitudinal cross section of a bush assemblage embodying the present invention;
FIG. 2 is an elevational view in longitudinal cross section of an outer sleeve used in the bush assemblage in FIG. 1;
FIG. 3 is a right-hand side end elevation of the outer sleeve of FIG. 2;
FIG. 4 is an elevational view in longitudinal cross section of a rigid sleeve used in the bush assemblage in FIG. 1;
FIG. 5 is a right-hand side end elevation of the rigid sleeve of FIG. 4;
FIG. 6 is an elevational view in longitudinal cross section of an outer assembly unit, in the bush assemblage in FIG. 1, produced by forming a resilient member through vulcanization between the outer sleeve and the rigid sleeve;
FIG. 7 is an elevational view in longitudinal cross section of the bush as a sliding member in the bush assemblage in FIG. 1;
FIG. 8 is a right-hand side end elevation of the bush of FIG. 7;
FIG. 9 is an enlarged view in cross section taken along line IX--IX of FIG. 7;
FIG. 10 is an elevational view in longitudinal cross section of an inner sleeve used in the bush assemblage in FIG. 1;
FIG. 11 is a right-hand side end elevation of the inner sleeve of FIG. 10;
FIG. 12 is a sectional view of one retainer on one side of the bush assemblage in FIG. 1;
FIG. 13 is a plan view of the retainer in FIG. 12;
FIG. 14 is a sectional view of the other retainer on the other side of the bush assemblage in FIG. 1;
FIG. 15 is a plan view of the retainer in FIG. 14;
FIG. 16 is an elevational view in longitudinal cross section of one collar on one side of the bush assemblage in FIG. 1;
FIG. 17 is a right-hand side end elevation of the collar of FIG. 16;
FIG. 18 is an elevational view in longitudinal cross section of the other collar on the other side of the bush assemblage in FIG. 1;
FIG. 19 is a right-hand side end elevation of the other collar of FIG. 18;
FIG. 20 is an elevational view in longitudinal cross section of another embodiment of this invention for explaining the state of attachment to a predetermined shaft;
FIG. 21 is a left-hand side end elevation of another bush as a sliding member used in the embodiment of FIG. 1;
FIG. 22 is an enlarged view in cross section taken along line XXII--XXII of FIG. 21;
FIG. 23 is an elevational view in longitudinal cross section of another embodiment of a bush assemblage according to the present invention;
FIG. 24 is an elevational view in longitudinal cross section of a rigid sleeve used in the bush assemblage in FIG. 23;
FIG. 25 is a right-hand side end elevation of the rigid sleeve of FIG. 24;
FIG. 26 is an elevational view in longitudinal cross section of an outer assembly unit produced by vulcanizing formation of a resilient member executed between an outer sleeve and the rigid sleeve in the bush assemblage in FIG. 23;
FIG. 27 is an elevational view in longitudinal cross section of one retainer in the bush assemblage in FIG. 23;
FIG. 28 is a right-hand side end elevation of the retainer of FIG. 27;
FIG. 29 is an elevational view in longitudinal cross section of the other retainer in the bush assemblage in FIG. 23;
FIG. 30 is a left-hand side end elevation of the other retainer of FIG. 29;
FIG. 31 is a left-hand side end elevation of another bush as a sliding member used in the embodiment of FIG. 23;
FIG. 32 is an enlarged view in cross section taken along line XXXII--XXXII of FIG. 31;
FIG. 33 is an elevational view in longitudinal cross section of yet another embodiment of a bush assemblage according to the present invention;
FIG. 34 is an elevational view in longitudinal cross section of a rigid sleeve used in the bush assemblage in FIG. 33:
FIG. 35 is a right-hand side end elevation of the rigid sleeve of FIG. 34; and
FIG. 36 is an elevational view in longitudinal cross section of an outer assembly unit produced by vulcanizing formation of a resilient member on the spot between an outer sleeve and the rigid sleeve, in the bush assemblage in FIG. 33.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
To further clarify the concept of the present invention, a few preferred embodiments of the invention will be described in detail by reference to the accompanying drawings.
Referring first to FIG. 1, there is shown a bush assemblage according to the present invention in an elevational view in longitudinal cross section. In this figure reference numeral 10 designates an outer metal sleeve of cylindrical shape, and at the innermost inside of the outer sleeve 10 an inner metal sleeve 12 of cylindrical shape is disposed coaxially or concentrically with the outer sleeve 10. Between the outer sleeve 10 and the inner sleeve 12 a cylindrical rubber block 14, as a cylindrical resilient member, is interposed. Between the inner sleeve 12 and the rubber block 14, a metallic sleeve 16 of rather high rigidity and a pair of bushes 18, 18 made of oil-containing plastic material, for example, oil-containing polyacetal resin, for constituting a pair of sliding members, are in turn interposed. So as to complete the such bush assemblage, retainers 20, 22 are disposed respectively at each end of the inner sleeve 12, and between retainers 20, 22 and respective ends of the metallic sleeve 16, sealing rubbers 24, 26 are respectively inserted.
The outer sleeve 10 is, as clearly shown in FIGS. 2 and 3, made into a stepped cylindrical body having a small-diameter portion 28 and a large-diameter portion 30. One end of the outer sleeve 10 on the side of the large-diameter portion 30 is formed into a radially outwardly extending flange 32, and the other end of the outer sleeve 10 is formed into a tapered surface 34, for making it easy to insert the bush assemblage into a predetermined attaching hole (not shown) in a control arm on a suspension or the like.
The metallic sleeve 16 is formed into a cylindrical body with a smaller diameter than that of the outer sleeve 10, and with a slightly longer axial length than that of the outer sleeve 10. On the ends, thereof outer flanges 36, 38, radially outwardly extending, are respectively formed. On the axially external surface of each outer flange 36, 38, the earlier mentioned sealing rubber 24, 26 is formed to be stuck thereon. The outer flange 36 of the metallic sleeve 16 is made of slightly larger diameter than the other outer flange 38, and the outer flange 36 is situated, when the bush assemblage is built up, on the side of the large-diametered portion 30 of the outer sleeve 10.
The outer sleeve 10 and the metallic sleeve 16 are arranged concentrically, and the afore-mentioned rubber block 14 is interposed therebetween. The rubber block 14 is preferably formed, in an annular vacant space which is formed by the concentric arrangement of the two members as is shown in FIG. 6, by means of vulcanizing a certain predetermined rubber material there on the spot. By doing so the rubber block 14 can be advantageously stuck or adhered on the inner surface of the outer sleeve 10 and the outer surface of the metallic sleeve 16 simultaneously of the vulcanizing operation, and the outer sleeve 10, the metallic sleeve 16, and the rubber block 14 can be made into an integral body to provide an outer assembly unit. Then, the outer sleeve 10 of the prepared outer assembly unit is subjected to a commonly practiced shrink drawing or reducing operation by means of a drawing die or dies, which will impart preliminary pressure to the rubber block 14 and help to firmly unite the three members.
In this embodiment the sealing rubbers 24, 26 are also, at the time of vulcanization of the rubber block 14, simultaneously formed therewith into an integral body. The sealing rubbers 24, 26 are respectively stuck or adhered, while being formed, onto the axially outer surface of each outer flange 36, 38. The sealing rubbers 24, 26 are respectively provided with, in the axially outer surface, i.e., in the surface at which they are abutted onto the retainer 20, 22, an annular V-shaped groove 40, 42 for fully enhancing the sealing effect. It is however permissible to form by vulcanization the sealing rubbers 24, 26 separately from the rubber block 14 and of different material. It is also permissible, on the contrary, to integrally form the rubber block 14 and the sealing rubbers 24, 26 before adhering them all at once onto the outer sleeve 10 and the metallic sleeve 16 and then secure them to the two members with an adhesive or the like.
On the other hand, the bushes 18, 18 are both, as illustrated in FIGS. 7-9, of cylindrical form having an outer diameter substantially similar to the inner diameter of the metallic sleeve 16. They are further provided respectively with, on one end thereof, a radially outwardly extending outer flange 44, and also four axial grooves 46, on the inner surface thereof, running with an equal angular interval from each other in the circumferential direction. Both of these bushes 18, 18 are press-fit into the inner side of the metallic sleeve 16, headed by the end 48 thereof where the outer flange 44 is not formed, until the outer flange 44 abuts on the end of the metallic sleeve 16. They are both fixed on the metallic sleeve 16, leaving however a gap of axially predetermined length between the two ends 48, 48. The outer diameter of the outer flange 44 of the bush 18 is made smaller than the outer diameter of either outer flange 36, 38 of the metallic sleeve 16, so that the sealing rubbers 24, 26 may be respectively abutted to the retainers 20, 22 by being stuck respectively on the external circumferential surface of the outer flange 36, 38 (see FIG. 1).
The outer diameter of the inner sleeve 12 is made, as is clearly shown in FIGS. 10 and 11, equal to or slightly smaller than the inner diameter of the bush 18, 18, and the axial length of the inner sleeve 12 is made equal to or slightly larger than the length between both ends of the pair of bushes 18, 18 when they have been press-fit along the inside of the metallic sleeve 16. The inner sleeve 12 is therefore inserted inside the bushes 18, 18 such that the outer circumferential surface thereof may be in contact with or extremely close to the inner circumferential surface of the bushes 18, 18, thereby permitting relative rotation or sliding between the inner sleeve 12 and the bushes 18, 18. A suitable inner shaft (not shown) is inserted through the inside of the inner sleeve 12, and is attached, by way of a suitable supporting member such as a bracket, to the side of a car body.
As a result of insertion of the inner sleeve 12 inside the pair of bushes 18, 18, a gap between the ends 48, 48 of bushes 18, 18 will form, by being confined by the inner sleeve 12 and the metallic sleeve 16 from either side, an annular hollow space 50. This space 50 can be advantageously used as a reservoir for a lubricant such as rubber grease by putting it in before the insertion of the inner sleeve 12, or in some cases the space 50 may be a place to accommodate a surplus of the lubricant smeared on the slidable surface of the bushes 18, 18 and the inner sleeve 12. Anyway such an annular hollow space 50 can contribute, by functioning as a reservoir of the lubricant for lubricating the whole sidable surfaces of the inner sleeve 12 and the bushes 18, 18, to making the relative rotation therebetween smooth and alleviating the friction therebetween. The longitudinal grooves 46 formed on the internal circumferential surface of the bushes 18 can also contribute to facilitation of the lubricant's movement in the axial direction, which greatly helps the lubricant reach easily even as far as a far distant place from the space 50. This space 50 should have a size large enough for satisfactorily functioning as an oil reservoir of this sort, which naturally determines the axial length of the pair of bushes 18, 18 when designing them.
The retainers 20, 22 to be attached to either axial end of the inner sleeve 12 are of doughnut shape, and have respectively circular holes 52, 54 in the center thereof with a substantially equal internal diameter as that of the inner sleeve 12, as can be clearly seen in FIGS. 12-15. The external diameter of the retainers 20, 22 is made respectively larger than that of the outer flanges 36, 38. The retainers 20, 22 are respectively attached to the inner sleeve 12 by way of collars 56, 58, which are constituted of cylindrical portions 60, 62, with an external diameter nearly as large as the internal diameter of the inner sleeve 12, and outer flanges 64, 66 which are radially outwardly extending respectively from one end of the cylindrical portions 60, 62. The cylindrical portions 60, 62 are inserted into the inside of the inner sleeve 12 at either end portion thereof so as to fix the retainers 20, 22 to either end portion of the inner sleeve 12.
When inserting the cylindrical portions 60, 62 into the inside of the inner sleeve 12, the outward end of the sealing rubbers 24, 26 stuck on the outer flange of the metallic sleeve 16 are respectively abutted on the inner side surface of the retainers 20, 22 and are deformed under pressure between the outer flange 36, 38 and the retainer 20, 22 respectively. It brings about effective sealing between the outer flanges 36, 38 and the retainers 20, 22 so as to prevent ingress of dirt, sand, mud water, etc., into the bush assemblage. The retainers 20, 22 are situated very closely face to face or in contact with the outer flanges 44, 44 of the pair of bushes 18, 18 on either end of the bush assemblage, for permitting the relative rotation of the retainers 20, 22 and the outer flanges 44, 44.
Passing through the inside of the inner sleeve 12 of the bush assemblage, the inner shaft is inserted for being mounted, as a front bush, rear bush, or lower bush, to a control arm, such as an A-arm or I-arm of the suspension on the side of the car body.
Since ingress of dirt, sand grains, mud water, etc., is effectively prevented in a bush assemblage of such a construction, due to effective sealing between both ends of the metallic sleeve 16 and the retainers 20, 22 with the sealing rubbers 24, 26, the relative rotation between the pair of bushes 18, 18 secured to the metallic sleeve 16 and the inner sleeve 12 can be substantially freed from damage caused by the aforementioned ingress of dirt, sand grains, mud water, etc. Formation of the V-shape grooves 40, 42 in the sealing rubbers 24, 26, and surface contact of the sealing rubbers 24, 26 onto the retainers 20, 22 under pressure, ensure the sealing effect. Interposing of the outer flanges 44, 44 of the bushes 18, 18 between the outer flanges 36, 38 of the metallic sleeve 16 and the retainers 20, 22, wherein the sealing rubbers 24, 26 are respectively mounted, prevents a relative position change between the outer flanges 36, 38 and the retainers 20, 22, which consequently prevents elastic deformation of the sealing rubbers 24, 26 owing to an axial load input, i.e., constantly maintains good sealing effect. It naturally elongates the life of the sealing rubbers 24, 26. When the sealing rubbers 24, 26 are, like in this embodiment, integrally formed by vulcanization at one time, an extra process of making the sealing rubbers 24, 26 can be meritoriously eliminated in the course of building up or assembling the bush assemblage.
Since the bushes 18, 18 are press-fit into the inside of the metallic sleeve 16, the latter functions as a resisting member for preventing the bushes 18, 18 from being deformed or cracked owing to a vibration load from outise. it maintains the bushes 18, 18 at a high degree of roundness, and thereby ensures effective reduction of the twisting spring action. By enhancing at the same time durability against heat or the like, it contributes to life elongation of the bush assemblage.
The hollow space 50, formed between the ends 48, 48 of the bushes 18, 18 functions as a reservoir of the lubricant such as rubber grease, so as to gradually lubricate the sliding surfaces of the bushes 18, 18 and the inner sleeve 12. It not only effectively mitigates wearing of the sliding members but also further enhances the mitigating effect of the twisting spring action caused by the bushes 18, 18. In particular, the axially longitudinal grooves 46 formed on the internal circumferential surface of the bushes 18, 18, in this embodiment, makes the above-mentioned effect more remarkable due to the thorough lubrication even as far as the remotest place from the hollow space 50.
In place of the collars 56, 58 with which the retainers 20, 22 are attached to either end of the inner sleeve 12, in this embodiment, the retainers 20, 22 may be attached by threading a nut 70 to a predetermined shaft or mounting bolt 68 as shown in FIG. 20. In this figure numeral 72 designates a suspension arm and 74 designates a bracket secured to a member (not shown) on the side of the car body. It is also permissible to utilize the bracket 74 as a retainer 20, 22 on either end of the bush assemblage.
Although in the above embodiment four axially longitudinal grooves 46 are formed only on the internal circumferential surface of the bushes 18, 18, four recesses 76 may be additionally formed on the axially external circumferential surface of the outer flanges 44, 44 in alignment with each of the four grooves 46, as shown in FIGS. 21 and 22, which will make lubrication between the outer flanges 44, 44 and the retainers 20, 22 far better. The recesses 76 need not to be formed in alignment with the grooves 46. The recesses can function by themselves, independent from the grooves 46, as an oil reservoir just like the hollow space 50.
Embodiments of the invention have been described above in detail with reference to the drawings, this invention can however be reduced to many different modes.
In the above embodiment, for example, the sealing rubbers 24, 26 are integrally formed with the rubber block 14 for being stuck on the sleeve 16. They may be, however, separately formed from the rubber block 14 for being optionally stuck on either the sleeve 16 or each of the retainers 20, 22. Even if the V-grooves 40, 42 formed on the outer ends of the sealing rubbers 24, 26 are omitted, the aimed sealing effect can be attained by and large.
The bushes 18, 18 in the above described embodiment are made relatively rotatable with the inner sleeve 12, but it is not the only possible structure. Other alternatives are permissible. For example, the bushes 18, 18 may be fixed onto the inner sleeve 12 to provide relative rotation between the bushes and the metallic sleeve 16, and it is also possible to leave the bushes 18, 18 unfixed so as to allow them instead to freely rotate in relation to either the metallic sleeve 16 and the inner sleeve 12.
In the embodiments, the slidable members are constituted of the pair of bushes 18, 18 so as to form the hollow space 50 between both ends 48, 48 of the bushes 18, 18. It is however not absolutely essential to leave the hollow space 50. It is permissible to form the sliding member into one integral cylindrical body, in place of the separated two pieces.
In place of the pair of bushes 18, 18, constituting the sliding members, made of oil-containing plastic material, they can be of metallic material, such as oil-containing bearing alloy.
In the embodiments, on either end of the bush assemblage the sealing rubbers 24, 26 are respectively put inserted. It is also possible to omit one of either 24 or 26, when the bush assemblage is so built as to relieve one side end of ingress of any undesirable matter due to its special attaching position.
Referring further to FIGS. 23 through 30, there will be described preferred embodiments of the bush assemblage according to another aspect of the present invention.
In the elevational view in longitudinal cross section of FIG. 23, reference numeral 110 designates an outer cylindrical sleeve of metallic material. At the innermost inside of the outer sleeve 110 an inner cylindrical sleeve 112 of metallic material is concentrically placed therewith. Between those two sleeves (110, 112) a cylindrical rubber block 114, as a cylindrical resilient member, is interposed. Between the rubber block 114 and the inner sleeve 112, a metallic sleeve 116 of relatively high rigidity, as a rigid sleeve member, and a pair of cylindrical members 118, 120, or bushes of oil-containing polyacetal resin material, constituting a sliding member, are respectively interposed. On the ends of the inner sleeve 112, retainers 122, 124 of substantially U-letter form in section are respectively attached to build up the bush assemblage. Between the retainers 122, 124 and the end of the metallic sleeve 116 annular sealing rubbers 126, 128 are inserted on the ends of the bush assemblage.
The metallic sleeve 116 is composed of, as shown in FIGS. 24 and 25, a cylindrical portion 138 which is of smaller diameter and of larger axial length than the outer sleeve 110, outer flanges 140, 142 respectively extending from the ends of the cylindrical portion 138 in a radial and outward direction, and two large-diameter cylindrical portions 144, 146, axially extending respectively from the outer circumferential edge of the outer flanges 140, 142 towards the opposite end. The outer diameter of one outer flange 140 is larger than that of the other outer flange 142, and the former is positioned, when the bush assemblage is built up or assembled, on the side of an outer flange 134 of the outer sleeve 110. The outer diameter of the other outer flange 142 is made smaller than the inner diameter of a small-diameter portion 130 of the outer sleeve 110.
The outer sleeve 110 and the metallic sleeve 116 are concentrically arranged, and the rubber block 114 is interposed therebetween. It is desirable that the outer sleeve 110 and the metallic sleeve 116 be concentrically arranged first, and then predetermined rubber material be vulcanized in an annular vacant space between the two members so as to form the rubber block 114 there while filling up the space at one time. The rubber block 114 will be stuck or adhered, while being vulcanized, to the internal surface of the outer sleeve 110 and the external surface of the metallic sleeve 116, so as to make the three members, i.e., outer sleeve 110, the metallic sleeve 116, and the rubber block 114, into one integral body to provide an outer assembly unit. A drawing process subjected thereafter on the outer sleeve 110 will impart preliminary compression to the rubber block 114 and bond the three members more firmly.
In this embodiment, however, the sealing rubbers 126, 128 are, separately from the vulcanizing formation of the rubber block 114, formed by vulcanization while being stuck of adhered on the outer circumferential surface of the large-diameter cylindrical portions 144, 146 respectively. On the outer circumferential surface of the sealing rubbers 126, 128 a plurality of circumferential grooves 148, 150 are formed for fully enhancing sealing effect. The sealing rubbers 126, 128 can also be integrally formed with the rubber block 114, by means of forming some notches or recesses on the large-diameter cylindrical portions 144, 146. They may be separately formed before they are stuck or adhered on the outer circumferential surface of the large-diametered cylindrical portions 144, 146 with an adhesive or the like.
The pair of cylindrical members, i.e., bushes 118, 120 are of cylindrical form, having almost the same size outer diameter as the inner diameter of the metallic sleeve 116, and they have respectively on one end thereof radially outwardly extending outer flanges 152, 154, and also have on their inner circumferential surfaces four axial grooves 156 (FIGS. 31 and 32) with an equal angular interval in the circumferential direction from each other. They are respectively press-fit inside the metallic sleeve 116, being led by the non-flanged end thereof, until the outer flanges 152, 154 abut on the ends of sleeve 116, where they are fixed. The pair of bushes 118, 120 are so designed as to leave a hollow space of a predetermined size between the ends thereof. When they are press-fit, the bush 118 is press-fit on the side of the outer flange 140 of the sleeve 116, and its outer flange 152 is larger than the outer flange 154 of the bush 120, in harmony with the larger outer flange 140 of the sleeve 116 on one side than the other outer flange 142 on the other side, while the axial length thereof is smaller than that of the bush 120.
When the inner sleeve 112 is inserted inside the bushes 118, 120, a gap between the two ends 160, 162 of the bushes 118, 120 is formed into an annular hollow space 164, being confined by the inner sleeve 112 and the sleeve 116, from both flanks. This space 164 is serviceable as a reservoir for lubricant such as rubber grease which is put in before the inner sleeve 112 is inserted, or as a pool for lubricant smeared over the sliding surfaces of the bushes 118, 120 and the inner sleeve 112. Anyway, the hollow space 164 of such a style can function as an oil reservoir for lubricant lubricating the sliding surfaces of the bushes 118, 120 and the inner sleeve 112. It greatly contributes to a good relative rotation of the two members and thereby to wear mitigation of both. The axial grooves on bushes 118, 120 are, in cooperation with the hollow space 164, serviceable to spread lubricant even to ends remote from the hollow space 164. The hollow space 164 must therefore be large enough for this object as the oil reservoir, which determines the length of the bushes 118, 120 when they are designed, e.g., to leave a satisfactory sized space.
On the ends of the inner sleeve 112, retainers 122, 124 are mounted for assembling the bush assemblage, which retainers are respectively of roughly U-letter shape in section, consisting of (as shown in FIGS. 27-30) circular disk portions 166, 168 of doughnut shape, inside cylindrical portions 170, 172, with an outer diameter almost equal to the inner diameter of the inner sleeve 112, extending from the inner circumferential edges of the circular disk portions 166, 168 in the perpendicular direction, and outside cylindrical portions 174, 176 extending from the outer circumferential edges of the circular disk portions 166, 168 in the same direction as the inside cylindrical portions 170, 172. The outer diameter of the circular disk portions 166, 168 is respectively larger than that of the outer flanges 140, 142 of the sleeve 116. The lengths of the outside cylindrical portions 174, 176 are respectively determined such that the inner circumferential surfaces thereof can be positioned face to face with the outer circumferential surfaces of the large cylindrical portions 144, 146 of the sleeve 116 on either axial side.
The retainers 122, 124 are at their inner cylindrical portions 170, 172 press-fit inside the inner sleeve 112, from either end, for being fixed there. On the inner circumferential surfaces of the outside cylindrical portions 174, 176, which are placed face to face with the outer circumferential surfaces of the large-diameter cylindrical portions 144, 146, the sealing rubbers 126, 128 are respectively abutted and at the same time deformed under pressure between those two members faced to each other. Effective sealing is achieved between the outside cylindrical portions 174, 176 and the large-diameter cylindrical portions 144, 146, preventing consequently ingress of dirt, sand grains, and water, etc., between the sleeve 116 and the inner sleeve 112. Pressing deformation of the sealing rubbers 126, 128 between the outside cylindrical portions and the large-diameter cylindrical portions 144, 146 will diminish the thickness of the sealing rubbers 126, 128 under compression, which thereby enhances the sealing effect.
The disk portions 166, 168 of the retainers 122, 124 are, due to the fact that the length of the inner sleeve 112 is made equal to, or slightly larger than, that between both ends of the pair of bushes 118, 120 press-fit inside the sleeve 116, respectively placed face to face with the outer flanges 152, 154, in contact with or closely approaching same. Relative rotation between the disk portions 166, 168 of the ratainers 122, 124 and the outer flanges 152, 154 of the sleeve 116 is therefore permitted. And on the radially outer sides of the outer flanges 152, 154 of the bushes 118, 120 annular hollow spaces 178, 180 (FIG. 23) are formed, which function just like the aforementioned hollow space 164 as an oil reservoir. This provides not only good lubrication between retainers 122, 124 and bushes 118, 120, but also more effective sealing between the outside cylindrical portions 174, 176 and the large-diameter cylindrical portions 144, 146, owing to the enclosing of oil in the annular hollow spaces 178, 180. The fact that the hollow space 164 is situated a little nearer to the side of the retainer 122 is reasonable for imparting good lubrication to that side, where the sliding area is larger in comparison with the side of the retainer 124, i.e., between the retainer 122 and the outer flange 152.
In a bush assemblage of such a structure, a gap between the large-diameter cylindrical portions 144, 146 and the outside cylindrical portions 174, 176 is sealed with the sealing rubbers 126, 128, which effectively prevents dirt, said grains, mud water, etc., from entering between the sleeve 116 and the inner sleeve 112. The relative rotation between those members by way of the bushes 118, 120 prevents spoiling or harming caused by the ingrees of the aforementioned undesirable matter. Since the sealing rubbers 126, 128 are disposed on the outer circumferential surface of the large-diametered cylindrical portions 144, 146 of the sleeve 116, and are also abutted under pressure on the inner circumferential surfaces of the outside cylindrical portions 174, 176 of the retainers 122, 124 good sealing effect is assured even when both, i.e., the retainers 122, 124 and the sleeve 116, are relatively rotated. If and when the bush assemblage is placed under a radial load, the large-diameter cylindrical portions 144, 146 and the outside cylindrical portions 174, 176 are protected from a relative position change in the radial direction, which guarantees a constant sealing effect and reduction of the wear of the sealing rubbers 126, 128 to a minimum, e.g., life elongation of same. Formation of a plurality of circumferential grooves 148, 150 on the sealing rubbers 126, 128, and the surface contact between the sealing rubbers 126, 128 and the outside cylindrical portions 174, 176 under pressure, ensure and enhance good sealing effect there.
