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BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to the field of information processing, more specifically, to an electronic dictionary that is maintained and used by the user community. The dictionary lets a user look up the native language definition of any foreign word.
[0003] 2. Description of Related Art
[0004] The present invention helps people understand a foreign word, an acronym, a short phrase, or any other media that can be encoded as a sequence of bytes, which is simply called word in this document. The word may be in any foreign language. The word might not be collected by any published dictionary for various reasons: it may be too new, too parochial, used by too few people, etc. The goal of the invention is that people encounter it can understand its basic meaning and continue his/her activities. The dictionary is community-updated. Although it may not have authentic definitions, it provides enough clues for a user to find the details from other sources.
[0005] More and more people around the world with different native languages are joining the Internet. Inevitably people will encounter unknown words while staying active on the Internet. People need to understand them to best continue their activities. One way to understand them is to look them up, either offline or online. There are many online dictionaries and encyclopedias.
[0006] Online dictionaries and encyclopedias are basically online versions of their paper counterparts. They provide a good source. There are two types of dictionaries, general ones that cover every aspects of life and specific ones that cover one domain of study. The former can not collect all words due to the volume of words. In many cases the word to be looked up can only be found in the latter. While the user gets “undefined” return from the former, he/she does not know which one of the latter to look up. So in many times a user cannot find the definitions even with the help of dictionaries. Due to the process how a new word is collected by a dictionary, it takes a long time since its inception for it to show up in any dictionaries. However, new words are mostly looked up by people who already understand “old” words. With the popularity of Internet, new words related to it are created almost daily. People not close with online chat room have hard time understanding all those acronyms. Besides, there are many words that may never be collected by a dictionary. Examples are words that become a fad then fade away soon, words that are used only by a parochial community, and acronyms or short phrases that are not considered worthy of dictionary entries by linguists.
[0007] People who create new words or use new words in a daily basis are the best source for their definitions. A dictionary that can be quickly updated by them will provide fast information for people who do not understand them. And in many occasions people looking up a word do not necessarily want to know the detailed definition. They are happy as long as their task at hand is not handicapped by the unknown word. We do not necessary need a linguist.
[0008] The Wikipedia community (http://www.wikipedia.org) is a good example of community supported knowledge base. Users contribute to the definition of word items. But its goal is to match the authenticity of other encyclopedias. The problems discussed above still exist.
[0009] A major problem this invention addresses is for people to look up words of a foreign language. The online language-to-language dictionaries are a very small set of all online dictionaries. This further frustrates online users of native languages other than English. The Wikipedia community has also started to create language-to-language dictionaries. Again, its goal is to match authentic counterparts. And we only see those for specific domains. We expect to see every language in the world showing up on the Internet. More and more people will encounter more and more foreign words on the Internet. It will be a problem for a user even to find the right dictionary to look up foreign words. The user may not even know what language an unknown word belongs to.
[0010] The goal of this invention is to provide a community-based online dictionary that a user of any native language can look up any words of any foreign language. An undefined word will be log by the dictionary and can be defined by other users later. This dictionary does not claim authentic definitions, although this should be the goal of the user community. The dictionary should provide the user enough information to continue his/her activities or know where to look further.
[0011] Google (http://www.google.com) allows the user to look up words or phrases such as typing “define tag” to find the definition of “tag”. This, however, depends on that a definition exists on the Web and that the definition is processed by the Google engine. Besides, it is still hard for people to find the definition in his/her native language.
[0012] It is common now for webpage to display advertisement. The information of many advertisements is also related to the content of the webpage. For example, a home improvement website may carry advertisement of companies that sell home building material. Google also allows companies to bid on the search words. This invention goes a step further to attach advertisement with dictionary content, including the words, the language, etc.
[0013] 3. Description of Related Patents
[0014] U.S. Pat. No. 6,708,311 described a method to help user to understand technical documents. In it a document is automatically scanned for unknown words and the user who provides the document also provides spell checks and definitions to the dictionary. This invention is mentioned here because its dictionary definitions are also provided by the user. But the new words are not provided by the users, and the purpose of the dictionary is not used for lookup. Besides, its dictionary does not accept incorrect word, whose definition can point to its correct version.
[0015] United States Patent Application 20010056352 also aims to help a reader of foreign language documents. Its dictionary is not maintained by the user community. It does not address the problem we discussed.
[0016] United States Patent Application 20020194300 also aims to help a user understand web pages in foreign languages. The invention provides translation from any language to any language. But it does not have its own dictionaries and its dictionary definitions are not supplied by the user community.
[0017] United States Patent Application 20020198699 is another method to help user understand documents in other languages. The server receives document translation from a user and another user can download the translation for viewing. This invention is mentioned here because it provides a means for the user to contribute. But it is no a dictionary and its purpose and workings serve a different goal.
[0018] United States Patent Application 20030023424 is yet another online dictionary that allows different forms of request and can translate from any language to any language. But again its dictionary is not user supported. And it interacts with the user through a special means.
[0019] United States Patent Application 20040117774 provides different entries for different variations of a word caused by case or orthographic variations. However, this invention does not allow entries of incorrectly spelled words. Again, its dictionary is not user supported.
[0020] United States Patent Application 20040243396 describes an electronic dictionary that a user can modify its entries. However, it applies to a single user rather than a user community. It is mainly an authentic dictionary with some updates from the user.
[0021] United States Patent Application 20050075858 provides another community based dictionary in which the translation of a word is fixed by the selected moderator of the community. However, the words of the dictionary are not provided by the user community. It requires a selected community and selected moderator, who are normally not the users of the dictionary. It also only addresses translating from one language to one language.
OBJECTS AND ADVANTAGES
[0022] Accordingly, several objects and advantages of this invention are:
1. The dictionary is a single source to translate any word from any language into any other language. 2. The user will find from this dictionary definitions that may not be found from other sources. Because the dictionary is user updated, new words will show up here faster than ordinary dictionaries. 3. The definitions are provides by people who know the words. A user not finding the definition is allowed to supply some of his/her guesswork that will help others looking up the same word. 4. User can look up words without knowing its language. We put all foreign words in the same dictionary for a native language. 5. The dictionary collects entries for words with typo or word that the user is not sure. The definition of those words will hopefully suggest the correct words. In many times, a user looking up a word may not remember the correct spellings, or the word he/she reads is spelled wrong. Not all standard dictionaries could help a user in this situation. 6. It links relevant target user to the advertisements. Because the dictionary will collect most up-to-date words which are in fashion, people will be willing to associate advertisement with those words.
[0029] Further objects and advantages of my invention will become apparent from a consideration of the drawings and the ensuing description.
SUMMARY OF THE INVENTION
[0030] This invention is an online dictionary implemented in software. This invention provides a single source to translate any word from any language into any other language. This invention includes a dictionary database that stores user-provided definitions, a server that manages the database, and a client that interfaces to the user. The dictionary data is organized by target languages. For each target language, records are organized by words. A word can be a word, an acronym, or a short phrase, etc. Each word has zero or more definitions. Each definition has several fields: source language, pronunciation, meaning in source and native language, and discussion log. The database also contains a sponsorship base that stores advertisement information. The advertisement will be part of the definition information returned back to the client.
[0031] The server retrieves and updates the dictionary database. It supports word lookup, word definition input, applying for advertisement, and administration.
[0032] The client serves as the interface for the user to interact with the database. A user can look up words, input/update definitions, and apply for advertisements. The administrator can also perform administration tasks.
[0033] The main usage of the invention is word lookup. The user pre-selects the native language then input the word to look up, or inputs the word and native language at the same time. The server will return all the definitions of the word in the native language. If no definition is available, the item will be inserted into the database as undefined and the definitions for other native language, if exist, will be returned. The display will be in the native language. If no native language is specified in the query, definitions for all native languages will be returned. In this case the display will be in default language, maybe in English. The returned information may also contain advertisements. If the user elect, he/she will feed back with which definition he/she accepts.
[0034] If the native language is selected, the user is allowed to add/update definitions for the words in the native language. If a word was accepted for a certain number of consecutive times, the word may not longer be updated. The user is also allowed to log comments in a separate input box. Previous logged comments can also be retrieved.
[0035] Another way for the user to provide definition is to request directly undefined items of a native language from the database and then select the words to define.
[0036] The administrator can also remove or finalize a definition or comments.
[0037] The advertiser can provide a piece of advertisement. He/she can associate it with a native language, or native language and words, or words only, or no association. The advertisement will be assigned a count that is related to the payment. Each time the advertisement is shown to a user, the count decreases by one. The advertisement will no longer be displayed once the count goes to zero. The advertiser can replenish the count by paying more.
THE EMBODIMENT OF THE INVENTION
[0038] This invention can be deployed on a large scale network such as the Internet. The database and server will be hosted at a web address. The client will be the webpage displayed in any web browser such as Internet Explorer from Microsoft or Fire Fox from open source society. This is the preferred embodiment of the invention.
[0039] Another possible embodiment can be an Internet website that only serves a single native language. In this case only definitions in the single native language are collected. Yet another possible embodiment of this invention can be a standalone electronic dictionary that a user can carry around. The user then constantly updates the dictionary as he/she moves around over time. The standalone dictionary can also be fixed in a certain location such as public places. Any user can walk to the location and interact with it.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] These and other objects and features and technical advantages of the present invention will be readily apparent from the following description of the preferred exemplary embodiments of the invention in conjunction with the accompanying drawings, in which
[0041] FIG. 1 is a diagram showing the overall components of a first embodiment of the present invention;
[0042] FIG. 2 is a diagram showing a tree structure of the dictionary objects;
[0043] FIG. 3 is a diagram showing a tree structure of the sponsorship database objects;
[0044] FIG. 4 is a diagram showing an example of the client display for the main page, the word lookup page;
[0045] FIG. 5 is a diagram showing an example of the client display for word definitions;
[0046] FIG. 6 is a diagram showing an example of the client display of words that needs definition;
[0047] FIG. 7 is a diagram showing an example of the client display for submitting new word definition;
[0048] FIG. 8 is a diagram showing an example of the client display for sponsor login;
[0049] FIG. 9 is a diagram showing an example of the client display for the sponsor to create advertisement configuration;
[0050] FIG. 10 is the flowchart of overall user interaction with the dictionary;
[0051] FIG. 11 is the flowchart of one complete sequence of user looking up the dictionary;
[0052] FIG. 12 is the flowchart of one complete sequence of user contributing new definitions;
[0053] FIG. 13 is the flowchart of user contributing one definition;
[0054] FIG. 14 is the flowchart of a complete sequence of a sponsor access.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0055] A system according to a first embodiment of the present invention will now be explained referring to FIG. 1 to FIG.14 . The system of this embodiment is a web-based version of our electronic dictionary. Any web browser serves as the client. The user interacts with the dictionary through web pages.
[0056] The client component 101 in FIG. 1 can be any web browser such as Microsoft Internet Explorer. The server 102 and the databases of dictionary 103 and sponsorship 104 reside at the website. The server 102 and the client 101 communicate via the Internet just like any web browser visiting any website. The server 102 can be implemented in any programming language such as C++, PHP, Ruby, etc. The databases 103 / 104 can be implemented with any database technology such as Oracle, MySQL, etc. The server 102 accesses the databases 103 / 104 using related programming methods.
[0057] As is depicted in FIG. 2 , the dictionary in this embodiment contains a collection of objects in tree structure. There is one Root object 201 that links to Native Language objects 202 , one per language. The Native Language object 202 is the root of all objects that serves for the users whose native language is that language. A Native Language object 202 contains a set of Word objects 203 . A Word object represents a word. Each Word object contains a set of Definition objects 204 . A Definition object 204 serves as one definition of the word in the Word object 203 . A Definition object 204 has 5 objects, Source Language 205 , Pronunciation 206 , Source Language Definition 207 , Native Language Definition 208 , and Comment 209 . The Source Language object 205 stores the language that the word belongs; the Pronunciation object 206 stores how the word is pronounced in its own language; the Source Language Definition 207 objects stores its definition in its own language; the Native Language Definition object 208 stores its definition in the native language; the Comment object 209 stores the comment by the user who provided the definition. A Definition object 204 is considered defined if it has at least information in the Source Language object 205 and Native language definition object 208 . The child objects of the Definition object 204 are all versioned, that is, whenever a user updates the definition, it is time-stamped and the old copies of them are archived. This implies that a user can never delete any information from the dictionary. Only the administrator of the website has full control of the dictionary and can delete any objects.
[0058] As is mentioned in the background of the invention, the dictionary does not intend to provide users detailed definition of a definition, rather it helps them what they are working on. So there is limit on the size of the user input, including values in the Word object 203 , the Source Language Definition object 207 , and the Native Language Definition object 208 . The user can, however, provide lengthy comments for Comment object 209 , which is not displayed on the word definition web page described in FIG. 5 .
[0059] As is depicted in FIG. 3 , the Sponsor database in this embodiment contains a collection of objects in tree structure. There is one Root object 301 that links to Sponsor objects 302 , one per sponsor. The Sponsor object 302 contains sponsor information and has a list of Advertisement objects 303 . An Advertisement object 303 defines an advertisement that can be displayed on the webpage returned to the user. It may contain a link to the sponsor's website. The Advertisement object 303 contains a list of Specification objects 304 . A Specification object defines when and how the advertisement is displayed. The Specification object 304 contains a Target Language object 305 , an End Date object 306 , a Total Count object 307 , and a Target Word object 308 . The Target language object 305 , if it has value, specifies that the advertisement is only displayed when a user's native language is the target language; the End Date object 306 , if it has value, specifies that the advertisement will not longer be displayed after the end date; the Total Count object 307 specifies how many times the advertisement will be displayed; the Target Word object 308 , if it has value, specifies with which word the advertisement must be displayed. Both Target Language object 305 and Target Word object 308 have a Count object 309 / 310 that specifies at least how many times the advertisement must be displayed for the target language or word. Again, a user can never delete any information from the database. Only the administrator of the website has full control of the database and can delete any objects.
[0060] Note the information described in FIG. 2 and FIG. 3 are not necessarily needed to be stored as tree structures. They can be saved in relational database tables. The only requirement is that the information in FIG. 2 and FIG. 3 are stored in the database.
[0061] FIG. 10 is the overall flowchart of the client server interaction in this embodiment. When a user types in the dictionary website in the browser's address line, the initial lookup main page as described in FIG. 4 is returned to the user's browser. Unless the user specifies the native language in the web address, the main page of the default language is returned to the user. The user can switch native language from the main page by selecting the native language from the language list selection 404 and click on the “Set Language” button 405 , which will retrieve a main page in the selected native language. From this point on all subsequent web pages will be written in the native language. The page design will still be the same among different native languages. English is used as the default language here. What is described in the following will be the same for other languages except that the web page shown to the user will be written in a different language.
[0062] The major use of the dictionary will be word lookup. The user types in the word in the edit box 401 where the word “tag” is shown in FIG. 4 . If the user knows the language of the word, he/she can select the language from the list 404 where “German” is shown in FIG. 4 . If the user does not know the language, he/she leaves the list box 404 empty. Then the user clicks on the “Lookup” button 403 to look up the word and the flow goes to the lookup flowchart in FIG. 11 , which shall be described later.
[0063] From the main page the user can also provide feedback to the administrator by input the feedback to the edit box 406 and click on the “Feedback” button 407 . The feedback will be stored and read by the administrator. The user stays with the main page after feedback.
[0064] Two major activities are also launched from the main page. By clicking on the “Supply Definition” button 408 , the user proceeds to the activities described in the define flowchart in FIG. 12 , which will be described later; by clicking on the “Supply Advertisement” button 409 , the user proceeds to the activities described in the advertise flowchart in FIG. 14 , which will be described later. The user must have selected a native language to supply definition.
[0065] FIG. 11 is the flowchart in this embodiment when the user is presented a word definition page, an example of which is shown in FIG. 5 . A list of definitions 504 for the word will be displayed. Each definition has associated two buttons, “Accept” button 502 and “Update” button 503 . The definition displays all information of the Definition object 204 in FIG. 2 for the user's native language except the comment 209 which is not necessary. By clicking on the “Accept” button 502 , the user indicates that this definition meets his/her need. This will be recorded by the dictionary. By clicking on the “Update” button 503 , the user indicates that he/she wants to update this definition, and he/she will be directed to the activities described later in the update flowchart in the FIG. 13 .
[0066] The dictionary does not use language specific information such as case, tense, and other orthographic variations for comparison. Different spellings will be recorded as different Words 203 . Their definitions, which are provided by the user, can be independent or can cross reference each other.
[0067] There are three other buttons not related to a single definition, “Accept None” 505 , “Add New Definition” 506 , and “Main Page” 507 . If the user clicks on the “Accept None” button 505 , he indicates that none of the displayed definitions meet his/her need. This will be recorded by the dictionary. If the user clicks on the “Add New Definition” button 506 , he intends to create a new definition and he/she will be directed to the activities described later in the update flowchart in the FIG. 13 . If the user clicks on the “Main Page” button 507 , the main page will be returned to the browser.
[0068] A definition 504 can be pinned down, which means the definition is finalized and can no longer be changed. In this case the “Accept” button 502 and “Update” button 503 will be disabled. Rules can be devised to pin a definition based on user feedback. For example if a definition is accepted consecutively for certain counts, then it is pinned down. The administrator can also pin a definition.
[0069] If no definition is found for the word, the word will be added to the dictionary and the user will receive a page without any definition. However, if definitions for the word in other native languages exist, they will be displayed as well. If the user does not specify native language, definitions for the word in all languages, if they exist, will be displayed. Only the “Add New Definition” 506 and “Main Page” 507 buttons will be displayed in cases described in this paragraph.
[0070] FIG. 12 is the flowchart in this embodiment when the user decides to contribute definitions for the existing words in the dictionary. He/she does this by clicking on the “Supply Definition” button 408 on the main page in FIG. 4 . The server will return a page of the word lists as is shown in FIG. 6 . Three lists of words are displayed, the ones that are not defined yet 601 , the ones that are defined but not complete 602 , and the ones whose definitions are not accepted by users 603 . As is explained for FIG. 2 , a word is defined if the Definition object 204 's Source Language object 205 and Native Language definition object 208 both have values. A word definition is complete if all the child objects of the Definition object 204 have values. If the user clicks on any of the words 604 in the list of undefined 601 , the server will return the update page for the word as described in FIG. 7 and the user proceeds to the activities as described in the update flowchart in FIG. 13 , which shall be described later. If the user clicks on any of the words 605 in the list of not complete 602 , the server will return the definition page for the word as described in FIG. 5 and the user proceeds to the activities as described in the lookup flowchart in FIG. 11 , which is already described. If the user clicks on any of the words 606 in the list of not accepted 603 , the server will return the definition page for the word as described in FIG. 5 and the user proceeds to the activities as described in the lookup flowchart in FIG. 11 , which is already described. Normally the page only displays a subset of all the words in the lists, the user can turn to the next subset or previous subset by clicking on the “Next List” button 608 and “Previous List” button 607 . And finally, the user can click on the “Main Page” button 609 to return to the dictionary main page.
[0071] FIG. 13 is the flowchart in this embodiment when the user updates one definition. The sample page displayed is shown in FIG. 7 . On this page, the word 701 and past comments 707 on the word are displayed. The user can type in values for the source language 702 , pronunciation 703 , definition in source language 704 , definition in native language 705 , and comment 706 . These correspond to 5 child objects 205 / 206 / 207 / 208 / 209 of the Definition object 204 described in FIG. 2 . The user can click on the “Save” button 708 to upload his/her change to the dictionary. If the language field 702 or the definition in native language 705 has no value, the user cannot save. In FIG. 7 the native language is English. Once the definition is saved, the server will return the definition page as shown in FIG. 5 back to the client browser. Three buttons will be displayed if the user is the administrator: “Pin” button 709 to pin down the definition, “Delete” button 710 to delete the definition from the dictionary, and “Delete Comment” button 711 to delete the comments from the dictionary. Once the definition is pinned, user can no longer update it. The user can also go back to the main page by clicking on the “Main Page” button 712 .
[0072] In the beginning, the administrator can pre-populate the dictionary with definitions and undefined words to make it more useful.
[0073] FIG. 14 is the flowchart in this embodiment when a sponsor accesses the website. The sponsor does this by clicking on the “Supply Advertisement” button 409 in the main page shown in FIG. 4 . The login page will be returned to the client browser as is shown in FIG. 8 . In FIG. 8 the sponsor clicks the “Register Sponsor” button 801 to create a new sponsor account. An existing sponsor simply logs in by clicking “Login” button 804 after typing in the sponsor name 802 and password 803 . After login, the sponsor can provide one or more advertisement displays, which can be included in web pages returned to other users. The size of an advertisement display is limited. The sponsor then can specify how and when the advertisement can be displayed. An advertisement can have one or more specifications 304 as is described in FIG. 3 . One specification is provided through the webpage as shown in FIG. 9 . The sponsor types in end date 902 , total count 903 , target language 904 and count 905 , target word 906 and count 907 . These correspond to the objects 306 / 307 / 305 / 309 / 308 / 310 described in FIG. 3 . By clicking on “Save” button 908 , the sponsor saves the specification in the sponsor database. By clicking on “Logout” button 909 , the sponsor logs out.
[0074] Once the sponsor has paid the fee, the advertisement will be displayed according to the specifications. If the specification specifies target language, the advertisement will be displayed when a user's native language is the target language; if the specification specifies target word, the advertisement will be displayed when that word is looked up. The specification will expire if the total count is reached or the end data is reached.
[0075] The sponsor account management and payment management are not part of this invention. They can be achieved with any known management methods such as used by current online companies.
[0076] Since this is an electronic dictionary, the expected features of an electronic dictionary such as wildcard search, browsing, etc. can all be supported by our dictionary. The implementation of those features is not part of this invention and not discussed here.
[0077] It is important to note that while the present invention has been described in the context of a fully functioning website, those of ordinary skill in the art will appreciate that the processes of the present invention are capable of being implemented as software in an isolated network or via wireless networks that the present invention applies equally. It can also be implemented in a standalone device that includes all components in FIG. 1 . The invention can also be reduced to having only one native language, or only one foreign language, or only one native and one foreign language.
[0078] The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
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This invention describes an electronic dictionary that is built and maintained by the user community. It is a single source to translate any word from any language into any other language. The dictionary resides with an online server. User with online connection specifies his/her native language and looks up any correct word, misspelled word, acronym, or phrase of any foreign language. The definitions and related information are also supplied by the user community. A user can also place advertisement. He/she can associate the advertisement with the entries in the dictionary. While the dictionary content is user maintained, the administrator has the full control.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority from Korean Patent Application No. 10-2013-0007032, filed on Jan. 22, 2013 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference, in its entirety.
BACKGROUND
Field
Apparatuses and methods consistent with the exemplary embodiments relate to an electronic apparatus and a voice processing method thereof. More particularly, the exemplary embodiments relate to an electronic apparatus capable of recognizing a user's voice and a voice processing method thereof.
Description of the Related Art
In addition to recent various functions of audio/video (AV) apparatuses such as a blue-ray Disc® (BD)/digital versatile disc (DVD) player, as well as a television, functions of using a microphone for voice recognition to control the apparatus have been used beyond an input method employing an existing remote controller.
A voice recognition method includes a voice command processing method of recognizing a previously stored instruction, and a method of processing a dialogue voice of recognizing not the previously stored instruction, but rather recognizing the voice. For example, to turn up the volume of the electronic apparatus, the volume of the electronic apparatus may be controlled by a previously stored instruction of “volume up” or by dialogue voice recognition of processing voice of “increase the volume” having the same meaning as “volume up” but not stored. In the case of the dialogue voice recognition, an external voice recognition server is used to analyze a user's voice and determine the meaning of the voice.
Such two voice recognition systems has currently used a method in which a user's spoken voice is analyzed in the voice recognition server. A determination has been made whether there is a command mode process. In response to a spoken voice corresponding to a previously stored instruction, a relevant function is performed; otherwise, the spoken voice is processed by a dialog mode process.
In the foregoing method, when a user speaks dialogue voice, the spoken voice has to unconditionally undergo both a command mode process and a dialog mode process. However, this causes a problem with respect to the time taken in carrying out both the command mode process and the dialog mode process, and the inefficiency of operating the system where the instruction process is wastefully performed.
SUMMARY
One or more exemplary embodiments may provide an electronic apparatus and method of processing a voice processing method thereof, in which time delay is decreased and efficiency of the apparatus is enhanced, with regard to recognition of user's voice.
Also, another exemplary embodiment provides an electronic apparatus and method of processing a voice, in which user experience can be induced and increased with regard to recognition of user's voice.
The foregoing and/or other aspects of the present disclosure may be achieved by providing an electronic apparatus including: a voice recognizer configured to recognize a user's voice; a storage configured to previously store instructions; a function executor configured to perform a predetermined function; and a controller configured to control the function executor to execute the function in response to the instruction in response to a user's voice corresponding to the instruction being input, and is configured to control the function executor to execute the function in accordance with results of an external server analyzing a user's voice in response to a preset dialogue selection signal and a dialogue voice for executing the function being input by a user.
According to an aspect of another exemplary embodiment, the dialogue selection signal may include a user's voice signal.
According to an aspect of another exemplary embodiment, the electronic apparatus may further include a user input configured to include a toggle button.
The foregoing and/or other aspects of exemplary embodiments may be achieved by providing an electronic apparatus including: a voice recognizer configured to recognize a user's voice; a storage configured to previously store instructions; a function executor configured to perform a predetermined function; and a controller configured to process a user's voice through one of an instruction process in which the function is executed in accordance with the instruction corresponding to a user's voice and a dialogue process in which the function is executed in accordance with results of an external server analyzing a user's voice, based on a process selection signal input by a user, and configured to control the function executor to execute the function corresponding to the processed user's voice.
According to an aspect of another exemplary embodiment, the process selection signal may include a user's voice signal for selecting one of the instruction process and the dialogue process.
According to an aspect of another exemplary embodiment, the voice recognizer is configured to sequentially receive a user's voice which corresponds to the process selection signal and a user's voice for executing the function from a user.
The foregoing and/or other aspects of the exemplary embodiments may be achieved by providing a voice processing method of an electronic apparatus including a storage which previously stores an instruction, the method including: recognizing a user's voice; determining whether a preset dialogue selection signal is input; and executing a predetermined function in accordance with results of an external server analyzing the recognized user's voice in response to a determination that the dialogue selection signal is input, and executing the function in response to the instruction corresponding to a user's voice in response to a determination that the dialogue selection signal is not input.
According to an aspect of another exemplary embodiment, the dialogue selection signal may include a user's voice signal in selecting a dialogue process.
Another exemplary embodiment may provide an electronic apparatus including: a function executor configured to perform a predetermined function; and a controller configured to control the function executor to execute the function in response to instructions received in response to a user's voice corresponding to the instruction being input, and controls the function executor to execute the function in accordance with results of an external server analyzing a user's voice in response to a preset dialogue selection signal and a dialogue voice for executing the function being input by a user.
The electronic apparatus may further include: a voice recognizer configured to recognize a user's voice and a storage configured to have previously stored instructions. The dialogue selection signal may include a user's voice signal.
The electronic apparatus may further include a user input comprising a toggle button, wherein the dialogue selection signal is generated by the toggle button.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and/or other aspects will become apparent and more readily appreciated from the following description of exemplary embodiments, taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a control block diagram of an electronic apparatus according to an exemplary embodiment;
FIG. 2 is a control flowchart which explains a method of controlling an electronic apparatus according to an exemplary embodiment;
FIG. 3 is a control flowchart which explains a method of controlling an electronic apparatus according to another exemplary embodiment; and
FIG. 4 is a control block diagram of an electronic apparatus according to an exemplary embodiment.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
Below, exemplary embodiments will be described in detail with reference to accompanying drawings so as to be easily understood by a person having ordinary knowledge in the art. The exemplary embodiments may be embodied in various forms without being limited to the embodiments set forth herein. Descriptions of well-known parts are omitted for clarity, and like reference numerals refer to like elements throughout.
FIG. 1 is a control block diagram of an electronic apparatus according to an exemplary embodiment. In this exemplary embodiment, the electronic apparatus 1 may include a television, a computer system, a settop box, a Blue-ray Disc® (BD) player, a digital versatile disc (DVD) player, an MP3 player, an audio/video (AV) device which can reproduce voice and image files, or the like. The electronic apparatus 1 may be implemented as a personal digital assistant (PDA), a tablet computer, a household or mobile phone, etc., or may be implemented as home appliances such as a washing machine and a microwave oven. In this exemplary embodiment, the electronic apparatus 1 may recognize a user's voice and may perform various functions in accordance with a user's voice. To this end, the electronic apparatus 1 includes a voice recognizer 10 , a storage 20 , a function executor 30 and a controller 40 .
The voice recognizer 10 includes a microphone which receives a user's voice or various sounds. The voice recognizer 10 extracts a user's voice from received sounds in response to receiving a user's voice, and converts the extracted user's voice into a machine language that can be processed by the electronic apparatus 1 , thereby determining the meaning of the extracted user's voice. Also, in response to the recognized voice being for executing a function based on voice recognition, the voice recognizer 10 transmits to the controller 40 information related to the voice.
According to another exemplary embodiment, the electronic apparatus 1 may include only the microphone for receiving the voice, and may determine a user's voice through the external server that extracts voice by analyzing the received sound and determines the meaning of the voice.
The storage 20 stores instructions for executing various functions of the electronic apparatus 1 , based on a user's voice. In response to the function of the electronic apparatus 1 being performed by input based on voice besides input based on a user's control using a key, a button, or a touch sensor, the previously set instructions for performing the functions are previously stored. For example, in response to the electronic apparatus 1 being a television, the instructions such as “volume up”, “volume down”, “channel change”, “record start”, etc. may be stored in the storage 20 . In response to the recognized user's voice being matched to the instruction stored in the storage 20 , the controller 40 carries out the function of the electronic apparatus 1 in accordance with the instruction. Thus, in response to receiving a user's voice which matches the instruction stored in the storage 20 , the controller 40 which determine a voice recognition process which performs the function as an instruction process. In the case of the instruction process, in response to the received user's voice being mismatched to the stored instruction or has the same or similar meaning as voice corresponding to the stored instruction, the controller 40 do not carry out any function in accordance with the user's voice.
A user may directly input various instructions to the storage 20 or may change or delete instructions. Frequently used instructions are stored so that functions can be quickly and rapidly carried out.
The function executor 30 symbolically represents an executor corresponding to various functions that can be executed by the electronic apparatus 1 . The function executor 30 may include any hardware or software necessary for carrying out various functions, and the functions may be performed not by a user's voice but rather by the direct control of a user.
The controller 40 controls a user's voice to undergo one of the instruction process and the dialogue process in response to receiving a recognition result of a user's voice from the voice recognizer 10 , thereby operating the function executor 30 . In the dialogue process, a user's voice is transmitted to the external server 2 and processed for carrying out a function based on analysis results from the server 2 in response to a user's voice not being matched to an instruction stored in the storage 20 . For example, in response to a user inputting voice such as “could you turn up volume?” or “more loudly”, which has similar meaning as the stored “volume up,” instead of “volume up,” the controller 40 transmits the recognized user's voice to the server 2 , allows the server 2 to determine the meaning of the voice, and receives the determined result from the server 2 . The server 2 determines a user's voice and transmits information related to one instruction from among the stored instructions or information related to an algorithm for performing the function to the electronic apparatus 1 .
In this exemplary embodiment, the controller 40 uses one of the instruction process and the dialogue process to process a user's voice in accordance with a preset dialogue selection signal input by a user. That is, in response to a user inputting the dialogue selection signal for processing voice through the dialogue process, the controller 40 processes a user's voice through the dialogue process. On the other hand, in response to the dialogue selection signal not being input, a user's voice may be processed through the instruction process.
For example, in response to a user inputting a voice of “dialogue” and voice for executing a function, the controller 40 transmits the voice for executing the function to the server 2 , thereby receiving analysis results from the server. In this case, the dialogue selection signal is a user's voice for selecting the dialogue process. In response to the dialogue selection signal being a user's voice, a user may set up various dialogue selection signals in accordance with his/her individual tastes. Thus, voice is input through the microphone and stored, so that the usability of the electronic apparatus 1 can be improved and a user can accumulate his/her experience of using the electronic apparatus 1 .
As is known, when a user inputs voice, his/her voice is processed through the instruction process. At this time, in response to a user's voice not being matched with the stored instruction, the voice is processed again through the dialogue process. Under the known control, the instruction process has to be wastefully implemented even in response to a user's voice not being matched to an instruction, and therefore time is delayed while responding to a user's voice and wasteful control deteriorates mechanical efficiency.
In this exemplary embodiment, a user can input a signal for selecting the process along with voice for command if he/she wants to process his/her voice to be processed through the dialogue process. Therefore, the electronic apparatus 1 can more quickly and efficiently respond to a user's command. Furthermore, even though a user may not remember, one by one, a lot of instructions stored in the storage 20 , a variety of verbalism can be used in order to carry out a function desired by a user.
In response to a user inputting only voice for carrying out a function without inputting the dialogue selection signal, the controller 40 processes a user's voice in accordance with the instruction process. At this time, in response to the voice input by a user not being matched with the stored instruction, the controller 40 switches to the dialogue process and processes a user's voice. This is because the function has to be implemented in accordance with a user's intention even though a user does not input the dialogue selection signal.
According to another exemplary embodiment, the controller 40 stores history and a record of a user's voice processed by the dialogue process. In response to a certain voice being repetitively input, this may be stored in the storage 20 . In the case where the function is carried out through the instruction stored in the storage 20 , it may be faster than that of using the external server 2 for carrying out the function. Therefore, a user's voice pattern is stored so as to induce the instruction process instead of the dialogue process. In this case, the controller 40 may inform a user through a graphic user interface (GUI) or the like that the instructions frequently used by a user are processed by not the dialogue process but the instruction process.
FIG. 2 is a control flowchart which explains a method of controlling an electronic apparatus according to an exemplary embodiment. Referring to FIG. 2 , a voice processing method of the electronic apparatus according to an exemplary embodiment is as follows.
The electronic apparatus 1 receives a user's voice for executing a function from a user and recognizes the voice (S 10 ).
The user's voice recognized by the voice recognizer 10 is transmitted to the controller 40 , and the controller 40 determines whether the user's voice involves a preset dialogue selection signal, that is, whether or not the dialogue selection signal is input (S 20 ).
In result, in response to a determination that the dialogue selection signal is being input, the controller 40 determines that the dialogue process is selected; requests an analysis of the recognized user's voice to the server 2 ; and executes the function of the electronic apparatus 1 in accordance with the analysis results received from the server 2 (S 30 ).
On the other hand, in response to a determination that the dialogue selection signal is not input, the controller 40 determines that the instruction process is selected; and executes the function of the electronic apparatus 1 in accordance the instruction matching with a user's voice (S 40 ).
FIG. 3 is a control flowchart which explains a method of controlling an electronic apparatus according to another exemplary embodiment. In this exemplary embodiment, the controller 40 uses one of the instruction process executing the function in accordance with the instruction from the external server 2 matching a user's voice and the dialogue process executing the function in accordance with an analysis result of a user's voice based on a selection signal for selecting the dialogue process or the instruction process, so as to process a user's voice, and controls the function executor 30 to execute the function corresponding to the processed user's voice. That is, the electronic apparatus 1 , according to an exemplary embodiment receives a selection signal from a user for clearly selecting the instruction process or the dialogue process.
As shown in FIG. 3 , according to an exemplary embodiment, a user inputs a process selection signal for selecting the process along with voice for executing a function to the electronic apparatus 1 (S 11 ). Such a process selection signal may include a user's voice for selecting one of the instruction process and the dialogue process. In this case, the voice recognizer 10 receives a user's voice for selecting the process and a user's voice for executing a function in sequence.
The controller 40 determines whether the process selection signal input by a user is a dialogue selection signal or an instruction selection signal (S 21 ).
In result, in response to the process selection signal being the dialogue selection signal, as shown in S 30 of FIG. 2 , the controller 40 analyzes the recognized user's voice through the server 2 and carries out the function of the electronic apparatus 1 in accordance with the analysis results (S 30 ).
Likewise, in response to the process selection signal not being the dialogue selection signal but rather the instruction selection signal, the controller 40 determines that the instruction process is selected, and carries out the function of the electronic apparatus 1 in accordance with an instruction matching the user's voice (S 40 ).
FIG. 4 is a control block diagram of an electronic apparatus according to an exemplary embodiment. As shown therein, the electronic apparatus 1 in this embodiment further includes a user input 50 . The user input 50 may include a toggle button 51 , and may further include a touch sensor such as a touch pad. A user may control the toggle button 51 to generate the dialogue selection signal or the process selection signal. That is, a user may use the toggle button 51 to select a process for a user's voice recognition. In response to a user wanting to execute the function of the electronic apparatus 1 through his/her voice, he/she may activate or inactivate the toggle button 51 , thereby selecting one of the instruction process and the dialogue process. Alternatively, Further, a user's favorite process may be set up while the toggle button 51 is activated, and it is therefore convenient for a user to execute the function though his/her voice.
Although a few exemplary embodiments have been shown and described, it will be appreciated by those skilled in the art that changes may be made in these exemplary embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
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Apparatuses and methods related an electronic apparatus and a voice processing method thereof are provided. More particularly, the apparatuses and methods relate to an electronic apparatus capable of recognizing a user's voice and a voice processing method thereof. An electronic apparatus includes: a voice recognizer configured to recognize a user's voice; a storage configured to have previously stored instructions; a function executor which performs a predetermined function; and a controller configured to control the function executor to execute the function in response to the instruction in response to a user's voice corresponding to the instruction being input, and controls the function executor to execute the function in accordance with results of an external server which analyzes a user's voice in response to a preset dialog selection signal and a dialog voice for executing the function being input by a user.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to a rock bolt and is particularly concerned with a rock bolt which can be used with an anchoring composition.
[0002] The expression “anchoring composition” is herein used to refer to a resinous mixture, a cementitious mixture or an equivalent mixture which is usable, as is known in the art, to secure a rock bolt in a borehole.
[0003] An anchoring composition is normally provided in two parts enclosed in separate frangible containers which can be broken by mechanical action of a rock bolt. The contents of the containers are mixed, in situ, by rotation of the rock bolt whereafter a setting process takes place. The rock bolt is then adhered in position to a surface of a borehole in which the composition and rock bolt are located.
[0004] The container, made from an appropriate flexible material, is pushed into the borehole and this is followed by insertion of the rock bolt into the borehole. The flexible material can normally be penetrated with ease by a leading end of the rock bolt. The material should be adequately shredded so that a maximum release of its contents occurs. Some materials which are used are, however, resistant to shredding. In one instance a fabric-type material is used and it can occur that as the rock bolt is inserted into the borehole the fabric is pushed by the rock bolt to a blind end of the hole. A build-up of the fabric at this end of the borehole can prevent complete insertion of the rock bolt into the borehole. Also, it might occur that the anchoring composition is not fully released from the flexible material. Another problem which can arise is that the flexible material is pierced by the rock bolt but then wraps around a shank of the rock bolt and prevents the anchoring composition from bonding directly to the rock bolt.
[0005] An object of the present invention is to provide a rock bolt which attempts to address the aforementioned factors.
SUMMARY OF INVENTION
[0006] The invention provides a rock bolt which includes an elongate shank with a leading end and a trailing end, a shear device fixed to the trailing end, the shank including a frusto-conical section at the leading end, and a shredding and mixing structure which extends from the frusto-conical section.
[0007] The shear device at the trailing end of the shank may be of any appropriate kind. The shear device should shear when it is used to impart torque at a predetermined level to the shank so that the shear device is then releasable from the shank. The ability to transmit torque to the shank is required to rotate the shank so that mixing of an anchoring composition can take place effectively. The device may include a nut which is theadedly engaged e.g. with a left-hand thread with the shank and which is then fixed to the shank using a shear pin which traverses at least part of the shank and the nut.
[0008] Preferably the frusto-conical section is formed integrally with the shank, for example in a forging process.
[0009] The frusto-conical section may terminate in a substantially planar surface which is transverse to a longitudinal axis of the shank. The shredding and mixing structure may project from this surface in a direction which is more or less parallel to the longitudinal axis.
[0010] The shredding and mixing structure may include a blade which, preferably, is centrally positioned on the planar surface. The blade, in outline (from one side), may be square or rectangular. A desirable aspect here is that each corner of the blade, remote from the planar surface, should form a right angle and, inherently, the corner should be sharp. Thus the corners are suited for piercing a flexible container which contains ingredients for an anchoring composition.
[0011] The blade may be flanked by mixing formations so that the structure is of cruciform shape (cross-shaped), viewed end-on.
[0012] In one preferred form of the invention the shank is formed from round bar with a diameter of 16 mm. The round bar is made from steel with a minimum yield strength of 580 mpa. With a shank of this size the frusto-conical section may have a maximum diameter of the order of 22 mm. The length of the blade measured in an axial direction of the shank may be of the order of 30 mm.
[0013] The shank may be coated with a release medium, as is known in the art so that it can de-bond from an anchoring composition (once set) and can then yield under load. The frusto-conical section at the leading end of the shank then acts as an anchor for the shank.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The invention is further described by way of example with reference to the accompanying drawings in which:
[0015] FIG. 1 is a perspective view of a rock bolt according to the invention;
[0016] FIG. 2 illustrates a part of the rock bolt of FIG. 1 , which is enclosed in a circle marked 2 ;
[0017] FIG. 3 is a side view of the rock bolt of FIG. 1 ;
[0018] FIG. 4 shows a part of the rock bolt which is enclosed in a circle marked 4 in FIG. 3 ; and
[0019] FIG. 5 is an end view of the rock bolt taken in the direction of an arrow marked 5 in FIG. 4 .
DESCRIPTION OF PREFERRED EMBODIMENT
[0020] FIG. 1 of the accompanying drawings is a perspective view of a rock bolt 10 according to the invention. Referring as well to FIG. 3 , which illustrates the rock bolt from one side, the rock bolt includes an elongate shank 12 which has a trailing end 14 and a leading end 16 . The leading end is shown from one side in FIG. 4 and an end view of the leading end is shown in FIG. 5 . FIG. 2 shows the leading end in perspective.
[0021] In one preferred form of the invention the shank is made from round bar with a diameter of about 16 mm and has a predetermined length. The shank preferably has a minimum yield strength of 580 mpa.
[0022] The trailing end 14 has a left-hand thread and a nut 20 is threadedly engaged therewith. A shear pin 22 extends through a passage bored radially into the nut and enters an in-register passage, not shown, at the trailing end 14 . In this way the nut and shear pin form a shear structure which, initially, is fixed immovably to the shank.
[0023] The leading end 16 has an integrally forged frusto-conical section 30 . This section, which typically has an axial length 32 of the order of 30 mm, has a maximum diameter 34 at one end which is of the order of 22 mm. An end of the frusto-conical section presents a substantially planar surface 36 which is at a right angle to a longitudinal axis 38 of the shank.
[0024] Shredding and mixing structure 40 , forged integrally with the section 30 , extends from the planar surface 36 . This structure includes a shedding blade 42 and mixing members 44 which project outwardly from and transversely to a base 46 of the blade. The blade and mixing members, viewed end-on present a cruciform shape.
[0025] The blade has a length 48 , taken from the planar surface 36 , which is of the order of 30 mm. Outer corners 50 of the blade are sharp and each corner defines a right angle. This is a feature which allows the blade to pierce a flexible housing, which contains an anchoring composition, with ease.
[0026] The mixing members 44 , viewed from one side (see FIG. 4 ) have a relatively short length 52 , of the order of 3 mm or 4 mm i.e. less than about 14% of the length of the blade. Sides 54 of the mixing members, and sides 56 of the base of the blade are chamfered (see FIG. 5 ).
[0027] In use of the rock bolt an anchoring composition in a flexible container, not shown, is inserted into a borehole formed in a body of rock. The leading end 16 of the rock bolt is then inserted into the borehole and the rock bolt is pushed fully into the hole. The shear structure at the trailing end 14 is engaged with a device which rotates the shank. As the shank is pushed home and rotated the blade 42 easily penetrates the flexible container. Due to its size and the sharp corners 50 the blade, upon rotation of the rock bolt, rapidly shreds the container irrespective of the material from which it is made. The anchoring composition inside the container is released and is mixed by ongoing rotation of the blade. The mixing members 44 which are simultaneously rotated help substantially in this regard.
[0028] The mixing members are relatively small compared to the blade and the likelihood that these members, which has chamfered sides 54 , will entrain parts of the flexible container is remote. The blade on the other hand shreds the container and, as noted, continues with the mixing process.
[0029] The anchoring composition sets fairly rapidly and starts bonding to the shank and the leading end. The rotational force required to rotate the shank increases and ultimately a point is reached at which the shear pin 22 shears. It is then no longer possible to impart torque to the shank. Typically the nut 20 is automatically unscrewed from the shank. Alternatively the nut is manually released from the shank. A load-spreading washer, if required, can then be engaged with the shank whereupon the nut is re-engaged with the shank.
[0030] The structure at the leading end 16 of the shank has been found, in practice, to be highly effective in shredding a flexible container and, then, in mixing an anchoring composition released from the container, while addressing the problems referred to in the preamble hereof.
[0031] If desired at least part of the shank can have a de-bonding agent applied to it. For example part of the shank can be coated with a thin plastic layer. The anchoring composition then does not bond directly to the shank but acts primarily against the frusto-conical section 30 . This feature allows the rock bolt to yield under load.
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A rock bolt has a rectangular blade, which can pierce and shred a flexible housing, extending from cross-shaped mixing formations at one end of an elongate rod.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of the filing date of U.S. Provisional Patent Application No. 60/546,230 filed Feb. 20, 2004, the disclosure of which is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
The bones and connective tissue of an adult human spinal column consist of more than twenty discrete bones coupled sequentially to one another by a tri-joint complex, which consists of an anterior disc and two posterior facet joints, the anterior discs of adjacent bones being cushioned by cartilage spacers referred to as intervertebral discs. These more than twenty bones are anatomically categorized as being members of one of four classifications: cervical, thoracic, lumbar, or sacral. The cervical portion of the spine, which comprises the top of the spine up to the base of the skull, includes the first seven vertebrae. The intermediate twelve bones are the thoracic vertebrae, and connect to the lower spine comprising the five lumbar vertebrae. The base of the spine comprises the sacral bones (including the coccyx). The component bones of the cervical spine are generally smaller than those of the thoracic spine, which are in turn smaller than those of the lumbar region. The sacral region connects laterally to the pelvis.
The spinal column is highly complex in that it includes these more than twenty bones coupled to one another, housing and protecting critical elements of the nervous system having innumerable peripheral nerves and circulatory bodies in close proximity. In spite of these complications, the spine is a highly flexible structure, capable of a high degree of curvature and twist in nearly every direction.
Genetic or developmental irregularities, trauma, chronic stress, tumors, and degenerative wear are a few of the causes that can result in spinal pathologies for which surgical intervention may be necessary. A variety of systems have been disclosed in the art that achieve immobilization and/or fusion of adjacent bones by implanting artificial assemblies in or on the spinal column. The region of the back that needs to be immobilized, as well as the individual variations in anatomy, determine the appropriate surgical protocol and implantation assembly. With respect to the failure of the intervertebral disc, the interbody fusion cage has generated substantial interest because it can be implanted laparoscopically into the anterior of the spine, thus reducing operating room time, patient recovery time, and scarification. Referring now to FIGS. 6 a and 6 b , in which a side perspective view of an intervertebral body cage and an anterior perspective view of a post implantation spinal column are shown, respectively, a more complete description of these devices of the prior art is herein provided. These cages 101 generally comprise tubular metal body 102 having an external surface threading 103 . They are inserted transverse to the axis of the spine 104 , into preformed cylindrical holes at the junction of adjacent vertebral bodies (in FIG. 6 b the pair of cages 101 are inserted between the fifth lumbar vertebra (L 5 ) and the top of the sacrum (S 1 )). Two cages 101 are generally inserted side by side with the external surface threading 103 tapping into the lower surface of the vertebral bone above (L 5 ), and the upper surface of the vertebral bone (S 1 ) below. The cages 101 include holes 105 through which the adjacent bones are to grow. Additional materials, for example autogenous bone graft materials, may be inserted into the hollow interior 106 of the cage 101 to incite or accelerate the growth of the bone into the cage. End caps (not shown) are often utilized to hold the bone graft material within the cage 101 .
These cages of the prior art have enjoyed medical success in promoting fusion and grossly approximating proper disc height. It is, however, important to note that the fusion of the adjacent bones is an incomplete solution to the underlying pathology as it does not cure the ailment, but rather simply masks the pathology under a stabilizing bridge of bone. This bone fusion limits the overall flexibility of the spinal column and artificially constrains the normal motion of the patient. This constraint can cause collateral injury to the patient's spine as additional stresses of motion, normally borne by the now-fused joint, are transferred onto the nearby facet joints and intervertebral discs. It would therefore, be a considerable advance in the art to provide an implant assembly which does not promote fusion, but, rather, which mimics the biomechanical action of the natural disc cartilage, thereby permitting continued normal motion and stress distribution.
It is, therefore, an object of the invention to provide an intervertebral spacer that stabilizes the spine without promoting a bone fusion across the intervertebral space.
It is further an object of the present invention to provide an implant device that stabilizes the spine while still permitting normal motion.
It is further an object of the present invention to provide a device for implantation into the intervertebral space that does not promote the abnormal distribution of biomechanical stresses on the patient's spine.
It is further an object of the present invention to provide an artificial intervertebral disc that provides limited rotation of the baseplates transverse to the axis of the spine.
It is further an object of the present invention to provide an artificial disc that provides limited angular rotation of the baseplates relative to a centroid of motion centrally located within the intervertebral space.
It is further an object of the present invention to provide an artificial intervertebral disc that supports compression loads.
It is further an object of the present invention to provide an artificial intervertebral disc that permits the baseplates to axially float toward and away from each other.
It is further an object of the invention to provide an artificial intervertebral disc that supports tension loads.
It is further an object of the present invention to provide an artificial intervertebral disc that prevents lateral translation of the baseplates relative to one another.
It is further an object of the present invention to provide an artificial intervertebral disc that provides a centroid of motion centrally located within the intervertebral space.
It is further an object of the present invention to provide artificial intervertebral disc baseplates having outwardly facing surfaces that conform to the concave surface of adjacent vertebral bodies.
Other objects of the present invention not explicitly stated will be set forth and will be more clearly understood in conjunction with the descriptions of the preferred embodiments disclosed hereafter.
SUMMARY OF THE INVENTION
The proceeding objects are achieved by the present invention, which is an artificial intervertebral disc or intervertebral spacer device having a pair of support members (e.g., spaced-apart baseplates), each with an outwardly-facing surface. Because the artificial disc of the present invention is to be positioned between the facing endplates of adjacent vertebral bodies, the baseplates are arranged in a substantially parallel planer alignment (or slightly offset relative to one another in accordance with proper lordotic angulation) with the outwardly-facing surfaces facing away from one another. The baseplates are to mate with the vertebral bodies so as not to rotate relative thereto, but rather to permit the spinal segments to bend (in some embodiments, actually compress) relative to one another in manners that mimic the natural motion of the spinal segment. This natural motion is permitted by the performance of a ball-and-socket-type joint using a spherical member disposed between the secured baseplates, and the securing of the baseplates to the vertebral bone may be achieved through the use of a vertebral body contact element attached to the outwardly-facing surface of each baseplate.
Preferably, vertebral body contact elements include, but are not limited to, one or more of the following: a convex mesh, a convex solid dome and one or more spikes, as disclosed in U.S. patent application Ser. No. 10/256,160, the disclosure of which is hereby incorporated by reference herein.
The ball and socket joint of the present invention permit rotation between the two elements by capturing a strap integrally formed with one of the baseplates within a groove of the other baseplate. The strap, preferably, has an inner surface having a curvature which is substantially equal to the curvature of a ball also disposed between the two baseplates, thereby permitting rotation and angulation of the strap about a central point of the ball. This further permits angulational movement and rotational movement of one baseplate relative to the other baseplate.
The groove of the other baseplate, i.e., second baseplate, has a wider dimension than the strap so as to permit the strap to move freely about the central point of the ball at least with a desired angulation and rotation range. Additionally, the groove has a depth, which, in conjunction with the space between the first baseplate and the ball, limits the ability of the strap to come into contact with a bottom surface of the groove, even during axial movement of the two baseplates.
In one preferred embodiment, the ends of the groove are angled relative thereto so as to reduce wear and tear between the strap and groove as the strap angulates and rotates about the central point of the ball within the groove.
In one embodiment of the present invention, the artificial intervertebral disc includes a first baseplate having a top surface, a bottom surface and an aperture extending therebetween. The first baseplate further includes a strap having a top surface, a bottom surface, a first end and a second end. The ends of the strap are remote from one another and are attached to the bottom surface of the first baseplate such that a portion of the strap underlies the aperture.
The artificial intervertebral disc of the present invention also includes a second baseplate having a top surface, a bottom surface and a cavity exposed at the top surface of the second baseplate. The cavity preferably includes a groove having a first sidewall and a second sidewall, with the sidewalls being remote from each other. A spherical element having a central point is disposed within the aperture of the first baseplate and overlies the strap. The spherical element is preferably attached to the first sidewall and second sidewall of the second baseplate such that the strap is positioned and captured within the groove, thereby permitting the first baseplate and the second baseplate to move in an angulational direction and a rotational direction relative to one another with the strap translating about the central point of the spherical element.
The first sidewall and second sidewall may each include an indent such that the spherical element is attached to the first sidewall and second sidewall at respective indents. Additionally, the first sidewall and second sidewall may have a plurality of ends that are angled, such that during rotational movement of the first baseplate or second baseplate the strap has an increased range of motion within the groove.
The artificial intervertebral implant of the present invention may also include a cover having a bottom surface. The cover is preferably designed to be at least partially disposed within the aperture such that the cover overlays the spherical element, thereby capturing the spherical element between the cover and strap.
In certain embodiments of the present invention, the cover may include a cap and post with the top surface of the first baseplate further including a recess circumferentially extending about the aperture such that the post of the cover is compression fit within the aperture and the cap of the cover is compression fit within the recess.
The groove of the second baseplate may have a bottom surface and the spherical element may have an apex. Additionally, a distance between the bottom surface of the groove to the apex of the spherical element is preferably greater than a distance between the bottom surface of the cover to the bottom surface of the strap. More preferably, the distance between the top surface of the strap to the bottom surface of the cover is greater than a diameter of the spherical element, such that the combination of the two permits the first baseplate and the second baseplate to move in an axial direction relative to one another.
In one preferred embodiment of the present invention, the bottom surface of the cover and top surface of the strap have a radius of curvature substantially equal to a radius of curvature of the spherical element, such that the strap and the cover pivot about the central point of the spherical element as the first baseplate moves relative to the second baseplate in both an angulational direction and a rotational direction.
In one aspect of the present invention a distance between the top surface of the strap and the bottom surface of the cover is greater than a length of the articulating element, such that the first baseplate and the second baseplate may move in an axial direction relative to one another.
The bottom surface of the cover and the top surface of the strap may have a radius of curvature substantially equal to a radius of curvature of the articulating element, such that the strap and the cover may translate about the articulating element.
In another aspect of the present invention the aperture may be partially defined by the strap and not be included within the first baseplate.
In another aspect of the present invention the articulating element may be stationary relative to a first element, with the strap being captured between the articulating element and the first element.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a perspective exploded view of a device according to the present invention;
FIG. 2 illustrates an exploded cross-sectional view of the device of FIG. 1 ;
FIG. 3 illustrates an assembled cross-sectional view of a device of FIG. 1 taken along the Y axis;
FIG. 4A illustrates an assembled perspective cross-sectional view of the device of FIG. 1 taken along the Y axis;
FIG. 4B illustrates an assembled cross-sectional view of the device of FIG. 1 taken along the Y axis;
FIG. 5 illustrates a top view of a lower baseplate used in the present invention;
FIG. 6A illustrates a prior art embodiments of an artificial intervertebral disc; and
FIG. 6B illustrates prior art embodiments of an artificial intervertebral disc.
DETAILED DESCRIPTION
The present invention will now be described with reference to the accompanying figures. The embodiments described herein are meant to be illustrative of the present invention and in no way should be thought of as limiting the present invention.
As shown in FIG. 1 , an artificial intervertebral disc 1 , according to the present invention, preferably includes an upper baseplate 10 , a lower baseplate 12 , a ball 14 and a cover 16 . Upper baseplate 10 is provided with a top surface 20 and a bottom surface 22 . Disposed within the boundary of top surface 20 is a recess 24 . Recess 24 includes a circular skirt 26 positioned adjacent top surface 20 and defining the outer boundary of recess 24 . Recess 24 further includes a shoulder 28 defining a lower limit of the recess. An aperture 30 is disposed adjacent shoulder 28 and extends from the shoulder to bottom surface 22 of upper baseplate 10 .
As best shown in FIG. 2 aperture 30 is defined by circumferential wall 32 which extends adjacent and between shoulder 28 and bottom surface 22 . Also as shown in FIG. 2 , upper baseplate 10 includes a strap 34 . Strap 34 preferably includes a substantially semispherical inner surface 36 and a substantial semispherical outer surface 38 . Inner surface 36 and outer surface 38 are attached to one another through edges 40 and 40 ′ extending between the two surfaces and defining remote sides of strap 34 . Inner surface 36 and outer surface 38 have ends remote from one another and preferably include a first chamfered end 42 and a second chamfered end 44 . Chamfered ends 42 , 44 extend from bottom surface 22 of upper baseplate 10 downward toward lower baseplate 12 and connect strap 34 to upper baseplate 10 . Strap 34 may be integral with upper baseplate 10 . As will be described below, aperture 30 as well as semispherical inner surface 36 of strap 34 preferably have a radius which is at least slightly larger than the radius of ball 14 .
As illustrated in FIGS. 1 and 2 , lower baseplate 12 preferably includes a top surface 50 and a bottom surface 52 . Top surface 50 preferably includes a cavity 54 exposed near a central portion of lower baseplate 12 . Cavity 54 preferably includes a groove 56 and a pair of indents 58 , 59 disposed on opposite sidewalls 60 , 61 positioned about groove 56 . Groove 56 preferably has a generally semicircular shape—when viewing from the direction X—with opposite sidewalls 60 , 61 positioned adjacent to indents 58 , 59 , respectively, and extending in the Y direction. Groove 56 is preferably larger in size than strap 34 , so that when the artificial intervertebral disc 1 is assembled and the strap is disposed within the bounds of groove 56 , as will be described below, strap 34 does not touch the bottom or sidewalls 60 , 61 of groove 56 . Although groove 56 is shown as having a semicircular shape—viewed from the direction X—the shape of groove 56 is not essential to the present invention so long as it is large enough such that strap 34 does not touch the bottom of groove 56 when the artificial intervertebral disc 1 is assembled. For clarity of illustration, it is to be understood that, as described below, the sizing and shaping of strap 34 and groove 56 are such that when the ball 14 is secured to lower baseplate 12 , the strap 34 is freely movable about ball 14 in the space between sidewalls 60 , 61 of groove 56 . As previously alluded to, indents 58 , 59 are disposed on opposite sidewalls 60 , 61 respectively and are preferably semispherical in shape to complementarily support ball 14 , as will be described below.
Ball 14 is sized so as to be able to fit within aperture 30 and be supported by strap 34 . In a method of assembly, ball 14 is placed into aperture 30 through recess 24 of top surface 20 .
As best illustrated in FIGS. 1 and 2 , cover 16 preferably includes a top surface 66 and a bottom surface 68 . Cover 16 further includes a circumferential edge 70 extending between top surface 66 and bottom surface 68 . Top surface 66 , bottom surface 68 and edge 70 define a cap portion 72 of cover 16 . Cover 16 further includes a cylindrical post 74 having a circumferential skirt 76 adjacent to and extending down from bottom surface 68 . Post 74 preferably further includes a concave bottom surface 78 , the concavity of which may extend into cap portion 72 of cover 16 . The radius of curvature of concave bottom surface 78 (best shown in FIG. 2 ) is preferably configured to approximate the curvature of ball 14 . In a preferred embodiment, cylindrical post 74 has a diameter that is slightly smaller than the diameter of aperture 30 extending through upper baseplate 10 .
In a method of assembly, ball 14 is placed within aperture 30 so as to be supported by strap 34 of upper baseplate 10 . Subsequently, cover 16 is placed within recess 24 of upper baseplate 10 with cylindrical post 74 preferably being compression-fit or locked within aperture 30 . Additionally, in a preferred embodiment cap portion 72 may also be compression fit to upper baseplate 10 by edge 70 of cover 16 being engaged with skirt 26 of the upper baseplate.
As best shown in FIGS. 4A and 4B , strap 34 preferably has a width extending from edge 40 to edge 40 ′ that is smaller than the width of groove 56 defined by sidewalls 60 and 61 . This configuration allows strap 34 and upper baseplate 10 to rotate around a central point of ball 14 about an axis parallel to axis Z ( FIG. 1 ) (angulational and rotational motion). Such a relative rotation in the transverse plane is limited to some extent by the limited space between sidewalls 60 and 61 of groove 56 and edges 40 and 40 ′ of strap 34 .
In one preferred embodiment, as shown in FIG. 5 , sidewalls 60 and 61 of groove 56 are angled at their respective ends 80 , 81 , 82 , and 83 relative to one another to accommodate desired rotation and angulation ranges and/or limit rotation to within a desired range of angles, without inviting excess wear or line contact endured by edges 40 and 40 ′ of strap 34 against sidewalls 60 and 61 . That is, if sidewalls 60 and 61 were not angled, the edges 40 and 40 ′ will dig into the sidewalls, causing undesirable wear characteristics over multiple articulations of the device; whereas if the sidewalls 60 and 61 are angled to align with the edges 40 and 40 ′ of strap 34 during the maximum desired axial rotation range, edges 40 and 40 ′ will hit flush against sidewalls 60 and 61 , minimizing wear debris and improving the wear characteristics of the device.
Rotation (or articulation) of upper baseplate 10 about an axis perpendicular to axis Z, (lateral bending articulation and flexion-extension articulations) relative to lower baseplate 20 can be limited by the distance between bottom surface 22 of upper baseplate 10 and top surface 50 of lower baseplate 12 . In other words, such articulation will be stopped when the two surfaces 22 and 50 come to meet each other. This distance can be determined by properly designing the size of ball 14 as well as the position (depth) of indents 58 and 59 on sidewalls 60 and 61 , respectively in lower baseplate 20 and the dimensions of groove 56 in the lower baseplate, which will be further described below.
Top surface 20 of upper baseplate 10 and bottom surface 52 of lower baseplate 20 are preferably designed to be convex in shape to match the concave shape of endplates of adjoining vertebral bones. Similarly, the top surface 66 of cover 16 preferably has a convex design and is a smooth extension of top surface 20 of upper baseplate 10 as best shown in FIGS. 1 and 3 .
To assemble the artificial intervertebral disc 1 of the present invention, as previously mentioned, ball 14 is placed through recess 24 of upper baseplate 10 and into aperture 30 so as to be supported by strap 34 . With ball 14 resting on semispherical inner surface 36 of strap 34 , the strap is placed within groove 56 of lower baseplate 12 , with portions 14 A, and 14 B of ball 14 , contacting respective indents 58 and 59 as best illustrated in FIGS. 4A and 4B . Portions 14 A and 14 B of ball 14 are then fixed to respective indents 58 and 59 by, for example, welding or an adhesive, whereby the ball is fixed to lower baseplate 12 , and strap 34 is retained in groove 56 by ball 14 . This also prevents upper baseplate 10 from disengaging from lower baseplate 12 . Cover 16 is next disposed within recess 24 of upper baseplate 10 . Preferably, cover 16 is secured to upper baseplate 10 by a compression lock, threading, an adhesive or the like.
After the assembling is finished, artificial intervertebral disc 1 can be implanted between the adjoining endplates of vertebral bones. Strap 34 and therefore upper baseplate 10 , can articulate and rotate about a center of ball 14 in universal directions relative to lower baseplate 12 . The distance between upper baseplate 10 and lower baseplate 12 limits the articulation about an axis perpendicular to axis Z. Moreover, upper baseplate 10 can move toward and away from (along axis Z) lower baseplate 12 with such a translation being limited by the space between cover 16 and ball 14 as well as the distance between ball 14 and the bottom surface of groove 56 . Angulational and rotation (rotation about an axis perpendicular to the axis Z) are limited by the difference between the width of strap 34 and the width of groove 56 and, preferably, opposing walls 60 and 61 of groove 56 being angled relative to one another to accommodate desired motion ranges, and/or limit motion to within a desired range of angles, without inviting excess wear or line contact of the edges 40 and 40 ′ against the sidewalls 60 and 61 .
Alternatively, although not shown in the drawings, edges 40 and 40 ′ of strap 34 and/or sidewalls 60 and 61 of groove 56 are not necessarily flat, but can be curved (concave/convex) in shape, which may result in a smoother contact between the strap and the groove.
Although the present invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.
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An artificial intervertebral implant including a first baseplate having a top surface, a bottom surface, an aperture extending therethrough and a strap attached to the bottom surface of the first baseplate and underlying the aperture. The implant further includes a second baseplate juxtaposed with the first baseplate. The second baseplate includes a top surface with a cavity exposed therein. An articulating element is attached to a pair of opposing sidewalls of the cavity for retaining the strap within the cavity.
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BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The invention relates generally to the treatment of muscle loss in a mammal, and more particularly, to the administration of one or more branched chain amino acid(s) (BCAA), a BCAA precursor, a BCAA metabolite, a BCAA-rich protein, a protein manipulated to enrich the BCAA content or any combination thereof in the treatment of such muscle loss. The invention further relates to nutritional formulations suitable for such administration.
[0003] 2. Background Art
[0004] Amino acids are the monomeric building blocks of proteins, which in turn comprise a wide range of biological compounds, including enzymes, antibodies, hormones, transport molecules for ions and small molecules, collagen, and muscle tissues. Amino acids are considered hydrophobic or hydrophilic, based upon their solubility in water, and, more particularly, on the polarities of their side chains. Amino acids having polar side chains are hydrophilic, while amino acids having non-polar side chains are hydrophobic. The solubilities of amino acids, in part, determines the structures of proteins. Hydrophilic amino acids tend to make up the surfaces of proteins while hydrophobic amino acids tend to make up the water-insoluble interior portions of proteins.
[0005] Of the common 20 amino acids, nine are considered indispensable (essential) in humans, as the body cannot synthesize them. Rather, these nine amino acids must be obtained through an individual's diet. A deficiency of one or more amino acids can cause a negative nitrogen balance. A negative nitrogen balance, for example, is wherein more nitrogen is excreted than is administered. Such a condition can lead to disruption of enzymatic activity and the loss of muscle mass.
[0006] A number of muscle-wasting conditions have been identified for which treatment with amino acid supplements has proved beneficial. For example, cachexia is a severe body wasting condition characterized by marked weight loss, anorexia, asthenia, and anemia. Cachexia is a common feature of a number of illnesses, such as cancer, sepsis, chronic heart failure, rheumatoid arthritis, and acquired immune deficiency syndrome (AIDS). Other muscle wasting diseases and disorders are known, including, for example, sarcopenia, an age-related loss of muscle mass.
Proteolysis-Inducing Factor (PIF)
[0007] It has been found that certain tumors may induce cachexia through the production of a 24 kDa glycoprotein called proteolysis-inducing factor (PIF). One proposed mechanism of action of PIF is to decrease protein synthesis; another proposed mechanism of PIF is an activation of protein degradation; a third proposed mechanism is a combination of the aforementioned decrease in protein synthesis and activation of protein degradation. It has been hypothesized that the decreased protein synthesis associated with PIF is the result of PIF's ability to block the translation process of protein synthesis. Another factor, Angiotensin II (Ang II) has shown similar effects and may be involved in the muscle wasting observed in some cases of cachexia.
[0008] The original role of PIF in the ubiquitin-proteosome pathway is known. PIF produces an increased release of arachadonic acid, which is then metabolized to prostaglandins and 15-hydroxyeicosatetraenoic acid (15-HETE). 15-HETE has been shown to produce a significant increase in protein degradation and nuclear binding of the transcription factor NF-κB (a nuclear factor that binds the kappa immunoglobulin light chain gene enhancer in B cells).
Regulation of Protein Synthesis Via Translation Initiation
[0009] The role of PIF in the inhibition of protein synthesis is hypothesized to be due to PIF's theorized ability to block translation via RNA-dependent protein kinase (PKR) activation of downstream factors. Inhibition of protein synthesis by PIF is attenuated by insulin at physiological concentrations and below. This suggests that PIF may inhibit protein synthesis at the initiation stage of translation, since insulin regulates protein synthesis through activation of the messenger RNA (mRNA) binding steps in translation initiation.
[0010] There are two steps in the initiation of translation that are subject to regulation: (1) the binding of initiator methionyl-transfer RNA (met-tRNA) to the 40s ribosomal subunit; and (2) the binding of mRNA to the 43s preinitiation complex.
[0011] In the first step, met-tRNA binds to the 40s ribosomal subunit as a ternary complex with eukaryotic initiation factor 2 (eIF2) and guanosine triphosphate (GTP). Subsequently, the GTP bound to eIF2 is hydrolyzed to guanosine diphosphate (GDP) and eIF2 is released from the ribosomal subunit in a GDP-eIF2 complex. The eIF2 must then exchange the GDP for GTP to participate in another round of initiation. This occurs through the action of another eukaryotic initiation factor, eIF2B, which mediates guanine nucleotide exchange on eIF2. eIF2B is regulated by the phosphorylation of eIF2 on its alpha subunit, which converts it from a substrate into a competitive inhibitor of eIF2B.
[0012] In the second step, the binding of mRNA to the 43s preinitiation complex requires a group of proteins collectively referred to as eIF4F, a multisubunit complex consisting of eIF4A (an RNA helicase), eIF4B (which functions in conjunction with eIF4A to unwind secondary structure in the 5′ untranslated region of the mRNA), eIF4E (which binds the m7GTP cap present at the 5′ end of the mRNA), and eIF4G (which functions as a scaffold for eIF4E, eIF4A, and the mRNA). Collectively, the eIF4F complex serves to recognize, unfold, and guide the mRNA to the 43s preinitiation complex. The availability of the eIF4E for the eIF4F complex formation appears to be regulated by the translational repressor eIF4E-binding protein 1 (4E-BP1). 4E-BP1 competes with eIF4G to bind eIF4E and is able to sequester eIF4E into an inactive complex. The binding of 4E-BP1 is regulated through phosphorylation by the kinase mammalian target of rapamycin (mTOR), where increased phosphorylation causes a decrease in the affinity of 4E-BP1 for eIF4E.
[0013] It is believed that mTOR is activated by phosphorylation and inhibition of the tuberous sclerosis complex (TSC) 1-TSC2 complex via signaling through the phosphatidylinositol 3 kinase (PI3K)/serine/threonine kinase pathway (PI3K/AKT pathway). mTOR also phosphorylates p70S6 kinase, which phosphorylates ribosomal protein S6, which is believed to enhance the translation of mRNA with an uninterrupted string of pyrimidine residues adjacent to the 5′ cap structure. Proteins encoded by such mRNA include ribosomal proteins, translation elongation factors, and poly-A binding proteins.
Anabolic Factors Involved in Translation Initiation
[0014] Many studies have shown that anabolic factors, such as insulin, insulin-like growth factors (IGFs), and amino acids increase protein synthesis and cause muscle hypertrophy. Branched chain amino acids (BCAAs), particularly leucine, can initiate signal transduction pathways that modulate translation initiation. Such pathways often include mTOR. Other studies have demonstrated that mitogenic stimuli, such as insulin and BCAAs, signal via eIF2. As such, amino acid starvation results in an increased phosphorylation of eIF2-α and a decrease in protein synthesis.
Signaling Pathways Involved in Protein Synthesis and Degradation
[0015] As noted above, PIF is known to induce protein degradation via the NF-κB pathway. Therefore, it is plausible that inhibition of protein synthesis by PIF occurs via a common signaling initiation point, which then diverges into two separate pathways, one promoting protein degradation via NF-κB and the other inhibiting protein synthesis through mTOR and/or eIF2.
[0016] AKT is a serine/threonine kinase, also known as protein kinase B (PKB). Activation of AKT occurs through direct binding of the inositol lipid products of the PI3K to its pleckstrin homology domain. PI3K-dependent activation of AKT also occurs through phosphoinositide-dependent kinase (PDK1)-mediated phosphorylation of threonine 308, which leads to autophosphorylation of serine 473. Although initially believed to operate as components of distinct signaling pathways, several studies have demonstrated that the NF-κB and AKT signaling pathways converge. Studies have shown that AKT signaling inhibits apoptosis in a variety of cell types in vitro, mediated by its ability to phosphorylate apoptosis-regulating components, including IκK, the kinase involved in NF-κB activation. Thus, activation of AKT stimulates activation of NF-κB. Although this would place AKT upstream of NF-κB activation in the sequence of signaling events, one study reports that AKT may be a downstream target of NF-κB. Overall, this suggests that AKT is involved in a catabolic pathway. Other data, however, suggest that AKT is also involved in anabolic processes through activation of mTOR and the consequent phosphorylation of p70S6 kinase and 4E-BP1, leading to an increase in protein synthesis.
[0017] PKR is an interferon-induced, RNA-dependent serine/threonine protein kinase responsible for control of an antiviral defense pathway. PKR may be induced by forms of cellular stress other than interferon. Some evidence suggests that tumor necrosis factor (TNF)-alpha also acts through PKR. Interestingly, both interferon and TNF-alpha have been implicated as causative factors of cachectic states. Following interaction with activating stimuli (e.g., insulin, IGF, BCAAs), PKR has been reported to form homodimers and autophosphorylate. As a result, PKR is able to catalyze the phosphorylation of target substrates, the most well-characterised being the phosphorylation of Serine 51 on the eIF2-α subunit. The eIF2 then sequesters eIF2B, a rate-limiting component of translation, resulting in the inhibition of protein synthesis. Recent studies suggest that PKR physically associates with the IκK complex and stimulates NF-κB-inducing kinase (NIK) while phosphorylating IκK, resulting in its subsequent degradation. Some studies suggest that NF-κB is activated by PKR by a mechanism independent from its eIF2 kinase activity, while other studies indicate that the phosphorylation of eIF2-α is required for the activation of NF-κB.
[0018] PKR-like ER-resident kinase (PERK) is another kinase that phosphorylates eIF2-α and activates NF-κB. However, it is unlikely that PIF acts through this pathway, since PERK causes the release of IκK from NF-κB, but not its degradation. In addition, PIF has been shown to cause the degradation of IκK during the activation of NF-κB.