As the bushes 118, 120 are press-fit inside the sleeve 116, the latter functions as a guard or resistor for the former, which prevents the bushes 118, 120 from being deformed or cracked due to vibration load from outside. The bushes 118, 120 are allowed to maintain a high degree of roundness, thereby maintaining the twisting spring action reducing effect. It also enhances resistivity against heat, etc., and prolongs the life of the device itself.
In this embodiment, between ends 160, 162 of the bushes 118, 120, and on the radially outer side of the outer flanges 152, 154, hollow spaces 164, 178 and 180 are respectively formed for functioning as reservoirs of lubricant. Lubricant such as rubber grease can be smeared to every corner of the sliding surface between the bushes 118, 120 and the inner sleeve 112 as well as between the bushes 118, 120 and the retainers 122, 124, and wearing of the related members is thereby remarkably reduced. and Furthermore, reduction of the twisting spring action by virtue of the bushes 118, 120 is also enhanced. The axial grooves formed on the inner circumferential surface of the bushes 118, 120 advantageously cooperate with the hollow space 164 in bringing the lubricant as far as most remote place from the hollow space 164.
Although the axial grooves are, in this embodiment, limited to the inner circumferential surface of the bush 118, if on the axially external surface of the outer flange 152 four similar grooves 182 are also formed in alignment with the axial grooves 156 so as to make them communicate with the annular hollow space 178 as shown in FIGS. 31 and 32, the sliding portion between the outer flange 152 and the retainer 122 will be better lubricated. The alignment of the grooves 182 with the grooves 156 is however not essential; mere connection of the grooves 182 with the annular hollow space 178 will allow similar lubricating effect. It goes without saying that similar grooves formed on the outer flange 154 of the other bush 120 gives good lubrication between the outer flange 154 and the other retainer 124.
In this embodiment, for example, the sealing rubbers 126, 128 are respectively disposed on the outer circumferential surfaces of the large-diameter cylindrical portions 144, 146; however, the sealing rubbers safely can be disposed on the inner circumferential surfaces of the outside cylindrical portions 174, 176.
Even when the grooves 148, 150 formed on the outer circumferential surfaces of the sealing rubbers 126, 128, in this embodiment, are omitted, the sealing effect by the sealing rubbers 126, 128 can be attained by and large.
In this embodiment, the bushes 118, 120 are placed in relative rotation with the inner sleeve 112. However modification is possible. That is to say, the bushes 118, 120 can be fixed on the inner sleeve 112 leaving the sleeve 116 relatively rotatable with respect to the bushes 118, 120, or the bushes 118, 120 can be unfixed, thereby leaving them relatively rotatable with respect to both the sleeve 116 and the inner sleeve 112.
Referring further to FIGS. 33-36, preferred embodiments of a bush assemblage will be described according to yet a further aspect of the invention.
In the elevational view in longitudinal cross section of FIG. 33, reference numeral 210 designates a metallic outer cylindrical sleeve. In the innermost inside thereof an inner cylindrical sleeve 212 of metallic material is concentrically arranged. Between the outer cylindrical sleeve 210 and the inner cylindrical sleeve 212 a rubber block 214 as a resilient member is interposed, and between the rubber block 214 and the inner sleeve 212 a metallic sleeve 216, as a rigid sleeve of relatively high rigidity, and a pair of cylindrical members 218, 218, constituting sliding members, of oil-containing polyacetal resin, are interposed. For assembling the bush assemblage of this sort, retainers 220, 220 are mounted at the ends of the inner sleeve 212. Between the retainers 220, 220 and the end of the sleeve 216 annular sealing rubbers 224, 224 are respectively arranged.
The sleeve 216 is, as shown in FIGS. 34 and 35, composed of a cylindrical portion 236, of smaller diameter and of slightly larger length than the outer sleeve 210, outer flanges 238, 238 radially outwardly extending from the ends of the cylindrical portion 236, and cylindrical extensions 242, 242 axially outwardly extending from the external circumferential edges of the outer flanges 238, 238.
Those two members, i.e., the outer sleeve 210 and the metallic sleeve 216, are concentrically arranged, with the rubber block 214 being interposed therebetween, to provide an outer assembly unit. It is preferble that a predetermined rubber material be, in an annular vacant space formed by the concentrical arrangement of the outer sleeve 210 and the metallic sleeve 216, vulcanized on the spot to form the rubber block 214. By doing so, the rubber block 214 is in the course of vulcanization stuck to the inner circumferential surface of the outer sleeve 210 and the outer circumferential surface of the metallic sleeve 216, so as to make three members, the outer sleeve 210, the metallic sleeve 216 and the rubber block 214, into one integral body. When drawing operation is thereafter applied to the outer sleeve 210, the rubber block 214 receives a preliminary compression and the three members, i.e., the outer sleeve 210, the metallic sleeve 216, and the rubber block 214, are bonded more firmly. Although the inner diameter of the small-diameter portion 228 of the outer sleeve 210 is, in FIGS. 33 and 36, indicated smaller than the outer diameter of the cylindrical extension 242, 242 of the metallic sleeve 216, it is a result of the drawing process. Before the application of the drawing, the metallic sleeve 216 can be inserted inside the outer sleeve 210.
In this embodiment, the sealing rubbers 224, 224 are also vulcanized at the same time as the vulcanization of the rubber block 214, although separated from the latter, for being struck in the course of the vulcanizing process on the inner circumferential surface of the cylindrical extensions 242, 242 respectively. On the inner circumferential surfaces of the sealing rubbers 224, 224, a plurality of grooves 246 are formed in the circumferential direction for the purpose of enhancing the sealing effect. Those sealing rubbers 224, 224 can be, by means of forming notches, etc., in the outer flanges 238, 238, integrally formed with the rubber block 214, or they may be formed as a separate body beforehand for being adhered on the inner circumferential surface of the cylindrical extensions 242, 242 with adhesive or the like.
On the other hand, the above-mentioned cylindrical member or bushes 218, 218 are all of cylindrical form having an outer diameter of almost the same size as the inner diameter of the sleeve 216. The bushes 218 are provided on one end thereof with radially outwardly extending outer flanges 250, and on the inner circumferential surfaces with four axial grooves (not shown) with equal circumferential angular intervals from each other. These two bushes 218, 218 are respectively press-fit inside the sleeve 216, being led by the non-flanged end, until the outer flanges 250 abut the ends of the sleeve 216, where both are fixed on the sleeve 216. At this time between each end 254, 254 of the bushes 218, 218 a hollow space 256 of a predetermined length is to be left. The outer diameter of the outer flanges 250 of the bushes 218 is smaller than the inner diameter of the cylindrical extensions 242, 242, and the inner circumferential surfaces of the sealing rubbers 224, 224 are respectively abutted on the outer circumferential surfaces of the outer flanges 250 such that the sealing rubbers 224, 224 are respectively compressedly sandwiched between the inner circumferential surfaces of the cylindrical extensions 242 242 and the outer circumferential surfaces of the outer flanges 250, to be deformed. This effectively provides sealing between the cylindrical extensions 242, 242 and the outer flanges 250, with the desirable result of preventing the ingress of dirt, sand grains, mud water, etc., between the sleeve 216 and the bushes 218.
As a result of insertion of the inner sleeve 212 inside the bushes 218, 218, an annular hollow space 256 is formed between both ends 254, 254 of the pair of bushes 218, 218, by being confined by the inner sleeve 212 and the metallic sleeve 216 on either flank. This hollow space 256 functions as an oil reservoir, by enclosing lubricant such as rubber grease before the inner sleeve 212 is inserted, or as a pool for receiving the lubricant smeared over the sliding surfaces of the bushes 218, 218 and the inner sleeve 212. In either case this hollow space 256 can greatly serve to pool the lubricant smeared on the sliding surfaces of the bushes 218, 218 and the inner sleeve 212, and consequently can provide uniform and even smearing of the members, resulting in smooth relative rotation (sliding) between them and reduced wear of the sliding portions. Axial grooves (not shown) formed on the inner circumferential surfaces of the bushes 218, 218 also provide to lubricant transportation in the axial direction, which facilitates good lubrication even to axially remote places from the hollow space 256. Considering such function of the hollow space 256, the axial length of the bushes 218, 218 must be determined so as to leave a necessary gap between them for a well functioning as the oil reservoir.
On the ends of the inner sleeve 212, circular retainers 220, 220 are attached, of substantially doughnut form with a central hole, whose diameter is almost the same size as that of the inner sleeve 212, and whose outer diameter is almost the same size as that of the outer flanges 250 of the bushes 218. The sealing rubbers 224, 224 stuck on the cylindrical extensions 242, 242 can therefore be similarly stuck on the outer circumferential surfaces of the retainers 220, 220, which ensures effective sealing between the cylindrical extensions 242 and the retainers 220, too, preventing ingress of dirt, sand grains, mud water, etc. between the metallic sleeve 216 and the inner sleeve 212. The lateral length of the cylindrical extensions 242 is made larger than the sum of the thickness of the outer flanges 250 and the thickness of the retainers 220, and the sealing rubbers 224 are also made wide enough to completely cover, when abutted, both the outer circumferential surfaces of the outer flanges 250 and the retainers 220.
The retainers 220, 220 of such a form are attached to the inner sleeve 212 on either end with collars 260, 260, each of which is constituted of a cylindrical portion equal in size to the inner diameter of the inner sleeve 212, and an outer flange radially outwardly extending from one end of the cylindrical portion. By press-fitting of the cylindrical portions into the inner sleeve 212, the retainers 220 are fixed to the ends of the inner sleeve 212. The retainers 220, 220 are, in this fixed state, placed in contact with or very close to the outer flanges 250, 250 of the bushes 218, 218, permitting relative rotation therebetween.
In a bush assemblage of such a structure, sealing between the cylindrical extensions 242, 242 on the side, and the outer flanges 250, 250 and the retainers 220, 220 on the opposite side, is attained with the sealing rubbers 224, 224, so as to effectively prevent ingress of dirt, sand grains, mud water, etc., between the sleeve 216 and the inner sleeve 212, which protects relative rotation between those members from damage or trouble caused by the ingress of such undesirable matter. As the sealing rubbers 224 are disposed on the inner circumferential surfaces of the cylindrical extensions 242, and are abutted on both outer circumferential surfaces of the outer flanges 250 and the retainers 220 under pressure, good sealing can be ensured even when both members are placed under relative rotation. A radial load possibly applied on the bush assemblage will never cause radial relative position change of the cylindrical extensions 242, the outer flanges 250 and the retainers 220, which ensures constant sealing and reduces wear of the sealing rubbers 224 to a minimum, thereby enhancing the life thereof. The grooves 246 formed plurally on the sealing rubbers 224 in the circumferential direction, and surface contact under compression between the sealing rubbers 224 on one side and both the outer flanges 250 and the retainers 220 on the other side, serve in mutual cooperation thereof to obtain certain sealing.
As the bushes 218, 218 are press-fit into the metallic sleeve 216, the latter functions as a guard or protector for the former, preventing the bushes 218, 218 from deformation or cracking caused by any vibration load coming from outside. The bushes 218, 218 can thereby be round in section constantly, consequently ensuring reduction of the twisting spring action and at the same time enhancement of durability against heat. It serves to elongate the life of the bushes and the bush assemblage itself.
In this invention the hollow space 256 is formed as stated earlier between the ends 254, 254 of the bushes 218, 218 for functioning as an oil reservoir, gradually supplying lubricant such as rubber grease all over the sliding surfaces of the bushes 218, 218 and the inner sleeve 212. It advantageously results in an effective reduction of wear in those members and enhanced of reduction of the twisting spring action by virtue of the bushes 218, 218. Formation of the axial grooves on the inner circumferential surface of the bushes 218, 218 contributes to good lubrication even to places remote from the annular hollow space 256.
In the above embodiment, the sealing rubbers 224, which are abutted on both outer circumferential surfaces of the outer flanges 250 and the retainers 220, can be altered to abut only on the outer circumferential surfaces of the retainers 220.
It will be obvious that the present invention may be embodied with various other changes, modifications and improvements which may occur to those skilled in the art without departing from the scope of the invention defined in the appended claims.
|
A bush assemblage having an inner sleeve, an outer sleeve disposed around the inner sleeve in co-axial and radially-spaced relation thereto, a rigid sleeve member disposed between the inner and outer sleeves, a cylindrical resilient member interposed between the outer sleeve and the rigid sleeve member, and a cylindrical sliding member interposed between the inner sleeve and the rigid sleeve member, a retainer member located at at least one of axial ends of the inner sleeve to extend radially outwardly, and a sealing device for sealing at least between the inner sleeve and the rigid sleeve member. The sealing device includes a rubber member which is disposed on the retainer member and an axial end of the rigid sleeve member corresponding to the at least one axial end of the inner sleeve, and which abuts against the other.
| 5
|
BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
The present invention relates generally to coolant systems, and more particularly, to a pressurized air powered turbine coolant system.
2. Description of Related Art
Aircraft typically employ an air cycle Environmental Control System (“ECS”), to cool, filter, pressurize and otherwise condition enclosures such as an aircraft cabin and cockpit. An air cycle ECS typically operates on a flow of bleed air taken from an intermediate or high pressure stage within a jet engine having multi-compression stages or from an Auxiliary Power Unit (“APU”) that is a separate turbine engine, not used for propulsion, to power the ECS. Since compressed ambient air or engine bleed air is readily available it is a convenient source of power for an airborne ECS. In most systems the engine bleed air is passed through a heat exchanger (HX), cooled by a ram air or fan driven arrangement thereby lowering its temperature. To further lower the temperature and pressure of the engine bleed air to usable levels, the bleed air is subsequently expanded in a refrigeration turbine. On a typical simple cycle system the turbine also drives the ram air fan. From the turbine, cold air is routed through the aircraft for various functions (cockpit cooling/pressurization, forced air avionics cooling, etc.). After this air has been used it is generally not reclaimed for any other use and it is discharged overboard.
The use of cooled air for the cooling requirements of current avionics is inefficient and/or impractical for high powered/liquid cooled equipment, particularly for performance sensitive aircraft such as military fighters and, more particularly for avionic retrofits. For example, an air supply duct will typically require 10 to 15 times the volume of a pair of coolant lines to cool the same heat load.
Additionally, ram air configurations and fan driven configurations both reduce the efficiency or performance of the aircraft. For, example, ram air configurations include air ducts that must run from the outer side of the aircraft, to the associated HX, which occupies additional space within the aircraft. This limitation not only consumes valuable interior space for new designs, it also makes retrofitting existing aircraft difficult or impossible. Further, an associated ram air scoop is typically exposed on an outside surface which can increase drag and increase the radar-cross-section of military aircraft. Fan driven and other types of auxiliary power devices require additional sources of power for drive. This additional work load further reduces fuel consumption efficiency and may require more equipment on board.
Vapor Cycle Systems (“VCS”) have also been used to provide cooling for the aircraft avionics without the excessive use of engine bleed air. VCS typically use a supply of power other than bleed air to cool avionics (electrical power, direct engine shaft power, etc). The electronically driven compressor is typically supplied with electric power from shaft driven generators. However, since electronic power or shaft power must be supplied by the aircraft engine to run the compressor, the efficiency gained by using less bleed air is lost by the power requirements of the compressor, particularly for aircraft which rely upon speed and power such as is the case with military aircraft.
Many of the above-described problems are exacerbated when avionics are added to existing aircraft in which the retrofit aircraft must supply both additional electric power and cooling to support the new avionics. The traditional approach to solving the problem of adding more cooling and electrical power to an existing aircraft usually involves changes to multiple systems. Installing a larger generator to get more electrical power can affect the Aircraft Mechanical Accessory Drive (“AMAD”) and its cooling requirements due to the higher power takeoff requirements. Adjacent systems (such as typically hydraulic pumps, emergency generators and engine starting drives), connection routing, and structure are also affected. Adding cooling capacity typically requires an increase in aircraft volume, typically involving movement of existing equipment to create the space in the airplane to install a larger ECS. A larger ECS usually requires significant changes to bleed air routing, such as larger ducts, and structural changes as well as additional ram air. The ECS bay is similar to the AMAD bay in that the available volume is fully utilized to install the highest capacity system possible during initial design of the aircraft. In order to increase available cooling the ECS would need to grow beyond its current volume. It is impractical to relocate ECS components to other bays because of the large connecting ducts. Therefore, moving avionics from an adjacent bay is a more viable approach. However, this involves re-routing many connecting harnesses that may ultimately affect other harnesses, structural penetrations, etc. which adds to the overall cost of the change. The equipment that was displaced requires new routing, racks, and structure. Removing fuel is generally considered a poor solution because it affects range and endurance.
When all of the costs associated with the above-mentioned changes are summarized, it is usually determined to be prohibitively expensive. In an industry faced with increasing fuel costs and heightened environmental concerns, considerable effort is made to reduce weight and energy requirements without sacrificing overall system performance. Many times the client must decide if it is better to buy new aircraft with the right capabilities or spend a lot of money on updating a used aircraft or compromise the capability of the new systems to live within the existing power and cooling constraints.
SUMMARY OF THE INVENTION
The present invention achieves technical advantages as an apparatus, system and method for providing chilled coolant and electrical power. Air is extracted from a pressurized air source. An air-to-air heat exchanger receives and cools the extracted pressurized air. Further, an expansion turbine receives at least a portion of the cooled pressurized air from an output of the air-to-air heat exchanger and is configured to expand the cooled pressurized air into chilled air while extracting work. An air-to-coolant heat exchanger receives the chilled air from the expansion turbine which is used to chill refrigerant coolant in a heat transfer relationship. The air-to-air heat exchanger also receives the chilled air reclaimed from the air-to-coolant heat exchanger, subsequent to chilling the refrigerant coolant, where the extracted pressurized air is cooled with the reclaimed chilled air. In one embodiment, the extracted work is used to drive a generator to supply electricity to a distribution system.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, of the preferred embodiment is made to the following detailed description taken in conjunction with the accompanying drawings, wherein like numerals refer to like elements, wherein:
FIG. 1 illustrates a block circuit diagram of a hybrid environmental control system in accordance with an exemplary embodiment of the present invention;
FIG. 2 shows a perspective view illustrating a hybrid turbine cooling system pack in accordance with an embodiment of the present invention;
FIG. 3A shows a perspective view of an exemplary aircraft illustrating retrofit mounting locations for the hybrid environmental control system in accordance with an embodiment of the present invention; and
FIG. 3B illustrates a more detailed view of the retrofit mounting location illustrated in FIG. 3 A.
DETAILED DESCRIPTION OF THE INVENTION
The numerous innovative teachings of the present application will be described with particular reference to the presently preferred exemplary embodiments. However, it should be understood that this class of embodiments provides only a few examples of the many advantageous uses and innovative teachings herein. In general, statements made in the specification of the present application do not necessarily delimit any of the various claimed inventions. Moreover, some statements may apply to some inventive features, but not to others.
Referring now to FIG. 1 there is illustrated a block circuit diagram of a hybrid environmental control system (ECS) 100 in accordance with an exemplary embodiment of the present invention. The hybrid ECS 100 receives a flow of extracted high temperature/high pressure compressed ambient air from a compression means (not shown). The compression means is preferably the compression section of a turbine engine and, more specifically, the received extracted air is compressor bleed air from an aircraft propulsive gas turbine engine compressor section. Beginning at the turbine engine, high pressure/temperature bleed air is extracted from the engine and routed via duct to an air-to-air HX 115 , through redundant shutoff valves ( 105 and 110 ), where the bleed air is cooled to a lower temperature and/or pressure by a flow of discharged air from the air-to-coolant HX 120 . The shutoff valves 105 , 110 enable redundancy in which they both have the ability to shutoff the bleed air and a failure of either one will not result in the introduction of bleed air to the ECS at engine pressures. More is said about the air-to-coolant HX 120 in a later section of the present Detail Description.
The shutoff valves 105 and 110 can be variable controlled valves. The valves 105 and 110 provide over-pressure protection and shutoff as in the case of a conventional system. The shutoff values can be controlled by the controller 150 to vary the amount of bleed air supplied to the air-to-air HX 115 . Additionally, the shutoff values can be controlled from a pilot initiated signal and/or manually.
After the bleed air is pre-cooled through HX 115 , the pre-cooled bleed air is routed, via duct, to a expansion turbine 130 . Air temperatures in the system can vary significantly depending on the amount of cooling required, the pressure and temperature of the bleed air, the moisture content of the air, and the amount of power generated. Typically the bleed air from the engine is approximately 1000 to 1200 degrees F and several hundred psi. Preferably, the pre-cooled bleed air can have a temperature reduction of several hundred degrees F and have an air pressure reduced to around 100 psi. The turbine 130 expands the air producing low pressure/cold air or chilled air and a significant amount of power. Preferably, air leaving the expansion turbine can be anywhere from approximately −100 to 50 degrees F and a few psi above ambient pressure. In one embodiment of the present invention, the turbine 130 is drivenly connected through a shaft, for example, to an electric generator 135 . The power from the air expansion process is used to drive the generator 135 to produce electricity. The power from an expansion turbine has traditionally been use to drive a compressor (for a bootstrap cooling system) or a ram air fan to pull ram air through a bleed-air to ram-air heat exchanger (for a simple cycle system). Ram air is commonly used as the heat sink for environmental control systems. However, since there is no compressor or ram air circuit in this embodiment of the present invention, power from the turbine is instead used to run the generator 135 , thus serving as an energy recovery means that uses a portion of the unrequired or unused energy from the air expansion process to produce electricity for the distribution system of an aircraft for example. This additional electricity can lower the output requirement of other airborne generator devices or can be used, for example, to power retrofit avionics.
Following the air expansion, the chilled air is cold enough to enable the air-to-coolant heat exchange portion of the coolant system. Depending on the type of avionics to be cooled, the avionics can require coolant at 60 degrees F to 80 degrees F, for example. Preferably, the air temperature should be at least 15 degrees F below the coolant temperature the avionics requires for efficient heat transfer. The chilled air is routed to the air-to-coolant HX 120 to cool the coolant. Typically, the coolant is poly alpha olefin (PAO) hydraulic fluid but it can include other types of fluids optimized for heat transfer. From the air-to-coolant HX 120 , the PAO is routed to the avionics equipment (not shown) for cooling.
Prior to entering the air-to-coolant HX 120 , a portion of pre-cooled bleed air is diverted, before reaching the expansion turbine 130 , through an add-heat-valve 125 , to controllably mix with the chilled air exiting the turbine 13 0 . The add-heat-valve air is mixed with the chilled air downstream of the turbine 130 for the purpose of modulating the temperature of the chilled air as it enters the air-to-coolant HX 120 to maintain a predetermined chill temperature of the PAO coolant and to prevent ice formation on the face of the heat exchanger during high ambient humidity conditions for example. The controller monitors and controls the system through connections with temperature sensors 140 and 145 , add-heat-valve 125 , and shutoff valves 105 and 110 . The controller can also be used to monitor and control the generator 135 . The controller can control coolant temperature inlet and discharge coolant temp from the avionics, system capacity (variable avionics loads), power generated (highly dynamic depending on load and engine power), and a load (not shown) separate of the avionics to dump excess unused power.
The air leaving the air-to-coolant HX 120 is still significantly cooler compared to the engine bleed air and is routed to the air-to-air HX 115 for use as a heat sink to cool the incoming engine bleed air. Subsequent to cooling the bleed air, the heat sink air leaving the air-to-air HX 115 is now low pressure/high temperature and is routed overboard.
Referring now to FIG. 2 there is shown a perspective view illustrating a hybrid turbine cooling system pack 200 in accordance with an embodiment of the present invention. As shown, bleed air is routed from the propulsion turbine engine (not shown), via duct, to the air-to-air HX 115 . From the air-to-air HX 115 , the bleed air is further routed to the turbine 130 where the air is expanded. A portion of the bleed air from the propulsion turbine engine is routed, via a bypass duct, through an anti-ice device 205 . The anti-ice device can be used to enable hot air to be mixed with the air from the turbine 130 to prevent ice formation on the face of the heat exchanger (good design would make this a rare event). The expansion of the air produces a predetermined amount of useful work and chilled air. Using the work produced in the expansion, the turbine 130 drives the generator 135 to supply electricity to the distribution system of the aircraft. From the turbine 130 , chilled air is routed first through the air-to-coolant HX 120 and, subsequently, back through the air-to-air HX 115 , and lastly is discharged overboard.
Since the hybrid turbine cooling system pack 200 does not require complex plumbing or a ram air circuit, it can be packaged in a fairly small volume. The size depends on how much cooling and power are required—with no ram air circuit or ram air HX the present system can reduce volume requirements by approximately 20%, even greater if the ram air circuit requires a long duct. The size of the device is dependent on how much cooling is required and to a lesser extent how much electrical power is required. The hybrid turbine cooling system pack 200 can be used, for example, in retrofit applications where existing aircraft require additional cooling and/or electrical requirements. Generally, during an aircrafts lifetime, avionics are added as technology advances or performance demand increases.
The hybrid turbine cooling system of the present invention is particularly advantageous, for high performance aircraft retrofits, over the typical methods of trying to make the existing air cycle system larger or trying to incorporated a vapor cycle system in the aircraft. Increasing the existing air cycle system disadvantageously increases the use of propulsion bleed air and can disadvantageously require additional ram air circuits. Vapor cycle packs are very heavy and require large amounts of electrical power. Furthermore, vapor cycle systems generally require a low to moderate temperature heat sink, no more than about 170° F. High performance aircraft can have ram air temperatures well over 200° F. requiring the use of complex ram air/fuel heat sinks. The proposed system does not suffer from excessive drag or weight associated with ram air circuits or high ram air temperatures since a ram air circuit is not used. The vapor cycle systems also have high electrical load demand resulting in the use of large generators.
FIG. 3A illustrates exemplary retrofit placement for the hybrid turbine cooling system pack 200 in a high performance aircraft. One exemplary retrofit location for the cooling pack 200 is under the tail root fairing 310 of a typical high performance aircraft. This location lends itself well because of the relative ease of routing bleed air to this location and because little or no fairing modification is needed to accommodate the retrofit. While it appears this same area could be used for installing a conventional air cycle system, it would require adding a ram air circuit and may require significant fairing modification. Other exemplary retrofit locations are shown by item 320 . Retrofitting these locations could require the addition of an outer blister to the top or side of the fuselage.
Referring now to FIG. 3B there is illustrated an exploded view of the tail root fairing 310 shown in FIG. 3A. A portion of the tail root fairing 310 is cut away to illustrate the placement of the hybrid turbine cooling system pack 200 .
Although preferred embodiments of the method and system of the present preferred embodiments has been illustrated in the accompanied drawings and described in the foregoing detailed description, it is understood that obvious variations, numerous rearrangements, modifications and substitutions can be made without departing from the spirit and the scope of the invention as defined by the appended claims.
|
Air is extracted from a pressurized air source. An air-to-air heat exchanger ( 115 ) receives and cools the extracted pressurized air. Further, an expansion turbine ( 130 ) receives at least a portion of the cooled pressurized air from the air-to-air heat exchanger and expands the cooled pressurized air into chilled air while extracting work. An air-to-coolant heat exchanger ( 120 ) receives the chilled air from the expansion turbine which is used to chill refrigerant coolant. The air-to-air heat exchanger ( 115 ) also receives the chilled air reclaimed from the air-to-coolant heat exchanger ( 120 ), subsequent to chilling the refrigerant coolant, to cool the air extracted from the pressurized air source. In one embodiment, the extracted work is used to drive a generator ( 135 ) to supply electricity to a distribution system.
| 5
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an installation structure of a base of an exterior wall that can be used at the time of external renovation of a wooden framework house in order to improve a seismic performance of the house.
[0003] 2. Description of Related Art
[0004] An example of conventional methods for improving the seismic performance of a wooden framework house is a structure in which an iron bracing material (brace) or frame material is attached to an outer side of a building for reinforcement. However, even though such a method has an advantage in that an occupant of a house can dwell in that house during reinforcement work because the reinforcement material is installed externally, the bracing material or the frame material attached to the outer side of an exterior wall will significantly reduce the aesthetic appearance of the house.
[0005] On the other hand, in the case of a seismic performance improvement method in which the reinforcement work is performed from the interior of a building, even though an existing exterior wall can be left intact and reused, the occupant comfort during a reinforcement work period will be significantly impaired, and furthermore, despite the costly repair work, an improvement in the quality of the house such as renewal of the appearance of the house cannot be achieved.
[0006] When many years have elapsed after a house was built, a mismatch occurs between the lifestyle of the occupant and the room layout or the interior design of the house. Thus, the occupant desires to renovate the interior of the building in accordance with a change in the lifestyle of the occupant. Furthermore, these days, there also have been increasing demands for exterior renovation, that is, renewal of the appearance of buildings, in addition to interior renovation.
[0007] Performing interior and exterior renovation simultaneously with seismic reinforcement of a building is desirable in that it is less wasteful of resources than constructing a new building.
[0008] As a method for improving the seismic performance of a wooden framework house at the same time as performing exterior renovation of that building, a method that uses a bearing face material as an exterior wall base member is known.
[0009] In this method that uses the bearing face material as the exterior wall base member, after removal of an existing external wall, a decayed or deteriorated portion of a skeleton of the house is repaired and joint metals are placed in proper positions, and then the bearing face material is installed, and this reinforcement is followed by finishing with ceramic siding or the like. The above-described method is widely known as a method that can perform seismic reinforcement and exterior renovation at the same time in compliance with diverse construction specifications.
BACKGROUND ART
[0010] JP 2010-7454A
[0011] JP 2006-28805A
[0012] JP 2003-3676A
[0013] JP 2003-3592A
SUMMARY OF THE INVENTION
[0014] When performing exterior renovation of wooden framework houses using a bearing face material as the exterior wall base member, it is required to perform the most suitable seismic reinforcement for various construction conditions of existing buildings, including differences in base configurations, such as the pillar size, the presence or absence of a stud, and a reinforcing post; differences in building elements, such as an ordinary wall portion, a corner wall portion, and an opening wall portion; and the like. When an existing building experiences seismic reinforcement, seismic design is performed with respect to the building whose structure has already been completed. Thus, unlike seismic design for construction of a new building, there are many restrictions, and it is required to perform seismic design under restrictions on the degree of freedom of design. Therefore, there are cases where only some of bearing walls are required to have a high wall strength factor.
[0015] As a method for enhancing the wall strength factor of only some of bearing walls, a method in which the wall strength factor of a bearing face material is changed by increasing the weight per unit area thereof by, for example, changing the type of the bearing face material according to the required wall strength factor is conceivable. However, the method in which the type of some of bearing face materials is changed leads to an increase in the number of types of bearing face materials and thus impairs the ease of installation. Moreover, although it is also possible to use bearing face materials of the same type with different thicknesses, this method leads to the occurrence of unevenness in the wall base member, and therefore this method significantly impairs the ease of installation as well.
[0016] As a method for enhancing the wall strength factor other than the above-described methods, a method in which the number of nails to be driven in to fix the bearing face material to a structural member of a wooden framework house is increased or the thickness of the nails is increased is conceivable. However, increasing the number of nails to be driven in causes cracking of the bearing face material or the structural member and thus increases the likelihood of an installation defect. On the other hand, the method in which the thickness of the nails is increased increases the risk of breakage of the bearing face material by a nailhead, that is, the occurrence of punching shear and the resulting breakage of the bearing face material by the nail. In particular, in the case of a bearing face material having a low specific gravity, the risk of breakage increases. Thus, it is not easy to enhance the wall strength factor by the method in which the number of nails to be driven in is increased or the method in which the thickness of the nails is increased.
[0017] Air permeability for discharging moisture within a house to the outside of the house is one of important performances requisite for a bearing face material. Known examples of a bearing face material having good air permeability are low-specific-gravity bearing face materials having an air dried specific gravity of about 0.6 to 1.0, such as softwood plywood, an MDF, a volcanic silicates fiber reinforced multi-layer board, and a pulp-silicate mixed cement board. However, due to the low specific gravity, these bearing face materials have low nail-holding power and also are susceptible to punching shear, and therefore it has not been easy to achieve a high wall strength factor with these materials.
[0018] The present invention has been made to solve problems as described above, and it is an object thereof to obtain a base of an exterior wall that can be used in external renovation of a wooden framework house in which a highly air-permeable bearing face material is used as an exterior wall base member and that provides a high degree of freedom of seismic design and, furthermore, facilitates installation of an exterior material such as ceramic siding after seismic reinforcement.
[0019] In order to solve the problems as described above, a first aspect of the present invention proposes a installation structure of a base of an exterior wall that can be used in external renovation of a wooden framework house in which a bearing face material is used as an exterior wall base member, wherein a reinforcement member for preventing punching shear is interposed between a bearing face material of a wall that is required to have a high wall strength factor by a seismic design and a nailhead of a nail for fixing the bearing face material to a structural member.
[0020] According to a second aspect of the invention, the reinforcement member is temporarily attached to the bearing face material beforehand.
[0021] According to a third aspect of the invention, at least two nails are driven in a single, continuous piece of the reinforcement member.
[0022] According to a fourth aspect of the invention, a type and a thickness of the bearing face material of the wall that is required to have a high wall strength factor by the seismic design are the same as those of a bearing face material of a wall that is not required to have a high wall strength factor.
[0023] According to a fifth aspect of the invention, the nails are of a single type and a single size.
[0024] According to a sixth aspect of the invention, the reinforcement member is a thin steel sheet.
[0025] According to a seventh aspect of the invention, the reinforcement member is a sheet selected from a glass fiber sheet and a carbon fiber sheet.
[0026] Hereinafter, the operation and effects of the present invention will be described.
[0027] As numerical values for judgement for evaluating means for enhancing the wall strength factor, single shear capacity of a nailed connection was used to perform the evaluation. As a method for determining the shear capacity of a nailed connection in which a bearing face material is used as a side member, the reference allowable stress and reference rigidity of joints (based on a monotonous loading test of joints) described in the “2002 Wakugumikabekoho Kenchikubutsu Kozokeisan Shishin (2002 guidelines for structural calculation of wood frame construction buildings)” of the Japan Two-by-Four Home Builders Association were adopted, and the single shear capacity of a nailed connection was determined.
[0028] This test was conducted using Japanese cedar as a structural member 1 serving as a main member; a sheet of structural plywood, a volcanic silicates fiber reinforced multi-layer board (manufactured by Daiken Corporation; product name: Dailite MS), and a pulp-silicate mixed cement board coated with an acrylic resin on both sides (manufactured by Nichiha Corporation; product name: Anshin), all having a thickness of 9 mm, as a bearing face material 2 serving as a side member; an iron wire nail N50 and an iron wire nail N75 (JIS A 5508:2009) as a nail 3 ; and a prepainted hot-dip 55% aluminum-zinc alloy-coated steel sheet (JIS G 3322:2008) having a thickness of 0.35 mm as a reinforcement member 4 .
[0029] FIG. 1 is a schematic diagram illustrating the determination of the shear capacity of a nailed connection in which a bearing face material is used as the side member, of a configuration in which the reinforcement member 4 is not employed.
[0030] FIG. 2 is a schematic diagram illustrating the determination of the shear capacity of the nailed connection in which a bearing face material is used as the side member, of a configuration in which the reinforcement member 4 is employed.
[0031] The results of the above-described test are shown in Table 1 below.
[0000]
TABLE 1
form of
maxi-
breakage
reinforcement
mum
of nailed
nail
member
bearing face material
load (N)
joint
N50
Not employed
structural plywood
1,094
pull-out
N75
Not employed
structural plywood
1,616
punching
shear
N75
55% aluminum-zinc
structural plywood
2,338
pull-out
alloy-coated steel
sheet
N50
Not employed
volcanic silicates fiber
841
pull-out
reinforced multi-layer
board
N75
Not employed
volcanic silicates fiber
996
punching
reinforced multi-layer
shear
board
N75
55% aluminum-zinc
volcanic silicates fiber
1,750
pull-out
alloy-coated steel
reinforced multi-layer
sheet
board
N50
Not employed
pulp-silicate mixed
1,220
pull-out
cement board coated
with acrylic resin on
both sides
N75
Not employed
pulp-silicate mixed
1,991
punching
cement board coated
shear
with acrylic resin on
both sides
N75
55% aluminum-zinc
pulp-silicate mixed
2,262
pull-out
alloy-coated steel
cement board coated
sheet
with acrylic resin on
both sides
[0032] In the case where the reinforcement member 4 was not employed and the N50 nail 3 was used, when a load 5 was applied, “pull-out”, which is a form of breakage of a nailed joint, occurred for all of the bearing face materials. Specifically, in “pull-out”, a nail body 3 b slips out of the structural member 1 while a situation in which a nailhead 3 a cuts into the bearing face material 2 to cause the nail 3 to come out does not arise, as shown in FIG. 3 . The maximum load at this time was 1094 N for the structural plywood, 841 N for the volcanic silicates fiber reinforced multi-layer board, and 1220 N for the pulp-silicate mixed cement board coated with an acrylic resin on both sides.
[0033] In the case where the reinforcement member 4 was not employed and the N75 nail 3 was used, when the load 5 was applied, “punching shear”, which is a form of breakage of a nailed joint, occurred for all of the bearing face materials. Specifically, in “punching shear”, the nailhead 3 a cuts into the bearing face material 2 to cause the nail 3 to come out of the bearing face material 2 before the nail body 3 b slips out of the structural member 1 , as shown in FIG. 4 . The maximum load at this time was 1616 N for the structural plywood, 996 N for the volcanic silicates fiber reinforced multi-layer board, and 1991 N for the pulp-silicate mixed cement board coated with an acrylic resin on both sides.
[0034] In the case where the reinforcement member 4 was employed and the N75 nail 3 was used, when the load 5 was applied, “pull-out”, which is a form of breakage of a nailed joint, occurred for all of the bearing face materials. Specifically, in “pull-out”, the nail body 3 b slips out of the structural member 1 while a situation in which the nailhead 3 a cuts into the bearing face material 2 to cause the nail 3 to come out does not arise, as shown in FIG. 5 . The maximum load at this time was 2338 N for the structural plywood, 1750 N for the volcanic silicates fiber reinforced multi-layer board, and 2262 N for the pulp-silicate mixed cement board coated with an acrylic resin on both sides.
[0035] As described above, with the installation structure of a base of an exterior wall according to the present invention, even when a combination susceptible to punching shear, of the bearing face material 2 , the structural member 1 , and the nail 3 is used, it is possible to prevent punching shear by interposing the reinforcement member 4 between the nailhead 3 a and the bearing face material 2 . Accordingly it is possible to achieve a high load value of shear capacity of nailed connection.
[0036] Therefore, in external renovation of a wooden framework house, even when a bearing face material that has good air permeability but is regarded as having a low strength against pull-out by a nailhead is used, it is possible to achieve a high wall strength factor by adopting the installation structure, in which a reinforcement member for preventing punching shear is interposed between a bearing face material serving as an exterior wall base member and a nailhead for fixing the bearing face material to a structural member, for a wall that is required to have a high wall strength factor by seismic design calculation. Therefore, a flat base of a wall can be obtained even when nails of a single type are used together with bearing face materials of the same type and the same thickness, and thus it is possible to perform design and installation in such a manner that walls having a high wall strength factor and walls having an ordinary wall strength factor coexist.
[0037] Therefore, the use of the installation structure of a base of an exterior wall according to the present invention eliminates the necessity to use an additional reinforcing metal fitting in order to enhance the wall strength factor, makes it possible to form a flat and smooth-surfaced base of a wall, and thus facilitates installation of an exterior material. Furthermore, since a bearing face material having good air permeability can be used, it is possible to impart a high wall strength factor to only a wall that is required to have a high wall strength factor by seismic design calculation while adopting a bearing face material having good air permeability. Consequently, an installation structure of a base of an exterior wall that provides a high degree of freedom of seismic design and a great ease of installation can be obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is a schematic diagram illustrating the determination of shear capacity of a nailed connection in which a bearing face material is used as a side member, of a configuration in which a reinforcement member 4 is not employed.
[0039] FIG. 2 is a schematic diagram illustrating the determination of the shear capacity of the nailed connection in which a bearing face material is used as the side member, of a configuration in which the reinforcement member 4 is employed.
[0040] FIG. 3 is a cross-sectional view illustrating a state in which pull-out has occurred in the determination of the shear capacity of the nailed connection in FIG. 1 .
[0041] FIG. 4 is a cross-sectional view illustrating a state in which punching shear has occurred in the determination of the shear capacity of the nailed connection in FIG. 1 .
[0042] FIG. 5 is a cross-sectional view illustrating a state in which pull-out has occurred in the determination of the shear capacity of the nailed connection in FIG. 2 .
[0043] FIG. 6 is a diagram illustrating a framework of a wooden framework house.
[0044] FIG. 7 is a diagram illustrating a bearing face material that has been installed on, as an exterior wall base member, the wooden framework in FIG. 6 by an ordinary installation technique.
[0045] FIG. 8 is a diagram of an example of the invention of the present application, illustrating a bearing face material that has been installed on, as the exterior wall base member, the wooden framework in FIG. 6 by an installation technique for achieving a high wall strength factor.
[0046] FIG. 9 is a diagram of another example of the present invention, illustrating a bearing face material that has been installed on, as the exterior wall base member, the wooden framework in FIG. 6 by the installation technique for achieving a high wall strength factor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] Hereinafter, the best mode for carrying out the present invention will be specifically described with reference to the drawings.
[0048] With the installation structure of a base of an exterior wall according to the present invention, seismic reinforcement of an exterior wall portion of an existing conventional wooden framework house is performed in the following manner: an existing exterior building material is removed, and then a bearing face material serving as an exterior wall base member is retrofitted for seismic reinforcement, and then a finishing material such as ceramic siding is installed for exterior renovation.
[0049] In order to design for seismic reinforcement, seismic design is performed using a wall strength factor of each installation specification that is defined for each bearing face material designated for each pillar size, framework configuration, and building element.
[0050] FIG. 6 , which shows a framework of a wooden framework house, is an explanatory diagram of a base frame of an ordinary wall portion provided with a stud, and reference numeral 8 indicates a girth, reference numeral 9 indicates a stud, reference numeral 10 indicates a pillar, reference numeral 11 indicates a reinforcing metal fitting, reference numeral 12 indicates a sill, and reference numeral 13 indicates a joint.
[0051] First, an exterior wall of a portion to be renovated of a house that experiences exterior renovation is removed to reveal a skeleton. Then, if a sill, a pillar, or the like is decayed or deteriorated, it is repaired or replaced.
[0052] In the present invention, the cross-sectional size of pillars, sills, beams, girths, and crossbeams is set to at least 105×105 mm, and bearing walls have pillars at their ends. It should be noted that the size of studs is set to at least 27×105 mm, and the cross-sectional size of joint studs on which bearing face materials are joined is set to at least 45×105 mm.
[0053] In the case where the pillars have different cross-sectional sizes, an adjustment material such as wood can be used to level an exterior surface. The adjustment material is required to be reliably attached to a pillar or a stud using an iron wire nail or the like.
[0054] With respect to capitals and bases of the pillars, a pull-out preventing measure appropriate for the wall magnification (effective magnification) of the relevant portions is taken in conformity with a previously created seismic reinforcement plan.
[0055] FIG. 7 shows an example in which the bearing face material 2 is installed on, as an exterior wall base member, the base frame of the ordinary wall portion provided with the studs in FIG. 6 by an ordinary installation technique, and the bearing face material 2 is nailed to the pillar 10 , the sill 12 , the girth 8 , the studs 9 , and the like with N50 nails 3 driven at intervals of 100 mm or less along the perimeter and at intervals of 200 mm or less along a central line. At this time, the edge distance of the nails 3 (the distance from an edge of the bearing face material to nailing positions) is set to about 15 mm. With regard to the pillar 10 , the sill 12 , the girth 8 , and the like, there is plenty of room for the edge distance, and therefore the edge distance is set to a slightly longer distance. Moreover, the distance to which the bearing face material overlaps the sill 12 , the pillar 10 , or the like is set to at least 30 mm. The nails 3 are driven into portions where the base frame is present, and too small and too large driving depths of the nails 3 should be avoided.
[0056] FIG. 8 shows an example in which the bearing face material 2 is installed on, as the exterior wall base member, the base frame of the ordinary wall portion provided with the studs in FIG. 6 by an installation technique for achieving a high wall strength factor. The installation is facilitated by temporarily attaching the reinforcement member 4 to the bearing face material 2 with a covering tape or the like in a state in which the bearing face material 2 is placed in a horizontal position. At this time, the temporary attachment of the reinforcement member 4 to the bearing face material 2 is performed with their edges aligned.
[0057] It should be noted that when an adhesive tape is previously affixed to a surface of the reinforcement member 4 that comes into contact with the bearing face material 2 , the necessity to use the covering tape is eliminated, and therefore the ease of installation and the installation quality are improved.
[0058] The bearing face material 2 is attached to the pillar 10 , the sill 12 , the girth 8 , the studs 9 , and the like by nailing the bearing face material 2 and the reinforcement member 4 on top of it with the N50 nails 3 driven at intervals of 100 mm or less along the perimeter and at intervals of 200 mm or less along a central line. At this time, the edge distance of the nails 3 (the distance from an edge of the bearing face material to nailing positions) is set to about 15 mm. Moreover, the distance to which the bearing face material overlaps the sill 12 , the pillar 10 , or the like is set to at least 30 mm. The nails 3 are driven into portions where the base frame is present, and too small and too large driving depths of the nails 3 should be avoided.
[0059] The bearing face material 2 is a rectangular material having a predetermined standardized size and the strength or functions of a bearing wall. For example, a bearing face material composed of structural plywood compliant with the JAS standards, a particleboard compliant with the JIS standards, an MDF, a volcanic silicates fiber reinforced multi-layer board, a pulp-silicate mixed cement board, or the like and having predetermined airtightness and dampproofness can be used. In addition to a single-layer board, composite boards composed of two or more different types of boards can be adopted as the bearing face material.
[0060] Particularly preferable examples of the bearing face material 2 in the present invention include highly air-permeable bearing face materials having an air dried specific gravity of about 0.6 to 1.0, such as softwood plywood, an MDF, a volcanic silicates fiber reinforced multi-layer board, and a pulp-silicate mixed cement board.
[0061] Preferable examples of the reinforcement member 4 include thin steel sheets having such a thickness that allows the nails to easily pass through, that is, a thickness of about 0.1 to 3.0 mm, such as iron, stainless steel, titanium, aluminum, zinc alloy-coated steel sheet, enameled steel sheet, clad steel sheet, laminated steel sheet (e.g., polyvinyl chloride-coated steel sheet), and sandwich steel sheet (e.g., seismic-response control steel sheet) (naturally, including colored metal sheets obtained by painting these sheets in tones of various colors). Furthermore, temporarily attaching, for example, sticking the reinforcement member 4 to the bearing face material 2 beforehand with an adhesive, a double-sided tape, or the like before fixing the reinforcement member 4 to the bearing face material 2 with the nails 3 makes handling further easier. The reinforcement member 4 formed of a thin steel sheet is not only effective in forming a bearing wall having excellent earthquake resistance once the bearing face material 2 has been fixed to the skeleton, but also facilitates conveyance and installation because the bearing face material 2 is not made bulky and also is not made very heavy, and improves the earthquake resistance of the bearing wall at a low cost.
[0062] In addition to the above-described thin steel sheets, any material that does not allow the nails to easily pass through, such as a glass fiber sheet, a carbon fiber sheet, or the like, can be used as the reinforcement member 4 in the same manner as the thin steel sheets. If the strength is the same, lighter reinforcement members provide better workability.
[0063] As the reinforcement member 4 , when a reinforcement member formed by combining two each of long and short strip-like steel sheets as shown in FIG. 8 or a reinforcement member formed by integrally molding a steel sheet, which is not shown, is arranged on the bearing face material 2 by sticking it to the surface of the bearing face material 2 with an adhesive, a double-sided tape, or the like, the workability is improved.
[0064] Furthermore, as shown in FIG. 9 , when reinforcement members of a single length are used in combination as the reinforcement member 4 and arranged on the bearing face material 2 by sticking them to the surface of the bearing face material 2 with an adhesive, a double-sided tape, or the like, reinforcement members of a single length can be used as the reinforcement member 4 , and therefore the number of materials is reduced.
[0065] Table 2 shows the wall strength factor of a base of a wall according to the present invention. Ordinary installation indicates an installation structure in which the reinforcement member 4 is not employed, and installation for achieving a high wall strength factor indicates an installation structure in which reinforcement member 4 is employed. The installation conditions are as follows: a pulp-silicate mixed cement board was used as the bearing face material 2 , N50 nails were used as the nails 3 , the size of the pillars 10 was set to at least 105 mm, and the bearing face material was installed on an ordinary wall portion provided with the studs 9 . It should be noted that in the case of installation for achieving a high wall strength factor, a prepainted hot-dip 55% aluminum-zinc alloy-coated steel sheet specified in JIS G 3322:2008 having a thickness of 0.35 mm and a width of 30 mm was used as the reinforcement member 4 .
[0000]
TABLE 2
wall strength factor
installation specifications*
(kN/m)
ordinary installation
6.5
installation for achieving high wall strength factor
7.8
*The pillar size is at least 105 mm, studs are provided, an ordinary wall portion.
[0066] In the case of installation for achieving a high wall strength factor, the wall strength factor was 7.8 kN/m, and a superior wall strength factor to the wall strength factor 6.5 kN/m in the case of ordinary installation was provided. The installation specifications of the above-described installation for achieving a high wall strength factor are applied to a wall that is required to have a high wall strength factor by a seismic design.
[0067] It should be understood that the foregoing description relates to only an embodiment of the installation structure of a base of an exterior wall according to the present invention, and the present invention is not limited to the description of the embodiment and various changes and variations may be made without departing from the gist of the invention.
|
In external renovation of a wooden framework house in which a bearing face material is used as an exterior wall base member, is capable of partly increasing the wall strength factor, thereby providing a high degree of freedom of seismic design and, furthermore, facilitating installation of an exterior material such as ceramic siding after seismic reinforcement.
A reinforcement member for preventing punching shear is interposed. Between a bearing face material of a wall that is required to have a high wall strength factor by a seismic design and a nailhead of a nail for fixing the bearing face material to a structural member.
| 4
|
FIELD OF THE INVENTION
[0001] The present invention relates to high pressure spark ignition direct injection (SIDI) fuel delivery, and more particularly to an attachment system for high pressure fuel injectors in an isolated SIDI fuel delivery system.
BACKGROUND OF THE INVENTION
[0002] Spark ignition direct injection (SIDI) combustion systems (and other direct injection combustion systems) for internal combustion engines provide improved fuel economy and increased power over conventional port fuel-injected combustion systems. A SIDI engine includes a high pressure fuel injection system that sprays fuel directly into a combustion chamber. The fuel is directed to a specific region within the combustion chamber. As a result, a homogeneous or stratified charge may be created in the combustion chamber as desired. Throttling requirements are less restrictive and fuel combustion characteristics are improved, thereby improving fuel economy and engine output.
[0003] Referring now to FIG. 1 , an exemplary SIDI engine 10 includes an engine block 12 that includes one or more cylinders 14 . A spark plug 16 extends into a combustion chamber 18 . The combustion chamber 18 is defined by a piston 20 , the cylinder 14 , and a cylinder head 21 . The cylinder 14 includes one or more exhaust ports 22 and corresponding exhaust valves 24 . The cylinder 14 includes one or more intake ports 26 and corresponding intake valves 28 . A fuel injector 30 extends into the combustion chamber 18 . One or more of the fuel injectors 30 are connected to a fuel rail 32 .
[0004] Referring now to FIGS. 1 and 2 , the fuel rail 32 provides fuel to the fuel injectors 30 . The fuel injectors 30 deliver fuel to the combustion chamber 18 according to performance requirements of the SIDI engine 10 . Typically, a low pressure (e.g. approximately 45-75 psi) fuel supply pump 40 is located within a fuel tank 42 . The low pressure fuel supply pump 40 delivers fuel to a high pressure injection pump 44 . The injection pump 44 pressurizes the fuel at approximately 750 to 2250 psi, depending on demand. The injection pump 44 provides the pressurized fuel to the fuel rail 32 . The fuel rail 32 is rigidly fastened to the cylinder head 21 of the cylinder 14 . For example, the fuel rail 32 is fastened to the cylinder head 21 via a fuel rail attachment assembly (not shown). The fuel injector 30 is rigidly fastened (e.g., clamped) between the fuel rail 32 and the cylinder head 21 , or another suitable fixture of the SIDI engine 10 . A location of the fuel injector 30 relative to the combustion chamber 18 , as well as a design of a fuel injector nozzle 46 , are optimized to achieve desired combustion characteristics.