Known Treatments for Muscle Loss
[0019] Treatment of conditions such as cachexia often includes nutritional supplementation, and, in particular, amino acid supplementation, in an attempt to increase protein synthesis. The three BCAAs are valine, leucine, and isoleucine. Previously, leucine has been shown to function, not only as a protein building block, but also as an inducer of signal transduction pathways that modulate translation initiation. Our recent novel research suggests that all three of the BCAAs possess the ability to reduce protein degradation and enhance protein translation comparably.
[0020] Cachexia is just one of the conditions, disorders, and diseases for which amino acid supplementation has proved beneficial. Amino acid supplementation has also been used to treat diabetes, hypertension, high levels of serum cholesterol and triglycerides, Parkinson's disease, insomnia, drug and alcohol addiction, pain, insomnia, and hypoglycemia. Supplementation with BCAAs, in particular, has been used to treat liver disorders, including compromised liver function, including cirrhosis, gall bladder disorders, chorea and dyskinesia, and kidney disorders, including uremia. BCAA supplementation has also proved successful in the treatment of patients undergoing hemodialysis, resulting in improvements in overall health and mood.
[0021] To date, the treatment of muscle loss, including treatments involving nutritional supplementation with amino acids, has focused on the promotion of muscle anabolism. For example, U.S. Patent Application Publication No. 2004/0122097 to Verlaan et al. describes nutritional supplements containing both leucine and protein for promoting the generation of muscle tissue. Leucine precursors, such as pyruvate, and metabolites, such as β-hydroxy-β-methylbutyrate and α-ketoisocaproate, exhibit properties similar to those of leucine. Of note, β-hydroxy-β-methylbutyrate is not produced by humans in any clinically relevant quantities and therefore must be supplemented.
[0022] Others have shown that insulin, an anabolic hormone, is capable of promoting protein synthesis when administered in large doses. Thus, known treatment approaches, while providing some benefit to individuals suffering from muscle loss through increased generation of muscle tissue, do not affect muscle loss itself. That is, known methods of treating muscle loss are directed toward increasing muscle anabolism rather than decreasing muscle catabolism.
[0023] The amino acids that comprise skeletal muscle are in a constant state of flux where new amino acids, either coming from administration by enteral or parenteral routes or recirculated, are deposited as protein and current proteins are degraded. Loss of muscle mass can be the result of many factors including decreased rate of protein synthesis with normal degradation, increased degradation with normal synthesis or an exacerbation of both reduced synthesis and increased degradation. As a result, therapies aimed at increasing synthesis only address one-half of the problem in muscle wasting disease(s).
[0024] Accordingly, there is a need in the art for a method of treating muscle loss that decreases muscle catabolism and, optionally, increases muscle anabolism.
SUMMARY OF THE INVENTION
[0025] The invention provides methods for treating muscle loss in an individual. In one embodiment, the invention includes administering to an individual an effective amount of a branched chain amino acid (BCAA), a BCAA precursor, a BCAA metabolite, BCAA-rich protein, protein manipulated to enrich the BCAA content, or any combination thereof. The invention further provides nutritional products for such administration, including orally-administrable nutritional products.
[0026] In a first aspect, the invention provides a method of treating muscle loss in an individual, the method comprising: administering to the individual an effective amount of at least one of: a branched chain amino acid (BCAA); a BCAA precursor; and a BCAA metabolite, a BCAA-rich protein, a protein manipulated to enrich the BCAA content, wherein at least one of the BCAA, BCAA precursor, BCAA metabolite, BCAA-rich protein, and protein manipulated to enrich the BCAA content antagonizes protein catabolism.
[0027] In a second aspect, the invention provides an orally-administrable nutritional product comprising at least one of the following: a branched chain amino acid (BCAA); a BCAA precursor, a BCAA metabolite, a BCAA-rich protein, a protein manipulated to enrich the BCAA content, wherein at least one of the BCAA, BCAA precursor, BCAA metabolite, BCAA-rich protein, and protein manipulated to enrich the BCAA content antagonizes protein catabolism.
[0028] The illustrative aspects of the present invention are designed to solve the problems herein described and other problems not discussed, which are discoverable by a skilled artisan.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] These and other features of this invention will be more readily understood from the following detailed description of the various aspects of the invention taken in conjunction with the accompanying drawings that depict various embodiments of the invention, in which:
[0030] FIG. 1 shows a graph of the depression of protein synthesis by proteolysis inducing factor (PIF) at various concentrations.
[0031] FIG. 2 shows a graph of the effect of amino acids on the phosphorylation of eIF2-α and PIF.
[0032] FIG. 3 shows a graph of the effect of insulin and insulin-like growth factor 1 (IGF) on the phosphorylation of eIF2-α of PIF.
[0033] FIG. 4 shows the structure of an RNA-dependent protein kinase (PKR) inhibitor suitable for use in the present invention.
[0034] FIG. 5 shows a graph of the effect of the PKR inhibitor of FIG. 4 on the proteolytic activity of PIF.
[0035] FIG. 6 shows a graph of the effect of the PKR inhibitor of FIG. 4 in reversing a PIF-mediated reduction in protein synthesis.
[0036] FIG. 7 shows a graph of the effect of the PKR inhibitor of FIG. 4 on the proteolytic activity of Angiotensin II.
[0037] FIG. 8 shows a graph of the effect of the PKR inhibitor of FIG. 4 in reversing an Angiotensin II-mediated reduction in protein synthesis.
[0038] FIG. 9 shows an alternative mechanism of protein degradation caused by proteolysis inducing factor (PIF) and inhibited by branch chain amino acids, insulin and IGF-1.
[0039] FIG. 10 shows a further alternative mechanism of protein degradation caused by proteolysis inducing factor (PIF) through activation of PKR and eIF2α that is inhibited by branch chain amino acids, insulin and IGF-1.
[0040] It is noted that the drawings of the invention are not to scale. The drawings are intended to depict only typical aspects of the invention, and therefore should not be considered as limiting the scope of the invention.
DETAILED DESCRIPTION
[0041] As indicated above, the invention provides methods and related products for the treatment of muscle loss in an individual. More specifically, the methods and products of the invention reduce muscle catabolism, particularly proteolysis-inducing factor (PIF)-mediated muscle catabolism.
[0042] As used herein, the terms “treatment” and “treat” refer to both prophylactic or preventive treatment and curative or disease-modifying treatment, including treatment of patients at risk of contracting a disease or suspected to have contracted a disease, as well as patients who are ill or have been diagnosed as suffering from a disease or medical condition. The terms “treatment” and “treat” also refer to the maintenance and/or promotion of health in an individual not suffering from a disease but who may be susceptible to the development of an unhealthy condition, such as nitrogen imbalance or muscle loss. Consequently, an “effective amount” is an amount that treats a disease or medical condition in an individual or, more generally, provides a nutritional, physiological, or medical benefit to the individual. A treatment can be patient- or doctor-related. In addition, while the terms “individual” and “patient” are often used herein to refer to a human, the invention is not so limited. Accordingly, the terms “individual” and “patient” refer to any mammal suffering from or at risk for a medical condition, such as muscle loss.
Experimental Data
[0043] In order to determine the efficacy of branched chain amino acids (BCAAs) and other agents in reducing muscle catabolism, murine C 2 C 12 myotubes were exposed to PIF or Angiotensin II in combination with amino acids (including BCAAs), insulin, insulin-like growth factor-1 (IGF-1), and a PKR inhibitor. PIF was extracted and purified from MAC16 tumors as described by Smith et al., Effect of a Cancer Cachectic Factor on Protein Synthesis/Degradation in Murine C 2C12 Myoblasts: Modulation by Eicosapentaenoic Acid , Cancer Research, 59:5507-13 (1999), which is hereby incorporated by reference. Protein degradation was determined using the method described by Whitehouse et al., Increased Expression of the Ubiquitin - Proteasome Pathway in Murine Myotubes by Proteolysis - Inducing Factor ( PIF ) is Associated with Activation of the Transcription Factor NF -κ B , British Journal of Cancer, 89:1116-22 (2003), which is also hereby incorporated by reference.
[0044] FIG. 1 shows a graph of the depression of protein synthesis of PIF at increasing concentrations, measured in counts per minute (CPM) as a percentage of a control containing no PIF. A significant reduction in protein synthesis is noted, with a maximum depression of protein synthesis occurring at a PIF concentration of 4.2 nM. The measured proteolytic activity of PIF can be more specifically described as ubiquitin-like degradation activity.
[0045] FIG. 2 shows a graph of the densitometric analysis of Western blots of phosphorylated eIF2-α in C 2 C 12 myotubes incubated with PIF, leucine, isoleucine, valine, methionine, and arginine, both alone and in combination with PIF. The control sample was incubated only in phosphate buffered saline (PBS). As can be seen in FIG. 2 , PIF increases phosphorylation of eIF2-α significantly, compared to the control. Each of the amino acids reduced eIF2-α phosphorylation in the presence of PIF, compared to PIF alone. However, the BCAAs (i.e., leucine, isoleucine, and valine) reduced such phosphorylation to about the level of the control or below, while methionine- and arginine-induced phosphorylation levels were greater than that of the control. Surprisingly, unlike known treatment methods directed toward increasing protein synthesis, and where leucine exhibits greater efficacy than the other BCAAs, these data show that all BCAAs are about equally effective in reducing PIF-induced phosphorylation of eIF2-α. In fact, the phosphorylation levels resulting from isoleucine and valine incubation were not different from that observed with leucine incubation.
[0046] FIG. 3 shows the results of similar experiments involving the incubation of insulin and IGF-1, alone and in combination with PIF. Both insulin and IGF-1 significantly reduced eIF2-α phosphorylation in the presence of PIF, compared to PIF alone. Thus, the ability of BCAAs to decrease PIF-mediated protein degradation may be supplemented or enhanced by the addition of insulin and/or IGF-1 or by treatments that increase the level of insulin and/or IGF-1.
[0047] FIG. 4 shows the structure of a PKR inhibitor useful in both decreasing PIF-induced protein degradation and increasing protein synthesis which was used as a positive control of PKR inhibition. FIGS. 5-8 show the results of experiments involving the incubation of the PKR inhibitor in combination with either PIF or Angiotensin II. In FIG. 5 , it can be seen that while PIF increased protein degradation up to 87% when incubated alone, the addition of the PKR inhibitor reversed protein degradation levels back to about those of the control. Similarly, in FIG. 6 , it can be seen that while PIF reduced protein synthesis up to about 25% when incubated alone, the addition of the PKR inhibitor reversed protein synthesis levels back to about those of the control.
[0048] FIGS. 7 and 8 show similar results upon the incubation of the PKR inhibitor with Angiotensin II. In FIG. 7 , Angiotensin increased protein degradation up to about 51%, compared to the control. The addition of the PKR inhibitor reversed this trend, maintaining protein degradation levels at about that of the control. Similarly, in FIG. 8 , Angiotensin II reduced protein synthesis by about 40% compared to the control, while the addition of the PKR inhibitor maintained protein synthesis levels at about that of the control.
[0049] The PKR inhibitor attenuated the actions of PIF and Angiotensin II in both protein degradation and protein synthesis. This suggests that both PIF and Angiotensin II mediate their effects through similar mechanisms and through a common mediator, likely involving PKR. More specifically, these results suggest that PIF activates PKR, which in turn causes phosphorylation of eIF2-α, inhibiting the binding of initiator methionyl-tRNA (met-tRNA) to the 40s ribosomal subunit. BCAAs, insulin, and IGF-1 attenuated the phosphorylation of eIF2-α caused by PIF, further supporting the hypothesis that PIF upregulates phosphorylation of eIF2-α to inhibit protein synthesis. Since PKR can inhibit protein synthesis and activate NF-κB, which leads to protein degradation, PKR is likely an early component in the signaling pathway of PIF.
[0050] There is also evidence that PKR is involved in the regulation of 4E-BP1 phosphorylation. Thus, if PIF does signal through PKR, it is likely that it can also reduce protein synthesis through PKR-mediated activation of the serine/threonine phosphatase PP2A, which can bring about the dephosphorylation of 4E-BP1, which in turn sequesters eIF4E into an inactive complex, preventing the formation of the 43s pre-initiation complex.
[0051] FIG. 9 shows an alternative mechanism. Both proteolysis inducing factor (PIF) and angiotensin II (Ang II) decrease protein synthesis by 40%, and the concentrations of both agents that are maximally effective in the depression of protein synthesis are the same as those that are maximally effective in the induction of protein degradation. The results suggest that both insulin and IGF1, at least partly, attenuate the protein degradation induced by PIF through inhibition of PKR and/or eIF2α phosphorylation. The mechanism of activation by PIF and Ang II may be through PACT (protein activator of interferon-induced protein kinase), a cellular protein activator of PKR, although PIF is also a polyanionic molecule, and thus may activate directly. Regardless, phosphorylation of eIF2α by PIF and Ang II seems to occur through PKR, since a PKR inhibitor attenuated the inhibitory effect of both agents on protein synthesis. The effect of both PIF and Ang II on protein translation appears to arise from an increased phosphorylation of eIF2α.
[0052] The inhibition of protein synthesis in apoptosis by tumor necrosis factor-α (TNF-α) is also associated with increased phosphorylation of eIF2α. Further support for the role of eIF2α phosphorylation in the inhibition of protein synthesis by PIF and Ang II is provided by the observation that both insulin and IGF1, which were effective in suppressing the inhibition of protein synthesis, completely attenuated the induction of eIF2α phosphorylation. Data collected suggests that the BCAAs also work through the same mechanism to inhibit the degradation pathway initiated by PIF. This study provides the first evidence of a relationship between the depression of protein synthesis in skeletal muscle by PIF (and Ang II), through activation of PKR, and eIF2α phosphorylation, and the enhanced degradation of the myofibrillar protein myosin, through activation of NF-κB resulting in an increased expression and activity of the ubiquitin-proteasome proteolytic pathway. This suggests that agents which target PKR (e.g., BCAAs) may be effective in the treatment of muscle atrophy in cancer cachexia.
[0053] FIG. 10 shows a further alternative mechanism. As previously stated, both proteolysis inducing factor (PIF) and angiotensin II (Ang II) increase protein degradation through phosphorylation of PKR and/or eIF2α. NF-κB may be activated by PIF or a downstream mediator of PIF (PKR and/or eIF2α) which occurs through the release of NF-κB. In this further alternative mechanism, NF-κB is not part of the same phosphorylation cascade despite having the same target to promote ubiquitin-tagging of proteins to be degraded.
[0054] Together, the data above support a number of novel aspects of the present invention. First, BCAAs may be employed to treat muscle loss in an individual by antagonizing protein catabolism mediated by PIF and/or Angiotensin II through inhibiting the activation of PKR and/or eIF2α. Second, each of the BCAAs is equally effective in such antagonization. Third, the co-administration of insulin, IGF-1, and/or a PKR inhibitor, or the use of treatments to increase level of either or both of insulin and IGF-1, may increase the efficacy of BCAA treatments by further antagonizing protein catabolism, enhancing protein synthesis, or both.
[0055] Nutritional products according to the invention may, therefore, include BCAAs, alone or in combination with insulin, IGF-1, and/or a PKR inhibitor. BCAAs may be administered in their free forms, as dipeptides, as tripeptides, as polypeptides, as BCAA-rich protein, and/or as protein manipulated to enrich the BCAA content. Dipeptides, tripeptides and polypeptides may include two or more BCAAs. Where non-BCAAs are included in a dipeptide, tripeptide, or polypeptide preferred amino acids include alanine and glycine, but non-BCAAs may be any of the dispensable or indispensable (essential or non-essential) amino acids. For example, preferred dipeptides include, but are not limited to, alanyl-leucine, alanyl-isoleucine, alanyl-valine, glycyl-leucine, glycyl-isoleucine, and glycyl-valine.
[0056] Nutritional products according to the invention may similarly include precursors and/or metabolites of BCAAs, particularly precursors and/or metabolites of leucine, in addition to or in place of BCAAs. Such products may further include any number of additional ingredients, including, for example, a protein, a fiber, a fatty acid, a vitamin, a mineral, a sugar, a carbohydrate, a flavor agent, a medicament, and a therapeutic agent.
[0057] The nutritional products of the present invention may be administered orally, via a feeding tube, or parenterally. Such products may be used in the treatment of an individual suffering from any number of muscle wasting diseases, disorders, or conditions, or any disease, disorder, or condition with which muscle loss is associated, including, for example, cachexia, cancer, tumor-induced weight loss, sepsis, chronic heart failure, rheumatoid arthritis, acquired immune deficiency syndrome (AIDS), sarcopenia, diabetes, hypertension, high levels of serum cholesterol, high levels of triglycerides, Parkinson's disease, insomnia, drug addiction, alcohol addiction, pain, insomnia, hypoglycemia, compromised liver function, including cirrhosis, gall bladder disorders, chorea, dyskinesia, and a kidney disorder, including uremia.
[0058] The foregoing description of various aspects of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously, many modifications and variations are possible. Such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of the invention as defined by the accompanying claims.
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The invention provides methods for treating muscle loss in an individual. In one embodiment, the invention includes administering to an individual an effective amount of a branched chain amino acid (BCAA), a BCAA precursor, a BCAA metabolite, a BCAA-rich protein, a protein manipulated to enrich the BCAA content or any combination thereof. The invention further provides nutritional products for such administration, including orally-administrable nutritional products
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority of European Patent Application No. EP07005675.9 filed Mar. 20, 2007.
FIELD OF THE INVENTION
The invention relates to a method of operating a hybrid drive system and to a hybrid drive system with a main driving machine, more particularly an internal combustion engine, and a supplementary driving machine, more particularly an electric machine, for a motor vehicle. Other types of driving machines are not excluded. For example, it is possible to provide two electric machines as the main driving machine and the supplementary driving machine or, in addition to an internal combustion engine as the main driving machine, a hydraulic machine as the supplementary driving machine.
BACKGROUND OF THE INVENTION
Vehicles with a hybrid drive system in the different embodiments have, in certain driving cycles, a more advantageous exhaust gas behaviour than vehicles which are driven entirely by an internal combustion engine. They therefore become more and more important on the market.
If an electric machine is used as the supplementary driving machine, it can be used as an engine and a generator. As far as the engine function is concerned, wherein it is necessary to provide a battery for power supply purposes, it is possible to use it to start an internal combustion engine or to use it as a driving motor. When used as a generator, the electric machine is used for charging the battery, wherein the energy is obtained from the internal combustion engine or from the recovery of the kinetic vehicle energy.
Hybrid drive systems are described for example in WO 2005/073005 A1, DE 100 49 514 A1 and DE 198 18 108 A1.
From DE 199 60 621 A1 there is known a hybrid drive for vehicles with a manual gearbox which comprises a first switchable partial drive which, optionally, can be connected in respect of drive to an internal combustion engine and/or an electric machine, as well as a second switchable partial drive which, in respect of drive, can be connected to the electric machine which can be operated as an electric motor or a generator. The first partial drive comprises a first lay-shaft and an output shaft as well as six transmission stages; the second partial drive comprises a second lay-shaft and the same output shaft and comprises three transmission stages.
SUMMARY OF THE INVENTION
It is therefore the object of the present invention to provide a method of operating a hybrid drive system which allows a simplified design, as well as a hybrid drive system which is characterised by a simplified design relative to the number of available transmission stages. More particularly it is desirable to provide a compact design for transverse installation in motor vehicles.
The objective is achieved by providing a method of operating a hybrid drive system with a main driving machine—more particularly an internal combustion engine—and a supplementary driving machine—more particularly an electric machine—for a motor vehicle, comprising
a first gear changing partial drive with an input shaft and an output shaft and a first group of gear changing pairs of gearwheels each having a gearwheel connected in a rotationally fast way to its shaft and a switching gearwheel which can be switcbably coupled to its shaft and whose input shaft can be coupled to the main driving machine;
a second gear changing partial drive with an input shaft and an output shaft and a second group of gear changing pairs of gearwheels each having a gearwheel connected in a rotationally fast way to its shaft and a switching gearwheel which can be switchably coupled to its shaft and whose input shaft can be connected in respect of drive to the supplementary driving machine;
wherein the two input shafts can be connected to one another in a rotationally fast way via a coupling unit, wherein, during operation by means of the main driving machine only, there is effected a gear change between two gears adjoining one another in the gear changing sequence, by changing the torque flow from one gear changing partial drive to the other gear changing partial drive.
Furthermore it is proposed according to a preferred embodiment that, during operation by means of the supplementary driving machine only there is effected a gear change between two gears adjoining one another in the gear changing sequence, by changing the torque flow from one gear changing partial drive to the other gear changing partial drive. In this way it is possible to reduce the number of gear changing pairs of gearwheels in both gear changing partial drives, combined, to the number of required gears.
Furthermore, the objective is achieved by providing a hybrid drive system with a main driving machine—more particularly an internal combustion engine—and a supplementary driving machine—more particularly an electric machine—for a motor vehicle, comprising
a first gear changing partial drive with an input shaft and an output shaft and a first group of gear changing pairs of gearwheels each having a gearwheel connected in a rotationally fast way to its shaft and a switching gearwheel which can be switchably coupled to its shaft and whose input shaft can be coupled to the main driving machine;
a second gear changing partial drive with an input shaft and an output shaft and a second group of gear changing pairs of gearwheels each having a gearwheel connected in a rotationally fast way to its shaft and a switching gearwheel which can be switchably coupled to its shaft and whose input shaft is connectable in respect of drive to the supplementary driving machine;
wherein the pairs of gear changing gearwheels, in the gear changing sequence, are alternately associated with one of the gear changing partial drives and wherein the two input shafts can be connected to one another in a rotationally fast way via a coupling unit.
The essential part of the solution consists in providing the drive in the form of two partial drives whose gear stages are distributed so as to alternate, i.e. the first, the third and the fifth gear are associated with the partial drive which is connectable to the main driving machine, i.e. the internal combustion engine, and the second, the fourth and the sixth gear are associated with the partial drive which is firmly connected to the supplementary driving machine, i.e. the electric machine.
The first gear is thus available for starting by means of the internal combustion engine and for starting electrically, there is available the first gear or the second gear. If the two input shafts are firmly connected to one another, it is possible to use gears one to six, and optionally, a reverse gear when using the internal combustion engine. In such a case, in gears one, three and five, the electric machine can remain disconnected from the drive and in gears two, four and six, the electric machine can remain torque-free. Furthermore, if the two input shafts are firmly coupled, when operating with the electric motor, it is possible to use gears one to six for gear changing purposes, while the internal combustion engine is disconnected by the friction coupling. When the input shafts are disconnected, gears two, four and six are available for driving the vehicle by the electric motor only. By coupling the two input shafts (gears two, four and six) and, respectively, by disconnecting the two input shafts (gears one, three and five) a boost operation is possible in all gears, i.e. operation by internal combustion engine with an additional electric drive.
By selecting an appropriate sequence of opening and closing the friction coupling of the internal combustion engine and the coupling unit between the two input shafts, followed by a suitably adapted sequence of operating the switching units for the different gears, a traction-force-interruption-free method of switching between the gears is possible. Prior to switching the coupling unit, it is advisable to synchronise the speeds of the input shafts. A decisive feature of this kind of operation is that with the inventive drive assembly, the element to be switched (manual clutch, switching unit) can always be disconnected, while at least one drive, either the electric machine or the internal combustion engine remains in a torque transmitting connection with the drive output, i.e. with an output gearwheel. During the switching process, the speeds of the elements to be switched can be adapted by controlling the electric machine and the internal combustion engine, so that at least said coupling unit for connecting the two input shafts can be provided in the form of a simple switching coupling (synchronising unit). The friction coupling of the internal combustion engine permits a slipping connection of the internal combustion engine, such as it is common practice.
Due to the inventive arrangement of the electric machine and the internal combustion engine, torque will be added up when both machines are operated. As will be explained below, it is possible to use the electric motor for starting purposes and to operate it as a generator in a recuperation mode.
The drive system is designed in such a way that under full load conditions and under permanent load conditions, only the internal combustion engine is used. However, the desired functions of a hybrid drive have been put into effect at low cost and without any limitations.
According to an advantageous first embodiment which permits a radial compact design it is proposed that both input shafts are arranged coaxially, especially in-line with one another, and are connectable to one another by a coaxially arranged coupling unit. More particularly, it is proposed that the two output shafts are in-line with one another and integrally connected to one another.
According to a second design embodiment which permits a short length for a transverse installation in the motor vehicle it is proposed that the two input shafts are arranged parallel to one another and that the coupling unit is arranged coaxially on one of the input shafts and acts on a switching gear wheel which is arranged on said input shaft and which forms a pair of gearwheels with a gearwheel firmly arranged on the other input shaft. Furthermore, it is proposed that the two output shafts are arranged so as to extend parallel to their input shaft and are each coupled by fixed gears to an individual output gear.
According to a third design embodiment which permits a short length for a transverse installation in the motor vehicle too it is proposed that the two input shafts are arranged parallel to one another and that the coupling unit is arranged coaxially on one of the input shafts and acts on a switching gear wheel which is arranged on said input shaft and which forms a geartrain with a gearwheel firmly arranged on the other input shaft. This geartrain especially can comprise an intermediate gearwheel being firmly connected to the supplementary driving machine. Furthermore, it is proposed that the two output shafts form one integral shaft member.
Further advantageous embodiments are described in the sub-claims to the contents of which reference is hereby made.
BRIEF DESCRIPTION OF THE DRAWINGS
The different operating conditions which, above, were indicated only, are described in greater detail in the following description of the drawings.
Three preferred embodiments of the invention are illustrated in the drawings and will be described below.
FIG. 1 shows the drive concept of an inventive hybrid drive system in a first embodiment in a three-shaft-design in a neutral position.
FIG. 2 shows the drive concept according to FIG. 1 when starting and driving the motor vehicle, using the electric machine EM.
FIG. 3 shows the drive concept according to FIG. 1 when starting the internal combustion engine CE by the electric machine EM in the stationary condition of the vehicle.
FIG. 4 shows the drive concept according to FIG. 1 when starting the internal combustion engine CE by the electric motor EM while the vehicle is driven electrically.
FIG. 5 a shows the drive concept according to FIG. 1 when changing up from the second gear to the third gear during a first phase and during the boost mode.
FIG. 5 b shows the drive concept according to FIG. 1 when changing up from the second gear to the third gear during a second phase.
FIG. 5 c shows the drive concept according to FIG. 1 when changing up from the second gear to the third gear during a third phase.
FIG. 5 d shows the drive concept according to FIG. 1 when changing up from the second gear to the third gear during a fourth phase.
FIG. 6 a shows the drive concept according to FIG. 1 when changing down from the third gear to the second gear during a first phase.
FIG. 6 b shows the drive concept according to FIG. 1 when changing down from the third gear to the second gear during a second phase.
FIG. 6 c shows the drive concept according to FIG. 1 when changing down from the third gear to the second gear during a third phase.
FIG. 6 d shows the drive concept according to FIG. 1 when changing down from the third gear to the second gear in a fourth phase and in the boost mode.
FIG. 7 a shows the drive concept according to FIG. 1 in the recuperation mode (second, fourth or sixth gear).
FIG. 7 b shows the drive concept according to FIG. 1 in the recuperation mode (first, third or fifth gear).
FIG. 8 shows the drive concept according to FIG. 1 when the vehicle is the stationary condition and driving a compressor.
FIG. 9 shows the drive concept of an inventive hybrid drive system in a second embodiment in a four-shaft-design in a neutral position.
FIG. 10 shows the drive concept according to FIG. 9 when starting and driving with the electric machine EM.
FIG. 11 shows the drive concept according to FIG. 9 when starting the internal combustion engine CE by the electric machine EM with the vehicle driving.
FIG. 12 shows the drive concept according to FIG. 9 when starting the internal combustion engine CE by the electric machine EM in the stationary condition of the vehicle.
FIG. 13 a shows the drive concept according to FIG. 9 a when changing up from the fourth gear to the fifth gear during a first phase.
FIG. 13 b shows the drive concept according to FIG. 9 when changing up from the fourth gear to the fifth gear during a second phase.
FIG. 13 c shows the drive concept according to FIG. 9 when changing up from the fourth gear to the fifth gear in a third phase.
FIG. 14 a shows the drive concept according to FIG. 9 in the boost mode (internal combustion engine CE in the first, the third or the fifth gear).
FIG. 14 b shows the drive concept according to FIG. 9 in the boost mode (internal combustion engine CE in the second, the fourth or the sixth gear).
FIG. 15 shows the drive concept according to FIG. 9 in the recuperation mode.
FIG. 16 shows the drive concept according to FIG. 9 in the stationary condition of the vehicle when driving a compressor.
FIG. 17 shows the drive concept of an inventive hybrid drive system in a third embodiment in a three-shaft-design in a neutral position.
FIG. 18 shows the drive concept according to FIG. 17 when starting and driving the motor vehicle, using the electric machine EM.
FIG. 19 shows the drive concept according to FIG. 17 when starting the internal combustion engine CE by the electric motor EM while the vehicle is driven electrically.
FIG. 20 shows the drive concept according to FIG. 17 when driving with the internal combustion engine CE.
FIG. 21 shows the drive concept according to FIG. 17 in the boost mode (internal combustion engine CE in the first, the third or the fifth gear).
FIG. 22 a shows the drive concept according to FIG. 17 when changing up from the second gear to the third gear during a first phase.
FIG. 22 b shows the drive concept according to FIG. 17 when changing up from the second gear to the third gear during a second phase.
FIG. 22 c shows the drive concept according to FIG. 17 when changing up from the second gear to the third gear during a third phase.
FIG. 22 d shows the drive concept according to FIG. 17 when changing up from the second gear to the third gear during a fourth phase.
FIG. 23 shows the drive concept according to FIG. 17 in the recuperation mode (first, third or fifth gear).
FIG. 24 shows the drive concept according to FIG. 17 when the vehicle is the stationary condition and driving a compressor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an inventive hybrid drive system in a first embodiment. The subsequent description of FIG. 1 , in principle, also applies to FIGS. 2 to 8 which merely show different switching conditions of the drive concept.
There is shown a hybrid drive system which comprises a main driving machine 11 , here in the form of an internal combustion engine CE, a supplementary driving machine 12 , here in the form of an electric machine EM, and an auxiliary driven machine 13 , here in the form of a compressor for an air conditioning system A/C. The internal combustion engine 11 is connectable by a friction clutch 14 (Cl) which can be provided in the form of a wet or dry clutch. The drive comprises two gear changing partial drives 15 , 16 (stepped gear changing boxes) which are characterised in that they each comprise their own input shafts 17 and 18 . The input shaft 17 of the first partial drive carries the gearwheels of gears 1 , 3 and 5 and is connectable by the friction clutch 14 to the internal combustion engine 11 . The input shaft 18 of the second partial drive 16 carries the gearwheels of gears 2 , 4 and 6 as well as an input gearwheel 19 which, by means of a gearwheel 20 , is in a stepped down driving connection with the electric machine 12 and, by means of a gearwheel 21 , with the air conditioning compressor 13 . In this embodiment, the output shafts 23 , 24 of the two partial drives 15 , 16 are firmly connected to one another; more particularly, they are provided in the form of a one-piece shaft. The switching gearwheels of the individual gears are positioned on the output shaft 23 , 24 , and there is provided a common switching unit 25 for gears 3 and 5 and a further common switching unit 26 for gears 1 and 6 , as well as a switching unit 27 for gears 2 and 4 . This concept does not include a reverse gear. Reversing can take place by reversing the direction of rotation of the electric machine 12 . In addition, by using a reversing gearwheel on an intermediate shaft and a further switching unit, it is also possible to reverse the vehicle in the usual way when it is operated by the internal combustion engine 11 . The output shaft 23 , 24 acts via a gearwheel 22 on an output gearwheel 28 of the drive, from which output can be taken. Between the input shafts 17 , 18 , in accordance with the invention, there is arranged a coupling unit CU which, more particularly if the speeds of the two input shafts are synchronised, can be switched so as to be suitable for various operating conditions which will be described below with reference to further figures.
The fixed gearwheels of gears 1 to 6 which are arranged in a rotationally fast way on the input shafts 17 , 18 have been given in the gear sequence the reference numbers 41 , 42 , 43 , 44 , 45 , 46 , and the respective switching gearwheels which are loose gearwheels suitable for being coupled to the output shafts 23 , 24 , have been given in the gear sequence the reference numbers 51 , 52 , 53 , 54 , 55 each in FIG. 1 only. The fixed gearwheels and the loose gearwheels could also be interchanged between the input and output shafts.
In FIG. 2 , the coupling unit 29 is disengaged, so that the input shafts 17 , 18 are separated from one another. Of the drive gears, only the second gear is engaged by the switching unit 27 . In this switched condition, electric starting the vehicle—depending on the direction of rotation for forward driving or reversing—can be effected by the electric machine, with driving the vehicle also being possible with the electric machine. It is conceivable to change up into the fourth or sixth gear, in which case the traction force would be interrupted. A darker line indicates the torque flow from the electric machine 12 to the output gearwheel 28 .
The following switched conditions apply:
torque from EM clutch Cl open coupling CU disengaged second gear engaged.
FIG. 3 shows the electric machine 12 in the starter function for the internal combustion engine. For this purpose, the coupling unit 29 is engaged and the function clutch 14 is closed. All gears are disengaged by the switching units 25 , 26 , 27 . A darker line shows the torque flow from the electric machine 12 to the internal combustion engine.
The following switched conditions apply:
torque flow from the electric machine EM coupling unit CU engaged clutch Cl closed starting of the internal combustion engine CE.
FIG. 4 shows the internal combustion engine 11 being started by the electric machine during electric driving of the vehicle. The second gear is engaged by the switching unit 27 , so that torque flows from the electric machine 12 via the pair of gearwheels of the second gear to the output gearwheel 28 of the drive, whereas at the same time the coupling unit 29 is engaged and the friction clutch 14 is closed in order to start the internal combustion engine 11 in the torque flow via the two input shafts 18 , 17 and the friction clutch 14 . Dark lines show the torque flow from the electric machine 12 to the internal combustion engine 11 and to the output gearwheel 28 .
The following switched conditions apply:
torque from the electric machine EM switching unit CU engaged clutch Cl closed second gear engaged.
The illustrations of FIG. 5 show different phases of changing up from the second into the third gear.
In FIG. 5 a the friction clutch 14 is closed and the coupling unit 29 is engaged. Furthermore, the second gear is engaged by the switching unit 27 . Torque flows from the internal combustion engine 11 via the input shafts 17 , 18 and the pair of gearwheels of the second gear to the output shaft 23 , 24 , so that the vehicle can be driven by the internal combustion engine. There is indicated an additional torque flow from the electric machine via the pair of gearwheels 20 , 19 to the input shaft 13 . This is the so-called boost mode in which additional torque is applied by the electric machine. The latter could also run in a torque-free condition. However, in the present case, the boost mode forms part of the switching process which follows. Covered lines indicate the torque flow from the internal combustion engine 11 and from the electric machine to the output gearwheel 28 .
The following switched conditions apply:
torque from the internal combustion engine CE clutch Cl closed coupling unit CU engaged additional torque from the electric machine EM second gear engaged.
In FIG. 5 b , the second gear is still engaged, but the friction clutch 14 is opened in order to separate the internal combustion engine 11 from the input shaft 17 and render it torque-free. Hereafter, the coupling unit 29 is disengaged in order to separate the input shaft 18 driven by the electric machine 12 from the input shaft 17 . A thickened line indicates the torque flow from the electric machine to the output gearwheel 28 .
The following switched conditions apply:
torque from the electric machine EM clutch Cl open coupling unit CU disengaged second gear engaged.
FIG. 5 c shows that the second gear continues to be engaged by the switching unit 27 , but at the same time, the third gear is engaged by the switching unit 25 . The input shaft 17 continues to be torque-free because the friction clutch 14 continues to be open. The torque flow takes place from the electric machine 12 via the fixed connection of the shafts 18 , 24 to the output gearwheel 28 .
The switched conditions are as follows:
torque from the electric machine EM clutch Cl open coupling unit CU disengaged second gear still engaged third gear already engaged.
FIG. 5 d shows how the switching process is concluded in that the second gear is disengaged by the switching unit 27 , whereas at the same time, by closing the friction clutch 14 , the gearwheels of the already engaged third gear are incorporated in the torque flow from the internal combustion engine 11 via the input shaft 17 into the torque flow to the output shaft and to the output gearwheel 28 . A thickened line indicates the torque flow from the internal combustion engine to the output gearwheel 28 .
The switched conditions are as follows:
torque from the internal combustion engine CE, clutch Cl closed coupling unit CU disengaged second gear disengaged third gear engaged.
The individual illustrations of FIG. 6 show different phases of changing down from the third to the second gear.
In FIG. 6 a , the friction clutch 14 is closed and the coupling unit 29 is disengaged, so that the input shafts 17 , 18 are separated from one another. The switching unit 25 couples the switching gearwheel of the third gear to the output shaft 23 , i.e. the third gear is engaged. Torque flows from the internal combustion engine 11 via the input shaft 17 and the pair of gearwheels of the third gear to the output shafts 23 , 24 and to the output gearwheel 28 . The thickened line symbolises the torque flow from the internal combustion engine 11 to the output gearwheel 28 .
The switched conditions are as follows:
torque from the internal combustion engine CE friction clutch Cl closed coupling unit CU disengaged third gear engaged.
FIG. 6 b shows that for preparing the gear change, the second gear is engaged by means of the switching unit 27 , with no torque flowing yet via the pair of gearwheels of the second gear because the coupling unit 29 continues to be open, with the input shaft 18 being disconnected from the input shaft 17 . The electric machine 12 thus does not receive any power. The thickened line symbolises the torque flow from the internal combustion engine 11 to the output gearwheel 28 .
The switched conditions are as follows:
torque from the internal combustion engine CE, friction clutch Cl closed coupling unit CU disengaged third gear engaged second gear engaged.
In FIG. 6 c , the friction clutch 14 is now open, so that the input shaft 17 is separated from the torque flow. The electric machine 12 , whose speed has already been synchronised, now takes over the torque for driving the vehicle in the second gear. The switching gearwheel of the third gear, which is torque-free, is separated by the switching unit 25 from the output shaft 23 . The thickened line symbolises the torque flow from the electric machine 12 to the output gearwheel 28 .
The switched conditions are as follows:
friction clutch Cl open coupling unit CU disengaged third gear disengaged second gear engaged.
FIG. 6 c shows the final phase of the gear change from the third to the second gear, with the coupling unit first being engaged, so that the input shafts 17 , 18 are coupled. Thereafter, the friction clutch 14 is closed, so that additional torque can flow from the combustion engine 11 via the input shafts 17 , 18 and the pair of gearwheels of the second gear to the output gearwheel 28 . Thereafter, the electric machine 12 can be taken out of the torque flow by disengaging the second gear. Thickened lines symbolise the torque flow from the internal combustion engine 11 and from the electric machine 12 to the output gearwheel 28 .
The switched conditions are as follows:
torque from the internal combustion engine CE torque from the electric machine EM (optional) friction clutch Cl closed coupling unit CU closed second gear engaged.
When the second gear is newly engaged or remains engaged, this represents the boost mode of the first gear. For each gear of the first partial drive 15 connected to the internal combustion engine 11 (first, third, fifth gear), there are four different stages of the boost mode which can be activated by engaging the second, forth or sixth gear of the second partial drive 16 or by engaging the coupling unit 29 .
FIG. 7 a shows a switched condition for energy recuperation when the vehicle is being pushed. The friction clutch 14 is open and the coupling unit 29 is disengaged. Via the engaged second gear, torque flows from the output gearwheel 28 via the output shaft 24 to the input shaft 18 , so that the electric machine 12 is generator-operated. A thickened line symbolises the torque flow from the output gearwheel 28 to the electric machine 12 .
The switched conditions are as follows:
torque to the electric machine EM friction clutch Cl open coupling unit CU disengaged second gear engaged.
When the coupling unit 29 is disengaged, the recuperation mode can alternatively being used in the second, forth, or sixth gear of the second partial drive 16 .
FIG. 7 b shows the switched condition in the recuperation mode, i.e. when the vehicle is being pushed, using the third gear. The switching gearwheel of the third gear is coupled by the switching unit 25 to the output shaft 23 , so that torque flows from the output gearwheel 28 via the output shaft 24 , 23 . Just as in the case when the first and the fifth gear are used, the coupling unit 29 has to be engaged so that torque is transmitted from the input shaft 17 to the input shaft 18 and from there to the electric machine 12 which is generator-operated. A thickened line symbolised the torque flow from the output gearwheel 28 to the electric machine 12 .
The switched conditions are as follows:
torque to the electric machine EM friction clutch Cl open coupling unit CU engaged third gear engaged.
When the coupling unit 29 is engaged, the recuperation mode can be alternatively being used in the first, third or fifth gear of the first partial drive 15 .
FIG. 8 shows the auxiliary output machine, i.e. the air conditioner compressor 13 , being operated by the electric machine 12 when the vehicle is stationary. The friction clutch 14 is open and the coupling unit 29 is also disengaged. All the switching units 25 , 26 , 27 are in the neutral position. The thickened line symbolises the torque flow from the electric machine 12 to the air conditioner compressor 13 .
The switched conditions are as follows:
torque from the electric machine EM friction clutch Cl open coupling unit CU disengaged all switching units in the neutral position.
FIG. 9 shows an inventive hybrid drive system in a second embodiment. The description of FIG. 9 , in principle, also applies to that of FIGS. 10 to 16 which show different switched conditions of the same drive concept which is shown in FIG. 9 in the neutral position. Identical components and assemblies have been given the same reference numbers as in FIGS. 1 to 8 . In this case, too, there is shown a hybrid drive system with a main driving machine 11 in the form of an internal combustion engine CE with a supplementary driving machine 12 in the form of an electric machine EM and an auxiliary output machine 13 in the form of an air conditioner compressor A/C, which comprise two gear changing partial drives 15 , 16 . The input shaft 17 of the first partial drive 15 is connectable by a friction clutch 14 to the internal combustion engine 11 . Furthermore, the partial drive 15 comprises an output shaft 23 ′ which carries the switching gearwheels of gears 1 , 3 and 5 as well as of the reverse gear R. The associated output shaft 23 ′ drives an output gearwheel 28 via a gearwheel 22 1 . The second partial drive 16 comprises an input shaft 18 which, via an input gearwheel 19 and a gearwheel 20 , is in a driving connection with the electric machine 12 . Via a farther gearwheel 21 , the input shaft 18 is also in a driving connection with the air conditioner compressor 13 . The input shaft 18 is connectable to the input shaft 17 by a coupling unit 29 via a pair of gearwheels 45 , 50 , with the gearwheel 45 being firmly positioned on the input shaft 17 , whereas the gearwheel 50 arranged on the input shaft 18 is a switching gearwheel which is switched by the coupling unit 29 . The coupling unit is part of the switching unit 32 which, at the same time, switches the sixth gear. A further switching unit 27 for the second and the fourth gear is positioned on the associated output shaft 24 ′ of the partial drive 16 . The output shaft 24 ′ acts via a gearwheel 22 2 also on the output gearwheel 28 which, for drawing reasons, is shown twice in this figure because, in actual fact, the shafts 17 , 18 , 23 ′, 24 ′ are not positioned in one plane. In this embodiment, the partial drive 15 also comprises a reverse gear which, via a switching unit 33 , is switched jointly with the first gear. The set of gearwheels of the reverse gear R comprises a reversing gearwheel 34 .
The fixed gearwheels of gears 1 to 5 and of the reverse gear R which are arranged in a rotationally fast way on the input shafts 17 , 18 are designated in said gear sequence with the reference numbers 41 , 42 , 43 , 44 , 45 , 47 and the corresponding switching gearwheels of the gears, which switching gearwheels are loose gearwheels connectable to the output shafts 23 ′, 24 ′ are designated in said gear sequence with reference numbers 51 , 52 , 53 , 54 , 55 , 57 each in FIG. 9 only. In contrast hereto, the fixed gearwheel 46 of the sixth gear is arranged on the output shaft 24 ′ in a rotationally fast way, whereas the respective switching gearwheel 56 is arranged on the second input shaft 18 in the form of a connectable loose gearwheel.
FIG. 10 shows the driving condition of the vehicle being effected electrically. The friction clutch 14 of the internal combustion engine 11 is open and the coupling unit 29 is also disengaged, whereas the second gear is engaged by the switching unit 27 . There occurs the torque flow, shown by thickened lines, from the electric machine 12 via the input shaft 18 to the output shaft 24 ′ and from there to the output gear 28 .
The switched conditions are as follows:
torque from the electric machine EM friction clutch Cl open coupling unit CU disengaged second gear engaged.
FIG. 11 shows the starting process of the internal combustion engine 11 when the vehicle is driven by the electric machine 12 . The second gear is engaged by the switching unit 27 . In addition, the coupling unit 29 is engaged and for starting the friction clutch 14 is closed. The torque flow symbolised by thickened lines takes place from the electric machine 12 to the internal combustion engine and to the output gearwheel 28 .
The switched conditions are as follows:
torque from the electric machine EM coupling unit CU engaged friction clutch Cl closed second gear engaged.
FIG. 12 shows the starting process of the internal combustion engine 11 by means of the electric machine 12 when the vehicle is stationary. The coupling unit 29 is engaged for coupling the input shafts 18 and 17 . The friction clutch 14 is closed. All gears are disengaged. The torque flow symbolised by thickened lines takes place from the electric machine 12 via the input shaft shafts 18 , 17 to the internal combustion engine 11 .
The switched conditions are as follows:
torque from the electric machine EM coupling unit CU engaged friction clutch CU closed.
The illustrations of FIG. 13 show different phases of the switching process from the fourth to the fifth gear.
In FIG. 13 a , the friction clutch 14 is closed and the coupling unit 29 is engaged. Torque flows from the input shaft 17 to the output shaft 18 ; the switching units 33 , 25 on the output shaft 23 ′ are in a neutral position, whereas the fourth gear is engaged by the switching unit 27 . Torque flows from the internal combustion engine 11 via the input shaft 24 ′ to the output gear 28 , as indicated by thickened lines.
The switched conditions are as follows:
torque from the internal combustion engine CE friction clutch Cl closed coupling unit CU engaged fourth gear engaged.
FIG. 13 b shows that by disengaging the coupling unit 29 , the input shaft 17 is disconnected from the input shaft 18 . At the same time, the electric machine 12 takes over the task of transmitting torque via the gearwheels of the fourth gear to the output shaft 24 ′. The internal combustion engine 11 is also uncoupled from the input shaft 17 by opening the friction clutch 14 . The fifth gear is engaged by the switching unit 25 . As indicated by thickened lines, the torque flow takes place from the electric machine 12 via the shafts 18 , 24 ′ to the output gearwheel 28 .
The switched conditions are as follows:
torque from the electric machine EM coupling unit CU disengaged friction clutch Cl open fourth gear engaged.
In FIG. 13 c , the friction clutch 14 is closed again, so that the internal combustion engine 11 transmits torque to the output gearwheel 28 via the input shaft 17 of the first partial drive 15 , the gearwheels of the fifth gear and the output shaft 23 ′. This corresponds to the so-called boost mode. However, the provision of power by the electric machine 12 can also be cancelled. The torque flow takes place from the combustion engine 11 via the shafts 17 , 23 ′ to the output gearwheel 28 and from the electric machine 12 via the shafts 18 , 24 ′ to the output gearwheel 28 , as shown by thickened lines.
The switched conditions are as follow;
torque from the internal combustion engine CE friction clutch Cl closed torque from the electric machine EM (optional) coupling unit CU disengaged fifth gear engaged fourth gear engaged.
The illustrations of FIG. 14 show the vehicle driving in the boost mode, i.e. both driving machines 11 , 12 provide torque.
In FIG. 14 a , the combustion engine 11 , with the clutch 14 being in the closed condition, is coupled to the output gearwheel 28 by means of the gearwheels of the third gear which is engaged by the switching unit 25 . At the same time, the electric machine 12 is coupled to the output gear 28 , with the fourth gear being engaged by the switching unit 27 . The coupling unit 29 necessarily has to be disengaged. The boost mode shown here can be set in the same way for gears 1 and 5 of the first partial drive 15 . The torque flow takes place from the internal combustion engine 11 via the shafts 17 , 23 ′ to the output gearwheel 28 and from the electric machine 12 via the shafts 18 , 24 ′ to the output gearwheel 28 .
The switched conditions are as follows:
torque from the internal combustion engine CE friction clutch Cl closed torque from the electric machine EM coupling unit CU disengaged third gear engaged fourth gear engaged.
With the coupling unit 29 being disengaged, the recuperation mode can be alternatively being used in the second, forth or sixth gear of the second partial drive.
FIG. 14 b shows the friction clutch 14 of the internal combustion engine 11 in a closed condition, but the switching units 33 , 25 of the first partial drive 15 are in the neutral position. However, the coupling unit 29 is engaged and the fourth gear is engaged by means of the switching unit 27 , so that torque is introduced into the input shaft 18 both by the electric machine 12 and by the internal combustion engine 11 and transmitted to the output shaft 24 ′. The switched condition shown here can also be used for gears 2 and 6 of the second partial drive 16 for the boost mode. The torque flow takes place from the internal combustion engine 11 via the shafts 17 , 18 , 24 ′ to the output gearwheel 28 .
The switched conditions are as follows:
torque from the internal combustion engine CE friction clutch Cl closed torque from the electric machine EM coupling unit CU engaged fourth gear engaged.
FIG. 15 shows the recuperation mode, i.e. the recovery of energy when the vehicle is being pushed. The friction clutch 14 of the internal combustion engine 11 is open or closed; in each case, however, the switching units 33 , 25 of the first partial drive are in the neutral position and the coupling unit 29 is disengaged. In the second partial drive, the fourth gear is engaged by the switching unit 27 . Torque flows from the output gearwheel 28 via the output shaft 24 ′ and the pair of gearwheels of the fourth gear to the input shaft 18 and thus to the electric machine which is generator-operated. The second and the sixth gear of the second partial drive 16 can be used in the same way for the recuperation mode.
The switched conditions are as follows:
friction clutch Cl open coupling unit CU disengaged fourth gear engaged.
FIG. 16 shows the air conditioner compressor 13 being driven by the electric machine 12 with the vehicle being in the stationary condition. All the switching units and the coupling unit 29 are in the neutral position. The friction clutch 14 can be open or closed. Torque flows from the electric machine 12 to the air conditioner compressor 13 , as indicated by a thickened line.
The switched conditions are as follows:
friction clutch Cl open coupling unit CU disengaged all switching units in the neutral position.
FIG. 17 shows an inventive hybrid drive system in a third embodiment. The subsequent description of FIG. 17 , in principle, also applies to FIGS. 18 to 24 which merely show different switching conditions of the drive concept.
There is shown a hybrid drive system which comprises a main driving machine 11 , here in the form of an internal combustion engine CE, a supplementary driving machine 12 , here in the form of an electric machine EM, and an auxiliary driven machine 13 , here in the form of a compressor for an air conditioning system A/C. The internal combustion engine 11 is connectable by a friction clutch 14 (Cl) which can be provided in the form of a wet or dry clutch. The drive comprises two gear changing partial drives 15 , 16 (stepped gear changing boxes) which are characterised in that they each comprise their own input shafts 17 and 18 . The input shaft 17 of the first partial drive carries the gearwheels of gears 4 , 6 and 2 and is connectable by the friction clutch 14 to the internal combustion engine 11 . The input shaft 17 is in direct driving connection with the air conditioning compressor 13 . The input shaft 18 of the second partial drive 16 carries the gearwheels of gears 5 , 1 and 3 as well as of the reverse gear R and an input gearwheel 19 which, by means of a gearwheel 20 , is in a stepped down driving connection with the electric machine 12 and, by means of a gearwheel 21 . In this embodiment, the output shafts 23 , 24 of the two partial drives 15 , 16 are integral with one another; more particularly, they are provided in the form of a one-piece shaft. The switching gearwheels of the individual gears are positioned on the input shaft 17 , 18 , and there is provided a switching unit 25 for gear 4 and a common switching unit 26 for gears 6 and 2 , as well as a switching unit 27 for gears 5 and 1 and another common switching unit 30 for gear 3 and the reverse gear R. The switching gear of the reverse gear acts via a reversing gearwheel on an intermediate shaft upon a fixed gearwheel on the output shaft 23 , 24 . Between the input shafts 17 , 18 , in accordance with the invention, there is a coupling unit 29 (CU) effective which, more particularly if the speeds of the two input shafts are synchronised, can be switched so as to be suitable for various operating conditions which will be described below with reference to further figures. The coupling unit 29 comprises a loose gearwheel 50 on the input shaft 17 which is switchable by the switching unit 25 , which gearwheel 50 is engaged with a drive gearwheel of the electric machine 12 .
The fixed gearwheels of gears 1 to 6 and R which are arranged in a rotationally fast way on the output shaft 23 , 24 have been given in the gear sequence the reference numbers 41 , 42 , 43 , 44 , 45 , 46 and 47 and the respective switching gearwheels which are loose gearwheels suitable for being coupled to the input shafts 17 , 18 , have been given in the gear sequence the reference numbers 51 , 52 , 53 , 54 , 55 , 56 and 57 each in FIG. 1 only. The fixed gearwheels and the loose gearwheels could also be interchanged between the input and output shafts.
In FIG. 18 , the coupling unit 29 is disengaged, so that the input shafts 17 , 18 are separated from one another. Of the drive gears, only the first gear is engaged by the switching unit 27 . In this switched condition, electric starting the vehicle—depending on the direction of rotation for forward driving or reversing—can be effected by the electric machine, with driving the vehicle also being possible with the electric machine. It is conceivable to change up into the third or fifth gear, in which case the traction force would be interrupted. A darker line indicates the torque flow from the electric machine 12 to the output shaft 23 , 24 .
The following switched conditions apply:
torque from EM clutch Cl open coupling CU disengaged first gear engaged.
FIG. 19 shows the internal combustion engine 11 being started by the electric machine during electric driving of the vehicle. The first gear is engaged by the switching unit 27 , so that torque flows from the electric machine 12 via the pair of gearwheels of the first gear to the output shaft 23 , 24 of the drive, whereas at the same time the coupling unit 29 is engaged and the friction clutch 14 is closed in order to start the internal combustion engine 11 in the torque flow via the input shafts 17 and the friction clutch 14 . Dark lines show the torque flow from the electric machine 12 to the internal combustion engine 11 and to the output shaft 23 , 24 .
The following switched conditions apply:
torque from the electric machine EM switching unit CU engaged clutch Cl closed first gear engaged.
FIG. 20 shows the state of driving with the internal combustion engine. The fourth gear is engaged by the switching unit 25 . A darker line shows the torque flow from the internal combustion engine to the output shaft 23 , 24 . The coupling unit 29 is to be engaged and the friction clutch 14 is to be closed. To use the gears 1 , 3 and 5 by means of the switching units 27 , 30 whereas the coupling unit 29 is to be disengaged and the friction clutch is to be closed to use the gears 2 , 4 and 6 by means of the switching units 25 , 26 .
The following switched conditions apply:
torque flow from the internal combustion engine CE coupling unit CU engaged clutch Cl closed forth gear engaged.
FIG. 21 show the vehicle driving in the boost mode, i.e. both driving machines 11 , 12 provide torque. In FIG. 21 , the combustion engine 11 , with the clutch 14 being in the closed condition, is coupled to the output gearwheel 28 by means of the gearwheels of the second gear which is engaged by the switching unit 26 . At the same time, the electric machine 12 is coupled to the output shaft 23 , 24 with the first gear being engaged by the switching unit 27 . The coupling unit 29 is disengaged. The boost condition shown here can be set in the same way by engaging gears 4 and 6 of the first partial drive 15 or by engaging the coupling unit 29 . The torque flow takes place from the internal combustion engine 11 via the shaft 17 to the output shaft 23 , 24 and from the electric machine 12 via the input shaft 18 to the output shaft 23 , 24 .
The switched conditions are as follows:
torque from the internal combustion engine CE friction clutch Cl closed torque from the electric machine EM coupling unit CU disengaged second gear engaged first gear engaged.
In all modes of the first partial drive 15 mentioned above the second partial drive 16 can alternatively being used for the boost mode in the first, third or fifth gear.
The illustrations of FIG. 22 show different phases of changing up from the second into the third gear.
In FIG. 22 a the friction clutch 14 is closed and the coupling unit 29 is engaged. Furthermore, the second gear is engaged by the switching unit 26 . Torque flows from the internal combustion engine 11 via the input shaft 17 and the pair of gearwheels of the second gear to the output shaft 23 , 24 , so that the vehicle can be driven by the internal combustion engine. There is indicated an additional torque flow from the electric machine via the pair of gearwheels 20 , 19 to the input shaft 18 . The third gear is already engaged by means of the switching unit 30 This is the so-called boost mode in which additional torque is applied by the electric machine. The latter could also run in a torque-free condition. However, in the present case, the boost mode forms part of the switching process which follows. Covered lines indicate the torque flow from the internal combustion engine 11 and from the electric machine to the output gearwheel 28 .
The following switched conditions apply:
torque from the internal combustion engine CE clutch Cl closed coupling unit CU disengaged additional torque from the electric machine EM second gear engaged, third gear engaged.
In FIG. 22 b , the second gear is still engaged, but the friction clutch 14 is opened in order to separate the internal combustion engine 11 from the input shaft 17 and render it torque-free. Hereafter, the second gear is disengaged by the switching unit 26 . A thickened line indicates the torque flow from the electric machine to the output shaft 23 , 24 .
The following switched conditions apply:
torque from the electric machine EM clutch Cl open coupling unit CU disengaged second gear disengaged.
FIG. 22 c shows that the coupling unit 29 is engaged by the switching unit 25 , to connect the input shaft 17 via the input shaft 18 to the output shaft 23 , 24 . The input shaft 17 continues to be torque-free because the friction clutch 14 continues to be open. The torque flow takes place from the electric machine 12 via the input shaft 18 to the output shaft 23 , 24 .
The switched conditions are as follows:
torque from the electric machine EM clutch Cl open coupling unit CU engaged second gear disengaged third gear already engaged.
FIG. 22 d shows how the switching process is concluded by closing the friction clutch 14 . The gearwheels of the already engaged third gear are incorporated in the torque flow from the internal combustion engine 11 via the input shaft 17 and the input shaft 18 to the output shaft 23 , 24 . A thickened line indicates the torque flow from the internal combustion engine to the output shaft 23 , 24 .
The switched conditions are as follows:
torque from the internal combustion engine CE, clutch Cl closed coupling unit CU engaged second gear disengaged third gear engaged.
FIG. 23 shows the switched condition in the recuperation mode, i.e. when the vehicle is being pushed, using the third gear. The switching gearwheel of the third gear is coupled by the switching unit 30 to the output shaft 23 , 24 , so that torque flows from the output shaft 24 , 23 to the input shaft 18 . The coupling unit 29 has to be disengaged so that torque is transmitted from the input shaft 18 to the electric machine 12 which is generator-operated. A thickened line symbolises the torque flow from the output shaft 23 , 24 to the electric machine 12 .
The switched conditions are as follows:
torque to the electric machine EM friction clutch Cl open coupling unit CU disengaged third gear engaged.
At the recuperation mode can be alternatively being used in the first, third or fifth gear of the second partial drive 16 , when the coupling unit 29 is disengaged, or in the second or sixth gear of the first partial drive 15 , when the coupling unit 29 is engaged.
FIG. 24 shows an auxiliary driven machine, i.e. the air conditioner compressor 13 , being operated by the electric machine 12 when the vehicle is stationary. The friction clutch 14 is open whereas the coupling unit 29 is engaged. The switching units 26 , 27 and 30 are in the neutral position. The thickened line symbolises the torque flow from the electric machine 12 to the air conditioner compressor 13 .
The switched conditions are as follows:
torque from the electric machine EM friction clutch Cl open coupling unit CU engaged.
With the coupling unit 29 being disengaged, any combination of one of the second, forth or sixth gear of the first partial drive 15 and any one of the first, third or fifth gear of the second partial drive 16 can be used to drive the compressor 13 from the electric machine 12 .
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A method of operating a hybrid drive system with an internal combustion engine and a supplemental electric machine for a motor vehicle including first and second gear changing partial drives each with gear changing gearwheels, wherein during operation there is torque flow from one gear changing partial drive to the other partial drive results in a gear change between gearwheels.
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BACKGROUND OF THE INVENTION
The present invention relates to a hosiery item spreading unit with pneumatic feed, usable with pneumatic hosiery item conveyance systems equipped with a centralized suction.
Conventional spreading units spread hosiery items leaving the machine that produces them or leaving a machine for turning them right way out after the closure of the toe, performed by means of specifically-provided looping machines.
Currently commercially available spreading units are substantially constituted by a structure which forms an elongated spreading chamber arranged so that its longitudinal axis is horizontal and connected, at its longitudinal ends, respectively to a hosiery item feed duct and to an actuation duct selectively connected, through valve means, to the suction duct or to the delivery duct of a fan wherewith the spreading unit is equipped.
In practice, when the actuation duct is connected to the suction duct of the fan, a stream of air along the spreading chamber occurs conveying the hosiery item, which arrives from the production machine or from the overturning machine, into the spreading chamber, where specific means are provided for gripping a longitudinal end of the hosiery item, usually constituted by the toe of said hosiery item. After the hosiery item has been engaged in this manner, the actuation duct is connected to the delivery duct of the fan, causing a reversal of the stream of air through the spreading chamber and thus spreading the hosiery item.
The spreading chamber is generally closed in a downward region by a door which can be opened so as to release the hosiery item by gravity after it has been spread.
Conventional spreading units are rather reliable in operation, but they entail the problem that they require, for their operation, the use of an independent fan and therefore of a corresponding independent motor for the actuation of said fan.
Therefore, in large hosiery factories using simultaneously a large number of hosiery-making machines, the adoption of a spreading unit for each hosiery-making machine significantly affects the overall investment costs of the production system.
SUMMARY OF THE INVENTION
A principal aim of the present invention is to solve the above problem by providing a hosiery item spreading unit with pneumatic feed which can be used with pneumatic hosiery item conveyance systems having a centralized suction without requiring an independent motor and fan.
Within the scope of this aim, an object of the invention is to provide a spreading unit which can operate correctly simply by using the stream of air generated by a suction duct connected to a centralized suction system.
Another object of the invention is to provide a spreading unit having significantly lower production costs than currently commercially available spreading units, thus making it convenient to adopt it, even in large numbers, in large production facilities.
This aim, these objects, and others which will become apparent hereinafter are achieved by a hosiery item spreading unit with pneumatic feed, usable with pneumatic hosiery item conveyance systems equipped with a centralized suction, comprising a structure which forms an elongated spreading chamber arranged so that its longitudinal axis is substantially horizontal and provided, at its longitudinal ends, respectively with a first opening, connected to a duct for feeding the hosiery item to be spread, and with a second opening, connected to a suction duct which can be connected to suction means; said spreading chamber being closed, in a downward region, by a door which can be opened on command to remove the spread hosiery item; said spreading chamber also containing means for gripping a longitudinal end of the hosiery item which are spaced from said first opening towards said second opening; characterized in that it comprises an auxiliary duct connecting said hosiery item feed duct to said suction duct and valve means which can be actuated on command selectively into a first operating position, wherein they close said auxiliary duct, connecting said suction duct to said feed duct through said spreading chamber in order to convey a hosiery item to be spread into the spreading chamber; into a second operating position, wherein they connect said suction duct to said feed duct through said auxiliary duct and connect said second opening to the outside to reverse the suction stream through said spreading chamber with respect to the suction stream determined by said first operating position; and into a third operating position, wherein they disconnect said spreading chamber from said suction duct.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages of the present invention will become apparent from the following detailed description of a preferred but not exclusive embodiment of the spreading unit according to the present invention, illustrated only by way of non-limitative example in the accompanying drawings, wherein:
FIG. 1 is a schematic sectional view of the spreading unit according to the present invention, with the valve means in the first operating position;
FIG. 2 is a schematic sectional view of the device according to the present invention, with the valve means in the second operating position;
FIG. 3 is a schematic sectional view of the device according to the present invention, with the valve means in the third operating position;
FIG. 4 is a schematic sectional view of FIG. 1, taken along the plane IV--IV;
FIG. 5 is a schematic sectional view of FIG. 1, taken along the plane V--V;
FIG. 6 is a schematic sectional view of FIG. 2, taken along the plane VI--VI; FIG. 7 is a schematic sectional view of FIG. 3, taken along the plane VII--VII;
FIG. 8 is a schematic sectional view of FIG. 2, taken along the plane VIII--VIII;
FIG. 9 is a schematic sectional view of FIG. 1, taken along the plane IX--IX;
FIG. 10 is a schematic sectional view of FIG. 1, taken along the plane X--X.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the above figures, the spreading unit according to the invention, generally designated by the reference numeral 1, comprises in a per se known manner a structure 2 which forms an elongated spreading chamber 3 arranged so that its longitudinal axis is horizontal and provided, at its longitudinal ends, respectively with a first opening 4, connected to a feed duct 5 for the hosiery item 6 to be spread, and with a second opening 7, connected to a suction duct 8, which can be connected to suction means.
The chamber 3 is closed in a downward region by a door 9 which can be opened on command to remove the spread hosiery item 6 by gravity.
Means for gripping the hosiery item 6, generally designated by the reference numeral 10, are also arranged in the spreading chamber 3.
According to the invention, the spreading unit comprises an auxiliary duct 11, connecting the feed duct 5 to the suction duct 8, and valve means, which can be actuated on command so as to produce a stream of air through the spreading chamber 3 in one direction, so as to convey the hosiery item 6 to be spread into the spreading chamber 3, and then a stream of air in the opposite direction along said spreading chamber 3, so as to spread the hosiery item 6, retained by the gripping means 10, simply by using the suction along the suction duct 8.
More particularly, the structure 2 forms a first compartment 12, which is arranged proximate to the first opening 4 and connects the feed duct 5 to the auxiliary duct 11. In practice, the first compartment 12 is provided with a port 13 connected to the auxiliary duct 11 and crossed by the feed duct 5, which is connected to the first opening 4. The portion of the feed duct 5 lying inside the compartment 12 is conveniently perforated so as to connect the first compartment 12 to the inside of the duct 5.
Proximate to the second opening 7 a second compartment 14 is provided, having: a first port 15, connected to the first opening 7 by means of a tubular segment 16; a second port 17, connected to the outside by means of a grille 18; and a third port 19, connected to a third compartment 20.
The third compartment 20 has in turn : a first port 21, connected to a fourth compartment 22; a second port 23, connected to the auxiliary duct 11; and a third port 24, in practice coinciding with the third port 19 of the second compartment 14.
The fourth compartment 22 is in turn provided with: a first port 25, connected to the suction duct 8; a second port 26, connected to the outside by means of a grille 27; and a third port 28, in practice coinciding with the first port 21 of the third compartment.
The valve means comprise a first gate 29 arranged on the feed duct 5 and slideable within a seat 30 formed in the portion of the structure 2 that delimits the first compartment 12. In practice, the gate 29 is constituted simply by a plate provided with a hole 31; through the sliding of said plate at right angles to the axis of the feed duct 5, the plate can be moved at said feed duct 5, so as to keep it open, or can be offset with respect to the feed duct 5, so as to close it.
The first gate 29 can be actuated, as shown in particular in FIGS. 4 to 6, by a fluid-actuated cylinder 32, preferably a pneumatic cylinder.
The valve means also comprise a second gate 33, which is also simply constituted by a sliding plate arranged in the region connecting the second compartment 14 to the third compartment 20 and the third compartment 20 to the auxiliary duct 11.
More particularly, the second port 17 of the second compartment 14, the third port 19 of said compartment 14, and the second port 23 of the third compartment 20 are located side by side and are arranged so that their axes lie transversely with respect to a same plane constituted by the plane of arrangement of the gate 33. The gate 33 has a hole 34 which, as a consequence of the movement of said gate 33 transversely to the axes of said ports, can be placed at the port 17 in order to connect the second compartment 14 to the outside, as shown in FIGS. 2, 3, 7, and 8, simultaneously opening the port 23 that connects the auxiliary duct 11 to the third compartment 20, or at the third port 19 of the second compartment 14, as shown in FIGS. 1, 9, and 10, in order to connect the second compartment 14 to the third compartment 20, simultaneously closing the second port 23 of the third compartment 20.
The second gate 33 can also be actuated simply by means of a fluid-actuated cylinder 35, for example a pneumatic cylinder, as shown in particular in FIGS. 7 to 10.
The valve means also comprise a third gate 36 opening and closing the second port 26 and the third port 28 of the fourth compartment 22. The third gate 36, too, can be simply constituted by a plate which is slideable at right angles to the axes of the ports 26 and 28 and is provided with a hole 37 which can be arranged, through the sliding of the gate 36, at the second port 26 in order to connect the fourth compartment 22 to the outside, simultaneously closing the third compartment 28, or at the third port 28, closing the second port 26.
The third gate 36, too, can be simply actuated by means of a fluid-actuated cylinder 38, preferably constituted by a pneumatic cylinder, as shown in particular in FIGS. 7 to 10.
Advantageously, proximate to the first opening 4, in the spreading chamber 3 a perforated flap 39 is oscillatably provided, about an axis 40 which is horizontal and perpendicular to the longitudinal axis of the spreading chamber 3, so as to close the first opening 4 partially or open it completely, as will become apparent hereinafter.
The means for gripping the hosiery item 6 comprise a presser element 41, located proximate to the second opening 7 and facing the door 9. The presser element 41 can be actuated, in a per se known manner, for example by means of a pneumatic cylinder 42, so as to clamp the first end of the hosiery item 6 that enters the spreading chamber 3 against the door 9. Moreover, proximate to the presser element 41, an inclined wall 43 is fixed to the side walls that delimit the spreading chamber 3 and forms a passage for the hosiery item 6 which tapers from the first opening 4 towards the second opening 7, so as to reliably position the first end of the hosiery item 6 that enters the spreading chamber 3 below the presser element 41, which is arranged almost at the end of said passage.
The door 9 is pivoted to the structure 2 about a substantially horizontal axis that is parallel to the longitudinal axis of the spreading chamber 3, and the opening and closing movements whereof can be actuated, in a per se known manner, by means of pneumatic actuators or by means of mechanical actuators which are not shown for the sake of simplicity.
The spreading unit according to the invention also comprises means for sensing the presence of a hosiery item 6 inside the spreading chamber 3. Said sensor means can be constituted by a photocell 44 laterally facing the spreading chamber 3, and the walls that delimit the spreading chamber 3, at least at the photocell 44, are made of a transparent material.
Operation of the spreading unit according to the invention is as follows.
In a first operating position of the valve means, shown in FIG. 1, the first gate 29 opens the feed duct 5, connecting it to the first opening 4, whilst the second gate 33 closes the second port 17 of the second compartment 14 and the second port 23 of the third compartment 20, simultaneously opening the third port 19 of the second compartment 14. In this operating position, the third gate 36 opens the third port 28 of the fourth compartment 22 and closes the second port 26 of said compartment 22. In this operating position, the suction duct 8 is connected, through the fourth compartment 22, the ports 28 and 21, the third compartment 20, the ports 24 and 19, and the second compartment 14, to the second opening 7 and therefore to the feed duct 5 through the spreading chamber 3, whilst the auxiliary duct 11 is closed. As a consequence of this fact, the stream of air generated by the suction along the duct 8 conveys a hosiery item 6 to be spread into the spreading chamber 3, moving one of its ends below the presser element 41; as soon as the photocell 44 detects the arrival of the hosiery item, said presser element is actuated so as to clamp the end of said hosiery item against the door 9, which is in its closed position.
At this point, the valve means are moved to a second operating position, illustrated in FIG. 2, wherein the first gate 29 closes the feed duct 5, whilst the second gate 33 connects the second compartment 14 and therefore the second opening 7 to the outside and connects the auxiliary duct 11 to the third compartment 20 while interrupting the connection of the second compartment 14 to the third chamber 20. In this operating position, the third gate 36 is kept in the previous position. In this manner, the suction duct 8 is connected to the spreading chamber 3 on the side of the first opening 4, whilst the second opening 7 is connected to the outside. As a consequence of this fact, inside the spreading chamber 3 a stream of air is provided, the direction whereof is opposite to the direction it had during the first operating step and therefore the hosiery item 6 is spread out. It should be noted that during this step the perforated flap 39 closes, because of the air stream onto the first opening 4, preventing the hosiery item 6 from being drawn out of the spreading chamber 3 if the grip of the presser element 41 is imperfect; the air stream is in any case not interrupted, since, as mentioned, the flap 39 is perforated.
Once correct spreading of the hosiery item 6 has been achieved, the third gate 36 is actuated so as to connect the suction duct 8 to the outside and so as to close the connection of the fourth compartment 22 to the third compartment 20, as shown in FIG. 3. In this manner, the suction along the duct 8 is cut off from the spreading chamber 3, wherein the door 9 is opened in order to remove the spread hosiery item by gravity.
At this point, the gates 29, 33, and 36 are returned to the position shown in FIG. 1 so as to draw into the spreading chamber 3 a new hosiery item 6 to be spread.
In practice, as explained above, the spreading unit according to the invention can operate correctly by simply connecting its suction duct 8 to a centralized suction system, without having to provide an independent fan and motor.
In practice it has been observed that the spreading unit according to the invention, since it can operate correctly even with centralized suction systems, fully achieves the intended aim, allowing a significant saving in terms of investments in hosiery factories having centralized suction systems and requiring a plurality of spreading units.
The spreading unit thus conceived is susceptible of numerous modifications and variations, all of which are within the scope of the inventive concept; all the details may also be replaced with other technically equivalent elements.
In practice, the materials employed, as well as the dimensions, may be any according to requirements and the state of the art.
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A hosiery item spreading unit with pneumatic feed, usable with pneumatic hosiery item conveyance systems equipped with a centralized suction, comprising: a structure which forms an elongated spreading chamber arranged with its longitudinal axis substantially horizontal and provided, at its longitudinal ends, respectively with a first opening, connected to a duct for feeding the hosiery item to be spread, and with a second opening, connected to a suction duct which can be connected to suction means; the spreading chamber being closed, in a downward region, by a door which can be opened on command to remove the spread hosiery item and containing also elements for gripping a longitudinal end of the hosiery item which are spaced from the first opening towards the second opening. The spreading unit further comprises an auxiliary duct which connects the hosiery item feed duct to the suction duct and valves which can be actuated on command selectively into first, second and third operating positions, for respectively conveying a hosiery item into the spreading chamber, spreading out and eventually allowing removal of the spread hosiery item.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is the U.S. National Phase under 35 U.S.C. §371 of International Application No. PCT/KR2013/010915, filed on Nov. 28, 2013, which in turn claims the benefit of Korean Application No. 10-2013-0029120, filed on Mar. 19, 2015, Korean Application No. 10-2013-0029121, filed on Mar. 19, 2015, and Korean Application No. 10-2013-0090931, filed on Jul. 31, 2013, the disclosures of which are incorporated by reference into the present application.
TECHNICAL FIELD
The present invention relates to an apparatus for adjusting a bicycle saddle angle, and in particular to an apparatus for adjusting a bicycle saddle angle in a seated position while driving which makes it possible to easily adjust a bicycle saddle angle in a state where a rider remains seated on a saddle or while a rider is riding or a rider needs to.
BACKGROUND ART
In general, a bicycle is designed to move forward by driving the wheels with the force from two legs in a state where a rider is seated on a saddle. The pedals are alternately stepped down with two feet with a rider on the saddle holding a handle to rotate the wheels connected through a chain.
The wheels in general are provided in pair. In rare case, there may be only one wheel or three wheels. Such a bicycle has been widely used as one of major transportation means which are driven by manpower. In recent years, the bicycle is being applied for various purposes as a recreation means while providing a health promotion effect as an exercise tool, and needs for the same increases thanks to its environment friendly characteristics.
As illustrated in FIG. 1 , the bicycle is configured in such a way that a plurality of frames 10 a to 10 g are connected in a trust structure. There are provided sprocket wheels 17 a and 17 b , a chain 19 , etc. which are able to transfer a driving force which generates by front and rear wheels 12 a and 12 b , a handle bar 14 , a saddle 22 , pedals 18 and an arm 16 , to a rear wheel 12 b , the operation of which is based on the supporters of the above-mentioned frames 10 a to 10 g.
At this time, the height of the saddle 22 can be adjusted through a saddle supporter 20 on the top of a saddle frame 10 a supported by a main shaft frame 10 b and a support frame 10 f which are among the plurality of the frames 10 a to 10 g.
As illustrated in FIG. 2 , the height adjustment of the conventional saddle 22 may be obtained by an engaging force of a fixing screw 24 provided at a side portion of the saddle frame 10 a in a state where the bottom of the saddle supporter 20 is inserted into the top of the pipe-shaped saddle frame 10 a.
In addition, a support 26 is fixed at the top of the saddle supporter 20 by a conventional method, for example, a welding method, etc., and a saddle plate 28 forming a frame of the saddle 22 is installed on the support plate 26 .
As seen in the installation structure of the conventional saddle 22 , a height adjustment in general is performed based on the engaging force of the fixing screw 24 with respect to the saddle frame 10 a. The upward, downward direction angles of the saddle corresponds to a user's body type and a user's posture and habit when riding, and its adjustment is necessary, but there is a hard relationship for the adjustment.
In addition, many persons, for example, a family or colleagues, can use a bicycle together. At this time, a lot of time may be necessary for each person to adjust the angle of the saddle 22 based on his body type, thus causing a lot of problems.
Furthermore, when riding a bicycle, since the angle of the saddle 22 cannot cope with any change in the user's posture when riding on a flat ground and a sloped road, for example, an uphill or a downhill, the user may have many inconveniences.
For example, when the user rides a bicycle on a uphill or a downhill, the user's posture tends to incline in a forward or backward direction of the bicycle. In this case, since the angle of the saddle 22 is fixed, the user may feel any inconvenience in his posture, thus causing a high risk to accident.
PRIOR ART TECHNICAL DOCUMENT
Patent Document
Korean Patent Publication No. 2009-0085900 (Aug. 10, 2009)
Korean Patent Publication No. 0981994 (Sep. 7, 2010)
DISCLOSURE OF INVENTION
Technical of Invention
Accordingly, the present invention is made to improve or resolve the above-mentioned problems. It is an object of the present invention to provide an apparatus for adjusting a bicycle saddle angle in a seated position while driving wherein the angle of a saddle can be easily adjusted based on a user's body type in a state where a user is riding a bicycle, and the apparatus can be compatible with a conventional bicycle structure, and while driving a bicycle on an inclined road, it is possible for a user to adjust in person the angle of a saddle based on any change in a user's posture due to the inclined road.
Solution to Problem
To achieve the above objects, there is provided an apparatus for adjusting a bicycle saddle angle in a seated position while driving, which may include, but is not limited to, a mount 100 which includes a first hinge pin the bottom of which is slidable upward and downward through the upper portion of a saddle frame 10 a , and the top of which connects a portion between them to the center of the top in a shape of a first fork 110 ; a supporter 116 which includes a second hinge pin 122 the bottom of which connects a portion between them to the center of the bottom in a shape of a second fork 120 , and the top of which is connected with the first hinge pin 114 and between the portions shaped like the first fork 100 ; and an actuator which is fixed with a bracket 210 to be spaced apart from one side of the mount 100 , wherein an extendable driving portion is connected to the second hinge pin 122 at a corresponding position, wherein a saddle 22 of the bicycle is fixed at the top of the supporter 116 , so the angle of the saddle 22 can be adjusted based on the rotation of the supporter 116 with the aid of a driving of the actuator 200 about the first hinge pin 114 .
At this time, the actuator 200 may include, but is not limited to, a hydraulic cylinder 220 which drives contractively the cylinder rod 222 hinged with the second hinge pin 122 ; a hydraulic circuit 250 which is connected communicating with the hydraulic cylinder 220 so as to change fluid; a motor 260 which is connected to the hydraulic circuit 250 and is configured to provide a pumping driving force with respect to the flow of fluid of the hydraulic cylinder 220 and the hydraulic circuit 250 based on a normal and reverse direction rotation as electric power is supplied; and a switch 270 which is configured to control of the supply of electric power with respect to a normal or reverse direction rotation and stop of the motor 260 .
In addition, a front end portion of the cylinder rod 222 further includes a connection member 240 hinged with the second hinge pin 122 to a longitudinal hole 230 having a predetermined length in upward and downward directions.
Also, the first hinge pin 114 and the second hinge pin 122 are disposed parallel with each other, and the bottom of the supporter 116 including the second hinge pin 122 is arranged rotatable about the first hinge pin 114 .
To achieve the above objects, there is provided an apparatus for adjusting a bicycle saddle angle in a seated position while driving, which may include, but is not limited to, a saddle supporter 116 ′ for supporting a saddle 22 ; a worm wheel 320 which is fixed at the bottom of a saddle supporter 116 ′; a worm shaft 330 which allows to rotate a worm wheel 320 ; a driving motor 340 which is configured to rotate in a normal and reverse rotation direction the worm shaft 330 ; and a housing 310 which is configured to accommodate the worm wheel 320 and the worm shaft 330 and is fixed at a mount 100 which is slidable upward and downward through the upper portion of a saddle frame 10 a.
In this case, the housing 310 is configured to accommodate the driving motor 340 .
In addition, the driving motor 340 is controlled to rotate in a normal or reverse rotation direction based on the operation of an operation switch “SW” installed at a handle bar 14 .
To achieve the above objects, there is provided an apparatus for adjusting a bicycle saddle angle in a seated position while driving, which may include, but is not limited to, a saddle supporter 116 ′ for supporting a saddle; a bracket 410 to which the saddle supporter 116 ′ is engaged rotatable, wherein the bracket 410 is supported by the mount 100 which is slidable upward and downward over the top of the saddle frame 10 a; a wire 420 both ends of which are supported by the bracket 410 , the wire 420 being configured to connect the bracket 410 and the saddle supporter 116 ′ in order for the saddle supporter 116 ′ to be rotatable with respect to the bracket 410 ; and an operation switch “SW” to which the wire 420 is connected, thus pulling the wire 420 or removing the pulling of the wire 420 , thus allowing to adjust the angle of the saddle 22 in such a way to rotate the saddle supporter 116 ′ with respect to the bracket 410 .
At this time, both ends of the wire 420 are supported spaced apart from the bracket 410 with the saddle supporter 116 ′ being disposed between them, and the wire 420 forms a closed loop.
In addition, there may be further provided at least one guide roller 440 a , 440 b which is disposed at both sides of the bracket 410 with the saddle supporter 116 ′ being disposed between them, thus guiding the movement of the wire 420 ; and at least on direction changing roller 450 a , 450 b which is disposed at both sides of the wire 420 while corresponding to the guide rollers 440 a, 440 b , thus changing the moving direction of the wire 420 .
In addition, one end of the wire 420 is wound around the guide roller 440 a of one side and the direction changing roller 450 a of one side in a zigzag shape, and the other end of the wire 420 is wound around the guide roller 440 b of the other side and the direction changing roller 450 b of the other side in a zigzag shape.
In addition, the guide rollers 440 a , 440 b and the direction changing rollers 450 a , 450 b are provided multiple in number, and the guide rollers 440 a, 440 b and the direction changing rollers 450 a , 450 b are arranged in the longitudinal direction of the saddle supporter 116 ′.
Advantageous Effects
In the apparatus for adjusting a bicycle saddle angle in a seated position while driving according to the present invention, a mount is installed at a saddle frame to adjust the height of a saddle like a conventional general type saddle supporter, and an actuator is installed on the mount, wherein the actuator is configured to adjust the angle of a saddle including a saddle and a support, whereupon the apparatus of the present invention can be used compatible with a conventional bicycle, and the angle of the saddle can be adjusted while driving based on a user's intention in such a way to perform a simple switch operation of the actuator, thus increasing a use convenience.
Since the angle of a saddle can be adjusted based on user's various body types, a user can ride a bicycle in a stable posture, and it is possible to have an effect on easily and freely adjusting the angle of a saddle based on a riding condition of a bicycle with smaller force in a seated position on the saddle.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is an exemplary perspective view illustrating a conventional bicycle.
FIG. 2 is an exemplary partial cross sectional view illustrating a saddle structure in FIG. 1 .
FIGS. 3 to 5 are exemplary partial cross sectional views illustrating an apparatus for adjusting a bicycle saddle angle in a seated position while driving according to a first exemplary embodiment of the present invention.
FIG. 6 is an exemplary front cross sectional view illustrating a connection relationship between a mount, a support and a cylinder rod so as to adjust a bicycle saddle angle according to a first exemplary embodiment of the present invention.
FIG. 7 is an exemplary side view illustrating an installation example of an apparatus for adjusting a bicycle saddle angle in a seated position while driving according to a second exemplary embodiment of the present invention.
FIG. 8 is a partially enlarged perspective view illustrating a saddle angle adjusting unit in FIG. 7 .
FIG. 9 is a cross sectional view illustrating a major component in FIG. 8 .
FIGS. 10 and 11 are exemplary use state cross sectional views illustrating an apparatus for adjusting a bicycle saddle angle according to a second exemplary embodiment of the present invention.
FIG. 12 is an exemplary side view illustrating an embodiment example of an apparatus for adjusting a bicycle saddle angle in a seated posture while driving according to a third exemplary embodiment of the present invention.
FIG. 13 is a cross sectional view illustrating a major component in FIG. 12 .
FIGS. 14 and 15 are exemplary use state cross sectional views illustrating an apparatus for adjusting a bicycle saddle angle according to a third exemplary embodiment of the present invention.
DETAILED DESCRIPTION
The terms or words used in the present specification and claims should be interpreted as a meaning and concept corresponding to the technical concepts of the present invention based on the principle wherein the inventor can appropriately define the concept of the term so as to describe in the best way his invention, not being interpreted as limiting to conventional or dictionary meaning.
It should be understood that the configurations illustrated in the embodiment and drawing in the present specification is provided as an exemplary embodiment, not representing all the technical concepts of the present invention, so there may be various equivalents and modification which could be substituted at the time the present application is filed.
Exemplary embodiments of the present invention will be described below with reference to the accompanying drawings.
[First Exemplary Embodiment]
The apparatus for adjusting a bicycle saddle angle according to an exemplary embodiment of the present invention, as illustrated in FIGS. 3 to 6 , may include, but is not limited to, a mount 100 and an actuator 200 .
At this time, the mount 100 may include, but is not limited to, a first fork 110 having a first open part 112 (refer to FIG. 6 ) the top of which is open in a U-shape, and a first hinge pin 114 which is inserted traversing the first open part 112 at the top of the first fork 110 .
In addition, the bottom of the first fork 110 is inserted slidable into the top of an saddle frame 10 a , so it can slide upward and downward and is fixed with a fixing screw 24 , whereupon the height thereof can be adjusted.
The bottom of the supporter 116 is inserted into the first open part 112 , and a part of the supporter 116 is fixedly hinged in place rotatable in the inside of the first open part 112 with the aid of the first hinge pin 114 .
At the bottom of the supporter 116 , there is formed a second fork 120 having a second open part 118 (refer to FIG. 6 ) which is open in a ∩-shape, and the second fork 120 may include a second hinge pin 122 which is inserted traversing the second open part 118 .
It is obvious that the bottom of the mount 100 is installed corresponding to the saddle frame 10 a and may change in shape based on the saddle frame 10 a , whereupon it is possible to estimate that the thicknesses of the top and bottom of the mount 100 may be formed different from each other, not limiting to the configuration in the drawings.
In addition, the first fork 110 and the second fork 120 are formed opposite in directions and same in shapes and include a first hinge pin 112 and a second hinge pin 122 , respectively.
In addition, the supporter 116 is basically disposed in parallel with the first fork 112 and between them, and a part of the length of the supporter 116 is hinged to the first hinge pin 112 , whereupon the bottom and top of the supporter 116 can rotate about the first hinge pin 112 .
Furthermore, the support plate 26 is fixed at a predetermined angle at the top of the supporter 116 so as to install the saddle 22 , and the saddle 22 including a saddle plate 28 is installed on the support plate 26 in a known way.
Meanwhile, the actuator 200 is fixed with a bracket 210 while being spaced apart from one side of the mount 100 wherein an extending and driving portion is connected to the second hinge pin 122 at a corresponding position, and the actuator 200 may include a hydraulic cylinder 220 which is installed to correspond to the direction where the bottom of the supporter 116 rotates, with the aid of the bracket 210 fixedly provided at the mount 100 within a range where it does not interfere with the rotation of the bottom of the supporter 116 with respect to an outer wall of each of both sides of the mount 100 or the first port.
At this time, the cylinder rod 222 is connected to the hydraulic cylinder 220 , and an end portion of the cylinder rod 222 is hinged at the second hinge pin 122 provided below the supporter 116 and can extend and operate in the direction where the second hinge pin 122 rotates.
Here, the configuration wherein the cylinder rod 222 is hinge-connected with respect to the second hinge pin 122 may be obtained in such a way that an end portion of the cylinder rod 222 is formed flat to be inserted between the second forks 120 , and a hinge connection with respect to the second hinge pin 122 may be obtained by forming and correspondingly connecting, to a flat portion of the cylinder rod 222 , a longitudinal hole 230 having a predetermined length in upward and downward directions so as to correspond to any displacement occurring due to the rotation of the second hinge pin 122 .
As illustrated in FIGS. 3 to 6 , the connection member 240 which separately forms the longitudinal hole 230 in a flat shape to be inserted between the second forks 120 may be installed at an end portion of the cylinder rod 222 .
At the top or lateral side of the hydraulic cylinder 220 , a hydraulic circuit 250 which allows to exchange fluid with the hydraulic cylinder based on the flow of fluid is installed. At the hydraulic circuit 250 , a motor 260 is installed, which allows to provide a pumping driving force with respect to the fluid flow of the hydraulic cylinder 220 and the hydraulic circuit 250 based on normal and reverse direction rotations based on electric power.
At the motor 260 , as stated above, there may be provided a switch 270 in order for a user to control the supply of electric power with respect to the normal and reverse direction rotations and stop for a pumping driving force for the flow of fluid.
In addition to the above configuration, a battery (not illustrated), etc. may be further provided at the actuator so as to supply electric power to the motor 260 through the switch 270 .
According to the thusly constituted apparatus for adjusting a bicycle saddle angle in a seated position while driving, the first hinge pin 114 and the second hinge pin 122 are arranged in parallel to each other, and the bottom of the supporter 116 including the second hinge pin 122 is rotatable about the first hinge pin 114 , and the rotational angle of the saddle 22 fixed on the top of the supporter 116 may be relationally determined based on the extensional driving and its level of the cylinder rod 222 of the corresponding actuator 200 , and such a driving may be relationally determined by the operation of the switch 270 of the user.
In a state where the saddle 22 remains parallel as illustrated in FIG. 3 , when the cylinder rod 222 moves backward, the supporter 116 rotates in a counterclockwise direction about the first hinge pin 114 operating as a rotation axis as illustrated in FIG. 4 , whereupon the saddle 22 , as illustrated in FIG. 4 , operates inclined forward as illustrated in FIG. 4 , and on the contrary, when the cylinder rod 222 moves forward, the supporter 116 rotates in a clockwise direction about the first hinge pin 114 operating as a rotation axis as illustrated in FIG. 5 , whereupon the saddle 22 operates to be upright toward the initial position.
In the above way, the apparatus for adjusting angle according to a first exemplary embodiment of the present invention has an advantage easily, conveniently and freely adjusting the rotation angle of the saddle 22 based on the operation of the hydraulic cylinder 220 .
[Second Exemplary Embodiment]
The second exemplary embodiment of the apparatus for adjusting a bicycle saddle angle according to the present invention which is different from the above-described first exemplary embodiment may be modified in such a way that the angle of the saddle 22 can be adjusted using the saddle angle adjusting nit 300 as illustrated in FIGS. 7 to 11 .
In this case, it does not need to install the first fork 110 (refer to FIG. 3 ) on the top of the mount 100 , and it is preferably formed in a cylindrical shape. The housing 310 may be fixed in a type where the insertion part 312 is inserted into the top of the mount 100 .
In this case, as illustrated in FIG. 9 , the insertion part 312 is a structure which extends downward from the lower surface of the housing 310 . The housing 310 is a formed in a box shape which defines an exterior of the saddle angle adjusting unit 300 .
In addition, according to the second exemplary embodiment of the present invention, the saddle 22 is supported by the saddle supporter 116 ′, and a worm wheel 320 is integrally fixed at the bottom of the saddle supporter 116 ′, and the worm wheel 320 is engaged in the inside of the housing 310 to the a worm shaft 330 and a gear.
At this time, the worm shaft 330 is assembled rotatable in the normal and reverse directions by the driving motor 340 disposed inside the housing 310 .
In addition, the worm wheel 320 is formed in a partially circular shape and includes teeth along its circumference to rotate engaged with the worm shaft 330 .
The saddle supporter 116 ′ is fixed integral with the top in the center of the worm wheel 320 .
In addition, the worm shaft 330 has a rod shape having a predetermined length, and teeth are formed on an outer circumference of the worm shaft 330 and rotate engaged with the worm wheel 320 along a longitudinal direction of the worm shaft 330 . Both ends of the worm shaft 330 are supported rotatable by a bearing 350 .
In addition, as described above, the driving motor 340 is directly connected to the worm shaft 330 and allows to rotate the worm shaft 330 in a normal or reverse direction.
In addition, the housing 310 has a hollow cylindrical shape at its one side wherein an opening 314 is formed and is supported by the mount 100 . The saddle supporter 116 ′ passes through the opening 314 . An insertion part 312 into which the mount 100 is inserted and engaged is formed at a lower side of the housing 310 . It is preferred that the insertion part 312 is arranged coaxial with the saddle supporter 116 ′ when the saddle 22 remains horizontal.
Here, the housing 310 may be formed in an integrated form or may be formed in a structure which can separate into upper and lower parts or into left and right parts.
In addition, the battery 360 is accommodated as an electric power supply part in the inside of a lower portion of the housing 310 so as to supply electric power to the driving motor 340 , and a control board 370 is accommodated as a control part in an inside of the lower portion thereof so as to control the driving of the driving motor 340 .
In this case, the driving motor 340 , the battery 360 , the control board 370 , etc. may be arranged at an outer side of the housing 310 , not being accommodated in the housing 310 .
Meanwhile, the battery 360 is connected via an electric wire “L” to the operation switch “SW” disposed at the handle bar 14 . Electric power can be supplied to the driving motor 340 from the battery 360 based on the operation of the operation switch “SW”, thus operating the driving motor 340 .
Here, the operation switch “SW” may be disposed at an outer side of the housing 310 , not being disposed at the handle bar 14 , which is not illustrated in the drawing.
With the above configuration, the apparatus for adjusting a bicycle saddle angle in a seated position while driving according to the second exemplary embodiment of the present invention operates as follows.
For example, in a state where the saddle 22 remains horizontal as illustrated in FIG. 9 , in order to drive the driving motor 340 , the user may control the operation switch “SW” for the driving motor 340 to rotate in a reverse direction (counterclockwise direction).
In this way, the worm shaft 330 rotates in a reverse direction, and the work wheel 320 engaged thereto rotates in a clockwise direction.
Since the worm wheel 320 rotates in a clockwise direction, the saddle supporter 116 ′ rotates in a clockwise direction. The angle can be adjusted in such a way that the front of the saddle 22 is lifted up since the saddle 22 rotates in a clockwise direction.
Meanwhile, as illustrated in FIG. 9 , in a state where the saddle 22 remains horizontal, the user operates the operation switch “SW” in order for the driving motor 340 to rotate in a normal direction (clockwise direction), thus driving the driving motor 340 .
Therefore, the worm shaft 330 rotates in a normal direction, and the worm wheel 320 tooth-engaged thereto rotates in a counterclockwise direction.
Since the worm wheel 320 rotates in a counterclockwise direction, the saddle supporter 116 ′ rotates in a counterclockwise direction. The angle can be adjusted in such a way that the front end of the saddle 22 descends and tilts downward.
Thus, the saddle angle adjusting function according to a second exemplary embodiment of the present invention allows to enable a user to ride a bicycle in the most comfortable posture based on the user's body type. When the bicycle runs up or down the inclined way, the user can easily adjust the angle of the saddle in response to such a situation, whereupon the user's body does not lean toward one direction, thus preventing any accident. In particular, it is possible to easily and freely adjust the angle of the saddle in such a way to drive the driving motor while riding the bicycle.
[Third Exemplary Embodiment]
The apparatus for adjusting a bicycle saddle angle according to a third exemplary embodiment of the present invention is obtained by modifying the structure of the second exemplary embodiment into another type as illustrated in FIGS. 12 to 15 .
As illustrated in FIG. 13 , the saddle angle adjusting unit 300 according to a third exemplary embodiment of the present invention may include, but is not limited thereto, a bracket 410 .
Here, the bracket 410 has at its one side a hollow container shape having an opening 412 and is supported by the mount 100 .
In addition, the saddle supporter 116 ′ passes through the opening 412 formed on the top of the bracket 410 , and at the bottom of the bracket 410 , an insertion part 414 into which the mount 100 is inserted is formed.
In this case, it is preferred that the insertion part 414 is arranged coaxial with the saddle supporter 116 ′ when the saddle 22 remains horizontal.
In addition, a first wire support 430 a and a second wire supporter 430 b configured to support both ends of the wire 420 are provided at both sides of the top of the inside of the bracket 410 with the saddle supporter 116 ′ being disposed between the first wire support 430 a and the second wire supporter 430 b.
Here, the bracket 410 may be integrally formed or may have a structure wherein the bracket 410 separates into upper and lower parts or left and right parts.
In addition, the wire 420 may include a predetermined length, and both ends of the wire 420 are supported by the first wire support 430 a and the second wire supporter 430 b of the bracket 410 .
In addition, the wire 420 is supported spaced apart from the bracket 410 with the saddle supporter 116 ′ being disposed between the wires 420 , and the wire 420 forms a closed loop.
In addition, the wire 420 interconnects the bracket 410 and the saddle supporter 116 ′ in order for the saddle supporter 116 ′ to be rotatable with respect to the bracket 410 .
In particular, the saddle supporter 116 ′ and the top of the mount 100 are hinged (HN) and are configured foldable.
The operation switch “SW” is connected to a pathway of the wire 420 , thus pulling the wire 420 or removing the pulling thereof.
The operation switch “SW” is installed rotatable with respect to the mount 100 by means of a pin “PIN” for the sake of a rotation by a predetermined angle.
Therefore, it is possible to adjust the angle of the saddle 22 by rotating the saddle supporter 116 ′ with respect to the bracket 410 in such a way to pull the wire 420 or remove the pulling of the wire 420 .
In the third exemplary embodiment of the present invention, it shows that the operation switch “SW” is provided on the mount 100 . It is obvious that the operation switch “SW” may be provided on the handle bar 14 .
Meanwhile, the bicycle according to a third exemplary embodiment of the present invention may further include, but is not limited to, a plurality of first and second guide rollers 440 a and 440 b configured to guide the movements of the wire 420 , and a plurality of first and second direction change rollers 450 a and 450 b configured to change the moving direction of the wire 420 .
The plurality of the guide rollers 440 a and 440 b are provided in the longitudinal direction of the saddle supporter 116 ′ and at both sides of the bracket with the saddle supporter 116 ′ being disposed between them.
Here, six guide rollers 440 a and 440 b are disposed at both sides of the bracket 410 in the third exemplary embodiment of the present invention, but the number of such guide rollers is not limited. At least one guide roller may be provided.
Hereinafter, the guide roller positioned at the left side in FIG. 13 is called a first guide roller 440 a , and the guide roller positioned at the right side is called a second guide roller 440 b.
Corresponding to the first and second guide rollers 440 a and 440 b, pluralities of first and second direction changing rollers 450 a and 450 b are disposed at both sides of the saddle supporter 116 ′. In the illustrated drawings, corresponding to the number of the first and second guide rollers 440 a and 440 b, six first and second direction changing rollers 450 a and 450 b are disposed at both sides of the saddle supporter 116 ′, respectively. Here, the number of such direction changing rollers is not limited. At least one direction changing roller may be provided.
In addition, in the first and second direction changing rollers 450 a and 450 b , the direction changing roller positioned at the left side is called a first direction changing roller 450 a , and the direction changing roller positioned at the right side is called a second direction changing roller 450 b.
Therefore, one end of the wire 420 is wound around the first guide roller 440 a and the first direction changing roller 450 a in a zigzag shape, and the other end of the wire 420 is wound around the second guide roller 440 b and the second direction switching roller 450 b in a zigzag shape.
According to the above described configuration, as illustrated in FIG. 13 , when the operation switch “SW” rotates at a predetermined angle toward the backside of the bicycle with the saddle 22 being horizontal, a tensional force occurs at the wire 420 which is the second wire supporter 430 b and the second guide roller 440 b and the second direction changing roller 450 b were located.
As illustrated in FIG. 14 , the saddle supporter 116 ′ rotates in a clockwise direction. Since the saddle supporter 116 ′ rotates in a clockwise direction, it is possible to adjust the angle in such a way that the saddle 22 rotate in a clockwise direction, and the front end of the saddle 22 is lifted upward.
Meanwhile, as illustrated in FIG. 15 , with the saddle 22 being horizontal, when the operation switch “SW” rotates at a predetermined angle toward the front side of the bicycle, a tensional force occurs at the wire 420 which is the first wire support 430 a and the first guide roller 440 a and the first direction changing roller 450 a were located.
As illustrated in FIG. 14 , the saddle supporter 116 ′ rotates in a counterclockwise direction. Since the saddle supporter 116 ′ rotates in a counterclockwise direction, it is possible to adjust the angle in such a way that the saddle 22 rotates in a counterclockwise direction, and the front end of the saddle 22 is tilted downward.
In this way, the function of a saddle angle adjustment according to a third exemplary embodiment of the present invention allows a user to ride a bicycle in the most comfortable posture based on the user' body type. When the bicycle runs up or down an inclined road, it is possible to easily adjust the angle of the saddle based on the inclination, whereupon the user's body does not tilt in one direction, thus preventing any accident. In particular, it is possible for a user to easily and freely adjust the angle of the saddle in such a way to drive the driving motor while the user is riding the bicycle.
As the present invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, it should also be understood that the above-described examples are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its spirit and scope as defined in the appended claims, and therefore all changes and modifications that fall within the meets and bounds of the claims, or equivalences of such meets and bounds are therefore intended to be embraced by the appended claims.
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Disclosed is an apparatus for adjusting a bicycle saddle angle in a seated position while driving, which enables a user on a bicycle saddle mounted on a bicycle to adjust an angle of the bicycle saddle with a simple operation according to a riding and driving state, or the user's needs. The apparatus according to the present invention comprises: a mount ( 100 ) of which the lower portion is slidable upward and downward through the upper portion of a saddle frame ( 10 a ) and of which the upper portion is in a first fork ( 110 ) shape and has a first hinge pin ( 114 ) penetrating the centers of the upper end portions thereof; a supporter ( 116 ) of which the lower portion is in a second fork ( 120 ) shape and has a second hinge pin ( 122 ) penetrating the centers of the lower end portions thereof and of which the upper side is connected between the upper end portions of the first fork ( 110 ) shaped portion by the first hinge pin ( 114 ); and an actuator ( 200 ) fixed with a bracket ( 210 ) to be spaced apart from one side of the mount ( 100 ) and having an expandably-driven portion connected to the second hinge pin ( 122 ) on the corresponding position, wherein a saddle ( 22 ) of a bicycle is fixed to the upper end of the supporter ( 116 ), and the angle of the saddle ( 22 ) is adjusted, about the first hinge pin ( 114 ), according to the movement of the supporter ( 116 ) resulting from the operation of the actuator ( 200 ).
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FIELD OF THE INVENTION
This invention relates to injection ports for capillary gas chromatographs, and more particularly concerns liner units for inlets wherein a liquid sample is vaporized into a sample gas and mixed with a carrier gas, and a portion of the gas mixture is delivered to the inlet end of a capillary tube of a gas chromatograph, and even more particularly concerns marking such liners to identify the type and source of the liners and to provide proper orientation of the liner in the gas chromatography instrument.
DESCRIPTION OF THE PRIOR ART
Gas chromatography (GC) is a well known analytical technique where gas phase mixtures are separated into their individual components and subsequently identified. The technique may be employed to obtain both qualitative and quantitative information about the components of the mixture [1].
Samples for GC are usually liquid and must be vaporized prior to introduction to the mobile phase gas stream. GC analysis is typically divided into four stages:
1. sample introduction, where liquid samples are introduced into the inlet, heated, and vaporized,
2. sample transfer, where the sample vapor is transferred all or in part onto the analytical column,
3. separation, where the sample is separated into its individual components as it passes through the analytical column, and
4. detection, where the separated components are identified as they exit the analytical column.
In conventional GC instrumentation the first two steps are achieved in the sample inlet hardware. Inlet hardware often includes a replaceable liner. Liners are normally operated at elevated temperatures, e.g., over 200° C. This enhances the rate of sample vaporization and reduces adsorption on the inner surface of the liner [1]. Many internal configurations are available for liners, as well as coatings for them [2-12].
In most cases the configuration serves to enhance the degree of sample vaporization from the point of exit from the syringe needle to the column entrance, and provide gas phase sample homogeneity of components within the liquid mixture having different boiling points. A simple configuration for an inlet liner is a straight cylindrical tube of glass having a consistent inner diameter along the longitudinal path. Other configurations include more complex inner paths intended to increase turbulence, affect the comparatively short residence time the liquid sample is in the liner, or interrupt the liquid stream leaving the syringe needle. These internal configurations include tapers or goosenecks, baffles, funnels, inverted cup elements, spiral regions, and other points of flow constriction along the longitudinal path of the liner.
Other optional elements of liners include small quantities of packing materials such as glass wool [1] or Carbofrit™ (Trademark of Restek Corporation) packing material, which serve as additional surface area sources for heat transfer into the sample and as a physical filter for any solid/nonvolatile contaminants present in the liquid sample.
Liners are manufactured from glass, primarily borosilicate, but also fused quartz, and less commonly from metal, mainly stainless steel [13]. Various chemical coatings are applied to liners in order to reduce the degree of interaction between the sample and the surface of the liner. Sample-surface interactions may result in sample adsorption in the coatings, decomposition of the coatings, and formation of new reaction products; in each case resulting in undesirable peaks (or loss of desirable ones) in detection measurements of the components contained in the sample being analyzed in the separation analysis. In addition to low sample-surface interactions, it is also desirable for the liner coating to be thermally stable in order to minimize background signal contributions originating from the liner coating itself detected by the analytical equipment. For glass substrate liners, common deactivation techniques include chemically treating the exposed silanol groups with organosilane reagents such as hexamethyldisilazane (HMDS), dimethyldichlorosilane (DMCS), and trimethylchlorosilane (TMCS) [13]. Prior to the deactivation process it is common for the liner substrate to undergo an aqueous acid leach process [13] whereby metal and metalloid impurities are removed from the surface.
It is often desirable for the liner to be optically transparent. It is particularly important to be able to see through the walls of these liners which contain packing material in order to ensure its proper plug position within the internal bore of the liner. It is also advantageous to be able to observe wool placement, and to be able to check for the presence of debris or other visual contaminants. For the purpose of this disclosure we will reference to liners that are manufactured from glass or other optically transparent materials.
Given the large number of GC instrument manufacturers, different instrument models, and considerable variety of liner designs, it is desirable to include markings on the liners that provide information relating to the variables listed above. It is further desirable to provide information relating to proper orientation of the liner in the GC instrument.
Information specific to liners is often provided by directly marking the liners with text, symbols, or logos. Methods for marking include silk screening or direct stamp printing on the outer surface of the liners. Marks are made on the surface using paint or ink, as well as mechanical and chemical etching techniques. These techniques, while widely used in the industry are often limited in their long term thermostability as well as their overall ease of visibility given the narrow dimensions of standard liners (e.g., on the order of 2-6 mm O.D.). Further, these techniques require additional steps in the liner manufacture, and may impact the subsequent chemical deactivation process following the mechanical forming of the glass substrate.
With the exception of the straight liner, which is essentially a straight glass tube having a uniform I.D and O.D. along the entire length, liners having more complex internal configurations are commonly manufactured by (1) heat fusing subcomponents to the inner surface of the straight tubing, or (2) thermoforming the outer wall of the straight tubing to create complex shapes on the inner wall. In the first case, glass subcomponents whose chemical compositions are compatible to the straight tubing are employed in order to ensure thorough fusing of the parts. In most cases the chemical composition of the subcomponents is essentially the same as the straight tube.
In some cases, more than one subcomponent is employed in the same straight tube. In still other cases, more than one subcomponent is employed where the first subcomponent resides inside the second subcomponent in a coaxial configuration.
SUMMARY OF THE INVENTION
We present an alternative to directly printing or otherwise marking the liner by taking advantage of the multicomponent nature of the liner assembly. We present replacing one or more of the liner subcomponents with dimensionally equivalent subcomponents made from pigment doped glass, the pigment for such glass preferably comprising inorganic pigments. In this fashion the liners whole or in part include a discreet colored region that is highly visible and can be employed to identify one liner from another or identify proper orientation in the GC instrument.
The liner unit at least comprises a tube having a bore extending between an inlet and outlet of the tube, but may also comprise an inlet expansion chamber in the bore for changing a liquid sample into a sample gas, a mixing chamber in the bore next to the inlet chamber, and an outlet chamber for delivering the thoroughly mixed sample and carrier gases to an inlet end of a capillary tube of a gas chromatograph. Employing one or more colored glass subassemblies of the liner during its manufacture enables easier identification of the liner type, proper orientation, or identification of the source of the liner.
Because of the techniques used in liner manufacture, any pigment employed in the glass subcomponents must be resistant to temperatures greater than the softening point of borosilicate glass (ca. 650° C.), and more preferably greater than the softening point of quartz (ca. 1650° C.). Inorganic ionic pigments such as cobalt (Co +2 ; blue color), nickel (Ni +2 ; green color) and iron (Fe +2 ; yellow to red color) are commonly employed as thermostable pigments in glass substrates [14] and are suitable examples for this application.
Employing a color doped subcomponent in the liner assembly provides a striking device to identify the liner without adding any steps beyond those essential to the liner manufacture. Preferably, the pigment concentrations in the glass liner subcomponents are sufficient to provide a noticeable color while maintaining optical transparency of the liner.
Employing pigment-doped glass for liner subcomponents allows for close melt compatibility between the doped and non-doped subcomponents. In the final assembly of the liner some of the glass surface of the subcomponent may be exposed to the sample path. Because the liner substrate undergoes an aqueous acid leach process prior to the deactivation process, inorganic pigment ions resident at or close to the surface of the colored glass would be removed and a higher purity silica surface would be presented to the deactivation chemistry.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a view in cross-section of a liner found in the prior art.
FIG. 1B is a view in cross-section of another liner found in the prior art.
FIG. 1C is a view in cross-section of another liner found in the prior art.
FIG. 1D is a view in cross-section of another liner found in the prior art.
FIG. 2A is a view in cross-section of a sample inlet liner having a gooseneck taper and a dimple, constructed in accordance with the invention.
FIGS. 2B and 2C are views in cross-section illustrating the fabrication of the gooseneck liner of FIG. 2A .
FIG. 3A-1 is a view in cross-section of a cylindrical gooseneck subassembly of the invention.
FIG. 3A-2 is an end view of the cylindrical gooseneck subassembly shown in FIG. 3A-1 .
FIG. 3B-1 is a view in cross-section of an alternative embodiment of a cylindrical gooseneck subassembly of the invention.
FIG. 3B-2 is an end view of the cylindrical gooseneck subassembly shown in FIG. 3B-1 .
FIG. 3C-1 is a view in cross-section of another alternative embodiment of a cylindrical gooseneck subassembly of the invention.
FIG. 3C-2 is an end view of the cylindrical gooseneck subassembly shown in FIG. 3C-1 .
FIG. 4A is a view in cross-section of a Cyclosplitter™ liner constructed in accordance with the invention.
FIGS. 4B , 4 C, and 4 D are views in cross-section illustrating the fabrication of the liner of FIG. 4A .
FIG. 5A is a view in cross-section of an alternative embodiment of a liner constructed in accordance with the invention.
FIG. 5B is an end view of the liner shown in FIG. 5A .
FIG. 5C is a view in cross-section of another alternative embodiment of a liner constructed in accordance with the invention.
FIG. 5D is a view in cross-section of another alternative embodiment of a liner constructed in accordance with the invention.
FIG. 5E is a view in cross-section of a further alternative embodiment of a liner constructed in accordance with the invention.
FIG. 5F is a view in cross-section of another alternative embodiment of a liner constructed in accordance with the invention.
FIG. 5G is an end view of the liner shown in FIG. 5F .
DETAILED DESCRIPTION
FIG. 1 shows some liner configurations commonly found in the industry.
In FIGS. 1A-1D , sectional views of various sample inlet liner configurations are illustrated as known in the prior art. FIG. lA is an example of a straight through sample inlet liner 10 having a straight tube wall 11 . FIG. 1B shows a liner 20 which is an example of the liner 10 incorporating a gooseneck taper 21 where the taper region has a reduced inner diameter and the same outer diameter of the straight liner tube wall 11 . The liner 20 also has a dimple 22 which is a region of the liner 20 having both a reduced inner diameter and outer diameter. FIG. 1C shows a liner 30 which is an example of the liner 20 incorporating a matrix 31 , which may be comprised of wool, particles, wire bundles, or other materials know in the art. FIG. 1D shows a liner 40 which is an example of a Cyclosplitter.TM. liner [ 5 ] which includes the physical features of liner 20 and also includes a glass spiral core baffle 41 permanently affixed to the inner surface of the liner 40 .
FIG. 2A is a sectional view of an inventive sample inlet liner 200 incorporating a gooseneck taper 202 where the taper region has a reduced inner diameter and the same outer diameter of the straight liner tube wall 201 and a dimple 203 which is a region of the liner 200 having both a reduced inner diameter and outer diameter. In FIGS. 2B to 2C the fabrication of the gooseneck liner 202 is illustrated. As shown in FIG. 2B , a glass subassembly 205 is inserted into the straight tube 204 and permanently heat fused into place. In this particular case the glass subassembly 205 is made of colored glass. With the exception of the glass pigment, the chemical composition of the subassembly 205 is preferably the same material as the liner tube 204 . This improves the physical and chemical compatibility between the two components and ensures successful fusing of the components together. In FIG. 2C the dimple 203 is shown to be added after heat fusing the gooseneck taper into place. Common manufacturing practices to create the dimple include thermoforming, whereby the straight tube 204 is heated in a localized region to at least the softening point of the glass and then pinched into place. Often the straight tube 204 is rotated along the longitudinal axis in order to ensure a symmetrical dimple around the radial axis of the tube 204 . In commercial manufacture of liners the order of the steps illustrated here may be changed.
FIG. 3A-1 is a detail illustration of a cylindrical gooseneck subassembly 300 having a through channel 302 . The subassembly is made of colored glass, preferably colored borosilicate glass. FIG. 3A-2 shows an end view of the subassembly 300 of FIG. 3A-1 . Both ends of the gooseneck are chamfered giving the cross section profile 301 . FIG. 3B-1 is a detail illustration of a cylindrical gooseneck subassembly 310 having a through channel 312 . FIG. 3B-2 shows an end view of the subassembly 310 of FIG. 3B-1 where the subassembly is made of one cylindrical layer of glass 313 surrounded by a second cylindrical layer of glass 311 , assembled in a coaxial configuration where the cumulative shape is equivalent to the single component gooseneck subassembly 300 . In this example either layer 313 or layer 311 or both contain color pigment. In the case where both layer 313 and 311 contain color pigment, they may be the same or different color. At some point during the manufacture of the liner, subassemblies 313 and 311 are fused together. FIG. 3C-1 is a detail illustration of a cylindrical gooseneck subassembly 320 having a through channel 322 . FIG. 3C-2 shows an end view of the subassembly 320 where the subassembly is made of one cylindrical layer of glass 324 surrounded by a second cylindrical layer of glass 323 , which is in turn surrounded by another cylindrical layer of glass 321 assembled in a coaxial configuration where the cumulative shape is equivalent to the single component gooseneck subassembly 300 . In this example any of the three layers 324 , 323 or 321 may contain color pigment. In the case where any of the three layers 324 , 323 or 321 contain color pigment, they may be the same or different color. At some point during the manufacture of the liner, the three layers 324 , 323 and 321 are fused together.
FIG. 4A shows a Cyclosplitter™ liner 400 , which is constructed in accordance with the invention, and which incorporates a gooseneck taper 402 where the taper region has a reduced inner diameter and the same outer diameter of the straight liner tube wall 404 , and a dimple 403 which is a region of the liner 400 having both a reduced inner diameter and outer diameter. The Cyclosplitter™ liner 400 also incorporates a glass spiral core baffle 406 permanently affixed to the inner surface of the liner.
In FIGS. 4B to 4D , the fabrication of the Cyclosplitter™ liner 400 is illustrated. In FIG. 4B , a glass spiral core baffle subassembly 406 is inserted into the straight tube 405 and permanently heat fused into place. In this particular case the core baffle subassembly 406 is made of colored glass. With the exception of the glass pigment, the chemical composition of the subassembly 406 is preferably the same material as the liner tube 405 . This improves the physical and chemical compatibility between the two components and ensures successful fusing of the components together. In FIG. 4C the gooseneck taper subassembly 407 is inserted into the straight tube 405 and permanently heat fused into place. In this particular case the glass subassembly 407 is made of colored glass. With the exception of the glass pigment, the chemical composition of the subassembly 407 is preferably the same material as the liner tube 405 . The color of spiral core baffle subassembly 406 may be the same as or different to the gooseneck taper subassembly 407 . In FIG. 4D the dimple 403 is applied to liner tube 405 in the same fashion as described previously. In commercial manufacture of liners the order of the steps illustrated here may be changed.
FIGS. 5A to 5G show straight liners having colored regions along the longitudinal path of the straight tube. Liners in FIGS. 5A to 5G are made of glass, preferably borosilicate glass. The glass subassemblies are heat fused together. In FIG. 5A a straight tube liner 500 having a through hole or pathway 503 includes a clear glass sheath 501 and a colored glass sheath 502 which are assembled in a coaxial fashion. FIG. 5B shows an end view of the final assembly of liner 500 .
In FIG. 5C the liner 510 , having a through hold or pathway 513 , is assembled with the colored glass sheath 511 on the outside of the clear glass sheath 512 . This configuration is preferable when the chemical composition of the colored sheath 511 is sufficiently different from the clear glass 512 as to be potentially less compatible with either the deactivation chemistry or the gas sample.
In FIG. 5D the straight tube liner 520 having a through hole or pathway 523 includes two separate colored sheaths 522 and 524 inserted coaxially into the straight tube 521 where the total length of the two colored sheaths 522 and 524 matches the length of the straight tube 521 . In this case the colored sheaths 522 and 524 may be the same color or different colors.
In FIG. 5E the straight tube liner 530 having a through hole or pathway 533 includes a clear sheath 531 and a colored sheath 532 where the length of colored sheath 532 is less than the length of clear sheath 531 . In order to ensure an even inner diameter along the entire length of the liner 530 , the glass tube 531 may be thicker in the region without the colored sheath 532 .
In FIG. 5F the straight tube liner 540 having a through hole or pathway 543 includes three glass sheaths 541 , 542 , and 544 which are assembled in a coaxial fashion. FIG. 5G shows an end view of the final assembly of liner 540 . Any or all of the glass sheaths 541 , 542 , and 544 may be colored and more than three sheaths may be included in the liner assembly. As was illustrated in FIG. 5C , any of the glass sheaths 541 , 542 , and 544 may be composed of more than one shorter glass sheath assembled end to end where the total length of the sheaths matches the length of the straight tube.
The glass sheaths in each of FIGS. 5A to 5G are fused together, preferably by heat fusing.
Pigment may be added to any or all of the glass components (e.g., glass subassemblies 205 , 300 , and 407 , glass layers 311 , 313 , 321 , 323 , and 324 , glass spiral core baffles 406 , and glass sheaths 502 , 511 , 522 , 524 , 531 , 541 , 542 , and 544 ) of the inventive liners, as desired, using conventional methods known to those of ordinary skill in the art, such as by mixing pigment into the glass melt from which the glass components are formed.
The references referred to in this specification and listed below are hereby incorporated herein by reference.
REFERENCES
1. Konrad Grob in “Split and Splitless Injection for Quantitative Gas Chromatography, 4 th Ed., Wiley-VCH, 2001.
2. Anal. Chem. 2002, 74, 10-16 “The Two Options for Sample Evaporation in Hot GC Injectors: Thermospray and Band Formation. Optimization of Conditions and Injector Design” Koni Grob and Maurus Biedermann.
3. U.S. Pat. No. 5,954,862 “Sample Inlet Liner” William H. Wilson.
4. U.S. Pat. No. 5,472,670 “Gas Chromatography Sample Injector and Apparatus Using Same” Peter de B. Harrington and Hans P. Whittenberg.
5. U.S. Pat. No. 5,119,669 “Sleeve Units for Inlet Splitters of Capillary Gas Chromatographs” Paul H. Silvis.
6. U.S. Pat. No. 6,565,634′“Injection Liner” Wil van Egmond.
7. U.S. Pat. No. 6,719,826 “Method and Apparatus for Sample Injecting in Gas Chromatography” Ryoichi Sasano, Motoaki Satoh, and Yutaka Nakanishi.
8. U.S. Pat. No. 6,498,042 “PTFE Matrix in a Sample Inlet Liner and Method of Use” William H. Wilson.
9. U.S. Pat. No. 4,035,168 “Nonreactive Inlet Splitter for Gas Chromatography and Method” Walter G. Jennings.
10. U.S. Pat. No. 5,997,615 “Large-Sample Accessory for a Gas Chromatograph” Huan V. Luong, Hsing Kuang Lin, Howard Fruwirth, George S. Mueller.
11. U.S. Pat. No. 6,203,597 “Method and Apparatus for Mass Injection of Sample” Ryoichi Sasano, Kazuhiko Yamazaki, Masahiro Furuno.
12. U.S. Pat. No. 6,494,939 “Zero-Dilution Split Injector Liner Gas Chromatography” Andrew Tipler.
13. “A Guide To Gas Chromatography”, W. Rodel and G. Wolm, Huthig Verlag, GmbH, Heidelberg, Germany.
14. “Coloured Glasses” by W. A. Weyl, 1959, Society of Glass Technology, Sheffield.
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A liner for mixing the sample gas and a carrier gas and delivering the gas mixture to the inlet end of a capillary tube of a gas chromatograph for analysis, comprises
(a) a transparent tube having an inlet and an outlet and a bore with an inside surface, and (b) at least one glass subcomponent permanently affixed to the liner tube wherein the subcomponent is at least one color.
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BACKGROUND OF THE INVENTION
The present invention relates in general to building structures, and, more particularly, to means for erecting insulated concrete wall panels.
Many buildings use precast concrete panels which are shipped to a building site, then erected into place. The assignee of the present invention produces such panels under the name COREWALL®. These panels include a layer of insulation sandwiched between a pair of concrete layers.
Heretofore, these panels have been moved into place using several different means. For example, lifting hooks have been cast into the front face of a panel. However, such means can only be used on panels which are not exposed, as the lifting hooks create unsightly marks on the face of the panel.
Threaded inserts have been used extensively in precast concrete panels. It is noted that COREWALL® panels are normally sawcut to length, which for all practical purposes, precludes the use of threaded inserts.
Since the aforementioned COREWALL® panels have an architectural finish on both sides, and full width insulation is required at the top of the panel, it is necessary to engage both layers of concrete when erecting the panels. This is accomplished by using two hairpin-shaped lifting hooks which are embedded in both layers of concrete. An erection bracket is then attached to these lifting hooks by two high strength "J"-bolts which are securely attached to a lifting carriage.
The bracket and carriage described above have been quite satisfactory for panels which extend above eave height. However, some buildings are designed with the top of the panel stopping just below the eaves height.
The erection bracket as described above is not suitable for use with panels stopping below eaves height, as the extended lifting plates will interfere with the final position of the panel. Using the known panel lifting device, the bolts had to be loosened, and the bracket taken off. A problem arises in the holding of the panel in position until a clevis or some other means of attachment can be made. This makes such prior lifting devices not only costly in time and effort, but creates a dangerous situation as well.
Accordingly, there is need for a means of positioning a building panel, which means will not interfere with the final position of the panel.
SUMMARY OF THE INVENTION
The device embodying the teachings of the present invention permits a panel, such as a COREWALL® panel to be properly, efficiently and safely positioned in a building wherein a building member, such as an eaves member, or the like, is located closely adjacent the top of the panel.
The device includes lifting plates rotatably and retractably mounted on a panel lifting carriage. The plates are attached to a hand crank and are rotated and retracted at suitable times during the panel positioning procedure.
A panel can thus be fixed into the final position thereof before detaching the lifting carriage therefrom. The panel is thus properly, efficiently and safely moved into the final position thereof.
OBJECTS OF THE INVENTION
It is the main object of the present invention to orient a prefabricated building panel into final position adjacent an overhanging building member in a safe, efficient manner.
It is another object of the present invention to orient a COREWALL® building panel into final position adjacent an overhanging building member in a safe, efficient manner.
It is yet another object of the present invention to orient a COREWALL® building panel into final position adjacent an eaves member in a safe, efficient manner.
These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming part hereof, wherein like reference numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view of a pair of building panels with a top panel being attached to a lifting carriage embodying the teachings of the present invention.
FIG. 2 is an exploded perspective of a building panel lifting carriage embodying the teachings of the present invention.
FIG. 3 is an end elevation view of a pair of building panels with a top panel being attached to a lifting carriage embodying the teachings of the present invention and being tilted into an upright orientation.
FIG. 4 is a perspective showing a building panel being suspended using a lifting carriage embodying the teachings of the present invention.
FIG. 5 is an end view of a building panel being finally positioned adjacent an eave member using a lifting carriage embodying the teachings of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Shown in FIG. 1 is a pair of panels P each of which includes a layer of insulation I sandwiched between layers of concrete K. The panels have outer surfaces OS and are stored in a horizontal position with spacer blocks S interposed therebetween. Preferably, the panels P are COREWALL® panels.
Each panel has a hairpin-shaped lifting pin L therein straddling the insulation layer and being embedded in the concrete layers. The bight B of each pin L is spaced above the top of the insulation layer to be exposed for connection to a panel lifting means, as will be discussed below. The topmost portion of each pin is slightly lower than the topmost surface T of the concrete layers as best shown in FIG. 5.
Preparatory to lifting a panel, a pipe R and a pallet W are positioned between the panel to be lifted and the means beneath that panel as shown in FIG. 1. The pipe permits proper movement of the lifted panel as that panel is being tilted upwardly as shown in FIG. 3, and the pallet protects the lowermost edge E of the lifted panel and the panel supporting means from damage due to contact between those two elements during the lifting motion.
A panel erection bracket 10 is best shown in FIG. 2. The bracket includes an L-shaped carriage 12 having an elongate planar base 14 which is width-wise sized to span the panel thickness and an upright leg 16 integrally attached to the base 14. The base is longer than the leg 16 so that a notch 20 is defined on each end of the carriage, and aprons 22 and 24 are defined by the base adjacent those notches. The width of the base is essentially equal to the thickness of the panel so that longitudinal side edges 28 and 30 of the base at the notch are essentially flush with surfaces 32 and 34 of the panel P. Protective plates, such as rasps, or the like, can be mounted on the front surface of the leg 16, if so desired.
A pair of mounting bolt receiving holes 34 and 36 are defined in the base 14 to be spaced apart along the longitudinal centerline of that base. Block U-shaped channel brackets 40 and 42 straddle the holes, and each bracket includes a first leg 46 and a second leg 48 which are welded to the base 14. A spanner plate 50 forms the top of each bracket and is welded to the legs 46 and 48. A crank arm receiving hole 54 is defined in the bracket top to be aligned with the bolt receiving hole associated therewith. The brackets can also be welded to the leg 16 to further secure the brackets to the carriage 12.
A pair of tether brackets 60 and 62 are fixed to the carriage to be spaced apart along the longitudinal centerline of the base 14 and to be inwardly spaced from the channel brackets 40 and 42, respectively. Each tether bracket is adjacent one of the channel brackets, and the tether brackets are spaced apart a distance sufficient to provide stability to a lifted panel as will be apparent from the discussion below. Each tether bracket includes a central block 66 sandwiched between a pair of outer spacer plates 68 and 70. The central block is fixably mounted on the base 14 and the spacer plates are fixed to the central block and provide proper sizing to the tether brackets for accepting hoisting cables used to lift the panel. The central block can be attached to the leg 16 to further affix that block to the carriage.
Coincident circular tether holes 72 are defined through the central block in the outer plates to receive a lifting cable C for attaching a panel to a hoisting means (not shown). The tether holes can also be oblong, as shown in FIG. 4, if so desired.
A panel attaching means 80 is best shown in FIG. 2 to include a J-bolt 82 having a head 84 attached to a threaded body 86. The head includes channel 88 which accommodates a lifting pin L, and the bolt body is received through the aligned bolt and crank arm receiving holes. The brackets 40 and 42 allow the J-bolts to be properly attached to the pins L.
A crank arm 90 includes an L-shaped handle 92 having a handgrip 94 and a rod 96 attached thereto. A tubular arm 100 is attached to the rod 96 on the end thereof remote from the handgrip 94 to be rotated about the longitudinal centerline thereof by circumrotation of the handgrip about the longitudinal centerline of the arm 100.
A polygonal nut 110 is attached to the end of the tubular arm 100 which is remote from the rod 96 as by welding or the like. The nut 110 is attached to a washer 112 as by welding or the like, and a tubular extension 116 is attached to the washer as by welding or the like.
The nut 110 is internally threaded to threadably receive the bolt body 86 in a secure manner, the washer is annular to accommodate the body 86 therethrough, and the tubular extension has a bore defined longitudinally thereof to accommodate the bolt body therethrough. The tubular extensions are accommodated through the crank arm receiving holes defined in the brackets 40 and 42, and the washer abuts the top surface of the spanner plates of those brackets.
As indicated in FIGS. 2 and 3, the bolt head is attached to a lifting pin, then the threaded body is positioned through the aligned holes and threadably coupled to the crank arm by engaging the body in the nut 110 and rotating the crank arm. The J-bolt is taken up until the panel is securely attached to the carriage 12. The cables C can then be attached to the tether brackets, and the panel moved as indicated in FIG. 3 into an upright position as shown in FIG. 4 to be suspended from the cables. The panel is then moved into position adjacent a roof deck D, or a purlin, or the like, as shown in FIG. 5. While still suspended via the cables C, the panel is maneuvered into the desired position.
As above-discussed, if the panel is to be located in a position wherein proper positioning thereof is difficult with the cables still attached, such as adjacent an eaves member H, or the like, prior art devices suffer drawbacks. Such drawbacks are not suffered by the device embodying the teachings of the present invention, as the erection bracket can remain attached to the panel while that panel is being maneuvered into the final position thereof.
The present device includes a panel lifting means 130 mounted on the carriage 12. The panel lifting means 130 is best shown in FIG. 2, and includes a pair of tubular collars 132 and 134 each attached, as by welding F, to the base aprons 22 and 24 to have one end thereof flush with the longitudinal edge 28 and the other end thereof flush with longitudinal edge 30. The tubular collars have bores defined longitudinally therethrough. Each of a pair of L-shaped arms 136 and 138 has a handgrip portion 140 and a base portion 142. Threads 144 are defined on the base portion 142. A pair of adjusting nuts 146 are threadably attached to the base portion so that the panel lifting means 130 can be adjusted to accommodate panels of various thicknesses. Panel thicknesses can be, for example, 8 inches or 10 inches, or the like. The base portion is received through the bore of the tubular collar associated therewith. A panel lifting plate 150 is attached to each base portion on the end thereof remote from the handgrip. The lifting plates are rectangular and are attached at one end thereof to the base portions for rotation therewith. Each lifting plate has an inner surface 152 and an outer surface 154.
The arm base portions are slidably and rotatably accommodated in the collar bores so that circumrotation of the handgrip portions rotates the lifting plates correspondingly about a center defined by the base portion, and movement axially of the base portion retracts the lifting plates. Such movement is indicated in FIG. 2 by arrows M and N, respectively.
Each base rod portion 142 can move axially thereof within the associated collar to move the lifting plate from a position wherein the inner surface 152 is flush with panel outer surface OS, as shown in FIG. 2, to assist in the panel lifting process shown in FIGS. 3 and 4, to a position wherein plate outer surface 154 is essentially flush with the panel outer surface OS and spaced therefrom as best shown in FIG. 5. The two plane movement of the plates 150 is also indicated in FIG. 4 wherein the plates are moved from the positions shown therefor in phantom lines, to the positions thereof shown in solid lines.
The panel erection bracket can be used to align a panel with a building structural member, such as a purlin, an eave member, or the like, while that panel is still suspended via the cable C and the carriage 12.
As this invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, the present embodiment is, therefore, illustrative and not restrictive, since the scope of the invention is defined by the appended claims rather than by the description preceding them, and all changes that fall within the metes and bounds of the claims or that form their functional as well as conjointly cooperative equivalents are, therefore, intended to be embraced by those claims.
|
An improved building panel erection bracket includes a panel lifting plate which is rotatable and retractable. The panel erection bracket permits a building panel to be fixed into the final position thereof before the erection bracket is detached from the panel.
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[0001] This application claims priority to U.S. Provisional Application No. 61/303,545 filed on Feb. 11, 2010, the entire disclosures of which are specifically incorporated herein by reference in their entirety without disclaimer.
FIELD
[0002] The present disclosure relates to a new chemical agent that demonstrates antiproliferative and cytotoxic activity against cancer cells. More particularly, but not exclusively, the present disclosure relates to a hybrid molecule capable of mixed retinoic acid receptor agonism and histone deacetylase inhibition. The present disclosure also relates to methods of synthesis.
BACKGROUND
[0003] Both retinoids and histone deacetylase inhibitors (HDACi) have been shown to possess anti-tumor properties in the clinic and have been shown to work cooperatively in combination in pre-clinical models. Retinoids can inhibit the growth of normal mammary epithelial cells and breast cancer cell lines by inducing G1 arrest and/or apoptosis. [1-6] However, despite their promise in breast cancer cell lines, retinoids have not performed well in breast cancer treatment, although they were shown to reduce second malignancies in the breast. [7-9] This may be due to intrinsic and/or acquired resistance, which can readily be observed in vitro in breast cancer and leukemic cell lines. [10-13] While estrogen receptor (ER) positive (ER+ve) cells, such as MCF7, are sensitive to the anti-proliferative effects of ATRA (Vesanoid®), most ER negative (ER-ve) cells are not. [14] This may be due to induction of RARα expression by estrogens and/or to other levels of cross-talk between the two receptors. [15-20] HER2 amplification, which occurs in 25% of breast tumors, has been reported to correlate with lack of ERα expression and resistance to RA. [ 21]
[0004] HDACi's have shown promise in pre-clinical models of solid tumors including breast cancer. It was shown that HDACi's repress transcription of ERα, a therapeutic target for ⅔ of breast tumors. [22] In addition, HDACi's down-regulate HER2, a proto-oncogene amplified in 25% breast tumors, both at the transcriptional level and through increased HER2 protein turnover, and sensitize HER2 amplified breast cancer cells such as SkBr3 to herceptin or chemotherapeutic drug treatment. [23,24]
[0005] It was previously reported that HDACi's synergize with RA (retinoic acid) to inhibit growth and induce apoptosis in breast cancer cells. [25] While both RA and the HDACi trichostatin A are anti-proliferative in MCF7 cells, comparison of patterns of gene expression upon treatment with either compound revealed only partial overlap in regulated genes, possibly explaining their cooperative action; e.g., while RA and TSA induce expression of CDKI p19, [26,27] TSA but not RA strongly suppressed expression of cyclin CCND1. Previous reports have shown that the combination of retinoic acid receptor agonists with histone deacetylase inhibitors can be advantageous in leukemia and breast cancer.
[0006] Triciferol, a hybrid molecule which combines vitamin D receptor agonism with HDACi activity and which displays improved cytostatic and cytotoxic activity relative to 1,25-dihydroxyvitamin D was previously reported.
[0007] The present description refers to a number of documents, the content of which is herein incorporated by reference in their entirety.
SUMMARY
[0008] The present disclosure relates to a hybrid molecule capable of mixed retinoic acid receptor agonism and histone deacetylase inhibition.
[0009] In an embodiment, the present disclosure relates to a hybrid molecule comprising a retinoic acid receptor agonist moiety and an HDAC inhibitor moiety.
[0010] In an embodiment, the present disclosure relates to a hybrid molecule or a pharmaceutically acceptable salt thereof having the formula:
[0000]
[0011] In an embodiment, the present disclosure relates to a pharmaceutical composition comprising an effective amount of the hybrid molecule or a pharmaceutically acceptable salt thereof having the formula:
[0000]
[0012] in association with one or more pharmaceutically acceptable carriers, excipients or diluents.
[0013] In an embodiment, the present disclosure relates to an admixture comprising an effective amount of the hybrid molecule or a pharmaceutically acceptable salt thereof having the formula:
[0000]
[0014] in association with one or more pharmaceutically acceptable carriers, excipients or diluents.
[0015] In an embodiment, the present disclosure relates to a method of treating breast cancer in a subject comprising administering to the subject a therapeutically effective amount of hybrid 3 or a pharmaceutically acceptable salt thereof.
[0016] In an embodiment, the present disclosure relates to a method of treating leukemia in a subject comprising administering to the subject a therapeutically effective amount of hybrid 3 or a pharmaceutically acceptable salt thereof.
[0017] In an embodiment, the present disclosure relates to a method of treating non-small cell lung cancer in a subject comprising administering to the subject a therapeutically effective amount of hybrid 3 or a pharmaceutically acceptable salt thereof.
[0018] In an embodiment, the present disclosure relates to a method of treating colon cancer in a subject comprising administering to the subject a therapeutically effective amount of hybrid 3 or a pharmaceutically acceptable salt thereof.
[0019] In an embodiment, the present disclosure relates to a method of treating melanoma in a subject comprising administering to the subject a therapeutically effective amount of hybrid 3 or a pharmaceutically acceptable salt thereof.
[0020] In an embodiment, the present disclosure relates to a method of treating ovarian cancer in a subject comprising administering to the subject a therapeutically effective amount of hybrid 3 or a pharmaceutically acceptable salt thereof.
[0021] In an embodiment, the present disclosure relates to a method of treating renal cancer in a subject comprising administering to the subject a therapeutically effective amount of hybrid 3 or a pharmaceutically acceptable salt thereof.
[0022] In an embodiment, the present disclosure relates to a method of treating prostate cancer in a subject comprising administering to the subject a therapeutically effective amount of hybrid 3 or a pharmaceutically acceptable salt thereof.
[0023] In an embodiment, the present disclosure relates to a method of treating cancer of the central nervous system in a subject comprising administering to the subject a therapeutically effective amount of hybrid 3 or a pharmaceutically acceptable salt thereof.
[0024] In an embodiment of the present disclosure, the subject to be treated is an in vitro or in vivo system. In a further embodiment of the present disclosure, the subject is a human.
[0025] The foregoing and other objects, advantages and features of the present disclosure will become more apparent upon reading of the following non restrictive description of illustrative embodiments thereof, given by way of example only with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] In the appended drawings:
[0027] FIG. 1 shows the virtual docking of TTNN (left) and hybrid 3 (right) to RARγ.
[0028] FIG. 2 a shows the effects of hybrid 3, ATRA (1), TTNN (2) and HX600 on RAR ligand binding using the BRET assay; FIG. 2 b shows the effects of TTNN and hybrid 3 in inducing RARα.
[0029] FIG. 3 shows the effects of hybrid 3 on either RAR or HDAC target gene regulation in the MDA-MB-231 and MCF7 cells lines.
[0030] FIG. 4 shows the hyperacetylation of proteins resulting from the effects of hybrid 3 on protein deacetylases.
[0031] FIG. 5 shows the effects of hybrid 3, TTNN, ATRA and SAHA on the growth of the MDA-MB-231, MCF7 and SkBr3 cell lines.
DETAILED DESCRIPTION
[0032] In order to provide a clear and consistent understanding of the terms used in the present specification, a number of definitions are provided below. Moreover, unless defined otherwise, all technical and scientific terms as used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure pertains.
[0033] The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and/or the specification may mean “one”, but it is also consistent with the meaning of “one or more”, “at least one”, and “one or more than one”. Similarly, the word “another” may mean at least a second or more.
[0034] As used in this specification and claim(s), the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “include” and “includes”) or “containing” (and any form of containing, such as “contain” and “contains”), are inclusive or open-ended and do not exclude additional, unrecited elements or process steps.
[0035] The term “about” is used to indicate that a value includes an inherent variation of error for the device or the method being employed to determine the value.
[0036] The present description refers to a number of chemical terms and abbreviations used by those skilled in the art. Nevertheless, definitions of selected terms are provided for clarity and consistency.
[0037] A novel class of chemical agents (i.e. a novel hybrid molecule) having mixed retinoic acid receptor agonism and histone deacetylase inhibitory properties are described herein.
[0038] The incorporation of histone deacetylase inhibitory activity (HDACi) into an RAR agonist results in a molecule with improved antiproliferative activity towards several breast cancer cell lines, including MCF-7, SKBr-3 and MDA-MB-231.
[0039] Although all-trans-retinoic acid (1) is a highly potent agonist for the RAR, its instability has led to a search for stable analogs (retinoids). 6-(5,6,7,8-tetrahydro-5,5,8,8-tetramethyl-2-naphthalenyl)-2-naphthalene carboxylic acid (TTNN, 2) is an RARP/γ selective agonist which has been shown to be active against ovarian, cervical and squamous cell carcinomas. [28-30] As with other known RAR agonists, a major component of TTNN binding to RARs is via a hydrogen bonding network with the carboxylic acid.
[0000]
[0040] The isosteric replacement of the carboxylic acid in RAR agonists has been found to be very difficult, with standard carboxylic acids isosteres including sulfonic acids, sulfonamides, amidines and tetrazoles being unsuccessful when incorporated into retinoids and/or retinoic acid itself. [31] A few exotic isosteres such as thiazolidindiones, 1,2,4-oxadiaxo1-5-ones and tropalones have been reported, but all result in molecules which bind to RAR less tightly and/or are less effective in inducing HL-60 differentiation when compared to ATRA and their parent retinoids. [32]
[0041] Despite difficulties in the use of carboxylic acid isosteres, it was surmised that a hydroxamic acid derivative of TTNN (e.g. 3) might be similar enough to enter into the required hydrogen bonding network in the receptor ligand binding pocket, allowing it to function as an RAR agonist. The binding of 3 with RAR using FITTED, a modeling suite for virtual screening, was investigated. FITTED reproduces binding modes of ATRA and other retinoids to RAR with high fidelity. Docking of 3 revealed that the hydroxamic acid can engage the same hydrogen bonding network as ATRA, TTNN and other retinoids, with the hydroxamate OH engaging a guanidine and serine in critical hydrogen bonds ( FIG. 1 ). It was also surmised that the introduction of a hydroxamic acid into TTNN would potentially render the resulting molecule an HDACi while preserving its ability to act as an agonist for RARs.
[0042] Hybrid 3 was prepared by treatment of the methyl ester of TTNN with excess hydroxylamine under alkaline conditions. The effects of hybrid 3 on RAR were initially assessed using a bioluminescence resonance energy transfer (BRET) assay. The BRET assay monitors agonist-dependent recruitment of coactivators to RARs in transfected HEK293 cells, chosen because of their high degree of transfectability. Energy transfer between luciferase (fused to RARα) and eGFP (fused to the LXXLL coactivator motif) occurs only when these moieties are juxtaposed by the RAR-LXXLL interaction, and can be detected by the emission of green fluorescence. Assaying at 1 μM concentration, ATRA (1), TTNN (2) and hybrid 3 were all shown to be agonists of RARα while HX600, an RXR selective ligand, afforded no increase in BRET signal ( FIG. 2 a ). Further dose-response comparison showed that 3 was in fact slightly more potent than 2 in inducing RARα (IC50=1.015 μM) ( FIG. 2 b ).
[0043] The agonist activity of 3 through its effects on RAR target genes was subsequently analyzed ( FIG. 3 ). In both the MCF-7 and MDA-MB-231 cell lines, RT-qPCR analysis showed clear induction of RARB2 and DHRS3. In contrast, both 1 and 2 only induce RARB2 in the MDA-MB-231 cell line. In the MCF-7 cell line no induction of either RARB1 or RARB2 was observed. Furthermore, genes that are reportedly regulated by HDACi such as RARB1 and CyclinD1 follow similar regulation by 3 in MDA-MB-231. [33]
[0044] The potential of 3 to act as an HDACi and cause deacetylation of a synthetic substrate or hyperacetylation of HDACs target proteins was subsequently assessed. Using a standard fluorescence assay, 3 was found to have IC50's of 5.0 μM and 148 nM against purified human HDAC3 and HDAC6, respectively. These potencies compare favorably to those observed with the vitamin D receptor agonist/HDACi hybrids against the same targets. Intracellular HDACi activity was assessed by measuring levels of acetylated histone H4 and tumor suppressor protein p53 in MDA-MB-231 cells by Western blotting. Similar to the effects observed with the highly potent HDACi SAHA, treatment with 10 μM 3 induced clear hyperacetylation of both HDAC targets, histone H4 and p53 over an 18-24 h time course ( FIG. 4 ). Interestingly, hyperacetylation of p53 has been shown to cause its activation and the transcription of p53 target genes such as the pro-apoptotic genes PUMA, NOXA and BAX.
[0045] Finally, the effects of 3 on the growth of several breast cancer cell lines [MCF-7 (ER-positive, HER2-negative, RA-sensitive); SkBr3 (ER-negative, HER2-amplified, RA-sensitive); and the normally RA-insensitive MDA-MB-231 (ER-negative, HER2-negative, RA-insensitive)] was assessed.
[0046] Impressively, under conditions where TTNN was inactive and SAHA had a shallow activity, hybrid 3 was active against all three cell lines, including MDA-MB231 ( FIG. 5 ). IC50's of 300 nM, 150 nM and 90 nM against the MDA-MB-231, MCF-7 and SkBr3 cell lines were measured respectively. Hybrid 3 was also active against another ER-negative, HER2-negative and RA-insensitive cell line (BT-20). Importantly, 3 displayed only minimal effects on the growth of non-tumorogenic immortalized mammary 184b5 cells and normal human mammary epithelial cells (HMEC) as compared to SAHA which causes strong inhibition of HMEC growth, indicating a potentially useful therapeutic window. For comparison, in the MDA-MB-231 cell line, retinoids such as ATRA and TTNN had little to no effect, while treatment with SAHA induced a modest decrease in cell growth. Importantly, combination treatment of SAHA and ATRA did not potentiate either compound's activity and resulted in an inhibition very similar to that of SAHA, indicating an advantage of the hybrid molecule over combination therapy.
[0047] Hybrid 3 was shown to possess HDACi activity while maintaining RAR agonist activity. This hybrid molecule inhibits the growth of breast cancer cell lines that are both sensitive (MCF-7, SkBr-3) and resistant (MDA-MB-231, BT-20) to retinoids and is more efficient in these cells than the combination of retinoids with SAHA. Hybrid 3 was also shown to be less toxic than SAHA in normal and immortalized non-tumorogenic cell lines.
[0048] In an embodiment, the present specification relates to pharmaceutical compositions comprising a pharmaceutically effective amount of 3 or pharmaceutically acceptable salts thereof, in association with one or more pharmaceutically acceptable carriers, excipients and/or diluents. The term “pharmaceutically effective amount” is understood as being an amount of 3 required upon administration to a mammal in order to induce RAR agonism and HDAC inhibition. Therapeutic methods comprise the step of treating patients in a pharmaceutically acceptable manner with 3 or compositions comprising 3 as disclosed herein. Such compositions may be in the form of tablets, capsules, caplets, powders, granules, lozenges, suppositories, reconstitutable powders, creams, ointments, lotions, or liquid preparations, such as oral or sterile parenteral solutions or suspensions, or inhalation powders or solutions.
[0049] Hybrid 3 may be administered alone or in combination with pharmaceutically acceptable carriers. The proportion of each carrier is determined by the solubility and chemical nature of the agent(s), the route of administration, and standard pharmaceutical practice. In order to ensure consistency of administration, in an embodiment of the present disclosure, the pharmaceutical composition is in the form of a unit dose. The unit dose presentation forms for oral administration may be tablets and capsules and may contain conventional excipients. Non-limiting examples of conventional excipients include binding agents such as acacia, gelatin, sorbitol, or polyvinylpyrolidone; fillers such as lactose, sugar, maize-starch, calcium phosphate, sorbitol or glycine; tabletting lubricants such as magnesium stearate; disintegrants such as starch, polyvinylpyrrolidone, sodium starch glycolate or microcrystalline cellulose; or pharmaceutically acceptable wetting agents such as sodium lauryl sulphate. Additional excipients include those used in lipid formulations, a non-limiting example of which is olive oil.
[0050] Hybrid 3 may be administered alone or in combination with other pharmaceutically active molecules, including but not limited to cytotoxic, antiproliferative, pro-apoptotic and anti-inflammatory agents.