SUMMARY
[0005] A fuel injector isolation system in a high pressure fuel injection system comprises an isolated fuel rail assembly. At least one cylinder has a cylinder head. A fuel injector is coupled to and in fluid communication with the fuel rail assembly, extends axially through an opening in the cylinder head, and is moveable within the opening in relation to the cylinder head.
[0006] In other features, a vehicle comprises an engine block that includes at least one combustion cylinder having a cylinder head and a combustion chamber. A high pressure fuel injection system delivers fuel directly into the combustion chamber. The high pressure fuel injection system includes an isolated fuel rail assembly and a fuel injector coupled to and in fluid communication with the fuel rail assembly that extends axially through an opening in the cylinder head and is moveable within the opening in relation to the cylinder head.
[0007] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0009] FIG. 1 is a cross-sectional view of a spark ignition direct injection (SIDI) engine cylinder according to the prior art;
[0010] FIG. 2 is a functional block diagram of a SIDI fuel rail assembly according to the prior art;
[0011] FIG. 3A is a graphical representation of SIDI fuel system noise according to the prior art;
[0012] FIG. 3B is a graphical representation of SIDI fuel system noise according to the prior art;
[0013] FIG. 4 is a cross-sectional view of a SIDI fuel injector arrangement according to a first implementation of the present invention;
[0014] FIG. 5 is a cross-sectional view of a SIDI fuel injector arrangement according to a second implementation of the present invention;
[0015] FIG. 6A is a cross-sectional view of a SIDI fuel injector mounting system according to a third implementation of the present invention;
[0016] FIG. 6B illustrates a retainer clip used in a SIDI fuel injector mounting system according to the present invention;
[0017] FIG. 6C is a cross-sectional view of an assembled SIDI fuel injector mounting system according to the present invention;
[0018] FIG. 7 is a cross-sectional view of a SIDI fuel injector mounting system according to a fourth implementation of the present invention;
[0019] FIG. 8A is a cross-sectional view of a SIDI fuel injector mounting system according to a fifth implementation of the present invention;
[0020] FIG. 8B is a cross-sectional view of an assembled SIDI fuel injector mounting system including a retainer plate according to the present invention; and
[0021] FIG. 8C is a fuel injector retainer plate according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. For purposes of clarity, the same reference numbers will be used in the drawings to identify similar elements.
[0023] A typical SIDI system generates undesirable noise during normal operation. As used herein, the term noise refers to any unwanted or undesirable noise that is generated during normal operation of electrical, mechanical, and/or electromechanical devices. The noise is not indicative of present and/or potential damage to these devices. As shown in FIGS. 3A and 3B , pressure pulsations (i.e. disturbances) on a right fuel rail and a left fuel rail are indicated at 60 and 62 , respectively. Pressure fluctuations are indicated at 64 for the fuel inlet line. The pressure pulses 60 , 62 , and 64 are synchronous with the electronic solenoid command signal 66 (e.g., from a Powertrain Control Module, or PCM) which controls the high pressure injection pump 44 . These system pressure disturbances 60 , 62 , and 64 excite various components of the SIDI engine to radiate unwanted noise pulses as indicated at 68 , 70 , 72 , and 74 , for example. Sharp pressure pulses generated within the high pressure pump 44 at each pump stroke contribute to unwanted audible noise. Conventionally, the high pressure injection pump is controlled electronically. For example, the high pressure injection pump includes a reciprocating plunger in communication with an electronic governed solenoid valve that maintains the desired fuel rail (injection) pressure. The electronic signal pulses 66 control the pump's solenoid valve as dictated by the PCM. Similarly, secondary high frequency rail pressure pulses 60 and 62 are generated at each injector firing as high pressure fuel is discharged (injected) into the combustion chamber 18 . Together, the pressure impulses generated by both the pump and injectors constitute the majority of impulsive noise excitation to the engine.
[0024] Additionally, operation of the fuel injectors cause the SIDI system to generate noise. An impulse is generated each time the fuel injector “fires” (i.e. delivers fuel to the combustion chamber), which can be seen to be coincident with the electronic PCM signal pulses 76 . These impulses are simultaneously comprised of both electromechanical (solenoid) and electro-hydraulic forces. The fuel injectors include electronically-controlled needle valve openings. The opening and closing actuation (e.g. electromechanical and/or hydraulic actuation) of the needle valve openings cause the noise pulses 78 .
[0025] As described above, operation of the injection pump and the fuel injectors contribute significantly to the impulsive noise that the SIDI system generates. In particular, rigid mechanical contact between the fuel rail and the cylinder head, as well as between the fuel injector and the cylinder head, transfer noise energy between the SIDI system and various components of the engine. The present invention provides a fuel injector attachment system for high pressure SIDI fuel delivery systems that incorporate noise isolation technology. More specifically, the present invention provides a SIDI system that directly couples the fuel injectors to the fuel rail assembly and isolates elements of the fuel injectors from the cylinder head to interrupt transmission paths of noise energy. With the injector fastened to the rail in the manner described herein, the rail isolation limits vibration energy from being transmitted into the engine.
[0026] Referring now to FIG. 4 , an isolated SIDI fuel injector system 100 according to the present invention is shown. A fuel injector 102 delivers fuel from an isolated fuel rail assembly 104 through a cylinder head 106 to a combustion chamber 108 . Conventionally, SIDI fuel injectors (as well as SIDI fuel rail assemblies) are rigidly mounted and/or affixed to the cylinder head 106 . In the present implementation, the fuel injector 102 is suspended from the fuel rail assembly 104 and is substantially mechanically isolated from the cylinder head 106 , especially in the axial direction. The fuel injector 102 is directly coupled to the isolated fuel rail assembly 104 via an injector cup boss 110 , an injector locating base 112 , an injector seat 114 , and a snap ring 116 . The injector seat 114 supports a posterior spherical portion 118 of the injector locating base 112 . The injector seat 114 (e.g. a split spherical seat or other suitable device) secures and maintains a desired position of the fuel injector 102 relative to the injector cup boss 110 . An 0 -ring 120 provides a wet seal.
[0027] The snap ring 116 provides additional support to maintain the desired position of the fuel injector 102 . The snap ring 116 may be removable to allow the fuel injector to be insertably coupled to and/or removed from the injector cup boss 110 . The SIDI fuel injector system 100 may also include an anterior injector seat (not shown) that contacts an upper portion of the fuel injector 102 within the injector cup boss 110 .
[0028] As described above, the fuel injector 102 is directly coupled to the fuel rail assembly 104 without rigid mechanical contact between the injector cup boss 110 and the cylinder head 106 . The injector seat 114 limits the axial position of the fuel injector 102 with respect to the injector cup boss 110 . In the present implementation, the injector seat 114 may be formed from an elastomeric material. Those skilled in the art can appreciate that the present invention is not limited to using elastomeric materials. Other materials, including, but not limited to, nylon, composites, and/ or metals are anticipated. For example, thermal conductivity of an elastomeric material forming the injector seat 114 may be increased by the addition of aluminum particles.
[0029] The cylinder head 106 includes an opening 122 that accommodates the fuel injector 102 and a fuel injector nozzle 124 . In conventional SIDI systems (as described in FIG. 1 ), there is rigid mechanical contact between the cylinder head 106 and the fuel injector 102 to maintain a position of the fuel injector. As a result, noise is transferred between the fuel injector 102 and the cylinder head 106 via contiguous axial contact. In the present implementation, the fuel injector 102 floats in the opening 122 , isolating the fuel injector 102 from the cylinder head 106 . The fuel injector 102 includes a combustion seal (e.g. a nylon or Teflon combustion seal) 126 located near the fuel injector nozzle 124 . The combustion seal 126 seals combustion gases from the combustion chamber 108 and is the only contact between the fuel injector 102 and the cylinder head. Thus, there is no metal-to-metal (i.e., rigid) contact of the injector with the cylinder head. In this manner, the isolated SIDI fuel injector system 100 eliminates substantial axial contact between the fuel injector 102 and the cylinder head 106 .
[0030] A biasing element, such as a spring 128 , may be included. The spring 128 provides a downward biasing force to position the fuel injector 102 within the cylinder head 106 . However, it is to be understood that a biasing element is not required for proper positioning of the fuel injector 102 . For example, an internal fuel rail pressure is typically sufficient to bias the fuel injector against the injector seat 114 . Further, although the spring 128 is shown disposed between the injector cup boss 110 and an intermediate portion 130 of the fuel injector 102 , those skilled in the art can appreciate that the spring 128 may be otherwise located. For example, the spring 128 may be located between an upper interior surface 132 of the injector cup boss 110 and an upper portion 134 of the fuel injector 102 as shown in FIG. 5 .
[0031] As described above, a longitudinal position of the fuel injector 102 is maintained. In this manner, proper positioning of the fuel injector nozzle 124 for optimized combustion is maintained. Further and as indicated at 136 , the configuration of the SIDI fuel injector system 100 allows angular rotation of the fuel injector 102 relative to the cylinder head 106 . For example, the spherical portion 118 of the injector locating base 112 and the injector seat 114 allow a degree of angular latitude to compensate for misalignment and/or slight positional errors. The opening 122 is sufficiently large to accommodate angular rotation of the fuel injector 102 while maintaining isolation between the fuel injector 102 and the cylinder head 106 . A gap between the fuel injector 102 and the cylinder head 106 as indicated at 138 allows for limited longitudinal movement of the fuel injector 102 . For example, if the injector seat 114 compresses and/or the snap ring 116 is damaged, the fuel injector 102 will not necessarily contact the cylinder head 106 . For example, a controlled clearance between the bottom of the injector base and the cylinder head port acts as a failsafe in the event of a improperly-positioned or snap ring 116 . The injector is trapped between the rail and head thereby maintaining the integrity of the wet seal (i.e., the O-ring 120 ), with increased noise being the only degradation to the system.
[0032] The isolated fuel injector arrangements of previous implementations may be combined and/or integrated with a fuel injector mounting system 150 as shown in FIGS. 6A , 6 B, and 6 C. A fuel injector 152 is inserted into an injector cup boss 154 of a fuel rail assembly 156 . A retainer clip 158 , shown in FIG. 6B and cross-sectionally in FIG. 6A , retains the fuel injector 152 within the injector cup boss 154 . The retainer clip 158 engages a stepped collar 160 disposed on the fuel injector 152 . As shown, the retainer clip 158 is a split-segmented snap retainer. However, those skilled in the art can appreciate that other types of retainer clips may be used. The fuel injector mounting system 150 allows for angular rotation and misalignment compensation as described in previous embodiments and facilitates attachment of the fuel injector 152 to the fuel rail assembly 156 . Any suitable tool may be applied to release the retainer clip 158 and remove the fuel injector 152 .
[0033] An alternative implementation of a fuel injector mounting system 170 is shown in FIG. 7 . A fuel rail assembly 172 includes one or more fuel injector retaining interfaces (e.g. injector cup bosses) 174 . The interface 174 includes a retainer clip groove 176 that is configured to receive a retainer clip 178 a (shown in profile at 178 b ). A fuel injector 180 is inserted within the interface 174 . An injector sleeve 182 is inserted over the fuel injector 180 and the interface 174 . The retainer clip 178 a is inserted into one or more retainer clip slots 184 and through the retainer clip groove 176 .
[0034] In this manner, the retainer clip 178 a, in combination with the injector sleeve 182 , maintains an axial/longitudinal position and a radial position of the fuel injector 180 . A clearance gap 188 between the injector and cylinder head provides isolation as described in previous implementations. The features of the fuel injector mounting system 170 may be combined and/or integrated with previous implementations of the isolated fuel injectors as described in FIGS. 4-6 .
[0035] Another implementation of a fuel injector mounting system 200 is shown in FIGS. 8A , 8 B, and 8 C. A fuel rail assembly 202 includes one or more injector retaining interfaces 204 . The interface 204 includes a retainer plate groove 206 . A fuel injector 208 is inserted into the interface 204 through an opening 210 in a retainer plate 212 . When the fuel injector 208 is suitably positioned, the retainer plate 212 slides in a direction 214 parallel to the fuel rail assembly 202 to lock the fuel injector 208 in position within the interface 204 . More specifically, a locking portion 216 of the opening 210 engages an injector retaining groove 218 of the fuel injector 208 .
[0036] The retainer plate 212 includes retainer clips 220 . When the retainer plate 212 is positioned to lock the fuel injector 208 in place, the retainer clips 220 engage the retainer plate grooves 206 . In this manner, the retainer plate 212 maintains a position of the fuel injector 208 as described in previous implementations. In an alternative implementation, a plurality of individual retainer plates (not shown) that correspond to a plurality of retaining interfaces 204 may replace the continuous retainer plate 212 .
[0037] Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present invention can be implemented in a variety of forms. Therefore, while this invention has been described in connection with particular examples thereof, the true scope of the invention should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, the specification and the following claims.
|
A fuel injector isolation system in a high pressure fuel injection system comprises an isolated fuel rail assembly. At least one cylinder has a cylinder head. A fuel injector is coupled to and in fluid communication with the fuel rail assembly, extends axially through an opening in the cylinder head, and is moveable within the opening in relation to the cylinder head.
| 5
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a corona discharge pollutant destruction reactor chamber with multiple inner electrodes, and a related pollutant destruction method.
2. Description of the Related Art
Passing a pollutant bearing gas through a corona discharge site is a known method of removing the pollutants from the gas. A general review of this technique is provided in Puchkarev et al., "Toxic Gas Decomposition by Surface Discharge," Proceedings of the 1994 International Conf. on Plasma Science, 6-8 Jun., 1994, Santa Fe, N. Mex., paper No. 1E6, page 88. Corona pollutant destruction has also been proposed for liquids, as disclosed in application Ser. No. 08/295,959, filed Aug. 25, 1994, "Corona Source for Producing Corona Discharge and Fluid Waste Treatment with Corona Discharge," and assigned to Hughes Aircraft Company, now doing business as Hughes Electronics.
In one system, described in Yamamoto et al., "Decomposition of Volatile Organic Compounds by a Packed Bed Reactor and a Pulsed-Corona Plasma Reactor," Non-Thermal Plasma Techniques for Pollution Control, NATO ASI Series Vol. G34 Part B, Ed. by B. M. Penetrante and S. E. Schultheis, Springer-Verlag Berlin Heidelberg, 1993, pages 87-89, brief high voltage pulses of about 120-130 nanoseconds duration are applied to the center conductor of a coaxial corona reactor through which gas is flowing. Each pulse produces a corona discharge that emanates from the center wire and floods the inside volume of the reactor with energetic electrons at about 5-10 keV. A similar system is described in U.S. Pat. No. 4,695,358, in which pulses of positive DC voltage are superimposed upon a DC bias voltage to generate a streamer corona for removing SO x and NO x from a gas stream. These processes have relatively poor energy efficiencies. With the reactor geometries that have been selected, it is necessary to deliver very short pulses to avoid arc breakdown between the electrodes, and consequent damage. The pulse-forming circuit loses approximately half of the power coming from a high voltage supply in a charging resistor, and additional energy is wasted in a double spark gap. Furthermore, the capacitive load of the coaxial corona reactor must be charged; this charging energy is typically much greater than the energy that is actually used in the corona reaction, and simply decays away into heat after each pulse without contributing to the pollutant destruction.
A single coaxial inner electrode that is centered along the chamber is capable of generating radial electric field lines to induce charges relatively evenly on the inner surfaces of the dielectric. However, one disadvantage of the coaxial inner electrode is that it is not structurally supported within the chamber and must be suspended from the ends of the chamber. Moreover, when high voltage electricity is applied to the inner electrode, a large amount of heat is produced. The coaxial inner electrode is surrounded only by an exhaust gas, and can thus overheat and burn out after a prolonged exposure to high temperature.
A similar approach, but with a different reactor geometry, is taken in Rosocha et al., "Treatment of Hazardous Organic Wastes Using Silent-Discharge Plasmas," Non-Thermal Plasma Techniques for Pollution Control, NATO ASI Series Vol. G34 Part B, Ed. by B. M. Penetrante and S. E. Schultheis, Springer-Verlag Berlin Heidelberg, 1993, pages 79-80, in which the corona discharge is established between parallel plates. This system also suffers from a poor specific energy due to inefficient pulse formation and non-recovery of reactor charging energy.
A block diagram of a generic corona discharge pollutant destruction apparatus is shown in FIG. 1. A corona discharge reactor 102 takes pollutant-bearing exhaust gas 112 from an engine 106 through an inlet conduit 108, treats the exhaust gas, and discharges the treated exhaust gas 114 through an outlet conduit 110. Major pollutants in the exhaust gas 112 from the engine 106 typically include various forms of nitrogen oxides (NO x ), hydrocarbons (HC) and carbon monoxide (CO). HC and CO are considered high energy level pollutants, which can be oxidized to produce water (H 2 O) and carbon dioxide (CO 2 ). NO x compounds are considered low energy level pollutants, and need to absorb energy to be reduced to harmless diatomic nitrogen (N 2 ) and oxygen (O 2 ). When a power source 104 supplies high voltage pulses to the corona discharge reactor 102, HCs are oxidized to become H 2 O and CO 2 , while CO is oxidized to become CO 2 . At each voltage peak, a corona discharge is emitted within the reactor 102, producing free radicals that oxidize HC to generate CO 2 and H 2 O, and CO to generate CO 2 . In general, high voltage pulses in the range of about 10-15 kV are very effective in destroying HC and CO, whereas lower voltage pulses are more suitable for the reduction of NO x .
SUMMARY OF THE INVENTION
The present invention provides two or more inner electrodes for a corona discharge pollutant destruction reactor. The inner electrodes are spatially separated from each other, and are preferably equally placed along the inner surface of a dielectric which defines the reactor's chamber. This facilitates a rapid cycling of the corona discharge throughout the chamber, and producing relatively evenly distributed corona discharges. In one embodiment, two inner electrodes are driven by respective out-of-phase pulsed sinusoidal voltage waveforms to achieve a relatively even distribution of electric field over each cycle. In another embodiment, the voltage pulses are transmitted to each of the inner electrodes in succession, such that at any instant only one inner electrode is charged. All of the inner electrodes are charged sequentially within each pulse repetition period to generate high intensity electric fields that are relatively evenly distributed in the entire volume of the reactor chamber.
These and other features and advantages of the invention will be apparent to those skilled in the art from the following detailed description, taken together with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1, described above, is a block diagram of a conventional corona discharge pollutant destruction apparatus;
FIG. 2a is a sectional view of a corona discharge reactor having two inner electrodes opposite each other, with a voltage maximum at the first electrode and a voltage null at the second electrode;
FIG. 2b is a sectional view of the same reactor as in FIG. 2a, but with a voltage maximum at the second inner electrode and a voltage null at the first one;
FIG. 3 is a plot of voltage versus time for a typical voltage waveform generated by the pulsed voltage source of FIGS. 2a and 2b;
FIG. 4a is a sectional view of a corona discharge reactor having three inner electrodes spaced equally apart from each other, with a pulse applied only to the first electrode;
FIG. 4b is a sectional view of the same reactor as in FIG. 4a, but with a pulse applied to the second electrode via a pulse delay circuit;
FIG. 4c is a sectional view of the same reactor as in FIG. 4a, but with a pulse applied to the third electrode via two pulse delay circuits in series;
FIG. 5 is a sectional view of a corona discharge reactor with two inner electrodes in a circular reactor chamber;
FIG. 6 is a section view of a reactor similar to FIG. 5, but with three inner electrodes; and
FIG. 7 is a block diagram of an automobile that includes a multi-inner-electrode reactor in accordance with the invention to treat engine exhaust gas.
DETAILED DESCRIPTION OF THE INVENTION
The several disadvantages of the coaxial inner electrode described above can be alleviated by placing an off-axis paraxial wire inner electrode in contact with an inner surface of the dielectric, as described in co-pending application Ser. No. 08/450,449, filed May 25, 1995, "Gaseous Pollutant Destruction Apparatus and Method Using Self-Resonant Corona Discharge," and assigned to Hughes Aircraft Company, now doing business as Hughes Electronics. While the off-axis inner electrode is provided with mechanical support and heat dissipation by the dielectric, the electric field lines emanating from the inner electrode are spaced unevenly within the reactor chamber, causing an uneven distribution of induced electric charges on the inner dielectric surface. Because the charging occurs with different intensity levels within the reactor chamber, the pollutants in an exhaust gas passing through the chamber will not be treated evenly.
The present invention provides a corona discharge pollutant destruction reactor with two or more inner electrodes to generate electric fields from different inner electrodes, resulting in a relatively even generation of corona discharges throughout the reactor chamber. Time separation for charging each of the inner electrodes in a cyclical order is achieved by at least one time delay circuit, which can be either a phase delay circuit or a pulse delay circuit.
A preferred embodiment of this invention with two inner electrodes is illustrated in FIGS. 2a and 2b, which show the same cross-sectional view of a reactor system with a phase delay circuit, but with different electric field patterns at different instants of time. A high voltage source 34 drives first and second paraxial inner electrodes 36 and 38 with a typical voltage waveform shown in FIG. 3. It is preferred that the voltage have a substantially sinusoidal waveform 40 modulated by substantially rectangular periodic pulses 42. The signal characteristics that are of most concern to the invention are the voltage level, the pulse width t, the pulse repetition period T and the oscillation frequency. The voltage level generated by the pulsed voltage source 34 is preferably in the range of about 5-15 kilovolts to produce a corona discharge. The average power of the pulse-modulated sinusoidal voltage waveform, and accordingly the average power of the resulting corona discharge, can be adjusted by changing any of the relevant signal characteristics, such as t and T, the ratio of which is defined as the pulse duty cycle. The embodiment illustrated in FIGS. 2a and 2b is also applicable to a corona generation system which uses a continuous-wave voltage source.
The inner electrodes are placed on the inner surface 46 of a hollow dielectric 48 which defines the reactor chamber 44. The inner electrodes are preferably attached to the inner dielectric surface by either bonding or metal vapor deposition to provide thermal dissipation and mechanical support. It is preferred that the reactor chamber have a hexagonal cross-section for strong structural integrity and for close packing of multiple chambers if required. The two inner electrodes 36, 38 are preferably sited along opposite vertices of the reactor chamber 44. The dielectric 48 has an outer surface 52 which is enclosed by a conductive layer that forms an outer electrode 50.
The ground node 54 of the pulsed voltage source 54 is connected to the outer electrode 50; its voltage-carrying node 56 is connected to the first inner electrode 36 directly and to the second inner electrode 38 via a delay circuit 58. In the configuration with two inner electrodes, the delay circuit 58 preferably produces a phase delay so that voltage peaks reach different inner electrodes at different times.
In a preferred embodiment, the phase delay is set at about either 90° or 270° of the oscillation frequency. In FIG. 2a, when the first inner electrode 36 is driven to the maximum positive voltage of the voltage source 34, the second inner electrode 38 is at zero voltage if the phase delay circuit 58 produces either a 90° or a 270° phase delay. The electric field at this time is illustrated by field lines 51 in FIG. 2a. This electric field pattern induces unevenly distributed negative surface charges 53 on the inner surfaces of the dielectric 48, with a greater charge concentration closer to the energized inner electrode 36.
In FIG. 2b, which shows the electric field pattern represented by the field lines 55 in the reactor chamber from FIG. 2a after a time interval equivalent to about 90° for a 90° phase delay circuit or 270° for a 270° phase delay circuit, the voltage at the first inner electrode 36 is nil while the second inner electrode 38 has reached the maximum positive voltage.
The voltage pattern will repeat every 360° for the duration of the pulse. When the voltage on either inner electrode is at a negative rather than a positive maximum, the other electrode is at zero voltage. The directions of the electric field lines 53 would thus be opposite to those shown in FIGS. 2a and 2b, resulting in positive instead of negative surface charges on the inner dielectric surface 46. With the alternating electric field patterns of FIGS. 2a and 2b, the time-averaged charge within the reactor chamber 44 thus become relatively evenly distributed over each sinusoidal period. When a pollutant-bearing gas flows through the reactor chamber, different portions of the gas are subjected to relatively evenly distributed corona discharge within each charging cycle, thereby resulting in a more thorough treatment of the pollutants.
In another embodiment, the delay introduced by the delay circuit 58 is longer than the pulse width, so that the circuit may be considered to be a pulse delay rather than a phase delay circuit. The interval between successive pulses is at least equal to and preferably greater than an individual pulse width, and the delay is selected to place the delayed pulse within this interval so that a pulse is sent to only one of the inner electrodes 36, 38 at a time, in a cyclical order. In this embodiment, the pulse duty cycle is preferably no more than 1/2. The time-averaged charges would be relatively evenly distributed over each pulse repetition period. Whereas the previous embodiment with a phase delay circuit is applicable to pulse-modulated or continuous-wave sinusoidal voltage waveforms, this embodiment with a pulse delay circuit is applicable to pulse waveforms as well as pulse-modulated sinusoidal waveforms.
The reactor can employ more than two inner electrodes, such as the three-inner-electrode reactor of FIGS. 4a-4c, in which electrodes 62, 64 and 70 are provided at alternate inner vertices of a hexagonal discharge chamber 74. It is preferred that pulse delay circuits be used to send pulses to the three inner electrodes one at a time. A pulsed voltage source 60 is connected directly to the first electrode 62, and to the second inner electrode 64 via a first pulse delay circuit 66. A second pulse delay circuit 68 is connected in series with the first pulse delay circuit 66 and feeds pulses from the voltage source 60 to the third inner electrode 70; the outer electrode 72 is grounded. The pulsed voltage source preferably generates a pulse-modulated sinusoidal voltage waveform as shown in FIG. 3. To separate the pulses in time so that only one inner electrode at a time is energized, the duty cycle (t/T) should be no more than 1/3. If the duty cycle is set at about 1/3, the delay circuits 66, 68 should each produce a pulse delay equal to t to accurately time the arrival of each pulse at each of the inner electrodes in a sequential order. FIG. 4a illustrates the electric field pattern when a first pulse is sent directly to the first electrode 62. Because the first and second pulse delay circuits 66, 68 delay the arrival of the pulse to the second and third inner electrodes 64, 70, respectively, they are at a voltage null at this time.