[0051] Hybrid 3 may be injected parenterally; this being intramuscularly, intravenously, or subcutaneously. For parenteral administration, 3 may be used in the form of sterile solutions containing solutes, for example sufficient saline or glucose to make the solution isotonic.
[0052] Hybrid 3 may be administered orally in the form of tablets, capsules, or granules, containing suitable excipients such as starch, lactose, white sugar and the like. Hybrid 3 may be administered orally in the form of solutions which may contain coloring and/or flavoring agents. Hybrid 3 may also be administered sublingually in the form of tracheas or lozenges in which the active ingredient(s) is/are mixed with sugar or corn syrups, flavoring agents and dyes, and then dehydrated sufficiently to make the mixture suitable for pressing into solid form.
[0053] The solid oral compositions may be prepared by conventional methods of blending, filling, tabletting, or the like. Repeated blending operations may be used to distribute the active agent(s) (i.e. hybrid 3) throughout the compositions, employing large quantities of fillers. Such operations are, of course, conventional in the art. The tablets may be coated according to methods well known in normal pharmaceutical practice, in particular with an enteric coating.
[0054] Oral liquid preparations may be in the form of emulsions, syrups, or elixirs, or may be presented as a dry product for reconstitution with water or any other suitable vehicle before use. Such liquid preparations may or may not contain conventional additives. Non limiting examples of conventional additives include suspending agents such as sorbitol, syrup, methyl cellulose, gelatin, hydroxyethylcellulose, carboxymethylcellulose, aluminum stearate gel, or hydrogenated edible fats; emulsifying agents such as sorbitan monooleate or acaci; non-aqueous vehicles (which may include edible oils), such as almond oil, fractionated coconut oil, oily esters selected from the group consisting of glycerine, propylene glycol, ethylene glycol, and ethyl alcohol; preservatives such as for instance methyl para-hydroxybenzoate, ethyl para-hydroxybenzoate, n-propyl para-hydroxybenzoate, n-butyl para-hydroxybenzoate and sorbic acid; and, if desired, conventional flavoring or coloring agents.
[0055] For parenteral administration, fluid unit dosage forms may be prepared by utilizing hybrid 3 and a sterile vehicle, and, depending on the concentration employed, hybrid 3 may be either suspended or dissolved in the vehicle. Once in solution, hybrid 3 may be injected and filter sterilized before filling a suitable vial or ampoule followed by subsequently sealing the carrier or storage package. Adjuvants, such as a local anesthetic, a preservative or a buffering agent, may be dissolved in the vehicle prior to use. Stability of the pharmaceutical composition may be enhanced by freezing the composition after filling the vial and removing the water under vacuum, (e.g., freeze drying). Parenteral suspensions may be prepared in substantially the same manner, except that hybrid 3 should be suspended in the vehicle rather than being dissolved and, further, sterilization is not achievable by filtration. Hybrid 3 may be sterilized, however, by exposing it to ethylene oxide before suspending it in the sterile vehicle. A surfactant or wetting solution may be advantageously included in the composition to facilitate uniform distribution of hybrid 3.
[0056] Topical administration can be used as the route of administration when local delivery of hybrid 3 is desired at, or immediately adjacent to the point of application of the composition or formulation comprising hybrid 3.
[0057] Hybrid 3 may also be dispensed as a dry or liquid inhalation formulation using any suitable device.
[0058] The pharmaceutical compositions of the present disclosure comprise a pharmaceutically effective amount of hybrid 3 as described herein and one or more pharmaceutically acceptable carriers, excipients and/or diluents. In an embodiment of the present disclosure, the pharmaceutical compositions contain from about 0.1% to about 99% by weight of hybrid 3. In a further embodiment of the present disclosure, the pharmaceutical compositions contain from about 10% to about 60% by weight of hybrid 3, depending on which method of administration is employed. Physicians will determine the most-suitable dosage of the present therapeutic agent (i.e. hybrid 3). Dosages may vary with the mode of administration of hybrid 3. In addition, the dosage may vary with the particular patient under treatment. The dosage of hybrid 3 used in the treatment may vary, depending on the condition, the weight of the patient, the relative efficacy and the judgment of the treating physician.
[0059] Both RARs and HDACs are ubiquitously expressed in cell lines and tissue. It was therefore surmised that hybrid 3 could display cytotoxic activities in a wide variety of cell lines. When tested in the NCI-60 panel of human tumor cell lines, hybrid 3 exhibited a broad spectrum cytotoxic activity across all tumor types. Under conditions where all cell lines show robust growth in the absence of test compound, treatment with hybrid 3 resulted in growth inhibition in all cell lines with GC-50 values ranging from 3.02×10 −7 M to 4.3×10 −6 M and total growth inhibition (TGI) concentrations ranging from 1.03×10 −6 M to 1.95×10 −5 M. (Table 1). In addition, a measure of the loss of total protein content from time zero (TZ) shows that, with the exception of two Leukemia cell lines (CCRF-CEM and RPMI-8226), hybrid 3 exerts a cytotoxic effect in all cell lines with LC-50 ranging from 4.31×10 ×6 M to 4.65×10 −5 M.
[0000]
TABLE 1
Functional studies of hybrid 3 on various cancer cell lines.
Panel/Cell line
GI50
TGI
LC50
Leukemia
CCRF-CEM
3.06E−07
1.95E−06
>0.0001
HL-60(TB)
3.53E−07
1.52E−06
7.66E−06
K-562
3.99E−07
1.46E−06
5.51E−06
MOLT-4
3.71E−07
1.46E−06
7.80E−06
RPMI-8226
6.89E−07
4.39E−06
>0.0001
SR
3.35E−07
1.20E−06
7.64E−06
Non-Small cell
lung cancer
A549/ATCC
4.73E−07
2.15E−06
7.80E−06
EKVX
6.86E−07
3.43E−06
1.84E−05
HOP-62
6.16E−07
2.19E−06
6.18E−06
HOP-92
1.93E−06
6.35E−06
2.72E−05
NCI-H226
1.22E−06
4.19E−06
1.88E−05
NCI-H23
9.96E−07
2.43E−06
5.90E−06
NCI-H322M
4.46E−07
3.50E−06
2.62E−05
NCI-H460
3.40E−07
1.07E−06
4.04E−06
NCI-H522
1.62E−06
3.59E−06
7.98E−06
Colon
COLO205
7.97E−07
2.33E−06
6.02E−06
HCC-2998
1.09E−06
2.51E−06
5.75E−06
HCT-116
4.24E−07
1.50E−06
4.03E−06
HCT-15
3.81E−07
2.03E−06
9.38E−06
HT29
5.75E−07
2.34E−06
7.60E−06
KM12
6.16E−07
1.88E−06
4.61E−06
SW-620
6.26E−07
1.94E−06
4.85E−06
CNS
SF-268
5.33E−07
1.85E−06
5.05E−06
SF-295
3.85E−07
1.77E−06
6.11E−06
SF-539
6.99E−07
7.26E−06
3.09E−05
SNB-19
1.09E−06
2.36E−06
5.09E−06
SNB-75
1.74E−06
6.10E−06
2.49E−05
U251
4.37E−07
1.69E−06
4.80E−06
Melanoma
LOX IMVI
3.72E−07
1.36E−06
4.19E−06
M14
7.08E−07
2.49E−06
7.43E−06
MDA-MB-435
8.79E−07
2.54E−06
6.80E−06
SK-MEL-2
2.42E−06
6.31E−06
3.36E−05
SK-MEL-28
1.81E−06
5.50E−06
2.17E−05
SK-MEL-5
9.77E−07
2.31E−06
5.37E−06
UACC-257
1.98E−06
7.34E−06
2.97E−05
UACC-62
5.12E−07
1.86E−06
5.17E−06
OVCAR-3
6.03E−07
1.88E−06
4.48E−06
OVCAR-4
5.33E−07
5.82E−06
2.91E−05
OVCAR-5
4.12E−06
1.95E−05
4.61E−05
OVCAR-8
4.59E−07
1.77E−06
5.12E−06
NCI/ADR-RES
5.02E−07
1.76E−06
5.34E−06
SK-OV-3
1.54E−06
1.17E−05
3.48E−05
Renal
786-0
1.10E−06
2.37E−06
5.12E−06
A498
1.66E−06
3.80E−06
8.71E−06
ACHN
3.93E−07
1.49E−06
5.09E−06
CAKI-1
3.02E−07
1.03E−06
4.31E−06
RXF393
1.26E−06
2.82E−06
6.27E−06
SN12C
1.05E−06
2.37E−06
5.34E−06
TK-10
1.10E−06
4.97E−06
2.50E−05
UO-31
4.04E−07
1.61E−06
4.53E−06
Prostate
PC-3
1.14E−06
4.25E−06
2.15E−05
DU-145
6.22E−07
1.90E−06
4.68E−06
Breast
MCF7
4.70E−07
1.68E−06
4.66E−06
MDA-MB-231/ATCC
1.20E−06
3.59E−06
1.20E−05
HS578T
3.02E−06
1.18E−05
6.48E−05
BT-549
1.42E−06
4.81E−06
1.97E−05
T-47D
1.27E−06
4.03E−06
2.80E−05
MDA-MB-468
1.18E−06
2.75E−06
6.39E−06
[0060] Materials and Methods
[0061] Cell transfection and BRET assays: HEK293 cells were grown to confluence, trypsinized and plated at a density of 500 k cells per well (12-well plates) in DMEM supplemented with 10% charcoal treated FBS (FBS-T). The following day, cells were transfected with PEI using 0.1 μg of RAR-RLuc vector and 1 μg of LXXLL-eGFP vector. 48 hours post-transfection, cells were treated with retinoids for 2 hours before taking BRET measurements as described previously.
[0062] Western Blotting: MDA-MB-231 cells were plated in DMEM 5% FBS-T at 600 k cells per well in 6-well plates. The next day cells were treated with DMSO, TTNN (10 μM), Hybrid 3 (10 μM) or SAHA (150 nM) and the cells were collected in 95° C. Laemmli buffer at various time points. Protein concentration of the extracts was analyzed by BioRad DC protein assay. 20 μg of proteins per condition were loaded on an SDS-PA gel and transferred to a nitrocellulose membrane for blotting. Blotting was done using ABCAM primary antibodies EP356 (anti-p53) T3526 (anti-Tubulin) and AB1761 (anti-acH4).
[0063] Cell Growth Measurement: Cells were plated at 40 k cells per well (6-well plate) in DMEM 5% FBS-T for all cell lines except for I-IMEC cells which were plated in supplemented MEBM from Clonetics. Cells were treated every 48 hours and media was refreshed every 96 hours. After 10 days of treatment cells were harvested in 0.1N NaOH and growth was quantified by analyzing protein content of lysates with a Lowry assay.
[0064] In Vitro Cancer Screen
[0065] The human tumor cell lines of the cancer screening panel are grown in RPMI 1640 medium containing 5% fetal bovine serum and 2 mM L-glutamine. For a typical screening experiment, cells are inoculated into 96 well microtiter plates in 100 μL at plating densities ranging from 5,000 to 40,000 cells/well depending on the doubling time of individual cell lines. After cell inoculation, the microtiter plates are incubated at 37° C., 5% CO 2 , 95% air and 100% relative humidity for 24 h prior to addition of experimental drugs.
[0066] After 24 h, two plates of each cell line are fixed in situ with TCA, to represent a measurement of the cell population for each cell line at the time of drug addition (Tz). Experimental drugs are solubilized in dimethyl sulfoxide at 400-fold the desired final maximum test concentration and stored frozen prior to use. At the time of drug addition, an aliquot of frozen concentrate is thawed and diluted to twice the desired final maximum test concentration with complete medium containing 50 μg/ml gentamicin. Additional four, 10-fold or ½ log serial dilutions are made to provide a total of five drug concentrations plus control. Aliquots of 100 μl of these different drug dilutions are added to the appropriate microtiter wells already containing 100 μl of medium, resulting in the required final drug concentrations.
[0067] Following drug addition, the plates are incubated for an additional 48 h at 37° C., 5% CO 2 , 95% air, and 100% relative humidity. For adherent cells, the assay is terminated by the addition of cold TCA. Cells are fixed in situ by the gentle addition of 50 μl of cold 50% (w/v) TCA (final concentration, 10% TCA) and incubated for 60 minutes at 4° C. The supernatant is discarded, and the plates are washed five times with tap water and air dried. Sulforhodamine B (SRB) solution (100 μl) at 0.4% (w/v) in 1% acetic acid is added to each well, and the plates are incubated for 10 minutes at room temperature. After staining, unbound dye is removed by washing five times with 1% acetic acid and the plates are air dried. Bound stain is subsequently solubilized with 10 mM trizma base, and the absorbance is read on an automated plate reader at a wavelength of 515 nm. For suspension cells, the methodology is the same except that the assay is terminated by fixing settled cells at the bottom of the wells by gently adding 50 μl of 80% TCA (final concentration, 16% TCA). Using the absorbance measurements [time zero, (Tz), control growth, (C), and test growth in the presence of drug at the five concentration levels (Ti)], the percentage growth is calculated at each of the drug concentration levels. Percentage growth inhibition is calculated as: [(Ti-Tz)/(C-Tz)]×100 for concentrations for which Ti>/=Tz; and [(Ti-Tz)/Tz]×100 for concentrations for which Ti<Tz.
[0068] Three dose response parameters are calculated for each experimental agent. Growth inhibition of 50% (GI50) is calculated from [(Ti-Tz)/(C-Tz)]×100=50, which is the drug concentration resulting in a 50% reduction in the net protein increase (as measured by SRB staining) in control cells during the drug incubation. The drug concentration resulting in total growth inhibition (TGI) is calculated from Ti=Tz. The LC50 (concentration of drug resulting in a 50% reduction in the measured protein at the end of the drug treatment as compared to that at the beginning) indicating a net loss of cells following treatment is calculated from [(Ti-Tz)/Tz]×100=−50. Values are calculated for each of these three parameters if the level of activity is reached; however, if the effect is not reached or is exceeded, the value for that parameter is expressed as greater or less than the maximum or minimum concentration tested (Table 1).
[0069] It is to be understood that the disclosure is not limited in its application to the details of construction and parts as described hereinabove. The disclosure is capable of other embodiments and of being practiced in various ways. It is also understood that the phraseology or terminology used herein is for the purpose of description and not limitation. Hence, although the present disclosure has been provided with illustrative embodiments, it can be modified without departing from the spirit, scope and nature as further defined in the appended claims.
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[0100] 31. Yamakawa, T.; Kagechika, H.; Kawachi, E.; Hashimoto, Y.; Shudo, K. J. Med. Chem. 1990, 33, 1430. b) Dawson, M. I,; Hobbs, P. D.; Kuhlmann, K.; Fung, V. A.; Helmes, C. T.; Chao, W.-R. J. Med. Chem. 1980, 23, 1013.
[0101] 32. a) Charton, J.; Deprez-Poulain, R.; Hennuyer, N.; Tailleux, A.; Staels, B.; Deprez, B. Bioorg. Med. Chem. Lett. 2009, 19, 489. b) Tashima, T.; Kagechika, H.; Tsuji, M.; Fukusawa, H.; Kawachi, E.; Hashimoto, Y.; Shudo, K. Chem. Pharm. Bull. 1997, 1805. c) Ebisawa, M.; Ohta, K.; Kawachi, E.; Fukusawa, H.; Hashimoto, Y.; Kagechika, H. Chem. Pharm. Bull. 2001, 49, 501.
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Hybrid molecules comprising a retinoic acid receptor agonist moiety and a histone deacetylase inhibitor (HDAC) moiety are disclosed. Hybrid molecule 3 (6-(5,5,8,8-tetramethyl-6,7-dihydronaphthalen-2-yl)naphthalene-2-hydroxamic acid) was proven to posses HDAC activity while maintaining RAR agonist activity. Hybrid molecule 3 and pharmaceutical compositions thereof can be used in the treatment of breast cancer, leukemia, non-small cell lung cancer, colon cancer, melanoma, ovarian cancer, renal cancer, prostate cancer and cancer of the CNS.
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This is a continuation, of application Ser. No. 174,757, filed Aug. 4, 1980, which is a continuation in part of application Ser. No. 025,795, filed Apr. 2, 1979 both abandoned.
This invention relates to aquatic toboggan slides, that is entertainment equipment in which toboggan-like vehicles are allowed to accelerate down a chute or slide into a body of water.
BACKGROUND OF THE INVENTION AND REVIEW OF THE PRIOR ART
Aquatic toboggan slides of the type outlined above are known in the art, being described for example in U.S. Pat. Nos. 1,399,469, issued Dec. 6, 1921 to Cucullu, 1,467,293 issued Sept. 4, 1923 to Matheson, and 1,497,754 issued June 17, 1924 to Howard. Equipment of the type disclosed in these patents is not to the best of applicant's knowledge currently in use in the recreational industry, and it is believed that the reasons for this are that the equipment presents a risk of injury to users which is unacceptable for present day commercial installations, it is to difficult and expensive to maintain in good working order, and its actual performance is somewhat unpredictable and largely beyond the control of the user. The objectives sought by the present applicant in the performance of his slide are similar to those sought by Cucullu, i.e. a rapid acceleration down the slide, followed by a planing over the surface of the water for a greater or lesser distance. In order to achieve this, Cucullu provides a slight upturn to the lower end of his chute so as to impart lift and a nose-up attitude to a toboggan leaving the chute. The toboggan will therefore fly through the air on leaving the chute until the action of gravity cancels the lift and causes the toboggan to fall back to water level. During this period, the nose-up attitude of the toboggan will tend to increase, because the weight of the rider will be concentrated towards the rear of the toboggan, and the air resistance to the forward movement of the toboggan will exert a turning moment about the combined centre of mass of the toboggan and rider. The net result of this is that the rear end of the toboggan will strike the water at an angle, producing the "ricocheting" action described by Cucullu. Unfortunately, the impact with the water will also tend to occur immediately beneath the point where the rider will be seated, and the resultant shock will thus be transmitted straight up the rider's spine, as well as applying considerable stress to the toboggan, which in Cucullu's slide is apparently of similar construction to traditional snow toboggans. The present applicant has experimented with the use of such toboggans on an aquatic slide, and has found that the impact with the water applies stresses which rapidly destroy a toboggan of conventional construction and are injurious to the rider.
The two remaining patents identified above both show slides which terminate at their lower ends in floating sections which are designed to discharge a toboggan level with the water surface. Although as drawn, both show end sections which are slightly upturned, it seems intended that the hinged floating end sections will dip under the combined effect of the weight of the toboggan and the reaction entailed in changing its direction as it rounds the curve at the lower end of the slide. This level discharge of the toboggan reduces the risk of injury but also probably suppresses the "ricochet" effect described by Cucullu; it is noteworthy that neither the Howard nor the Matheson patents describe such an effect. Moreover, wave effects acting on the discharge section will render the exact direction of discharge unpredictable.
As pointed out above, conventionally constructed toboggans are not really suitable for use on the type of slide with which the present invention is concerned, since they are neither strong enough nor afford sufficient protection to the rider. Moreover, they are not designed for optimum planing characteristics over water. In Canadian Pat. No. 236,089, issued Dec. 4, 1923, Matheson describes a toboggan specifically designed for aquatic use. A specially reinforced toboggan frame is covered by a watertight skin so as to provide extra rigidity and buoyancy. Whilst the extra buoyancy may be a convenience and a safety factor if the toboggan is used in deep water, the protection it affords against injury to the user is probably no better than in the case of a conventional toboggan. In particular, there is no protection against the transmission of water impact, and nothing to guard against the user's limbs contacting the slide.
In the arrangements discussed above, the slides employed utilize roller conveyors. Proposals have also been made to utilize wheeled toboggans on plain slides, although this has the disadvantages of making it difficult to streamline the bottom of the toboggan and increasing the cost of construction. Such toboggans are shown in Canadian Pat. Nos. 27,770 and 246,640 although it is not clear whether they are intended for aquatic use. Where roller conveyors are used, it is of course important to minimize frictional losses in the conveyor, and corrosion is a major problem. It is also important to provide a slide structure which minimizes the risk of injury to its users. The Howard and Matheson structures rely on engagement of wheels and rollers with the runners of the toboggan to provide lateral guidance, which carries the risk of derailment, particularly in view of the necessarily fairly light weight of the toboggans relative to that of the user, and both would be extremely hazardous in the event of a user falling off a toboggan. The Cucullu structure relies on shallow side walls for guidance but there is nothing to prevent hands or feet being trapped between a toboggan and the sides of the slide; although the structure is less hazardous than that of Howard or Matheson to an unseated rider, the wide spacing of the rollers, the shallow side walls and the roller bearing arrangements all present risks of injury. It is believed that the wide spacing of the rollers and wheels in all the structures may be intended to reduce frictional losses as well as the cost of the structure, but it will reduce the safety of the slide, increase the stresses on both rollers and toboggan, and provide a rough ride around the bottom curve.
SUMMARY OF THE INVENTION
The present invention seeks to provide an aquatic toboggan slide which represents a marked improvement over the prior art and overcomes the difficulties outlined above.
According to the invention an aquatic toboggan slide comprises the combination of a downwardly inclined chute, a plurality of toboggans dischargable down the chute, and a body of water adjacent the lower end of the chute; the chute being in the shape of a trough with continuous side walls and a load bearing low friction bed free of dangerous projections, said chute being configured and constructed so that a toboggan and rider discharged down it will be confined between the walls of the chute and acquire, by the time they leave the chute, a velocity of at least 35 feet per second, the lower discharge end of the chute being level and about 12 to about 20 inches above the surface of the body of water, and the curvature of the lower end of the chute being such that the rider of the toboggan will not be subjected to more than about 2 G; the body of water extending a distance in feet beyond the bottom of the chute which is at least about 3 times the velocity in feet per second at which a toboggan will leave the chute; each toboggan having a continuous bottom wall defining an undersurface inclined upwardly at its front end to a prow, raised side walls, a resilient seat member at the rear of the toboggan extending between the side walls and spaced from the bottom wall without being directly supported thereby, a leg space extending forwardly of the seat towards the prow of the toboggan, and hand grips extending from the toboggan structure within the side walls and to either side of the leg space.
By arranging that the chute discharges parallel with the water surface but 12-20, preferably 14-16 inches above the water level, the risk of excessive impact with the water is greatly reduced without spoiling the "ricochet" effect sought by Cucullu. The vertical component of motion of the toboggan when it hits the water will be limited to the velocity it acquires in falling 12-20 inches, and the initially level attitude of the toboggan as it leaves the chute will limit the turning moment due to air resistance. This turning moment will be to some degree controllable according to the attitude the user adopts on the toboggan, thus allowing the exercise of skill to achieve the optimum planing effect when the toboggan strikes the water.
Because the rider is sitting on a seat which is not directly supported on the bottom of the toboggan, much of the water impact is absorbed by the toboggan structure without being transmitted to the rider's spine. A further safety factor is provided by the use of a backless seat, this avoiding the risk of the rider being bounced onto the back of the seat. Preferably the toboggan is moulded from a synthetic plastic material such as polyethylene, and may incorporate a buoyancy chamber, preferably filled with foamed plastic.
An important feature of the toboggan is the positioning of the hand grips. Since these are within the side walls and to either side of the leg space, they ensure that both the user's legs and hands are kept within the toboggan, thus reducing the risk of injury during passage down the slide. The trough shape of the slide also contributes to this, as does the freedom of the load bearing bed of dangerous projections. This can conveniently be achieved by forming this bed of fairly closely spaced smooth surfaced rollers so that even a rider who has fallen off a toboggan should pass down the chute without suffering serious injury or falling through the structure.
It is preferred that the main part of the chute is disposed at a considerable angle to the vertical, preferably about 45° as compared to about 30° or less used in prior art structures. This has the advantages that the rate of acceleration of the toboggans is greater, so that the overall length of the chute and the space required for it is reduced, and where the bed is formed by rollers the number of rollers required and the load upon them is also reduced. On the other hand, the thrill to the rider is increased. The bottom curve of the chute where its transition to the horizontal occurs should be such as to avoid excessive centripetal loads on either the equipment or the rider, and loads should not exceed about 2 G.
The invention also extends to the chute and to the toboggans. A preferred chute construction utilizes a continuous unitary trough member having side walls and a central well beneath a bed of rollers extending laterally between longitudinally extending continuous bearing blocks secured to longitudinal support rails flanking the well. Such a structure involves no dangerous projections, and is easy to construct from corrosion resistant materials. The side walls of the trough should be substantially vertical to at least the level of the top of the side walls of the toboggans, and then flared outwardly.
Further features of the invention will be apparent from the following description of a preferred embodiment with reference to the accompanying drawings.
SHORT DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a side elevation of a chute employed in the aquatic toboggan slide of the invention;
FIG. 1A is a section through the far side of a body of water located at the bottom of the chute;
FIG. 2 is a section through the chute of FIG. 1 on the line 2--2;
FIG. 3 is a perspective view of a toboggan for use with the chute;
FIG. 4 is a transverse cross section through the toboggan of FIG. 3, near its rear end;
FIG. 5 is an underside plan view of an alternate embodiment of toboggan; and
FIG. 6 is a fragmentary cross sectional view through a longitudinal rib of a toboggan.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A typical aquatic toboggan slide in accordance with the invention comprises a chute 2 and a body of water 4 as shown in FIG. 1 together with a number of toboggans 6 as shown in FIG. 3. Means (not shown) will of course be provided to enable the toboggans and their riders to reach a platform 8 at the top of the chute 2. The chute itself is trough shaped in cross section as seen in FIG. 2, with side walls 10 with down-turned reinforcing flanges and a load bearing bottom surface in the form of a bed of lateral rollers 12 extending across a well 14 formed integrally with the side walls 10. The side walls extend vertically above the roller bed to at least the height of the latter and are then flared outwardly to provide elbow room for riders of the toboggans. Typically the vertical portions are 8 inches high and the flared portions extend a further 5 inches. The well and side walls are preferably moulded in one piece from fibre reinforced synthetic resin so as to provide a smooth, strong, corrosion resistant unit. The moulding is supported to either side of the well by channel section support rails 16, to which are bolted continuous longitudinally extending bearing blocks 18 which support the ends of axle rods 20 of the rollers. At least one of the bearing blocks is split into upper and lower parts 22, 24 so as to permit rollers to be removed and replaced after the half 22 is removed. The bearing blocks may be of synthetic plastic, and the rollers themselves should be constructed of corrosion resistant materials. Thus the axle rods 20 may be of coated steel, the roller bodies 26 of plastic coated or sleeved steel, and the bearings 28 of plastic and/or stainless steel. The ends of the axle rods 20, which are preferably hexagonal in section, are located in the bearing blocks 18 by cylindrical bushes 19 having hexagonal bores and locating flanges external of the bearing block.
The resulting chute is light and strong in construction, and presents no dangerous projections or apertures on its inner surface. Typically, the side walls of the chute are about twenty-eight inches apart, and the rollers are 2-2.5 inches in diameter and are quite closely spaced at least around the bottom curve of the chute so as to provide a smooth ride and so as to avoid any opening through which a rider or his limbs could pass. Thus a rider should pass safely down the chute even after falling from a toboggan. The side walls 10 are higher than side walls of the toboggans thus making it extremely improbable that a toboggan can leave the slide accidentally.
The chute is configured so that there is an abrupt transition from the horizontal top platform 8 to a central portion 30 of the chute inclined at an angle of about 45° to the vertical, followed by a more gradual transition to a horizontal exit portion 32 of the chute positioned so that the top surface of the roller bed is parallel to and about 12-20 inches and preferably 14-16 inches above the surface of the body of water 4. The vertical drop down the chute is such as to provide a desired velocity at the exit portion, which velocity should be at least about 35 feet per second. Development of such a velocity requires a vertical drop of about 20 feet. A 32 foot vertical drop will theoretically provide an exit velocity of about 45 feet per second, assuming no losses through friction or air resistance occur; in practice for these reasons the velocity will be less than the theoretical although the steep slope and short length of the chute will minimize losses. When a toboggan descends such a chute, the rider will first feel an abrupt reduction to about one third of normal gravity as the toboggan drops down the chute, followed by an increase to well above normal gravity as the toboggan rounds the transition into the exit section of the chute. If the radius of this curve is about 16 feet, then the rider will be subject to a total force rising to the equivalent of about 2 G after which the toboggan will fly off the end of the chute and travel some feet through the air before striking the water. The water 4 extends beyond the bottom of the chute and in the same direction for at least about three times that distance in feet which corresponds to the velocity of the toboggan as it leaves the chute, i.e. about 135 feet in the example discussed, although about 150 feet is preferable. The behaviour of a toboggan 6 when it strikes the water is dependent on the structure of the toboggan, which will be discussed next.
The toboggan 6 shown in FIGS. 3 and 4 is formed by rotationally moulding from polyethylene a hollow body having upper and lower shells formed together as one piece, and injecting a foamable plastic material 35 to fill the interior. The lower shell forms a bottom wall 36 which provides a continuous lower planing surface with an inclined prow portion 38 at the front and longitudinally extending ribs 40 which assist the toboggan in planing in a straight line, stiffen the bottom wall, and engage the rollers 12. The bottom wall should be continuous so as to avoid the large openings which exist in many conventional toboggans since these generate excessive drag. The upper shell defines raised side walls 42, a raised seat portion 44, and a foot rest 46. Two hand grips are moulded into it within a well defined between the walls 42 and to either side of a leg space 50. The resulting double walled construction and the foamed filling 35 impart a degree of resiliency to the seat portion 44, which is not in any way directly supported on the bottom wall, whilst imparting strength and buoyancy to the toboggan. A typical toboggan is about two feet wide, four feet long, and six inches deep at the side walls. A rider mounting a toboggan at the platform 8 sits on the seat portion 44 and grips the hand grips 48, the rider's legs extending into the leg space 50 between the hand grips. The toboggan is then pushed forward onto the portion 30 of the chute which it descends as previously described. Since the rider's hands are within the walls 42 and the legs between the arms, there is no danger of limbs being trapped between the toboggan and the chute. When the toboggan strikes the water, the upturned prow prevents it from nosing under, and because of its high forward velocity, it will plane or hop over the water surface for a considerable distance. The angle of incidence with the water will affect its behaviour, and may be controlled to some extent after the toboggan leaves the slide by movement of the rider's centre of gravity. The resiliency of the seat portion protects the back of the user, whilst the construction of the toboggan provides it with the flexibility to resist impact without suffering damage. The backless construction of the seat portion 44 avoids the possibility of back injury should the rider be jerked rearwardly.
In an installation having several parallel chutes, it is desirable to divide the water into separate "lanes" by barriers to avoid the possibility of collision between toboggans from adjacent slides. The water should be deep enough in those areas where the toboggans are still travelling rapidly to avoid the risk of injury to riders falling off the toboggans; about four to six feet of water is satisfactory. The water may become gradually shallower at the side of the body of water opposite the chute or chutes to assist riders in leaving the water and to provide for "beaching" of toboggans which manage to plane for greater than usual distances.
FIG. 5 illustrates features of an alternative embodiment of toboggan which is of lighter and simpler construction. The upper shell is dispensed with except for the seat portion 144, which extends between side walls 142 integral with the bottom wall 136. Between and recessed relative to the longitudinal ribs 140 in the bottom surface are lateral ribs 152 of sawtooth form such as to stiffen the bottom surface, the sawtooth configuration being such as to provide a fluid bearing action enhancing the planing effect. Planing is further enhanced by the provision of inclined planing surfaces 154 between the side and bottom walls. A buoyancy element such as a slab of resilient plastic foam may be provided between the seat portion 144 and the bottom wall. The lateral ribs and planing surfaces may of course be incorporated in the toboggan of FIGS. 3 and 4, as may the feature shown in FIG. 6. FIG. 6 shows a longitudinal rib 240 in cross section, this rib structure replacing the ribs 40 or 140. THe rib comprises spaced side flange 241, between which a replaceable ribbing strip 243 is retained by cross pins 245 which may be bolts or countersunk rivets. It is the bottom of the ribs, in this case provided by the ribbing strips 243, that sustain the most wear and engender the most friction, and thus it is advantageous to be able to repair an otherwise serviceable toboggan by replacing the strips, which may if desired be made of lower friction and/or harder wearing material than the remainder of the toboggan, i.e. nylon. Since flexure of the toboggan structure during use means that the centre rib is subject to the most wear, only this rib need have a replaceable ribbing strip although preferably all of the ribs are so constructed.
Although it is preferred that the bed of at least the curve at the bottom of the chute is formed by closely spaced rollers so as to minimize frictional losses, rollers on the remainder of the chute may be more widely spaced provided that the gaps between them do not provide a major hazard, or the upper part of the chute could have a plain bed of low-friction material.
A purpose built pool will normally be desirable to provide the body of water, since it is unlikely that any existing pool will be available having the desired characteristics, i.e. a sufficient extent beyond the bottom of the chute, sufficient but not excessive depth beneath the landing area of the toboggans, shallow water or a beach 5 at the limit of planing of the toboggans (see FIG. 1A), control of the water level relative to the lower end of the chute, and physical separation between portions of the water extending beyond adjacent chutes if more than one is provided.
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An aquatic toboggan slide has a trough like chute with side walls and a bed of closely spaced rollers, the toboggans discharging horizontally from the chute about 12-20 inches above a body of water so as to skip or plane over the water surface. The toboggans are of moulded plastic with a planing bottom surface and resilient seats spaced from the bottom surface to protect the user's spine against water impact shocks. The toboggans may be double walled and foam filled or single walled with transverse ribs in the bottom surface to stiffen the structure and enhance planing.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a divisional of application Ser. No. 09/901,569, filed Jul. 11,2001, now U.S. Pat. No. 6,537,727 which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a chemically amplified resist composition, and more particularly, the present invention relates to a resist composition comprising a photosensitive polymer having lactone in its backbone.
2. Description of the Related Art
As the integration density and complexity of semiconductor devices continue to increase, the ability to form ultra-fine patterns becomes more and more critical. For example, in 1-Gigabit or higher semiconductor devices, a pattern size having a design rule of 0.2 μm or less is needed. For this reason, in lithography processes, the lower wavelength ArF eximer laser (193 nm) has emerged as a preferred exposure light source to the more conventional and higher wavelength KrF eximer laser (248 nm).
However, compared with conventional (KrF) resist materials, resist materials which are suitable for use with the ArF eximer laser suffer from a variety drawbacks. The most serious problems relate transmittance and resistance to dry etching.
Almost all well-known ArF resist compositions contain (meth)acryl-based polymers. Among these polymers, a methacrylate copolymer having an alicyclic protecting group, which is expressed by the formula below, has been suggested ( J. Photopolym. Sci. Technol ., 9(3), pp. 509 (1996))
This polymer has an adamantyl group, which contributes to enhancing resistance to dry etching, and a lactone group, which improves adhesiveness, in its methacrylate backbone. As a result, the resolution of the resist and the depth of focus are improved. However, resistance to dry etching is still weak, and serious line edge roughness is observed after line patterns are formed from the resist layer.
Another drawback of the aforementioned polymer is that the raw material used to synthesize the polymer is expensive. In particular, the manufacturing cost of a polymer having a lactone group, which is introduced to improve adhesiveness, is so high that its practical use as a resist is difficult.
As another conventional resist composition, a cycloolefin-maleic anhydride (COMA) alternating polymer having the following formula has been suggested ( J. Photopolym. Sci. Technol ., Vol. 12(4), pp. 553 (1999), and U.S. Pat. No. 5,843,624)
In the production of a copolymer, such as a COMA alternating polymer having the formula above, the production cost of raw material is relatively inexpensive, but the yield of the polymer sharply decreases. In addition, the transmittance of the polymer is very low at a short wavelength region, for example at 193 nm. The synthetic polymers have in their backbone the alicyclic group, which exhibits prominent hydrophobicity, and thus the adhesiveness to neighboring material layers is very poor.
The copolymer has a glass transition temperature of 200° C. or more due to the structural characteristic of the backbone. As a result, it is difficult to carry out an annealing process for eliminating free volume from the resist layer formed of the polymer, and accordingly the resist layer is influenced by ambient conditions which can cause, for example, a T-top profile of corresponding resist patterns. In addition, the resist layer itself becomes less resistant to ambient conditions during post-exposure delay, so that many problems can occur during subsequent processes with respect to the photoresist layer.
To improve the resolution of the resist layer, the polymer system must be charged with a polar group. In recent years, a technique of introducing a lactone group into a methacrylate monomer having an alicyclic protecting group, using the following alicyclic compounds with a lactone group, has been suggested so as to enhance the resistance to dry etching ( J. Photopolym. Sci. Technol ., Vol. 13(4), pp. 601 (2000), and Japanese Patent Laid-open No. hei 12-26446):
Unfortunately, the yield of the monomer having the above formula is so low as to substantially increase manufacturing costs.
SUMMARY OF THE INVENTION
It is an objective of the present invention to provide a resist composition that can be produced at relatively low costs while exhibiting improved dry etching resistance, improved adhesiveness to underlying material layers, improved line edge roughness of line patterns, and improved contrast characteristics.
To achieve the objective of the present invention, there is provided a resist composition comprising a photosensitive polymer polymerized with (a) at least one of the monomers having the respective formulae:
where R 1 and R 2 are independently a hydrogen atom, alkyl, hydroxyalkyl, alkyloxy, carbonyl or ester, and x and y are independently integers from 1 to 6, and (b) at least one comonomer selected from the group consisting of (meth)acrylate monomer, methacrylate monomer, maleic anhydride monomer, and norbornene monomer; and a photoacid generator (PAG).
In one embodiment of the resist composition, the comonomer may be maleic anhydride monomer, and the formula of the photosensitive polymer may be one selected from the formulae:
where m/(m+q) is in the range of 0.01–0.5,
where n/(n+q) is in the range of 0.01–0.5, and
where (m+n)/(m+n+q) is in the range of 0.01–0.5.
In another embodiment of the resist composition, the comonomer may include a (meth)acrylate monomer and a maleic anhydride monomer, and the formula of the photosensitive-polymer may be selected from the formulae:
where R 3 is a hydrogen atom or methyl, R 4 is an acid-liable group, and m/(m+p+q) is in the range of 0.01–0.5, p/(m+p+q) is in the range of 0.1–0.6, and q(m+p+q) is in the range of 0.1–0.6,
where R 3 is a hydrogen atom or methyl, R 4 is an acid-liable group, and n/(n+p+q) is in the range of 0.01–0.5, p/(n+p+q) is in the range of 0.1–0.6, and q(n+p+q) is in the range of 0.1–0.6, and
where R 3 is a hydrogen atom or methyl, R 4 is an acid-liable group, and (m+n)/(m+n+p+q) is in the range of 0.01–0.5, p/(m+n+p+q) is in the range of 0.1–06, and q(m+n+p+q) is in the range of 0.1–0.6.
It is preferable that R 4 is t-butyl, tetrahydropyranyl, or substituted or unsubstituted alicyclic hydrocarbon having from 6 to 20 carbon atoms. More preferably, R 4 is 2-methyl-2-norbornyl, 2-ethyl-2-norbornyl, 2-methyl-2-isobornyl, 2-ethyl-2-isobornyl, 8-methyl-8-tricyclo[5.2.1.0 2,6 ]decanyl, 8-ethyl-8-tricyclo[5.2.1.0 2,6 ]decanyl, 2-methyl-2-adamantyl, 2-ethyl-2-adamantyl, 1-adamantyl-1-methylethyl, 2-methyl-2-fenchyl or 2-ethyl-2-fenchyl.
In another embodiment of the resist composition, the comonomer may include (meth)acrylate monomer, maleic anhydride monomer and norbornene monomer, and the formula of the photosensitive polymer may be one selected from the formulae:
where R 3 is a hydrogen atom or methyl; R 4 is an acid-liable group; R 5 and R 6 , are independently a hydrogen atom, hydroxyl, hydroxymethyl, 2-hydroxyethyloxycarbonyl, carboxyl, t-butoxycarbonyl, methoxycarbonyl, or substituted or unsubstituted alicyclic hydrocarbon having from 6 to 20 carbon atoms;
m/(m+p+q+r) is in the range of 0.01–0.5; p/(m+p+q+r) is in the range of 0.1–0.6; q/(m+p+q+r) is in the range of 0.1–0.6; and r/(m+p+q+r) is in the range of 0.1–0.3,
where R 3 is a hydrogen atom or methyl; R 4 is an acid-liable group; R 5 and R 6 are independently a hydrogen atom, hydroxyl, hydroxymethyl, 2-hydroxyethyloxycarbonyl, carboxyl, t-butoxycarbonyl, methoxycarbonyl, or substituted or unsubstituted alicyclic hydrocarbon having from 6 to 20 carbon atoms;
n/(n+p+q+r) is in the range of 0.01–0.5; p/(n+p+q+r) is in the range of 0.1–0.6; q/(n+p+q+r) is in the range of 0.1–0.6; and r/(n+p+q+r) is in the range of 0.1–0.3, and
where R 3 is a hydrogen atom or methyl; R 4 is an acid-liable group; R 5 and R 6 are independently a hydrogen atom, hydroxyl, hydroxymethyl, 2-hydroxyethyloxycarbonyl, carboxyl, t-butoxycarbonyl, methoxycarbonyl, or substituted or unsubstituted alicyclic hydrocarbon having from 6 to 20 carbon atoms;
(m+n)/(m+n+p+q+r) is in the range of 0.01–0.5; p/(m+n+p+q+r) is in the range of 0.1–0.6; q/(m+n+p+q+r) is in the range of 0.1–0.6; and r/(m+n+p+q+r) is in the range of 0.1–0.3.
In another embodiment, the present invention provides a resist composition comprising a photosensitive polymer polymerized with (a) at least one of the monomers having the respective formulae:
where v and w are independently integers from 1 to 6, and (b) at least one comonomer selected from the group consisting of a acrylate monomer, methacrylate monomer, maleic anhydride monomer, and norbornene monomer; and a photoacid generator (PAG).
In one embodiment of the resist composition above, the comonomer may be maleic anhydride monomer, and the formula of the photosensitive polymer may be one selected from the formulae:
where k/(k+q) is in the range of 0.01–0.5,
where l/(l+q) is in the range of 0.01–0.5, and
where (k+l)/(k+l+q) is in the range of 0.01–0.5.
In another embodiment of the resist composition, the comonomer may include a (meth)acrylate monomer, and the formula of the photosensitive polymer may be selected from the formulae:
where R 3 is a hydrogen atom or methyl, R 4 is an acid-liable group, and k/(k+p) is in the range of 0.3–0.8,
where R 3 is a hydrogen atom or methyl, R 4 is an acid-liable group, and l/(l+p) is in the range of 0.3–0.8, and
where R 3 is a hydrogen atom or methyl, R 4 is an acid-liable group, and (k+l)/(k+l+p) is in the range of 0.3–0.8.
In another embodiment of the resist composition, the comonomer may include a (meth)acrylate monomer and maleic anhydride monomer, and the formula of the photosensitive polymer may be one selected from the formulae:
where R 3 is a hydrogen atom or methyl; R 4 is an acid-liable group; k/(k+p+q) is in the range of 0.01–0.5; p/(k+p+q) is in the range of 0.1–0.6; and q/(k+p+q) is in the range of 0.1–0.6,
where R 3 is a hydrogen atom or methyl; R 4 is an acid-liable group; l/(l+p+q) is in the range of 0.01–0.5; p/(l+p+q) is in the range of 0.1–0.6; and q/(l+p+q) is in the range of 0.1–0.6, and
where R 3 is a hydrogen atom or methyl; R 4 is an acid-liable group; (k+l)/(k+l+p+q) is in the range of 0.01–0.5; p/(k+l+p+q) is in the range of 0.1–0.6; and q/(k+l+p+q) is in the range of 0.1–0.6.
In another embodiment of the resist composition, the comonomer may include a maleic anhydride monomer and norbornene monomer, and the formula of the photosensitive polymer may be one selected from the formulae:
where R 5 and R 6 are independently a hydrogen atom, hydroxyl, hydroxymethyl, 2-hydroxyethyloxycarbonyl, carboxyl, t-butoxycarbonyl, methoxycarbonyl, or substituted or unsubstituted alicyclic hydrocarbon having from 6 to 20 carbon atoms;
k/(k+q+r) is in the range of 0.01–0.5; q/(k+q+r) is in the range of 0.1–0.6; and r/(k+q+r) is in the range of 0.1–0.3,
where R 5 and R 6 are independently a hydrogen atom, hydroxyl, hydroxymethyl, 2-hydroxyethyloxycarbonyl, carboxyl, t-butoxycarbonyl, methoxycarbonyl, or substituted or unsubstituted alicyclic hydrocarbon having from 6 to 20 carbon atoms;
l/(l+q+r) is in the range of 0.01–0.5; q/(l+q+r) is in the range of 0.1–0.6; and r/(l+q+r) is in the range of 0.1–0.3, and
where R 5 and R 6 are independently a hydrogen atom, hydroxyl, hydroxymethyl, 2-hydroxyethyloxycarbonyl, carboxyl, t-butoxycarbonyl, methoxycarbonyl, or substituted or unsubstituted alicyclic hydrocarbon having from 6 to 20 carbon atoms;
(k+l)/(k+l+q+r) is in the range of 0.01–0.5; q/(k+l+q+r) is in the range of 0.1–0.6; and r/(k+l+q+r) is in the range of 0.1–0.3.
In another embodiment of the resist composition, the comonomer may include a (meth)acrylate monomer, maleic anhydride monomer, and norbornene monomer, and the formula of the photosensitive polymer may be one selected from the formulae:
where R 3 is a hydrogen atom or methyl; R 4 is an acid-liable group; R 5 and R 6 are independently a hydrogen atom, hydroxyl, hydroxymethyl, 2-hydroxyethyloxycarbonyl, carboxyl, t-butoxycarbonyl, methoxycarbonyl, or substituted or unsubstituted alicyclic hydrocarbon having from 6 to 20 carbon atoms;
k/(k+p+q+r) is in the range of 0.01–0.5; p/(k+p+q+r) is in the range of 0.1–0.6; q/(k+p+q+r) is in the range of 0.1–0.6; and r/(k+p+q+r) is in the range of 0.1–0.3,
where R 3 is a hydrogen atom or methyl; R 4 is an acid-liable group; R 5 and R 6 are independently a hydrogen atom, hydroxyl, hydroxymethyl, 2-hydroxyethyloxycarbonyl, carboxyl, t-butoxycarbonyl, methoxycarbonyl, or substituted or unsubstituted alicyclic hydrocarbon having from 6 to 20 carbon atoms;
l/(k+p+q+r) is in the range of 0.01–0.5; p/(l+p+q+r) is in the range of 0.1–0.6; q/(l+p+q+r) is in the range of 0.1–0.6; and r/(l+p+q+r) is in the range of 0.1–0.3, and
where R 3 is a hydrogen atom or methyl; R 4 is an acid-liable group; R 5 and R 6 are independently a hydrogen atom, hydroxyl, hydroxymethyl, 2-hydroxyethyloxycarbonyl, carboxyl, t-butoxycarbonyl, methoxycarbonyl, or
substituted or unsubstituted alicyclic hydrocarbon having from 6 to 20 carbon atoms; (k+l)/(k+l+p+q+r) is in the range of 0.01–0.5; p/(k+l+p+q+r) is in the range of 0.1–0.6; q/(k+l+p+q+r) is in the range of 0.1–0.6; and r/(k+l+p+q+r) is in the range of 0.1–0.3.
In another embodiment, the present invention provides a resist composition comprising a photosensitive polymer including at least one of the monomers having the respective formulae:
where R 7 , R 8 , R 9 , R 10 , R 11 , R 12 , R 13 , R 14 , and R 15 are independently a hydrogen atom or alkyl, and z is an integer from 1 to 6.
In the resist compositions according to the present invention, the photosensitive polymer has a weight average molecular weight of 3,000 to 100,000.
The amount of the photoacid generator (PAG) is in the range of 1 to 30% by weight based on the weight of the photosensitive polymer. It is preferable that the photoacid generator (PAG) comprises triarylsulfonium salts, diaryliodonium salts, sulfonates or a mixture of these materials. More preferably, the photoacid generator (PAG) comprises triphenylsulfonium triflate, triphenylsulfonium antimonate, diphenylionium triflate; diphenyliodonium antimonate, methoxydiphenyliodonium triflate, di-t-butyldiphenyliodonium triflate, 2,6-dinitrobenzyl sulfonates, pyrogallol tris(alkylsulfonates), N-hydroxysuccinimide triflate, norbornene-dicarboximide-triflate, triphenylsulfonium nonaflate, diphenyliodonium nonaflate, methoxydiphenyliodonium nonaflate, di-t-butyldiphenyliodonium nonaflate, N-hydroxysuccinimide nonaflate, norbornene-dicarboximide-nonaflate, triphenylsulfonium perfluorooctanesulfonate (PFOS), diphenyliodonium PFOS, methoxydiphenyliodonium PFOS, di-t-butyldiphenyliodonium triflate, N-hydroxysuccinimide PFOS, norbornene-dicarboximide PFOS, or a mixture of these compounds.
It is preferable that the resist composition further comprises an organic base. It is preferable that the amount of the organic base is in the range of 0.01 to 2.0% by weight based on the weight of the photosensitive polymer. The organic base preferably comprises a tertiary amine compound alone or a mixture of at least two tertiary amine compounds. More preferably, the organic base comprises triethylamine, triisobutylamine, triisooctylamine, triisodecylamine, diethanolamine, triethanolamine or a mixture of these compounds.
It is preferable that the resist composition further comprises a surfactant in an amount of 30 to 200 ppm.
It is preferable that the resist composition further comprises a dissolution inhibitor in an amount of 0.1 to 50% by weight based on the weight of the photosensitive polymer.
The photosensitive polymer, which constitutes the photoresist composition according to the present invention, includes a hydrophilic cyclic lactone in its backbone. Thus, the resist composition prepared from the photosensitive polymer has superior adhesiveness to the underlying material layer, excellent resistance to dry etching, and improved transmittance. When forming line patterns from the resist layer deposited with the resist composition according to the present invention, line edge roughness characteristic is improved. The dissolution contrast characteristic, which appears after developing, sharply increases, thereby enlarging the depth of focus (DOF) margin. The photosensitive polymer of the resist composition according to the present invention has a desirable glass transition temperature, so that the resist composition prepared with the photosensitive polymer exhibits superior lithography characteristics.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
SYNTHESIS EXAMPLE 1
Synthesis of Terpolymer
SYNTHESIS EXAMPLE 1-1
(R 3 =methyl, R 4 =2-methyl-adamantyl)
12.0 g 2-methyladamantylmethacrylate (MAdMA), 3.4 g maleic anhydride (MA), and 1.66 g α-angelicalactone (AGL) were dissolved in 17 g tetrahydrofuran (THF). 1.38 g dimethyl 2,2′-azobisisobutyrate (V601) was added to the solution, degassed and polymerized at 70° C. for 20 hours.
After the reaction was completed, the obtained reaction product was precipitated with excess isopropyl alcohol twice, filtered, and dried in a vacuum oven for 24 hours, so that the terpolymer having the formula above was obtained with a yield of 72%.
The obtained terpolymer had a weight average molecular weight (Mw) of 11,400, and a polydispersity (Mw/Mn) of 2.4.
In the synthesis of the terpolymer, the mixing ratio of the monomers can be varied to adjust the solubility of the polymer. The various mixing ratios of the monomers and the characteristics of the resultant five terpolymers are listed below in Table 1.
TABLE 1
Mixing Ratio
Con-
Solvent-
of Monomers
centration
to-Monomer
Polymeriza-
(MAdMa:MA:
of Initiator
ratio
tion Time
AGL)
(mol %)
(by weight)
(hr)
Yield (%)
Mw
Mw/Mn
3:4:1
AIBN 0.05
0.5
24
68
32,100
3.3
3:3:1
AIBN 0.05
0.5
24
87
21,000
2.2
3:2:1
AIBN 0.05
0.5
24
80
17,300
2.7
3:1:2
V601 0.05
1
20
56
7,200
1.7
3:2:1
V601 0.05
1
20
73
9,800
2.8
SYNTHESIS EXAMPLE 1-2
(R 3 =methyl, R 4 =8-ethyl-8-tricyclo[5.2.1.0 2,6 ]decanyl])
14.8 g 8-ethyl-8-tricyclo[5.2.1.0 2,6 ]decanylmethacrylate (ETCDMA), 3.4 g maleic anhydride (MA), and 1.66 g α-angelicalactone (AGL) were dissolved in 20 g tetrahydrofuran (THF). 1.38 g dimethyl 2,2′-azobisisobutyrate (V601) was added into the solution, degassed and polymerized at 70° C. for 20 hours.
After the reaction was completed, the obtained reaction product was precipitated with excess isopropyl alcohol twice, filtered, and dried in a vacuum oven for 24 hours, so that the terpolymer having the formula above was obtained with a yield of 65%.
The obtained terpolymer had a weight average molecular weight (Mw) of 12,100, and a polydispersity (Mw/Mn) of 2.6.
SYNTHESIS EXAMPLE 1-3
(R 3 =methyl, R 4 =1-methylcyclohexyl)
5.5 g 1-methylcyclohexylmethacrylate (MChMA), 1.7 g maleic anhydride (MA), and 0.83 g α-angelicalactone (AGL) were dissolved in 8 g tetrahydrofuran (THF). 0.69 g dimethyl 2,2′-azobisisobutyrate (V601) was added to the solution, degassed and polymerized at 70° C. for 20 hours.
After the reaction was completed, the obtained reaction product was precipitated with excess isopropyl alcohol twice, filtered, and dried in a vacuum oven for 24 hours, so that the terpolymer having the formula above was obtained with a yield of 71%.
The obtained terpolymer had a weight average molecular weight (Mw) of 11,000, and a polydispersity (Mw/Mn) of 2.6.
SYNTHESIS EXAMPLE 2
Synthesis of Tetrapolymer
In the above formula, R 3 is methyl and R 4 is 2-methyl-adamantyl.
6 g 2-methyladamantylmethacrylate (MAdMA), 1.9 g maleic anhydride (MA), 1.0 g 5,6-dihydro-2H-pyrane-2-one (DHPone) and 0.63 g norbornene (Nb) were dissolved in 9.7 g tetrahydrofuran (THF). 0.74 g dimethyl 2,2′-azobisisobutyrate (V601) was added to the solution, degassed and polymerized at 70° C. for 20 hours.
After the reaction was completed, the obtained reaction product was precipitated with excess isopropyl alcohol twice, filtered, and dried in a vacuum oven for 24 hours, so that the tetrapolymer having the formula above was obtained with a yield of 71%.
The obtained tetrapolymer had a weight average molecular weight (Mw) of 12,000, and a polydispersity (Mw/Mn) of 2.1.
SYNTHESIS EXAMPLE 3
Synthesis of Tetrapolymer
In the above formula, R 3 is methyl and R 4 is 2-methyl-adamantyl.
6 g 2-methyladamantylmethacrylate (MAdMA), 1.9 g maleic anhydride (MA), 1.2 g α-angelicalactone (AGL) and 0.63 g norbornene (Nb) were dissolved in 9.7 g tetrahydrofuran (THF). 0.74 g dimethyl 2,2′-azobisisobutyrate (V601) was added to the solution, degassed and polymerized at 70° C. for 20 hours.
After the reaction was completed, the obtained reaction product was precipitated with excess isopropyl alcohol twice, filtered, and dried in a vacuum oven for 24 hours, so that the tetrapolymer having the formula above was obtained with a yield of 72%.
The obtained tetrapolymer had a weight average molecular weight (Mw) of 12,600, and a polydispersity (Mw/Mn) of 1.9.
In the synthesis of the tetrapolymer, the mixing ratio of the monomers can be varied to adjust the solubility of the polymer. The various mixing ratios of the monomers, and the characteristics of the resultant six tetrapolymers are listed below in Table 2.
TABLE 2
Mixing Ratio
of Monomers
Concentration
Solvent-to-
Polymeriza-
(MAdMA:MA:
of Initiator
Monomer ratio
tion Time
Nb:AGL)
(mol %)
(by weight)
(hr)
Yield (%)
Mw
Mw/Mn
4:3:2:1
V601 0.05
1
24
74
8,300
2.6
4:3:1:2
V601 0.05
1
24
62
7,700
2.1
4:3:2:2
V601 0.05
1
24
65
6.700
2.2
4:2:2:2
V601 0.05
1
20
59
6,700
2.0
4::1:1:2
V601 0.05
1
20
31
6,800
1.7
4:1:1:3
V601 0.05
1
20
62
5,600
1.6
SYNTHESIS EXAMPLE 4
Synthesis of Terpolymer
In the above formula, R 3 is methyl and R 4 is 2-methyl-adamantyl.
12.0 g 2-methyladamantylmethacrylate (MAdMA), 3.4 g maleic anhydride (MA), and 1.66 g α-methylenebutyrolactone (α-MBL) were dissolved in 17 g tetrahydrofuran (THF). 1.38 g dimethyl 2,2′-azobisisobutyrate (V601) was added to the solution, degassed and polymerized at 70° C. for 20 hours.
After the reaction was completed, the obtained reaction product was precipitated with excess isopropyl alcohol twice, filtered, and dried in a vacuum oven for 24 hours, so that the terpolymer having the formula above was obtained with a yield of 73%.
The obtained terpolymer had a weight average molecular weight (Mw) of 15,400, and a polydispersity (Mw/Mn) of 2.9.
SYNTHESIS EXAMPLE 5
Synthesis of Tetrapolymer
SYNTHESIS EXAMPLE 5-1
(R 3 =methyl, R 4 =2-methyl-adamantyl)
6 g 2-methyladamantylmethacrylate (MAdMA), 1.88 g maleic anhydride (MA), 0.63 g α-methylenebutyrolactone (α-MBL), and 1.21 g norbornene (Nb) were dissolved in 9.7 g tetrahydrofuran (THF). 0.74 g dimethyl 2,2′-azobisisobutyrate (V601) was added to the solution, degassed and polymerized at 70° C. for 20 hours.
After the reaction was completed, the obtained reaction product was precipitated with excess isopropyl alcohol twice, filtered, and dried in a vacuum oven for 24 hours, so that the tetrapolymer having the formula above was obtained with a yield of 88%.
The obtained tetrapolymer had a weight average molecular weight (Mw) of 15,800, and a polydispersity (Mw/Mn) of 3.3.
In the synthesis of the tetrapolymer, the mixing ratio of the monomers can be varied to adjust the solubility of the polymer. The various mixing ratios of the monomers, and the characteristics of the resultant three tetrapolymers are listed below in Table 3.
TABLE 3
Mixing Ratio
of Monomers
Concentration
Solvent-to-
Polymeriza-
(MAdMA:MA:
of Initiator
Monomer ratio
tion Time
α-MBL:Nb)
(mol %)
(by weight)
(hr)
Yield (%)
Mw
Mw/Mn
3:3:1:2
V601 0.05
1
20
87
13,300
3.6
4:3:1:2
V601 0.05
1
20
88
15,800
3.4
5:3:1:2
V601 0.05
1
20
86
18,600
3.7
SYNTHESIS EXAMPLE 5-2
(R 3 =methyl, R 4 =2-methyl-adamantyl)
6.4 g 2-ethyladamantylmethacrylate (EAdMA), 1.88 g maleic anhydride (MA), 0.63 g α-methylenebutyrolactone (α-MLB), and 1.21 g norbornene (Nb) were dissolved in 9.7 g tetrahydrofuran (THF). 0.74 g dimethyl 2,2′-azobisisobutyrate (V601) was added to the solution, degassed and polymerized at 70° C. for 20 hours.
After the reaction was completed, the obtained reaction product was precipitated with excess isopropyl alcohol twice, filtered, and dried in a vacuum oven for 24 hours, so that the tetrapolymer having the formula above was obtained with a yield of 78%.
The obtained tetrapolymer had a weight average molecular weight (Mw) of 11,600, and a polydispersity (Mw/Mn) of 3.0.
SYNTHESIS EXAMPLE 5-3
(R 3 =hydrogen, R 4 =2-methyl-adamantyl)
6.2 g 2-methyladamantylacrylate (MAdA), 2.06 g maleic anhydride (MA), 0.69 g α-methylenebutyrolactone (αMBL), and 1.32 g norbornene (Nb) were dissolved in 9.7 g tetrahydrofuran (THF). 0.74 g dimethyl 2,2′-azobisisobutyrate (V601) was added to the solution, degassed and polymerized at 70° C. for 20 hours.
After the reaction was completed, the obtained reaction product was precipitated with excess isopropyl alcohol twice, filtered, and dried in a vacuum oven for 24 hours, so that the tetrapolymer having the formula above was obtained with a yield of 76%.
The obtained tetrapolymer had a weight average molecular weight (Mw) of 7,010, and a polydispersity (Mw/Mn) of 1.96.
SYNTHESIS EXAMPLE 6
Synthesis of Tetrapolymer
In the above formula, R 3 is methyl and R 4 is 2-methyl-adamantyl.
6.4 g 2-methyladamantylmethacrylate (MAdMA), 1.88 g maleic anhydride (MA), 0.63 g γ-methylenebutyrolactone (γ-MBL), and 1.21 g norbornene (Nb) were dissolved in 9.7 g tetrahydrofuran (THF). 0.74 g dimethyl-2,2′-azobisisobutyrate (V601) was added to the solution, degassed and polymerized at 70° C. for 20 hours.
After the reaction was completed, the obtained reaction product was precipitated with excess isopropyl alcohol twice, filtered, and dried in a vacuum oven for 24 hours, so that the tetrapolymer having the formula above was obtained with a yield of 82%.
The obtained tetrapolymer had a weight average molecular weight (Mw) of 14,300, and a polydispersity (Mw/Mn) of 2.8.
SYNTHESIS EXAMPLE 7
Synthesis of Monomer
A solution of 30 g 2-bromomethylacrylic acid ethyl ester in 100 ml anhydrous THF was added dropwise with vigorous stirring under nitrogen to a mixture of 10.6 g zinc and 15.5 g adamantanone in 50 ml anhydrous THF. The reaction mixture was reacted at 60° C. for 10 hours. The reaction product was cooled down to room temperature, poured into 500 ml diluted hydrochloric acid solution, and extracted with 700 ml ether twice. The extracted solution was washed with 400 ml aqueous sodium hydrogencarbonate (NaHCO 3 ) and with 400 ml water, and then dried over anhydrous sodium sulfate (Na 2 SO 4 ). The dried product was evaporated with ether under reduced pressure. The residue was recrystallized from methylene dichloride and hexane, so that white solid monomer A was obtained with a yield of 62%.
SYNTHESIS EXAMPLE 8
Synthesis of Terpolymer
In the above formula, R 3 is methyl and R 4 is 2-methyl-adamantyl.
7.03 g 2-methyladamantylmethacrylate (MAdMA), 1.96 g maleic anhydride (MA), and 2.18 g Monomer A synthesized in SYNTHESIS EXAMPLE 7 were dissolved in 11.2 g tetrahydrofuran (THF). 0.69 g dimethyl 2,2′-azobisisobutyrate (V601) was added to the solution, degassed and polymerized at 70° C. for 4 hours.
After the reaction was completed, the obtained reaction product was precipitated with excess isopropyl alcohol twice, filtered, and dried in a vacuum oven for 24 hours, so that the tetrapolymer having the formula above was obtained with a yield of 86%.
The obtained terpolymer had a weight average molecular weight (Mw) of 8,200, and a polydispersity (Mw/Mn) of 2.0.
In the synthesis of the terpolymer, the mixing ratio of the monomers can be varied. The various mixing ratios of the monomers, and the characteristics of the resultant three terpolymers are listed below in Table 4.
TABLE 4
Mixing Ratio
of Monomers
Concentration
Solvent-to-
Polymeriza-
(MAdMA:MA:
of Initiator
Monomer ratio
tion Time
Monomer A)
(mol %)
(by weight)
(hr)
Yield (%)
Mw
Mw/Mn
3:6:1
V601 0.05
1
4
62
5,700
2.1
3:4:1
V601 0.05
1
4
72
7,000
2.0
3:2:1
V601 0.05
1
4
86
8,200
2.0
SYNTHESIS EXAMPLE 9
Synthesis of Tetrapolymer
In the above formula, R 3 is methyl and R 4 is 2-methyl-adamantyl.
9.7 g 2-methyladamantylmethacrylate (MAdMA), 4.06 g maleic anhydride (MA), 3 g Monomer A synthesized in SYNTHESIS EXAMPLE 7, and 2.6 g norbornene (Nb) were dissolved in 19.6 g tetrahydrofuran (THF). 1.6 g dimethyl 2,2′-azobisisobutyrate (V601) was added to the solution, degassed and polymerized at 70° C. for 20 hours.
After the reaction was completed, the obtained reaction product was precipitated with excess isopropyl alcohol twice, filtered, and dried in a vacuum oven for 24 hours, so that the tetrapolymer having the formula above was obtained with a yield of 86%.
The obtained tetrapolymer had a weight average molecular weight (Mw) of 5,500, and a polydispersity (Mw/Mn) of 2.4.
EXAMPLE 1
Preparation of Resist Composition
1.0 g each of the polymers obtained in SYNTHESIS EXAMPLEs 1-1 through 1-3, SYNTHESIS EXAMPLE 2, and SYNTHESIS EXAMPLE 3, 0.01 g triphenylsulfonium trifluoromethanesulfonate (triflate) as a photoacid generator (PAG), and 3.2 mg triisodecylamine as an organic base, were completely dissolved in a mixed, solution of 4.0 g propylene glycol monomethyl ether acetate (PGMEA) and 4.0 g cyclohexanone, and filtered through a membrane filter of 0.2 μm, so that resist compositions were obtained. Each of the resist compositions was coated on a silicon (Si) wafer treated with organic anti-reflective coating (ARC) to a thickness of about 0.35 μm.
The wafers coated with the respective resist compositions were soft baked at 130° C. for 90 seconds, exposed using an ArF eximer laser stepper (NA=0.6), and subjected to a post-exposure bake (PEB) at 120° C. for 60 seconds.
The resultant wafers were developed using 2.38% by weight tetramethylammonium hydroxide solution for about 60 seconds. As a result, 0.17–0.23 μm line and space patterns of photoresist were formed with an exposure dosage of 10 to 30 mJ/cm 2 .
EXAMPLE 2
Preparation of Resist Composition
1.0 g each of the polymers obtained in SYNTHESIS EXAMPLE 4, Synthesis Examples 5-1 through 5-3, and SYNTHESIS EXAMPLE 6, 0.01 g triflate as a PAG, and 3.2 mg triisodecylamine as an organic base, were completely dissolved in a mixed solution of 4.0 g PGMEA and 4.0 g cyclohexanone, and filtered through a membrane filter of 0.2 μm, so that resist compositions were obtained. Each of the resist compositions was coated on a silicon (Si) wafer treated with organic anti-reflective coating (ARC) to a thickness of about 0.35 μm.
The wafers coated with the respective resist compositions were soft baked at 130° C. for 90 seconds, exposed using an ArF eximer laser stepper (NA=0.6), and subjected to a post-exposure bake (PEB) at 120° C. for 60 seconds.
The resultant wafers were developed using 2.38% by weight tetramethylammonium hydroxide solution for about 60 seconds. As a result, 0.17–0.23μ line and space pattern of photoresist were formed with an exposure dosage of 10 to 30 mJ/cm 2 .
The photosensitive polymer, which constitutes the photoresist composition according to the present invention, includes a cyclic lactone in its backbone. Thus, the manufacturing cost is very low, and the problems of the conventional polymers used in the production of ArF resists can be largely overcome. The resist composition prepared from the photosensitive polymer exhibits excellent resistance to dry etching, superior adhesiveness to underlying material layers, and improved transmittance. The cyclic lactone included in the polymer backbone is highly hydrophilic. When forming space and line patterns from the resist layer deposited with the resist composition according to the present invention, line edge roughness characteristic is improved. The dissolution contrast characteristic, which appears after developing, sharply increases, thereby enlarging the depth of focus (DOF) margin.
The photosensitive polymer of the resist composition according to the present invention has a desirable glass transition temperature of 140 to 180° C. As for the resist layer which contains the photosensitive polymer according to the present invention, the free volume of the resist layer can be decreased due to a sufficient annealing effect during a baking process. As a result, the resist layer becomes more resistant to the ambient environment during post-exposure delay (PED). Thus, use of the resist composition according to the present invention in a photolithography process exhibits superior lithography characteristics, and is therefore useful in the manufacture of future generation semiconductor devices.
While this invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made thereto without departing from the spirit and scope of the invention as defined by the appended claims.
It is noted that priority has been claimed to Korean Patent Application No. 00-39562, filed 11 Jul. 2000, and Korean Patent Application No. 00-75485, filed 12 Dec. 2000. Both of these Korean application are incorporated herein in their entirety.
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This invention is directed to a coating composition used for original equipment manufacturing or refinishing uses in the automotive industry, which coating composition utilizes an acrylic polymer which contains substituted or unsubstituted exomethylene lactones or lactams as a comonomer.
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FIELD OF THE INVENTION
[0001] This invention relates to unique abrasive and/or thickening materials that are in situ generated compositions of precipitated silicas and silica gels. Such compositions exhibit different beneficial characteristics depending on the structure of the composite in situ generated material. With low structured composites (as measured via linseed oil absorption levels from 40 to 100 ml oil absorbed/100 g composite), simultaneously high pellicle film cleaning properties and moderate dentin abrasion levels are possible in order to accord the user a dentifrice that effectively cleans tooth surfaces without detrimentally abrading such surfaces. Increased amounts of high structure composite materials tend to accord greater viscosity build and thickening benefits together with such desirable abrasion and cleaning properties, albeit to a lesser extent than for the low structure types. Thus, mid-range cleaning materials will exhibit oil absorption levels from an excess of 100 to 150, and high thickening/low abrasion composite exhibit oil absorption properties in excess of 150. Such an in situ, simultaneously produced precipitated silica/silica gel combination provides such unexpectedly effective low abrasion and high cleaning capability and different thickening characteristics as compared to physical mixtures of such components. Encompassed within this invention is a unique method for making such gel/precipitated silica composite materials for such a purpose, as well as the different materials within the structure ranges described above and dentifrices comprising such.
BACKGROUND OF THE PRIOR ART
[0002] An abrasive substance has been included in conventional dentifrice compositions in order to remove various deposits, including pellicle film, from the surface of teeth. Pellicle film is tightly adherent and often contains brown or yellow pigments which impart an unsightly appearance to the teeth. While cleaning is important, the abrasive should not be so aggressive so as to damage the teeth. Ideally, an effective dentifrice abrasive material maximizes pellicle film removal while causing minimal abrasion and damage to the hard tooth tissues. Consequently, among other things, the performance of the dentifrice is highly sensitive to the extent of abrasion caused by the abrasive ingredient. Conventionally, the abrasive cleaning material has been introduced in flowable dry powder form to dentifrice compositions, or via redispersions of flowable dry powder forms of the polishing agent prepared before or at the time of formulating the dentifrice. Also, and more recently, slurry forms of such abrasives have been provided to facilitate storage, transport, and introduction within target dentifrice formulations.
[0003] Synthetic low-structure silicas have been utilized for such a purpose due to the effectiveness such materials provide as abrasives, as well as low toxicity characteristics and compatibility with other dentifrice components, such as sodium fluoride, as one example. When preparing synthetic silicas, the objective is to obtain silicas which provide maximal cleaning with minimal impact to the hard tooth surfaces. Dental researchers are continually concerned with identifying abrasive materials that meet such objectives.
[0004] Synthetic silicas (of higher structure) have also been utilized as thickening agents for dentifrices and other like paste materials in order to supplement and modify the Theological properties for improved control, such as viscosity build, stand up, brush sag, and the like. For toothpaste formulations, for example, there is a need to provide a stable paste that can meet a number of consumer requirements, including, and without limitation, the ability to be transferred out of a container (such as a tube) via pressure (i.e., squeezing of the tube) as a dimensionally stable paste and to return to its previous state upon removal of such pressure, the ability to be transferred in such a manner to a brushhead easily and without flow out of the tube during and after such transference, the propensity to remain dimensionally stable on the brush prior to use and when applied to target teeth prior to brushing, and the exhibiting of proper mouthfeel for aesthetic purposes, at least, for the benefit of the user.
[0005] Generally, dentifrices comprise a majority of a humectant (such as sorbitol, glycerin, polyethylene glycol, and the like) in order to permit proper contact with target dental subjects, an abrasive (such as precipitated silica) for proper cleaning and abrading of the subject teeth, water, and other active components (such as fluoride-based compounds for anticaries benefits). The ability to impart proper Theological benefits to such a dentifrice is accorded through the proper selection and utilization of thickening agents (such as hydrated silicas, hydrocolloids, gums, and the like) to form a proper network of support to properly contain such important humectant, abrasive, and anticaries ingredients. It is thus evident that formulating proper dentifrice compositions can be rather complex, both from a compounding standpoint as well as the number, amount, and type of components present within such formulations. As a result, although it is not a high priority within the dentifrice industry, the ability to reduce the number of such components, or attempt to provide certain components that meet at least two of these needed properties could potentially reduce formulation complexity, not to mention potentially reducing the overall manufacturing costs.
[0006] A number of water-insoluble, abrasive polishing agents have been used or described for dentifrice compositions. These abrasive polishing agents include natural and synthetic abrasive particulate materials. The generally known synthetic abrasive polishing agents include amorphous precipitated silicas and silica gels and precipitated calcium carbonate (PCC). Other abrasive polishing agents for dentifrices have included chalk, magnesium carbonate, dicalcium phosphate and its dihydrate forms, calcium pyrophosphate, zirconium silicate, potassium metaphosphate, magnesium orthophosphate, tricalcium phosphate, perlite, and the like.
[0007] Synthetically-produced precipitated low-structure silicas, in particular, have been used as abrasive components in dentifrice formulations due to their cleaning ability, relative safeness, and compatibility with typical dentifrice ingredients, such as humectants, thickening agents, flavoring agents, anticaries agents, and so forth. As known, synthetic precipitated silicas generally ate produced by the destabilization and precipitation of amorphous silica from soluble alkaline silicate by the addition of a mineral acid and/or acid gases under conditions in which primary particles initially formed tend to associate with each other to form a plurality of aggregates (i.e., discrete clusters of primary particles), but without agglomeration into a three-dimensional gel structure. The resulting precipitate is separated from the aqueous fraction of the reaction mixture by filtering, washing, and drying procedures, and then the dried product is mechanically comminuted in order to provide a suitable particle size and size distribution.
[0008] The silica drying procedures are conventionally accomplished using spray drying, nozzle drying (e.g., tower or fountain), wheel drying, flash drying, rotary wheel drying, oven/fluid bed drying, and the like.