After a time delay of t, the pulse arrives at the second inner electrode 64 after passing through the first pulse delay circuit 66, causing the second inner electrode 64 to generate an electric field pattern as illustrated in FIG. 4b. At this time, no pulse is delivered to either the first or the third inner electrodes 62 and 70. After a further time delay of t, the pulse has passed through the first and second pulse delay circuits 66, 68 and arrives at the third inner electrode 70, causing it to generate an electric field pattern as illustrated in FIG. 4c. When the first pulse has finished driving the third inner electrode 70, the voltage source 60 delivers a second pulse to the first inner electrode 62, starting another cycle of driving each of the three inner electrodes successively. Therefore, the time-averaged electric field patterns generated by the three inner electrodes 62, 64, 70 are relatively evenly distributed throughout the reactor chamber 74 over a single pulse repetition period T. Because the inner electrodes are separated only 120° apart, the corona discharge would be more evenly distributed within the reactor chamber than the two-inner-electrode reactor of FIGS. 2a-2b over each pulse repetition period.
For a corona discharge reactor employing more than two inner electrodes, shorter delays that allow pulses to be applied to more than one electrode at a time can also be used. However, there will be instants when two or more inner electrodes have nearly the same voltage, creating equipotential surfaces that reduce the electric field intensities. Nevertheless, the phase delay circuits may still generate cyclical electric field patterns that produce relatively even time-averaged corona discharges throughout the reactor chamber.
The multiple inner electrode configuration is also applicable to reactor chambers with circular cross-sections, as shown in FIGS. 5 and 6. In FIG. 5, two inner electrodes 76 and 78 are placed about 180° apart from each other on the inner surface 80 of a circular dielectric cylinder 82. The inner electrodes 76 and 78 are substantially parallel to each other along the length of the cylinder 80. In FIG. 6, three inner electrodes 84, 86 and 88 are separated by about 120° from each other and are also substantially in parallel. Additional inner electrodes can also be provided on the inner dielectric surface to distribute the electric field patterns more evenly.
This invention is applicable to pollutant treatment using corona discharge in automobiles to meet stringent air quality standards. In FIG. 7, an automobile 90 has an internal combustion engine 92 which generates a pollutant-bearing exhaust gas that is conveyed through an engine exhaust pipe 96 to a multi-inner-electrode corona discharge reactor 94, which treats the pollutants in the exhaust gas and releases the treated gas to the atmosphere through a tailpipe 98. The reactor 94 may have any of the configurations shown in FIGS. 2a-2b, 4a-4c, 5 and 6 and described above.
While several illustrative embodiments of the invention have been shown and described, numerous variations and alternate embodiments will occur to those skilled in the art. Such variations and alternate embodiments are contemplated, and can be made without departing from the spirit and scope of the invention as defined in the appended claims.
|
A corona discharge pollutant destruction reactor employs two or more electrodes to enhance the effective corona discharge treatment volume by distributing a varying electric field pattern over the reactor's interior chamber. Appropriate delay circuitry allows the inner electrodes to be driven out of phase with each other by a sinusoidal voltage waveform, or corona producing voltage pulses to be cyclically supplied to the inner electrodes in sequence, preferably without overlapping the pulses.
| 5
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a threshold value setting circuit, and is directed more particularly to a threshold value setting circuit suitable for use with an apparatus for extracting a specific pattern.
2. Description of the Prior Art
In the art, there have been proposed various methods to catch picture information from a video sensor or the like and then to extract a specific pattern from the picture information. For example, it is proposed that when a screen, which consists of a number of picture elements arranged in the vertical and horizontal direction (or mesh pattern), is scanned, the screen is divided into a plurality of small picture screens each consisting of 3×3=9 picture elements which is then detected to determine whether a specific pattern exists on the screen or not. In such a case, it is usual that the extraction of the specific pattern is achieved with the information being divided into two values of white and black. Namely, in general, such a floating method is used in which a certain threshold value is set for the zero potential and then a value higher than the threshold value is judged as the white level while a value lower than the threshold level is judged as a black level, or an average value of the bright and dark levels of a picture screen is set as a threshold level and then the + side thereof is judged as the white level while the - side thereof is judged as the black level.
In the above threshold value setting method, it becomes a problem how to set the threshold value without being affected by scratches, dirty portions and so on of a pattern, how to adjust the light source which will irradiate the picture screen, and how to adjust the gain of an amplifier used therein. That is, if much attention is not paid to the above operations, it is impossible to accurately extract a specific pattern.
Now, an example of the prior art pattern extracting method will be described with reference to FIGS. 1A, 1B, 2A, 2B, 3A, 3B, 4A and 4B. As shown in the figures, a picture screen (the whole screen is not shown in the figure) is divided into a plurality of small picture screens each consisting of 3×3=9 picture elements P1, P2, . . . P8, P9 which are arranged in the vertical and horizontal directions (one small picture screen is shown in FIGS. 1A to 3B). In this case, an inverse L-shaped pattern PL, which is an example of the specific patterns, will be extracted from the screen. Therefore, in this case, the specific pattern PL is projected onto the picture elements P1, P2, P3, P4 and P7 of the small picture screen as shown in FIGS. 1A, 2A and 3A. If it is assumed that the information from the respective picture elements are accurately made as two values, the picture elements P1, P2, P3, P4 and P7 become the black level, while the picture elements P5, P6, P8 and P9 become the white level as shown in FIG. 1B.
While, if, for example, a dirty portion exists on one of picture elements such as the picture element P8 as shown in FIG. 2A, the information from the picture element P8, which should be in the white level, may be judged as the black level as shown in FIG. 2B dependent upon the manner in which the threshold value is set.
That is, as shown in FIG. 4A by a dotted line, if a threshold value SH is set at a relativly high value near a white level W (in FIG. 4A, WL represents a portion of the white level and IL and BL respectively represent black level portions), the picture element P8, which contains the dirty portion, is at a level lower than the threshold level SH (in this case, it becomes the level IL). Thus, the picture element P8 is erroneously judged as the black level, and accordingly it becomes impossible to accurately judge the pattern.
In order to avoid the above erroneous judgement, if the threshold value is lowered to SHL40 as shown in FIG. 4B by a dotted line, another defect will be caused. That is, if, for example, a scratch is present on, for example, the picture element P2 (on which a part of the pattern PL is projected and hence which is in the black level) as shown in FIG. 3A, the level of the picture element P2 becomes the level IL and is higher than the threshold level SH' as shown in FIG. 4B. Thus, the picture element P2 is erroneously judged as the white level. Accordingly, the case of FIG. 3A is such that a part of the black portion of the small picture screen is cut away i.e. the picture element P2, which is to be a black portion by the projection of the pattern, becomes the white level as shown in FIG. 3B.
Accordingly, in the prior art, the threshold value must be carefully set in consideration of various conditions as set forth above, which is troublesome and further, the threshold value is easily affected by the background of the pattern.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a novel threshold value setting circuit.
It is another object of the invention to provide a threshold value setting circuit which is effective when it is employed in extracting a specific pattern.
It is a further object of the invention to provide a threshold value setting circuit which can avoid the erroneous judgement of a pattern when it is used in extracting a specific pattern.
According to an aspect of the invention, a threshold value setting circuit is provided which comprises a means for detecting the brightest or highest level of a screen which consists of a number of picture elements, and means for reducing the brightest or highest level to thereby set a threshold value.
The other objects, features and advantages of the present invention will become apparent from the following description taken in conjunction with the accompanying drawings through which the like references designate the same elements and parts.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1A, 1B, 2A, 2B and 3A, 3B are schematic diagrams explaining the prior art, respectively;
FIG. 4A and 4B are graphs used for explaining the prior art;
FIG. 5 is a circuit diagram, partially in block, showing an example of the threshold value setting circuit according to the present invention;
FIG. 6 is a schematic diagram explaining the invention; and
FIG. 7 is a graph explaining the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will be hereinafter described with reference to the attached drawings.
In the following description, such a case will be described in which the present invention is applied to extract a specific pattern such as an inverse L-shaped pattern which is projected on a small picture screen consisting of, for example, 3×3=9 picture elements which are arranged in the vertical and horizontal directions as described in connection with the description of the prior art.
Turning to FIG. 5, an example of the threshold value setting circuit according to the present invention will be described. In FIG. 5, references I1, I2, . . . , I9 designate input terminals to which the picture informations from picture elements P1, P2, . . . P9 forming a divided small picture screen (shown in FIG. 6) are applied. The input terminals I1, I2, . . . I9 are respectively connected through resistors R1 to one of the input terminals of the operational amplifiers C1, and the output terminals of the respective operational amplifiers C1 are connected through diodes D1 in the forward direction to the other one of the input terminals of the operational amplifiers C1. In this case, each of the triplets consisting of the operational amplifier C1, resistor R1 and diode D1 forms a so-called peak selector PS. The cathodes of the diodes D1 connected to the output terminals of the respective operational amplifiers C1 are connected together to a potentiometer PM which will set a common threshold value. The output terminal i.e. the movable piece of the potentiometer PM is commonly connected to one of the input terminals of each of a plurality of comparator C2, which correspond in number to the respective sets of the diode D1, operational amplifier C1 and resistor R1, and the input terminals I1, I2, . . . I9 are respectively connected to the other one of the input terminals of each of the comparators C2 through resistors R2. From the output sides of each of the comparators C2 there is led output terminals 01, 02, . . . 09, respectively. The output signals delivered to the output terminals 01 to 09 will be supplied to a computer (not shown) in which the pattern extraction is carried out by the known technique. Therefore, the description thereof will be omitted.
In the example of the invention shown in FIG. 5, the cathodes of the respective diodes D1 are connected together, so that only the operational amplifier C1, to which the information signal having the highest voltage of all of the signals applied to the input terminals I1 to I9 corresponding to the picture elements P1 to P9 is supplied, functions as a half-wave rectifier circuit and only the output therefrom is applied to the potentiometer PM. Accordingly, the signal, which is commonly applied to the respective comparators C2 from the potentiometer PM as the reference level (threshold value) thereof, is equal with one another and always corresponds to the highest level (peak value) of the picture screen or small picture screen. In other words, the reference level for the comparators C2 is the level or threshold value which corresponds to the highest level (peak value) lowered or reduced suitably by the potentiometer PM. Thus, each of the respective comparators C2 compares its input signal with the same reference level or threshold value so as to judge the input signal to be one of two values or black and white levels. In other words, the threshold value of the example of the invention shown in FIG. 5 is automatically set to a value provided by suitably reducing the highest level of the input signals through the potentiometer PM.
Next, a case where the above threshold value setting circuit of the invention is used to judge a pattern will be described with reference to FIGS. 6 and 7.
As shown in FIG. 6 and described above, a picture screen or screen SC is divided into a plurality of small picture screens each consisting of 3×3=9 picture elements P1, . . . , P9 arranged in the horizontal and vertical directions. When an inverse L-shaped pattern, by way of example, is extracted from the screen SC, the information signal from the respective picture elements P1 to P9 are each divided into two values of black and white as set forth above. In FIG. 6, the inclined left upper portion of the screen SC with no hatching is a bright portion, while the inclined right lower portion of the screen SC with the hatching is a dark portion, respectively. Now, if the potentiometer PM is so adjusted that the threshold value set thereby, for example, 1/3 of the level W of the highest input signal from the bright picture portion, the pattern PL of the small picture screen on the bright portion of the screen SC becomes such that its white level WL is higher than the threshold level SH and its black level BL is lower than the threshold value SH as shown in FIG. 7A. Thus, there is caused no error upon judging the black and white, and accordingly the pattern PL can be positively extracted from the screen SC.
In the case of the dark picture portion in the screen SC, as described above, the threshold level SH' is automatically set to 1/3 of the level W of the highest signal of this dark portion, so that the white level WL is higher than the threshold level SH' and the black level BL is lower than the threshold level SH'. Therefore, in this case, the judgement of the black and white can also be positively carried out and hence the pattern PL can be accurately and positively extracted from the screen SC.
In the above description, the reducing factor of the potentiometer PM is selected as 1/3, but it is of course not critical that the reducing factor be limited to the above value. It is of course possible to select the reducing factor in accordance with the degree of darkness and brightness of the screen SC to be scanned.
Further, in the above example of the invention, the peak selectors PS, each cosisting of the operational amplifier C1, diode D1 and resistor R1, whose number is same as that of the input signals, are used. It is, however, of not necessary that the peak selector PS be limited to the illustrated and described construction, but a peak selector consisting of, for example, only a diode may be employed or a peak selector with other construction may be used in this invention with the same effect.
Further, it is not essential that the screen, from which a pattern is extracted by utilizing the present invention, be limited so that the screen is divided into a plurality of small picture screens each consisting of 9 picture elements. That is, it is possible to form the respective small picture screen of picture elements whose number is a suitable one other than 9. In this case, it is sufficient that the circuit of the invention shown in FIG. 5 except the potentiometer PM be modified in response to the number of the picture elements used therein.
It wil be apparent that many modifications and variations could be effected by one skilled in the art without departing from the spirit or scope of the novel concepts of the present invention, so that the scope of the invention should be determined by the appended claims only.
|
A threshold setting circuit having a detector for detecting the brightest or highest level of a screen which consists of a plurality of picture elements and a device for setting a threshold value by suitably reducing the brightest or highest level detected by the detector.
| 7
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to a method and apparatus for recovering crude oil and similar oily substances from oil soaked beach sands and other earth materials by a combined mechanical and hydraulic agitation process.
2. Background
It has been observed that heavy concentrations of hydrocarbon materials such as crude oils and refined oily wastes associated with oil spills and discharges into collection pits results in substantial penetration or percolation of the oil into sandy or other granular soil surfaces. In attempting to recover spilled oil from marine oil spills, it has been discovered that along shore lines having relatively coarse bottom sediments, crude oil washed onto the shore will penetrate into the sediments forming the shoreline and the sea bottom in shallow waters. The penetration of oil into a relatively wide area is aggravated in tidal waters if the oil cannot be quickly recovered by conventional surface recovery techniques. This penetration of oil into the earth's surface not only reduces the amount of oil recovered, and may be environmentally damaging, but prevents the complete removal of the oil after a spill or when the eradication of dumping pits or holding ponds for oily wastes and the like is required. Moreover, the complete removal of the oil soaked sediments or sand for processing at a remote site to remove the entrapped oil is very impractical or even impossible if large quantities of oil are washed ashore or soak into the sediments.
SUMMARY OF THE INVENTION
Notwithstanding the seemingly impossible task of freeing absorbed quantities of crude oil and other oily substances from coarse sediments such as relatively coarse beach sands and marine shorelines, the present invention has resulted in the discovery that by combined mechanical and hydraulic agitation, of multistage hydraulic agitation, of the bottom sediment that oleaginous substances such as crude oil, petroleum products and other oily wastes may be freed from entrapment in such sediments and floated to the surface of a body of water covering the sediments for removal by conventional recovery methods.
The present invention contemplates a method of recovering crude oil and other oleaginous substances from entrapment or absorbtion into relatively coarse bottom sediments along seashores and oil dumping or containment pits wherein a body of water covering the oil-soaked sediments is utilized as a source of hydraulic agitation which may penetrate the sediment to a sufficient depth to free the entrapped oil from the sediment particles whereby the oil will normally migrate to the surface of the body of water for recovery by absorbtion, adsorption or mechanical skimming techniques.
In accordance with the present invention there is also provided an improved apparatus for recovering crude oil and the like from entrapment in coarse beach sands and other relatively coarse sediment beds utilizing mechanical agitation means and hydraulic agitation and cleansing action to free the entrapped oil fluids from the sediments. One embodiment of the present invention utilizes a conventional terrain traversing vehicle such as a crawler tractor having mechanical ripping or agitating teeth which are arranged in combination with a plurality of hydraulic nozzles to severely stir and agitate beach sands and other coarse earth sediments to free entrapped oil for flotation to the surface of a body of water normally covering the sediments. In another embodiment of the invention, a marine vessel is provided which is equipped with an array of hydraulic jet nozzles which may be disposed directly above the sea bottom for severe agitation of the sand or sediment to a depth sufficient to free entrapped oil. In both embodiments of the invention, the source of hydraulic jetting fluid is preferably the body of water covering the oil soaked sediments.
Moreover, in one embodiment of the invention, a unique arrangement of nozzles is provided which cut or plow the bottom sediment followed by severe agitation of the sediment material by a second set of nozzles.
Those skilled in the art will recognize the above described features and advantages of the present invention, as well as other superior aspects thereof, upon reading the detailed description which follows in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a seashore area which has been fouled with sediment absorbed crude oil and the like which is being recovered by a vehicle equipped in accordance with the method and apparatus of the present invention;
FIG. 2 is a side elevation of the vehicle shown in FIG. 1, illustrating the arrangement of the mechanical and hydraulic sediment agitating apparatus;
FIG. 3 is a detail view of one of the hydraulic jet nozzles used in conjunction with the apparatus illustrated in FIGS. 1 and 2;
FIG. 4 is a side elevation of a marine vessel comprising a unique apparatus for agitating bottom sediments in accordance with the method of the present invention;
FIG. 5 is a front view of the vessel illustrated in FIG. 4;
FIG. 6 is a detail view of a modification of the nozzle array for use with the apparatus illustrated in FIG. 1 or FIG. 4;
FIG. 7 is a detail view of the nozzle array of the embodiment illustrated in FIG. 6; and
FIG. 8 is a schematic diagram of a hydraulically driven water pump used in the apparatus of FIGS. 1 or 4.
DESCRIPTION OF PREFERRED EMBODIMENTS
In the description which follows, like parts are marked throughout the specification and drawing with the same reference numerals, respectively. The drawing figures are not necessarily to scale and certain features of the invention may be shown exaggerated in scale or in somewhat schematic form in the interest of clarity and conciseness.
Referring to FIG. 1, there is illustrated one preferred method and appartus for recovering crude oil and the like which has become deposited on and absorbed into a coarse sediment such as a sand beach, generally designated by the numeral 10. The beach sediment or sand 10 is shown covered with a body of water 13 having a surface 12 and which body may be tidal or nontidal. In the instance where the water 13 recedes and then again covers the sand 10, in particular, a relatively large amount of oil from a marine oil spill or the like may absorb or percolate into the sand. This absorption of oil from a marine spill or other source may be aggravated in tidal areas wherein the total thickness of the liquid on the sand surface upon ebbing of the water will permit the oil to more thoroughly absorb into the sand. Recent incidents of marine oil spills have indicated that a substantial quantity of oil may absorb or percolate into a course sediment such as the sand 10 and, upon removal of free floating oil from the water surface 12, oil will reappear upon completion of every tidal cycle or in response to heavy wave action. It has been discovered that in connection with some oil spills that crude oil, for example, will soak or absorb into a coarse sediment surface such as the sand 10 to depths of from six to twelve inches and remain substantially entrapped in the sediment material. The shoreline of the Juan de Fuca Strait near Port Angeles, Wash., is exemplary of the type of sediments which may be freed of up to 70% of entrapped oil by the method and apparatus of the present invention.
FIG. 1 illustrates an improved apparatus for dislodging the entrapped or absorbed oil in the sand 10 comprising a terrain traversing vehicle such as a conventional crawler tractor 14. The crawler tractor 14 includes a boom 16 mounted on one side thereof for pivotal movement laterally away from the direction of movement provided by spaced apart crawler tracks 17 and 18. The boom 16 may be part of a conventional pipe laying apparatus used on crawler tractors and similar equipment. The boom 16 is pivotally connected to the tractor frame at 19 and may be raised or lowered by a hoist cable 20 suitably connected to a winch or the like, not shown. The crawler tractor 14 is also equipped with a conventional earth ripper device, generally designated by the numeral 22, see FIG. 2 also, including an elongated transversely extending bar 24 on which is mounted plow means comprising a plurality of spaced apart depending ripper teeth 26. The bar 24 is mounted for substantially vertical movement on the frame 15 of the tractor 14 by a conventional hydraulic cylinder type actuator 28.
In order to thoroughly agitate the oil soaked beach sand 10 to release entrapped oil, the tractor 14 has been modified to provide a manifold 30 extending generally parallel to the ripper tooth support bar 24 and mounted thereon for movement with the ripper teeth 26 with respect to the frame 15. The manifold 30 includes a plurality of spaced apart hydraulic jet nozzles 32 which extend normal to the longitudinal axis of the manifold and are preferably spaced such that a nozzle 32 is generally aligned with each of the ripper teeth 26 and points generally downwardly toward the surface 11 of the sand 10. The manifold 30 is connected to a flexible hose 34 which is trained through a sling 36 attached to a tractor roll-bar frame 38 along the same lateral side of the tractor 14 as is mounted the boom 16. The boom 16 supports a hydraulic motor driven pump unit, generally designated by the numeral 42, which is submerged below the surface of the water 12 and is connected to the hose 34 for delivering a relatively high pressure, high volume stream of water to the manifold 30. A protective screen or filter 44 is disposed around the pump unit 42 and the entire pump unit is supported by a flexible cable 46 depending from the boom 16. A block and tackle 47 is interposed between the boom 16 and the cable 46 for adjusting the submerged depth of the pump unit 42.
Referring briefly to FIG. 8, there is illustrated a somewhat simplified schematic of a propulsion system for operating the pump unit 42. The pump unit 42 includes a hydraulic motor driven pump 48 operably connected to a hydraulic motor 50 which is in circuit with a source of hydraulic fluid such as an engine driven pump 52 on the tractor 14. A suitable control valve 54 is interposed in the hydraulic circuit between the motor 50 and the pump 52 for controlling the speed of the motor and displacement of the pump 48. The pump 48 is adapted to receive an intake stream from the body of water 13 in which the tractor 14 is operating to free entrapped or percolated oil from the sand 10. By mounting the pump unit 42 submerged and laterally spaced from the tractor 14 on the boom 16, the source of intake water for the pump is relatively free of oil or agitated sand and thus relatively clean water is pumped to the manifold 30 for discharge through the nozzles 32.
Referring briefly to FIG. 3, one of the nozzles 32 is shown mounted to a fitting 33 which is formed as part of the manifold 30. The nozzle 32 may be of a type commercially available such as manufactured by Spraying Systems Company of Wheaton, Ill., and may be conveniently demounted from the fitting 33 for repair or replacement. The nozzle 32 is also of a type which discharges a generally conical spray pattern 35 uniformly from the distal end of the nozzle, as shown in FIGS. 1 and 3. Alternatively, it has been determined that in the exemplary nozzle arrangement of FIGS. 1 through 3 that the nozzles 32 may be replaced by 1.0 inch nominal diameter sections of pipe or tube serving as nozzles. The end of the manifold 30 opposite the end which is connected to the hose 34 may have a removable cover or plug 37 for cleaning the manifold free of any accumulated debris such as fine sand particles entrained with the jet flow stream discharged by the pump 48.
In carrying out a preferred method of recovering oil which has aborbed into the sand 10, the tractor 14 is traversed generally parallel to a shoreline of the body of water 13 over side by side paths with the ripper teeth 26 lowered to a sufficient depth below the surface 11 to plow up or agitate the sand 10 while at the same time the pump unit 42 is operated to discharge high velocity jets of water through each of the nozzles 32. As the sand 10 is mechanically agitated or "turned" by the ripper teeth 26, the jets 35 emitting from the respective nozzles 32 also thoroughly agitate the sand to free heavy oleoganeous substances from entrapment in the sand particles. In most instances, the oil will then float to the water surface 12 where it may be contained by containment boom means 60 and sorbed by conventional means, including sorbent sweeps 62 or by conventional skimming techniques, not illustrated. Thanks to supporting the pump unit 42 spaced from and laterally alongside the tractor vehicle 14, the source of water jetted through the manifold 30 will be largely free of agitated sand which can settle back to the surface 11 after being freed of oil.
Referring now to FIGS. 4 and 5, another embodiment of apparatus of the present invention is illustrated and characterized by an array of nozzles 70 which are mounted on a generally horizontal or laterally projecting tubular manifold 72, FIG. 5. The manifold 72 is characterized further by spaced apart vertically projecting tubular support members 74 which are supported on a floating vessel 76 by sleeve type brackets 78. The brackets 78 are pivotally connected to respective clevis members 80, one shown in FIG. 4, which are mounted on a forward bulwark portion 79 of the vessel 76. The vessel 76 may be suitably propelled by conventional marine propulsion means such as an inboard engine or an inboard outdrive, neither shown in FIGS. 4 or 5, or by winching the vessel through severely fouled waters. The manifold 72 is supported for adjustable vertical positioning with respect to the sand surface 11 and an adjustable angle of attack of the water jets emanating from the nozzles 70 by a support arrangement including a boom 82 which is mounted for pivotal movement in a vertical plane at a pivot connection 84 supported by a deck 81 on vessel 76. The boom 82 is stayed by opposed shrouds 88 and 90 which are each adjustable by suitable block and tackle means 92, one shown in FIG. 4. The boom 82 is also stayed by a third block and tackle arrangement 94 and the manifold 70 is supported for vertical adjustment relative to the boom by a fourth block and tackle arrangement 96 interconnecting the boom with a transverse support member 75.
The vessel 76 is equipped with a hydraulic fluid power supply unit 99 which includes a source of hydraulic fluid for powering respective pump units 42 which are suitably supported in the body of water 13 astern of the vessel 76. The pump units 42 are each operable to have their respective water pumps 48 in communication with the manifold 72 by way of flexible supply hoses 101 which are each suitably connected to the tubular support members 74 for charging the manifold 72 and the respective nozzles 70. As illustrated in FIG. 5, the nozzles 70 each have a somewhat inverted "Y" shaped configuration with opposed laterally angled discharge heads 71, respectively. A suitable nozzle configuration has been determined to be a fabricated pipe fitting comprising a two and one-half inch nominal diameter standard schedule 40 pipe base portion reduced to one and one-half inch diameter nozzle heads 71 extending at approximately 45° to the vertical to provide overlapping jet streams of water which may be directed generally downward in a vertical plane or angled forward of the bow 77 of the vessel 76 depending on the position of the boom 82 and the block and tackle supports 94 and 96 for the manifold 72. Accordingly, not only may the vertical position of the nozzles 70 be adjusted, but the angle and position of the nozzles with respect to the vessel 76 may also be selected according to water depth and the ability of the vessel to progress into shoal waters.