[0009] As it is, such conventional abrasive materials suffer to a certain extent from limitations associated with maximizing cleaning and minimizing dentin abrasion. The ability to optimize such characteristics in the past has been limited generally to controlling the structures of the individual components utilized for such purposes. Examples of modifications in precipitated silica structures for such dentifrice purposes are described in the art within such publications as U.S. Pat. Nos. 3,967,563, 3,988,162, 4,420,312, and 4,122,161 to Wason, U.S. Pat. Nos. 4,992,251 and 5,035,879 to Aldcroft et al., U.S. Pat. No. 5,098,695 to Newton et al., and U.S. Pat. Nos. 5,891,421 and 5,419,888 to McGill et al. Modifications in silica gels have also been described within such publications as U.S. Pat. Nos. 5,647,903 to McGill et al., U.S. Pat. No. 4,303,641, to DeWolf, II et al., U.S. Pat. No. 4,153,680, to Seybert, and U.S. Pat. No. 3,538,230, to Pader et al. Such disclosures teach improvement in such silica materials in order to impart increased pellicle film cleaning capacity and reductions in dentin abrasion levels for dentifrice benefits. However, these typical improvements lack the ability to deliver preferred property levels that accord a dentifrice producer the ability incorporate such an individual material in different amounts with other like components in order to effectuate different resultant levels of such cleaning and abrasion characteristics. To compensate for such limitations, attempts have been undertaken to provide various combinations of silicas to permit targeting of different levels. Such silica combinations involving compositions of differing particle sizes and specific surface areas are disclosed in U.S. Pat. No. 3,577,521. to Karlheinz Scheller et al., U.S. Pat. No. 4,618,488 to Macyarea et al., U.S. Pat. No. 5,124,143 to Muhlemann, and U.S. Pat. No. 4,632,826 to Ploger et al. Such resultant dentifrices, however, fail to provide desired levels of abrasion and high pellicle cleaning simultaneously.
[0010] Another attempt has been made to provide physical mixtures of precipitated silicas of certain structures with silica gels, notably within U.S. Pat. No. 5,658,553 to Rice. It is generally accepted that silica gels exhibit edges, and thus theoretically exhibit the ability to abrade surfaces to a greater degree, than precipitated silicas, even low structured types. Thus, the blend of such materials together within this patent provided, at that time, an improvement in terms of controlled but higher levels of abrasiveness coupled with greater pellicle film cleaning ability than precipitated silicas alone. In such a disclosure, it is shown that separately produced and co-incorporated silica gels and precipitated silicas can permit increased PCR and RDA levels but with apparently greater control for lower abrasive characteristics than for previously provided silicas exhibiting very high PCR results. Unfortunately, although these results are certainly a step in the right direction, there is still a largely unfulfilled need to provide a silica-based dental abrasive that exhibits sufficiently high pellicle film cleaning properties with simultaneously lower radioactive dentin abrasive characteristics such that film removal can be accomplished without deleterious dentin destruction. In effect, the need is for a safer abrasive that exhibits a significantly higher PCR level versus RDA level than has previously been provided within the dental silica industry. Again, the Rice patent is merely a start toward desirable abrasive characteristics. Furthermore, the requirement to produce these separate gel and precipitate materials and meter them out for proper target levels of such characteristics adds costs and process steps to the manufacturing procedure. A manner of providing the benefits of such combinations, but to a very high level of pellicle film cleaning and at a relatively low to moderate degree of dentin abrasion, with simultaneous facilitation of incorporation within dentifrice formulation are thus unavailable to the industry at this time.
[0011] There is always a desire to limit the number of additives required for purchase, storage and introduction within dentifrice formulations. As such, the ability to provide simultaneous thickening and abrasive characteristics to avoid the addition of multiple components for such properties is an unmet need within the industry.
OBJECTS AND SUMMARY OF THE INVENTION
[0012] It has now been found that modifications in the processes for producing precipitated silicas can result in the in situ simultaneous production of targeted amounts of silica gels therein, particularly those in which the final structure of the in situ generated composite can be controlled. Such a novel method thus permits the production of in situ generated gel/precipitate silica materials that provide excellent dentin abrasion and pellicle film cleaning capabilities within dentifrices or, in the alternative, such formulations that exhibit excellent thickening properties as well as desirable abrasive and cleaning properties through the introduction of such a singularly produced, stored, and introduced additive.
[0013] In particular, the specific in situ formed composites exhibit very high levels pellicle film cleaning properties compared with lower radioactive dentin abrasion results such that the resultant materials can be added with other abrasive materials (such as lower structure precipitated silicas, calcium carbonates, and the like) for the dentifrice producer to target certain high levels of cleaning with lower abrasiveness thus providing the optimization of cleaning while providing a larger margin of abrasion protection to the ultimate user. It is also believed, without intending to be bound to any specific scientific theory, that the increased amount of silica gel within the final composite materials aids in providing narrower particle size ranges in order to contribute a controlled result of high cleaning and reduced dentin abrasion levels. As will be discussed in greater detail below, the physically mixed combination of such materials (i.e., not simultaneously produced within the same reaction) has been found to impart limited levels of such properties, namely the need to provide materials (particularly a precipitated silica component) that exhibits an extremely high, potentially deleterious dentin abrasion level in order to impart, at the same time, an acceptable high pellicle film cleaning level. The novel in situ generated precipitated/gel combination silicas unexpectedly provide a higher degree of pellicle film cleaning with a significantly lower dentin abrasion value, thus according the dentifrice industry not only a potentially more desirable lower abrasive material for better dental protection. It has been realized that the presence of varied amounts of such a silica gel component permits the benefit of the sharp edges exhibited by the gel agglomerates for abrasiveness, with the coexistence of variable levels of silica precipitates of different structures to accord an overall composite exhibiting one of three general properties: high cleaning, mid-range cleaning, or thickening/low cleaning. Such general properties are all dependent upon the structure of the overall gel/precipitate composite, as measured by linseed oil absorption (as noted previously). When produced in situ, such a resultant gel/precipitate material provides unexpectedly improved properties as compared with dry blends of such separately produced components. In such a manner, as one example for the high cleaning variation, it has been found that although the pellicle film cleaning level is quite high, in fact the resultant dentin abrasion level is limited, thereby imparting an excellent cleaning material without also imparting too high an abrasion level to the target dental substrate.
[0014] Alternatively, but by no means any less important, is the ability to produce materials of silica-based components simultaneously within the same reaction medium that imparts dentin abrasion and pellicle film cleaning characteristics (albeit to a lesser degree than for those noted in the previous paragraph) and coexistent thickening properties in order to accord such beneficial results with a single additive. The ability to control the level of a silica gel in a final composite and/or the target high-, medium-, or low-structure of the precipitate component therein through modifications in starting material concentration and/or gel and/or precipitate reaction conditions provides the ability to control the overall cleaning, abrasive, and/or thickening characteristics of the composite itself. Thus, a composite exhibiting greater thickening and reduced but effective pellicle film cleaning characteristic will include either higher amounts of silica gel and/or higher amounts of high-structure precipitate such that the overall composite exhibits sufficiently high linseed oil absorption (greater than 150 ml/100 g material) to provide the target desired thickening/low abrasion properties. Thus, by controlling such silica gel/precipitate production parameters, it has been found that a single additive can provide these diverse cleaning, abrasion, and/or thickening properties without resorting to multiple additions of potentially expensive and/or difficult to incorporate materials for the same purpose.
[0015] All parts, percentages and ratios used herein are expressed by weight unless otherwise specified. All documents cited herein are incorporated by reference.
[0016] Accordingly, it is one object of the present invention to provide a precipitated silica and gel silica composite material providing improved pellicle film cleaning without an unacceptably high corresponding increase in dentin or enamel abrasion. Another object of the present invention is to provide a new method for the production of such effective precipitated/gel silica combinations wherein such materials are produced simultaneously and in situ, thereby permitting the proper ratios of such materials to be made during production of the materials, rather than during dentifrice production. Also an object of this invention is to provide an in situ generated precipitated/gel silica composite material wherein the linseed oil absorption levels exhibited thereby are within one of three ranges: 40 to 100 ml oil absorbed/100 g composite material for a very high cleaning material, greater than 100 and up to 150 ml/100 g for a mid-range high cleaning material, and in excess of 150 for a cleaning/thickening/low abrasion material.
[0017] Accordingly, this invention encompasses a method for producing simultaneously silica gels and precipitated silicas, said method comprising the sequential steps of
[0018] a) admixing a sufficient amount of an alkali silicate and an acidulating agent together to form a silica gel composition; and without first washing, purifying, or modifying said formed silica gel composition,
[0019] b) simultaneously introducing to said silica gel composition a sufficient amount of an alkali silicate and an acidulating agent to form a precipitated silica, thereby producing a precipitate/gel silica combination. Encompassed as well within this invention is the product of such a process wherein the silica gel amount present therein is from 5 to 80% by volume of the total precipitated/gel silica resultant simultaneously produced combination. Further encompassed within this invention are the composite materials listed above in the three ranges of oil absorption measurements, and dentifrice formulations comprising such materials as well as the product of the inventive process noted above.
[0020] Generally, synthetic precipitated silicas are prepared by admixing dilute alkali silicate solutions with strong aqueous mineral acids under conditions where aggregation to the sol and gel cannot occur, stirring and then filtering out the precipitated silica. The resulting precipitate is next washed, dried and comminuted to desired size.
[0021] Generally, as well, silica gels include silica hydrogels, hydrous gels, aerogels, and xerogels. Silica gels are also formed by reacting alkali silicate solutions with strong acids or vice-versa, to form a hydrosol and aging the newly formed hydrosol to form the hydrogel. The hydrogel is then washed, dried and comminuted to form the desired materials.
[0022] As noted above, the separate production of such materials has historically required manufacture of these separate materials, and proper metering of the two together during the incorporation within a dentifrice formulation in such a way as to provide the desired cleaning/abrasion levels thereof.
[0023] To the contrary, the inventive method for simultaneous production of such materials permits the producer to target a range of amounts of silica gel and precipitated silica components as well as structures of precipitated components to impart the desired level of cleaning/abrasion through controlled parameters during production, a significant difference from previous physicals mixtures (i.e., dry blends) of such materials through separate incorporation. Basically, the novel method entails targeting the amount of silica gel desired and specifically selecting certain reaction conditions in order to generate such a desired level during amorphous precipitated silica production.
[0024] The inventive abrasive compositions are ready-to-use additives in the preparation of oral cleaning compositions, such as dentifrices, toothpastes, and the like, particularly suited as a raw material in a toothpaste making process. Furthermore, such silica products can be utilized in applications wherein sharp edges and lower abrasiveness may be desired, such as, without limitation, foam inhibitors within certain formulations, such as, without limitation, automatic dishwashing detergents. Additional potential uses of such materials include food carriers, rubber additives and carriers, cosmetic additives, personal care additives, plastic antiblocking additives, and pharmaceutical additives, without limitation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a graphical representation of the correlation between dentin abrasion and pellicle film cleaning ratios for a dentifrice composition for inventive in situ produced composites of gel/precipitated silica and comparative physical mixtures of such materials.
[0026] FIG. 2 is a graphical representation of the correlation between thickening ability and silica gel structure for inventive in situ produced composites of gel/precipitated silica and comparative physical mixtures of such materials.
[0027] FIG. 3 is a graphical representation of the correlation between the values of dentin abrasion and pellicle film cleaning measurements for a dentifrice composition for inventive in situ produced composites of gel/precipitated silica and the values of the same measurements for comparative conventional dental abrasives.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The abrasive and/or thickening combinations used in the present invention are in-situ formed materials that can be readily formulated on demand with other ingredients to prepare oral cleaning compositions having a high cleaning efficacy without causing undue abrasion on tooth surfaces. The essential as well as optional components of the abrasive and/or thickening compositions and related methods of making same of the present invention are described in more detail below.
[0000] General Production Method
[0029] The silica compositions of the present invention are prepared according to the following two-stage process with a silica gel being formed in the first stage and precipitated silica formed in the second stage. In this process, an aqueous solution of an alkali silicate, such as sodium silicate, is charged into a reactor equipped with mixing means adequate to ensure a homogeneous mixture, and the aqueous solution of an alkali silicate in the reactor preheated to a temperature of between about 40° C. and about 90° C. Preferably, the aqueous alkali silicate solution has an alkali silicate concentration of approximately 3.0 to 35 wt %, preferably from about 3.0 to about 25 wt %, and more preferably from about 3.0 to about 15 wt %. Preferably the alkali silicate is a sodium silicate with a SiO 2 :Na 2 O ratio of from about 1 to about 4.5, more particularly from about 1.5 to about 3.4. The quantity of alkali silicate charged into the reactor is about 10 wt % to 80 wt % of the total silicate used in the batch. Optionally, an electrolyte, such as sodium sulfate solution, may be added to the reaction medium (silicate solution or water). Next, an aqueous acidulating agent or acid, such as sulfuric acid, hydrochloric acid, nitric acid, phosphoric acid, and so forth (preferably sulfuric acid), added as a dilute solution thereof (e.g., at a concentration of between about 4 to 35 wt %, more typically about 9.0 to 15.0 wt %) is added to the silicate to form a gel. Once the silica gel is produced and the pH adjusted to the desired level, such as between about 3 and 10, the acid addition is stopped and the gel is heated to the batch reaction temperature, preferably between about 65° C. to about 100° C. It is important to note that after this first stage is completed, the produced silica gel is not modified in any way. Thus, this resultant gel is not washed, purified, cleaned, etc., prior to commencement of the second stage.
[0030] Next, the second stage begins after the gel reaction temperature is increased, with the simultaneous addition to the reactor of: (1) an aqueous solution of the same acidulating agent previously used and (2) additional amounts of an aqueous solution containing the same species of alkali silicate as is in the reactor, the aqueous solution being preheated to a temperature of about 65° C. to about 100° C. The rate of acidulating agent and silicate additions can be adjusted to control the simultaneous addition pH during the second stage reaction. This pH control can be used to control product physical properties, generally with higher average batch pH providing lower structure silica products and relatively lower average batch pH providing higher structure silica products. High shear recirculation may be utilized, and the acid solution addition continues until the reactor batch pH drops to between about 4 to about 9. For purposes of this inventive method, the term “average batch pH” is intended to mean the average pH obtained by measuring the pH level every 5 minutes during the precipitate formation stage and averaging the total aggregate over total time elapsed.
[0031] After the inflows of the acidulating agent and the alkali silicate are stopped, the reactor batch allowed to age or “digest” for between 5 minutes to 30 minutes, with the reactor contents being maintained at a constant pH. After the completion of digestion, the reaction batch is filtered and washed with water to remove excess by-product inorganic salts until the wash water from the silica filter cake results in at most 5% salt byproduct content as measured by conductivity.
[0032] The silica filter cake is slurried in water, and then dried by any conventional drying techniques, such as spray drying, to produce an amorphous silica containing from about 3 wt % to about 50 wt % of moisture. The silica may then be milled to obtain the desired median particle size of between about 3 μm to 25 μm, preferably between about 3 μm to about 20 μm. Classification of even narrower median particle size ranges may aid in providing increased cleaning benefits as well.
[0033] In addition to the above-described production process methodologies of precipitating the synthetic amorphous silicas, the preparation of the silica products is not necessarily limited thereto and it also can be generally accomplished in accordance with the methodologies described, for example, in prior U.S. Pat. Nos. 3,893,840, 3,988,162, 4,067,746, 4,340,583, and 5,891,421, all of which are incorporated herein by reference, as long as such methods are appropriately modified to incorporate recirculation and high shear treatments. As will be appreciated by one skilled in the art, reaction parameters which affect the characteristics of the resultant precipitated silica include: the rate and timing at which the various reactants are added; the levels of concentration of the various reactants; the reaction pH; the reaction temperature; the agitation of the reactants during production; and/or the rate at which any electrolytes are added.
[0034] Alternative methods of production for this inventive material include in slurry form such as, without limitation, procedures taught within U.S. Pat. No. 6,419,174, to McGill et al., as well as filter press slurry processes as described within and throughout U.S. Published Pat. Appl. No. 20030019162 to Huang.
[0035] The inventive silica composite materials may be characterized and separated, as discussed above, into three distinct categories, dependent upon the linseed oil absorption ranges exhibited within each. The oil absorption test, discussed in greater detail below, is generally used to determine structures of precipitated silica materials as set forth in J. Soc. Cosmet. Chem., 29,497-521 (August 1978), and Pigment Handbook: Volume 1, Properties and Economics, 2 nd ed., John Wiley & Sons, 1988, p. 139-159. For this invention, however, it is important to note that such a test has now been utilized to determine the structure of the overall gel/precipitate silica composite instead. Thus, the three basic types of inventive materials are categorized as defined above, and as discussed in the following sections.
[0036] The inventive in situ generated composites (also referred to as “combinations”) of silica gel and precipitate are useful for various functions, including, without limitation, three primary types: i) high-cleaning, dental abrasives with correlative lower abrasiveness (with an RDA level of less than 250, for instance) than typical high-cleaning silica-based products; ii) mid-range cleaning dental abrasives with reduced high cleaning levels (as compared with the high cleaning materials from above), but much lower RDA measurements (at most about 150, for instance); and iii) thickening (viscosity-modifying) products that exhibit certain levels of cleaning and abrasiveness (such as an exhibited PCR of less than 90 and a measured RDA of below 80). Production of each type is based upon different factors, such as reaction conditions (e.g., temperature, agitation/shear, addition rates of reactants, amount of gel component, and the like), and concentrations of reactants (e.g., mole ratios of silicate to acid, as one example). These will be further delineated separately below.
[0000] High-Cleaning Abrasive Materials
[0037] The in situ process of this invention has surprisingly yielded, with selectivity followed in terms of reaction pH, reactant composition, amount of gel component, and, as a result, structure of the resultant gel/precipitate silica composite materials made therefrom, abrasive materials that exhibit exceedingly high pellicle film cleaning properties. Such high-cleaning materials may be adjusted to target lower radioactive dentin abrasion levels without compromising the cleaning benefits, again, through the production of certain low structure gel/precipitate silica composite materials. Such materials are exemplified below in Examples 4, 6, 7, 11, and 15, at least and show the ability to clean without detrimental exaggerated dentin abrasion (within dentifrice formulas 1, 3, and 4, for example). Such products may be utilized as the sole cleaning/abrasive component within a dentifrice or, in one potentially preferred embodiment, may be used as a supplement with other lower abrasive additives, for targeting an overall cleaning and abrasive level for a dentifrice formulation.
[0038] For this high cleaning material, the gel component is present in an amount between 5 and 50% by volume of the ultimately formed gel/precipitate silica composite material (and thus the precipitated silica component is present in an amount of from 95 to 50% by volume as a result). Although the amount of gel possible to form a high cleaning material may be as high as 50% of the composite material, preferably such an amount is much lower mainly because it was found that the higher the amount of gel present within a high cleaning material, the greater amount of low structure precipitated silica component required to be produced during the following phase. Thus, the overall amount of gel to be produced is preferably relatively low (from 10 to 25%, for instance). Such percentages of gel component actually represent the amount of silicate present during the production phases for each different silica material. Thus, a 10% gel measurement reflects the presence of 10% of the total silicate reactant volume within the reactor during which the gel is initially made (as one example). Subsequent to initial gel production, the remaining 90% silicate reactant volume is used for precipitated silica component production. It is important to note, however, that upon the initiation of the precipitate formation phase, some of the silicate may actually produce gel, but the determination of percentages of each component within the ultimately formed composite material does not reflect such a possibility. Thus, the percentages noted above are merely best estimates, rather than concrete determinations of final amounts of components. Such an issue exists within the remaining in situ gel/precipitate composite material categories as well.
[0039] Generally, it has been determined that such specific high-cleaning abrasives may be produced through a method of admixing a suitable acid and a suitable silicate starting material (wherein the acid concentration, in aqueous solution, is from 5 to 25%, preferably from 10 to 20%, and more preferably from 10 to 12%, and the concentration of the silicate starting material is from 4 to 35%, also within an aqueous solution), to initially form a silica gel. Subsequent to gel formation, sufficient silicate and acid are added (without any appreciable degree of washing, or other type of purification, or physical modification of the gel) to the formed gel for further production of varying structure (preferably low in structure, but other structures silica products may result during manufacturing as long as the overall structure is sufficient to accord the necessary levels of pellicle film cleaning) precipitated silica component desired for a high cleaning composite material to be formed. The pH of the overall reaction may be controlled anywhere within the range of 3 to 10, with a higher pH desired for low-structure precipitated silica production. It has been realized that in order to provide a high cleaning, moderate to low abrasive material through this process, the amount of gel is preferably lower (as noted above, from 10 to 30% by volume of the composite) and the amount of low structure precipitated silica is preferably relatively high (from 90 to 70% by volume of the composite). In order to exhibit the proper PCR and RDA levels associated with this category, the resultant gel/silica composite material must exhibit a linseed oil absorption of between 40 and 100 ml oil/100 g material.
[0040] Broadly, the inventive high cleaning gel/precipitated silica combination generally have the following properties: 10% Brass Einlehner hardness values in the range between about 5 and 30 mg loss/100,000 revolutions, and, within a test dentifrice formulation (as presented below within the examples) RDA (Radioactive Dentin Abrasion) values between about 180 to about 240, and (within the same test dentifrice formulation) PCR (Pellicle Cleaning Ratio) values of 90 to 160, with a ratio of PCR to RDA within the range of 0.45 to 0.7.
[0000] Mid-Range Cleaning Abrasives
[0041] The in situ process of this invention has also surprisingly yielded, with similar degrees of selectivity followed in terms of reaction pH, reactant concentrations, amount of gel component, and, as a result, overall structure of the resultant gel/precipitate silica composite materials made therefrom as for the high cleaning materials described above, a method for producing a mid-range product (essentially reduced, but still relatively high, cleaning levels with lower abrasion levels) composites as well. Thus, selection of differing concentrations, pH levels, ultimate gel proportions, among other things, can produce gel/precipitate silica composite materials of overall medium structures in order to accord relatively high pellicle film cleaning results, with lower abrasive properties as compared with the high cleaning materials described above. Examples 5, 10, 12, 14, 16, and 17, at least, below show certain methods of producing such mid-range abrasive products (and further exemplified within dentifrice formulations 2, 7, 9, and 10, below).
[0042] For this mid-range cleaning material, the gel component is present in an amount between 10 and 60% by weight of the ultimately formed gel/precipitate silica composite material (and thus the precipitated silica component is present in an amount of from 90 to 40% by weight as a result). Although the amount of gel possible to form a high cleaning material may be as high as 60% of the composite material, preferably such an amount is much lower mainly because it was found that the higher the amount of gel present within a mid-range cleaning material, the greater amount of low structure precipitated silica component required to be produced during the following phase. Thus, the overall amount of gel to be produced is preferably relatively low (from 20 to 33%, for instance). Such percentages of gel component actually represent the amount of silicate present during the production phases for each different silica material, as described above for the high cleaning material.
[0043] Generally, it has been determined that such specific mid-range cleaning abrasives may be produced through a method of admixing a suitable acid and a suitable silicate starting material (wherein the acid concentration, in aqueous solution, is from 5 to 25%, preferably from 10 to 20%, and more preferably from 10 to 12%, and the concentration of the silicate starting material is from 4 to 35%, also within an aqueous solution), to initially form a silica gel. Subsequent to gel formation, sufficient silicate and acid are added (without any appreciable degree of washing, or other type of purification, or physical modification of the gel) to the formed gel for further production of appropriately structured precipitated silica component desired for a mid-range cleaning composite material to be formed. The pH of the overall reaction may be controlled anywhere within the range of 3 to 10. Depending on the amount of gel initially formed, the amount and structure of precipitated silica component may be targeted in much the same way as for the high cleaning material. It has been realized that in order to provide a mid-range cleaning, low abrasive material through this process, as compared with the high cleaning materials noted above, the amount of gel is preferably higher (as noted above, from 10 to 60% by volume of the composite, preferably from 20 to 33%) and the amount of low structure precipitated silica is preferably lower (from 90 to 40% by volume of the composite, preferably from 80 to 67%). In order to exhibit the proper PCR and RDA levels associated with this category, the resultant gel/silica composite material must exhibit a linseed oil absorption of greater than 100 up to 150 ml oil/100 g material.
[0044] Broadly, the inventive mid-range cleaning gel/precipitated silica combination generally have the following properties: 10% Brass Einlehner hardness values in the range between 2.5 and 12.0, and, within a test dentifrice formulation (as presented below within the examples) RDA (Radioactive Dentin Abrasion) values between about 95 to about 150, and (within the same test dentifrice formulation) PCR (Pellicle Cleaning Ratio) values of 90 to 120, with a ratio of PCR to RDA within the range of 0.7 to 1.1.
[0000] Thickening Cleaners/Abrasives
[0045] Lastly, again, in much the manner as the two above types of abrasives, it has surprisingly been found that silica-based viscosity-modifying materials may be provided that also exhibit a certain degree of abrasiveness and cleaning through the utilization of the inventive in situ process. The presence of a simultaneously produced gel/precipitate appears to surprisingly accord a certain abrasive property within a material that, when produced via a high structure silica production method, provides an effective thickening (or other type of viscosity modification) within dentifrice formulations. In such a manner, such a thickening agent may be added not only for its viscosity-modifying effect, but also to supplement simultaneously present higher cleaning and/or abrasive dentifrice components. Examples 3, 8, 9, and 13, at least, provide a showing of general methods of producing such thickening abrasives (and further exemplified within dentifrice formulations 5, 6, and 8, below).
[0046] For this low cleaning level material, the gel component is present in an amount between 20 and 85% by volume of the ultimately formed gel/precipitate silica composite material (and thus the precipitated silica component is present in an amount of from 80 to 15% by volume as a result, with such a component preferably present in a high structure form). Although the amount of gel possible to form a high cleaning material may be as low as 20% of the composite material, preferably such an amount is much higher mainly because it was found that the lower the amount of gel present within a thickening abrasive material, the greater amount of high structure precipitated silica component required to be produced during the following phase. Thus, the overall amount of gel to be produced is preferably relatively high (from 45 to 65%, 50% more preferably, for instance). Such percentages of gel component actually represent the amount of silicate present during the production phases for each different silica material, as described above for the other categories of cleaning materials.
[0047] Generally, it has been determined that such specific thickening abrasives may be produced through a method of admixing a suitable acid and a suitable silicate starting material (wherein the acid concentration, in aqueous solution, is from 5 to 25%, preferably from 10 to 20%, and more preferably from 10 to 12%, and the concentration of the silicate starting material is from 4 to 35%, also within an aqueous solution), to initially form a silica gel. Subsequent to gel formation, sufficient silicate and acid are added (without any appreciable degree of washing, or other type of purification, or physical modification of the gel) to the formed gel for further production of high structure precipitated silica component desired for a thickening abrasive composite material to be formed. The pH of the overall reaction may be controlled anywhere within the range of 3 to 10. Depending on the amount of gel initially formed, the amount and structure of precipitated silica component may be targeted by reacting the subsequent silicate and acid reactants within a more acidic medium to form greater amounts of high structure precipitated silica components. It has been realized that in order to provide a thickening abrasive material through this process, the amount of gel is preferably higher (as noted above, from 20 to 85% by volume of the composite, preferably from 45 to 65%) and the amount of low structure precipitated silica is preferably relatively low (as low as possible), while the amount of high structure precipitated silica is preferably relatively high (from 80 to 15% by volume of the composite, preferably from 55 to 35%). In order to exhibit the proper PCR and RDA levels associated with this category, the resultant gel/silica composite material must exhibit a linseed oil absorption of greater than 150, possibly with a maximum of about 225 ml oil/100 g material.
[0048] Broadly, the inventive thickening abrasive gel/precipitated silica combination generally have the following properties: 10% Brass Einlehner hardness values in the range between 1.0 and 5.0 mg loss/100,000 revolutions, and, within a test dentifrice formulation (as presented below within the examples) RDA (Radioactive Dentin Abrasion) values between about 20 to about 80, and (within the same test dentifrice formulation) PCR (Pellicle Cleaning Ratio) values of about 50 to 80, with a ratio of PCR to RDA within the range of 0.8 to 3.5.
[0000] Dentifrice Uses of the Inventive Materials
[0049] The inventive in situ generated gel/precipitate silica composite materials described herein may be utilized alone as the cleaning agent component provided in the dentifrice compositions of this invention, although, at least for the high cleaning category materials, the moderately high RDA levels may be unacceptable to some consumers. Thus, a combination of the inventive composite materials with other abrasives physically blended therewith within a suitable dentifrice formulation is potentially preferred in this regard in order to accord targeted dental cleaning and abrasion results at a desired protective level. Thus, any number of other conventional types of abrasive additives may be present within inventive dentifrices in accordance with this invention. Other such abrasive particles include, for example, and without limitation, precipitated calcium carbonate (PCC), ground calcium carbonate (GCC), dicalcium phosphate or its dihydrate forms, silica gel (by itself, and of any structure), amorphous precipitated silica (by itself, and of any structure as well), perlite, titanium dioxide, calcium pyrophosphate, hydrated alumina, calcined alumina, insoluble sodium metaphosphate, insoluble potassium metaphosphate, insoluble magnesium carbonate, zirconium silicate, aluminum silicate, and so forth, can be introduced within the desired abrasive compositions to tailor the polishing characteristics of the target formulation (dentifrices, for example, etc.), if desired, as well.
[0050] The precipitate/gel silica combination described above, when incorporated into dentifrice compositions, is present at a level of from about 5% to about 50% by weight, more preferably from about 10% to about 35% by weight, particularly when the dentifrice is a toothpaste. Overall dentifrice or oral cleaning formulations incorporating the abrasive compositions of this invention conveniently can comprise the following possible ingredients and relative amounts thereof (all amounts in wt %):
Dentifrice Formulation Ingredient Amount Liquid Vehicle: humectant(s) (total) 5-70 deionized water 5-70 binder(s) 0.5-2.0 anticaries agent 0.1-2.0 chelating agent(s) 0.4-10 silica thickener* 3-15 surfactant(s) 0.5-2.5 abrasive 10-50 sweetening agent <1.0 coloring agents <1.0 flavoring agent <5.0 preservative <0.5
[0051] In addition, as noted above, the inventive abrasive could be used in conjunction with other abrasive materials, such as precipitated silica, silica gel, dicalcium phosphate, dicalicum phosphate dihydrate, calcium metasilicate, calcium pyrophosphate, alumina, calcined alumina, aluminum silicate, precipitated and ground calcium carbonate, chalk, bentonite, particulate thermosetting resins and other suitable abrasive materials known to a person of ordinary skill in the art.
[0052] In addition to the abrasive component, the dentifrice may also contain one or more organoleptic enhancing agents. Organoleptic enhancing agents include humectants, sweeteners, surfactants, flavorants, colorants and thickening agents, (also sometimes known as binders, gums, or stabilizing agents),
[0053] Humectants serve to add body or “mouth texture” to a dentifrice as well as preventing the dentifrice from drying out. Suitable humectants include polyethylene glycol (at a variety of different molecular weights), propylene glycol, glycerin (glycerol), erythritol, xylitol, sorbitol, mannitol, lactitol, and hydrogenated starch hydrolyzates, as well as mixtures of these compounds. Typical levels of humectants are from about 20 wt % to about 30 wt % of a toothpaste composition.
[0054] Sweeteners may be added to the toothpaste composition to impart a pleasing taste to the product. Suitable sweeteners include saccharin (as sodium, potassium or calcium saccharin), cyclamate (as a sodium, potassium or calcium salt), acesulfane-K, thaumatin, neohisperidin dihydrochalcone, ammoniated glycyrrhizin, dextrose, levulose, sucrose, mannose, and glucose.
[0055] Surfactants are used in the compositions of the present invention to make the compositions more cosmetically acceptable. The surfactant is preferably a detersive material which imparts to the composition detersive and foaming properties. Suitable surfactants are safe and effective amounts of anionic, cationic, nonionic, zwitterionic, amphoteric and betaine surfactants such as sodium lauryl sulfate, sodium dodecyl benzene sulfonate, alkali metal or ammonium salts of lauroyl sarcosinate, myristoyl sarcosinate, palmitoyl sarcosinate, stearoyl sarcosinate and oleoyl sarcosinate, polyoxyethylene sorbitan monostearate, isostearate and laurate, sodium lauryl sulfoacetate, N-lauroyl sarcosine, the sodium, potassium, and ethanolamine salts of N-lauroyl, N-myristoyl, or N-palmitoyl sarcosine, polyethylene oxide condensates of alkyl phenols, cocoamidopropyl betaine, lauramidopropyl betaine, palmityl betaine and the like. Sodium lauryl sulfate is a preferred surfactant. The surfactant is typically present in the oral care compositions of the present invention in an amount of about 0.1 to about 15% by weight, preferably about 0.3% to about 5% by weight, such as from about 0.3% to about 2%, by weight.
[0056] Flavoring agents optionally can be added to dentifrice compositions. Suitable flavoring agents include, but are not limited to, oil of wintergreen, oil of peppermint, oil of spearmint, oil of sassafras, and oil of clove, cinnamon, anethole, menthol, thymol, eugenol, eucalyptol, lemon, orange and other such flavor compounds to add fruit notes, spice notes, etc. These flavoring agents consist chemically of mixtures of aldehydes, ketones, esters, phenols, acids, and aliphatic, aromatic and other alcohols.
[0057] Colorants may be added to improve the aesthetic appearance of the product. Suitable colorants are selected from colorants approved by appropriate regulatory bodies such as the FDA and those listed in the European Food and Pharmaceutical Directives and include pigments, such as TiO 2 , and colors such as FD&C and D&C dyes.
[0058] Thickening agents are useful in the dentifrice compositions of the present invention to provide a gelatinous structure that stabilizes the toothpaste against phase separation. Suitable thickening agents include silica thickener; starch; glycerite of starch; gums such as gum karaya (sterculia gum), gum tragacanth, gum arabic, gum ghatti, gum acacia, xanthan gum, guar gum and cellulose gum; magnesium aluminum silicate (Veegum); carrageenan; sodium alginate; agar-agar; pectin; gelatin; cellulose compounds such as cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxymethyl cellulose, hydroxymethyl carboxypropyl cellulose, methyl cellulose, ethyl cellulose, and sulfated cellulose; natural and synthetic clays such as hectorite clays; as well as mixtures of these compounds. Typical levels of thickening agents or binders are from about 0 wt % to about 15 wt % of a toothpaste composition.
[0059] Therapeutic agents are optionally used in the compositions of the present invention to provide for the prevention and treatment of dental caries, periodontal disease and temperature sensitivity. Examples of therapeutic agents, without intending to be limiting, are fluoride sources, such as sodium fluoride, sodium monofluorophosphate, potassium monofluorophosphate, stannous fluoride, potassium fluoride, sodium fluorosilicate, ammonium fluorosilicate and the like; condensed phosphates such as tetrasodium pyrophosphate, tetrapotassium pyrophosphate, disodium dihydrogen pyrophosphate, trisodium monohydrogen pyrophosphate; tripolyphosphates, hexametaphosphates, trimetaphosphates and pyrophosphates, such as; antimicrobial agents such as triclosan, bisguanides, such as alexidine, chlorhexidine and chlorhexidine gluconate; enzymes such as papain, bromelain, glucoamylase, amylase, dextranase, mutanase, lipases, pectinase, tannase, and proteases; quartemary ammonium compounds, such as benzalkonium chloride (BZK), benzethonium chloride (BZT), cetylpyridinium chloride (CPC), and domiphen bromide; metal salts, such as zinc citrate, zinc chloride, and stannous fluoride; sanguinaria extract and sanguinarine; volatile oils, such as eucalyptol, menthol, thymol, and methyl salicylate; amine fluorides; peroxides and the like. Therapeutic agents may be used in dentifrice formulations singly or in combination at a therapeutically safe and effective level.
[0060] Preservatives may also be optionally added to the compositions of the present invention to prevent bacterial growth. Suitable preservatives approved for use in oral compositions such as methylparaben, propylparaben and sodium benzoate may be added in safe and effective amounts.
[0061] The dentifrices disclosed herein may also a variety of additional ingredients such as desensitizing agents, healing agents, other caries preventative agents, chelating/sequestering agents, vitamins, amino acids, proteins, other anti-plaque/anti-calculus agents, opacifiers, antibiotics, anti-enzymes, enzymes, pH control agents, oxidizing agents, antioxidants, and the like
[0062] Water provides the balance of the composition in addition to the additives mentioned. The water is preferably deionized and free of impurities. The dentifrice will usually comprise from about 20 wt % to about 35 wt % of water.
[0063] Useful silica thickeners for utilization within such a toothpaste formulation include, as a non-limiting example, an amorphous precipitated silica such as ZEODENT® 165 silica Other preferred (though non-limiting) silica thickeners are ZEODENT® 163 and/or 167 and ZEOFREE®153, 177, and/or 265 silicas, all available from J. M. Huber Corporation, Havre de Grace Md., U.S.A.
[0064] For purposes of this invention, a “dentifrice” has the meaning defined in Oral Hygiene Products and Practice, Morton Pader, Consumer Science and Technology Series, Vol. 6, Marcel Dekker, NY 1988, p. 200, which is incorporated herein by reference. Namely, a “dentifrice” is “ . . . a substance used with a toothbrush to clean the accessible surfaces of the teeth. Dentifrices are primarily composed of water, detergent, humectant, binder, flavoring agents, and a finely powdered abrasive as the principal ingredient . . . a dentifrice is considered to be an abrasive-containing dosage form for delivering anti-caries agents to the teeth.” Dentifrice formulations contain ingredients which must be dissolved prior to incorporation into the dentifrice formulation (e.g. anti-caries agents such as sodium fluoride, sodium phosphates, flavoring agents such as saccharin).
[0065] The various silica and toothpaste (dentifrice) properties described herein were measured as follows, unless indicated otherwise.
[0066] The Brass Einlehner (BE) Abrasion test used to measure the hardness of the precipitated silicas/silica gels reported in this application is described in detail in U.S. Pat. No. 6,616,916, incorporated herein by reference, involves an Einlehner AT-1000 Abrader generally used as follows: (1) a Fourdrinier brass wire screen is weighed and exposed to the action of a 10% aqueous silica suspension for a fixed length of time; (2) the amount of abrasion is then determined as milligrams brass lost from the Fourdrinier wire screen per 100,000 revolutions. The result, measured in units of mg loss, can be characterized as the 10% brass Einlehner (BE) abrasion value.
[0067] The oil absorption values are measured using the rubout method. This method is based on a principle of mixing linseed oil with a silica by rubbing with a spatula on a smooth surface until a stiff putty-like paste is formed. By measuring the quantity of oil required to have a paste mixture which will curl when spread out, one can calculate the oil absorption value of the silica—the value which represents the volume of oil required per unit weight of silica to saturate the silica sorptive capacity. A higher oil absorption level indicates a higher structure of precipitated silica; similarly, a low value is indicative of what is considered a low-structure precipitated silica. Calculation of the oil absorption value was done as follows:
Oil absorption = ml oil absorbed weight of silica , grams × 100 = ml oil / 100 gram silica
[0068] As a first step in measuring refractive index (“RI”) and degree of light transmission, a range of glycerin/water stock solutions (about 10) was prepared so that the refractive index of these solutions lies between 1.428 and 1.46. The exact glycerin/water ratios needed depend on the exact glycerin used and is determined by the technician making the measurement. Typically, these stock solutions will cover the range of 70 wt % to 90 wt % glycerin in water. To determine Refractive index, one or two drops of each standard solution is separately placed on the fixed plate of a refractometer (Abbe 60 Refractometer Model 10450). The covering plate is fixed and locked into place. The light source and refractometer are switched on and the refractive index of each standard solution is read.
[0069] Into separate 20-ml bottles, accurately weighed was 2.0±0.01 ml of the inventive gel/precipitate silica product and added was 18.0±0.01 ml of each respective stock glycerin/water solution (for products with measured oil absorption above 150, the test used 1 g of inventive gel/precipitate silica product and 19 g of the stock glycerin/water solution). The bottles were then shaken vigorously to form silica dispersion, the stoppers were removed from the bottles, and the bottles were placed in a desiccator, which was then evacuated with a vacuum pump (about 24 inches Hg).
[0070] The dispersions were then de-aerated for 120 minutes and visually inspected for complete de-aeration. The % Transmittance (“% T”) at 590 nm (Spectronic 20 D+) was measured after the samples returned to room temperature (about 10 minutes), according to the manufacturer's operating instructions.
[0071] The % Transmittance was measured on the inventive product/glycerin/water dispersions by placing an aliquot of each dispersion in a quartz cuvette and reading the % T at 590 nm wavelength for each sample on a 0-100 scale. The % Transmittance vs. RI of the stock solutions used was plotted on a curve. The Refractive index of the inventive product was defined as the position of the plotted peak maximum (the ordinate or X-value) on the % Transmittance vs. the RI curve. The Y-value (or abscissa) of the peak maximum was the % Transmittance.
[0072] The surface area of the precipitated silica/silica gel reported herein is determined by the BET nitrogen adsorption method of Brunaur et al., J. Am. Chem. Soc., 60, 309 (1938).
[0073] The total pore volume (Hg) is measured by mercury porosimetry using a Micromeritics Autopore II 9220 apparatus. The pore diameters can be calculated by the Washburn equation employing a contact angle Theta (θ) equal to 140° and a surface tension gamma equal to 485 dynes/cm. This instrument measures the void volume and pore size distribution of various materials. Mercury is forced into the voids as a function of pressure and the volume of the mercury intruded per gram of sample is calculated at each pressure setting. Total pore volume expressed herein represents the cumulative volume of mercury intruded at pressures from vacuum to 60,000 psi. Increments in volume (cm 3 /g) at each pressure setting are plotted against the pore radius or diameter corresponding to the pressure setting increments. The peak in the intruded volume versus pore radius or diameter curve corresponds to the mode in the pore size distribution and identifies the most common pore size in the sample. Specifically, sample size is adjusted to achieve a stem volume of 25-75% in a powder penetrometer with a 5 ml bulb and a stem volume of about 1.1 ml. Samples are evacuated to a pressure of 50 μm of Hg and held for 5 minutes. Mercury fills the pores from 1.5 to 60,000 psi with a 10 second equilibrium time at each of approximately 103 data collection points.
[0074] Median particle size is determined using a Model LA-930 (or LA-300 or an equivalent) laser light scattering instrument available from Horiba Instruments, Boothwyn, Pa.
[0075] Two criteria for describing the tightness of the particle size distribution are particle size span ratio and beta values as measured using a Horiba laser light scattering instrument. By “particle size span ratio” it is meant the cumulative diameter of the particles in the tenth percentile (D10) minus the cumulative volume at the ninetieth volume percentile (D90) divided by the diameter of the particles in the fiftieth volume percentile (D50), i.e. (D10-D90)/D50. A lower span ratio indicates a narrower particle size distribution. By “particle size beta value” it is meant cumulative diameter of the particles in the twenty-fifth volume percentile (D25) divided by the diameter of the particles in the seventy-fifth volume percentile (D75), i.e. D25/D75. A higher beta value indicates a narrower particle size distribution.
[0076] CTAB external surface area of silica is determined by absorption of CTAB (cetyltrimethylammonium bromide) on the silica surface, the excess separated by centrifugation and determined by titration with sodium lauryl sulfate using a surfactant electrode. The external surface of the silica is determined from the quantity of CTAB adsorbed (analysis of CTAB before and after adsorption). Specifically, about 0.5 g of silica is placed in a 250-ml beaker with 100.00 ml CTAB solution (5.5 g/L), mixed on an electric stir plate for 1 hour, then centrifuged for 30 minutes at 10,000 rpm. One ml of 10% Triton X-100 is added to 5 ml of the clear supernatant in a 100-ml beaker. The pH is adjusted to 3.0-3.5 with 0.1 N HCl and the specimen is titrated with 0.0100 M sodium lauryl sulfate using a surfactant electrode (Brinkmann SUR1501-DL) to determine the endpoint.
[0077] The % 325 mesh residue of the inventive silica is measured utilizing a U.S. Standard Sieve No. 325, with 44 micron or 0.0017 inch openings (stainless steel wire cloth) by weighing a 10.0 gram sample to the nearest 0.1 gram into the cup of the 1 quart Hamilton mixer Model No.30, adding approximately 170 ml of distilled or deionized water and stirring the slurry for at least 7 min. Transfer the mixture onto the 325 mesh screen; wash out the cup and add washings onto the screen. Adjust water spray to 20 psi and spray directly on screen for two minutes. (Spray head should be held about four to six inches above the screen cloth. Wash the residue to one side of the screen and transfer by washing into an evaporating dish using distilled or deionized water from a washing bottle. Let stand for two to three minutes and decant the clear water. Dry (convection oven @ 150° C. or under infrared oven for approx. 15 min.) cool and weigh residue on analytical balance.
[0078] Moisture or Loss on Drying (LOD) is the measured silica sample weight loss at 105° C. for 2 hours. Loss on ignition (LOI) is the measured silica sample weight loss at 900° C. for 2 hours (sample previously predried for 2 hours at 105° C.). The pH values of the reaction mixtures (5 weight % slurry) encountered in the present invention can be monitored by any conventional pH sensitive electrode.
[0079] Sodium sulfate content was measured by conductivity of a known concentration of silica slurry. Specifically, 38 g silica wetcake sample was weighed into a one-quart mixer cup of a Hamilton Beach Mixer, model Number 30, and 140 ml of deionized water was added. The slurry was mixed for 5 to 7 minutes, then the slurry was transferred to a 250-ml graduated cylinder and the cylinder filled to the 250-ml mark with deionized water, using the water to rinse out the mixer cup. The sample was mixed by inverting the graduated cylinder (covered) several times. A conductivity meter, such as a Cole Palmer CON 500 Model #19950-00, was used to determine the conductivity of the slurry. Sodium sulfate content was determined by comparison of the sample conductivity with a standard curve generated from known method-of-addition sodium sulfate/silica composition slurries.
[0080] Further tests followed below were utilized to analyze the structure of initially produced silica gel during the overall in situ gel/precipitate production method. Included within these analyses was porosity. Such a property of accessible porosity was obtained using nitrogen adsorption-desorption isotherm measurements. The BJH (Barrett-Joiner-Halender) model average pore diameter was determined based on the desorption branch utilizing an Accelerated Surface Area and Porosimetry System (ASAP 2010) available form Micromeritics Instrument Corporation, Norcross, Ga. Samples were out-gassed at 150-200° C. until the vacuum pressure was about 5 μm of Mercury. Such an analyzer was an automatic volumetric type at 77 K. Pore volume was obtained at a pressure P/P 0 =0.99. Average pore diameter is derived from pore volume and surface area assuming cylindrical pores. Pore size distribution (ΔV/ΔD) was calculated using the BJH method, which provides the pore volume within a range of pore diameters. A Halsey thickness curve type was used with pore size range of 1.7 to 300.0 nm diameter, with zero fraction of pores open at both ends.
[0081] The toothpaste (dentifrice) viscosity is measured utilizing a Brookfield Viscometer Model RVT equipped with a Helipath T-F spindle and set to 5 rpm by measuring the viscosity of the toothpaste at 25° C. at three different levels as the spindle descends through the toothpaste test sample and averaging the results. Brookfield viscosity is expressed in centipoise (cP).
[0082] The Radioactive Dentin Abrasion (RDA) values of dentifrices containing the silica compositions used in this invention are determined according to the method set forth by Hefferen, Journal of Dental Res., July-August 1976, 55 (4), pp. 563-573, and described in Wason U.S. Pat. Nos. 4,340,583, 4,420,312 and 4,421,527, which publications and patents are incorporated herein by reference.
[0083] The cleaning property of dentifrice compositions is typically expressed in terms of Pellicle Cleaning Ratio (“PCR”) value. The PCR test measures the ability of a dentifrice composition to remove pellicle film from a tooth under fixed brushing conditions. The PCR test is described in “In Vitro Removal of Stain With Dentifrice” G. K. Stookey, et al., J. Dental Res., 61, 1236-9, 1982. Both PCR and RDA results vary depending upon the nature and concentration of the components of the dentifrice composition. PCR and RDA values are unitless.
Preferred Embodiments of the Invention
[0084] The inventive materials were prepared by sequentially forming (in situ) a first silica gel (or gel-like material) and adding thereto sufficient amounts of reactants to form a precipitated silica component present simultaneously with the initially produced gel (or gel-like material). The amount of gel is controlled by the quantity of reactants in the first stage while the amount of precipitated silica is controlled by the quantity of reactants in the second stage. The structure of the final product is controlled by the amount of gel first produced as related to the amount of precipitated silica, as well as reaction parameters, such as temperature, rates, concentrations, pH, and so forth, as discussed in greater detail above.
[0000] Initial Gel Formation
EXAMPLE 1-2
[0085] The first two examples show the initial production of silica gel within the overall gel/precipitate production method. After initial production, some of these samples were then washed and purified in order to analyze the resultant material to determine if an actual gel is first formed as well as for other gel properties exhibited by such a sample. It is important to note that the remainder of the samples was utilized in the further production of gel/precipitate products below without any washing, purifying, etc.
[0086] In each example, a volume of aqueous solution of 3.3 mole ratio sodium silicate of specified concentration was charged within a 30 gallon reactor and agitated therein at 60 rpm. The reactor contents were then heated to 50° C. and then 11.4% sulfuric acid (heated to 30° C.) was added at a specified rate and for a specified time and the resultant product was then allowed to form into a gel-like material. This material was then filtered and subsequently washed with water (at about 60° C.) and spray-dried. Such collected and dried material was then tested for a number of properties as noted below, the tests for which were delineated above. The following Table 1 includes reaction parameters and conditions; Table 2 provides analyzed properties for these initially produced gel products. It was evident that, upon analysis, a silica gel material was initially formed. Again, the filtering and washing steps performed after collection thereof were only necessary to further analyze the formed gel for certain properties in accordance with Table 2, below. Such analysis is not generally performed during the actual inventive in situ production of the target gel/precipitate silica combination. It was merely an interest to determine if a silica gel had been produced initially and the properties thereof for classification purposes. Furthermore, for this table as well as throughout this disclosure, any data that was unavailable or unmeasured is represented by dashes. Additionally, it is important to note that the oil absorption properties measured for the silica gel alone is not an indication of nor is it to be confused with the determination of oil absorption for the entire inventive gel/precipitate silica combination.
TABLE 1 Reaction Parameters Example No. 1 2 Silicate Conc. % 13 6 Silicate Volume, l 60 60 Acid Addition Rate, lpm 0.47 0.47 Acid Addition Time, min 41.4 24.35 Final Reaction pH 9.0 5.28
[0087] TABLE 2 Example No. 1 2 % Gel 100 100 % LOD 5.1 10.7 % LOI 5.8 8.00 % 325 Mesh Residue 3.3 0.53 5% pH 9.76 6.90 % Na 2 SO 4 3.97 3.18 MPS, μm 16.3 10.1 Particle Size Span — 2.10 Particle Size Beta 0.39 0.43 CTAB, m 2 /g 207 211 BET, m 2 /g 232 433 BJH Desorption Average 196 37 Pore Diameter (Å) Oil Absorption, ml/100 g 120 81 Pore Volume, cc/g 2.1 1.29 BE, mg loss/100,000 rev. 12.73 6.65 RI 1.457 1.451 % T 11 10
In Situ Gel/Precipitate Composite Production
EXAMPLES 3-7
[0088] Examples 3-7 contained from about 10 to about 23% by volume gel and thus from about 90% to about 77% by volume precipitated silica (as noted in the accompanying tables). The products of these examples had silica structure levels varying from low structure (LS) to medium structure (MS) to high structure (HS).
[0089] A first step was followed in which a volume of aqueous solution of sodium silicate (Silicate Volume A) of specified concentration (Silicate Concentration A) and a SiO 2 :Na 2 O ratio of 3.3 was charged within a reactor and agitated therein (depending upon the size of the reactor, the agitation speed was from about 60 to about 92 rpm, although any speed may be utilized for such a procedure). The reactor contents were heated to 50° C. and then 11.4% sulfuric acid was added at a specified rate (Acid Rate A) for a specified time (Acid Addition Time A). (For Example 5, for instance, the agitator speed was set to 60 rpm, except it was increased briefly for 1 minute to 120 RPM during Acid Addition Time 4-5 minutes.) At this point, a specified Water Volume, if indicated, was added to the formed silica gel. A silica gel was then visually recognized and the pH of the slurry was tested and optionally maintained at pH 5.0, as indicated, by adjusting the acid addition rate. The resultant slurry was then heated to as high as 93° C. (with others heated to lower temperatures, as low as 80° C., but allowed to continue to heat up to 93° C. after the second stage precipitation was started), and such a temperature was then maintained for the duration of the batch production. Subsequently, simultaneous addition began of a second amount of an aqueous solution of sodium silicate pre-heated to 85° C. at specified concentration (Silicate Concentration B) at a specified rate (Silicate Rate B) and the same sulfuric acid at a specified rate (Acid Rate B). Recirculation of the reactor contents at a rate of 75 LPM began after simultaneous addition of acid and silicate commenced and continued through digestion. After a specified time (Silicate Addition Time B) of sodium silicate introduction, its flow was stopped. The pH of the reactor contents was continuously monitored during the simultaneous addition stage. The acid addition continued until the entire batch pH dropped to about 7.0. Once this pH was attained, the acid flow was slowed to about 2.7 liters per minute and continued at such a rate until the overall pH of the resultant batch was dropped to 4.6. The finished batch was then heated at 93° C. for 10 minutes (digestion), while maintaining the batch pH at 4.6. The resultant slurry was then recovered by filtration, washed to a sodium sulfate concentration of less than about 5% (preferably less than 4%, and most preferably below 2%) as determined by monitoring the filtrate conductivity and then spray dried to a level of about 5% water utilizing an inlet temperature of ˜480° C. The dried product was then milled to uniform size. Parameters used for Examples 3-7 are described in Table 3. The Acid rate levels for some of the examples were adjusted during the reaction, as noted below.
TABLE 3 Reaction Parameters Example No. 3 4 5 6 7 Silicate Conc. A, % 6 13 13 13 13 Silicate Volume A, l 138 60 60 60 60 Acid Addition Rate A, lpm 5 4.7 5 4.7 4.7 Acid Addition Time A, min 5 5 5 5 5 Water Volume, liters 0 0 150.5 0 0 Reaction pH adjusted to 5.0 Yes No Yes No No Silicate Conc. B, % 14.95 13 17.35 13 13 Silicate Rate B, lpm 9.6 12.8 8.1 12.8 12.8 Acid Rate B, lpm 4.6-4.8 4.7 4.7-5.1 4.7 4.7 Silicate Addition Time B, min 48 42 48 42 42 Average Simultaneous 4.9 8.1 6.4 8.57 8.0 Addition pH
[0090] Several properties of Examples 3-7 were determined according to the methods described above and the results are summarized in Table 4.
TABLE 4 Example No. 3 4 5 6 7 % Gel 22.9 10 13.4 10 10 Structure HS LS MS LS LS % LOD 6.7 4.9 1.9 5.5 4.5 % LOI 4.4 4.3 4 4.6 3.6 % 325 Mesh 0.4 0 0.02 0.48 0 Residue 5% pH 6.61 7.47 6.79 7.09 6.53 % Na 2 SO 4 0.35 <.35 0.74 <.35 0.98 MPS, μm 11.3 7.9 9.5 12.2 4.11 Particle Size Span 1.5 2.2 1.95 2.12 1.90 Particle Size Beta 0.47 0.26 0.45 0.3 0.46 CTAB, m 2 /g 248 54 147 71 76 BET, m 2 /g 453 81 252 102 81 Oil Absorption, 168 82 117 75 81 ml/100 g Pore Volume, cc/g 2.32 1.66 2.18 1.59 1.59 BE, mg loss/ 3.98 18.37 11.4 25.16 7.92 100,000 rev. RI 1.457 — 1.451 1.438 1.441 % T 47 — 30 4 10
EXAMPLES 8-12
[0091] Examples 8-12 contained about 25-35% by volume gel and about 75-65% by volume precipitated silica. The products of these examples had silica structure levels varying from very low structure to high structure. These examples were prepared according to the procedure given in Example 3-7, except with the parameters described in Table 5 below (note that Example 12 was produced within a very large reactor, about 40,000 liters in volume, with an agitation speed of about 92 rpm and a high shear recirculation flow rate of about 3050 liters/minute).
TABLE 5 Reaction Parameters Example No. 8 9 10 11 12 Silicate Conc. A, % 6 13 6.0 32.5 13 Silicate Volume A, l 200 200 200 60.3 6105 Acid Addition Rate A, lpm 4.7 4.7 4.7 4.7 191.3 Acid Addition Time A, min 8 16 8 14.1 11.75 Water Volume, liters 0 0 0 120 0 Reaction pH Adjusted No No No No No to 5.0 Silicate Conc. B, % 16.21 13 16.21 13 13 Silicate Rate B, lpm 8.33 12.8 8.33 12.8 521 Acid Rate B, lpm 4.5-4.7 4.7 4.7-2.0 4.7 191.3 Silicate Addition Time B, 48 31 48 32.9 35.3 min Average Simultaneous 4.34 8.02 7.1 7.9 — Addition pH
[0092] Several properties of Examples 8-12 were determined according to the methods described above and the results are summarized in Table 6.
TABLE 6 Properties Example 8 9 10 11 12 % Gel 33 33 33 30 25 Structure HS HS MS LS MS % LOD 5.7 5.0 2.0 4.4 7 % LOI 5 3.8 3.3 4.8 4.1 % 325 Mesh Residue 0 1.05 0.02 0.11 2 5% pH 6.14 6.96 6.15 8.03 7.52 % Na 2 SO 4 2.24 0.43 3.97 <0.35 0.82 MPS, μm 10.2 15.5 10.3 12.4 12.6 Particle Size Span 1.13 1.96 1.26 — 2.28 Particle Size Beta 0.56 0.37 0.53 0.48 0.3 CTAB, m 2 /g 318 191 164 50 77 BET, m 2 /g 522 242 194 84 118 Oil Absorption, ml/100 g 185 167 142 58/53 122 Pore Volume, cc/g 2.97 3.05 2.9 2.64 2.12 BE, mg loss/100,000 rev. 1.96 4.27 6.79 18.76 2.94 RI 1.457 1.457 1.448 1.438 1.448 % T 57 67 25 6 65.6
EXAMPLES 13-14
[0093] Examples 13-14 contained about 50% gel and about 50% precipitated silica. The products of these examples had silica structure levels varying from low structure to very high structure. These examples were prepared according to the procedure given in Example 3-7, except with the parameters described in Table 7 below.
TABLE 7 Reaction Parameters Example No. 13 14 Silicate Conc. A, % 13 35 Silicate Volume A, l 300 91.2 Acid Addition Rate A, lpm 4.7 4.7 Acid Addition Time A, min 23.5 23.5 Water Volume, liters 0 209 Reaction pH adjusted to 5.0 No No Silicate Conc. B, % 13 13 Silicate Rate B, lpm 12.8 12.8 Acid Rate B, lpm 4.71 4.7 Silicate Addition Time B, min 23.5 23.5 Average Simultaneous Addition pH 7.92 7.29
[0094]
TABLE 8
Example No.
13
14
% Gel
50
50
Structure
HS
MS
% LOD
4.9
4.4
% LOI
3.7
4.1
% 325 Mesh Residue
0.08
0.07
5% pH
6.75
7.83
% Na 2 SO 4
0.59
1.61
MPS, μm
15.4
10.4
Particle Size Span
1.69
—
Particle Size Beta
0.44
0.42
CTAB, m 2 /g
251
90
BET, m 2 /g
377
127
Oil Absorption, ml/100 g
210
111
Pore Volume, cc/g
4.39
1.98
BE, mg loss/100,000 rev.
1.46
6.47
RI
1.457
1.441
% T
84
14
EXAMPLES 15-17
[0095] Examples 15-17 reflected the ability to adjust the gel level and the silica structure through pH modifications of the precipitated silica component during gel/precipitate production as well as through changes in reactant concentrations. These examples were prepared according to the procedure given in Examples 3-12, except with the parameters described in Table 9 below and within the same reactor and under the same agitation conditions as noted for Example 12, above. Examples 15 and 17 had no high shear recirculation, however, whereas Example 16 utilized the same high shear recirculation flow rate as Example 12.
TABLE 9 Reaction Parameters Example No. 15 16 17 Silicate Conc. A, % 13.0 6.0 13.0 Silicate Volume A, l 2442 8140 4884 Acid Addition Rate A, lpm 191.3 191.3 191.3 Acid Addition Time A, min 5 8 11.5 Water Volume, liters 0 0 0 Reaction pH Adjusted to 5.0 No No No Silicate Conc. B, % 13.0 16.21 13.0 Silicate Rate B, lpm 521 339 521 Acid Rate B, lpm 191.3 191.3 231.7 Silicate Addition Time B, min 42 48 37.6 Average Simultaneous Addition pH 9.7 7.2 5.4
[0096] Several properties of Examples 15-17 were determined according to the methods described above and the results are summarized in Table 10.
TABLE 10 Properties Example 15 16 17 % Gel 10 33 20 Structure LS MS MS % LOD 5 2.9 4.1 % LOI 4.3 3.2 4.5 % 325 Mesh Residue 2.6 4.2 0.43 5% pH 7.2 6.69 7.17 % Na 2 SO 4 0.59 0.82 0.51 MPS, μm 12.4 13.21 10.35 Particle Size Span 2.83 2.79 2.52 Particle Size Beta 0.29 0.34 0.41 CTAB, m 2 /g 92 151 185 BET, m 2 /g 91 166 265 Oil Absorption, ml/100 g 79 115 150 Pore Volume, cc/g 1.39 2.08 2.64 BE, mg loss/100,000 rev. 22.47 5.79 3.83 RI 1.432 1.454 1.454 % T 5 67 57
Dentifrice Formulations
[0097] Toothpaste formulations were prepared using several of the above-described gel/precipitated silica examples to demonstrate the ready-to-use on demand capabilities of the inventive compositions without furthering metering of the two components for optimum dental protection benefits.
[0098] To prepare the dentifrices, the glycerin, sodium carboxymethyl cellulose, polyethylene glycol and sorbitol were mixed together and stirred until the ingredients were dissolved to form a first admixture. The deionized water, sodium fluoride, tetrasodium pyrophosphate and sodium saccharin were also mixed together and stirred until these ingredients are dissolved to form a second admixture. These two admixtures were then combined with stirring. Thereafter, the optional color was added with stiring to obtain a “pre-mix”. The pre-mix was placed in a Ross mixer (Model 130 LDM) and silica thickener, abrasive silica and titanium dioxide were mixed in without vacuum. A 30-inch vacuum was drawn and the resultant admixture was stirred for approximately 15 minutes. Lastly, sodium lauryl sulfate and flavor were added and the admixture was stirred for approximately 5 minutes at a reduced mixing speed. The resultant dentifrice was transferred to plastic laminate toothpaste tubes and stored for future testing. The dentifrice formulations are given in Table 11 below. The dentifrice formulation utilized was considered a suitable test dentifrice formulation for the purposes of determining PCR and RDA (as well as viscosity) measurements for the inventive and comparative cleaning abrasives. Changes in the amount of carboxymethylcellulose to permit proper formation of the dentifrice from physical and aesthetic perspectives were made in certain situations with an offset in the amount of deionized water added, but the overall base dentifrice formulation remained essentially static for the tests followed as noted above.
TABLE 11 Form. Form. 1 Form. 2 Form. 3 Form. 4 Form. 5 Form. 6 Form. 7 Form. 8 Form. 9 10 Glycerin 11 11 11 11 11 11 11 11 11 11 (99.5%), % Sorbitol 40 40 40 40 40 40 40 40 40 40 (70%), % Deionized 20 20.4 20 20.2 20.7 20 20.4 20 20.2 20.7 water, % Carbowax 3 3 3 3 3 3 3 3 3 3 600 1 , % CMC-7MXF 2 , % 1.2 0.8 1.2 1.0 0.5 1.2 0.8 1.2 1.0 0.5 Tetrasodium 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 pyrophosphate Sodium 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 Saccharin, % Sodium 0.243 0.243 0.243 0.243 0.243 0.243 0.243 0.243 0.243 0.243 Fluoride, % Silica 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 thickener Zeodent ® 165, % Example 4 20 silica, % Example 5 20 silica, % Example 6 20 silica, % Example 7 20 Silica, % Example 8 20 Silica, % Example 9 20 silica, % Example 10 20 silica, % Example 13 20 silica, % Example 16 20 Silica, % Example 17 20 Silica, % TiO 2 , % 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 Sodium lauryl 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 sulfate, % Flavor, % 0.65 0.65 0.65 0.65 0.65 0.65 0.65 0.65 0.65 0.65 1 A polyethylene glycol available from the Union Carbide Corporation, Danbury, CT 2 A carboxymethylcellulose available from the Aqualon division of Hercules Corporation, Wilmington, DE; also acceptable is CEKOL ® 2000, a CMC available from Noviant
[0099] The dentifrice formulations prepared above were evaluated for PCR and RDA properties, according to the methods described above; the measurements, as well as the PCR:RDA ratios for each dentifrice formulation are provided in Table 12 below. The PCR data for Formulations 1, 3, and 8 were obtained from Southeastern Dental Research Corporation of Port Allen, La., and the remaining PCR data from Oral Health Research Institute of Indianapolis, Ind.
TABLE 12 Form Form 1 Form 2 Form 3 Form 4 Form 5 Form 6 Form 7 Form 8 Form 9 10 PCR 123 100 153 95 76 64 98 74 97 91 RDA 204 143 233 182 66 73 134 23 117 107 PCR/ 0.60 0.7 0.65 0.52 1.15 0.88 0.73 3.22 0.83 0.93 RDA
[0100] The results show varied performance with highly effective cleaning capabilities with relatively low dentin abrasion properties.
[0101] Several other dentifrice formulations were prepared using a combination of 2 inventive silicas for Formulations 12-14 and a combination of an inventive silica and a commercial silica (ZEODENT® 115 from J.M. Huber Corporation) for Formulation 11. The dentifrice formulations were prepared according to the method provided above and with much the same ingredients as described above in Table 11. The following Table 13 provides the formulas for these toothpastes incorporating blends of different silica abrasives in relation to the invention described herein.
TABLE 13 Formula Formula Formula Formula 11 12 13 14 Glycerin (99.5%), % 11 11 11 11 Sorbitol (70%), % 40 40 40 40 Deionized water, % 20.2 20.6 20.6 20.7 Carbowax 600, % 3 3 3 3 CMC-7MXF, % 1.0 0.6 0.6 0.5 Tetrasodium 0.5 0.5 0.5 0.5 pyrophosphate Sodium Saccharin, % 0.2 0.2 0.2 0.2 Sodium Fluoride, % 0.243 0.243 0.243 0.243 Silica thickener 1.5 1.5 1.5 1.5 Zeodent ® 165, % Example 5 silica, % 15 0 0 0 Example 7 silica, % 0 5 0 0 Example 8 silica, % 0 15 10 6 Example 10 silica, % 0 0 10 14 ZEODENT ® 115 silica, 5 0 0 0 % 1 TiO 2 , % 0.5 0.5 0.5 0.5 Sodium lauryl sulfate, % 1.2 1.2 1.2 1.2 Flavor, % 0.65 0.65 0.65 0.65 1 A low structure precipitated silica available from J.M. Huber Corporation, Havre de Grace, Maryland.
[0102] The dentifrice formulations prepared above were evaluated for PCR and RDA properties, according to the methods described above; the measurements, as well as the PCR:RDA ratios for each dentifrice formulation are provided in Table 14 below.
TABLE 14 Formula Formula Formula Formula 11 12 13 14 PCR 97 90 92 95 RDA 168 96 97 113 PCR/RDA 0.58 0.94 0.95 0.84
[0103] The cleaning ability of these combinations, in particular Formulas 12, 13, and 14, evince a highly surprising and effective dental polishing and film removal material with much lower abrasion levels.
DETAILED DESCRIPTION OF THE DRAWINGS
[0104] FIG. 1 shows in graphical representation the ratios of RDA and PCR available within some of the dentifrice formulations listed above, as compared with physical mixtures of silica gel and precipitated silica, produced in much the same way as those disclosed within U.S. Pat. No. 5,658,553 to Rice. The slope of each line indicates the general results accorded by each different formulation and shows that the simultaneously formed combination of this invention imparts greater PCR results with correlated lower RDA. Thus, it has been unexpectedly found that such an inventive combination permits greater cleaning ability without simultaneously unacceptably high dentin abrasion.
[0105] All dentifrices exhibited acceptable viscosity, fluoride availability, and excellent aesthetics (stand-up, texture, dispersion). Particularly, in view of the graphical representation within FIG. 1 , it is evident that the comparative physical blends of such materials do not exhibit the same desired increase in pellicle film cleaning efficiency with lower RDA values as those of the in situ generated invention combinations.
[0106] Likewise, in FIG. 2 there is provided a comparison of the thickening capabilities of the inventive in situ silica combinations versus those physical blends of gels and precipitates described within the Rice patent (within the same test dentifrice formulation as listed above). It is evident that there is a significant difference in overall structure and resultant function of these different types of materials as the in situ generated composite materials exhibit differing degrees of thickening over the spectrum of amounts of gel/precipitate present therein than the Rice patent blends. Clearly, then, there is a distinction in form and characteristics for these two different types of dentifrice additives.
[0107] Furthermore, FIG. 3 shows in graphical representation the measurements of the PCR vs. RDA readings for the inventive gel/precipitate composite materials over a wide range as compared with the same measurements for the conventional precipitated silica abrasives (again as measured within the same test dentifrice formulation as presented above). It is evident from this representation that the inventive gel/precipitate silica composite materials accord much higher PCR results with correlative lower RDA properties than the conventional abrasive materials, showing the significant differences between the comparative abrasives and the inventive in situ produced types. In this manner, surprisingly, it has been realized that the in situ production of blends of silica gels and precipitated silica materials provides improved pellicle film cleaning benefits while simultaneously exhibiting much lower dentin abrasion readings, thereby providing a more effective cleaning material with a lower propensity to deleteriously abrade tooth surfaces during use.
[0108] While the invention will be described and disclosed in connection with certain preferred embodiments and practices, it is in no way intended to limit the invention to those specific embodiments, rather it is intended to cover equivalent structures structural equivalents and all alternative embodiments and modifications as may be defined by the scope of the appended claims and equivalence thereto.
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Unique abrasive and/or thickening materials that are in situ generated compositions of precipitated silicas and silica gels are provided. Such compositions exhibit different beneficial characteristics depending on the structure of the composite in situ generated material. With low structured composites (as measured via linseed oil absorption levels from 40 to 100 ml oil absorbed/100 g composite), simultaneously high pellicle film cleaning properties and moderate dentin abrasion levels are possible in order to accord the user a dentifrice that effectively cleans tooth surfaces without detrimentally abrading such surfaces. Increased amounts of high structure composite materials tend to accord greater viscosity build and thickening benefits together with such desirable abrasion and cleaning properties, albeit to a lesser extent than for the low structure types. Thus, mid-range cleaning materials will exhibit oil absorption levels from an excess of 100 to 150, and high thickening/low abrasion composite exhibit oil absorption properties in excess of 150. Such an in situ, simultaneously produced precipitated silica/silica gel combination provides such unexpectedly effective low abrasion and high cleaning capability and different thickening characteristics as compared to physical mixtures of such components. Encompassed within this invention is a unique method for making such gel/precipitated silica composite materials for such a purpose, as well as the different materials within the structure ranges described above and dentifrices comprising such.
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This application is a continuation of application Ser. No. 261,445, filed May 5, 1981, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to vehicle wheel alignment equipment, and more particularly to such equipment for measuring the angle of toe for individual vehicle wheels either relative to the centerline of the vehicle chassis or relative to the average rolling direction of the non-steerable wheels.
2. Description of the Prior Art
Apparatus providing rearward projecting light beams for use in determining the inclinations of front steerable wheels relative to the axis of rotation of one of the rear non-steerable wheels are found in U.S. Pat. Nos. 4,154,531, Roberts, Jr. et al, issued May 15, 1979; 4,150,897, Roberts, Jr. et al, issued Apr. 24, 1979; 4,130,362, Lill et al, issued Dec. 19, 1978; and 4,097,157, Lill, issued June 27, 1978, all of which are currently assigned to the Assignee of record of the invention disclosed herein. The '531 patent discloses apparatus wherein the rearward projected beam is caused to swing through a predetermined angle. The beam is reflected by a mirror mounted in predetermined relationship with the axis of rotation of one of the rear non-steerable wheels so that the oscillating beam is reflected back to a target mounted on the front steerable wheel on the same side of the vehicle. The time relationship between the instants when the projected oscillating beam is received by light sensitive devices when reflected toward a front wheel mounted target is used to determine the inclination of the front steerable wheel in the horizontal or toe plane.
The '362 patent disclosure provides a multiplicity of beams projected at known angles relative to a reference angle from a projector mounted on one of the steerable front wheels of the vehicle. A mirror mounted on the rear wheel on the same side of the vehicle in predetermined relationship with the axis of rotation of the rear wheel reflects one of the projected beams back to the front wheel assembly. The reflected and received beam from the multiplicity of beams determines the inclination of the front wheel in the horizontal or toe plane.
The '157 patent disclosure makes reference to a rearwardly projected beam which is reflected by a mirror mounted in predetermined relationship with a non-steerable wheel on the same side of the vehicle. The reflected beam is received at an encoding target which is mounted on the front wheel on the same side of the vehicle to provide an indication of the inclination of the front wheel in the horizontal or toe plane relative to the axis of rotation of the rear wheel.
The '897 patent disclosure relates to a rearwardly transmitted light beam from a front steerable wheel mounted assembly which is reflected by a rear wheel mounted mirror having predetermined orientation relative to the axis of rotation of the rear wheel. The front steerable wheels are adjusted in steering direction until the beam reflected from the rear wheel mounted mirror strikes a calibration point on the front wheel mounted assembly. The mirror on the rear wheel is then moved laterally so that the projected beam falls on a scale on the mirror at a point which is related to the desired toe setting for the front steerable wheels of the vehicle. The front steerable wheel is adjusted in toe so that the projected beam moves to a desired location on the rear mirror thereby setting known front wheel toe into the one front steerable wheel. The toe of the other front steerable wheel is set in the usual manner to obtain the desired total front steerable wheel toe. The apparatus automatically adjusts for different vehicle wheel spacings.
SUMMARY OF THE INVENTION
According to the present invention apparatus is provided for measuring individual wheel toe of a steerable wheel pair and a non-steerable wheel pair which support a chassis of a vehicle. An alignment head pair is adapted for mounting equidistant from a center point between the wheel pairs, first on the non-steerable wheel pair and then on the steerable wheel pair. The alignment heads provide an individual toe signal for the wheel on which each head is mounted. Means is provided for receiving the toe signals and for providing a total toe value for the wheels on which the heads are mounted. A sighting system is provided in each alignment head which defines a line of sight generally in a direction longitudinal of the vehicle chassis. Means for adjusting the line of sight is provided so that the line of sight assumes a fixed direction relative to the direction of the plane of the wheel on which the head is mounted. Means is coupled to the means for adjusting for providing an electrical output signal indicative of the line of sight direction relative to respective ones of the wheel planes of the wheel pairs. Further, means is provided for receiving the electrical output signals and for providing a wheel pair steering direction value relative to the chassis centerline when the lines of sight are adjusted to intercept the points near the opposing wheel axes which are equidistant from a center point between the opposing wheel pair. Means is provided for combining one-half of the total toe value and the wheel pair steering direction value to thereby obtain an actual toe value for each of the wheels in the pair. Means for comparing a value corresponding to the individual toe signal at each wheel with the corresponding actual toe value is provided, thereby obtaining a toe correction factor value for each wheel in that wheel pair. Memory means provides for storing the correction factor value, whereby the values corresponding to individual toe are continuously corrected while the wheel toe is adjusted and steering direction is changed.
The method disclosed in conjunction with the apparatus described herein relates to measurement of toe for wheels supporting a vehicle chassis wherein the wheels include pairs of non-steerable and steerable wheels. A pair of alignment heads are utilized which are adapted to be mounted on ones of the wheels and which provide signals indicative of the individual toe of the wheels on which the heads are mounted. An optical system is incorporated in each head having an aimable optical axis extending therefrom. The method includes the steps of mounting an alignment head on each of the non-steerable wheels and aiming each optical axis in a fixed direction at separate ones of a pair of points equidistant from a point on the centerline of the vehicle chassis. An electrical signal is then provided indicative of the angular departure of each aimed optical axis from the plane of the non-steerable wheel on which the respective head is mounted. Combining the angular departure signals and providing a steering or average rolling direction value for the non-steerable wheels is followed by calculating a value indicative of the total toe of the non-steerable wheels utilizing the individual toe signals. The step of combining one-half of the total toe value with the average rolling direction value to obtain an actual toe value is followed by comparing the actual and individual toe values to obtain a toe correction factor. The alignment heads are removed from the non-steerable wheels and mounted on the steerable wheels. Each optical axis is aimed in a fixed direction at separate ones of a pair of points equidistant from the centerline of the vehicle chassis approximately at the position of the non-steerable wheels. An electrical signal is provided indicative of the angular departure of each aimed optical axis from the plane of the steerable wheel on which the respective head is mounted. A value indicative of total toe of the steerable wheels is calculated, wherein the steerable wheel individual toe signals are utilized. One-half of the steerable wheel total toe and the angular departure signal are combined with the stored non-steerable wheel rolling direction signal so that an actual toe signal for each steerable wheel is obtained which is referenced to the non-steerable wheel average rolling direction. The actual toe for one steerable wheel is compared with the individual toe for that wheel to obtain a steerable wheel toe correction factor and the steerable wheel correction factor is stored for application steerable wheel individual toe for other steering angles and toe adjustments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic plan view of the apparatus and method of the present invention utilized to measure individual steerable wheel toe relative to a vehicle chassis centerline.
FIG. 2 is a diagrammatic plan view showing the apparatus and method of the present invention utilized to measure individual non-steerable wheel toe relative to a vehicle chassis centerline.
FIG. 3 is a diagrammatic plan view showing the apparatus and method of the present invention utilized to measure individual steerable wheel toe relative to the non-steerable wheel average rolling direction.
FIG. 4 is a top sectional view of a portion of one of the alignment heads shown in FIGS. 1 through 3 showing the incorporation of an aimable viewfinder in accordance with the present invention.
FIG. 5 is an elevation sectional view of the aimable viewfinder of FIG. 4.
FIG. 6 is a sectional view taken along the lines 6--6 of FIG. 5.
FIG. 7 is a perspective view showing a plano prism configuration used in the disclosed embodiment of the invention.
FIG. 8 is a perspective view showing a turning mechanism for the plano prisms in the disclosed embodiment.
FIG. 9 is a block diagram showing one embodiment of the present invention.
FIG. 10 shows the utilization of the combination of FIG. 9 with the alignment heads on a steerable wheel pair.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Wheel mounting alignment heads 11 and 12 are shown in FIG. 1 such as those disclosed in U.S. Pat. Nos. 4,097,157 or 4,150,897 mentioned hereinbefore. The alignment heads are mounted on a pair of front steerable wheels 13 and 14 supporting the front end of a vehicle chassis having a centerline 16 passing therethrough. A pair of non-steerable rear wheels 17 and 18 support the rear end of the chassis. The alignment heads 11 and 12 are modified as compared to those disclosed in the aforementioned U.S. Patents. The heads each contain an aimable viewfinder which may best be described by reference to FIGS. 4 through 6.
An aimable viewfinder 19 is shown in FIG. 4 having an objective lens 21 exposed to light rays from an object located on a viewing path 22 extending from the viewfinder. The viewing path therefore extends from the rear side of the alignment heads 11 and 12 as seen in FIG. 1. The viewing path 22 may be adjusted through a limited angle alpha (α) on either side of the viewing path 22 in a substantially horizontal plane as shown in FIG. 4. The objective lens 21 is mounted in an aperture in the rear of the existing alignment head structure. A tubular member 23 is fixed in the alignment head surrounding an optical axis 25 extending through the lens. Adjacent to the objective lens 21 and on the image side of the lens, is a pair of holding rings 24 and 26, as seen in any of FIGS. 4, 5, 7 or 8. Fixed in the holding rings are a pair of plano prisms 27 and 28. The holding rings are mounted in a groove 29 formed in the interior of the alignment head structure so that they may rotate about the optical axis 25 of the objective lens 21. The holding rings 24 and 26 are captured between a shoulder 31 adjacent to the mounting boss for the objective lens and a shoulder 32 which is adjacent to a bore 30 in the alignment head structure which surrounds and engages the outside diameter of a tube member 23 (FIGS. 4 and 5).
A bevel gear 33 is formed on the holding ring 24 and a facing bevel gear 34 is formed on the holding ring 26 as best seen in FIG. 8. The alignment head outer structure has a bore 36 therethrough in which is situated a bearing 37 supporting shaft 38 for rotation therein. The shaft extends through a rotary potentiometer 39 and is engageable at a knob 41 mounted on an accessible extension of the shaft 38. The shaft has a bevel pinion 42 disposed on the inward end thereof which engages the bevel gears 33 and 34 simultaneously. It may thus be seen that if the knob 41 is turned, the potentiometer wiper (not shown) is also turned, providing an output change from the rotary potentiometer 39. The shaft 38 and the bevel pinion 42 are also turned which causes the bevel gears 33 and 34 and the holding rings 24 and 26 to rotate in opposite directions within the groove 29.
The plano prisms 27 and 28 are fixedly mounted within the holding rings 24 and 26 respectively. As may be seen in FIGS. 5 or 7, the prisms have flat angled faces 27a and 28a on one side and flat faces 27b and 28b on the other side. The latter flat faces are perpendicular to the cylindrical outer surfaces of the prisms and are mounted in the rings so that they are adjacent, parallel to one another and situated substantially perpendicular to the optical axis 25 through the tube member 23. The angled faces 27a and 28a are situated parallel to one another when the plano prisms are oriented so as to cause no lateral deflection through any portion of the angle alpha for the rays passing through the objective lens 21 from an object on the viewing path 22. This orientation of the plano prisms may be seen in FIGS. 5 and 7, wherein the prism 27 causes an upward deflection of rays passing through the objective lens and the plano prism 28 causes an equal and opposite downward deflection. Therefore, the rays passing through the plano prisms when oriented as shown in FIG. 5 will proceed through the tube member 23 in the same direction as they approach the objective lens from the object. However, when the knob 41 is rotated causing one holding ring and plano prism to rotate in one direction and the other holding ring and plano prism to rotate in the opposite direction, while the vertical components of ray deflection will continue to cancel out, the lateral ray deflection components will add. Therefore, the rays passing through the objective lens 21 will appear to be adjusted angularly as they proceed through the tube member 23 apparently swinging through some portion of the angle alpha to one side or the other of the viewing path 22 dependent on the degree to which and the direction in which the knob 41 is turned. The rotary potentiometer 39 will provide an electrical output which is indicative of the rotation imparted to the plano prisms and therefore indicative of the angle in the substantially horizontal plane through which the rays from the object being viewed are deflected. This may be seen to be distinct from the practice wherein purely mechanical adjustment is provided as disclosed in copending U.S. patent application Ser. No. 261,440 filed of even date herewith and issued Mar. 1, 1983 as U.S. Pat. No. 4,375,130.
The objective lens 21 in this embodiment may have a focal length of approximately 11 inches. Considering the wheel bases of most vehicles on which this equipment is intended to be used, an optical assembly shown generally at 43 is mounted at a distance along the tube member from the objective lens which is about at the back focal distance of the objective lens for objects about wheel base distance in front of the lens. The optical assembly includes a vertically disposed plane mirror 44 mounted at about a 45° angle to a diameter of the tube member. Mirror 44 intercepts rays traveling through the tube member and reflects them through an opening 46 in the side of the tube member to impinge upon an oblique plane mirror 47 which is mounted just outside the tube member. The oblique mirror is mounted at an angle which is nearly 45° with the vertical if the rays are to be reflected directly from the oblique mirror to a viewing lens. The oblique mirror is mounted on the path of rays passing through the objective lens substantially at the aforementioned back focal distance of the lens. In this example the back focal distance may be approximately 125/8 inches. Therefore, a real image is constructed approximately at the surface of the oblique mirror 47. An index line 48 is formed from top to bottom centrally on the surface of the mirror. The index line will therefore appear superimposed on the real image constructed by the objective lens to an observer of the rays reflected from the oblique mirror 47.
If it is desirable or required to erect the real image formed by the objective lens 21 at the oblique mirror 47, an arrangement of erecting mirrors 49 and 51 as shown in FIG. 6 may be used. The image may thereby be erected before the rays are directed to a viewing lens 52 which may provide some magnification, by a factor of 2 for example, for the image for presentation to an observer. The observing point is ideally situated at an eye relief distance of about 8 to 12 inches from the surface of the viewing lens 52 to that an operator will not have to stoop too close to the viewing lens to ascertain the direction in which the aimable viewfinder is being aimed.
Returning now to FIG. 1 of the drawings, the viewing path or lines of sight 22 may be seen emanating from the rear portions of the alignment heads 11 and 12. The lines of sight are directed toward points 53 and 54 which are equidistant from a point along the centerline 16 of the vehicle chassis. Specifically, the points 53 and 54 are equidistant from the midpoint between the non-steerable wheels 17 and 18 and are therefore any two similar points on opposite sides of the vehicle chassis. The reference position for the viewing path 22 is in a direction which is parallel to the rotation planes of the wheels upon which the aligner heads are mounted, the front steerable wheels 13 and 14 in the embodiment of FIG. 1. The viewing paths 22 may be seen to diverge from the reference direction by an angle AR for the steerable wheel 13 and AL for the steerable wheel 14.
A mounting error known as runout is usually present when an alignment head is mounted on a vehicle wheel. The alignment heads utilized herein may have runout compensation structure included therein such as that disclosed in U.S. Pat. No. 4,180,915, Lill et al, issued Jan. 1, 1980; U.S. Pat. No. 4,192,074, Chang, issued Mar. 11, 1980; or U.S. Pat. No. 4,138,825, Pelta, issued Feb. 13, 1979. Such a runout angle for a particular rotational position of the right steerable wheel 13 is shown as ER and for the left steerable wheel 14 as EL in FIG. 1. Runout compensation values in accordance with the runout angles may be stored in a micro-computer (not shown) which is associated with the alignment heads 11 and 12 so that the departure angle signals for the sighting system of each wheel may be corrected to bring the "home" position for each sighting system effectively precisely parallel to the plane of its associated wheel.
With the foregoing in mind the following quantity definitions and relationships provide information identifying individual steerable wheel toe in relation to the vehicle chassis centerline 16 as seen in FIG. 1. It should be noted that the quantities AR and AL as combined and corrected here provide a quantity which is indicative of the average steering direction of the steerable wheels 13 and 14. The quantities R and L are signals generated by the alignment heads 11 and 12 respectively which relate to the individual toe of the steerable wheels. ##EQU1##
The foregoing illustrates how the quantities are combined to provide an average steering direction quantity for the steerable front wheels 13 and 14 as well as how an actual toe setting signal TL is obtained for the left steerable wheel 14 by utilizing one half the total toe signal provided by the alignment heads 11 and 12 and the average steering direction signal. The actual left toe is obtained in accordance with the appropriate sign conventions by adding the average steering direction signal to the one half total toe signal to obtain the actual left toe indicative signal and by subtracting the average steering direction signal from the one half total toe signal to obtain the actual right toe indicative signal in the embodiment of FIG. 1. Once the alignment heads 11 and 12 have been set up as shown in FIG. 1 a correction factor may be obtained by comparing the individual toe signal (L or R) provided by either alignment head with the actual toe indicative signal (TL or TR). The difference between the signals is equivalent to a correction factor which may then be stored and utilized for correcting the individual toe signal (L or R) provided by each alignment head (12 or 11) while the toe of either of the front steerable wheels 14 or 13 is adjusted or the steering direction of both wheels is changed. Sign convention requires that the correction factor be continuously added to the signal from the left projector and continuously subtracted from the signal from the right projector.
With reference now to FIG. 2 of the drawings the pair of front steerable wheels 13 and 14 are shown together with a pair of non-steerable rear wheels 17 and 18 with the alignment heads 11 and 12 mounted on the non-steerable rear wheels. The alignment heads are reversed on the rear wheels in order to find clearance under the vehicle for the cross toe measurements L' and R' as shown in FIG. 2. As a result the sign of the toe signal must be changed and the values derived by the alignment head 12 must be displayed on the right meter and the values derived by the alignment head 11 must be displayed on the left meter because they are mounted on the right and left rear wheels respectively. A front and rear wheel mode selection switch (not shown) is provided so that the switch may be selected to the position which conforms with the position at which the alignment heads are mounted, front or rear. A correction factor switch (not shown) is also provided so the appropriate correction factors and average rear wheel rolling direction signal may be stored when appropriate.
With the alignment heads 11 and 12 mounted on the non-steerable rear wheel pair 17 and 18, targets 56 and 57 about 7 inches in length and having graduated scales thereon are mounted at the axes of the front steerable wheel 13 and 14 as shown. The aimable viewfinders as disclosed hereinbefore are adjusted by means of the knobs 41 (FIG. 4) so that the index lines 48 in each of the aimable viewfinders appears at the same graduated point on the target graduated scales 56 and 57 or at any two similar points on opposite sides of the chassis as hereinbefore described. The viewing paths 22 are therefore directed to points which are equidistant from a point on the chassis centerline, specifically the mid-point between the front steerable wheels 13 and 14. An electrical signal is therefore generated by each potentiometer 39 in the aimable viewfinders 19, wherein the signals are indicative of the angles A'L and A'R as seen in FIG. 2. The runout errors E'L and E'R are obtained as hereinbefore described and together with the individual toe signal values L' and R' are used to perform calculations in accordance with the following relationships. ##EQU2##
It may be seen from the foregoing relationships that the quantity D is representative of the average rolling direction of the pair of rear wheels 17 and 18 and is obtained by combining the signals which indicate the deviations of the lines of sight 22 from a direction parallel to the planes of the wheels 17 and 18 in an average steering direction circuit 61 shown in FIG. 9. The actual toe for the left rear wheel is computed relative to the chassis centerline 16 by adding the average rolling direction for the rear wheels to a quantity provided by the alignment heads from circuitry 62 (FIG. 9) contained therein, such quantity being equal to one half of the total toe of the rear wheels. Total toe is obtained from a total toe circuit 63 receiving the individual toe signals from the heads 11 and 12 as disclosed in the U.S. Pat. Nos. 4,097,157 and 4,150,897 mentioned hereinbefore. A signal T'L indicative of actual toe for the right rear wheel is computed by subtracting the rear rolling direction quantity from the half total rear toe signal in a circuit 64 as seen in FIG. 9. The correction factor K't may be computed in a correction factor circuit 66 shown in FIG. 9 with the set up as described for FIG. 2 by subtracting the actual rear toe for either wheel from the individual toe signal value provided by the corresponding alignment head. With the alignment mode switch set to the rear position, a correction factor switch is actuated which stores the correction factor in a correction factor storage 67 and average rear rolling direction signals in a steering direction storage 68 to be used for purposes to be hereinafter described. The correction factor K't is used to provide the corrected individual rear toe display signal from an individual toe correction circuit 69 for each rear wheel so that subsequent rear wheel toe adjustment may be appropriately corrected when made for the chassis for which the rear wheel toe correction factor K't was obtained.
Subsequent to obtaining the rear wheel toe relative to the chassis centerline 16 and the signal indicative of the average rear wheel rolling direction the aligner heads 11 and 12 are removed from the left and right rear wheels 18 and 17 respectively and mounted on the right and left front steerable wheels 13 and 14 respectively as shown in FIG. 3. FIG. 10 contains the same elements as FIG. 9 described hereinbefore, but has the signal lines labeled to indicate the signals obtained by means of the following description of adjustments to and computations by the various elements common to FIGS. 9 and 10 when the alignment heads are mounted on the steerable wheels. Once again the aimable viewfinders are aimed at a pair of points which are equidistant from a point on the vehicle centerline, preferably the mid-point between the non-steerable wheels 17 and 18. The points are identified in the embodiment of FIG. 3 by directing the viewing paths or lines of sight 22 to like points on the scales 56 and 57 now mounted on the axes of the non-steerable wheels 17 and 18 respectively or to similar points on opposite sides of the vehicle chassis such as represented by points 53 and 54 in FIG. 1. The aiming of the viewfinders generates an electrical signal (A"L and A"R which is proportional to the angle between the optical axis or line of sight and the plane of the steerable wheel on which a particular alignment head 11 or 12 is mounted. Electrical signals are obtained from the alignment system which are indicative of the total toe angle between the planes of the front wheels 13 and 14 so that the average steering direction of the front wheels may be obtained as described in conjunction with the description of FIG. 1. Having thus obtained a signal which is indicative of a portion (one half) of the total toe between the front wheels (Tav), a signal which is indicative of the average steering direction of the front wheels (S"), and having fetched a signal from storage which is indicative of the average rear wheel rolling direction (D), a combination of the signals in the actual toe computation circuit 64 provides for actual front wheel toe settings T"L as shown in the relationships immediately following. ##EQU3##
It may be seen from the foregoing and from FIG. 10 that a correction factor for the front steerable wheels K"t may be obtained from the signals obtained from the specific set-up described immediately hereinbefore by comparing an individual toe reading (L" or R") from one of the alignment heads 11 or 12 with the actual toe at that particular setting for either the left steerable wheel 13 (T"L) or the right steerable wheel 14 (T"R) respectively. The correction factor K"t obtained is placed in storage 67 by actuating the correction factor switch (not shown) while the front and rear alignment switch is in the front position. As explained hereinbefore, the correction factor is continuously added to the signal L" from the left alignment head 12 and continuously subtracted from the signal R" obtained from the right alignment head 11. The correction factor K"t may thus be combined with the individual toe indicative signals L" and R" from the alignment heads to continuously obtain a corrected toe signal t"L and t"R for display while individual wheel toe is being adjusted or the steering direction is being changed. The correction factor is constant for any of the situations for FIGS. 1 through 3 described herein and may be obtained by one careful set-up of the alignment heads 11 and 12 and aimable viewfinders 19 contained therein. Thereafter, having stored the correction factor, no special care need be taken in adjusting individual toe of the wheels on the vehicle to assume predetermined toe angle inclinations, while nonetheless being assured of corrected toe inclination displays.
Although the best mode contemplated for carrying out the present invention has been herein shown and described, it will be apparent that modification and variation may be made without departing from what is regarded to be the subject matter of the invention.
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An apparatus and method is disclosed which utilizes modified wheel aligner heads and which accomplishes measurement of individual wheel toe on a vehicle having a pair of non-steerable rear wheels and a pair of steerable front wheels. The apparatus and method provides measurement of a steering or a rolling direction for the front and the rear wheel pair as a result of optical measurements taken relating the orientation of the planes of the wheels to the centerline of the vehicle chassis. Once the steering direction of the front wheels is obtained, individual toe measurements for the front wheels may be made relative to the chassis centerline. Alternatively, once the steering or average rolling direction of the rear wheels is obtained individual toe measurements for the rear wheels may be made relative to the chassis centerline and individual toe measurements for the front wheels may be made relative to the rear wheel rolling direction. Neutral steering of the front wheels may thus be made to coincide directionally with the rear wheel rolling direction. The optical measurements are made with an aimable viewfinder utilizing contrarotating plano prisms which are monitored in rotational position to provide data utilized in calculating wheel pair steering direction and correction factors for the measurements taken by the aligner heads.
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BACKGROUND OF THE INVENTION
The present invention relates to an automatic cleaning device for TV game cassette, and more particularly to an automatic cleaning device which is used to automatically clean copper foil contacts of TV game cassette so as to ensure normal contact between the TV game cassette and TV game main frame.
The TV game has been the most popular entertaining measure for the past many years. Currently, the volume of the TV game is greatly reduced and portable TV game is widely developed. Various kinds of TV game cassettes are commercially available to provide different types of games for a consumer. Many TV game manufacturers produce different TV game main frames and cassettes with different specifications. Therefore, in order to enjoy playing all kinds of TV games, a player must purchase all these TV game main frames and cassettes. However, no matter how the specifications of these cassettes are different from each other, such cassettes have similar structures. That is, each cassette includes a plastic cartridge and a printed circuit board enclosed therein. Integrated circuits recorded with TV game programs are inserted on the circuit board and many copper foil contacts are printed on one edge of the circuit board. The contacts protrudes out of an insertion socket of the cartridge for inserting into and electrically contacting with the connector of the TV game main frame so as to load the TV game programs of the cassette thereinto. Accordingly, a player can play the TV game through a monitor.
Because the copper foil contacts of the cassette protrude out of the insertion socket thereof and are frequently inserted into or withdrawn from the connector, the copper foil contacts are apt to be contaminated by dusts or dirts which will seriously affect the contacting effect. Therefore, it is necessary to timelily clean the copper foil contacts.
FIG. 22 shows a conventional manually operated cleaner 130 which is used to clean up the copper foil contacts of the TV game cassette. Such cleaner 130 includes a thin plastic tongue plate 131 covered by a cleaning member 132 and a handle 134. When used, a user must hold the handle 134 with fingers and extend the cleaning member 132 into the insertion socket of the cassette to reciprocally wipe the copper foil contacts.
According to the above arrangements, several shortcomings exist as follows:
1. It is laborious, inconvenient and time-wasting to the player to clean the contacts with such cleaner.
2. The player can hardly uniformly exert a force on the cleaner so that it is difficult to achieve an evenly cleaning effect.
Therefore, it is necessary to provide an improved cleaning device for the TV game cassette to eliminate the above shortcomings.
SUMMARY OF THE INVENTION
It is therefore a primary object of the present invention to provide an automatic cleaning device for TV game cassettes, which is able to automatically clean the copper foil contacts of the TV game cassette many times. According to the above object, the cleaning device includes a housing composed of an upper case and a lower case. The upper case includes at least one insertion socket formed on a surface thereof, whereby the cassette can be inserted and located in the insertion socket, and at least one linear guide rail formed in the housing corresponding to the insertion socket; at least one cleaning assembly which can be a brush made of hairs and which is slidably disposed on the guide rail, the cleaning assembly being able to reciprocally sliding along the guide rail to back and forth clean contact portions of the cassette; a cleaning arm having one end pivotally disposed in the housing and another end slidably connected with the cleaning assembly, the cleaning arm being formed with slide slots; a crank having a rotary center and a driving section, the rotary center being rotatably disposed in the housing, the driving section being slidably connected with the slide slots of the cleaning arm, whereby by means of the rotation of the crank, the cleaning arm is driven to reciprocally swing so as to drive the cleaning assembly to reciprocally move along the guide rail; and a motor disposed in the housing for driving the crank to rotate.
In a preferred embodiment of the present invention, the housing includes two insertion sockets for different types of TV game cassettes to insert thereinto.
Several locating tenons are further disposed in one or both of the insertion sockets. The locating tenons are positioned in the housing and extended into the insertion sockets for engaging with one or two ends of a relatively small TV game cassette. The locating tenons have inclined sides, whereby a relatively large TV game cassette can press said inclined sides of the locating tenons to retract the same into the housing, so that the larger TV game cassette can be smoothly inserted into the insertion sockets and securely located therein by means of a tightening effect provided by the locating tenons.
The locating tenons have resilient portions integrally formed on the locating tenons. One of the resilient portions is fixed in the housing, making the locating tenon resiliently biased toward the insertion sockets.
In another preferred embodiment of the present invention, the cleaning device further comprise a cleaning time setting means including a switch fixedly disposed in the housing for controlling activation/stopping of the motor; a cam rotatably disposed in the housing and adjacent to the switch for controlling closing/opening thereof; and a transmission gear disposed between the cam and the crank for setting rotary speed ratio therebetween. The cam is disk-like and disposed on the crank, having a large diameter rim portion and a small diameter rim portion. A spring is disposed between the cam and the lower case for lifting the cam. The bottom of the upper case is formed an annular projection corresponding to a rotational track of the crank. A recess is formed on the annular projection, whereby the driving section of the crank is able to upward abut against the projection to force the crank and cam to move downward so that the large diameter rim portion of the cam can trigger the switch. The recess of the projection permits the driving section of the crank to slide thereinto, whereby by means of the spring, the cam and crank are lifted to make the small diameter rim portion of the cam aligned with the switch so as to cut off power for the motor and thus rest the cleaning assembly at the ends of the guide rails.
The transmission gear has a lifting portion for lifting or lowering the cam and the driving section of the crank.
The cleaning arm includes two arm members pivotally connected with each other and a torsion spring disposed between the two arm members, whereby when the cleaning arm is folded for relatively short travel cleaning operation and unfolded for relatively long travel cleaning operation.
The advantages of the present invention are as follows:
1. The cleaning assembly can automatically back and forth clean the contacts of the cassette many times.
2. After the cleaning operation is completed, the cleaning assembly is automatically rested on a lateral portion of the housing so as to prevent the dirts from remaining on the contacts of the cassette and ensure the cleaning effect.
3. The cleaning device is able to clean various types and specifications of TV game cassettes.
The present invention can be best understood through the following description and accompanying drawing, wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the present invention;
FIG. 2 is a top view of the present invention;
FIG. 3 is a top view according to FIG. 2, wherein the upper case is removed;
FIG. 4 is an enlarged view of the area 4 encircled by phantom line of FIG. 2;
FIG. 5 is a sectional view taken along line 5--5 of FIG. 4;
FIG. 6 is a sectional view taken along line 6--6 of FIG. 5;
FIG. 7 is a sectional view taken along line 7--7 of FIG. 2;
FIG. 8 is a perspective view showing that a first kinds of TV game cassette as shown in FIG. 17 is inserted into the cleaning device of the present invention;
FIG. 9 is a perspective view showing that a fourth kinds of TV game cassette as shown in FIG. 20 is inserted into the cleaning device of the present invention;
FIG. 10 is a sectional view taken along line 10--10 of FIG. 8;
FIG. 11 is a sectional view taken along line 11--11 of FIG. 9;
FIG. 12 is a sectional view taken along line 12--12 of FIG. 8, wherein the first kinds of TV game cassette of FIG. 17 is inserted into the cleaning device of the present invention;
FIG. 13 is a sectional view showing that a second kinds of TV game cassette as shown in FIG. 18 is inserted into the cleaning device of the present invention;
FIG. 14 is a sectional view showing that a third kinds of TV game cassette as shown in FIG. 19 is inserted into the cleaning device of the present invention;
FIG. 15 is a sectional view taken along line 15--15 of FIG. 9, wherein the fourth kinds of TV game cassette of FIG. 20 is inserted into the cleaning device of the present invention;
FIG. 16 is a sectional view showing that a fifth kinds of TV game cassette as shown in FIG. 21 is inserted into the cleaning device of the present invention;
FIG. 17 is a perspective view of the first kinds TV game cassette;
FIG. 18 is a perspective view of the second kinds TV game cassette;
FIG. 19 is a perspective view of the third kinds TV game cassette;
FIG. 20 is a perspective view of the fourth kinds TV game cassette;
FIG. 21 is a perspective view of the fifth kinds TV game cassette; and
FIG. 22 is a perspective view of a conventional manually operated cleaner for the TV game cassette.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Please refer to FIGS. 1 to 7. The automatic cleaning device 50 of the present invention includes a housing 51, two cleaning assemblies 52, 65, a cleaning arm 53, a crank 54 and a motor 55. The housing 51 consists of an upper case 57 and a lower case 58. The upper case 57 includes two (at least one) cassette insertion sockets 56, 69 formed on the surface of the upper case 57, whereby different kinds of TV game cassettes 91, 92, 93, 94, 95 as shown in FIGS. 17, 18, 19, 20, 21 can be inserted and located therein to form the states as shown in FIGS. 12, 13, 14, 15, 16.
Please refer to FIGS. 3, 7, 10 and 11. The lower case 58 has two (at least one) linear guide rails 61, 107 formed inside the lower case 58 corresponding to the insertion sockets 56, 69 respectively.
The cleaning assemblies 52, 65 are slidably disposed on the guide rails 61, 107 and extended into the insertion sockets 56, 69 respectively. The cleaning assemblies 52, 65 can reciprocally move along the guide rails 61, 107 to clean the contacts 60 of the TV game cassettes 91, 92, 93, 94, 95 of FIGS. 12 to 16.
Please refer to FIG. 7. Each cleaning assembly 52, 65 includes a slide seat 74 and a cleaning member 59. Two slide channels 75, 76 are formed on two lateral sides of the slide seat 74. The guide rails 61, 107 are slidably fitted in the slide channels 75, 76. The cleaning member 59 has an insertion section 83 inserted in an insertion receptacle 111 of the slide seat 74. Therefore, once the cleaning member 59 is contaminated, the same can be taken out and replaced by a clean one. In a preferred embodiment of the present invention, the cleaning member 59 is a brush made of hairs or other materials such as unwoven fabrics.
Please refer to FIGS. 3 and 7, one end of the cleaning arm 53 is pivotally disposed in the lower case 58 via a pivot pin 109, while the other end thereof is slidably connected under the cleaning assemblies 52, 65. The cleaning arm 53 has three slide slots 62, 90, 101, wherein the slots 90, 101 are respectively slidably and pivotally connected with two pin members 108 under the slide seats 74. The cleaning arm 53 can simultaneously drive the pin members 108 through the slide slots 90, 101, making the cleaning assemblies 52, 65 reciprocally slide respectively along the linear guide rails 61, 107 at the same time for back and forth performing the cleaning operation. The other slide slot 62 of the cleaning arm 53 is slidably and pivotally connected with an upper driving section 64 of the crank 54.
The cleaning arm 53 further includes two arm members 87, 88 pivotally connected with each other via pivot pins 86 and a torsion spring 89 disposed between the arm members 87, 88, whereby when the cleaning arm 53 travels through a relatively short distance to clean a smaller TV game cassette, the cleaning arm can be folded for a shorter cleaning travel. However, the cleaning arm 53 will not be folded with respect to a longer cleaning travel.
Please refer to FIGS. 3, 4 and 5. The crank 54 includes a rotary center 63 and a driving section 64. The rotary center 63 is rotatably disposed on the lower case 58 through a shaft member 110. The driving section 64 is slidably and pivotally connected with the slide slot 62 of the cleaning arm 53. By means of the rotation of the crank 54, the cleaning arm 53 is driven to reciprocally swing so as to further drive the cleaning assemblies 52, 65 to reciprocally move along the guide rails 61, 107.
Please refer to FIGS. 3 and 6. The motor 55 is disposed in the lower case 58 for driving the crank 54 to rotate and make the cleaning assemblies 52, 65 reciprocally move along the linear guide rails 61, 107 for back and forth cleaning the contacts 60 of the TV game cassettes 91, 92, 93, 94, 95 as shown in FIGS. 12 to 16.
Please refer to FIGS. 1 and 3. A cell box 66 and a cell cover 67 are disposed on the bottom of the lower case 58 for containing a cell to supply the power for the motor 55. Alternatively, the cleaning device can be connected to civil power supply through a DC socket 68 and an adapter.
Please refer to FIGS. 1, 2, 7, 8, 9, 12, 13, 14, 15 and 16. Various kinds and specifications of TV game cassettes can be inserted and located in the two (or more) insertion sockets 56, 69 of the upper case 57.
Please refer to FIGS. 2, 12, 13, 14, 15 and 16. In one or both of the insertion sockets 56, 69 are further disposed locating tenons 70, 71, 72 and 73 having resilient portions 102, 103, 104, 105. One end of each of the resilient portions 102, 103, 104, 105 is integrally formed on the locating tenons 70, 71, 72, 73 respectively. The other ends of the resilient portions 102, 103, 104 have fixing sections 112, 113 fixed in the upper case 57. The other resilient portion 105 is directly integrally connected with the upper case 57 as shown in FIGS. 2, 12, 13, 14, 15 and 16, making the locating tenons 70, 71, 72, 73 resiliently biased toward the insertion sockets 56, 69. The locating tenons 70, 71, 72, 73 are positioned in the upper case 57 and extended into the insertion sockets 56, 69 for latching one end (or two ends) of the relatively small TV game cassettes 92, 93, 94.
The locating tenons 70, 71, 72, 73 have inclined sides 96, 97, 98, 99, whereby the relatively large TV game cassettes 91, 92, 93 can press the inclined sides of the locating tenons 70, 71, 72, 73 to retract the same into the upper case 57, whereby the larger TV game cassettes 91, 92, 93 can be smoothly inserted into the insertion sockets 56, 69 and securely located therein by means of the tightening effect provided by the locating tenons 70, 71, 72, 73.
Please refer to FIGS. 4, 5 and 6. The cleaning device of the present invention further includes a cleaning time setting means 77 which includes a switch 78, a cam 79 and a transmission gear set 80. The switch 78 is fixedly disposed in the lower case 58 for controlling the activation/stopping of the motor 55.
The cam 79 is rotatably disposed in the lower case 58 and adjacent to the switch 78 for controlling the opening/closing thereof.
The transmission gear set 80 is disposed between the cam 79 and the crank 54 for setting the rotary speed ratio therebetween, whereby each time the cam 79 rotates through a set number of circles, the switch 78 is triggered to cut off the power for the motor 55. The transmission gear set 80 includes a spiral rod 114, a spiral wheel 115 and gears 116, 117, 118, 119, 120, 121, 122, 123. The motor 55 sequentially drives the spiral rod 114, spiral wheel 115 and gears 116, 117, 118, 119 to rotate and further drives the cam 79 to rotate via the gear 119 and driving shaft 110. Also, through the gear 119, the motor 55 further sequentially drives the gears 121, 122 to make the gear 123 rotate at a relatively slow speed. That is, each time the cam 79 rotates through certain circles, the gear 123 rotates through only, one circle. The gear 123 is not driven by the driving shaft 110 and is rotated relative to the driving shaft 110.
The cam 79 is disk-like and disposed on the crank 54, having two rim portions 81, 82 with different diameters. A spring 83 is disposed between the cam 79 and the lower case 58 to ascend the cam 79.
On the bottom of the upper case 57 is formed an annular projection 84 corresponding to the rotational track of the crank 54. A recess 85 is formed on a portion of the projection 84. The driving section 64 of the crank 54 upward abuts against the projection 84 to force the crank 54 and cam 79 to move downward, whereby the large diameter rim portion 81 of the cam 79 can trigger the switch 78. The recess 85 of the projection 84 permits the driving section 64 of the crank 54 to slide thereinto. By means of the spring 83 and a lifting section 100 disposed on the gear 123, the cam 79 and the driving section 64 are forced to ascend, whereby the small diameter rim portion 82 of the cam 79 is aligned with the switch 78 to separate two resilient contacts 125, 126 thereof from each other so as to cut off the power for the motor 55. Accordingly, the cleaning assemblies 52, 65 are rested at the ends of the guide rails 61, 107 respectively.
Please refer to FIGS. 1 to 5. The upper case 57 is disposed with a through hole 124 for a depression key 106 to pass therethrough to contact with the cleaning arm 53. Becasue the cleaning arm 53 is resilient, when the depression key 106 is depressed, through the cleaning arm 53, the cam 79 and the gear 123 are both pressed downward. While when the depression key 106 is released, the same is lifted by the resilient force of the cleaning arm 53.
When it is desired to clean the TV game cassette 90 (or 91, 92, 93, 94), the cassette is inserted into the insertion socket 56 or 69 with the contacts 60 of the cassette faced downward as shown in FIGS. 8 and 12. Then the depression key 106 is pressed downward to through the cleaning arm 53 press down the cam 79 and the gear 123. After the cam 79 is depressed, the driving section 64 thereof is moved downward and separated from the recess 85. Meanwhile, the large diameter rim portion 81 of the cam 79 is moved downward to shift the resilient contact 125 of the Switch 78 toward the other resilient contact 126, whereby the two contacts 125, 126 contact with each other to power on the motor 55. Accordingly, the motor 55 rotates to sequentially drive the spiral rod 114, spiral wheel 115 and gears 116, 117, 118 and 119 and further through the gear 119 and driving shaft 110 drive the cam 79 to rotate.
By means of the rotation of the driving section 64, the cam 79 drives the cleaning arm 53 to move along the two slide slots 90, 101 and simultaneously drive the two pin members 108, making the cleaning assemblies 52, 65 reciprocally slide respectively along the linear guide rails 61, 107 at the same time so as to back and forth clean the contacts 60 of the TV game cassette 90 as shown in FIGS. 8 and 12.
After the cam 79 is pressed down, through the gear 119 the gears 121,122 are further driven in sequence to make the gear 123 rotate at relatively slow speed. Once the cam 79 rotates, the driving section 64 separates from the recess 85 and continuously rotates under and along the annular projection 84. Meanwhile, the lifting section 100 of the gear 123 is also pressed down by the cam 79 to separate from a hole 129 of a board member 127. The lifting section 100 of the gear 123 has an inclined face 128 so that once the gear 123 rotates, the inclined face 128 contacts with the wall of the hole 129 to make the lifting section 100 completely separated from the hole 129. Once the lifting section 100 of the gear 123 is separated from the hole 129, the lift section 100 continuously rotates along with the gear 123 and contacts with the bottom face of the board member 127 to compress the spring 83, whereby during the cleaning operation, the spring 83 is prevented from bounding upward to lift the cam 79 and interrupt the cleaning operation.
When the cleaning operation is completed, the lifting section 100 finishes its rotation through one circle and moves back to the position under the hole 129. At this time, the driving section 64 is right aligned with the recess 85 and the spring 83 lifts the gear 123 and the cam 79 at the same time. Accordingly, the small diameter rim portion 82 of the cam 79 is moved upward and aligned with the switch 78 to separate the resilient contacts 125, 126 thereof and cut off the power for the motor 55 and thus terminate the cleaning operation.
It is to be understood that the above description and drawings are only used for illustrating one embodiment of the present invention, not intended to limit the scope thereof. Any variation and derivation from the above description and drawings should be included in the scope of the present invention.
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An automatic cleaning device for TV game cassettes, which is able to automatically clean the copper foil contacts of the TV game cassette many times. The cleaning device has a housing formed with insertion sockets for different types and specifications of TV game cassettes to insert thereinto. A motor is used to drive a cleaning arm to swing left and right so that a cleaning assembly disposed at an end of the cleaning arm can back and forth clean the copper foil contacts of the cassette. When the number of the cleaning times reaches a predetermined number, a cleaning time setting means works to cut off the power for the motor, making the cleaning assembly rested on a lateral portion of the housing so as to prevent the dirts from remaining on the contacts of the cassette and ensure the cleaning effect.
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BACKGROUND AND SUMMARY OF THE INVENTION
[0001] Exemplary embodiments of the present invention relate to a process for working up an emulsion formed in the hydrometallurgical winning of a metal and to a process for the hydrometallurgical winning of a metal.
[0002] In the hydrometallurgical winning of metals, a solids-containing emulsion is formed at the phase boundary between the organic phase and the aqueous phase in a solvent extraction step. This solids-containing emulsion influences the efficiency of the hydrometallurgical winning process since the emulsion forms a relatively large proportion compared to the organic phase and the aqueous phase and can be separated off only with difficulty by means of conventional sedimentation in the sedimentation tanks provided for this purpose. The impurities in the emulsion are carried further both in the organic phase and in the subsequent course of the process through to the electrolyte solution, so that the life of the cathode in the electrochemical winning of the metal is reduced and the setting of the pH of the electrolyte solution becomes problematical. The impurities likewise turn up in the aqueous phase of the solvent extraction, so that this phase cannot readily be recovered from the leaching solution.
[0003] PCT international application WO 2006/133804 discloses the use of a decanter for the three-phase separation of an emulsion in the hydrometallurgical winning of a metal. To adjust the separation zone and/or the pond depth in the drum, the pressure is altered in an annular chamber in which a peeling plate is arranged. A fluid feed line through which a fluid, e.g. a gas, can be introduced from the outside opens into the annular chamber. This type of setting/regulation of the separation zone and/or the pond depth has been found to be useful but should be optimized further.
[0004] Accordingly, exemplary embodiments of the present invention are directed to an improved process for working up an emulsion formed in hydrometallurgical winning and to an improved process for the hydrometallurgical winning of a metal.
[0005] Exemplary embodiments of the invention provide a process for the centrifugal work-up of a solids-containing emulsion formed in the hydrometallurgical winning of a metal, where the work-up is carried out in at least one decanter (full-barrel screw centrifuge) to form a first lighter liquid phase, a second liquid phase and a solids phase, characterized by the following steps:
[0006] i) determining an actual value of the density of the first liquid phase,
[0007] ii) comparing the actual value with a guide parameter, in particular a prescribed density value, and
[0008] iii) setting of the outflow pressure of the first liquid phase as a function of the guide parameter.
[0009] The adjustment of the separation zone as a function of the density of the first liquid phase is carried out in such a way or has the consequence that the residence time of this phase in the decanter is optimized so that the phase is discharged with good removal of solids.
[0010] As a result the first liquid phase can always be recirculated to the hydrometallurgical process as solvent for the solvent extraction. At the same time, the second liquid phase can also be discharged from the decanter with only low solids contamination and optionally be recirculated as leaching solution to the hydrometallurgical process. At relatively high metal ion concentrations, the first liquid phase, preferably as organic phase, can also be fed to the backextraction in order to achieve maximization of the yield of metal in the hydrometallurgical winning process. In both cases, the efficiency of the hydrometallurgical process is increased. In addition, the solvents used in the hydrometallurgical process can be recovered to a greater extent.
[0011] A phase separation to form a first liquid phase, a second liquid phase, and a solids phase is carried out here. A setting of the outflow pressure in the outflow line of a peeling plate for discharge of the first phase is preferably carried out. For this purpose, the density of the first liquid phase is determined as actual value and compared with at least one prescribed value. If the actual value deviates from the prescribed value, the outflow pressure of the first liquid phase is altered.
[0012] The regulation is preferably configured in such a way that the system regulates the associated pressure according to the minimum of the density.
[0013] In the case of an excessively abrupt increase in the outflow pressure, part of the organic phase could be discharged together with the aqueous phase from the decanter. To avoid this, it is advantageous to determine an additional process parameter and set it to a predetermined prescribed value. This can, for example, be effected by determining the yield, the conductivity and/or the purity of the organic phase and/or the aqueous phase.
[0014] The above-described process is also suitable as part of a process for the hydrometallurgical winning of a metal, which preferably comprises the following steps:
[0015] A) providing a metal ore;
[0016] B) leaching the metal ore to form a metal ion-containing aqueous solution or slurry;
[0017] C) solvent extraction to transfer metal ions into an organic solvent phase;
[0018] D) backextraction of the metal ions with addition of an electrolyte solution to the organic solvent phase; and
[0019] E) electrochemical winning of the metal.
[0020] A solids-containing emulsion is formed during the solvent extraction and this is worked up by one of the above processes. The work-up of the emulsion improves the efficiency of the hydrometallurgical winning process. Fluctuations caused by the inhomogeneous composition of the metal ore, in particular by a changing proportion of silicates or sand, influence the efficiency of the hydrometallurgical winning process to only a small extent.
[0021] To achieve an efficient mode of operation, it is particularly advantageous that the liquid phases recovered from the emulsion can be recirculated as organic solvent or leaching liquid to the extraction process, so that an environmentally friendly and economical mode of operation is made possible.
[0022] An advantageous variant of the invention is illustrated below with the aid of the drawings.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0023] The drawings show:
[0024] FIG. 1 : a schematic depiction of a hydrometallurgical process for winning a metal;
[0025] FIG. 2 : a schematic depiction of a subregion of a decanter for working up an emulsion;
[0026] FIG. 3 : a schematic depiction of an operating state with a relatively low outflow pressure in the outflow line downstream of a peeling plate of the decanter;
[0027] FIG. 4 : a schematic depiction of an operating state with an increased outflow pressure compared to FIG. 3 ;
[0028] FIGS. 5-7 : various graphs to illustrate the prevailing relationships in the processing of the emulsion.
DETAILED DESCRIPTION
[0029] FIG. 1 shows an exemplary process flow diagram for the hydrometallurgical winning of a metal.
[0030] Proceeding from the provision of a metal ore in step A, for example a copper-, nickel- or cobalt-containing ore, leaching of the metal ore is first carried out in step B. A leaching solution is added here. As a result, metal ions are at least partially dissolved. The leaching solution is preferably an aqueous solution.
[0031] After leaching, a solvent extraction is carried out in step C. Here, an organic solvent is preferably added to the leaching solution to form a two-phase system composed of an organic phase and an aqueous phase but in which a solids-containing emulsion is formed at the phase boundary because of the impurities. The work-up is described in more detail below with reference to FIGS. 2-7 .
[0032] After the metal ions have been transferred into the organic phase, a backextraction is carried out in step D by addition of an aqueous electrolyte solution, with the organic phase being able to be recovered so as to be reused in the preceding solvent extraction.
[0033] After the solvent extraction and the backextraction, the electrochemical winning and optionally additional refining of the metal M is carried out in step E, taking into account the deposition potential of the respective metal.
[0034] FIG. 2 illustrates an advantageous way of working up the emulsion formed in the solvent extraction during the hydrometallurgical winning of a metal, as shown in FIG. 1 .
[0035] Particular preference is given to using a decanter, in particular a three-phase decanter, for working up the emulsion.
[0036] In the case of the three-phase decanter 1 shown in FIG. 2 , emulsion 2 to be worked up is introduced via a feed tube 4 into a drum interior 3 of a drum 16 .
[0037] This emulsion 2 is separated in the centrifugal field of the drum 16 of the decanter 1 into an organic phase 5 , an aqueous phase 6 and a solids phase 7 . A separation zone diameter T and a pond depth or a pond depth diameter TD are formed.
[0038] The organic phase 5 is discharged from the decanter 1 via a peeling plate 8 with peeling plate shaft and an outflow line 9 arranged downstream of this by means of a pump (not shown).
[0039] The heavier aqueous phase 6 is, by way of example, discharged radially from the decanter interior 3 at an outlet 19 , collected in the collection space 10 and from there discharged from the decanter.
[0040] The solids phase 7 is preferably conveyed by means of a screw 17 on a side of the drum 16 opposite the outlet for the organic phase 5 and there discharged from the drum 16 (not shown).
[0041] A weir 11 , via which the organic phase 5 flows to the peeling plate 8 , is arranged in the drum interior 3 .
[0042] The weir 18 serves, in contrast, as discharge overflow for the aqueous phase 7 to the preferably radial outlet from the drum 16 .
[0043] To set the separation zone or the separation zone diameter T (see also FIGS. 3 and 4 ) in the decanter 1 , a valve 12 installed in the outflow line 9 is switched; this valve 12 can be controlled via a regulating device 13 for adjusting the valve 12 as a function of a process parameter, in particular as a function of the pressure of the organic phase.
[0044] This regulating device 13 has at least one means for determining a process parameter. A preferred means for determining the process parameter is preferably a means for density measurement 14 , in particular for measuring the density of the organic phase 5 .
[0045] If the density deviates from a guide parameter (preferably a fixed or variable prescribed density value which reflects a maximum contamination of the organic phase 5 ) or a prescribed density value associated therewith, the degree of throttling of the value 12 is altered appropriately.
[0046] Increased throttling of the valve 12 results in less light phase 5 being discharged, as a result of which the diameter of the separation zone T in the drum 16 of the decanter is shifted outward and at the same time the pond depth DT is increased radially in an inward direction.
[0047] The adjustment of the outflow pressure associated with adjustment of the valve 12 brings about a shift of the separation zone T in the decanter as a function of the density of the organic phase. An increase in the density of the organic phase is equivalent to an increase in contamination of this phase. Determination of the density makes it possible to detect contamination in the organic phase 5 in a simple way. A fixed or variable prescribed value for the density gives the upper limit for possible contamination. If this is exceeded, countermeasures for reducing the density are undertaken, e.g. altering the outflow pressure in the outflow line 9 . Determination of the density thus allows automatic adaptation of the mode of operation of the decanter in continuous operation.
[0048] FIG. 3 shows a possible state of the decanter 1 in which the valve 12 (not shown here) has not been throttled or throttled only very slightly. In this state, the organic phase is present in only a very small amount.
[0049] If the contamination of the valuable organic phase increases, this increased contamination can be determined by the means shown in FIG. 2 for density measurement 14 , e.g. in the outflow line 9 , and the valve 12 can subsequently be throttled to increase the outflow pressure. The increased outflow pressure shifts the separation zone T outward, so that a smaller amount of solids is present in the region of the outflow for the organic phase and the aqueous phase. In addition, the pond zone diameter TD moves radially inward. FIG. 4 shows the state of the decanter 1 in the case of a more greatly throttled pressure valve 12 compared to FIG. 3 , in which state the outflow pressure is increased, which shifts the separation zone T further outward and the pond depth TD inward.
[0050] The graph in FIG. 5 schematically shows the dependence of the ratio of separation zone diameter T/drum diameter on the ratio of pond depth Td/drum diameter.
[0051] The graph in FIG. 6 describes the dependence of the density of the contaminated organic phase on the degree of contamination. A pure organic phase has a density of 845 kg/m3. However, this density increases further, preferably linearly, with increasing contamination. A direct conclusion as to the prevailing contamination can therefore be drawn by determining the density of the organic phase.
[0052] Such a graph is determined experimentally. The outlet pressure which is particularly advantageous at a given contamination is also determined in the experiment. Such a relationship can then be stored in the computer and employed for determining the outflow pressure to be set.
[0053] Thus, the graph of FIG. 7 shows the dependence of the separation zone diameter to the drum diameter T on the pressure at the peeling plate or centripetal pump as a result of throttling of the valve 12 .
[0054] It can be seen that when the pressure generated by the pump increases, the separation zone diameter T increases in an outward direction. The increase in the separation zone diameter T corresponds to an increase in the volume of organic phase in the drum and thus an increase in the retention time, i.e. the time which the organic phase takes to run through the decanter.
[0055] The increase in the separation zone diameter T thus also results in a higher purity of the organic phase. The adaptation of the outflow pressure and, associated therewith, the separation zone diameter T as a function of the measured density of the organic phase can be carried out in real time in a continuous process.
[0056] However, if the outflow pressure increases too greatly, for example as a result of a large reduction in the outflow volume of the organic phase, an organic phase having a high purity is obtained but in this case part of the organic phase is lost during discharge of the aqueous phase. Solids are sometimes also lost in this way. In this case, an additional determination and adjustment of the yield, the conductivity and the purity of the organic phase or optionally also the aqueous phase can be carried out. The yield can, for example, be determined using means for measuring the volume flow 15 , which means are, as shown in FIG. 2 , arranged in the region of the outlet for the organic phase.
[0057] It should be noted that suitable means for measuring the density are known to those skilled in the art. Mention may be made of optical methods (shining light through the phase: increase in turbidity indicates an increase in density). Furthermore, other suitable means for density measurement can be employed. The density measurement is preferably carried out continuously, for example on the product exiting from the outflow line 9 .
[0058] The experiments were carried out using a decanter centrifuge model DCE 345 02.32 from GEA WESTFALIA GROUP GMBH, Oelde, Germany.
[0059] The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.
REFERENCE NUMERALS
[0000]
1 Decanter
2 Emulsion
3 Decanter interior
4 Feed tube
5 Organic phase
6 Aqueous phase
7 Solids phase
8 Peeling plate
9 Outflow line
10 Collection space
11 Weir
12 Valve
13 Regulator
14 Means for density measurement
15 Means for measuring the volume flow
16 Drum
17 Screw
18 Overflow weir
19 Outlet
Step A Provision of metal ore
Step B Leaching
Step C Solvent extraction
Step D Backextraction
Step E Electrochemical winning
Step F Work-up of the emulsion
M Metal
T Separation zone
Td Pond depth
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A method for centrifugal reprocessing of a solids-containing emulsion formed during the hydrometallurgical recovery of a metal involves performing the reprocessing in at least one decanter to form a first lighter liquid phase, a second liquid phase, and a solids phase. An actual value of the density of the first liquid phase is determined, the actual value is compared with a desired value for the density of the first liquid phase, and the outlet pressure of the first liquid phase is set in dependence upon the determined actual value/desired value comparison.
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BACKGROUND OF THE INVENTION
The present invention relates to an annular knitting machine with at least one needle carrier with slide needles having controlled head and slide, with cam curves for controlling the needles for knitting, tucking or welting and with sinkers which cooperates with the slide needles and are controlled by a sinker cam curve.
Annular knitting machines with slide needles are known or proposed while by the exchange of a needle tongue by a controlled needle slide high needle displacement speeds can be obtained. In connection with this also a knitting machine is proposed in U.S. Pat. No. 4,751,829 in which the slide of the slide needles, which cooperates with sinkers, is held not displaceably on a constant height. It has been however shown that with a not controlled needle slide, certain limitations in the displacement width of the cam parts must be taken into consideration, when a high operational safety in each control position of the knitting tool must be guaranteed. However it is desired to utilize the slide needles in a circular knitting machine with needle selecting device for a needle position of knitting, tucking or welting, the latter sometimes also called floating, non-knitting, running through or circular motion. With the known control of the slide needles in which, without consideration of the proposal in the U.S. Pat. No. 4,751,829 the needle slide and the remaining needle is especially controlled by a means of a special control curve, a needle selecting device must also have the path for the needle slide changing points, which for a needle exchange device with a three-way technique involves a considerable expense. Also during the utilization of the so-called three-way technique with several cam paths, in which special cam paths for knitting, tucking and welting are provided and the needles are used for control feet directed to the individual cam paths, it is necessary with the known control technique of slide needles to provide for each of the three needle cam paths a respective slide cam curve. Thereby, great cam heights and corresponding great needle lengths and needle slide lengths are produced, and higher needle masses must be moved
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a circular knitting machine which avoids the disadvantages of the prior art.
More particularly, it is an object of the present invention to provide a circular knitting machine with controllable slide needles which is formed so that it is not necessary to provide an increase of the mass of slide needles and the expense on control devices of a needle exchange device as well as the expense for cam parts, as compared with the known and comparable annular knitting machines, despite the fact that no limitation to the variation width of the known machines must take place.
In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a circular knitting machine of the above mentioned general type in which for the slides of the slide needles for all needle cam curves, only one cam curve which cause longitudinal movement of the slide is provided.
In the annular knitting machine in accordance with the present invention no selecting devices or displacement devices for the needle slide must be provided, regardless of the fact whether a three-way technique in the event Jacquard needle selection or camming with one or several cam paths are used. In the annular knitting machine according to the present invention with slide needles the needles can be controlled with no limitation within a loop row in the needle positions of knitting, tucking or welting in accordance with a pattern
The highest number of revolutions is obtained with knitting machines with one row of needles, in which the needles cooperate with sinkers. In accordance with this, the inventive approach is also developed for such machines. It has been shown that both for the case when during the thread sinking the slide needles perform a longitudinal movement and also for the case when the thread sinking is partially performed by a longitudinal movement of the needles and partially by a longitudinal displacement of combined jack or knock-over sinkers, the slide cam curve can have a shape to which all possible needle cam curves for knitting, tucking or welting can be adapted so that the respective needle function can be performed with no problem with higher machine speed. The needle slide curve is formed so that it raises with the delay relative to the needle curve for knitting, and raises relative to the needle curve for tucking simultaneously or with an offset.
When the circular knitting machine is designed in accordance with the present invention, the above described objects are completely achieved. The cam construction is not complicated, the size of the system, the slide needles and the needle support must not be increased relative to the known and comparable constructions. All needle positions are reachable with no limitation for extensive pattern possibilities.
The drawing illustrate the present invention with two examples, wherein the showing is limited to the inventive cam path to show by the control of the needle head and the needle slide the different needle functions, and for one example a radial partial portion of a circular knitting machine is presented.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a view showing a radial section of an annular knitting machine provided with slide needles and sinkers which are controlled in accordance with the embodiment of FIGS. 9-14;
FIG. 2 is a view showing four cam passages for the needles and a cam passage for the needle slide, or four systems, together with the slide needles associated with the four needle cam paths;
FIG. 3 is a view showing the slide cam path, the needle cam path for knitting and the sinker cam path, over one system when the sinkers are provided for only moving radially with respect to the needle cylinder;
FIG. 4 shows eight relative positions of the slide needles and sinkers on points 1-8 of FIG. 3;
FIGS. 5 and 6 are views showing the positions corresponding to FIGS. 3 and 4 with the needle cam path for tucking;
FIGS. 7 and 8 are views showing the position corresponding to FIGS. 3 and 4 with the needle cam path for welting;
FIGS. 9 and 10 are views corresponding to FIGS. 3 and 4 with the needle cam path for knitting, in an example in which jack or knock-over sinkers are provided and move longitudinally in certain regions in opposite direction to the slide needles;
FIGS. 11 and 12 are views corresponding to FIGS. 9 and 10 with the needle cam curve for tucking; and
FIGS. 13 and 14 are views corresponding to FIGS. 9 and 10 with the needle cam curve for welting.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An annular knitting machine shown in FIG. 1 has a rotatable cylindrical knitting tool carrier 10/14 which is subdivided into a needle cylinder part 10 and a sinker cylinder part 14. Both parts are firmly connected with one another by screws 15.
An outer surface of the needle cylinder part 10 is provided in a known manner with axis-parallel guide webs 11 which accommodate therebetween shafts 12.1 of slide needles 12. The sinker cylinder part 14 is arranged coaxially with the needle cylinder part 10 and is provided with axis-parallel guiding webs 16 for accommodating therebetween jack or knock-over sinker 17 which will be called sinkers hereinbelow. The sinkers 17 are arranged in a longitudinally displaceable and turnable manner. The guiding web 16 for the sinkers 17 in the sinker cylinder part 14 are arranged with the same distance as the guiding webs 11 of the needle cylinder part 10. However, they form gaps with the guiding webs 11 of the needle cylinder part 10. The needle shafts 12.1 slide with their needle rear sides against the end side of the sinker guiding webs 16. The needle cylinder part 10 and the axial sinker cylinder part 14 are surrounded by a common cam housing 18 which is provided in a known manner with cam parts for controlling the slide needles 12, the needle slide 13, and the sinkers 17. A holding-down member 57 acts upon the needle shaft 12.1 under a head 12.2 of the slide needles 12.
The needle slide 13 which serves for closing the needle heads 12.2 is formed so that its tip 13.1 can pass the needle head 12.2. It extends with its foot 13.2 into a slide cam path 41 of the cam housing 18. The details of the construction of the slide needles 12 and the support for the slide 13 in the needle shaft 12.1 is not germaine to the present invention and therefore is not shown in detail.
The slide needles 12 are provided with a control foot 21 in the region of the needle shaft 12.1 between the guide webs 11 on the needle cylinder part 10. The control foot 21 can be located on one of four possible locations which have a different distance from the needle head 12.2 and extends in one of several needle cam paths 20.1-20.4 formed in the cam housing 18, as can be seen from FIG. 2.
The sinkers 17 which are shown in FIG. 1 are formed as jack or knock-over sinkers with a head part which is characteristic for this type of sinkers. The head part has a knock-over edge 23 which merges at its end in a jack or clear throat 25 for clearing the loops. The longitudinal displacement of the sinkers 17 is activated on a central control foot 26, at which height the sinker is supported with a rounded projection 27 against the sinker cylinder part 14. The turning movement of the sinkers 17 about the projection 27 is controlled through pressure feet 29 and 30 which are located on opposite sides of the control foot 26 on a relatively short sinker shaft.
In the shown annular knitting machine a loop length change is performed by an adjustment of the displacement path of the jack or knock-over sinkers 17. For this purpose cam parts 48 and 49 which act on the control foot 26 of the sinkers 17 are mounted on a displaceable cam plate 42. The cam plate 42 is coupled through an eccentric shaft 53 with an outwardly extending adjusting shaft 54 which ends in an outer adjusting disc 55. The sinking path of the sinkers 17 can be adjusted by the adjusting disc 55.
FIG. 2 shows in its left part four slide needles 12 which are provided for cooperating with known horizontally supported jack (clearing) sinkers and thereby have somewhat different dimensions that the slide needle 12 in FIG. 1. The four slide needles 12 shown in FIG. 2 differ only in a different arrangement of their control foot 21. The control feet 21 are directed to four needle cam paths 20.1, 20.2, 20.3, or 30.2 shown in the right part of FIG. 2. They are represented by four systems I-IV of the annular knitting machine. The four needle cam paths 20.1-20.4 have a different course in correspondence with the three-way technique achieved by them for needle control in the sequentially arranged systems. In contrast, the upper slide cam curve 41 for the control foot 13.2 of the needle slide 13 has in each system the exactly identical course.
The slide needles 12 which extend with their control foot 21 into the uppermost needle cam path 20.1 are driven in the system I up to the knitting position, in the system II only up to the tucking position, they remain in the system III in the welting position, and again driven in the system IV up to the knitting position. The slide needles 12 which extend with their control foot 21 into the needle cam path 20.2 are driven in the system I up to the tucking position, remain in the system II in the welting position, and in the subsequent systems III and IV are driven up to the knitting position. With the aid of the four needle paths, a texture pattern is produced with a pattern width having four loops. The height of the pattern is dependent upon the number of systems of the annular knitting machine. For allowing the slide cam path 41 to be maintained always with the same course for each type of the needle cam path, its course for knitting, tucking and welting motion, the cam paths must have a course which is determined relative to one another and is not shown in FIG. 2 but instead can be seen from subsequent FIGS. 3-14. Also, a Jacquard pattern is possible with individual needle selection by known mechanic or electronic pattern devices or selecting devices.
FIGS. 3, 5 and 7 show for a circular knitting machine with slide needles and horizontally displaceble sinkers extending transversely to the longitudinal direction of the needles, the movement curve for the needle slide tip, the movement curves of the needle head for the possible needle positions of knitting, tucking and welting and additionally the curve of the sinker movement. Moreover, FIGS. 4, 6 and 8 show the relative position of the needle shaft and the needle slide at eight points 1-8 identified in FIGS. 3, 5 and 7.
The arrow A identifies in FIGS. 3, 5, 7, 9, 11, 13 the needle passage direction through the system and a thread supply point 28 is identified by a schematically shown thread guide. In FIGS. 3-8 the known sinkers which in deviation from FIG. 1 can also be supported in a special sinker ring, are identified with reference numeral 17'.
FIG. 3 shows a needle slide cam curve 32 which follows the needle slide tip 13.1 and the curve 33 which follows the needle head 12.2 in the needle position of knitting. In addition, a curve 37 follows the jack throat 25 of the sinkers 17'. The needle slide cam curve 32 shows that during passage of one system the slide tip 13.1 first is lifted prior to the position 1 to a height which corresponds to the welting height of the needle head 12.2 and the height of the knock-over edge 23 of the sinker 17'. On this height the slide tip 13' remains until the point 3. Subsequently, between points 3 and 4, the needle slide tip 13.1 is driven up to approximately the height of the thread supply point 28 from the point 5, thereby before reaching the thread supply point 28, but is again lowered below the thread supply height and subsequently to the point 7 to a height which lies above the loop knock-over height. Between, the points 7 and 8, the needle slide tip 13.1 is drawn to the thread knock-over height identified on the position 8 in FIG. 3 with 38, so as to coincide with the curve 33 for the needle head 12.2. The curve 33 for the position of knitting shows that the needle head 12.2 is already driven from the point 1 and thereby substantially earlier than the needle slide 13, until it reaches the knitting position between the points 3 and 4. As the associated FIG. 4 shows, by the earlier drive of the needle head 12.2 the slide tip 13.1 disappears from the point 2 in the shaft of the slide needle 12 and releases the needle head 12.2. By the substantially parallel course of curves 32 and 33 between the points 4 and 6, the needle head 12.2 remains open also over the thread supply point 28. Since the needle slide 13 during the drawing movement of the needle head 12.2 between the points 6 and 7 remains unchanged, the old loop 40 remains on the needle slide 13 and it clears the needle head up to the point 17 and clears the newly supplied thread 39. During the further drawing movement of the needle head 12.2 between the points 7 and 8, when the needle slide cam curve 32 of the needle slide tip 13.1 runs in coincidence with the curve 33, the needle head remains closed, so that the old loop 40 can pass over the closed needle head while a new loop 45 is drawn.
FIG. 5 shows in addition to the needle slide cam curve 32 for the needle slide tip 13.1, the curve 34 which the needle head 12.2 passes for the position tucking. A comparison with FIG. 3 shows that here the drive out of the needle head 12.2 is performed substantially later than in the position of knitting. The drive out proper of the needle head 12.2 in the tucking position assumed between the points 4 and 6 starts first at the point 3. FIG. 6 shows that between the points 2 and 5 the slide tip 13.1 does not disappear as in the knitting position in the needle shaft, but instead projects out of the needle shaft and the needle head 12.2 is open only in half. This means that an old loop 4 which is available in the needle head cannot slide out of the needle head. By the lowering of the needle slide tip 13.1 between the points 5 and 6 under the thread supply height, it is guaranteed that the new thread 39 can be inserted on the point 6 reliably in the needle head 12.2, prior to closing of the needle head by the needle slide between the points 6 and 7, and for old loop 40 a new tucking hook 46 is formed during the remaining drawing movement up to the point 8.
FIG. 7 shows the conditions for the needle position of welting. In FIG. 7 in addition to the needle slide cam curve 32 for the needle slide tip 13.1, a curve 35 is shown which follows the needle head 12.2. The curve 35 substantially follows the needle slide cam curve 32 so that the needle head 12.2 is particularly always closed by the needle slide 13, as shown in FIG. 8. The slide tip 13.1 projects between the points 4 to 7 over the needle head 12.2. At the point 8, the needle head 12.2 is again released in half by the slide tip 13.1. By the lowering of the curve 35 relative to the needle slide cam curve 32 for the needle slide between the points 6 and 7, the needle head does not prevent the insertion of the thread in a preceding needle. The needle slide cam curve 32 for the slide tip 13.1 does not lower very far. Therefore, it is insured that in the operation of knitting the old loop 40 located between the points 6 and 7 on the slide 13 (see FIG. 4) cannot fall again back into the needle head 12.2.
FIGS. 9-14 show the profile and the relative course of the curve slide needles which cooperate in the embodiment shown in FIG. 1 with the sinkers 17 which are adjustable in correspondence with a curve 36 shown in FIGS. 9, 11 and 13 in the longitudinal direction of the slide needle. A needle slide cam curve 32' for the needle slide tip 13.1 which is shown in FIGS. 9, 11, 13 has the same course for all needle positions of knitting, tucking and welting, however this course is different from the course of needle slide cam curve 32 in FIGS. 3, 5, 7. During passage of one system the needle slide cam curve 32' of the slide tip 13.1 remain first over at least one-third of the system length, here up to the point 4, in deepest drawn position which corresponds to the height 38. Prior to the thread supply point 28, the slide tip 13.1 is driven out to a height located under the thread supply height, in which it remains held over the thread insertion point 5, and first after the thread supply point 28 is driven together with the sinker 17 to the height at the points 6 and 7 in FIGS. 10, 12 and 14. Finally, the needle tip 13.1 is further drawn in coincidence with the sinking portion of the curve for the needle head 12.2, to the deepest drawn position 38.
FIG. 9 shows the needle slide cam curve 32' for the needle slide tip 13.1 together with a curve 33' which follows the needle head 12.2 in the position of knitting. The relative position of the slide needle 12, needle slide 13 with the needle slide tip 13.1 and the jack-knock-over sinkers 17 produced by the course of the needle slide cam curve 32', 33' and the curves 36, and 37' for the sinkers 17, on the points 1-8 is shown in FIG. 10. Similar to FIGS. 3 and 4, the needle head 12.2 is already raised from the point 2 and thereby substantially earlier than the needle slide 13, until it reaches the knitting position between the points 3 and 4. FIG. 10 shows position between the points 3 and 4. FIG. 10 shows that the slide tip 13.1 disappears from the point 2 in the shaft of the slide needle 12 and releases the needle head 12.2. By the course of curves 32 and 33 between the points 4 and 6 as shown in FIG. 9, the needle head 12.2 remains open also over the thread supply point 28, even if the slide tip 13 extends somewhat into the needle head 12.2. At point 6 the head 12.2 is completely closed. Since the needle slide 13 during the lowering movement of the needle head 12.2 between the points 6 and 7 remains unchanged, the old loop 40 remains on the needle slide 13. During the further drawing-down movement of the needle head 12.2 between the points 7 and 8, when the needle slide cam curve 32 of the needle slide tip 13.1 runs in coincidence with the curve 33, the needle head remains closed, so that the old loop can pass over the closed needle head with a new loop is drawn.
FIG. 11 shows the needle slide cam curve 32' for the needle slide tip 13.1 together with a curve 34' which follows the needle head 12.2 in the needle position of tucking. Here also the comparison of FIGS. 9 and 11 shows that the needle drive out for the position of tucking is performed later than for the position of knitting, and thereby in accordance with FIG. 12 for the position of tucking it is insured that the slide tip 13.1 of the needle head is never completely open, but always projects out of the needle shaft. FIG. 12 further shows the relative position of individual moveable parts at the points 1-8 of the system. FIG. 11 shows in addition to the needle slide cam curve 32 for the needle slide tip 13.1 the curve 34 which the needle head 12.2 passes for the operation tucking. A comparison with FIG. 9 shows that here the raising of the needle head 12.2 is performed substantially later than in the operation knitting. The raising of the needle head 12.2 in the tucking operation starts first at the point 4. FIG. 12 shows that between the points 1 and 4 the slide tip 13.1 does not disappear in the needle shaft, but instead projects out of the needle shaft and the needle head 12.2 is open only in half. This means that an old loop which is available in the needle head cannot slide out of the needle head. By the guiding of the needle slide tip 13.1 between the points 4 and 5 under the thread supply height, it is guaranteed that the new thread can be inserted at the point 5 reliably in the needle head 12.2, prior to closing of the needle head by the needle slide between the points 5 and 6. Additionally to the old loop a new tucking hook is formed during the remaining drawing-down movement up to the point 8.
FIGS. 13 and 14 show the condition for the needle position of welting. FIG. 13 shows in addition to the needle slide cam curve 32', also a curve 35' which follows the needle head 12.2 and which is substantially parallel to the slide cam curve 32. Between the points 1 and 2, the needle head 12.2 is driven out relative to the needle slide tip 13.1 so far that the needle head 12.2 is not completely closed. FIG. 14 shows however that on the other points 3-8 the needle head is always closed by the needle slide tip 13.1 which moves outwardly over the needle head.
The movement of the sinkers 17 are always the same during the operations knitting, tucking and welting as shown in FIGS. 9-14. A cam curve in the lower part of FIG. 9, 11 and 13 substantially corresponds to cam curve 37 of FIG. 3. Contrary thereto, cam curve 36 of FIG. 9, 11 and 13 shows the movements of the sinkers 17 parallel but substantially opposite to the movements of the needle heads 12.2. As is particularly depicted in FIGS. 10, 12 and 14, the sinkers 17 are first lowered to some extent between points 1 and 4 and then again raised between points 5 and 8. By this, the sinkers 17 move in a direction opposite to that of the slide needles particularly between points 6 and 9 for assisting in a known manner the forming of the loops (U.S. Pat. No. 4,751,829).
The invention is not limited to the sinker guide and sinker support shown in FIG. 1. The invention can also be used on machines with horizontal sinkers supported in a special sinker ring.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the invention has been illustrated and described as embodied in a circular knitting machine with slide needles, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
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A circular knitting machine has at least one needle carrier, and a plurality of slide needles having a head portion with a head and a slide portion with a tip. Sinkers cooperate with the slide needles, a plurality of knitting systems are arranged along the needle carrier, and a control is provided at the knitting systems for causing relative movements of the needle portions, the slide portions, and the sinkers for performing knitting, tacking and running-through operations. The control includes at each of the knitting systems a sinker cam curve for controlling the sinkers, a slide portion cam curve for controlling the slide portions, and a head portion cam curve for controlling the head portions. The slide portion cam curves have portions for raising and lowering the slide portions in a same manner irrespective of performance of knitting, tucking, or non-knitting operation of the systems.
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[0001] The present invention relates generally to managing domain name abuse and specifically to a system and method for automatically responding to allegations of abuse based on information from a plurality of disparate resources.
BACKGROUND
[0002] Domain names are subject to various forms of abuse. These include publically defined forms such as spam, phishing, and malware as well as policy defined forms of abuse such as trademark, copyright and restricted use behaviour. Policies defining abuse come both from the Internet Corporation for Assigned Names and Numbers (ICANN), which is a regulatory body for the Internet, and a domain name registry operator, which is an entity responsible for domain names registered in a top-level domain TLD. Further, registrars, which are entities accredited to sell domain names, and registrants, who are the holders of the domain names, can also have specific policies defining abuse.
[0003] The domain registry operator is responsible for all elements of a given Top Level Domain (TLD) including who may register a domain name and what defines permitted use of the domain name. There are two basic types of TLD operator: a generic TLD (gTLD) and a country code TLD (ccTLD). The gTLD operator falls fully under ICANN's overreaching policies and a ccTLD operator operates TLDs on behalf of a given country authority. CcTLD operators are beholden to their country's policies and controls.