A suitable vessel of the type generally configured in accordance with the previous description and the drawing FIGS. 4 and 5 comprises a vessel having an overall length of approximately 30 feet constructed in a somewhat barge shaped configuration with an onboard internal combustion engine driven hydraulic power supply unit 99 driving two pump units discharging approximately 500 gallons per minute at 100 psig pressure to the nozzles 70. Traversal of the coarse sediments in which oil is entrapped may be carried out in the same manner as for the embodiment of the present invention illustrated in FIGS. 1 through 3. The vessel 76 may be moved forward or astern during agitation and stirring of the sand 10 and the placement of the pump units 42 avoids ingestion of severely sand or oil contaminated water.
Referring now to FIGS. 6 and 7, an alternate embodiment of the nozzle arrangement for use with the vessel 76 or a similar vessel is illustrated and includes a tubular manifold 110 similar to the manifold 72 having spaced upright tubular support portions 112 which may be supported in the sleeve type brackets 78. The manifold 110 includes a plurality of spaced apart nozzzle assemblies 114, each including a generally downward extending nozzle head 116, FIG. 7, and an angled nozzle head 118, both in communication with the manifold 110 for receiving high pressure water therefrom. The nozzle heads 118 are of a type which discharge a somewhat planer fan-shaped jet stream 120 in a plane which may include the longitudinal axis 111 of the manifold 110. The nozzle heads 116 may be of a type which discharge a generally conical jet 117, similar to the jet pattern of the nozzle heads 32, or a straight cylindrical pipe type of nozzle. By providing a so-called "V" shaped or planar jet stream 120 at an angle ahead of the agitating and washing jet stream 117, oil soaked and may be loosened and severely agitated before the more thorough and complete agitating action of the nozzle jet streams 117 contacts the loosened and agitated sand. The direction of movement of the manifold 110 relative to the sediment bottom or sand 10 is normally as indicated by the arrow 121 in FIG. 7.
Operations to recover oil from heavily oiled sand beaches utilizing the arrangement illustrated in conjunction with drawing FIGS. 1 through 7 have been carried out using suitable containment and recovery equipment including containment booms such as the boom 60 and rows of sorbent sweeps 62 arranged at least two or three deep and extending parallel to the beach surfline. The tractor vehicles 14 preferably are moved parallel to the surfline and follow any tidal movements to maintain the ripper teeth 26 and the nozzles 32 submerged. In deeper waters, of course, the vessel 76 is typically employed to carry out the agitation and cleansing process.
Although preferred embodiments of the present invention have been described in detail herein, those skilled in the art will recognize that various substitutions and modifications may be made to the specific embodiments described without departing from the scope and spirit of the invention as recited in the appended claims.
|
Crude oils and other oleaginous substances which have washed onto and soaked thoroughly into coarse bottom sediments such as sand beaches and sediments forming the bottom of certain holding ponds may be released for recovery by mechanical or hydraulic plowing of the relatively loose sediments followed by hydraulic agitation of the sediments to permit the substances to float to the surface of the body of water. Shallow water beach areas may be plowed by a conventional crawler tractor having an array of ripper teeth fitted with hydraulic jet nozzles for severely agitating the sands which are plowed by the ripper teeth. A submersible pump or pump intake is preferably supported spaced from the normal path of the tractor and in the body of water to collect relatively clean water for discharge through the nozzles. A nozzle array may be mounted on a manifold supported from a floating vessel for vertical and angular adjustment relative to the bottom sediments utilizing the body of water as a source of hydraulic plowing and agitating fluid. An array of nozzles may include an angled nozzle having a generally planar jet pattern which acts to cut or plow the sand ahead of a full conical jet nozzle which thoroughly agitates the plowed or turned over sand to free the oil.
| 8
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional Application 61/089,622 filed Aug. 18, 2008 and titled “Figure with Controlled Motorized Movements.”
FIELD OF THE INVENTION
[0002] The present invention relates to a figure with controlled motorized movements.
BACKGROUND OF THE INVENTION
[0003] There have been numerous varieties of children's toys that are non-interactive and interactive. A continual need for improvements in more realistic play qualities along with improved electronics and mechanics provide for new arrangements which improve or change the play and interaction between the child and the toy.
[0004] Numerous other advantages and features of the invention will become readily apparent from the following detailed description of the invention and the embodiments thereof and from the accompanying drawings.
SUMMARY OF THE INVENTION
[0005] In one or more embodiments of the present invention, a toy figure with controlled motorized movements is provided having a head, two arms and two legs. The head, two arms and two legs are pivotally and/or rotatably attached to a chassis. A first motor secured to the chassis and drives a tail mechanism attached to the chassis with a tail segment rotatably and pivotally attached to the tail mechanism. The tail mechanism also includes a tail linkage with forward and rearward linkage channels. The forward linkage channel is in communication with the inside rim of a tail cam, which is rotated by the first motor. As such, the movement of the forward linkage channel directs movement of the rearward linkage channel. The rearward linkage channel is in communication with a tail column that fits within the tail segment having a rearward projecting tail segment and a forward projecting segment pin. The forward projecting segment pin is positioned to move against an actuator having a cutout and a pair of flanges. The movement of the tail column moves the forward projecting segment pin against the pair of flanges to create a pivoting and rotating movement of the rearward projecting tail segment. Further, the pivoting and rotating movement of the rearward projecting tail segment may move along a figure eight pattern. An integrated circuit with electronics may be included to receive signals generated in response to a triggering means and for controlling movement of the tail mechanism in response to the signals.
[0006] Based thereon other aspects of the invention and other embodiments can be disclosed. For example, there may be provided an interactive toy figure with a chassis having rear and front sections with a pair of rear legs and a pair of front legs secured to respective sections. The chassis has a first substantially horizontal configuration with the rear and front legs being in communication with a surface and having a first front and rear leg configurations. A motor in communication with a mechanically operated means for raising and lowering the front section of the chassis is secured to the chassis. The motor may also move the rear section of the chassis upwardly and downwardly to cause a change in the center of gravity and define at least two configurations where at least one of the configurations is defined as a pouncing configuration. The mechanically operated means for lowering and raising the chassis in communication with a triggering means further includes an integrated circuit with electronics for receiving signals generated in response to the triggering means and for controlling movement of the mechanically operated means for lowering and raising the chassis.
[0007] Numerous other advantages and features of the invention will become readily apparent from the following detailed description of the invention and the embodiments thereof, from the claims, and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] A fuller understanding of the foregoing may be had by reference to the accompanying drawings, wherein:
[0009] FIG. 1 is a front perspective view of a figure from the right in accordance with an embodiment of the present invention;
[0010] FIG. 2 is a front perspective view of the figure from FIG. 1 from the left in accordance with an embodiment of the present invention.
[0011] FIG. 3 a is a top view of FIG. 1 ;
[0012] FIG. 3 b is a front view of FIG. 1 ;
[0013] FIG. 3 c is a side view of FIG. 1 ;
[0014] FIG. 3 d is a rear view of FIG. 1 ;
[0015] FIG. 3 e is a bottom view of FIG. 1 ;
[0016] FIG. 4 is a perspective view of the figure from FIG. 1 in accordance with one embodiment of the present invention illustrating a partial view of an arm mechanism and a head mechanism;
[0017] FIG. 5 is an enlarged rear perspective view of the figure from FIG. 1 in accordance with one embodiment of the present invention illustrating a partial view of the arm mechanism and head mechanism;
[0018] FIG. 6 a is an enlarged rear perspective view of the figure from FIG. 1 in accordance with one embodiment of the present invention illustrating a view of a tail mechanism;
[0019] FIG. 6 b is a perspective view of FIG. 6 a from a lower angle;
[0020] FIG. 6 c is a rear perspective view the figure from FIG. 1 where a portion of the tail mechanism is removed;
[0021] FIG. 7 a is a front perspective view of the figure from FIG. 1 illustrating the figure in an upright position;
[0022] FIG. 7 b is a front view of FIG. 7 a ;
[0023] FIG. 7 c is a front perspective view of the figure from FIG. 1 illustrating the figure in a lowered position;
[0024] FIG. 8 a is an enlarged rear perspective view of the figure from FIG. 1 where a portion of the figure is removed to show internal components of the figure where the figure is in a sitting position;
[0025] FIG. 8 b is an enlarged rear perspective view of the figure from FIG. 1 where a portion of the figure is removed to show internal components of the figure where the figure is in an upright position;
[0026] FIG. 8 c is a front perspective view of FIG. 8 b;
[0027] FIG. 9 is a front left perspective view of the figure from FIG. 1 where a portion of the figure is removed to show internal components.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0028] While the invention is susceptible to embodiments in many different forms, there are shown in the drawings and will be described herein, in detail, the preferred embodiments of the present invention. It should be understood, however, that the present disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the spirit or scope of the invention or the embodiments illustrated.
[0029] Referring now to FIGS. 1 through 3 e , in accordance to an embodiment of the present invention, there is illustrated a FIG. 10 that includes a set of arm mechanisms, two head mechanisms, a tail mechanism and a chassis mechanism. In this embodiment, the FIG. 10 uses two motors to move the figure into and out of an assortment of movements and actions by varying the distribution and direction of power to the motors. A variety of external coverings (not shown) may be used for the FIG. 10 , such as different types of animals or characters.
[0030] Referring now also to FIG. 4 , the FIG. 10 includes a set of arm mechanisms and a first head mechanism. Each arm mechanism includes an arm 25 , a shoulder 30 and a shoulder cam 35 . The arm mechanisms are further rotatably attached separately to either end of a front axle 40 . An arm transfer gear 45 is fixedly attached to the front axle 40 , such that the front axle 40 and arm transfer gear 45 rotate together. Additionally, a head transfer gear 50 is fixedly attached to the front axle 40 , such that the head transfer gear rotates together with the front axle 40 and arm transfer gear 45 . The arm transfer gear 45 and head transfer gear 50 are meshed to a gear train 55 , which may be set at different ratios as desired. The gear train 55 is further meshed to a clutch gear 60 fixedly attached to a front clutch 65 and a tail clutch 70 . The front clutch 65 is in meshed communication with a belt drive 75 that is driven by a first motor gear 80 . The first motor gear 80 is driven by a first motor 15 , which is secured to the chassis 20 (shown in FIG. 1 ).
[0031] When the first motor 15 is powered in a clockwise direction, the front clutch 65 engages and transfers rotation, rotating the front axle 40 . As the front axle 40 rotates, the shoulder cams 35 rotate accordingly.
[0032] A pin 85 is positioned on the outside of each shoulder cam 35 and at positions approximately 180 degrees different from each other. Varying degree positions may be used as desired. The upper portion of each arm 25 is rotatably attached to its respective pin 85 . Each arm 25 also includes and aim channel 90 to receive a pin 95 positioned at the lower portion of each shoulder 30 to guide movement of the arms 25 . When the shoulder cams 35 rotate, the arms 25 move up and down as the pin 95 slides along the arm channel 90 . Positioning the pins 85 on the shoulder cams 35 at different degree points drives the arms 25 to move up and down opposite one another.
[0033] Continuing to refer to FIG. 4 and now additionally FIG. 5 the first head mechanism is illustrated. A head segment 100 moves simultaneously to the movement of the arm mechanisms described above. The first head mechanism includes the head transfer gear 50 , a spool actuator 110 , the head segment 100 and a neck housing 115 . The spool actuator 110 has two triangularly shaped flanges 120 extending from the interior of each side and is fixedly attached to the head transfer gear 50 . The head segment 100 includes a lower portion 125 that is pushed from side to side in a pendulum-type motion by the flanges 120 as the spool actuator 110 rotates. Further, the head segment 100 has a spherical shaped extrusion 130 at the mid section to create a ball joint 135 in combination with the neck housing 115 . Thus, an upper portion 140 of the head segment 100 moves from side to side (and additionally in all directions) when the first motor 15 powers in the clockwise direction. The upper portion 140 may take on the form of a head for a variety of characters or animals, such as a cat.
[0034] Another example of the movements executed by the FIG. 10 includes the use of a tail mechanism as illustrated in FIGS. 6 a - 6 c . The first motor 15 also drives the movement of a tail mechanism when the first motor 15 is powered in a counterclockwise direction. The belt drive 75 rotates a tail gear 145 which in turn drives the clutch gear 60 and engages the tail clutch 70 . The tail clutch 70 is meshed to a bevel gear 150 fixed to a tail cam 155 . A pin 160 is positioned on the upper side of the tail cam 155 and positioned in a forward linkage channel 165 at the forward portion of a tail linkage 170 . The rear portion of the tail linkage 170 includes a rear linkage channel 175 to receive a pin 180 on a tail transfer segment 185 included in the tail mechanism. The tail mechanism further includes a tail column 190 , a tail segment 195 , a tail segment pin 200 and an actuator 205 with a heart-shaped cutout 210 . The tail transfer segment 185 is fixed to the upper portion of the tail column 190 while the base of the tail column 190 is rotatably attached to a ledge 215 extending from the actuator 205 and rotates freely. The tail segment 195 is pivotally attached to the tail column 190 via a pin 220 . The tail segment pin 200 extends from one end of the tail segment 195 such that it is positioned within the cutout 210 . As movement is transferred to the tail mechanism via the tail linkage 170 , the tail column 190 and tail segment 195 move in a pattern directed by the path the tail segment pin 200 travels. As the tail mechanism moves, the tail segment pin 200 travels along the outer rim of the cutout 210 , then is pushed to the other side of the cutout 210 when the tail segment pin 200 encounters one of two flanges 225 extruding form the base of the cutout 210 . Thus, the tail segment pin 200 travels in a figure eight type (shown with dotted lines in FIG. 6 c ) path as the tail mechanism moves. As such, by powering the first motor in the counterclockwise direction, power and rotation is transferred to the tail mechanism to create a movement similar to that of a “wagging tail.” Further, the figure eight type path directs a movement that is a more fluid motion in comparison to a rigid mechanical movement.
[0035] An additional example of a movement of the FIG. 10 where the FIG. 10 moves from a sitting position ( FIG. 1 ) to substantially an upright position ( FIGS. 7 a and 7 b ), however, it is within the scope to bring the FIG. 10 to an angled position above the horizontal. A second motor 230 is secured to the chassis 20 . The second motor 230 has a motor gear 235 meshed to a clutch gear 240 fixed to an up clutch 245 and a bounce clutch 250 . When the second motor 230 is powered in a clockwise direction, the up clutch 245 engages and transfers rotation to a mid axle 255 with a transfer gear 260 and an up cam 265 fixedly attached thereto. A pin 270 is positioned on the outside of the up cam 265 and is rotatably attached to an up linkage 275 . The opposite end of the up linkage 275 is rotatably attached to a left hip 280 . When the mid axle 255 rotates as directed by the second motor 230 , the up cam 265 rotates therewith. The rotatable connection between the up linkage 275 and the up cam 265 drives the chassis 20 upward to an upright position. Continuing to power the second motor 230 and subsequently the rotation of the up cam 265 will further drive the chassis to a lowered position as seen in FIG. 7 c . One full revolution of the up cam 265 will drive the chassis from the sitting position, then to the upright position, then to the lowered position and then back to the sitting position.
[0036] Further, adjusting the power distribution to the motor when the figure is in the sitting position provides for additional movement utilizing the mechanisms described above to raise the figure to the aforementioned upright or angled position. For example, a “pouncing” movement utilizes the weight and center of gravity of the figure along with a timing sequence related to the power distribution to the second motor. A switch is positioned such that it triggers in a range where the weight of the chassis causes the figure to lean slightly forward, generally in a range where the chassis is raised halfway to the full upright position. Triggering this switch pauses the application of power to the motor, providing time for the figure to lean forward. Power is then reapplied to continue extending the chassis as the figure leans forward, such that the figure then lies flat on a surface. Continuing to apply power to the motor will return the figure to the sitting position.
[0037] As the second motor 230 is powered in the clockwise direction and is raising the chassis 20 , a second head mechanism additionally directs movement of the first head mechanism and the arm mechanism as illustrated in FIGS. 8 a - 8 c . The second head mechanism includes a hip disc 285 , a first linkage 290 , a second linkage 295 and third linkage 300 . The hip disc 285 is secured to a right hip 305 and includes a hip channel 310 and two pins positioned on the inside of the hip disc 285 . The first linkage 290 has a first linkage channel 315 at one end to receive a pin 317 fixed to the hip disc 285 . A pin 320 is positioned just up from the first linkage channel 315 and is positioned in hip channel 310 . The other end of first linkage 290 is rotatably attached to the inner side of the right shoulder cam 35 . One end of the second linkage 295 is rotatably attached to the hip disc 285 via a pin 325 . The other end of the second linkage 295 is rotatably attached to the third linkage 300 . The third linkage 300 is in rotatable communication with the first head mechanism via a head axle 330 . As the chassis 20 rotates upward, the hip channel 310 guides the movement of the first linkage 290 as pin 320 travels along the hip channel 310 , which in turn drives the right arm mechanism upward. An arm shaft 335 directs the left arm mechanism to move up simultaneously such that both arms are now in a raised position as seen in FIGS. 7 a and 7 b . The second linkage 295 moves along with the first linkage 290 and directs the third linkage 300 to rotate the head axle 330 forward and thus rotate the first head mechanism forward with the chassis 20 in the upright position.
[0038] It should also be known that while the chassis 20 and first head mechanism are in the upright position, powering the first motor 15 in the clockwise direction directs the arm mechanisms to activate and move the arms up and down as described above. Further, powering the first motor 15 in the counterclockwise direction, while the FIG. 10 is in the upright position, directs the tail mechanism to activate and wag as described above.
[0039] Referring again to FIGS. 7 a and 7 b and now additionally FIG. 9 , the second motor 230 also powers an up and down movement of the chassis 20 when the chassis 20 is in the upright position. When the second motor 230 is powered in the counterclockwise direction, the clutch gear 240 rotates and engages the bounce clutch 250 which is meshed to a rear axle gear 340 fixed to a rear axle 345 . A right hip cam 350 and a left hip cam (not shown) are rotatably attached at either end of the rear axle 345 . A pin 357 is positioned on the outside of both the left hip cam 355 and the right hip cam 350 . Each pin is positioned in an upper leg channel 360 included in two legs 365 fixed to the left hip 280 and the right hip 305 , respectively. The lower portion of each leg 365 includes a lower leg channel 370 to receive pins 375 positioned at the base of each hip. When rotation is transferred to the left hip cam 355 and right hip cam 350 , the chassis 20 moves up and down as the pins 357 travel in the upper leg channels 360 while the pins 375 travel up and down in the lower leg channels 370 . As such, when the second motor 230 is powered in the counterclockwise direction, the chassis 20 moves up and down in a bouncing type motion. It should be noted that varying the degree positioning of the pins 357 on the left hip cam 355 and right hip cam 350 can create a chassis motion that is more fluid and less rigid.
[0040] In the first embodiment, the FIG. 10 includes a means to move from a sitting position to an upright position in accordance to a variety of preprogrammed responses triggered by switches or user input.
[0041] Further and in accordance with the first embodiment, the FIG. 10 includes a means to move from an upright position to a lying down position in accordance to a variety of preprogrammed responses triggered by switches or user input.
[0042] The first embodiment also includes a means for the FIG. 10 to “pounce” from a sitting or upright position to a lying down position in accordance to a variety of preprogrammed responses triggered by switches or user input.
[0043] Additionally, the first embodiment includes a means to “wag” the tail of the FIG. 10 in accordance to a variety of preprogrammed responses triggered by switches or user input.
[0044] Also, the first embodiment includes a means to move the head and arms of the FIG. 10 in accordance to a variety of preprogrammed responses triggered by switches or user input.
[0045] Further, the first embodiment includes a means for the FIG. 10 to move up and down in a “bouncing” type motion while in an upright position in accordance to a variety of preprogrammed responses triggered by switches or user input.
[0046] Additionally, the first embodiment includes a means for the FIG. 10 to “pounce” and wag the tail of the FIG. 10 in accordance to a variety of preprogrammed responses triggered by switches or user input.
[0047] Also, the first embodiment includes a means for the FIG. 10 to “pounce” and move the head and arms of the FIG. 10 in accordance to a variety of preprogrammed responses triggered by switches or user input.
[0048] Further, the first embodiment includes a means for the FIG. 10 to move up and down in a “bouncing” type motion while the tail of the figure “wags” in accordance to a variety of preprogrammed responses triggered by switches or user input.
[0049] Additionally, the first embodiment includes a means for the FIG. 10 to move up and down in a “bouncing” type motion while moving the head and arms of the FIG. 10 in accordance to a variety of preprogrammed response triggered by switches or user input.
[0050] As mentioned above, the FIG. 10 executes a variety of movements and actions by alternating the direction to which each motor is powered. Further, different combinations of directional powering are available to create additional movements. The options for additional movements are increased when different amounts of power are distributed to the motors in addition to varying the direction. Each of the various movements may be triggered by several different control systems. For example, switches can be positioned throughout the figure to activate preprogrammed responses contained in an integrated circuit when triggered, such as when a user presses the head of the FIG. 10 . Another example of a control system is the inclusion of a microphone in the FIG. 10 that activates preprogrammed responses contained in an integrated circuit when the microphone picks up certain audio signals. Yet another example is the use of remote control, where a user would input commands to a controller with a transmitter, and a receiver receives these commands and transfers the commands to an integrated circuit to direct movement of the FIG. 10 .
[0051] From the foregoing and as mentioned above, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the novel concept of the invention. It is to be understood that no limitation with respect to the specific methods and apparatus illustrated herein is intended or inferred.
|
A toy figure with controlled motorized movements is provided having a head, two arms two legs and a tail which are pivotally and/or rotatably attached to a chassis. Mechanisms and electronics are included to move the head, arms, legs and tail in a variety of play patterns and movements.
| 0
|
This is a divisional of co-pending application Ser. No. 08/587,067 now U.S. Pat. No. 5,871,597, issued Feb. 16, 1999, filed on Jan. 16, 1996, claiming priority of French patent application 95/00933, filed Jan. 20, 1995.
BACKGROUND OF THE INVENTION
The present invention relates to a radial carcass tire having a crown reinforcement of small hysteresis loss, with improved rolling resistance.
Since savings in fuel and the need to protect the environment have become a priority, it is desirable to employ rubber compositions which can be used for the manufacture of various semifinished products entering into the construction of tires, such as, for instance, cushion and calendering rubbers for cord fabric plies or treads in order to obtain tires having reduced resistance to rolling.
It is known to the person skilled in the art that the first and main factor affecting the resistance to rolling of a radial carcass tire resides in the rubber composition forming the tread of the tire.
Significant progress has been achieved in the field of tires having at the same time reduced resistance to rolling, excellent adherence both on dry and on snowy ground, very good resistance to wear, and reduced rolling noise, by the use, as tire tread, of a rubber composition, described in European Patent Application EP 0 501 227, which is vulcanizable by sulfur, obtained by the thermo-mechanical working of a conjugated diene polymer and an aromatic vinyl compound prepared by solution polymerization with 30 to 150 parts by weight of a highly dispersible precipitated silica to 100 parts by weight of elastomer.
It is also known to the person skilled in the art that the second factor which exerts a dominant influence with respect to the rolling resistance of a radial carcass tire is the crown reinforcement.
The crown reinforcement is generally formed of two plies of cord fabric having non-stretchable cords parallel to each other in one ply and crossed from one ply to the next, forming equal or different angles of between 10° and 45 ° with the circumferential direction. The cords are either metal cables, in particular of steel, or synthetic textile cords, in particular of aramids. These plies which are inclined with respect to the circumferential direction are referred to as “working” plies.
Particularly in the case of tires intended for high speed passenger vehicles the crown reinforcement can have, in addition to the working plies, one or more cord fabric plies, strips of cord fabric or of helically wound thread, the component cords or threads of which are substantially not inclined with respect to the circumferential direction, that is to say, they form an angle of zero degrees or close to zero degrees and are known as “zero-degree plies”. The cord is generally a cord of synthetic textile, in particular a polyamide.
The calendering rubber used for the working plies is generally formed exclusively of natural rubber or by a blend of natural rubber and a diene synthetic rubber or a mixture of diene synthetic rubbers, natural rubber being present, however, in a preponderant amount by weight. This calendering rubber is ordinarily reinforced by carbon black as a major filler. However, it is known to the person skilled in the art, for instance from French patent application FR 80 22131 and U.S. Pat. No. 4,229,640, to use silica in a small amount, on the order of 10 to 15 parts by weight, in order to increase the adherence of the rubber to the metal cable and in particular to a brass-plated metal cable. However, the silica is used in combination with a reinforcing resin, generally one having a base of resorcinol, in order to increase the modulus of the calendering rubber, it being well-known to the person skilled in the art that the use of silica in tires as reinforcing filler has been retarded for a long time due, inter alia, to the lower modulus of elasticity of silica-filled rubber mixes.
The use of silica in tires also been extensively retarded due to difficulties in working resulting from silica-silica interactions which tend, in raw state, to cause an agglomerating of the silica particles before and even after mixing, making the working more difficult than with carbon black and leading to hard raw rubbers as soon as the percentage of silica used in the composition is relatively high. Due to their hardness, such rubbers are unsuitable as calendering rubbers for cord fabric and furthermore give rise to major problems of coherence in cured state. The use of such rubbers leads to a premature separation of the cords from the rubber, in particular at the ends of the working plies.
U.S. Pat. No. 5,066,721 describes a rubber composition having a base of a diene polymer functionalized by means of a special silane compound having a non-hydrolyzable aryloxy group capable of being used as calendering rubber for the cord fabric, in particular of crown reinforcement working plies and capable of containing up to 20 parts by weight of a conventional silica, that is to say a silica which has a high CTAB specific surface area of more than 100 m 2 /g and is only slightly dispersible. The improvement in the rolling resistance of the tire is essentially due to the nature of the functionalized diene polymer, which makes it possible to increase in a very small proportion the silica content of the calendering rubber, but also, at the same time, to increase the problem of internal coherence of the rubber and the risk of premature separation of the cord fabric from the rubber.
SUMMARY OF THE INVENTION
The object of the present invention is essentially to decrease the rolling resistance of a radial carcass tire without significantly impairing the other properties of the tire, such as adherence, resistance to wear, and resistance to fatigue, particularly of the crown reinforcement, and without resulting in a significant impairment with respect to the manufacture of the tire, particularly in the field of the raw working and cohesion in cured state of the rubber composition used for the production of the crown reinforcement of said tire.
The applicant has discovered that the purpose in view is achieved in accordance with the invention by the use of a silica having a low CTAB and BET specific surface area as reinforcing filler for diene elastomer compositions which can be used as crown reinforcement rubber of a radial carcass tire.
The object of the invention is a radial carcass tire having a tread, two non-stretchable beads, two sidewalls connecting the beads to the tread, and a crown reinforcement located between the carcass and the tread having at least two cord fabric plies, said crown reinforcement comprising a diene elastomeric rubber containing, as reinforcing filler, a silica mentioned above which has a CTAB specific surface area less than or equal to 125 m 2 /g and a BET specific surface area less than or equal to 125 m 2 /g.
Another object of the invention is a diene elastomeric composition which can be used in the forming of a crown reinforcement of a radial carcass tire containing as reinforcing filler a silica having a CTAB specific surface area less than or equal to 125 m 2 /g and a BET specific surface area less than or equal to 125 m 2 /g.
The silica which can be used as reinforcing agent of the diene elastomeric rubber used in the overhead reinforcement is preferably a highly dispersible silica having a CTAB specific surface area of between 50 and 120 m 2 /g. When the specific surface area is less than 50 m 2 /g, the reinforcement is less and the cohesion reduced. When the CTAB specific surface area is more than 125 m 2 /g, rubber mixes of increased hardness are obtained which is detrimental for forming crown reinforcement calendering rubbers.
By highly dispersible silica there is understood any silica having the capability of disagglomeration and dispersion in a very large polymeric matrix, as can be observed by electronic or optical microscopy on fine sections. The dipersibility of the silica is also evaluated by means of an ultrasonic disagglomeration aptitude test (Fd) followed by a measurement, by diffraction on a granulometer, of the size of the silica particles in order to determine the median diameter (D50) of the particles after disagglomeration as described in European Patent Application EP 0 520 862, the content of which is incorporated herein, or as described in the article published in the magazine “Rubber World” of June 1994, pages 20 to 24, entitled “Dispersibility Measurement of Prec. Silicas”.
More preferably, the highly dispersible silicas used in the present invention are all silicas which satisfy the characteristics of the CTAB and BET specific surface areas defined above, having a median diameter, after ultrasonic disagglomeration, of less than 5 μm and having an ultrasonic disagglomeration factor (Fd) of more than 2 ml and preferably more than 4 ml when the CTAB specific surface area is more than 100 m 2 /g. By way of example of such a silica, mention may be made of the silica Zeosil 85 MP of Rh{circumflex over (o)}ne-Poulenc. The use of a highly dispersible silica reduces to a minimum fatigue failures of the elastomeric rubber and therefore the risks of separation of the rubber from the cords.
One can, of course, also use blends of different silicas of a CTAB specific surface area less than or equal to 125 m 2 /g. The CTAB specific surface area is determined by NFT method 45007 of November 1987. The BET specific surface area is determined by the method of Brunauer, Emmet, and Teller described in “The Journal of the American Chemical Society”, Vol. 80, page 309 (1938), corresponding to NFT Standard 45007 of November 1987. The silicas used in accordance with the invention generally have a DOP oil absorption equal to or greater than 180 ml/100 g of silica and, more preferably, between 190 and 250 ml/100 g. The DOP oil absorption is determined in accordance with NFT Standard 30-022, using dioctylphtalate.
As diene elastomeric rubber which can be used as crown reinforcement rubber, that is to say, as cord fabric ply calendering rubber or as rubber cushion arranged above or below the working plies, natural rubber or a blend of natural rubber and a diene synthetic rubber or a mixture of diene synthetic rubbers are suitable. The natural rubber is preferably present in preponderant amount, representing more particularly between 75 and 100% by weight. The diene synthetic rubbers which can be used alone or in mixture with each other, in a blend with natural rubber, include any homopolymer obtained by polymerization of a conjugated diene monomer having 4 to 12 carbon atoms and any copolymer obtained by copolymerization of one or more conjugated dienes with each other or with one or more aromatic vinyl compounds having 8 to 20 carbon atoms are suitable. Suitable conjugated dienes include, in particular, butadiene-1,3, 2-methyl-1,3-butadiene, the 2,3-di(C 1 to C 5 alcoyl)-1,3-butadienes, such as, for instance, 2,3-dimethyl-1,3-butadiene, 2,3-dimethyl-1,3-butadiene, 2-methyl-3-ethyl-1,3-butadiene, 2-methyl-3-isopropyl- 1,3-butadiene, phenyl- 1,3-butadiene, 1,3-pentadiene,2,4-hexadiene, etc.
Suitable aromatic vinyl compounds include, in particular, styrene, ortho- meta- and para-methylstyrenes, the commercial “vinyl toluene” mixture, para-tertiobutyl-styrene, the methoxy-styrenes, the chloro-styrenes, vinyl mesitylene, divinyl benzene, vinyl naphthalene, etc.
The copolymers may contain between 99% and 20% by weight of diene units and 1% to 80% by weight of aromatic vinyl units. The polymers may have any microstructure, which is a function of the conditions of polymerization used, in particular the presence or absence of a modifying or randomizing agent and the amounts of modifying and/or randomizing agent employed. The polymers may be block, statistical, sequenced, microsequenced polymers, etc. and can be prepared in dispersion or in solution, be coupled and/or starred or be functionalized.
By way of preference, polybutadienes are suitable, in particular the cis-1,4 or 1,2-syndiotactic polybutadienes and those having a content of 1,2 units of between 4% and 80%, the polyisoprenes, the butadiene-styrene copolymers and, in particular, those having a styrene content of between 5 and 50% by weight and more particularly between 20% and 40% by weight, a content of 1,2 bonds of the butadiene part of between 4% and 65%, a content of trans-1,4 bonds of between 30% and 80%, and butadiene-styrene-isoprene copolymers.
Preferably, a mixture of butadiene-styrene copolymer and polybutadiene is used, blended with the natural rubber in an amount up to 25% by weight.
The diene elastomeric rubber which can be used as overhead reinforcement rubber contains, to be sure, the other components and additives customarily employed in rubber mixes, such as plasticizers, pigments, antioxidants, sulfur, vulcanization accelerators, extender oils, one or more silica coupling agents and/or one or more silica covering agents such as polyols, amines, alkoxysilanes, etc., as well as agents for adherence of the rubber to the metal such as, for instance, the cobalt salts and complexes such as cobalt naphthenate, stearate or hydroxide, the compound Manobond 680 C sold by Manchem, etc., when the diene elastomeric rubber is used as calendering rubber of working plies having metal cables.
The beneficial effect with respect to the properties, in particular the rolling resistance, is also obtained when using both silica and carbon black as reinforcing filler of the crown reinforcement rubber.
The amount of carbon black can vary within wide limits, it being, however, understood that the improvement of the properties will be greater the larger the amount of silica present. The amount of carbon black present is preferably equal to or less than 100% of the amount of silica present in the composition, and more preferably it represents 1% to 50% by weight of the total reinforcing filler.
All the carbon blacks conventionally used in tires and in particular in the overhead reinforcement rubbers are suitable. One may also use a small proportion by weight of silica of a CTAB specific surface area of more than 125 m 2 /g and/or of a BET specific surface area of more than 125 m 2 /g which is highly dispersible or conventional.
The beneficial effect with respect to the decrease in hysteresis of the crown reinforcement rubber and therefore the decrease in the rolling resistance (see Tire Technology International, 1993, pages 58 to 62) is optimal when, in a tire without zero degree plies, the crown reinforcement rubber in accordance with the invention constitutes the calendering rubber for all of the working plies. The beneficial effect is, to be sure, less if only some of the working plies are calendered with this crown reinforcement rubber reinforced with the highly dispersible silica of low CTAB and BET specific surface areas. In the case of a tire having one or more zero degree plies, it is preferable that the calendering rubber of the cord fabric, whether present in the form of a ply of a certain width, that is to say close to the width of the working plies, or of strips or of sheathed unit thread also have such a calendering rubber. A beneficial effect, although smaller, is also obtained when the crown reinforcement is produced in conventional manner with a crown reinforcement rubber for the working plies and the zero degree ply or plies, if any, and when a cushion of diene elastomeric rubber reinforced with the highly dispersible silica of low specific surface area is arranged either below the working ply close to the carcass or above, along the crown reinforcement, the working ply or the zero degree ply close to the tread. This rubber cushion can also constitute the underlayer of the tread.
The crown reinforcement in accordance with the invention can be used in any radial carcass tire, whether the tread be reinforced with preponderant amount silica or not, or with carbon black exclusively. Of course, when the tire of the invention also has a tread reinforced with a preponderant amount of by highly dispersible silica of a CTAB specific surface area greater than 125 m 2 /g, as described in European Patent Application EP 0 501 227, the rolling resistance of the tire is least.
This beneficial effect with regard to the rolling resistance of the tire of the invention is obtained without significant impairment of the other properties of the tire and without significant impairment with regard to the working in raw state of the crown reinforcement rubber which remains substantially unchanged as compared with that of a conventional crown reinforcement rubber filled with a majority of carbon black and with respect to the cohesion in cured state of said rubber which retains good cohesion, particularly with respect to tearability and this even after aging.
In accordance with one variant, there can be associated with the silica filler a resin or a mixture of resins, and preferably a formyl phenol or formyl resorcinol resin in order to increase the modulus at small deformations while substantially retaining the other properties.
The invention is applicable to all types of radial carcass tires, that is to say passenger car tires, van tires, heavy-vehicle tires, and airplane tires.
The invention is illustrated, but not limited, by the examples, which do not constitute a limitation on the scope of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
In the examples, the properties of the crown reinforcement rubber compositions are evaluated as follows:
Modules of elongation at 10% (ME 10), 100% (ME 100), and 300% (ME 300), measured in accordance with ISO Standard 471 in MPA
Elongation upon rupture (ER) in % at 23° C. and at 100° C.
Hysteresis losses (HL): measured by rebound at 60° C. in accordance with ISO Standard R 17667 and expressed in %
The hysteresis is expressed by the measurement of tan δ at 80° C. at 10 Hertz in accordance with NFT Standard 46026.
Fatigue (MFTR): expressed in number of cycles, measured upon deformation imposed on a test piece subjected to an elongation of 90% until rupture of the test piece by means of an Monsanto MFTR apparatus in accordance with AFNOR Standard T46-021.
Fatigue (MFTRV): expressed in number of cycles, measured with deformation imposed on a test piece subjected to an elongation of 90% after aging for 10 days in a stove at 77 ° C., until rupture of the test piece.
Fatigue with notch (MFTRN) expressed in number of cycles: measured on a test piece containing a notch of 1 mm and subjected to an elongation of 60% by means of a Monsanto MFTR apparatus until rupture of the test piece in accordance with AFNOR Standard T46-021.
Mooney viscosity ML (1+4) at 100° C., measured in accordance with ASTM Standard D-1646
Heating (H): measured in degrees Celsius with a GOODRICH flexometer in accordance with ASTM Standard D-623-78
Dynamic properties as a function of the temperature: the hysteresis is expressed by the measurement of tan δ at 80° C. at 10 Hertz in accordance with NF Standard T 46-026.
The rolling resistance (RR) is measured in accordance with ISO Standard 8767 with a radial carcass tire.
In the examples, all parts are parts by weight.
EXAMPLE 1
Five tests were carried out permitting a comparison of the properties of the diene elastomeric compositions of the invention (tests D and E) with 3 reference compositions, as well as the rolling resistance properties of tires having a crown reinforcement based on said compositions.
The compositions are produced by thermo-mechanical working in a single step which lasts about 4 minutes with an average speed of the pallets of 45 rpm, until reaching a maximum temperature of decrease of 160° C. followed by a finishing step carried out at 30° C. with the formulations indicated in Table I.
TABLE I
COMPOSITION
Test A
Test B
Test C
Test D
Test E
Natural rubber
100
100
100
100
100
Carbon black N326
52
Silica ULTRASIL
50
VN2 (a)
Silica ULTRASIL VN3*
50
Silica Zeosil 85MP (b)
57
Silica E (f)
53
Bonding agent (c)
2.5
2.5
2.5
2.5
Zinc oxide
7
7
7
7
7
Stearic acid
1
1
1
1
1
Antioxidant (d)
1.9
1.9
1.9
1.9
1.9
Sulfur
5
5
5
5
5
Sulfenamide (e)
1
1
1
1
1
(a)*Silicas of high specific surface area marketed by DEGUSSA under the names ULTRASIL VN2 and ULTRASIL VN3 having CTAB and BET specific surface areas of 128 m 2 /g and 132 m 2 /g respectively, a median diameter D50 of 11 μm, a disagglomeration factor (Fd) of 2 ml for the first and CTAB and BET specific surface areas of 169 m 2 /g and 180 m 2 /g, a median diameter (D50) of 9 μm and a disagglomeration factor (Fd) of 3 ml.
(b)Silica marketed by Rh{circumflex over (o)}ne-Poulenc under the name Zeosil 85MP having CTAB and BET specific surface areas of 60 m 2 /g and 83 m 2 /g, a median diameter D50 of 3 μm, and a disagglomeration factor (Fd) of 2.5 ml.
(c) Polysulfur organosilane marketed by DEGUSSA under the name SI 69.
(d) Antioxidant: N-(1,3-dimethyl-butyl)-N′-phenyl-p-phenylene diamine.
(e) Sulfenamide: tertio-butyl benzothiazole sulfenamide (TBBS)
(f)Precipitated silica in the form of microbeads having a CTAB specific surface area of 105 m 2 /g, a BET specific surface area of 120 m 2 /g, a median diameter (D50) of 4 μm, and disagglomeration factor (Fd) of 10 ml.
The vulcanization is effected at 150° C. for 40 minutes. The properties of these 5 compositions are compared with each other both in unvulcanized state and in vulcanized state. The rolling resistance of these compositions is also compared in conventionally manufactured radial carcass tires of size 175/70-13 MXT which are identical in all respects except for the constitution of the diene elastomeric composition serving as calendering rubber of the two metal working plies constituting the overhead reinforcement.
The results are set forth in Table II.
TABLE II
Composition
A
B
C
D
E
Rubber property:
75
90
95
74
78
Mooney
Properties in vulcanized state
ME 10
6.82
6.6
10.8
6.7
6.7
ME 100
6.0
4.2
6.2
6.0
5.1
ME 300
12
7.4
10
11.6
10.6
ER % 23° C.
500
550
520
475
520
MFTR·10 3
190
175
180
120
250
MFTRV
70
1500
1000
2000
1500
MFTRN·10 3
33
25
30
53
35
HL at 60° C.%
20
25
27
14
20
H° C.
22
24
25
11
18
Tan δ at 80° C.
0.104
0.110
0.122
0.064
0.080
RR
100
101
102
95
98
It can be noted that the compositions used in accordance with the invention make it possible to retain a level of viscosity very close to that of the control mix having a base of carbon black (Test A) which is relatively small and which makes it possible to obtain a good calendering property, while compositions B and C lead to hard mixes which are not suitable for constituting crown reinforcement calendering rubbers.
It is also noted that compositions D and E in accordance with the invention have the smallest hysteresis, that is to say better hysteresis than the control composition A filled with carbon black which is customarily used as crown reinforcement calendering rubber, while retaining good adherence in cured state, and in particular good resistance to fatigue and to notch propagation. The hysteresis of compositions B and C is clearly higher not only than that exhibited by compositions D and E but also than that exhibited by composition A.
Tires having a crown reinforcement produced by composition D or E have a rolling resistance which is clearly improved without significantly impairing the fatigue resistance, that is to say the life of the tire.
EXAMPLE 2
The purpose of this example is to show that it is possible to increase the modulus at small deformations of the diene elastomeric rubber comprising the silica of low specific surface area as in the case of a reinforcement by means of carbon black while retaining a low hysteresis and good properties of cohesion in cured state, particularly after aging.
Three tests were carried out with the formulations indicated in Table III.
TABLE III
Composition
Test F
Test G
Test H
Natural rubber
100
100
100
Carbon black N326
55
Silica ULTRASIL VN2 (a)
47
Silica Zeosil 85MP (b)
60
Bonding agent (c)
2.5
2.5
Antioxidant (d)
1.9
1.9
1.9
Formyl phenol resin
0.7
3
3
Zinc oxide
7
7
7
Stearic acid
1
1
1
Sulfur
5
5
5
Sulfenamide
1
1
1
Diphenyl guanidine
0.6
0.6
Hexamethylene tetramine
0.3
1
1
(a) (b) (c) (d): identical to those used in Example 1.
The results are set forth in Table IV.
TABLE IV
Composition
Test F
Test G
Test H
Properties in vulcanized state
ME 10
9.5
9.35
9.0
ME 100
7.3
6.0
7.6
ME 300
14.6
10.8
13
ER 100° C.%
420
440
410
MFTR·10 3
145
123
136
MFTRV
9000
12000
16000
MFTRN·10 3
21
20
61
HL at 60° C.%
23
22
17
H° C.
24.5
24
13
It can be noted that mixture H is particularly suitable for use as crown reinforcement elastomeric rubber, in particular as calendering rubber for working and/or overhead plies.
EXAMPLE 3
The purpose of this example is to show that the improved properties are also obtained when the reinforcing filler does not consist exclusively of silica of low specific surface area but, for instance, is a black/silica mixture;
In this example, the formulation used in Example 2 is employed, except with respect to the amounts of carbon black, Zeosil 85MP silica, bonding agent, diphenyl guanidine and formyl phenol resin.
Two tests were carried out, I and J, containing a 50%:50% silica/black filler and a 66%:34% silica/black filler. The results are set forth in Table V.
TABLE V
Composition
Test F
Test I
Test J
Black N326
55
20
30
Silica Zeosil 85 MP (b)
40
30
Bonding agent (c)
2
1.5
Diphenyl guanidine
0.6
Formyl phenol resin
0.6
2
2
Properties in vulcanized state
ME 10
9.5
9.25
8.95
ME 100
7.3
7.9
6.84
ME 300
14.6
14.4
12.8
ER 100° C.%
420
330
470
HL at 60° C.%
23
19
20.5
H° C.
24.5
17.5
20
(b) and (c): identical to those used in Example 1.
|
A radial carcass tire comprising a tread, two non-stretchable beads, two sidewalls connecting the beads to the tread, and a crown reinforcement located between the carcass and the tread, the crown reinforcement including a diene elastomeric rubber having, as reinforcing filler, a highly dispersible precipitated silica having a CTAB specific area less than or equal to 125 m 2 /g and a BET specific surface area less than or equal to 125 m 2 /g.
| 8
|
CLAIM OF PRIORITY UNDER 35 U.S.C. §120
[0001] The present Application for Patent is a Continuation in Part/Continuation and claims priority to patent application Ser. No. 10/011,961 entitled “METHOD AND APPARATUS FOR PREFERRED ROAMING LIST COMPRESSION” filed Nov. 5, 2001, now allowed, and assigned to the assignee hereof and hereby expressly incorporated by reference herein.
FIELD
[0002] The present invention relates generally to communications, and more specifically to a novel and improved method and apparatus for Preferred Roaming List (PRL) compression.
BACKGROUND
[0003] Wireless communication systems are widely deployed to provide various types of communication such as voice, data, and so on. These systems may be based on code division multiple access (CDMA), time division multiple access (TDMA), or some other modulation techniques. A CDMA system provides certain advantages over other types of systems, including increased system capacity.
[0004] A CDMA system may be designed to support one or more CDMA standards such as (1) the “TIA/EIA-95-B Mobile Station-Base Station Compatibility Standard for Dual-Mode Wideband Spread Spectrum Cellular System” (the IS-95 standard), (2) the standard offered by a consortium named “3rd Generation Partnership Project” (3GPP) and embodied in a set of documents including Document Nos. 3G TS 25.211, 3G TS 25.212, 3G TS 25.213, and 3G TS 25.214 (the W-CDMA standard), (3) the standard offered by a consortium named “3rd Generation Partnership Project 2 ” (3GPP2) and embodied in a set of documents including “C.S0002-A Physical Layer Standard for cdma2000 Spread Spectrum Systems,” the “C.S0005-A Upper Layer (Layer 3) Signaling Standard for cdma2000 Spread Spectrum Systems,” and the “C.S0024 cdma2000 High Rate Packet Data Air Interface Specification” (the cdma2000 standard), (4) the “TIA/EIA-IS-856 CDMA2000 High Rate Packet Data Air Interface Specification” (the IS-856 standard), and (5) some other standards.
[0005] Cellular communication system users commonly have a service agreement with a cellular provider. The system operated by a cellular provider may cover a limited geographical area. When a user travels outside of this geographical area, service may be provided by another system operator, under a roaming agreement. There is often more than one service provider in a particular region, so a user may have a choice as to which service provider to roam with. As cellular communication systems have proliferated, networks of cellular systems have been organized under common service providers, or with contractual agreements between service providers. Roaming fees are minimized or eliminated when a user transfers between systems which are party to such agreements. As such, modern mobile stations often make use of Preferred Roaming Lists (PRLs), which contain information about the preferred systems for roaming and various parameters needed for communication therewith. PRLs may be pre-programmed in a mobile station when service is initiated. Alternatively, PRLs can be programmed with over-the-air data transfers. Such programming is described in “TIA/EIA-683-B Over-the-Air Service Provisioning of Mobile Stations in Spread Spectrum Systems”, a standard compatible with the above named wireless communication systems.
[0006] The list of sectors in a typical PRL can be quite large, and will likely grow larger as more mobile stations are equipped for international roaming. Furthermore, in data communication systems, such as the HDR standard, each sector is assigned an IPv6 (Internet Protocol version 6) address which is 128 bits in length. As the length of the PRL increases, and as the information in each record in the PRL expands, the memory requirements to store the PRL will grow accordingly. Furthermore, over-the-air updates to the PRL will take longer as the PRL size expands. There is therefore a need in the art for efficient storage and retrieval of Preferred Roaming Lists.
SUMMARY
[0007] Embodiments disclosed herein address the need for efficient storage and retrieval of Preferred Roaming Lists (PRL). In one aspect, PRL entries are stored in two tables. One table contains records that are common to two or more PRL entries. Another table stores any information that is unique to a PRL entry, as well as an indicator of which common record is associated with it. The common record is concatenated with the unique information to generate the uncompressed PRL entry. Various other aspects of the invention are also presented. These aspects have the benefit of reducing the memory requirements for storing a PRL. In addition, time required to download the compressed PRL is reduced.
[0008] The invention provides methods and system elements that implement various aspects, embodiments, and features of the invention, as described in further detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The features, nature, and advantages of the present invention will become more apparent from the detailed description set forth below when taken in conjunction with the drawings in which like reference characters identify correspondingly throughout and wherein:
[0010] FIG. 1 is a general block diagram of a wireless communication system capable of supporting a number of users;
[0011] FIG. 2 depicts a mobile unit configured in accordance with an embodiment of the present invention;
[0012] FIG. 3 depicts a compressed PRL;
[0013] FIG. 4A illustrates a process for generating a compressed PRL;
[0014] FIG. 4B illustrates a method for accessing a subnet from a compressed PRL;
[0015] FIG. 5 depicts a detailed embodiment of a compressed PRL;
[0016] FIG. 6 depicts an embodiment of a method for accessing the compressed PRL of FIG. 5 ;
[0017] FIG. 7 depicts a procedure for retrieving common information from a subnet table;
[0018] FIG. 8 depicts an alternate detailed embodiment of a compressed PRL;
[0019] FIG. 9 depicts an embodiment of a method for accessing the compressed PRL of FIG. 8 ;
[0020] FIG. 10 depicts an alternate procedure for retrieving common information from a subnet table; and
[0021] FIG. 11 depicts an exemplary network ID, subnet mask, subnet address, and their inter-relationship.
DETAILED DESCRIPTION
[0022] FIG. 1 is a diagram of a wireless communication system 100 according to one embodiment that supports a number of users, and which can implement various aspects of the invention. System 100 may be designed to support one or more CDMA standards and/or designs (e.g., the W-CDMA standard, the IS-95 standard, the cdma2000 standard, the IS-856 standard). For simplicity, system 100 is shown to include three base stations 104 in communication with two mobile stations 106 . The base station and its coverage area are often collectively referred to as a “cell”. In IS-95 systems, a cell may include one or more sectors. In the W-CDMA specification, each sector of a base station and the sector's coverage area is referred to as a cell. As used herein, the term base station can be used interchangeably with the term access point. The term mobile station can be used interchangeably with the terms user equipment (UE), subscriber unit, subscriber station, access terminal, remote terminal, or other corresponding terms known in the art. The term mobile station encompasses fixed wireless applications.
[0023] Depending on the CDMA system being implemented, each mobile station 106 may communicate with one (or possibly more) base stations 104 on the forward link at any given moment, and may communicate with one or more base stations on the reverse link depending on whether or not the mobile station is in soft handoff. The forward link (i.e., downlink) refers to transmission from the base station to the mobile station, and the reverse link (i.e., uplink) refers to transmission from the mobile station to the base station. The word “exemplary” is used exclusively herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments.
[0024] FIG. 2 shows an embodiment of mobile unit 106 . For clarity, only a subset of the components is shown. Signals are received at antenna 210 , and delivered to receiver 220 where amplification, down-conversion, sampling, and demodulating takes place. Various techniques for receiving CDMA signals are known in the art. In addition, the principles of the present invention apply with equal force to wireless communication systems deploying air interfaces other than those based on CDMA. Receiver 220 is in communication with a central processing unit (CPU) 230 . CPU 230 may be a microprocessor or digital signal processor (DSP), or one of various processors known in the art. CPU 230 communicates with memory 240 , which is shown containing PRL 250 . PRL 250 can be programmed via over-the-air programming in conjunction with antenna 210 and receiver 220 , or the data for the PRL can come in from other inputs to CPU 230 , labeled “alternate input” in FIG. 2 . CPU 230 is also connected to transmitter 260 , for transmitting messages, data, voice, etc., using any of the techniques for transmission known in the art. Transmitter 260 is connected to antenna 210 , for transmission to a base station, such as base station 104 . Receiver 220 and transmitter 260 , in conjunction with antenna 210 , can be used to communicate with one or more systems identified in PRL 250 when the mobile station is roaming.
[0025] In an IS-856 system, each sector has a unique IPv6 address, which is 128 bits in length. In some instances, a network operator may deploy numerous sectors within a system. The IP addresses of these sectors may differ only slightly (i.e., in the least significant bits) since a large portion of each sector address identifies the carrier. In addition, various parameters associated with each of these sectors may be common among the sectors due to their collocation within the network, such as frequency, PN offset, and the like. As used herein, the term subnet refers to an entry in the PRL associated with a group of sectors. The principles of the present invention apply to the concept of a subnet as defined for Internet Protocol (IP) addresses. However, these principles apply more generally to compression of a PRL regardless of the exact nature of the information stored in each record of the PRL. As such, the term subnet, as used herein, should be construed to refer to any of the myriad possibilities of PRL records.