[0004] Domain name abuse affects TLD operators, registrars (those who resell domains) and registrants (those who hold domains), as well as countless Internet users that may have interacted with a domain name under abuse. Abuse is mitigated, by some parties, through a series of disparate tools, sources of data, custom analytics and mostly manual review and mediation by analysts. Most parties will respond to external requests to domain name abuse detected by others. The problem with this approach is that typically the greatest damage caused by domain name abuse happens within hours of its onset. Reactive mitigation, while helpful, does not alleviate the vast majority of damage caused by domain abuse.
[0005] Accordingly, a number of abuse service providers collect data about domain name abuse and provide data feeds accordingly. These abuse service providers typically offer their services through an application program interface (API), reporting mechanism, or both. They are also specialized to one or a few forms of abuse and may or may not be independently confirmed or verified, leading to a disparity in the quality and accuracy of their abuse reporting. Accordingly, it can be an expensive and complex procedure for a TLD operator, registrar or registrant to receive and process such information.
[0006] Accordingly, there is a need for a mechanism that allows TLD operators to efficiently and automatically detect and react to domain name abuse.
SUMMARY OF THE INVENTION
[0007] The present invention provide a mechanism to pro-actively combat domain abuse that can be used by one or more of TLD operators, registrars and their delegated resellers, and ultimately registrants. The net benefit is to all parties, including Internet end-users, by reducing costs and harms associated with domain name abuse, such as fraud, theft, false products, false medication, and the like.
[0008] In accordance with an aspect of the present invention there is provided a method for providing an abuse sentry service for responding to domain name abuse, comprising the steps of: receiving, at a computer, a plurality of disparate abuse feeds, each abuse feed comprising data relating to particular subset of potential domain name abuse; applying one or more filters to the data to create a custom abuse feed; grouping the filtered data from the custom abuse feed into groups of data based on priority levels; and for each of the groups of data, executing one or more corresponding workflows as a response to the potential domain name abuse.
[0009] In accordance with a further aspect of the present invention there is provided a computer readable medium having stored thereon instructions for execution by a computing device, which when executed cause the computing device to implement the steps of receiving a plurality of disparate abuse feeds, each abuse feed comprising data relating to particular subset of potential domain name abuse; applying one or more filters to the data to create a custom abuse feed; grouping the filtered data from the custom abuse feed into groups of data based on priority levels; and for each of the groups of data, executing one or more corresponding workflows as a response to the potential domain name abuse.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Embodiments of the present invention will now be described by way of example only with reference to the following drawings in which:
[0011] FIG. 1 is a block diagram illustrating a system for detecting and reacting to domain name abuse;
[0012] FIG. 2 is a flow chart illustrating steps taken by a client to set up an abuse sentry service to monitor and react to domain name abuse; and
[0013] FIG. 3 is a flow chart illustrating steps taking by the abuse sentry service to to monitor and react to domain name abuse.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] For convenience, like numerals in the description refer to like structures in the drawings. Referring to FIG. 1 , a system for automatically detecting and reacting to domain name abuse is illustrated generally by numeral 100 . The system comprises a plurality of abuse service providers 102 , an abuse sentry service 104 , a communication network 106 , and a plurality of clients 108 .
[0015] The abuse service providers 102 include a number service providers that provide abuse feeds for domain names. The particular service providers selected to be the abuse service providers 102 depend on the implementation and may change over time as new service providers are introduced. The abuse sentry service 104 is a program executed on a computer that is configured to receive the data feeds from all of the abuse service providers 102 . In the present embodiment, the computer is separate from the clients, but that need not be true. The abuse sentry service 104 is further configured to filter and react to information in the data feeds, as will be described. The communication network 106 is a wide-area communication network such as the Internet. Other means for establishing the communication network 106 can be used without detracting from the invention as claimed. The clients 108 may include one or more of TLD registry operators, registrars, registrar agents, or domain name owners. The clients 108 may include other entities that wish to track domain name abuse, without detracting from the invention as claimed.
[0016] In general terms, the abuse sentry service 104 aggregates abuse data feeds offered by the abuse service providers 102 . It then allows each of the clients 108 to not only select one or more of the abuse data feeds, but also a selective portion of one or more of the abuse data feeds. The client 108 may, for instance, select a small portion of three abuse data feeds and a complete fourth abuse data feed. This allows the client to build a custom abuse data feed comprised of potentially many originating sources.
[0017] Once the client 108 has established their custom abuse data feed, the client can define a number of different abuse priority levels based on a predefined criteria. The abuse data received in custom abuse feed is automatically grouped or sorted based on its abuse priority level.
[0018] Further, the client 108 can define a number of custom workflows. Each workflow comprises a predefines series of actions or event. Each workflow can be assigned to one or more of the abuse priority levels. Further, each abuse priority level can have a plurality of assigned workflows.
[0019] Referring to FIG. 2 , a flow chart illustrating steps taken by the client 108 to set up the name sentry service 104 to monitor potential domain name abuse on its behalf is illustrated generally by numeral 200 . At step 202 , the client 108 accesses the name sentry service 104 using a computing device connected to the communication network 106 . The computing device may be any one of a number of network connected devices including, for example, personal computers (including desktops, notebooks and netbooks), tablets, smart phones and the like. The client 108 can use either a web browser or a dedicated application installed on the computing device to access the name sentry service 104 .
[0020] At step 204 , the client 108 logs in to the client's account using a user name and password. As is standard in the art, the user name and password may be stored on the computing device and accessible by the web browser or dedicated application to automatically log in to the client's account at the name sentry service 104 . As is standard in the art, the client's account can be initially set up either offline or online.
[0021] At step 206 , the client 108 creates their custom abuse data feed. In the present embodiment, the client 108 is presented with a list of available abuse data feeds. Optionally, detailed information about the abuse data feeds is also provided. Such information may include, for example, the type of abuse(s) monitored by the corresponding abuse service provider 102 , the domains monitored, and the like. The client 108 is further presented with a list of predefined abuse data feed filters and an option to create a custom abuse data feed filter.
[0022] Thus for example, an abuse service provider 102 may report spam for TLDs .ca, .uk, .com, au, and .eu. Predefined filters for this type of abuse data feed may include filters for each of the available TLDs. As another example, an abuse service provider 102 may report multiple types of abuse for a given TLD. Predefined filters for this type of abuse data feed may include filters for each of the available types of abuse. Accordingly, the predefined filters can vary between implementation and will depend on the nature of the abuse data feeds received from the abuse service providers 102 .
[0023] Examples of custom filters for this type of abuse data feed may include one or more second-level of the TLDs as well as abuse policies specific to the client.
[0024] At step 208 , the client 108 creates their abuse priority levels. In the present embodiment, for each abuse priority level, the client 108 is presented with a list of criteria. The criteria is based, at least in part, on the data available in the custom abuse data feed. Thus, for example, if the custom abuse data feed includes data relating to phishing, spam, and trademark abuse, each of these types of abuse is available as one of the criteria. Some clients 108 may consider spam a simple nuisance and assign a low abuse priority level. Other clients 108 may wish to take spam abuse incidents seriously and assign a high priority level.
[0025] Further, the reliability or credibility of each of the abuse service providers 102 can be used as one of the criteria. The reliability of the abuse service providers 102 can be provided by the abuse servers 102 themselves, a trusted third party, the name sentry service 104 , or a combination thereof.
[0026] At step 210 , the client establishes a plurality of workflows. In order to define the workflows, the client 108 is presented with a list of predefined workflows and an option to create custom workflows. Examples of predefined workflows include alerting the client via an e-mail message, creating a report and the like. Examples of custom workflows include opening a ticket in a third party ticketing system, using data to update industry ranking, alert a user, and the like.
[0027] The workflows are highly configurable and may vary greatly between different ones of the clients 108 . For example, a TLD operator could do anything, from nothing to notifying an assigned Registrar, to notifying a Registrant directly, to taking the domain name out of active use directly. A Registrar may do anything, from nothing to taking the domain out of active use, to suspending all additional domains associated with that Registrant after investigation. A Registrant may find that their domain has been compromised or flagged erroneously as a spam source and seek to correct these problems.
[0028] At step 212 , the client 108 assigns one or more of the plurality of workflows to corresponding ones of the abuse priority levels. The name sentry service 104 , checks the assigned workflow to ensure that there are no conflicts in the workflows. At this point, the name sentry service 104 is ready to act upon perceived domain name abuses as they occur, or shortly thereafter, thereby reducing potential harm to the client 108 .
[0029] Referring to FIG. 3 , a flow chart illustrating steps taken by the name sentry service 104 to implement the policies established by the clients 108 is illustrated generally by numeral 300 . At step 302 , the name sentry service 104 receives the plurality abuse data feeds from a plurality of disparate abuse service providers 102 .
[0030] At step 304 , for each of the clients 108 , the data from the plurality of abuse data feeds is filtered, based on the defined abuse data feed filters, to created the custom abuse data feed. At step 306 , each custom abuse data feed is sorted based on the corresponding created abuse priority levels. Data having the same abuse priority level is grouped together. At step 308 , for each group of data, one or more established workflows is executed to respond to the potential domain name abuse.
[0031] Thus, the abuse sentry service 104 provides a mechanism to aggregate a number of disparate abuse data feeds and allow the clients 108 to subscribe to custom portion of the abuse data feeds that is relevant to a particular business case. Further, the abuse sentry service 104 provides a mechanism to create and allocate abuse priority levels to these detected forms of abuse, based on individual policy considerations and mitigation practices. Once the abuse priority level for the data has been assigned, predefined actions are automatically taken on behalf of the client 108 , based on the workflow(s) assigned to that abuse priority level. This will provide the client 108 with automated, proactive steps that can reduce costs and harms associated with domain name abuse.
[0032] Yet further, the abuse sentry service 104 provides the ability for the client 108 to effectively subscribe to a fraction of the abuse data feed provided by the abuse data service 102 . Accordingly, it may be possible to reduce subscriber fees thereby reducing the cost of monitoring domain name abuse.
[0033] Using the foregoing specification, the invention may be implemented as a machine, process or article of manufacture by using standard programming and/or engineering techniques to produce programming software, firmware, hardware or any combination thereof.
[0034] Any resulting programs, having computer-readable program code, may be embodied within one or more computer-usable media such as memory devices or transmitting devices, thereby making a computer program product or article of manufacture according to the invention. As such, the terms “software” and “application” as used herein are intended to encompass a computer program existent (permanently, temporarily, or transitorily) on any computer-usable medium such as on any memory device or in any transmitting device.
[0035] Examples of memory devices include, hard disk drives, diskettes, optical disks, magnetic tape, semiconductor memories such as FLASH, RAM, ROM, PROMS, and the like. Examples of networks include, but are not limited to, the Internet, intranets, telephone/modem-based network communication, hard-wired/cabled communication network, cellular communication, radio wave communication, satellite communication, and other stationary or mobile network systems/communication links.
[0036] A machine embodying the invention may involve one or more processing systems including, for example, CPU, memory/storage devices, communication links, communication/transmitting devices, servers, I/O devices, or any subcomponents or individual parts of one or more processing systems, including software, firmware, hardware, or any combination or subcombination thereof, which embody the invention as set forth in the claims.
[0037] Using the description provided herein, those skilled in the art will be readily able to combine software created as described with appropriate general purpose or special purpose computer hardware to create a computer system and/or computer subcomponents embodying the invention, and to create a computer system and/or computer subcomponents for carrying out the method of the invention.
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A method for providing an abuse sentry service for responding to domain name abuse is described. The method comprises the following steps. A plurality of disparate abuse feeds is received, each comprising data relating to a subset of potential domain name abuse. Filters are applied to the data to create a custom abuse feed. Data from the custom abuse feed is grouped based on priority levels. For each of the groups, one or more corresponding workflows are executed as a response to the potential domain name abuse. A computer readable medium including instructions for implementing the method is also described.
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PRIORITY
[0001] This application claims priority from the disclosure of U.S. Provisional Patent Application Ser. No. 61/102,223, entitled “Method for Making a Multilayer Adhesive Laminate,” filed Oct. 2, 2008, the disclosure of which is incorporated by reference herein.
FIELD OF THE INVENTION
[0002] This invention is in the field of pressure sensitive adhesive coatings.
BACKGROUND
[0003] Pressure-sensitive adhesive laminates are common in products from numerous industries, including the medical and consumer healthcare industries. Within these industries, pressure-sensitive adhesive laminates may be used for transdermal patches, medical tapes, wound dressings, and topical skin patches. While this section and the disclosure herein may focus on medical and consumer healthcare applications, it should be understood that this disclosure is not limited to these applications or industries.
[0004] A common process used to manufacture pressure-sensitive adhesive laminates involves a continuous solvent-based adhesive coating process. Such a process may employ any suitable type of solvent, including water. However, the thickness of the adhesive coating produced by such a process is limited. For instance, to achieve a thicker adhesive-coated product using a solvent-based adhesive coating processes, it is necessary to slow production speeds to give thicker adhesive coatings adequate drying time, or increase temperatures, which may cause the formation of surface imperfections. Alternatively, one may use such a process in batch mode to combine layers to produce thicker adhesive laminates. These approaches to producing thick or multilayer adhesive laminates are cost intensive and inefficient. Therefore, there is a need for a process that allows for continuous rapid manufacture of a relatively thick adhesive laminate.
SUMMARY
[0005] The processes described herein allow for continuous rapid manufacture of relatively thin adhesive coatings, where the thin coatings are continuously manufactured into a single thicker adhesive laminate.
[0006] In one embodiment, this disclosure pertains to a method of continuously manufacturing a multilayer pressure-sensitive adhesive laminate including the steps of: (1) producing a web having a first surface with an adhesive layer and a second surface with a release liner; (2) slitting the web longitudinally into a first section and a second section, each section having a first surface with an adhesive layer and a second surface with a release liner; (3) positioning the first section and second section so the adhesive layer of the first section faces the adhesive layer of the second section along the length of the first and second sections; and (4) laminating the first section and second section together such that the adhesive layers of the first and second sections are attached. The resultant laminate has two surfaces each having a release liner and an inner area having an adhesive layer.
[0007] In another embodiment, this disclosure pertains to a method of continuously manufacturing a multilayer pressure-sensitive adhesive laminate including the steps of: (1) producing a web having a first surface with an adhesive layer and a second surface with a release liner; (2) slitting the web longitudinally into a first section and a second section, each section having a first surface with an adhesive layer and a second surface with a release liner; (3) laminating a backing film to the adhesive layer of the first section; (4) removing the release liner of the laminate of step (3) and exposing the adhesive layer of the first section; (5) positioning the laminate of step (4) and the second section so the exposed adhesive layer of the laminate of step (4) faces the adhesive layer of the second section; and (6) laminating the second section to the laminate of step (4), wherein the adhesive layer of the laminate of step (4) is combined with the adhesive layer of the second section. The final laminate has one surface having a backing film, one surface having a release liner, and an inner area having an adhesive layer.
[0008] In another embodiment, this disclosure pertains to a method of continuously manufacturing a multilayer pressure-sensitive adhesive laminate including the steps of: (1) producing a web having a first surface with an adhesive layer and a second surface with a release liner; (2) slitting the web longitudinally into a plurality of sections, each of the plurality of sections having a first surface with an adhesive layer and a second surface with a release liner; (3) laminating a backing film to the adhesive layer of a first section of the plurality of sections; (4) removing the release liner of the laminate of step (3) and exposing the adhesive layer associated with the first section; (5) positioning the laminate of step (4) and a next section of the plurality of sections so the exposed adhesive layer of the laminate of step (4) faces the adhesive layer of the next section; (6) laminating the next section to the laminate of step (4), wherein the adhesive layer of the laminate of step (4) is combined with the adhesive layer of the next section; (7) removing the release liner of the laminate of step (6) exposing the adhesive layer associated with the next section; and (8) repeating steps (5) through (7) to achieve a desired number of laminated layers; wherein step (7) is omitted with the final laminated section of the plurality of sections. The final laminate has one surface having a backing film, one surface having a release liner, and an inner area having an adhesive layer.
[0009] The above embodiments are exemplary only and should not be interpreted to limit the scope of this disclosure. It should be understood that this disclosure encompasses numerous embodiments, some of which are not explicitly disclosed within this section. Ultimately, the scope of this disclosure is defined by the broadest reading of the claims herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The accompanying drawings are incorporated in and constitute a part of this specification. Together with the detailed description given below, the drawings serve to explain how the teachings of this application could be implemented. It should be understood that the teachings of this application are not limited to being implemented in the precise arrangements shown. In the drawings:
[0011] FIG. 1A depicts a flow diagram of a method to make a multilayer adhesive laminate having an adhesive coating between two release liners.
[0012] FIG. 1B depicts a schematic diagram of an exemplary process for the method shown in FIG. 1A .
[0013] FIG. 1C depicts a cross-section view of the adhesive coated release liner strips used in the lamination process of FIG. 1B .
[0014] FIG. 1D depicts a cross-section view of the multilayer adhesive laminate produced in the lamination process of FIG. 1B .
[0015] FIG. 2A depicts a flow diagram of a method to make a multilayer adhesive laminate having an adhesive coating between a release liner and a backing film.
[0016] FIG. 2B depicts a schematic diagram of an exemplary process for the method shown in FIG. 2A .
[0017] FIG. 2C depicts a cross-section view of the adhesive coated release liner strips used in the lamination process of FIG. 2B .
[0018] FIG. 2D depicts a cross-section view of the adhesive coated release liner strip containing the backing film as used in the lamination process of FIG. 2B .
[0019] FIG. 2E depicts a cross-section view of the strip of FIG. 2D with the release liner removed.
[0020] FIG. 2F depicts a cross-section view of the multilayer adhesive laminate produced in the lamination process of FIG. 2B .
[0021] FIG. 3A depicts a flow diagram of a method to make a multilayer adhesive laminate having an adhesive coating between a release liner and a backing film.
[0022] FIG. 3B depicts a schematic diagram of an exemplary process for the method shown in FIG. 3A .
[0023] FIG. 3C depicts a cross-section view of the adhesive coated release liner strips used in the lamination process of FIG. 3B
[0024] FIG. 3D depicts a cross-section view of the adhesive coated release liner strip containing the backing film as used in the lamination process of FIG. 3B .
[0025] FIG. 3E depicts a cross-section view of the strip of FIG. 3D with the release liner removed.
[0026] FIG. 3F depicts a cross-section view of the strip of FIG. 3E after an additional strip of adhesive coated release liner has been laminated to the strip of FIG. 3E .
[0027] FIG. 3G depicts a cross-section view of the strip of FIG. 3F with the release liner removed.
[0028] FIG. 3H depicts a cross-section view of the strip of FIG. 3G after an additional strip of adhesive coated release liner has been laminated to the strip of FIG. 3G .
[0029] FIG. 3I depicts a cross-section view of the multilayer adhesive laminate produced in the lamination process of FIG. 3B .
DETAILED DESCRIPTION
[0030] In discussing the figures, specific frame of reference conventions are designated, which includes describing an upward and downward orientation. When viewing the exemplary process figures ( FIGS. 1B , 2 B, and 3 B), an upward orientation is associated with an object facing out-of-the-page, whereas a downward orientation is associated with an object facing into-the-page. When viewing the laminate schematic figures ( FIGS. 1C-1D , 2 C- 2 F, and 3 C- 3 I), an upward orientation is associated with an object facing the top of the page, whereas a downward orientation is associated with an object facing the bottom of the page. These frame of reference conventions are used only for aiding in understanding the disclosure. In no sense should the disclosure be limited to such a frame of reference as other suitable manners of description fall within the scope of this disclosure.
[0031] FIG. 1A describes a process for manufacturing a multilayer adhesive laminate by pairing two adhesive coatings between release liners. At step 100 , a coating of adhesive is applied to a release liner, using any suitable coating method, to produce a coated web. Step 105 is a curing process, using any suitable method, where the adhesive-coated web is converted from a fluid to a fixed film. A suitable curing process may include, but is not limited to, a drying process. At step 110 , the cured web is slit into two strips using any suitable slitting method. At step 115 , the separate strips are directed through the process to orient the adhesive layers of the two strips such that they face one another in preparation for lamination. At step 125 , the adhesive layers of the two strips are laminated together, using any suitable lamination method, to form a multilayer adhesive laminate having an inner adhesive layer surrounded on both sides by a release liner.
[0032] Referring to FIG. 1B , a schematic shows an exemplary way to direct the strips to achieve the multilayer adhesive laminate discussed in FIG. 1A . In FIG. 1B , web section 130 is the adhesive coated web after curing step 105 of FIG. 1A . Web section 130 travels through slitter 135 where web section 130 is divided into strip sections 140 and 145 . Strip section 140 travels over 45-degree turning roller 160 , which causes a change in the surface orientation of strip section 140 , and causes strip section 140 to change its direction of travel by about 90-degrees. FIGS. 1B and 1C show that before strip section 140 passes over 45-degree turning roller 160 , adhesive layer 175 of strip section 140 faces upward (and conversely the release liner 180 faces downward). After passing over 45-degree turning roller 160 , adhesive layer 175 of strip section 140 faces downward (and conversely the release liner 180 faces upward).
[0033] Still referring to FIG. 1B , strip section 145 is directed to 90-degree turning roller 150 , which causes a change in the surface orientation of strip section 145 , and causes strip section 145 to reverse its direction of travel. As shown from FIGS. 1B and 1C , adhesive layer 190 of strip section 145 faces upward (and conversely the release liner 185 faces downward) before passing over 90-degree turning roller 150 . After passing over 90-degree turning roller 150 , adhesive layer 190 of strip section 145 faces downward (and conversely the release liner 185 faces upward). Strip section 145 is then directed to 45-degree turning roller 155 , which causes a change in the surface orientation of strip section 145 , and causes strip section 145 to change its direction of travel by about 90-degrees. As shown in FIG. 1B , 45-degree turning roller 155 is located such that after turning roller 155 , strip section 145 aligns with strip section 140 , and strip section 140 travels above strip section 145 in the same direction. Those of ordinary skill in the art will appreciate that heights of strip sections 140 and 145 may be manipulated by positioning turning rollers or web guides at different heights with respect to a common plane of reference. Furthermore, as shown in FIG. 1B , after passing over 45-degree turning roller 155 , adhesive layer 190 of strip section 145 now faces adhesive layer 175 of strip section 140 .
[0034] Still referring to FIG. 1B , with strip sections 140 and 145 oriented as described above, strip sections 140 and 145 then pass through a lamination section 165 . Lamination section 165 causes the adhesive layers 175 and 190 , of strip sections 140 and 145 respectively, to join forming a multilayer adhesive laminate 170 . As shown in FIGS. 1B and 1D , the multilayer adhesive laminate 170 has a combined adhesive layer 195 , surrounded on either side by release liners 180 and 185 . It should be noted that combined adhesive layer 195 is comprised of adhesive layer 175 of strip section 140 and adhesive layer 190 of strip section 145 .
[0035] Now referring to FIG. 2A , a process is shown for manufacturing a multilayer adhesive laminate by pairing two adhesive coatings between a release liner and a backing film. At step 200 , an adhesive coating is applied to a release liner using any suitable coating method. At step 205 , the web containing the adhesive coating and release liner is cured using any suitable method. At step 210 , the web is slit into two strips using any suitable slitting method. At step 215 a backing film is attached to the adhesive layer of one of the strips. From this same strip, at step 220 , the release liner is removed, thus exposing the adhesive layer of the strip opposite the side of the backing film. At step 223 , the separate strips are then directed through the process to orient the adhesive layers of the two strips such that they face one another in preparation for lamination. At step 225 the adhesive layers of the two strips are laminated together using any suitable lamination method to form a multilayer adhesive laminate.
[0036] Referring to FIGS. 2B-2F , a schematic shows an exemplary way to direct the strips to achieve the multilayer adhesive laminate discussed in FIG. 2A . In FIG. 2B , web section 230 is the adhesive-coated web after curing step 205 of FIG. 2A . Web section 230 travels through slitter 235 where web section 230 is divided into strip sections 240 and 245 . Strip section 245 travels to backing film application section 255 , where backing film 250 is attached to adhesive layer 295 of strip section 245 to produce strip section 290 having a backing film 250 , an adhesive layer 295 , and a release liner 265 as shown in FIGS. 2B and 2D . Strip section 290 then travels to a release liner removal section 260 . Release liner 265 is removed from strip section 290 to produce strip section 296 . As shown in FIG. 2E , strip section 296 has backing film 250 on top of adhesive layer 295 , which now has an exposed adhesive surface where release liner 265 was formerly positioned. Strip section 296 travels over 45-degree turning roller 275 , which causes a change in the surface orientation of strip section 296 , and causes strip section 296 to change its direction of travel by about 90-degrees. FIGS. 2B and 2E show that before strip section 296 passes over 45-degree turning roller 275 , backing film 250 of strip section 296 faces upward (and conversely the adhesive layer 295 faces downward). After passing over 45-degree turning roller 275 , backing film 250 of strip section 296 faces downward (and conversely the adhesive layer 295 faces upward).
[0037] Still referring to FIGS. 2B-2F , strip section 240 is directed into 45-degree turning roller 270 , which causes a change in the surface orientation of strip section 240 , and causes strip section 240 to change its direction of travel by about 90-degrees. FIGS. 2B and 2C show that before strip section 240 passes over 45-degree turning roller 270 , adhesive layer 299 of strip section 240 faces upward (and conversely the release liner 297 faces downward). After passing over 45-degree turning roller 270 , adhesive layer 299 of strip section 240 faces downward (and conversely the release liner 297 faces upward). As shown in FIG. 2B , 45-degree turning rollers 270 and 275 are located such that strip sections 240 and 296 align, and such that strip section 240 is traveling above strip section 296 and in the same direction and speed. Those of ordinary skill in the art will appreciate that heights of strip sections 240 and 296 may be manipulated by positioning turning rollers or web guides at different heights with respect to a common plane of reference. Furthermore, as shown in FIGS. 2B , 2 C, and 2 E, after passing over 45-degree turning roller 270 , adhesive layer 299 of strip section 240 is now oriented facing adhesive layer 295 of strip section 296 .
[0038] Still referring to FIGS. 2B-2F , with strip sections 240 and 296 oriented as described above, strip sections 240 and 296 then pass through a lamination section 280 . Lamination section 280 causes the adhesive layers of strip sections 240 and 296 , to join forming a multilayer adhesive laminate 285 . As shown in FIGS. 2B and 2F , the multilayer adhesive laminate 285 has a combined adhesive layer 298 surrounded on one side by backing film 250 and one the other side by release liner 297 . It should be noted that combined adhesive layer 298 is comprised of adhesive layer 299 of strip section 240 and adhesive layer 295 of strip section 245 .
[0039] Now referring to FIG. 3A , a process is shown for manufacturing a multilayer adhesive laminate by combining a multitude of adhesive coatings between a single release liner and single backing film. At step 300 , an adhesive coating is applied to a release liner using any suitable coating method. At step 305 , the web containing the adhesive-coating and release liner is cured using any suitable method. At step 310 the web is slit into several strips using any suitable slitting method. At step 315 a backing film is attached to the adhesive layer of a first strip. From this first strip, at step 320 , the release liner is removed, thus exposing the adhesive layer of the first strip, opposite the side of the backing film. At step 323 , a second strip is then directed through the process to orient its adhesive layer such that it faces the exposed adhesive layer of the first strip. At step 325 , the adhesive layer of the second strip is laminated to the exposed adhesive layer of the first strip using any suitable lamination process. At step 330 , the release liner of the second strip is removed, thus exposing the adhesive layer of the second strip, opposite the side laminated to the first strip. At step 333 , a third strip is then directed through the process to orient its adhesive layer such that it faces the exposed adhesive layer of the second strip. At step 335 , the adhesive layer of the third strip is laminated to the exposed adhesive layer of the second strip using any suitable lamination process. At step 340 , steps 330 , 333 , and 335 are repeated with the next available strip for lamination. However, step 340 concludes by not removing the release liner of the final laminated strip, thus forming the multilayer adhesive laminate.
[0040] Referring to FIGS. 3B-3H , a schematic shows an exemplary way to direct the strips to achieve the multilayer adhesive laminate discussed in FIG. 3A . In FIG. 3B , web section 345 is the adhesive coated web after curing step 305 of FIG. 3A . Web section 345 travels through slitter section 346 where web section 345 is divided into a plurality of strip sections 347 , 348 , 349 , 350 , 351 , 352 , 353 , and 354 . Strip section 354 has an adhesive layer 391 on a release liner 356 as shown in FIG. 3C . Each of strip sections 347 , 348 , 349 , 351 , 352 , and 353 have a similar adhesive layer on release liner structure as shown in FIG. 3C with respect to strip section 354 .
[0041] Still referring to FIGS. 3B-3H , strip section 354 travels to backing film application section 363 , where backing film 355 is attached to adhesive layer 391 of strip section 354 to produce a strip section 393 having a backing film 355 , an adhesive layer 391 , and a release liner 356 as shown in FIG. 3D . Strip section 393 then travels to a release liner removal section 371 . Release liner 356 is removed from strip section 393 to produce strip section 394 . As shown in FIG. 3E , strip section 394 has backing film 355 on adhesive layer 391 , which now has an exposed adhesive surface where release liner 356 was formerly positioned.
[0042] Strip section 353 travels into 45-degree turning roller (shown in phantom in drawing), which causes a change in the surface orientation of strip section 353 , and causes strip section 353 to change its direction of travel by about 90-degrees. FIG. 3B shows that before strip section 353 passes over the 45-degree turning roller, the adhesive layer of strip section 353 faces upward (and conversely the release liner 357 faces downward). After passing over the 45-degree turning roller, the adhesive layer of strip section 353 faces downward (and conversely the release liner 357 faces upward). Strip section 353 continues into another 45-degree turning roller (shown in phantom in drawing), which again causes a change in the surface orientation of strip section 353 , and causes strip section 353 to change its direction of travel by about 90-degrees. FIG. 3B shows that before strip section 353 passes over the second 45-degree turning roller, the adhesive layer of strip section 353 faces downward (and conversely the release liner 357 faces upward). After passing over the second 45-degree turning roller, the adhesive layer of strip section 353 faces upward (and conversely the release liner 357 faces downward). As shown in FIGS. 3B and 3E , the 45-degree turning rollers that guide strip section 353 are located such that, at the exit of the second 45-degree turning roller, strip section 353 aligns with strip section 394 , and strip section 353 is traveling below strip section 394 in the same direction and speed. Those of ordinary skill in the art will appreciate that heights of strip sections 353 and 394 may be manipulated by positioning turning rollers or web path guides at different heights with respect to a common plane of reference. Furthermore, after passing over the second 45-degree turning roller, the adhesive layer of strip section 353 faces the exposed adhesive layer 391 of strip section 394 .
[0043] Still referring to FIGS. 3B-3H , with strip sections 353 and 394 oriented as described above, strip sections 353 and 394 then pass through a lamination section 364 . Lamination section 364 causes the adhesive layers of strip sections 353 and 394 , to join together forming a strip section 395 as shown in FIG. 3F . Strip section 395 has a combined adhesive layer 392 surrounded on one side by backing film 355 and on the opposite side by release liner 357 . It should be noted that combined adhesive layer 392 is comprised of adhesive layer 391 of strip section 394 and the adhesive layer of strip section 353 .
[0044] Still referring to FIGS. 3B-3H , strip section 395 then travels to a release liner removal section 372 . Release liner 357 is removed from strip section 395 to produce strip section 396 . As shown in FIG. 3G , strip section 396 has backing film 355 on top of combined adhesive layer 392 , which now has an exposed adhesive surface where release liner 357 was formerly positioned.
[0045] Strip section 352 travels into 45-degree turning roller 383 , which causes a change in the surface orientation of strip section 352 , and causes strip section 352 to change its direction of travel by about 90-degrees. FIG. 3B shows that before strip section 352 passes over 45-degree turning roller 383 , the adhesive layer of strip section 352 faces upward (and conversely the release liner 358 faces downward). After passing over 45-degree turning roller 383 , the adhesive layer of strip section 352 faces downward (and conversely the release liner 358 faces upward). Strip section 352 continues into another 45-degree turning roller 389 , which again causes a change in the surface orientation of strip section 352 , and causes strip section 352 to change its direction of travel by about 90-degrees. FIG. 3B shows that before strip section 352 passes over 45-degree turning roller 389 , the adhesive layer of strip section 352 faces downward (and conversely the release liner 358 faces upward). After passing over 45-degree turning roller 389 , the adhesive layer of strip section 352 faces upward (and conversely the release liner 358 faces downward). As shown in FIGS. 3B and 3G , 45-degree turning rollers 383 , 389 that guide strip section 352 are located such that, at the exit of 45-degree turning roller 389 , strip section 352 aligns with strip section 396 , and strip section 352 is traveling below strip section 396 in the same direction and speed. Those of ordinary skill in the art will appreciate that heights of strip sections 352 and 396 may be manipulated by positioning turning rollers or web path guides at different heights with respect to a common plane of reference. Furthermore, after passing over 45-degree turning roller 389 , the adhesive layer of strip section 352 faces the exposed adhesive layer 392 of strip section 396 .
[0046] Still referring to FIGS. 3B-3H , with strip sections 352 and 396 oriented as described above, strip sections 352 and 396 then pass through a lamination section 365 . Lamination section 365 causes the adhesive layers of strip sections 352 and 396 , to join forming a strip section 397 as shown in FIG. 3H . Strip section 397 has a combined adhesive layer 398 surrounded on one side by backing film 355 and on the opposite side by release liner 358 . It should be noted that combined adhesive layer 398 is comprised of adhesive layer 392 of strip section 396 and the adhesive layer of strip section 352 .
[0047] As shown in FIGS. 3A and 3B , the process described in the preceding paragraphs repeats to achieve the desired laminate thickness. More specifically, release liner 358 of strip section 397 is removed and strip section 351 is positioned using 45-degree turning rollers for lamination. As shown in FIG. 3B , after final strip section 347 is laminated to the intermediate product, the release liner of strip section 347 is maintained on the laminate to produce the final multilayer adhesive laminate 390 as shown in FIGS. 3B and 3I . The final multilayer adhesive laminate 390 has a combined adhesive layer 399 surrounded on one side by backing film 355 and on the other side by release liner 400 . It should be noted that combined adhesive layer 399 is comprised of the adhesive layers of strip sections 354 , 353 , 352 , 351 , 350 , 349 , 348 , and 347 .
[0048] While the above paragraphs have described several product features, this disclosure should not be limited to the precise features shown and described. For example, the adhesive coating disclosed may be of any of several types. For instance, the adhesive coating may be a solvent based adhesive coating for use in a transdermal or topical medical patch. In such examples, the adhesive coating may contain medicinal formulations for the treatment of certain ailments. By way of example and not limitation, to treat skin pain or discomfort, lidocaine may be combined with the adhesive to create a skin treatment patch. Those of ordinary skill in the art will appreciate that the adhesive may be combined with any suitable medicinal formulation, where topical or transdermal drug delivery is desired.
[0049] Additional medical related applications for a multilayer adhesive laminate as disclosed herein may include medical tapes, wound dressings, ostomy adhesives, and numerous others. Similarly, the multilayer adhesive laminate disclosed herein, may have applications in other industries where a thick coating of pressure-sensitive adhesive is desirable; for example, applications may exist in consumer products, automotive, and home improvement industries.
[0050] Some additional product features described include release liners and backing films. It should be understood that this disclosure shall encompass any variety of release liners and backing films suitable for adhering to an adhesive coating. By way of example only, release liners and backing films may be manufactured from natural or synthetic fibers that may be woven, nonwoven, melt cast, or extruded. Furthermore, a combination of natural or synthetic fibers may be used. Those of ordinary skill in the art will appreciate the variety of materials suitable for use as both release liners and backing films.
[0051] The above disclosure also describes several process features, and the disclosure should not be limited to the precise process features shown or described. For example, several web-guiding structures are disclosed including 45-degree and 90-degree turning rollers. It should be understood, that in some embodiments such turning rollers may be driven or braked, while in other embodiments such turning rollers may be freely rotating. Still in other embodiments, turning rollers may be interchanged with turning or guide bars that do not rotate. Similarly, the precise degrees specified for the turning rollers are not required and maybe substituted with turning rollers having other degree configurations.
[0052] Some additional process features described include coating, curing, slitting, and laminating processes. It should be understood that this disclosure is not intended to be limited to a specific method for conducting any of these processes. For example, several types of coating, curing, slitting, and laminating processes may be compatible with this disclosure. By way of example only, the adhesive coating may be accomplished in a spray application, a metered roller application, or any other suitable coating method. By way of example only, the curing process may be accomplished using a steam-filled-can drying system, a through-air drying system, a radiation curing system, or any other suitable method. By way of example only, the slitting process may be accomplished using a slitting blade that may be comprised of a metal or ceramic, a rotating slitting wheel, an air or water jet, or any other suitable slitting method. By way of example only, the laminating process may be accomplished by compressing the laminate layers between two rollers, by ultrasonic bonding, by chemical adhesion, or any other suitable laminating method. Those of ordinary skill in the art will appreciate the variety of methods suitable for use in coating, curing, slitting, and laminating.
[0053] Having shown and described various embodiments, further adaptations of the methods and systems described herein may be accomplished by appropriate modifications by one of ordinary skill in the art without departing from the scope of this disclosure. Several of such potential modifications have been mentioned, and others will be apparent to those skilled in the art. For instance, the examples, embodiments, geometrics, materials, dimensions, ratios, steps, and the like discussed above are illustrative and are not required. Accordingly, the scope of the present invention should be considered in terms of whatever claims recite the invention, and is understood not to be limited to the details of structure and operation shown and described in the description.
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A method allows for rapid manufacture of relatively thick adhesive coatings using a continuous process, where a single thin coating is continuously converted into a single thicker adhesive laminate. An exemplary process includes the steps of: (1) producing a web having a first surface with an adhesive layer and a second surface with a release liner; (2) slitting the web longitudinally into a first section and a second section, each section having a first surface with an adhesive layer and a second surface with a release liner; (3) laminating a backing film to the adhesive layer of the first section; (4) removing the release liner of the laminate of step (3) exposing the adhesive layer of the first section; (5) positioning the laminate of step (4) and the second section so the exposed adhesive layer of the laminate of step (4) faces the adhesive layer of the second section; and (6) laminating the second section to the laminate of step (4), wherein the adhesive layer of the laminate of step (4) is combined with the adhesive layer of the second section. The resultant laminate of this exemplary process has one surface having a backing film, one surface having a release liner, and an inner area having an adhesive layer.
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FIELD OF THE INVENTION
The invention relates to a current limit circuit and more specifically to a temperature compensated current limit circuit implemented in a solid state switch.
BACKGROUND OF THE INVENTION
Voltage regulation integrated circuits provide a regulated output voltage to a load. These circuits often include a current limitation feature that prevents current in excess of a predefined limit from flowing in the integrated circuit if the load increases to an unacceptable level. Another class of circuits that rely on accurate current limit protection are solid state switch circuits. These circuits provide a low impedance connection between two nodes and limit current to less than a predetermined value. Without compensating for temperature variations, a shift in the current limit value can occur. For example, the current limit value can shift by more than forty percent over a range of −40° C. to +85° C. due to temperature dependent electrical characteristics of the materials used in the circuit components. Thus, the current limiting portion of the circuit may not provide adequate protection in certain applications. What is needed is a circuit that provides a stable current limit over a wide temperature range.
SUMMARY OF THE INVENTION
The present invention relates to a circuit and a method of stabilizing the current limit over a range of temperatures. The present invention is directed to limiting the amount of current flow through a metal interconnect, thus providing temperature current limit protection.
One aspect of the invention relates to a temperature compensated current limit circuit used in a solid state switch. The circuit, under normal operating conditions, fully enhances an integrated MOSFET, resulting in a reduced voltage drop across the switch. When the load current increases to an unacceptable level, the switch limits the current delivered to a load via a servo loop. The current delivered to a load without exhibiting any current limit behavior is often referred to as current compliance.
The circuit includes a first resistive element, a second resistive element, a load current controller, a current module, and an amplifier. The first resistive element has a first terminal adapted to receive an input voltage and has a second terminal. The first resistive element has a temperature dependent resistivity. The second resistive element has a first terminal configured to receive the input voltage and has a second terminal. The load current controller has a first terminal in communication with the second terminal of the first resistive element, a second terminal in communication with a load, and a control terminal adapted to receive a control signal. The amplifier has a first input terminal in communication with the second terminal of the first resistive element, a second input terminal in communication with the second terminal of the second resistive element, and an amplifier output terminal in communication with the control terminal of the load current controller. The amplifier provides the control signal at its output terminal in response to a load current, the resistivity of the first resistive element, the resistivity of the second resistive element, and a temperature dependent current generated by the current module. The current module has a first terminal in communication with the second terminal of the second resistive element and the second terminal of the amplifier. The current module provides a temperature dependent current at its first terminal.
In one embodiment, the load current controller is a current controlling transistor. In another embodiment, the current module generates a current that is proportional to absolute temperature (PTAT). In still another embodiment, the second resistive element includes a primary resistive element, and a secondary resistive element, each having first and second terminals. The first terminal of the primary resistive element is in communication with the first terminal of the second resistive element. The first terminal of the secondary resistive element is in communication with the second terminal of the primary resistive element. The second terminal of the secondary resistive element is in communication with the second terminal of the second resistive element. In a further embodiment, the resistivity of the primary resistive element is greater than the resistivity of the secondary resistive element.
Another aspect of the invention relates to a method of providing a voltage across a load with a temperature independent current compliance. The method includes the steps of generating a first temperature dependent voltage drop in response to the current through the load, generating a second temperature dependent voltage drop in response to a temperature dependent reference current, and amplifying the difference of the first temperature dependent voltage drop and the second temperature dependent voltage drop to generate a control signal. Additionally, the method includes the step of applying the control signal to a load current controller to provide the voltage having a temperature independent current compliance across the load. The method can be applied repeatedly to achieve a continuing current limitation function.
In another aspect, the method includes the steps of comparing a first temperature dependent voltage drop to a second temperature dependent voltage drop, wherein the second temperature dependent voltage drop is responsive to a temperature dependent current, generating a control signal in response to the comparison, and generating the voltage having a temperature independent current compliance in response to the control signal.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is pointed out with particularity in the appended claims. The advantages of the invention may be better understood by referring to the following description taken in conjunction with the accompanying drawing in which:
FIG. 1 is a schematic diagram depicting an embodiment of a temperature compensated current limit circuit according to the present invention;
FIG. 2 is a schematic diagram depicting another embodiment of a temperature compensated current limit circuit according to the present invention;
FIG. 3 is a schematic diagram depicting another embodiment of a temperature compensated current limit circuit according to the present invention; and
FIG. 4 is a flow chart representation of an embodiment of a method for providing a voltage across a load according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1, in overview, one embodiment of the present of invention includes a first resistive element 10 , a second resistive element 16 , a load current controller 22 , a current module 28 , and an amplifier 34 . First resistive element 10 includes a first terminal 40 and second terminal 46 , and has a temperature dependent resistance (R 1 ). First terminal 40 of the first resistive element 10 is adapted to receive a supply voltage V SUPPLY . Second resistive element 16 includes a first terminal 52 and second terminal 58 , and has a resistance (R 2 ). First terminal 52 of the second resistive element 16 is adapted to receive supply voltage V SUPPLY . In one embodiment, in which the circuit is fabricated as an integrated circuit, the first resistive element 10 is an aluminum interconnect on an integrated circuit providing a nominal resistance (e.g., approximately 25 mΩ) and the second resistive element 16 is a P+ diffusion resistor providing a substantially greater resistance (e.g., approximately 25 kΩ). In such an embodiment, the ratio of resistances of the first resistive element 10 and the second resistive elements 16 is about 1×10 6 .
Load current controller 22 includes a first terminal 64 in communication with the second terminal 46 of the first resistive element 10 , a control terminal 70 configured to receive a control signal CONTROL, and an output terminal 76 in communication with a load 82 . In one embodiment, load current controller 22 is a Metal-Oxide Semiconductor Field Effect Transistor (MOSFET), and first resistive element 10 is the interconnect of the drain terminal of the MOSFET. Current module 28 includes a terminal 88 in communication with the second terminal 58 of the second resistive element 16 . Amplifier 34 includes a first terminal 96 in communication with the second terminal 46 of the first resistive element 10 and the first terminal 64 of load current controller 22 , a second input terminal 102 in communication with the second terminal 58 of the second resistive element 16 and terminal 88 of current module 28 , and an output terminal 108 in communication with the control terminal 70 of the load current controller 22 .
During operation, supply voltage (V SUPPLY ) is applied to the first terminals 40 and 52 of first and second resistive elements 10 and 16 , respectively. A drain current (I F ) flows through first resistive element 10 . A voltage (V F ) which is the product of the temperature dependent resistance (R 1 ) and drain current (I F ) exists across the first resistive element 10 . Additionally, current module 28 generates a temperature dependent current (I CM ). In one embodiment, temperature dependent current (I CM ) is proportional to absolute temperature. Consequently, a reference voltage (V R ) which is the product of temperature dependent current (I CM ) and resistance (R 2 ) is generated across the second resistive element 16 . Amplifier 34 amplifies the difference between voltage (V P ) (i.e., V SUPPLY −V F ) applied to its first terminal 96 and voltage (V N ) (i.e., V SUPPLY −V R ) applied to its second terminal 102 . In response, amplifier 34 generates a control signal CONTROL at its output terminal 108 . When voltage (V N ) is less than voltage (V P ) control signal CONTROL remains at the maximum supply voltage applied to the amplifier. In response, load current controller 22 provides a load current (I L ) to load 82 that approximately equals the drain current (I F ). As load current (I L ) and drain current (I F ) increase, the difference between voltages (V P ) and (V N ) decreases. When drain current I F reaches a predetermined maximum value, the difference between voltage (V P ) and voltage (V N ) becomes zero and load current controller 22 provides load current I L at a predetermined maximum value in response to the modulation of the current controller 22 according to control signal CONTROL.
As the operating temperature varies, the temperature dependent resistance (R 1 ) and temperature dependent current (I CM ) also vary in such a way as to provide a proper temperature compensated current limit. Resistance (R 2 ) and temperature dependent current (I CM ) are selected to define the limit voltage (V N ) which is compared with voltage (V P ) as the temperature varies. In one embodiment, current module 28 is designed such that the temperature dependent current (I CM ) is generated by a PTAT circuit. For example, the PTAT circuit can be a (ΔVbe)/R circuit which includes a resistor comprised of a material having a temperature dependent resistance similar to a temperature dependent resistance (R 2 ) of the second resistive element 16 . Consequently, the temperature dependence of the reference current (I CM ) generated by the (ΔVbe)/R circuit is designed such that the product of the reference current (I CM ) and the resistance (R 2 ) of the second resistive element 16 (i.e., voltage V R ) directly tracks changes in voltage (V F ) due to temperature variations for a fixed load current.
FIG. 2 illustrates an embodiment of the circuit of FIG. 1 in more detail. In this embodiment, current controller 22 is implemented as an N-Channel MOSFET 23 . The second resistive element 16 includes a primary resistive element 114 and a secondary resistive element 120 . Primary resistive element 114 includes a first terminal 144 which is the first terminal 52 of the second resistive element 16 and a second terminal 150 , and has a resistivity R P . Secondary resistive element 120 includes a first terminal 156 connected to the second terminal 150 of primary resistive element 114 and a second terminal 162 which is the second terminal 58 of second resistive element 16 , and has a resistivity R S . In one embodiment, the primary resistivity R P is greater than the secondary resistivity R S . In another embodiment, the primary resistive element 114 and secondary resistive element 120 are both P+ diffusion resistors.
In this embodiment, the circuit also includes a charge pump 126 , a reset-switch 132 , and a comparator 138 . Charge pump 126 includes a first input terminal 166 configured to receive a charge pump supply voltage (V SUPPLY2 ), a second input terminal 172 configured to receive a reference voltage (V PREF ), and an output terminal 178 connected to a supply terminal 184 of amplifier 34 . Reset-switch 132 includes a first terminal 190 connected to the gate 71 of MOSFET 23 of load current controller 22 , a second terminal 196 configured to receive a reference voltage (e.g., ground), and a control terminal 202 configured to receive a reset-enable signal (RESETEN). Comparator 138 includes a first input terminal 208 connected to the junction of the second terminal 150 of primary resistive element 114 and the first terminal 156 of the secondary resistive element 120 , a second input terminal 214 connected to the second terminal 46 of the first resistive element 10 and to the first input terminal 96 of amplifier 34 , and a comparator output terminal 220 .
In operation, supply voltage (V SUPPLY ) is applied to first terminal 144 of primary resistive element 114 . Consequently, a voltage drop (V PRI ) develops across primary resistive element 114 and a voltage V SEC develops across secondary resistive element 120 . Comparator 138 generates a flag signal FLAG at output terminal 220 in response to a voltage V N′ (equal to V SUPPLY −V PRI ) existing at common terminals 150 , 156 of the primary and secondary resistive elements 114 and 120 respectively. Voltage V N′ is slightly greater than voltage V N because of the additional voltage drop across secondary resistive element 120 . As the current I F through the first resistive element increases towards a maximum allowable limit, voltage V P decreases. When voltage V P decreases to less than voltage V N′ , flag signal FLAG transitions to logic HIGH thereby indicating that current I F is near or at the predetermined current limit.
Charge pump 126 provides a pump voltage V PUMP at output terminal 178 to amplifier 34 . Generally, pump voltage V PUMP is a magnification of the charge pump supply voltage V SUPPLY2 . In one embodiment, charge pump 126 is a doubler, thereby doubling charge pump supply voltage V SUPPLY2 . In another embodiment, charge pump supply voltage V SUPPLY2 is substantially equal to supply voltage V SUPPLY . The higher pump voltage V PUMP allows the amplifier 34 to generate a control signal CONTROL of sufficient magnitude to fully enhance MOSFET 23 to operate in the triode region under normal operating conditions when the load current (I L ) is less than the maximum allowable current.
Reset-switch 132 receives reset signal RESETEN at control terminal 202 . In response, reset-switch 132 connects or disconnects gate 71 of MOSFET 23 to ground. When gate 71 is coupled to ground, the gate capacitance of the MOSFET 23 is discharged. Consequently, when reset signal RESETEN changes state to activate the circuit, load current I L gradually increases as the gate capacitance of MOSFET 23 is again charged.
Referring to FIG. 3, an alternative embodiment to the circuit of FIG. 2 includes a level shifter 50 and reconfigured comparator 138 ′. The charge pump output terminal 178 is connected to input terminal 54 of the level shifter 50 . The output terminal 56 of the level shifter 50 is connected to gate 71 of MOSFET 23 in load current controller 22 . Comparator 138 ′ has a negative input terminal 214 ′ connected to the output terminal 108 of amplifier 34 .
In operation, the level shifter 50 provides the control signal CONTROL to modulate the load current controller 22 . The control signal CONTROL is of sufficient magnitude to fully enhance MOSFET 23 to operate in the triode region under operating conditions when the load current (I L ) is less than the maximum allowable current. Comparator 138 ′ compares the voltage generated at amplifier terminal 108 and a reference voltage (V X ) applied to its positive input terminal 208 ′. The reference voltage (V X ) is selected to correspond to the voltage at terminal 108 of amplifier 34 when the load current I L is substantially at the maximum allowable current. As current (I F ) increases to equal the maximum allowable current, flag signal FLAG transitions from logic LOW to logic HIGH to indicate that the circuit is operating at the current limit.
With reference to FIG. 4, one embodiment of the present invention relates to a method 300 for providing a voltage across a load in which the voltage has a temperature independent current compliance. In step 310 a first temperature dependent voltage (V P ) indicative of a load current is generated. For example, the voltage (V P ) can be generated by conducting the load current through a know resistance. In step 320 , a temperature dependent reference voltage (V N ) is generated. A control signal CONTROL is generated (step 330 ) by amplifying the difference of the temperature dependent voltages (V P ) and (V N ). The control signal CONTROL is applied (step 340 ) to a load controller. The load controller provides a current having a temperature independent current compliance to the load. The steps of the method 300 are preferably directed to a feedback loop therefore, after completing step 340 , the method returns to step 310 to again perform steps 310 through 340 .
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. For example, all polarities of logic and voltage signals are shown to represent such polarities in a single functional embodiment. One skilled in the art can easily choose different polarities and arrange the specific components and logic accordingly. The foregoing embodiments are therefore to be considered in all respects illustrative rather than limiting on the invention described herein. Scope of the invention is thus indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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The present invention relates to a circuit and method of providing a voltage having a temperature independent current compliance to a load. The circuit includes a first resistive element having a temperature dependent resistivity, a second resistive element, an amplifier, a current module generating a temperature dependent current, and a load current controller. Temperature dependent voltages developed across the resistive elements track each other to enable a constant current limit over a wide temperature range.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to modem technology, and in particular maintaining connection during loss of controller synchronism.
2. Background
Modems typically connect two computers across telephone lines. Current telephone lines are designed to carry voice signals in the form of a modulated analog wave form. Modems convert digital data from a computer into an audio wave form that can be sent over current telephone lines. A first computer system, designated calling computer, instructs a modem to dial and establish a connection with a second modem. The second modem is connected to another computer system, designated receiving computer. The first modem converts digital information from the calling computer into an audio wave form to send across telephone lines. The second modem receives the audio wave form from the telephone lines and converts the wave forms into digital information which is sent to the receiving computer. This communication link can be bi-directional. In other words, both computer systems may send and receive information through the modems to the other computer system.
The modems communicate to each other via communication protocols. These communication protocols include modulation protocols, error control protocols and data compression protocols. Modulation protocols define the specific techniques of encoding and decoding the digital bits into the audio wave form and the data transfer speed. Two modems can establish a connection only when they share a common modulation protocol.
So that modems from different manufactures can communicate, there are several industry established communication protocols. Two standard modulation protocols for high speed modems are V.32 and V.32bis, established by the CCITT (the International Telegraph and Telephone Consultative Committee). V.42, established by CCITT, is an example of an error control protocol. V.42bis, established by CCITT, is an example of a data compression protocol.
To establish a connection between two modems, a training signal is typically used. This involves establishing a reference signal in the form of an audio wave form between the two modems in order to synchronize the interfaces. Once synchronization is established, the modems can send and receive data. All subsequent audio wave forms received are compared to the reference signal in the decoding of the digital information. A training signal occasionally needs to be reconfigured after a connection is already established. This occurs to recover from various disruptions such as line outages, bursts of noise on the line, or other such line interference.
The conversion of the digital data from a computer into an audio wave form by the sending modem is accomplished by using the reference wave form. By varying the amplitude and phase of the audio wave form compared to the reference wave form, digital data can be encoded. Different states are assigned to different bits. Amplitude is the loudness of the signal. There may be two or more states for amplitude, such as states loud and soft. Phase refers to the phase angle difference of the audio wave form when compared to the reference wave form. Adding phase states allows more data bits to be encoded. For example, with two amplitudes, and four phases, three bits of data can be encoded. Data bits 000 can be defined as soft, zero degree phase, data bits 001 can be defined as soft, 90 degree phase, data bits 111 as loud, 270 degree phase, etc. The addition of more amplitude and phase states allows additional data to be encoded.
The sending modem converts digital data from the computer system and sends the information across phone lines to another computer system. Occasionally, the computer system fails to send enough data to the modem to keep the line active.
When not enough data is received by the sending modem, the modem typically runs out of data to send and the connection may be lost. A variety of conditions may cause the computer system to fail to send enough data to the modem. For example, the computer may be too busy doing other tasks. Some applications bog down a computer system when large amounts of data need to be transferred causing the bus to exceed bandwidth limitations.
Loss of the communication link can be annoying as well as expensive to a computer user. The connection must be reestablished, transferred data may be lost and must be resent, reconnection costs are incurred including additional toll charges and on-line service charges, and time is lost.
SUMMARY OF THE INVENTION
An improved modem that maintains connections during loss of computer system synchronism is disclosed. The improved modem first detects a loss of synchronism from a computer system by detecting a lack of, or impending lack of, data from the computer system to send. The intelligent modem then notifies the computer system of the condition. The intelligent modem also supplies alternate data to keep the interface active and the connection established until the controller regains synchronization.
A further understanding of the nature and advantages of the present invention may be realized by reference to the remaining portions of the specification and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited advantages and features of the present invention, as well as others which will become apparent, are attained and can be understood in detail, a more particular description of the invention summarized above may be had by reference to the embodiment thereof which is illustrated in the appended drawings, which drawings form a part of this specification. It is to be noted, however, that the appended drawings illustrate only typical embodiments of the invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a block diagram of a system utilized by the present invention.
FIG. 2A is a block diagram of the data sending portion of a prior art modem.
FIG. 2B is a block diagram of the data sending portion of another prior art modem.
FIG. 2C is a block diagram of the data sending portion of a third prior art modem.
FIG. 3A is a block diagram of the data sending portion of a modem implementing the present invention.
FIG. 3B is a block diagram of the data sending portion of another embodiment of a modem implementing the present invention.
FIG. 3C is a block diagram of the data sending portion of a third embodiment of a modem implementing the present invention.
FIG. 4 is a flow diagram of a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 is a block diagram of a system utilized by the present invention. Host A 20 communicates to Host B 50 through the use of Modem A 10 , a telephone network 30 , and Modem B 40 . Host A 10 , typically a computer system, is connected to Modem A 10 via host bus 25 . Host bus 25 is typically a digital bus on a motherboard, such as an ISA or PCI bus, but may also be an internal motherboard connector or an external cable connector. Modem A 10 communicates to Modem B 40 across a telephone network 30 . Modem A 10 is connected to telephone network 30 via local telephone line 15 . Telephone network 30 may include several links into switches, T 1 trunk lines, etc. Modem B 40 is connected to telephone network 30 via local telephone line 45 . Modem B 40 is connected to Host B 50 via host bus 55 .
For Host A 20 to establish a communication link with Host B 50 , Host A 20 instructs Modem A 10 to establish a connection with Modem B 40 . Modem A 10 dials Modem B 40 though the telephone network 30 . Once Modem A 10 and Modem B 40 have synchronized interfaces and established a common communication protocol, Host A 20 sends digital data to Modem A 10 . The digital data is converted into the established common communication protocol and into an audio wave form by Modem A 10 . The audio wave form is sent to Modem B 40 which converts the wave form back into digital data. Modem B 40 sends the digital data to Host B 50 .
FIG. 2A is a block diagram of the data sending portion of a prior art modem. Host interface 110 receives instructions and digital data from a host or computer system across host bus 25 . Host interface 110 typically receives data from host bus 25 in bit, byte (8 bits), word (16 bits), or d-word (32 bits) format. Host interface 110 typically has buffers to store large amounts of data. This enables the host to periodically send large amounts of data to be processed instead of continuously sending smaller amounts.
Host interface 110 sends the digital data to microcontroller 120 . Microcontroller 120 formats the digital data according to a communication protocol. Microcontroller 120 sends the data in protocol format to DSP 130 (Digital Signal Processor). DSP 130 modulates the data according to an established common modulation protocol. The modulated data is sent to CODEC 140 . CODEC 140 converts the modulated data into analog signals in the form of an audio wave form. The analog signals are sent to DAA 150 (Data Access Arrangement). DAA 150 conditions the analog signals for coupling to the telephone line. The conditioned audio wave form is sent to local telephone line 15 . Microcontroller 120 , DSP 130 , CODEC 140 and DAA 150 together form data encoding unit 100 .
FIG. 2B is a block diagram of the data sending section of another prior art modem. In this modem, there is not a microcontroller. The host must send data in protocol format to the modem. Host interface 210 receives data in protocol format from a host or computer system across host bus 25 . Host interface 210 typically receives data from host bus 25 in bit, byte (8 bits), word (16 bits), or d-word (32 bits) format. Host interface 210 typically has buffers to store large amounts of data. This enables the host to periodically send large amounts of data to be processed instead of continuously sending smaller amounts.
Host interface 210 sends the data in protocol format to DSP 230 (Digital Signal Processor). DSP 230 modulates the data according to an established common modulation protocol. The modulated data is sent to CODEC 240 . CODEC 240 converts the encoded data into analog signals in the form of an audio wave form. The analog signals are sent to DAA 250 (Data Access Arrangement). DAA 250 conditions the analog signals for coupling to the telephone line. The conditioned audio wave form is sent to local telephone line 15 . DSP 230 , CODEC 240 and DAA 250 together form data encoding unit 200 .
FIG. 2C is a block diagram of the data sending section of a third prior art modem. In this modem, the data encoding unit 700 consists of a CODEC and a DAA. The host must send modulated data to the modem. Host interface 710 receives data in protocol format from a host or computer system across host bus 25 . Host interface 710 typically receives modulated data from host bus 25 in bit, byte (8 bits), word (16 bits), or d-word (32 bits) format. Host interface 710 typically has buffers to store large amounts of data. This enables the host to periodically send large amounts of data to be processed instead of continuously sending smaller amounts.
Host interface 710 sends the modulated data to CODEC 740 . CODEC 740 converts the encoded data into analog signals in the form of an audio wave form. The analog signals are sent to DAA 750 (Data Access Arrangement). DAA 750 conditions the analog signals for coupling to the telephone line. The conditioned audio wave form is sent to local telephone line 15 . CODEC 740 and DAA 750 together form data encoding unit 700 .
FIG. 3A is a block diagram of the data sending section of a modem implementing the present invention. Host interface 310 receives instructions and digital data from a host or computer system across host bus 25 . Host interface 310 typically receives data from host bus 25 in bit, byte (8 bits), word (16 bits), or d-word (32 bits) format. Host interface 310 typically has buffers to store large amounts of data. This enables the host to periodically send large amounts of data to be processed instead of continuously sending smaller amounts.
Host interface 310 sends the digital data to a first input port of multiplexer 390 . Multiplexer 390 selects data from either of two input ports and sends that data, unchanged, to microcontroller 320 . Microcontroller 320 formats the digital data according to a communication protocol. Microcontroller 320 sends the data in protocol format to DSP 330 (Digital Signal Processor). DSP 330 modulates the data according to an established common modulation protocol. The modulated data is sent to CODEC 340 . CODEC 340 converts the encoded data into alalog signals in the form of an audio wave form. The analog signals are sent to DAA 350 (Data Access Arrangement). DAA 350 conditions the analog signals for coupling to the telephone line. The conditioned audio wave form is sent to local telephone line 15 . Microcontroller 320 , DSP 330 , CODEC 340 and DAA 350 together form data encoding unit 300 .
Detection unit 370 monitors the digital data received by host interface 310 and detects when the host loses synchronism. Loss of host synchronism is indicated by a lack of enough data received from the host needed to keep the communication link between the two modems established. The lack of enough data received from the host causes the buffers in host interface 310 to be empty or almost empty.
When a loss of host synchronism is detected, detection unit 370 notifies notification unit 360 and supply unit 380 of the condition. Notification unit 360 notifies the host of the condition via communication port 365 . Communication port 365 may be an interrupt signal to the host, a read register that the host routinely polls or any other communication method to notify the host of the loss of synchronism. Supply unit 380 provides data to keep the communication link established. Data is sent to a second input of multiplexer 390 .
Data provided is any communication protocol instruction or digital data that does not require the sending of digital data received from the host such that the communication link remains established between two modems. For example, supply unit 380 may supply a training instruction, such that the communication link remains established synchronizing the two modems without having to send data. Supply unit 380 may supply other instructions and data such as an idle signal or a negotiation handshake. By sending such instructions or data to multiplexer 390 and then on to data encoding unit 300 , the communication link is kept active without having to send digital data received from the host. The receiving modem is unaware of the loss of sending host synchronism since the communication link is still active.
When host synchronism is regained, the host will take the necessary steps to continue sending data. This may include completing a handshake operation that supply unit 380 has begun, resetting the interface, or simply supplying host interface 310 with digital data and instructions to send.
FIG. 3B is a block diagram of the data sending section of another embodiment of a modem implementing the present invention. In this modem implementing the present invention, there is not a microcontroller. The host must send data in protocol format to the modem. Host interface 410 receives data in protocol format from a host or computer system across host bus 25 . Host interface 410 typically receives data from host bus 25 in bit, byte (8 bits), word (16 bits), or d-word (32 bits) format. Host interface 410 typically has buffers to store large amounts of data. This enables the host to periodically send large amounts of data to be processed instead of continuously sending smaller amounts.
Host interface 410 sends the data in protocol format to a first input port of multiplexer 490 . Multiplexer 490 selects data from either of two input ports and sends that data, unchanged, to DSP 430 (Digital Signal Processor). DSP 430 modulates the data according to an established common modulation protocol. The modulated data is sent to CODEC 440 . CODEC 440 converts the encoded data into analog signals in the form of an audio wave form. The analog signals are sent to DAA 450 (Data Access Arrangement). DAA 450 conditions the analog signals for coupling to the telephone line. The conditioned audio wave form is sent to local telephone line 15 . DSP 430 , CODEC 440 and DAA 450 together form data encoding unit 400 .
Detection unit 470 monitors the data received by host interface 410 and detects when the host loses synchronism. Loss of host synchronism is indicated by a lack of enough data received from the host needed to keep the communication link between the two modems established. The lack of enough data received from the host causes the buffers in host interface 410 to be empty or almost empty.
When a loss of host synchronism is detected, detection unit 470 notifies notification unit 460 and supply unit 480 of the condition. Notification unit 460 notifies the host of the condition via communication port 465 . Communication port 465 may be an interrupt signal to the host, a read register that the host routinely polls or any other communication method to notify the host of the loss of synchronism. Supply unit 480 provides data to keep the communication link established. Data is sent to a second input of multiplexer 490 .
Data provided is any communication protocol instruction or digital data that does not require the sending of digital data received from the host such that the communication link remains established between two modems. For example, supply unit 480 may supply a training instruction, such that the communication link remains established synchronizing the two modems without having to send data. Supply unit 480 may supply other instructions and data such as an idle signal or a negotiation handshake. By sending such instructions or data to multiplexer 490 and then on to data encoding unit 400 , the communication link is kept active without having to send digital data received from the host. The receiving modem is unaware of the loss of sending host synchronism since the communication link is still active.
When host synchronism is regained, the host will take the necessary steps to continue sending data. This may include completing a handshake operation that supply unit 480 has begun, resetting the interface, or simply supplying host interface 410 with digital data and instructions to send.
FIG. 3C is a block diagram of the data sending section of a third embodiment of a modem implementing the present invention. In this modem implementing the present invention, the data encoding unit 500 consists of a CODEC and a DAA. The host must send modulated data to the modem. Host interface 510 receives modulated data from a host or computer system across host bus 25 . Host interface 510 typically receives data from host bus 25 in bit, byte (8 bits), word (16 bits), or d-word (32 bits) format. Host interface 510 typically has buffers to store large amounts of data. This enables the host to periodically send large amounts of data to be processed instead of continuously sending smaller amounts.
Host interface 510 sends the data in protocol format to a first input port of multiplexer 590 . Multiplexer 590 selects data from either of two input ports and sends that data, unchanged, to CODEC 540 . CODEC 540 converts the encoded data into analog signals in the form of an audio wave form. The analog signals are sent to DAA 550 (Data Access Arrangement). DAA 550 conditions the analog signals for coupling to the telephone line. The conditioned audio wave form is sent to local telephone line 15 . CODEC 540 and DAA 550 together form data encoding unit 500 .
Detection unit 570 monitors the data received by host interface 510 and detects when the host loses synchronism. Loss of host synchronism is indicated by a lack of enough data received from the host needed to keep the communication link between the two modems established. The lack of enough data received from the host causes the buffers in host interface 510 to be empty or almost empty.
When a loss of host synchronism is detected, detection unit 570 notifies notification unit 560 and supply unit 580 of the condition. Notification unit 560 notifies the host of the condition via communication port 565 . Communication port 565 may be an interrupt signal to the host, a read register that the host routinely polls or any other communication method to notify the host of the loss of synchronism. Supply unit 580 provides data to keep the communication link established. Data is sent to a second input of multiplexer 590 .
Data provided is any communication protocol instruction or digital data that does not require the sending of digital data received from the host such that the communication link remains established between two modems. For example, supply unit 580 may supply a training instruction, such that the communication link remains established synchronizing the two modems without having to send data. Supply unit 580 may supply other instructions and data such as an idle signal or a negotiation handshake. By sending such instructions or data to multiplexer 590 and then on to data encoding unit 500 , the communication link is kept active without having to send digital data received from the host. The receiving modem is unaware of the loss of sending host synchronism since the communication link is still active.
When host synchronism is regained, the host will take the necessary steps to continue sending data. This may include completing a handshake operation that supply unit 580 has begun, resetting the interface, or simply supplying host interface 510 with digital data and instructions to send.
FIG. 4 is a flow diagram of an embodiment of the present invention. In operation 610 normal data transmission occurs. This includes setting up a communication link between two modems, establishing a common communication protocol, receiving data from a host, encoding the received data according to the established common communication protocol, and transmitting the data as an analog wave form on a telephone line.
Operation 620 monitors the data received from a host and detects when a data under flow condition occurs. When an under flow is detected, operation 630 notifies the host of the data under flow. In addition, operation 640 provides alternate data to be encoded in substitute for the data from the host. The alternate data provided is typically an instruction or other action that requires no data from the host and keeps the communication link active. For example, a training instruction, an idle signal or a handshake negotiation instruction may be sent. Operation 630 notifies the host of the data under flow via either an interrupt message to the host, setting a condition flag in a readable port that is routinely polled by the host, or any other method of providing the host with notification of the event. When the host regains synchronism in operation 650 , the host will take the necessary steps to continue sending data. This may include completing a handshake operation that operation 640 has begun, resetting the interface, or simply supplying the modem with digital data and instructions to send. The processing returns to operation 610 , normal data transmission.
The modem of the preferred embodiment keeps the communication link between the two modems established. The present invention provides alternate data to keep the link active when there is a data under flow condition in the data received from the host or computer system. The receiving modem and receiving computer system are unaware of the loss of sending computer synchronism.
The present invention saves the computer user frustration, cost and time. When a communication link is lost, the connection must be reestablished and data previously sent may need to be resent. This may incur additional telephone toll charges, additional on-line service charges, and loss of time. When working with an on-line service, the link may not be reestablished immediately due to busy signals, and other on-line service problems.
There is no need for both modems to implement the present invention to gain the benefits of the invention. When the sending modem detects a loss of sending host synchronism, the present invention supplies alternate data to be sent to the receiving modem. The receiving modem and receiving host are unaware of the action and continue processing as normal.
The modem of the preferred embodiment of the invention corrects many types of loss of host synchronism. A computer system performing extensive bandwidth hungry applications such as multimedia applications may temporarily lose synchronism. A computer system may also lose synchronism when changing system parameters requiring reboot while working with an on line service.
Although the present invention has been fully described above with reference to specific embodiments, other alternative embodiments will be apparent to those of ordinary skill in the art. Therefore, the above description should not be taken as limiting the scope of the present invention which is defined by the appended claims.
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An improved modem is disclosed. In a preferred embodiment, the improved modem detects a loss of host synchronism, indicated by an under flow event such as a lack of, or impending lack of data from the host. Normally, the under flow event would result in a lack of data to be sent to a receiving modem, causing a communication link between the two modems to be broken. The improved modem notifies the host of the under flow event and supplies alternate data to the data encoding unit of the modem in order to keep the communication link established. The alternate data supplied is typically an instruction or other action that requires no data from the host and keeps the communication link active. When the host regains synchronism, the host sends data to the modem and normal processing continues.
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This application is related to the following U.S. Patent Applications, which are assigned to the same assignee as the present invention, and which are incorporated herein by reference in their entirety: U.S. patent application Ser. No. 09/473,352 (IRI03914), filed on Dec. 28, 1999, entitled “MEMORYLESS NONLINEAR PREDISTORTION OF DIGITAL AMPLITUDE MODULATION”; U.S. patent application Ser. No. 09/473,174 (IRI03915), filed on Dec. 28, 1999, entitled “METHOD FOR LOCALLY ADAPTED FRACTIONALLY SPACED LINEAR PREDISTORTER”; and U.S. patent application Ser. No. 09/473,457 (IRI03916), filed on Dec. 28, 1999, entitled “LOCALLY ADAPTED PARALLEL T-SPACED LINEAR PREDISTORTER”.
FIELD OF THE INVENTION
The present invention relates to a system and method for predistorting a signal prior to input to an amplifier in order to cancel out memory components introduced prior to input to the amplifier by a filtering effect and, more particularly, to equalization of a postamplifier signal for use only in the predistortion of transmitted signals.
BACKGROUND OF THE INVENTION
Transmitters used in high data rate communication links, such as in certain satellite communications systems typically employ high power amplifiers (HPAs), such as traveling wavetube amplifiers (TWTAs) and solid state power amplifiers (SSPAs),. These types of high speed communication systems typically need a relatively high output power so that the signal being transmitted can travel greater distances before being significantly attenuated. In these types of communication systems, a low frequency digital baseband signal comprising a stream of digital data bits is transmitted after modulation onto a high frequency carrier wave.
Different modulation schemes in the art distinguish the digital bits. Example digital modulation schemes for different applications include amplitude-shift keying (ASK), frequency-shift keying (FSK), binary phase-shift keying (BPSK), quadrature-phase shift keying (QPSK), and quadrature amplitude modulation (QAM). Also, the digital baseband signals may be multilevel (M-ary) signals requiring multilevel modulation methods. Quadrature modulation schemes provide both amplitude and phase modulation of the carrier because both complex and imaginary representations of the signal are used.
In quadrature modulation schemes, such as QAM, each bit is converted to a bit symbol representing a complex value having an in-phase (real) component and a quadrature-phase (imaginary) component. A constellation pattern represents a group of symbols positioned within a circle around the origin of an imaginary axis and a real axis. The distance from the origin represents the amount of power being transmitted. For example, a group of four bits transmitted at a particular time is represented as sixteen (2 4 ) symbols in the circle. Each symbol in the pattern identifies a complex voltage value having an in-phase component and a quadrature-phase component and represents the voltage value for a particular symbol period, which is the time during which each symbol is transmitted. The analog voltage value for each symbol is used to modulate a carrier wave. The symbols in the constellation pattern are geometrically spread so that they are equally spaced apart to more readily distinguish the symbols and reduce bit errors and may be positioned on one or more circles centered about the origin of the constellation pattern. Preferably, the constellation patterns get processed through the transmitter without being distorted so that the bits are readily distinguishable from each other at the receiver end.
High power amplifiers (HPAs) are desirable in high speed communication applications because they provide high gain over wide bandwidths. However, the input signals to a HPA must be controlled because the HPA exhibits non-linear transfer characteristics. At lower input powers, the output-input power relationship of the HPA is approximately linear. However, at peak power output, the HPA saturates and further increases in the input power beyond the saturation point actually decrease the output power of the amplifier.