[0026] FIG. 3 depicts an embodiment of PRL 250 . Recall that PRL 250 is contained in memory 240 . PRL 250 contains two tables, system table 310 and subnet table 320 . System table 310 contains entries corresponding to each record of the PRL. In each system table 310 entry, information unique to that entry will be stored, along with an indicator for accessing corresponding data in subnet table 320 . Subnet table 320 contains records which are shared in common with one or more entries in system table 310 . Thus, rather than including duplicate copies of information in various entries of system table 310 , one common copy is stored in subnet table 320 , and an indicator for accessing that common copy will be stored in each corresponding entry in system table 310 .
[0027] Consider the following example as illustrated in FIG. 4A . The proposed IS-856 system record comprises, among other fields, a network ID and a subnet mask length, m. In an exemplary embodiment, PRL 250 comprises a plurality of these system records. The network ID is a 128-bit value. A subnet mask can be formed using a subnet mask length m by concatenating m ones with 128-m zeros. FIG. 11 depicts this example. When network ID 1100 is bit-wise ANDed with subnet mask 1110 , subnet address 1120 ( FIG. 4A, 440 ) is the result. All the sectors within a subnet will share a common subnet address, and will be distinguished using the 128-m least significant bits. The size of the subnet is limited by the number of bits assigned to distinguish the sectors within it. Performing the operation shown in FIG. 11 on the network ID, included in the system record, for all sectors in a subnet will yield an identical result for each subnet address. So, the subnet identifies a group of sectors. It is expected that the most significant k bits of the subnets associated with a particular wireless operator to be the same. Therefore, the upper k bits of the subnet address can be stored once in subnet table 320 , and the lower 128-k bits can be stored for each record in the system table 310 . Note that m is the length of the subnet ( FIG. 4A, 450 ), whereas k is the length of the common part of the subnet that is to be factored out.
[0028] System table 310 and subnet table 320 will be detailed more fully below in the descriptions of various embodiments deploying them. Note that these tables, and the PRL, are shown as discrete entities for clarity only. While, in an alternative embodiment, each table could be housed in a discrete memory, a more common embodiment will have system table 310 and subnet table 320 , which make up PRL 250 , as a subspace of a common memory element 240 .
[0029] FIG. 4B depicts an embodiment of a method for accessing a PRL, such as PRL 250 . In step 410 , a record from the system table 310 is retrieved, which corresponds to an entry in the PRL 250 . The record will contain any information that is unique to the entry, as well as an indicator of common information, if any. A variety of techniques for indexing, storing, and accessing the common information can be employed, examples of which are detailed in embodiments described below. In step 420 , a common portion of the subnet is retrieved from a subnet table 320 , if there is a common portion corresponding to the record. In step 430 , the common portion is concatenated with the unique portion to form the complete subnet record.
[0030] The creation of a system table 310 and a subnet table 320 from a PRL can be accomplished by reversing the steps depicted in FIG. 4B . The details of partitioning and indexing will depend on the procedure chosen, examples of which are detailed below. The resultant system table 310 and subnet table 320 form a compressed PRL 250 . Thus, the time required to transmit the compressed PRL to mobile station 106 is reduced, whether the transmission occurs via a wired connection or is updated over the air, as described in IS-683.
[0031] An exemplary embodiment of a method for compressing a PRL comprises the following steps: First, data that is common to two or more subnets is factored out and stored in a subnet table ( FIG. 4A, 470 ). The remaining data, not factored out, is stored in the symbol table, with an indicator for accessing the associated common information in the system table ( FIG. 4A, 480 ). As described in an example above, one convenient way to factor out common information is to look for common characteristics, such as shared subnet address, frequency, and the like.
[0032] It may be that, in some cases, a larger common portion can be factored out of a first subset of PRL records, but a smaller common sub-portion of that common portion can be factored out of a second, larger subset of PRL records. One example of this may occur in a system that allows subnets within subnets. In such a system, records corresponding to one subnet within a larger subnet will share a large part of their network address in common. Another set of records, corresponding to a different subnet within the same larger subnet, will similarly share a large part of their network address in common. However, all of the records in both subnets, within the larger subnet, will still have in common the portion of the network address identifying the larger subnet, although the common portion will be smaller than the common portion of their individual subnets.
[0033] A variety of techniques for factoring fall within the scope of the present invention. One technique is to apply a multi-pass factoring step, which calculates and compares various compression results (accounting for multiple factoring options), selecting the best compression result. Another technique is to extend the two-table example to allow nested tables. For example, if subnets within subnets are available in the system, then subnet tables can be equipped with indicators to locate common elements within a sub-subnet table. Yet another technique is to store more than one indicator in a record in the system table, each of the indicators identifying a separate entry in the subnet table. Those of skill in the art will recognize how to deploy various combinations of the techniques disclosed herein to accommodate various system configurations.
[0034] FIG. 5 depicts an exemplary embodiment of compressed PRL 250 . It comprises system table 310 and subnet table 320 . Each table contains records identified by a system record field and an associated field length, in bits. System table 310 comprises N records, 510 A- 510 N, corresponding to N entries in the PRL. Subnet table 320 comprises M common records, 550 A- 550 M, which are associated with various of the N system table records, 510 A- 510 N. System table records 510 A- 510 N comprise the fields SUBNET_TAG 520 A- 520 N, SUBNET_RESIDUAL_LENGTH 530 A- 530 N, and SUBNET_RESIDUAL 540 A- 540 N. Subnet table records 550 A- 550 M comprise the fields SUBNET_TAG 560 A- 560 M, SUBNET_COMMON_LENGTH 570 A- 570 M, and SUBNET_COMMON 580 A- 580 M, respectively.
[0035] In this embodiment, each SUBNET_TAG 520 A- 520 N and 560 A- 560 M is eight bits in length. A system table SUBNET_TAG 520 A- 520 N corresponds to at most one subnet table SUBNET_TAG 560 A- 550 M. A value of zero in a system table SUBNET_TAG indicates that none of the subnet table records 550 A- 550 M correspond with that system table record. For non-zero values, the system table SUBNET_TAG identifies one subnet table record with the corresponding SUBNET_TAG value.
[0036] The arrows shown in FIG. 5 depict exemplary mappings. For example, system table records 510 A and 510 K both correspond with subnet table record 550 M. Thus, SUBNET_TAG 520 A, SUBNET_TAG 520 K, and SUBNET_TAG 560 M are identical. When retrieving the common information for either of system table records 510 A or 510 K, subnet table record 550 M is identified by the SUBNET_TAG value 560 M. Then, SUBNET_COMMON_LENGTH 570 M, a seven-bit field in this example, identifies the length of the common information, contained in SUBNET_COMMON 580 M. The SUBNET_COMMON_LENGTH field 570 M may indicate the length of SUBNET_COMMON 580 M in any unit of data length—bits or bytes are typically convenient measures. The amount of data contained in SUBNET_COMMON 580 M as delineated by SUBNET_COMMON_LENGTH 570 M can then be retrieved from subnet table 320 for association with the system table record, in this example 510 A or 510 K. Similarly, subnet table record 550 A is associated with system table record 510 N.
[0037] In this embodiment, SUBNET_RESIDUAL_LENGTH 530 A- 530 N is a seven-bit field which indicates the length of SUBNET_RESIDUAL 540 A- 540 N. SUBNET_RESIDUAL is the unique information associated with each system table record 510 A- 510 N.
[0038] FIG. 6 depicts an exemplary embodiment of a procedure for accessing a PRL 250 , such as that shown in FIG. 5 . In step 610 , retrieve SUBNET_TAG from the system table 310 . Proceed to decision block 620 to test if SUBNET_TAG is equal to zero. If it is zero, there is no common element to be retrieved from the subnet table 320 . Proceed to step 630 , and retrieve SUBNET_RESIDUAL from the system table. The subnet is identified completely by SUBNET_RESIDUAL.
[0039] If, in decision block 620 , SUBNET_TAG is not equal to zero, proceed to step 640 and retrieve SUBNET_COMMON corresponding to SUBNET_TAG from the subnet table 320 . Proceed to step 650 and retrieve SUBNET_RESIDUAL from system table 310 . Proceed to step 660 . Concatenate SUBNET_COMMON with SUBNET_RESIDUAL to identify the subnet.
[0040] FIG. 7 is a more detailed embodiment of step 640 . In step 710 , locate SUBNET_TAG in subnet table 320 . In step 720 , retrieve SUBNET_COMMON_LENGTH to determine how much common data to retrieve. Proceed to step 730 to retrieve the amount of data, from subnet table 320 , as specified in SUBNET_COMMON_LENGTH.
[0041] FIG. 8 depicts another exemplary embodiment of compressed PRL 250 . This embodiment uses an index into the subnet table instead of a subnet tag. It also comprises a system table 310 and a subnet table 320 . As before, each table contains records identified by a system record field and an associated field length, in bits. System table 310 comprises N records, 510 A- 510 N, corresponding to N entries in the PRL. Subnet table 320 comprises M common records, 550 A- 550 M, which are associated with various of the N system table records, 510 - 510 N. However, in this alternative embodiment, system table records 510 A- 510 N comprise the fields SUBNET_LSB_LENGTH 820 A- 820 N, SUBNET_LSB 830 A- 830 N, and SUBNET_COMMON_OFFSET 840 A- 840 N. Subnet table records 550 A- 550 M comprise the fields SUBNET_COMMON_LENGTH 840 A- 840 M, and SUBNET_COMMON 850 A- 850 M. In contrast to the embodiment of FIG. 5 , note that SUBNET_TAG is not a field in either system table 310 or subnet table 320 .
[0042] In this embodiment, SUBNET_LSB_LENGTH 810 A- 810 N performs substantially the same function as SUBNET_RESIDUAL_LENGTH 530 A- 530 N. It is a seven-bit field which indicates the length of SUBNET_LSB 820 A- 820 N, a field which performs substantially the same function as SUBNET_RESIDUAL 540 A- 540 N. SUBNET_LSB is the unique information associated with each system table record 510 A- 510 N.
[0043] In this embodiment, each SUBNET_COMMON_OFFSET 840 A- 840 N is an index into subnet table 320 , the index in this example is 12 bits in length. Each SUBNET_COMMON_OFFSET 830 A- 830 N corresponds to at most one subnet table record 550 A- 550 M. A value of zero in a SUBNET_COMMON_OFFSET indicates that none of the subnet table records 550 A- 550 M corresponds with that system table record.
[0044] The arrows shown in FIG. 8 depict exemplary mappings. For example, system table records 510 A and 510 K both correspond with subnet table record 550 M. Thus, SUBNET_COMMON_OFFSET 830 A and 830 N are identical, and point to subnet table record 550 M. Then, SUBNET_COMMON_LENGTH 840 M, a four-bit field in this example, identifies the length, in bytes, of the common information, contained in SUBNET_COMMON 850 M. The amount of data contained in SUBNET_COMMON 850 M as delineated by SUBNET_COMMON_LENGTH 840 M can then be retrieved from subnet table 320 for association with the system table record, in this example 510 A or 510 K. Similarly, subnet table record 550 A is associated with system table record 510 N.
[0045] FIG. 9 depicts an exemplary embodiment of a procedure for accessing a PRL 250 , such as that shown in FIG. 8 . In step 910 , retrieve a record from system table 310 . Proceed to step 920 to retrieve the SUBNET_COMMON from the subnet table corresponding to SUBNET_COMMON_OFFSET contained in the system table record. A SUBNET_COMMON_OFFSET of zero means that no common information is to be retrieved. Proceed to step 930 , concatenate SUBNET_COMMON with SUBNET_LSB to identify the subnet.
[0046] FIG. 10 is a more detailed embodiment of step 920 . In step 1010 , the process accesses SUBNET_COMMON_LENGTH from the subnet table with the pointer SUBNET_COMMON_OFFSET. Proceed to step 1020 . In Step 1020 , access SUBNET_COMMON by retrieving a number of bytes specified by the value of SUBNET_COMMON_LENGTH.
[0047] Another alternative, not shown, is to nest both the subnet table and the system table in one table. In this alternative, the first occurrence of a common record is included in the record with which it is associated. A tag and/or common record length field may be inserted prior to the common record. Subsequent records in the table, which are associated with the common record, can simply include a pointer or tag, depending on the implementation chosen, to indicate the previously stored common record is to be accessed.
[0048] It should be noted that in all the embodiments described above, method steps can be interchanged without departing from the scope of the invention.
[0049] Those of skill in the art will understand that information and signals may be represented using any of a variety of different technologies and techniques. For example, data, instructions, commands, information, signals, bits, symbols, and chips that may be referenced throughout the above description may be represented by voltages, currents, electromagnetic waves, magnetic fields or particles, optical fields or particles, or any combination thereof.
[0050] Those of skill will further appreciate that the various illustrative logical blocks, modules, circuits, and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, computer software, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present invention.
[0051] The various illustrative logical blocks, modules, and circuits described in connection with the embodiments disclosed herein may be implemented or performed with a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
[0052] The steps of a method or algorithm described in connection with the embodiments disclosed herein may be embodied directly in hardware, in a software module executed by a processor, or in a combination of the two. A software module may reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a CD-ROM, or any other form of storage medium known in the art. An exemplary storage medium is coupled to the processor such the processor can read information from, and write information to, the storage medium. In the alternative, the storage medium may be integral to the processor. The processor and the storage medium may reside in an ASIC. The ASIC may reside in a user terminal. In the alternative, the processor and the storage medium may reside as discrete components in a user terminal.
[0053] The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
|
Techniques for efficient storage and retrieval of Preferred Roaming Lists are disclosed. In one aspect, PRL entries are stored in two tables. One table contains records that are common to two or more PRL entries. Another table stores any information that is unique to a PRL entry, as well as an indicator of which common record is associated with it. The common record is concatenated with the unique information to generate the uncompressed PRL entry. Various other aspects of the invention are also presented. These aspects have the benefit of reducing the memory requirements for storing a PRL. In addition, time required to download the compressed PRL is reduced.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit under 35 USC 119(e) of U.S. Provisional Patent Application No. 60/771,188, filed Feb. 7, 2006 titled Method for Using Out-Of-Band Captured Protocol Traffic to Facilitate In-Band Traffic Capturing.
FIELD OF THE INVENTION
[0002] This invention is related generally to the capturing, recording and analyzing of Certified Wireless USB (“WUSB”) transmissions between devices, and more particularly to a portable or other Ultra-Wideband (UWB) test and debug platform that preferably combines non-intrusive recording with extensive decoding features.
BACKGROUND OF THE INVENTION
[0003] Ultra-Wideband Technology
[0004] UWB technology has been available for over 40 years for military and civilian applications and was originally referred to as either impulse radio or carrier-free communications. More recently, the FCC definition for UWB includes any radio technology with a spectrum that occupies greater than 20 percent of the center frequency or a minimum of 500 MHz. In 2002, the FCC allocated unlicensed radio spectrum from 3.1 GHz to 10.6 GHz expressly for enterprise and consumer applications. The FCC defined a specific minimum bandwidth of 500 MHz at a −10 dB level. As current UWB implementations allow communication that requires high data rates over short distances, one immediate UWB application is WPAN (Wireless Personal Area Network).
[0005] Multi-band OFDM technology, promoted by the WiMedia Alliance, is one technology that can utilize the allocated band for UWB. The MB-OFDM transmits data simultaneously over multiple carriers spaced apart at precise frequencies. This approach provides benefits like high spectral flexibility and resiliency to RF interference and multi-path effects. These WiMedia UWB specifications are available from the WiMedia Alliance. The URL for the WiMedia website is http://www.wimedia.org
[0006] WiMedia UWB Specification Ecosystem
[0007] The WiMedia Alliance has developed specifications for ultra-wide-band (UWB) devices. The main goal of the WiMedia UWB specifications is to create a UWB “ecosystem” that allows easy and secure operation and interoperation of UWB devices. The WiMedia UWB specifications have a first-generation data rate of 480 Mbps, which enables a multitude of innovative wireless devices. UWB devices that follow the WiMedia UWB specifications can co-exist in the same physical environment, even if they have unrelated applications.
[0008] The WiMedia UWB specification first-generation data rate of 480 Mbps provides a basis for delivering WUSB devices that can perform comparably with USB 2.0 devices. The Certified Wireless-USB protocol maintains the same host-device model as the wired USB protocol, but the Certified Wireless-USB protocol makes many optimizations for operating efficiently on a wireless medium.
[0009] The WUSB specification is available from the USB Implementers Forum (USB-IF). The URL for the USB-IF website is: http://www.usb.org/home
[0010] As with all electronic devices, there is a need to be able to properly test various devices to confirm that they conform to a desired standard. Further, when in operation, it may be necessary to debug or troubleshoot any communication or operational problems that arise. Therefore it would be beneficial to provide an improved method and apparatus that allow for this type of testing to be performed in accordance with this new standard.
SUMMARY OF THE INVENTION
[0011] Therefore, in accordance with the invention, a test and measurement apparatus and method are provided that provide full protocol decoding and analysis from low-level packets to higher-level protocols like the Wire Adapter transfers Wireless-USB-protocol devices. It is also contemplated that to the extent any other protocol definitions employ similar attributes, the features of the invention would be applicable thereto.
[0012] Furthermore, in accordance with a first aspect of the invention, the method and apparatus described herein allow capturing and analyzing in band traffic of a certain data protocol using out of band data of a different protocol.
[0013] In accordance with the invention, the inventor has recognized that the WUSB specifications support several security measures that include the “association” (or ‘pairing’) of two devices. The association process provides a device the means to create a common secret, the Connection Context, which is then used to verify and authenticate the peer device. The Connection Context also provides the means to generate a common encryption key without giving away the key to potential eavesdroppers. The encryption key is used later on by each pair of devices, encrypting traffic at the transmitter device and decrypting it back at the receiver device. The Connection Context creation process does not necessarily take place every time two devices try to create a link, but it might change every time the devices are performing an association process.
[0014] Two basic association models are supported by the WUSB:
[0015] 1. In band model—where the association process is performed through the UWB channel.
[0016] 2. Out of band model—where another type of protocol that is considered to be equivalent or better in security to the in band protocol, is used to perform the association process.
[0017] The later method has typically relied on user's action to physically associate two devices, for example, by connecting them momentary through a cable, or by bringing the devices in proximity to each other.
[0018] The first association protocol that was defined for the Certified-WUSB specifications is the USB Cable Association. Other potential out-of-band association procedures can use other wired or wireless protocols. An example for an out-of-band wireless protocol that can be used for the association is NFC (near, field communication).
[0019] However, as has been recognized by the inventor of the present invention, to be able to decrypt traffic and view decoding of protocol layers that are higher than the WiMedia frames, the protocol is required to be able to decrypt the secured traffic “on-the-fly” (or in substantially “real-time) and track the security keys changes during the recording session. If the out-of-band association procedure is used between two devices-under-test, the analyzer needs to use the association key for decrypting the traffic. There are two methods of providing the association information to the analyzer system:
[0020] 1. User Input
[0021] 2. In accordance with the invention, automatic detection by a secondary sub-system (different than the main sub-system designed for capturing and recording in-band traffic), that further allows for real time processing and use of this out of band information.
[0022] User input might be cumbersome or completely useless in some cases, when the user does not know in advance the association information. Therefore, in accordance with the invention, the inventor has provided an automated processing system for function in this real time mode.
[0023] More particularly, as the WUSB specifications suggest, there is no way for the user to know what the Connection Context information between two devices looks like ahead of time as it is based on randomly generated data. This means also that in a regular usage case the user of, for example, a UWBTracer™ protocol analyzer, from LeCroy Corporation, or other protocol analyzer, needs to have prior knowledge of the Connection Context information that would be used for the association, and input it into the system. This is not always possible, as the connection Context information in regular WUSB implementation is not fixed. Also, eavesdropping only to the in band channel would not provide this information as it may be transmitted only in the out of band channel. Additionally, as recognized by the inventor of the present invention, the use of a separate capturing system for capturing the out of band traffic and extracting the connection connect information, without means to deliver the data in real-time to the in band analyzer (Protocol Data Collector), would result in inability to use the connection context information immediately when the association is established, resulting in inability of decrypting the in band traffic.
[0024] The method described in accordance with the invention particularly deals with the out of band (OOB) model. More specifically, the first OOB model as described in accordance with the invention will use a Wired USB channel. Of course, other wired or wireless protocol channels may be employed.
[0025] Out of band communication signaling and data refers to all the signaling and data exchange that is performed on a channel that is separated from channels used for the “regular” in band data/information. In band signaling and data refers to the exchange of signaling and data on the same (“main”) channel that the regular data and signaling is using.
[0026] Traditionally, all LeCroy Corporation protocol analyzers capture, record and analyze specific communication protocols, requiring, in some cases, preliminary data that is not always known to the user or cannot be retrieved from the in band data traffic (for instance, security keys that allows the analyzer to decrypt secured data traffic). In accordance with the method presented in accordance with the invention, an analyzer system can capture specific portions of data that are exchanged between two or more transceivers on an out of band channel, and then use this data in substantially real-time to capture and decode an in band channel traffic that might be using the same or a completely different protocol.
[0027] Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification and the drawings.
[0028] The invention accordingly comprises the several steps and the relation of one or more of such steps with respect to each of the others, and the apparatus embodying features of construction, combination(s) of elements and arrangement of parts that are adapted to effect such steps, all as exemplified in the following detailed disclosure, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] For a more complete understanding of the invention, reference is made to the following description and accompanying drawings, in which:
[0030] FIG. 1 depicts a logical block diagram for presenting an apparatus and method, and associated data flow in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] In accordance with the invention, references to “analyzing” may be construed as referring to capturing, recording, and analyzing the traffic, but may also refer to merely capturing, analyzing and distilling portions of data that are desired (not necessarily requiring “recording”).
[0032] In accordance with the first aspect of the invention, and as shown in FIG. 1 , a system 100 constructed in accordance with the invention is shown. System 100 further may comprise two types of protocol analyzers connected through a wired interface, or incorporated into a single system; the first ( 110 ) is used for analyzing of a main in band channel and the other ( 120 ) is used for analyzing an out of band (OOB) channel. The two analyzers may be connected via a communication connection 130 , so that Connection Context information 131 , once extracted from the OOB channel by analyzer 120 , is delivered to analyzer 110 preferably in substantially real time. This Connection Context information 131 may be used to aid in the processing of the in band information by analyzer 110 , allowing recording flow without requiring user interaction.
[0033] In a particular preferred embodiment constructed in accordance with the invention, a WUSB/WiMedia UWB protocol analyzer may be employed for the in band traffic analyzer 110 and a wired USB analyzer sub-system (with some modification from a standard system) may be employed for the OOB channel analyzer 120 . The OOB channel analyzer 120 further includes an OOB protocol front end 122 for receiving OOB traffic 102 , an OOB acquisition subsystem 124 for acquiring OOB traffic 102 from front end 122 (and for determining the precise protocol used to transmit the OOB traffic 102 , if the protocol is previously unknown), and a traffic analysis sub-system 126 for acting, preferably in substantially real time, upon OOB traffic 102 received from acquisition subsystem 124 . Sub-system 126 is designed to identify and capture the OOB data from traffic 120 that is relevant for use by analyzer 110 , and thus extract and/or generate Connection Context information 131 . This information 131 is forwarded to analyzer 110 also in substantially real time via connection 130 noted above.
[0034] Once appropriate Connection Context information 131 (including at least an encryption key) is captured and detected as such by traffic analysis sub-system 126 from the OOB traffic 102 , and forwarded via connection 130 in substantially real time, the information 131 is received by an out of band management sub-system 116 of analyzer 110 . Sub-system 116 acts as a Connection Context Management sub-system in analyzer 110 , and using the 131 data, is therefore able to track and decrypt in band traffic 101 passing via an in band channel to analyzer 110 .
[0035] Analyzer 110 further includes an in band protocol front end 112 for receiving in band traffic 101 , and an in band acquisition system 114 for acquiring in band traffic 101 received by front end 112 . For processing of this acquisition, in band acquisition system 114 employs information 131 , including at least a transmitted encryption key, determined by OOB management sub-system 116 . After processing, post processed data 118 is forwarded to a protocol reader and analysis subsystem 140 , which may comprise a software program, or other hardware and software processing combination. This component post processes the acquired data 118 in any manner desired according to known protocol analyzation techniques and can also store the data for later use.
[0036] The ability to process Connection Context Information in substantially real time is important as this information may be changed during processing. Without such real time extraction of the Connection Context Information from the OOB signal, and forwarding the information to Analyzer 110 for use in processing the in band data, such processing may not be possible. Nevertheless, Connection Context information 131 may also be stored as data 132 in subsystem 140 coupled with, or running on the WUSB/UWB analyzer system 100 . Therefore, if in band traffic 101 is to be acquired at a later time, in such a later recording session, when the Connection Context Information may be the same, such stored information can be retrieved as data 133 and programmed into OOB management sub-system 116 of analyzer 110 for decrypting in band traffic 101 on the in band channel. Thus, processing can be restarted without requiring a repeat of the OOB acquisition and association process each and every time acquisition of an in band signal is to take place. Thereafter, real time processing as noted above may resume for both the in band data, and OOB information if the Connection Context Information changes.
[0037] Therefore, in accordance with a preferred embodiment of the invention, two analyzers are combined and work “automatically” without user data input. Also, the storing of the OOB information allows easy and faster operation over multiple sessions.
[0038] This model for processing of OOB and in band data may also be employed for other association models in the future (such as Near Field Communication) and may be applied to other protocols in the future that employ a similar in band and OOB communication configuration.
[0039] While the invention has been described applicable to WUSB, the invention is intended to be equally applicable to other protocol definitions and to electronic apparatuses in general.
[0040] It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above construction(s) without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawing(s) shall be interpreted as illustrative and not in a limiting sense.
[0041] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall there between.
|
A method and apparatus for processing electronic data are provided. The method comprises the steps of receiving an out of band data transmission and processing the out of band data transmission to retrieve a Connection Context Information key in substantially real time. Thereafter, an in band data transmission is received and processed employing the encryption key in substantially real time.
| 7
|
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.