The non-linearity of the HPA affects the position of the symbols in the constellation pattern by moving them away from the origin. Therefore, it is known to provide amplifier predistortion techniques in the transmitter when the amplifier is being operated in its non-linear range near peak output power. This predistortion approach typically includes using a memoryless mapping function that employs look-up tables that preset the constellation pattern symbols closer to the origin, so that when the signal passes through the amplifier, the symbols are moved towards locations representative of a linear transfer function.
High power amplifiers also include filtering distortions that cause the amplifier to have memory of previous constellation symbols already transmitted. The term “amplifier memory” refers to the effect that the transmission of one symbol or group of symbols has on the transmission of the following symbol or groups of bits. High gain amplifiers introduce AM/AM (amplitude modulation) and AM/PM (phase modulation) distortion as a result of the non-constant envelope nature of the signals that are provided as inputs to the amplifier. Because the data is digitally encoded on a waveform, the pulse shape of the waveform creates artifact portions, where preceding pulses combine to interfere with the particular pulse being sampled. This is known as intersymbol interference (ISI), and requires that the signal pulses be shaped to reduce the memory of the amplifier.
Multiple possible transmission paths of a signal through a transmitter exist for an input signal. A typical input signal into a HPA, such as a TWTA, undergoes a filtering effect by the transmitter hardware before the amplifier. The input signal also experiences filtering effects of the HPA as a result of its memory. Because the amplifier has memory, a symbol can follow different paths, depending on what symbols were transmitted before the current symbol period. The non-linearity of the amplifier distorts the filtered input signal due to its nonconstant envelope. By applying memory predistortion techniques, the ISI of the amplifier can be reduced, thus limiting the distortion.
Locally-adapted linear predistorters typically intend to invert the filtering prior to the HPA (pre-HPA filtering) and ignore filtering after the HPA (post-HPA filtering). The presence of filtering after the non-linearity of HPA will provide a linear signal at the receiver. The receiver equalizer typically suitably removes most filtering with minimal distortion so long as only linear distortion exists. However, post-HPA filtering complicates the linear predistortion by introducing non-linear, memory components to the signal. This non-linear memory interferes with the desired operation of the predistorter algorithm, thus, it is desirable to eliminate the post-HPA filtering to enhance the predistortion.
BRIEF DESCRIPTION OF THE DRAWING
The various advantages of the present invention will become apparent to one skilled in the art by reading the following specification and appended claims, and by referencing the following drawing in which:
FIG. 1 is a schematic block diagram of a transmitter and receiver system arranged in accordance with the principals of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 depicts a block diagram of a communication system 10 for exchanging modulated data signals between a transmitter 12 and a receiver 14 via a communication link 16 , such as a air link or a hard-wired interconnection, arranged in accordance with the principles of the present invention. Transmitter 12 includes a modulator 18 which receives a digital data stream at baseband frequency. Modulator 18 modulates the data stream, utilizing a quadrature amplitude modulation (QAM) format, or other modulation format such as binary phase-shift keying (BPSK), differential phase-shift keying (DPSK), and quadrature phase-shift keying (QPSK), or other known M-ary PSK modulation formats. Modulator 18 modulates the bits onto an analog carrier wave. During modulation, modulator 18 identifies for each bit pattern a symbol that includes an in-phase and quadrature phase component, and maps the symbols into a constellation pattern for transmission. The modulated signal has an analog voltage for each symbol to be transmitted. The modulator 18 can be any suitable quadrature modulator for the purpose described herein, as will be apparent to those skilled in the art.
The modulated signal is input into a predistorter 20 . Predistorter 20 is embodied, in a preferred embodiment, as a programmable filter, as will be described in greater detail herein. Predistorter 20 adds a predistortion signal to the modulated signal, which is an inverse of the distortion introduced by transmitter 12 and modeled as pre-HPA filter 22 . The distortion signal is later cancelled by distortion intentionally introduced by other components of transmitter 12 . Predistorter 20 may be embodied as a fractionally spaced predistorter which performs a plurality of calculations on each symbol so that intersymbol interference (ISI) is introduced at a plurality of locations during a given period. As will be discussed in more detail below, predistorter 20 receives voltage signals from predistorter update system 15 which receives the amplified signal that has been distorted by amplifier system 26 .
Predistorter 20 is an inverse filter that changes the linear combination of various points in the constellation pattern by performing a weighted sum on the points to change the complex voltage value output by modulator 18 . The predistorter 20 can be a linear finite impulse response (FIP) or infinite impulse response (IIP) filter. For example, predistorter 20 can employ a path delay-line digital filter to provide digital filtering. The weighted sum is based on the voltage of previous symbols that have already been transmitted. This inverse filtering adjustment predistorts the constellation pattern representing the complex signal so that when the distortion from amplifier system 26 occurs, the signal actually returns to desirable undistorted state for transmission. In this embodiment, predistorter 20 is positioned after modulator 18 and acts as an analog-type predistorter. However, as will be appreciated by those skilled in the art, predistorter 20 can be a digital predistorter. For example, modulator 18 can output digital symbols that have been modulated, where predistorter 20 operates on digital symbols and a digital-to-analog converter (not shown) after predistorter 20 can provide digital-to-analog conversion. Predistorter 20 outputs a predistorted, modulated signal which is shown as being input into a pre-HPA filter 22 . Pre-HPA filter 22 merely represents the filtering effect of the physical circuitry in transmitter 12 .
The radio frequency (RF) signal from modulator 18 and predistorted by predistorter 20 is at a baseband frequency and must be upconverted to a high frequency for transmission. A mixer 24 upconverts the baseband frequency with a high frequency signal, such as cos(T c t). Mixer 24 converts the in-phase and quadrature-phase representations of the complex voltage from the modulation process to a single high frequency RF signal. The predistortion technique of the present invention can also be done at RF frequency, where predistorter 20 would be located after mixer 24 . The upconverted RF signal is then applied to the amplifier system 26 that significantly increases the power for transmission. The operation of the mixing step and amplification step for a transmitter of this type is well understood to those skilled in the art.
The upconverted, amplified signal from amplifier system 26 has been distorted back to is desirable pattern and is applied to a RF filter 32 for subsequent RF filtering for conforming with Federal Communications Commission (FCC) requirements and then to an antenna (not shown) for transmission. The amplified signal from amplifier system 26 is also applied to an update system 15 from a test point 48 , as will be described herein, following amplifier system 26 . A suitable power coupler (not shown) would be provided at test point 48 to remove a small portion of the high power signal from amplifier system 26 . Any type of suitable power splitter can be used to split the signal at test point 48 to send a portion of the signal to update system 15 .
According to the invention, update system 15 continually provides a voltage signal to predistorter 20 to make adaptive changes to the arrangement of the constellation pattern to invert the filtering caused by amplifier system 26 , which changes over time. It is necessary to continually test the amplified signal because it is not possible to measure the filtering generated by amplifier system 26 .
Amplifier system 26 includes a high power amplifier (HPA) 30 and also includes a filter 28 which represents a memory filtering effect which is a natural by product of operation of amplifier system 26 and, in particular, HPA 30 . HPA 30 may be embodied as a solid state power amplifier (SSPA) or a travelling wave tube amplifier (TWTA). In addition to the filtering effect represented by filter 28 , HPA 30 also introduces a memoryless non-linearity into the RF signal output by amplifier system 26 and input to RF filter 32 .
The signal output by RF filter 32 is broadcast across a channel 34 via communication link 16 . The signal is received at receiver 14 by an antenna (not shown) that applies a signal to a receiver filter 36 . The receiver filter 36 provides initial filtering of the received signal, for filtering channel noise and the like, and is typically closely matched to the transmitted signal. Receiver filter 36 rejects thermal noise and allows optimal reception. A mixer 38 downconverts the RF signal to an intermediate frequency signal by mixing the signal with a high frequency signal cos(T c t). The downconverted signal from mixer 38 includes baseband in-phase and quadrature-phase components. The downconverted signal is applied to low-pass filter 40 to provide filtering at baseband frequencies. Thus, receiver filter 36 typically acts as a course filter, and low-pass filter 40 typically acts as a fine filter.
The filtered baseband signal from low-pass filter 40 is applied to a linear equalizer 42 that removes the ISI from transmission of the signal through channel 34 . Receiver filter 36 and low-pass filter 40 may also generate the ISI. Linear equalizer 42 typically includes a tapped delay line filter, which is known in the art, where the taps are adjusted by a data estimator 44 . Data estimator 44 takes the voltage represented by the in-phase and quadrature-phase values and converts it back to bits. Data estimator 44 can use any suitable algorithm to perform this function, such as a known zero-forcing algorithm. Data estimator 44 measures the symbol locations, and generates an estimate between the actual symbol locations and the desired symbol locations. Thus data estimator 44 provides an error correction between the constellation pattern actually received versus the expected constellation pattern. The equalizer update signal sent from data estimator 44 to linear equalizer 42 provides a filter correction to achieve the desired constellation pattern based on the error of calculation. With particular interest to the present invention, transmitter 12 includes an update system 15 . The low power signal at test point 48 is input to post-HPA equalizer 46 . Post-HPA equalizer 46 functions as an analytic equalizer for the primary purpose of providing a signal for generating predistorter tap weights. This allows for a significantly lower processing rate because the HPA output will have virtually no time-varying responses. In a preferred embodiment, post-HPA equalizer 46 samples data in a burst fashion at test point 48 at intervals which are less than continuous so that such sampling does not significantly reduce the speed of transmitter 12 . A continuous sample approach may also be used.
The post-HPA equalizer 46 and pre-HPA predistorer 20 are adaptive systems. The taps for predistorter 20 are adaptively driven to cause the predistorter 20 to invert the filtering in the system prior to the non-linearity in the HPA 30 while the taps for the equalizer are adapted to cause the post-HPA equalizer 46 to invert the memory after this non-linearity. The filtering or memory in the system can be physically located internal to the HPA 30 or it can be in various parts of the overall system. When both post-HPA equalizer 46 and predistorter 20 are fully adapted to the final solution, the predistorter 20 effectively inverts the memory prior to the non-linearity in the HPA 30 and the post-HPA equalizer 46 inverts the memory after the non-linearity.
In the present invention, the memory of the system is decomposed into two linear parts separated by a memoryless non-linear element. Linear memory or filtering effects can be inverted by linear processing elements by known methods to those skilled in the art. However, inversion of the non-linear memory if taken as a whole is a much harder problem to solve and requires non-linear processing with memory. If the linear predistorter algorithm were operated without the equalizer and related method taught by this invention, then the predistorter would respond to the complete memory of the system.
The linear predistorter correction element that is only capable of inverting the linear memory prior to the non-linearity by the algorithms would see the memory after the non-linearity. Without the post-HPA equalizer 46 of the present invention, the taps generated by the algorithm would not completely invert the memory prior to the non-linearity because of the linear restrictions of the predistorter 20 , but would try to invert the complete memory of the system. The optimum solution for such a linear predistorter 20 is to completely invert the memory it is capable of inverting, and this memory is the memory prior to the non-linearity. By allowing predistorter 20 to respond to the memory after the non-linearity, the predistorter arrives at a sub-optimum solution. The present invention addresses this problem.
The equalizer 46 taught by this invention inverts the memory after the non-linearity and causes the predistorter algorithm to see only the memory prior to the non-linearity. In this sense, the predistorter would operate like it was in a system that did not have any filtering after the non-linearity. Similarly, the predistorter 20 in its adapted state inverts the memory prior to the non-linearity and causes the equalizer to adapt substantially as it would if it were placed in a system that did not have any memory prior to the non-linearity. The decoupling of these two correction elements represents a significant improvement over the prior art because either element placed in the system alone would see the memory of the system on the other side of the non-linearity and would respond to this memory thereby providing a suboptimial solution. It is only when both are operated together that the desired solution for each element is achieved.
When operated together, the post-HPA equalizer 46 and the predistorter 20 adapt such that the memory of the system is eliminated. This result is reached by decomposing the error term normally used in an equalizer update algorithm into a magnitude and phase component. This decomposition effectively decouples the two algorithms such that when operated together, the desired tap solutions are generated.
Error estimator 50 compares the equalized signal received from post-HPA equalizer 46 to an expected signal which represents the output from pre-HPA filter 22 . Error estimator 50 outputs a magnitude error 52 and a phase error 54 . The magnitude error is input to equalizer tap update block 56 . Equalizer tap update block 56 correlates the error to the data and outputs a tap update signal to post-HPA equalizer 46 . Similarly, error estimator 50 outputs a phase error 54 to predistorter tap update block 58 . Predistorter tap update block 58 is embodied as an analog tap delay filter and as such may have bandlimiting. Because the bandlimiting is seen by the algorithm, this bandlimiting would be corrected, and this is a self-correcting feature of the invention. Predistorter tap update block 58 outputs a tap signal to predistorter 20 in order to vary the predistortion introduced by predistorter 20 .
From the foregoing, one skilled in the art will recognize that the communication system 10 provides a novel method for equalization of the post-HPA test point signal for use only in predistortion of transmitted signals. This configuration isolates the predistortion section from post-HPA filtering, which is best removed by receiver-based equalizer algorithms. Further, cancellation of the post-HPA filtering occurs only in the feedback path provided by the post-HPA equalizer. Further yet, such equalization is performed locally at the transmitter and does not involve the receiver 14 .
While specific embodiments have been shown and described in detail to illustrate the principles of the present invention, it will be understood that the invention may be embodied otherwise without departing from such principles. For example, one skilled in the art will readily recognize from such discussion and from the accompanying drawings and claims that various changes, modifications and variations can be made therein without departing from the spirit and scope of the invention as described in the following claims.
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A post-HPA filter rejection equalizer system and method locally equalizes post-HPA filtering. A predistorter ( 20 ) uses a phase error to control the predistortion, and an equalizer ( 46 ) uses a magnitude error to control the equalization. The equalizer samples the HPA output multiple occurrences in a burst fashion. The equalized signal is then used to determine phase and magnitude errors. The phase errors ( 54 ) are used to update the predistorter ( 20 ), and the magnitude errors ( 52 ) are used to update the analytic equalizer.
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FIELD OF THE INVENTION
The present invention pertains to an apparatus for filling containers with a liquid.
BACKGROUND OF THE INVENTION
The filling of containers with soup, juice and other food products has been accomplished by a number of different machines. In general, the containers (e.g., cans, jars, etc.) are moved seriatim along a prescribed path which feeds the containers into and through a filling machine. The containers are then typically transferred to a closing apparatus which applies ends, lids or caps to close the containers.
The filling operation is at times accomplished by individual spouts which direct a liquid from an overhead tank into individual containers (see, for example, U.S. Pat. No. 4,024,896). This construction, however, requires the coordination of a large number of components including even the tank which are raised, lowered and rotated. Other filling machines which involve fewer moving parts have relied upon an elongated stationary tank provided with a weir over which the liquid spills into the passing containers (see, for example, U.S. Pat. No. 4,103,720). In addition, funnels have also been used to direct the liquid from the weir to the containers. For products requiring further processing, the weir, the funnels, and the containers are typically placed in alignment at an incline to ensure the presence of an air bubble within the containers.
The past filling machines have been designed to dispense a specific volume of liquid into a prescribed container. However, there is a need to vary the volume based not only on different sizes of the containers, but also because of the addition of solids to the containers, such as with soups. While the dispensing volume can be varied by adjusting the speed of the containers along the prescribed path, accurate control of the operation across a wide range of volumes has not been possible. As a result, filling machines for soups and the like have generally provided spill tanks beneath the containers to collect the overflow liquid. An overflow of excess liquid can, though, result in solids (e.g., spices, meats, vegetables, etc.) being washed from the container with the liquids. As can be appreciated, this phenomenon reduces quality control of the materials within the containers. Further, due to the presence of solids in the spill tank, the excess liquid cannot be returned to the supply tank for reuse. Consequently, significant waste of the liquid is realized.
Spillage can also occur as the containers are moved from the filling machine to the closing machine. In particular, the containers typically engage and push each other through the filling machine as containers are added to the queue. However, since the closing machine requires separation of the containers, the drive mechanism for the closing machine operates to accelerate the lead container from the following container. This acceleration of the containers can cause some of the contents within the container to be spilled.
Further, as discussed above, funnels are used to direct the liquid from the weir to the container. Generally, the filling machines are continuously run on shifts of about eight hours, at which time the accumulated liquid residue needs to be cleaned from the funnels. Cleaning of the funnels requires the machine to be shut down. As a result, production time is lost not only during the actual cleaning operation, but also during a lag time to bring the machine back up to a steady state flow.
SUMMARY OF THE INVENTION
An apparatus in accordance with the present invention provides a more efficient filling operation with less waste. More specifically, the apparatus includes a plurality of tanks positioned successively along the track supporting the containers. Each tank includes a weir which overlies the track for filling the containers with a liquid. The tanks are selectively fed with the liquid depending on the volume needed in the containers. As a result, the volume of liquid dispensed into each container can be more accurately controlled.
The apparatus of the present invention preferably includes a filling assembly to dispense liquid into the containers and a closing assembly to attach closure elements to close the containers. A single drive mechanism is used to move the containers through the filling assembly and the closing assembly so that spillage during the transition is avoided.
Funnels are provided for directing the liquid dispensed by the weirs into the open tops of the containers. The funnels are oriented vertically and close to the chain drive, even when the containers are inclined. In this way the loads placed on the chain drive for the funnels are lessened, which in turn, increases the mechanism's useful life. In addition, the funnels are passed through a cleaning assembly during a return segment to obviate periodic machine shut downs to clean the funnels and thereby maximize the efficiency of the operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of an apparatus in accordance with the present invention.
FIG. 2 is a top plan view of the apparatus.
FIG. 3 is a top plan view of the tanks of the apparatus.
FIG. 4 is a front elevational view of the tanks.
FIG. 5 is a cross-sectional view taken along line 5--5 in FIG. 3.
FIG. 6 is a partial end elevational view of the filling assembly of the apparatus.
FIG. 7 is a partial top plan view of the funnels and accompanying chain drive of the apparatus.
FIG. 8 is a partial front elevational view of the funnels and accompanying chain drive of the apparatus.
FIG. 9 is a partial end elevational view of the container drive mechanism of the apparatus.
FIG. 10 is a partial perspective view of the funnels passing through the cleaning assembly of the apparatus.
FIG. 11 is a schematic view illustrating the operation of the apparatus.
FIG. 12 is a schematic view illustrating the operation of the filling assembly of the apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An apparatus 10 in accordance with the present invention includes a filling assembly 12 and a closing assembly 14 (FIGS. 1 and 2). Containers 16 (e.g., cans, jars, etc.) having an open end 17 are fed into apparatus 10 (FIG. 6) to be filled with a liquid 15 by filling assembly 12, and closed with an end panel, cap, or lid by closing assembly 14.
A plurality of tanks 18a, 18b, 18c, 18d are provided to dispense liquid 15 into the containers (FIGS. 1-5). Although four tanks are disclosed, a wide range of tanks could be used as desired. The tanks are arranged in a row successively along the front side 20 of apparatus 10. The tanks are each isolated so that the contained liquid does not flow from one tank to another. Each tank 18a-d has a generally parallelepiped shape with a front wall 22, a rear wall 24, a pair end walls 26, 28, and a bottom wall 30 to define an interior cavity 32 (FIGS. 3-5). While the tops of the tanks are open in the preferred construction, covers could be provided if desired.
A supply duct 34 transports the liquid to tanks 18a-d from a vat or the like (not shown), where the liquid, such as soup, juice, or other liquid food product, is stored and/or prepared (FIGS. 1-5). A feed pipe 38 for each tank 18a-d is fluidly coupled to supply duct 34 for directing the liquid into the corresponding tank. A valving system 40 is provided to control the rate of liquid flow through feed pipe 38 and into the corresponding tank (FIGS. 3-5). Feed pipe 38 directs the liquid to a longitudinal distribution pipe 42 which preferably extends across the entire length of each tank. Distribution pipe 42 is provided with a series of spaced apart apertures 44 through which liquid 15 is fed into tanks 18a-d (FIG. 4)
A series of valves 46a, 46b, 46c are provided along the length of supply duct 34 so that tanks 18a-d can be selectively fed with liquid 15 (FIGS. 1-5). Valves 46a-c are opened or closed to permit or preclude liquid 15 from flowing into tanks 18b-d. Specifically, when valve 46a is closed, liquid 15 is fed only to tank 18a. When valve 46a is open but valve 46b is closed, the liquid flows into tanks 18a and 18b. Similarly, when valves 46a-b are open and valve 46c is closed, the liquid flows into the first three tanks 18a-c. Finally, when all of the valves 46a-c are open, all of the tanks 18a-d are fed with the liquid from supply duct 34.
The front wall 22 of each tank 18a-d is provided with a weir 50 which extends across substantially the entire length of the tank (FIGS. 1 and 3-5). Each weir 50 has a lower sloped surface 52 over which liquid 15 spills and flows down to be dispensed into containers 16. Weirs 50 are preferably enclosed with a cover 54, but could be left open as desired. A squeegee element 56 is provided over each weir to prevent surface bubbles and the like from being swept into the containers (FIG. 5).
An endless series of funnels 58 are positioned to pass continuously beneath weirs 50 to ensure that the liquid dispensed from the tanks is received into containers 16 (FIGS. 6-8). Each funnel 58 is provided with an elongate, generally rectangular hopper portion 60 along its upper end. To avoid loss of the liquid, hopper portions 60 overlap with one another along their front and rear ends 62, 64. In particular, the front end 62 of each funnel 58 is cut away on its upper end to receive a rear overhang 66 from the adjacent funnel. The hopper portions of the funnels taper downwardly to form tubular outlets 68 through which the liquid is directed into containers 16.
Each funnel 58 further includes a mounting flange 70 which projects horizontally to connect the funnel to a drive chain 72 (FIGS. 6-8). The drive chain extends about drive sprocket 74 and idle sprocket 76 to direct funnels 58 about filling assembly 12 (FIGS. 2 and 11). As the funnels pass along the front side of filling assembly 12, liquid 15 pouring off one or more of the weirs is collected by hopper portions 60 and directed into containers 16 (FIGS. 6 and 12). One funnel corresponds and travels with one container across the front of the filling assembly. A trough 78 is positioned beneath the funnels as they travel about sprocket 76 and the first segment of the rear side 80 of filling assembly 12 to collect any liquid which drips from funnels 58 (FIGS. 2 and 11).
Following trough 78, funnels 58 pass into a cleaning assembly 82 wherein the funnels are rinsed with a high pressure spray of water or other suitable liquid to clean the residue of the liquid from the funnels (FIGS. 2 and 10-12). In the preferred construction, a spray pipe 84 with a pair of nozzles 86 is positioned about funnels 58 (FIG. 10). A housing 88 is positioned to at least partially enclose the funnels being cleaned. In the preferred construction, housing 88 is secured to spray pipe 84 via a support bar 90. Nevertheless, other arrangements of nozzles and housings could be used.
In the preferred embodiment, cleaning assembly 82 is followed by a drying assembly 92, although the funnels could at times be left to air dry (FIGS. 2 and 12). Drying assembly 92 includes a hood 94 overlying funnels 58 for bathing the funnels in a stream of air. The air is pumped through air duct 96 to the top of hood 94. Although the air could be heated if necessary, air at room temperature is generally sufficient.
Containers 16 are moved with funnels 58 along a track 98 so as to pass beneath weirs 50 (FIGS. 6 and 12). Track 98 is composed of elongate segments which form a continuous path through the filling and closing assemblies 12, 14. Containers 16 are initially fed into apparatus 10 along a horizontal support surface 101. While the containers can be maintained vertically throughout the entire filling operation, the track can be adjusted to set containers 16 at a slight incline (e.g., 5°) as they pass beneath weirs 50 (FIGS. 9 and 12). Track 98 is preferably secured to a stationary bed 103 provided with an arcuate guideway (not shown) for permitting the desired inclination of containers 16 (FIG. 9). The containers are inclined to ensure that a bubble or air space is provided in the container after it is sealed. The air bubble is commonly needed for proper processing of the product after closing. Once containers 16 pass weirs 50, they are again oriented vertically for passage through closing assembly 14. Movement of the containers between the vertical and inclined positions is accomplished by transition segments (not shown) which provide a generally smooth adjustment.
Containers 16 are guided along track 98 by a framework 105 (FIG. 9). Framework 105 includes bars 109 which support elongate horizontal guide rods 111 that extend along the length of the track and engage the sides of the containers. Support bars 109 are adjustable via connectors 113 both vertically and horizontally along posts 115 in order to properly position guide rods 111 to accommodate different sizes of containers. Posts 115 are mounted on bases 117 which, in turn, are connected to track 98. Consequently, framework 105 rotates with track 98.
Despite the rotation of track 98, funnel 15 remains in a vertical orientation. In this way, the funnels can be held closer to chain 121 as compared to the past practice of inclining the funnels with the containers. As a result, smaller moment loads are placed on the chain, which in turn, increases the chain's useful life.
Fingers 118 are provided in an opposed relationship with framework 105 to engage and move containers 16 along track 98 (FIGS. 2, 6, 9 and 11). More specifically, fingers 118 each include an L-shaped base 119 for attachment to a chain 121, and a narrowing projection 123 to engage container 16. As seen in FIG. 2, a gap is defined between each pair of adjacent projections 123 to receive a container. Chain 121 and fingers 118 forms an endless drive mechanism for pushing the containers through filling assembly 12 and closing assembly 14. In the preferred construction, chain 121 is looped about a pair of sprockets 133, 135 at opposite ends 125, 127 of apparatus 10 (FIG. 11). One of the sprockets is driven by a motor (not shown) to move the chain and attached fingers. The upper section 129 of the loop defines a chain drive for moving the containers along track 98 (FIG. 6). The lower section 131 of the loop defines a return path for the chain.
In operation, containers 16 are fed seriatim onto track 98 wherein they are individually engaged by fingers 118 (FIG. 11). Fingers 118 are moved forward by chain drive 121 to advance containers 16 along a preferably straight path defined by the track. As discussed above, the segments of the track underlying weirs 50 are rotated to incline containers 16 (FIGS. 9 and 11). In filling assembly 12, funnels 58 are synchronized to travel with containers 16 between weirs 50 and containers 16.
Apparatus 10 is used to fill containers 16 with a number of different products including soups, juices, fruits, etc. Depending on the ultimate product, containers 16 may at the time they enter apparatus 10 be empty or filled with a variety of solids, such as spices, vegetables, meats, or other ingredients. Accordingly, different volumes of liquid are needed to fill the containers, even when the containers of different runs are of the same size. The number of tanks 18a-d filled during any particular run will depend on the volume of liquid which needs to be dispensed into the containers. For instance, if a large volume of liquid is needed (i.e., if the containers are empty or large) then all the valves 46a-c are opened to fill all four tanks 18a-d with liquid 15 (FIGS. 1-6). In this way, liquid spills over the weirs 50 of each tank 18a-d, through funnels 58, and into containers 16 as the containers travel along track 98. However, if a smaller amount of liquid is required, then one or more of valves 46a-c can be closed to run less than all of the tanks. Under these circumstances, containers 16 will only receive liquid from the tanks in operation. While the containers will still travel beneath the weirs of the unused tanks, they will receive no extra liquid. The control of the volume of liquid dispensed can additionally be fine tuned by adjusting the speed of the chains 72, 121 for the funnels 58 and containers 16.
While unprecedented control in the filling of containers with a wide variety of volumes can be achieved with apparatus 10, a reclaim tank 133 is still positioned beneath containers 16 in filling assembly 12 to recapture any of the liquid which may spill (FIGS. 6 and 12). The spillage, however, is small and thus is not contaminated with solids washed out of the containers. As a result, the recaptured liquids can be recycled to the main vat or the like for reuse in tanks 18a-d (FIG. 12). Reclaim tank 133 also collects any of the liquid which may not be received by containers 16 in a start up or transition phase.
After filling, funnels 58 are rotated about sprocket 76 and fed through cleaning assembly 82 and drying assembly 92 (FIGS. 2, 11 and 12). A trough 78 preferably underlies the funnels as they travel from weirs 50 to cleaning assembly 82 to catch liquid which may drip from the funnels (FIGS. 2 and 11). The liquid caught by trough 78 is preferably recycled to tanks 18a-d to minimize loss of material.
After filling, the containers are moved to closing assembly 14 (FIGS. 1, 2 and 11). Closing assembly 14 is a conventional device for attaching a closure element over the open end 17 of the container. As examples, closing assembly 14 may seam an end panel to a can or attach a lid to a jar in a manner well known to those in the industry. Accordingly, the details of the closing assembly are not herein discussed. In any event, the chain drive 121 functions to continuously move containers 16 at a steady rate along track 98 into and trough closing assembly 14. In this way, the contents of the containers are not spilled during a transitional phase of moving from one assembly to another.
The above discussion concerns the preferred embodiments of the present invention. Various other embodiments as well as many changes and alterations may be made without departing from the spirit and broader aspects of the invention as defined in the claims.
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An apparatus for filling containers with a liquid which includes a plurality of independent tanks positioned successively along a track that supports a series of containers. Each tank includes a weir for dispensing a liquid into the containers. The tanks are selectively fed with the liquid depending on the volume needed in the container. As a result, the volume of liquid dispensed into each container can be more accurately controlled. Funnels are provided for directing the liquid dispensed by the weirs into the open tops of the containers. The funnels are oriented vertically and close to the chain drive, even with the containers inclined, in order to lessen the loads placed on the chain drive for the funnels and thereby increase the mechanism's useful life. In addition, the funnels are passed through a cleaning assembly during a return segment to alleviate the need to shut down the machine to clean the funnels and thereby maximize the efficiency of the operation. The apparatus further includes a filling assembly, a closing assembly and a single drive mechanism for moving the containers through the filling assembly and the closing assembly.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Patent Application Ser. No. 61/759,246 filed on Feb. 31, 2013 entitled “Ambidextrous charging handle for AR style rifles”, the disclosure of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to charging handles for rifles, and more specifically, to an ambidextrous charging handle for use with an AR-15® type rifle that does not use a latch to secure the charging handle to the rifle.
2. Description of the Related Art
Modern repeating firearms utilize a bolt to engage and fire ammunition. The ignition of the ammunition not only fires the bullet, but also causes the bolt to cycle. Most firearms then utilize a system to return the bolt to a firing position, battery, which is usually a mechanical return spring. Sometimes, however, the weapon may experience a minor malfunction, either in the feeding of ammunition or in the return system or some other malfunction, which causes the bolt to jam in a position that does not allow firing. To this end, early charging handles, which were essentially a part of the bolt carrier group itself and cycled with the bolt, were used to return the bolt to firing position. These reciprocating charging handles worked in both directions to retract the bolt and to act as a forward assist, closing the bolt with additional pressure beyond that of the return spring. However, these externally reciprocating parts could cause malfunctions or user injury if accidentally contacted during firing. Hence, non-reciprocating designs, in which the charging handle is separate and will selectively engage the bolt carrier, have become more popular.
Common charging handles are configured as an elongated rod with a rearward handle disposed in a perpendicular orientation with respect to the rod (commonly described as a “T” shape); the handle is grasped and pulled backward, which moves the rod (and the bolt carrier to which it is engaged) in a rearward direction. It is also known within the existing art to provide charging handles with latching mechanisms, commonly called tactical latches, to prevent unintended rearward movement of the charging handle during operation or inspection of the weapon. The forward end of the latch engages the side of the receiver housing, thereby holding the charging handle in position.
Generally, the latch provides a pivoting mechanism held in tension by a spring. The receiver end of the pivoting mechanism features a ramped forward edge which enables the passage of the tensioned latch onto the notched portion of the receiver. Once within the receiver notch, a flattened rear edge of the pivot latch prevents the latch from sliding rearwards, effectively locking the charging handle into the receiver. Once the distal end of the pivoting latch is depressed, the charging handle may be released.
Automatic and semi-automatic rifles, called carbines, are gaining in popularity as a firearm of choice for law enforcement agencies, including police departments of larger metropolitan areas. Agencies have begun a shift from issuing shotguns with multiple projectile rounds to M-16® military and civilian variants able to deliver single projectile rounds with improved accuracy and extended distance. Training officers to properly operate a carbine takes many hours, and the officer has to practice the techniques for handling this new weapon through thousands of repetitions to render the handling techniques habitual and instinctive, which is crucial to enable the officer to respond correctly under stressful situations.
While carbines have certain recognized advantages in different situations, problems have been identified with commonly available charging handles. For example, most charging handles have been designed for right-handed operators; supporting the rifle with the left hand, the operator uses two fingers of the right hand (one on either side of the charging handle rod) to pull backwards on the charging handle in a straight line parallel to the bolt carrier of the rifle, disengaging the latch, and requiring the operator to remove the right hand from the weapon trigger.
Ambidextrous charging handles are known within the art. To ease torsion of the charging handle assembly, manufacturers have taken to adding material to both sides of the charging handle in order for both index and middle fingers to place even linear forces upon the charging bar.
In both single-sided and ambidextrous charging handles, the charging-handle latch must be acted upon in order to release the bolt. This can often be challenging if the firearm has optical devices overriding the charging handle, or limited access to the handle is presented. This task can be even more challenging if the user is wearing gloves, or is situationally compromised such as firing the rifle from a position that prevents access to both sides of the rifle, as when using a tree as a brace for the rifle.
It could be said there exists a need for a latchless ambidextrous charging handle which remains in the forward position unimpeded until use is required. The present invention meets this need by providing the user with a charging handle which sees the standard pivoting latch replaced by a detent ball system, thus allowing the user to release the charging handle easier and more efficiently while still allowing for full retention of the charging handle when not in use.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a latchless charging handle that allows for the charging of a rifle without the need to first release a charge handle latch. The latchless charging handle contains a detent ball assembly that engages a latch pocket on the rifle's upper receiver that acts as the charging handle's latch mechanism. When a rifle operator charges the rifle, the operator exerts a pulling force on the latchless charging handle that causes the detent ball to depress thereby freeing the charging handle from the rifle's upper receiver. When the rifle's bolt returns to battery, the detent ball assembly re-engages the latch pocket on the rifle's upper receiver and secures the charging handle.
Embodiments of the present invention are generally used to cock the hammer or striker of a rifle, but can also facilitate several other functions. The latchless charging handle can be actuated to eject a spent shell casing or an unfired cartridge from a rifle's chamber, load a cartridge from a magazine that has been inserted into the rifle or that has been manually inserted into the rifle's chamber, clear a blockage or jam, allow a rifle operator to visually inspect a rifle's chamber or verify that the chamber is empty of rounds, act as a forward assist and move the rifle's bolt into battery, or release a bolt locked to the rear if a rifle is equipped with a last-round-hold-open feature.
Embodiments of the present invention can be used ambidextrously, by either hand of a rifle operator, from either side of the rifle.
The preceding brief description is intended to merely outline some functions and advantages of the present invention. The following disclosure will set forth other functions and advantages of the present invention along with novel features that distinguish the present invention from the prior art. It is to be understood that the following disclosure is by no means intended to limit the scope of the present invention or any of its embodiments. It is also to be understood that the accompanying illustrations are presented for descriptive purposes only and similarly are not intended to limit the scope of present invention or any of its embodiments. The following disclosure and accompanying illustrations may describe various features of novelty that characterize the invention. The invention does not reside any particular feature when taken in the singular, but in the combination of features as described herein.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a perspective view of an exemplary latchless charging handle as according to one embodiment of the present invention;
FIG. 2 is a top plan view of an exemplary latchless charging handle as according to one embodiment of the present invention;
FIG. 3 is a side elevation view of an exemplary latchless charging handle as according to one embodiment of the present invention;
FIG. 4 is a side detail view of a detent ball assembly and roll pin in a latchless charging handle as according to one embodiment of the present invention; and
FIG. 5 is a rear cross-sectional view of an exemplary a latchless charging handle as according to one embodiment of the present invention.
A further understanding of the present invention can be obtained by reference to a preferred embodiment set forth in the accompanying description. Although the illustrated embodiments are merely exemplary of apparatus for carrying out the present invention, both the organization and construction of the invention, in general, together with further objectives and advantages thereof, may be more easily understood by reference to the illustrations and the following description. The figures are not intended to limit the scope of this invention, but merely to clarify and exemplify the invention.
Certain figures contain labels, measurements, or other alphanumeric indicators. None of the aforementioned are intended to limit the scope of the invention, but are included merely to clarify and exemplify the invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following detailed description, reference is made to the accompanying images that show, by way of illustration, specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. It is to be understood that the various embodiments of the invention, although different, are not necessarily mutually exclusive. Furthermore, a particular feature, structure, or characteristic described herein in connection with one embodiment may be implemented within other embodiments without departing from the scope of the invention. In addition, it is to be understood that the location or arrangement of individual elements within each disclosed embodiment may be modified without departing from the scope of the invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by appended claims, appropriately interpreted, along with the full range of equivalents to which the claims are entitled.
Further, the purpose of the Abstract of the Disclosure herein is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The Abstract is neither intended to define the invention of this application nor is it intended to be limiting as to the scope of the invention in any way.
The word “exemplary” is used 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. Likewise, the terms “embodiment(s) of the invention”, “alternative embodiment(s)”, and “exemplary embodiment(s)” do not require that all embodiments of the apparatus include the discussed feature, advantage or mode of operation. The following descriptions of the preferred embodiments are merely exemplary in nature and is in no way intended to limit the invention, its application, or use.
For the purpose of clarity, all like elements will have the same numbering and designations in each of the images. The terms “latchless charging handle”, “charging handle”, “present invention”, and “invention” may be used interchangeably. In addition to the functions, features, components, and abilities of the apparatus already discussed in this specification, the latchless charging handle may also have, but not be limited to, the following features contained within the description set forth herein.
Several preferred embodiments of the latchless charging handle are discussed in this section. However, the invention is not limited to these embodiments. A latchless charging handle, as according to the present invention, is any charging handle for a firearm that does not utilize a charge handle latch and can be used from either side of the firearm.
Embodiments of the present invention are well-suited for use with rifles designed by Eugene Stoner of the Fairchild ArmaLite Corporation, particularly the AR type of rifles and all derivations thereof including the AR-15® rifle. However, those skilled in the art may readily and easily, without undue experimentation, adapt the present invention for use with other rifle or firearm types.
Referring now to FIGS. 1-5 , that will be discussed together, there are shown views of an exemplary latchless charging handle as according to one embodiment of the present invention. The latchless charging handle comprises a bolt interface ( 100 ) that interfaces with a bolt or a bolt assembly of a firearm, such as a rifle. The bolt interface ( 100 ) is used to retract the bolt of a rifle so that the bolt locks in a rearward position making the rifle ready to accept a cartridge for firing. Once the bolt interface ( 100 ) has moved the bolt to a rearward position, the releasing of the bolt will cause the cartridge to load into the rifle's firing chamber. It should be noted that the bolt interface ( 100 ) can also be used to eject a spent shell casing or unfired cartridge from the rifle's chamber, clear a blockage; jam; misfire; or obstruction, allow the rifle's operator to inspect the chamber, act as a forward assist to move the bolt into battery, or release a bolt locked to the rear if a rifle is equipped with a last-round-hold-open feature.
The bolt interface ( 100 ) is a generally elongated member with an upper surface that is oriented toward the upper side of a firearm when in use. The upper side of the firearm being the surface where the sights or a mounted scope system of a rifle is located. The bolt interface ( 100 ) also has a lower surface that is oriented toward the lower portion of the firearm. The lower portion of the rifle being the area where the trigger or magazine are located. The forward part of the bolt interface ( 100 ) is the area that interfaces with the bolt or bolt assembly of the firearm. In some embodiments of the present invention, the forward part of the bolt interface ( 100 ) directly contacts the bolt or bolt assembly of a firearm. The bolt interface ( 100 ) also has a rear part that is connected, by way of a roll pin ( 103 ) to a charging bar handle ( 101 ). The rear part of the bolt interface ( 100 ) is also the part of the latchless charging handle that contains the detent ball assembly ( 102 ) that secures the latchless charging handle to the firearm.
Other components of the latchless charging handle include a charging bar handle ( 101 ) that is located at the opposite end of the latchless charging handle from the bolt interface ( 100 ) and is connected to the bolt interface ( 100 ), a detent ball assembly ( 102 ), and a roll pin ( 103 ). The charging bar handle ( 101 ) allows a user to grasp and actuate the latchless charging handle. Actuating the latchless charging handle can be done for a plurality of reasons including loading a cartridge into the chamber, clearing the chamber of obstructions or debris, or moving the bolt so the rifle's user can inspect the chamber. The charging bar handle ( 101 ) is positioned and shaped so that a user of either-hand dominance can use the present invention. Furthermore, the charging bar handle ( 101 ) allows users to actuate the latchless charging handle from either side of the rifle. The charging bar handle ( 101 ) does not interfere with a rifle-mounted scope system, if such a system is employed on the weapon.
The charging bar handle ( 101 ) has one or more handholds that extend from the latchless charging handle. The handholds are shaped so that a user can easily actuate the latchless charging handle with their fingers, or palm of their hand. The handholds are roughly concave in shape and extend outward from the centerline of the charging bar handle ( 101 ). Some embodiments of the present invention have two mirror-image handholds in a planar orientation extending out from the center of the charging bar handle, in a “T” formation.
The detent ball assembly ( 102 ) is a ball-and-spring assembly located in the bottom rear portion of the latchless charging handle. The detent ball assembly ( 102 ) is the mechanical arrangement of the present invention that holds the latchless charging handle in a fixed position relative to the rifle. The detent ball assembly ( 102 ) prevents unwanted sliding of the latchless charging handle when the charging handle is not actuated by a user.
The detent ball assembly ( 102 ) comprises a detent ball ( FIG. 4 , ( 104 )) residing within a bored detent ball assembly cylinder ( FIG. 4 , ( 105 )) that is held in place by the pressure of a spring also residing within the detent ball assembly cylinder ( FIG. 4 , ( 105 )). The detent is a portion of the detent ball assembly cylinder ( FIG. 4 , ( 105 )) that is of a smaller diameter than the detent ball ( FIG. 4 , ( 104 )) that prevents the ball from exiting the detent ball assembly cylinder ( FIG. 4 , ( 105 )) due to the pressing force of the spring. When a user actuates the latchless charging handle, the additional pressure of the user retracting the charging handle causes the detent ball ( FIG. 4 , ( 104 )) to depress into the detent ball assembly cylinder ( FIG. 4 , ( 105 )), compressing the spring. When the charging handle is returned, the detent ball ( FIG. 4 , ( 104 )) engages with a latch pocket on the rifle's upper receiver. The latch pocket forms a recess that allows the detent ball ( FIG. 4 , ( 104 )) to protrude from the detent ball assembly cylinder ( FIG. 4 , ( 105 )), due to the spring pressure, and acts as the charging handle's latch mechanism. The use of a detent ball assembly ( 102 ) instead of a traditional charging handle latch provides greater clearance between the present invention and the rifle. A mounted scope system can be installed on the rifle without concerns of interfering with the action of the charging handle.
A roll pin ( 103 ) is used to connect the charging bar handle ( 101 ) to the bolt interface ( 100 ). The roll pin ( 103 ) is a mechanical fastener having a cylindrical pin passing through a hole in the charging bar handle ( 101 ) and the bolt interface ( 100 ). The pin is slotted to allow for some flexibility during insertion. It should be noted that some embodiments of the present invention may use a spring pin in place of the roll pin ( 103 ) as the mechanical fastener that connects the charging bar handle ( 101 ) to the bolt interface ( 100 ).
A gas tube hole ( FIG. 5 , ( 106 )) is bored through the bolt interface ( 100 ) that directs combusted powder gases to cause operation of a rifle's bolt or bolt assembly within the receiver. When a cartridge is fired, the gases produced by the burning powder are directed through the gas tube hole ( FIG. 5 , ( 106 )) to exert a rearward force upon a rifle's bolt carrier that results in the unlocking of the bolt and movement of the bolt to a rearward, open position. The direction of the gases through the gas tube hole ( FIG. 5 , ( 106 )) to the bolt is necessary to cycle the next cartridge and continue the firing operations of the rifle.
Some embodiments of the present invention contain components that are manufactured by the Computer Numerical Control (CNC) machining of metallic materials. Particularly, in some embodiments of the present invention, the bolt interface ( 100 ) and charging bar handle ( 101 ) are CNC machined from billet aluminum and are hard anodized and colored per military specification MIL-A-8625 type 3 class 2 black. In these or other embodiments of the present invention, the roll pin ( 103 ) and detent ball assembly ( 102 ) may be made of the same or different materials. Furthermore, other embodiments of the present invention may use different grades of aluminum, varying grades of steel, or other anodizing and coloring methods as required for the particular application. One skilled in the art can vary the method of manufacture and material used to form the components without undue effort or experimentation.
As set forth in this description and the attached images, a new latchless charging handle has been developed that improves upon conventional charging handles. The various embodiments of the improved latchless charging handle described herein can be used in a wide variety of applications.
The preceding exemplary embodiments are not intended to be limiting, but are merely illustrative for the possible uses of the latchless charging handle.
Although certain example apparatus and articles of manufacture have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all apparatus and articles of manufacture fairly falling within the scope of the invention either literally or under the doctrine of equivalents.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the components of the latchless charging handle, to include variations in size, materials, shape, form, function and the manner of operation, and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the images and described in the specification are intended to be encompassed by the latchless charging handle.
Directional terms such as “front”, “back”, “in”, “out”, “downward”, “upper”, “lower”, “top”, “bottom”, “lateral”, “vertical” and the like have been used in the description. These terms are applicable to the embodiments shown and described in conjunction with the images. These terms are merely used for the purpose of description in connection with the images and do not necessarily apply to the positions in which the latchless charging handle may be used.
Therefore, the foregoing is considered as illustrative only of the principles of the latchless charging handle. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the latchless charging handle to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the latchless charging handle. While the above description describes various embodiments of the present invention, it will be clear that the present invention may be otherwise easily adapted to fit any configuration where a latchless charging handle is desired or required.
As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying images shall be interpreted as illustrative and not in a limiting sense.
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A latchless charging handle that allows for the charging of a rifle without the need to first release a charge handle latch is provided herein. The latchless charging handle contains a detent ball assembly that engages a latch pocket on the rifle's upper receiver and acts as the charging handle's latch mechanism. When a rifle operator charges the rifle, the operator exerts a pulling force on the latchless charging handle that causes the detent ball to depress thereby freeing the charging handle from the rifle's upper receiver. When the bolt returns to battery, the detent ball assembly re-engages the latch pocket on the rifle's upper receiver and secures the charging handle.
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BACKGROUND
The invention relates generally to signal processing, and more particularly to systems and methods used in the transformation of image signals between the analog and digital domains to aid in image signal processing.
Signal processing is a valuable tool for various applications that involve data transmission, data storage, and the like. One aspect of signal processing, for certain applications, is to convert an analog signal into its digital equivalent to facilitate storage, transmission, workability, signal conditioning, noise filtering, and the like. For example, a digital X-ray panel may convert a scanned X-ray image into a digital format for subsequent processing, storage and image reconstruction.
Various signal processing techniques exist that provide transformation of image signals between the analog and digital domains. One such method for performing analog-to-digital (A/D) signal conversion utilizes a single digital-to-analog converter (DAC) for providing a base analog signal for comparison to an input analog signal that requires conversion.
Although such a method provides high accuracy, one disadvantage with A/D conversion using a single DAC is that the process is slow. This is because each input analog signal is converted individually into a digital equivalent by a dedicated channel, and all the channels are driven by the same DAC. The counter that provides a digital count to the DAC, therefore, has to run from the lowest count to the highest count before all channels perform conversion of each input analog signal into digital equivalents.
Attempts have been made to increase the speed of A/D conversion process. One method of increasing the speed is by increasing the number of DACs so that each channel has a dedicated DAC. However, such a method may not be cost effective in certain applications. For example, a digital X-ray panel using a single DAC for A/D conversion process has a speed of 30 frames per second (fps), which may not be suitable for applications requiring higher frame rate. The speed may be improved by increasing the number of DACs. However, due to the increase in cost and complexity of the additional circuitry, such a digital X-ray panel becomes prohibitively expensive and complex.
There is therefore a need for a system and method to improve the speed of A/D conversion process.
BRIEF DESCRIPTION
According to one aspect of the present technique, a system and a method for converting an analog signal to a digital signal are provided. The technique includes receiving a sampled analog signal, and selecting one of a plurality of segments of a segmented relation between DAC output values and desired ADC input values. Desired gain and offset values are applied to the DAC output values or to the sampled analog signal based upon the selected segment. The sampled analog signal is then converted to a digital signal based upon the desired gain and offset values. The system and method may be implemented in digital X-ray systems.
DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
FIG. 1 is a diagrammatic view of an exemplary digital X-ray system, in which signal conversion is implemented in accordance with aspects of the present technique;
FIG. 2 is a diagrammatic view of an exemplary digital X-ray panel of a type that may be used in a system such as that of FIG. 1 for generating analog signals to be converted to digital signals in accordance with aspects of the present technique;
FIG. 3 is a diagrammatic view of an exemplary digital acquisition system for the digital X-ray panel shown in FIG. 2 ;
FIG. 4 is a diagrammatic view of an exemplary system shown in FIG. 3 , in accordance with aspects of the present techniques;
FIG. 5 is a graphical view of a path followed by the DAC output signal, illustrating a segmentation process in accordance with aspects of the present technique;
FIG. 6 is a diagrammatic view of an exemplary embodiment of the system shown in FIG. 3 in accordance with aspects of the present technique;
FIG. 7 is a detailed diagrammatic view of the architecture of the system shown in FIG. 6 ;
FIG. 8 is a diagrammatic view of an exemplary memory stack utilized in the digital acquisition system in accordance with aspects of the present technique;
FIG. 9 is a graphical illustration of the segmented linear-polynomial path followed by the DAC output signal in accordance with aspects of the present technique; and
FIG. 10 is a flowchart illustrating an exemplary digital signal conversion process in accordance with an exemplary embodiment of the invention.
DETAILED DESCRIPTION
In the subsequent paragraphs, various aspects of a technique for signal conversion will be explained in detail. The various aspects of the present technique will be explained, by way of example only, with the aid of figures hereinafter. Referring generally to FIG. 1 , the present technique for conversion of analog signals to digital signals will be described by reference to an exemplary digital X-ray system designated generally by numeral 10 . It should be borne in mind, however, that the technique may find application in a range of settings and systems, and that its use in the X-ray system shown is but one such application.
The digital X-ray system 10 of FIG. 1 is operable to capture an X-ray projection of a portion of the body of a subject 12 under medical examination. However, as will be appreciated by those skilled in the art, the digital X-ray system 10 may also be utilized for non-destructive evaluation (NDE) of materials, such as castings, forgings, or pipelines, inspection of parts, parcels and baggage, and other such applications. The digital X-ray system 10 comprises an X-ray source 14 that is used to scan the subject 12 . The X-ray source 14 generates X-ray beams that penetrate through the subject 12 . In a typical medical application, the X-ray beams may be attenuated based on the texture of the organs, skin, lesions, muscle, bones and the like, in the various portions of the body of the subject 12 . The attenuated X-rays are captured by a digital X-ray panel 16 , as illustrated in FIG. 1 , which comprises a plurality of photodiodes that form a pixel array. The projection thus formed, is read row-by-row or column-by-column by one or more data modules 18 , where each line of pixels may be enabled for scanning, by one or more scan modules 20 . Control circuitry 22 is used to control the operation of the data modules 18 and the scan modules 20 .
FIG. 2 is a diagrammatic view of an exemplary digital X-ray panel 16 . The digital X-ray panel 16 comprises a plurality of rows 24 , each of which contains a plurality of photodiodes defining the pixels 26 arranged contiguously to form a pixel matrix or a pixel array. During operation of the X-ray panel 16 , received X-ray radiation is converted to a lower energy form, and each of the photodiodes 26 has an initial charge that is depleted by an amount representative of the amount of X-ray radiation incident on the respective location of each photodiode 26 . The data modules 18 are operable to read the amount of charge from each of the photodiodes 26 . Each row 24 is scanned by the data modules 18 in conjunction with the scan modules 20 to read the amount of charge from all the pixels 26 in that row 24 (or column). The scan module 20 corresponding to a row 24 enables reading the pixels 26 in that row 24 . When the pixel 26 is enabled for reading, the data module 18 corresponding to that pixel 26 reads the charge stored on the photodiode or pixel 26 by recharging the photodiode. Having read the charge value from the plurality of photodiodes 26 , the data module 18 converts the charge value into a digital equivalent for further processing.
Turning now to FIG. 3 , a diagrammatic view of an exemplary digital acquisition system 28 for the digital X-ray panel 16 of FIG. 2 is illustrated. The digital acquisition system 28 comprises an analog readout chip (ARC) 30 , which comprises circuitry for reading the charge from (in practice the recharge to) the photodiodes 26 in the X-ray panel 16 . The ARC 30 processes and digitizes the charge from the photodiodes 26 . Detailed functionality of the ARC 30 will be explained later in the description. For facilitating digitization of the charge from the photodiodes 26 , a digital-to-analog converter (DAC) 32 may be utilized. Driven by a counter, the DAC 32 provides a DAC output signal for circuitry in the ARC 30 to compare the charge values read from the photodiodes 26 . The DAC output signal may define a linear portion and a polynomial portion, such as a linear portion, a quadratic portion, a cubic portion, and the like. The DAC output signal will be explained in further detail below.
In accordance with the present technique, the DAC output signal may be divided into segments to improve the speed of scanning an entire row 24 of pixels 26 and, consequently, the overall speed of digitizing the X-ray image. Therefore, a segment that comprises the location of charge value (input signal) may be desirably located. For locating a segment, segment-gain information may be required, which may be provided by a programming element 34 . Moreover, other programmable options, such as dynamic bandwidth control and the data readout may be set by the programming element 34 . A data logger 36 collects the digitized data from the ARC 30 and transmits the data to digital circuitry for image processing and reconstruction of a useful image.
FIG. 4 is a diagrammatic view of the exemplary ARC 30 shown in FIG. 3 , in accordance with aspects of the present techniques. ARC 30 comprises a plurality of channels 38 , each being operable to read the charge value from a photodiode or pixel 26 and to provide the digital equivalent. The DAC 32 is common to all the channels 38 , so that the DAC 32 provides the DAC output signal to each of the channels 38 , which respectively compare the charge value with the common DAC output signal. An input signal 40 , comprising a charge value from a photodiode or pixel 26 , is provided to the channel 38 , as illustrated. Each channel comprises an integrator 42 , which integrates the input signal 40 (charge value Q in ) for conversion into an equivalent voltage value, V int , which is fed into a low-pass-filter 44 for reducing noise. Voltage signal outputted from the low-pass-filter 44 , V lpf , is fed into a double sampling amplifier 46 , which provides a desirable gain to V lpf . The output of the double sampling amplifier 46 , V dsa , is sampled and held in sample and hold (S/H) circuitry 48 . The double sampling amplifier 46 in conjunction with the low-pass-filter 44 provides correlated double sampling process to reduce offset and flicker noise. Integrator 42 , low-pass-filter 44 , and double sampling amplifier 46 together form an analog front-end. The analog front-end may therefore be decoupled from the rest of the channel 38 by the S/H circuit 48 . Pipelined conversion is thus achieved by the use of the S/H circuit 48 .
The output of the S/H circuit 48 , V sh , and the DAC output signal provided by the DAC 32 may be fed as input into a comparator 50 for comparison. The comparator 50 provides either a high or a low output based on the comparison of V sh and the DAC output signal provided by the DAC 32 . The channel 38 also comprises a register 52 , which is provided with a counter value from a counter 54 . The counter value provided by counter 54 is proportional to the digital code provided to the DAC 32 for generating the DAC output signal. The output of the comparator 50 may be configured to freeze the counter value in the register 52 when the output of the S/H circuit 48 and the DAC output signal provided by the DAC 32 are equal. Because the counter value provided to DAC 32 and register 52 are proportional, the frozen counter value in the register 52 is representative of the digitized output of the input signal (charge value) of the corresponding pixel 26 read by channel 38 .
A state machine 56 may be utilized to synchronize the counter 54 and the count value provided to the DAC 32 at any instant. It may be noted that the integrator 42 , low-pass-filter 44 , double sampling amplifier 46 , S/H circuit 48 , comparator 50 and register 52 comprise a single channel 38 that reads a single photodiode or pixel 26 . In one embodiment, there are thirty-two different channels 38 hard-wired into a single ARC 30 . DAC 32 is common to the entire system. Counter 54 , and state machine 56 , however, are separate components, within the ARC 30 that are common to all thirty-two channels 38 . Each of the data modules 18 , described previously with reference to FIG. 2 , may comprise eight analog readout chips 30 , and a single digital analog readout chip. Therefore, each data module 18 can read and digitize 256 pixels simultaneously. Thus, if a row of 1024 pixels 26 has to be read simultaneously, 4 (=1024/256) data modules 18 may be employed. Detailed operation of the ARC 30 will be explained below.
Referring now to FIG. 5 , a graphical illustration 58 of a path followed by the DAC output signal is shown. The illustration 58 shows the output signal values, in counts, on the y-axis 60 plotted against ramp counter values on the x-axis 62 . The ramp counter value 62 is proportional to the digital code values that are fed into the DAC 32 for generating the DAC output signal that follows a linear-polynomial ramp 64 . Therefore, the DAC output signal increases in steps or counts. The linear-polynomial ramp 64 defined by the DAC output signal begins with a linear portion 66 until a desirable ramp counter value C. Beyond ramp counter value C, the ramp may advantageously define a polynomial portion 68 for improvement of signal-to-noise ratio of the digital output of the scanned X-ray image.
Quantum noise is the noise intrinsic to an X-ray image. The amount of quantum noise produced by an X-ray beam is equal to the square root of the number of X-rays incident on the detector 16 . Therefore, at high X-ray flux, the system may be prone to more quantum noise and relatively less electronic noise. Advantageously, quantization step can made proportional to the quantum noise, without any loss of information. In other words, when the signal is small, small steps may be employed, and when the signal is large, step size may be increased.
In one specific embodiment, the linear-polynomial ramp 64 may define a linear portion 66 followed by a quadratic portion 68 , and may be therefore termed as a linear-quadratic ramp. Furthermore, the polynomial portion 68 may define a cubic curve, or other polynomial curves that may be advantageously employed. The particular relationship between the input and output (count) values may follow other profiles and relations in other applications. Moreover, the segmentation of the relationship, as described below, may result in more or fewer segments than those described here, and will typically result in different offsets and gains (slopes) for each segment, also as described below.
Referring back to FIG. 4 , the output of the S/H circuit 48 is provided to the comparator 50 . The value of the DAC output signal (initially zero) is checked against V sh . If the DAC output signal at that instant is not equal to the output of the S/H circuit 48 , the ramp counter value that provides counts to the DAC 32 and the register 52 is increased to the next count value. The linear-polynomial relationship (linear-quadratic, linear-cubic, etc.) between the ramp counter and the digital code may be appropriately implemented based on the applications. For example, for the linear portion, the ramp counter and the digital code to the DAC may be equal. Beyond a certain ramp counter value, e.g. C in FIG. 5 , the relationship may be polynomial. The ramp counter in FIG. 5 and the counter 54 in FIG. 4 increment linearly. However, the digital code provided to the DAC 32 and the resulting analog signal will be linear-polynomial. When the DAC output signal becomes equal to V sh , the comparator 50 provides a signal that freezes the counter value residing in the register 52 . Therefore, the register 52 contains a digital value corresponding to the input signal from the respective channel (i.e., the charge value for the photodiode or pixel 26 of FIG. 2 in the X-ray system implementation). By applying the relationship between the DAC digital code and the ramp counter value, an equivalent DAC digital code to the counter value yields the charge value stored on the photodiode 26 .
Those skilled in the art will appreciate that if the maximum possible value of the output of S/H circuit 48 is divided by a greater number of total counts (i.e. a finer comparison), the resolution of the digital output corresponding to the input signal will be increased. For example, if the maximum value attained by the output of S/H circuit 48 is 5 volts, and the total number of counts that may be provided to the DAC 32 is 1024, the step size of the ramp counter value will be 5/1024. However, if the total number of counts that may be provided to the DAC 32 is 2048, the step size of the ramp counter value will be 5/2048, which, being smaller, provides higher resolution. Also, for digitizing a signal in the higher range (e.g., 5 volts) at the S/H circuit 48 , about 2048 steps may have to be provided to the DAC 32 . Furthermore, if the signal to be digitized is greater (e.g., 10 volts), then to produce the desired resolution, more number of steps (ramp counter values) may be required.
In the X-ray system implementation described above, because the thirty-two different channels 38 are provided with the same DAC output signal that is used for comparison in each of the channels 38 , and given that these different channels 38 may have different charge values to be compared, the DAC 32 may provided for all the counts from minimum to the maximum count. The amount of time required for the whole image to be digitized is therefore limited by the time taken for the DAC 32 to traverse from the minimum to maximum count. Therefore, this may limit the frame rate of scanning the digital X-ray panel. However, by using the linear-polynomial ramp 64 , it will be understood that much fewer than 2048 steps may be needed to dynamically cover the range of 5 volts.
The graphical illustration 58 further shows a segmentation process for achieving a higher signal conversion rate. Segmentation may be achieved by using the generally linear portion 66 , and transforming it to generate portions of the polynomial portion 68 . In other words, counter values provided to the DAC 32 follow a linear ramp, until the ramp counter value C, hereinafter referred to as the base ramp 66 . The base ramp 66 is common to the entire ramp 64 . The remaining portions of the curve 64 may be generated within the ARC 30 on a channel-by-channel basis by applying gain and offset values to the base ramp 66 .
Moreover, while digitizing the input signal 40 , the ARC 30 may coarsely compare V sh against ramp count values C, 2C, 3C, 4C, and 5C. If the comparator 50 on a given channel actuates (i.e., changes output state) on application of any of the above ramp count values, such actuation is indicative of V sh lying in the segment ending that ramp count value. For example, at 2C if the comparator 50 does not actuate, and at 3C, the comparator 50 actuates indicating that V sh is less than 3C, then the coarse A/D conversion registers that the output of S/H circuit 48 lies between the counts 2C and 3C, or in segment 72 . The base ramp 64 received by this particular channel 38 is manipulated by applying gain and offset values to recreate the segment 72 . Once a segment is identified as having the digital equivalent of the output of S/H circuit 48 , then a fine A/D conversion similar to that described previously with respect to linear-polynomial ramp 64 , may be performed. For example, the counts between 2C and 3C are compared against the output of S/H circuit 48 , such that the counts follow the path defined by segment 72 . Such an auto-ranging process enhances the speed of A/D conversion. It may be noted that any of the segment to be traced could be generated using a base ramp 66 and by adding an offset and multiplying by a gain value. This may be performed to achieve the desired linear portion in the corresponding segment, which has the desired starting value and slope. In general, then, a segment i can be described by the following equation:
V( i )=V offset ( i )+Gain( i )*V base
where, V(i) is the desired output voltage for comparison in segment i; V base is the base voltage of linear portion 66 ; Gain(i) is the gain value, which is multiplied to base voltage V base to transform V base to the desired slope in segment i; V offset (i) is the desired offset voltage that is added to Gain(i)*V base to reach segment i.
It will be understood by those skilled in the art that the base ramp, which in the above example is the generally linear portion 66 of the linear-polynomial ramp 64 , may lie in any of the segments. In other words, if the generally linear portion 66 lies in the middle of the linear-polynomial ramp 64 , then the offset voltage V offset (i) corresponding to a segment i in the left of the base ramp would be negative.
Referring now to FIG. 6 , a diagrammatic view of an exemplary embodiment of the ARC 30 of FIG. 3 is illustrated. The charge value Q in 40 from the detector 16 is converted to a voltage by the integrator 42 . The output of the integrator 42 is fed to a low-pass-filter 44 and amplified by the double sampling amplifier 46 . A coarse A/D conversion is performed by block 80 to determine a suitable segment. After being processed by block 80 , the output comprises a digital equivalent of the segment information. This segment information may comprise one or more bits indicating the segment. The bits also form the exponent of the digital output of the charge value Q in 40 . Based on the segment information, appropriate gain Gain(i) and offset values V offset (i) may be selected by a gain/offset selector 82 . Once the gain and offset values are selected, appropriate gain values are provided, such as gain G int to integrator 42 , gain G dsa to double sampling amplifier 46 , gain G s to S/H circuit 48 , and gain G p to a fine A/D conversion block 84 . The gain/offset selector 82 therefore manipulates the base ramp 66 from the DAC 32 by applying gains G int , G dsa , G s , G p and V offset (i) to generate the i th segment. The offset voltage V offset is generated by an offset multiplexer 86 . The signal gain of channel 38 may therefore be defined by G channel =G int *G dsa *G s . The transposed signal is then sampled and held by the S/H circuit 48 before being digitized by the fine A/D conversion block 84 to provide the mantissa. The segment offsets and references for both coarse and fine ADC are generated by time division multiplexing of the DAC, and, pipelining the charge value Q in 40 in the S/H circuit 48 .
The output of the fine A/D conversion block 84 comprises the mantissa of the digital value. Thus, the digitized signal corresponding to the charge value Q in 40 comprises the segment information from block 80 and the output of the fine A/D conversion block 84 .
FIG. 7 is a detailed diagrammatic view of the architecture of ARC 30 , shown in FIG. 6 . The charge value Q in 40 from the detector 16 is fed to the integrator 42 comprising an integration capacitor 88 in a feedback loop of an amplifier 90 . In addition to storing the charge value Q in 40 temporarily, the integrator 42 may serve to convert the charge value Q in 40 into a voltage equivalent. It may be noted that the low noise integrator 42 is reset each time prior to reading a fresh charge value Q in 40 so as to remove any charge stored in the capacitor 88 . This voltage is fed into the low-pass-filter 44 , which comprises a tunable resistor R 92 , and tunable capacitors C b 94 and C ds 96 . Because resistor R 92 , and capacitors C b 94 and C ds 96 are tunable, the low-pass-filter 42 may be utilized to dynamically change the low-pass-filter bandwidth of the channel 38 during A/D conversion to obtain faster settling times and lower noise effective bandwidth.
The double sampling amplifier 46 , comprising an integration capacitor 98 in a feedback loop of an amplifier 100 , amplifies the output of the low-pass-filter 44 . The double sampling amplifier 46 may be a correlated double sampling amplifier, for removing any reset-offset pedestal, as well as any kTC and reset noise of the integrator 42 .
The output of double sampling amplifier 46 is sampled and held on a capacitor C sh 102 , in the S/H circuit 48 , at the input of the comparator 50 . Digitization is achieved by disabling the parallel load of the counter value provided to the register 52 when the linear-polynomial ramp 64 exceeds the value held on the sample and hold capacitor C sh 102 . The resulting conversion is transmitted via one of eight serial outputs (four channels per serial output) in a simultaneous fashion, thereby allowing transmission of digital data from all the thirty-two different channels 38 simultaneously. Pipelined conversion is facilitated by the S/H circuit 48 . Integration, conversion and transmission are pipelined in consecutive Sync cycles, which comprise the reading cycles. The dynamic range of the system may be further extended by providing a bank of integration capacitors 86 .
Because charge value Q in 40 is compared to the linear-polynomial ramp 64 during the fine ADC, therefore either the linear-polynomial ramp 64 or the charge value Q in 40 may be manipulated. Alternatively, both the linear-polynomial ramp 64 and the charge value Q in 40 may be manipulated. If the linear-polynomial ramp 64 is manipulated to generate a segment, which encompasses the charge value Q in 40 , then the gain of the linear-polynomial ramp 64 may be changed by changing G p alone, and applying an offset V offset (i) to implement equation V(i)=V offset (i)+Gain(i)*V base .
The linear-polynomial ramp 64 can be created by alternatively using a switch selectable capacitor bank having capacitors C 1 , C 2 , and C 3 (not shown) instead of capacitor C dac 104 prior to the comparator 50 . Once the gain/offset selector 82 , selects the gain value Gain(i) and the offset value V offset , the offset value V offset provided by the offset multiplexer 86 may be applied through a capacitor, C os 106 . However, changing only gain G p of the linear-polynomial ramp 64 to generate the segment may cause C dac 104 to become extremely large for implementation of all gains. Advantageously, gain decomposition may be implemented for changing gain G p of the linear-polynomial ramp 64 . The ramp based fine A/D conversion compares the charge in the capacitors C 1 -C 3 . Capacitor C 1 may be the same as C dac 104 in gain decomposition implementation and provides an amplified version of the base ramp 66 . Capacitor C 2 , which may be the same as C sh 102 , contains the sampled and held signal from the double sampling amplifier 46 . The offset V offset is applied using C 3 , which may be the same as C os 106 . The voltage V X at node 108 is given by:
V X = G * V ramp * C 1 + V offset * C 3 - V signal * C 2 C 1 + C 2 + C 3 Therefore ,
V X = G C 1 + C 2 + C 3 * [ V ramp * C 1 + V offset G * C 3 - V signal * C 2 G ] .
When the voltage V X at node 108 transitions from positive to negative, or vice-versa, comparator 50 trips (i.e., is actuated) because the charge in C 1 (=C dac ) exceeds the charge from C 2 (=C sh ) and C 3 (=C os ). The equation can be rewritten as decomposition of a single channel gain G channel distributed into gains of integrator 42
( A int = 1 G int ) ,
double sampling amplifier 46
( A dsa = 1 G dsa ) ,
S/H circuit 48
( A s = 1 G s ) ,
and gain G p , as follows:
V X = A int * A dsa * A s C 1 + C 2 + C 3 * [ G p * V ramp * C 1 + V offset A int * A dsa * A s * C 3 - V signal * C 2 A int * A dsa * A s ]
where A int , A dsa , A s are the attenuation factors applied to reduce the gain of integrator 42 , double sampling amplifier 44 , and sampling capacitor ratio C sh 102 , respectively. Consequently, the actual channel gain changes from the original
G
channel
=
G
int
*
G
dsa
*
G
s
to
G
channel
=
(
G
int
A
int
)
*
(
G
dsa
A
dsa
)
*
(
G
s
A
s
)
.
The gain values G int , G dsa , G s , and G p may be implemented as switch selectable capacitor banks, C int 88 , C dsa 96 , C s 102 , and C dac 104 . The offset may be implemented by applying V offset through capacitor C os 106 at either node 108 or 110 . By choosing node 110 , a single capacitor bank implementing the gain of the double sampling amplifier 46 manipulates both the signal and offset optimally. Therefore, the gain of the channel changes as a function of the signal, providing optimal signal-to-noise performance.
In one embodiment, the detector 16 may use an amorphous silicon field effect transistor (FET), as a switch to release the charge value Q in 40 from the detector 16 . The amorphous silicon FET may subject the detector 16 to transients, which may provide incorrect auto-ranging. Thus, in this architecture, G int is set as a constant to overcome incorrect auto-ranging. The value of G int may be application specific. Hence, without loss of generality, the total gain may be considered as G=A dsa *A s *A p . In other words, the total gain G will be dynamically distributed to A dsa , A s , and A p . Because double sampling amplifier 46 has the maximum impact on the noise performance in the back-end stages, to optimize noise performance, A dsa may be minimized (i.e. G dsa is maximized), and As may be minimized (i.e. G s is maximized). If A dsa is small, G p may be minimized. If both A dsa and A s are minimum, then G p will be maximized.
For example, in an exemplary application, G dsa can be set to 1, 2, or 4; G s to 1, 2, or 4; and G p to 1 or 2. Given these conditions, to achieve a total DAC gain of G=4, then G dsa may be set according in the following manner: A dsa can be set 1, i.e. G dsa =4, which is the maximum gain of double sampling amplifier 46 . Thus,
A s * G p = G A dsa = 4 1 = 4 ,
which will be distributed to A s and G p . Because the maximum gain for G s is 4, we set A dsa =2, i.e. G s =2. Moreover, because
G p = G A dsa * A s = 4 1 * 2 = 2 ,
therefore, the final gain distribution for a total DAC gain of 4 is A dsa =1, A s =2, and G p =2. Alternatively, A dsa =2, A s =2, and G p =1, or, A dsa =4, A s =1, and G p =1. However, such alternatives may not achieve better signal-to-noise ratio because the signal gain is not maximized. Thus, each segment has properties of gain (G dsa , G s , G p ) and offset V offset associated with it. These properties may be encoded and stored in a register file within the ARC 30 .
An auto-ranging algorithm that may be followed is as below:
V os0 ≦V dsa <V os1 , then V os =0 and G=1;
V os1 ≦V dsa <V os2 , then V os =V os1 and G=G 1 ;
V os2 ≦V dsa <V os3 , then V os =V os2 and G=G 2 ;
V os3 ≦V dsa <V os4 , then V os =V os3 and G=G 3 ;
V osN-1 ≦V dsa <V osN , then V os =V osN-1 and G=G N ;
An alternate algorithm that maximizes SNR is as follows
V os0 ≦V dsa <V os1 , then V os =0 and G channel =G max
V os 1 ≤ V dsa < V os 2 , then V os = V os 1 ( G max G 1 ) and G channel = G max G 1 V os 2 ≤ V dsa < V os 3 , then V os = V os 2 ( G max G 2 ) and G channel = G max G 2 V os 3 ≤ V dsa < V os 4 , then V os = V os 3 ( G max G 3 ) and G channel = G max G 3 V os N - 1 ≤ V dsa < V os N , then V os = V os N - 1 and G channel = 1
where G max =G int Max *G dsa Max *G s Max =G N . The original base ramp 66 is multiplied by G max to span the entire power supply. It may be noted that the channel gain is selected after the comparator 50 at the output of the double sampling amplifier 46 has determined the segment.
Gain distribution may be implemented in the architecture shown in FIG. 7 . The DAC 32 is distributed to the double sampling amplifier 46 and sampling capacitor ratio during fine A/D conversion. The coarse ADC quantizes the output of double sampling amplifier 46 to determine signal range and then the gain/offset selector 82 applies appropriate offset V offset to the input of double sampling amplifier 46 and gain to the following stages, including double sampling amplifier 46 .
Referring generally to FIG. 8 , a diagrammatic view of an exemplary memory stack 112 utilized in the digital acquisition system is illustrated. The memory stack 112 comprises information stored in registers 114 , each having bit allocations for the various gain and offset values, such as, hints G int , G dsa , G s , and V offset . As illustrated, in register 114 , M1 bits may be allocated to G int , M2 bits may be allocated to G dsa , M3 bits may be allocated to G s , and M4 bits may be allocated to V offset . During the coarse A/D conversion, the segment is determined. Once the segment is determined, the gain/offset selector 82 selects the various gains and offset values noted above from the memory stack 112 . Thus, memory stack 112 serves as a look-up-table that stores the different gain & offset combinations to be used in a given segment. It may be noted that in the memory stack 112 , there may be N registers, and therefore, the size of the memory stack 112 may be equal to N*(M1+M2+M3+M4) bits. Such implementation of the technique may be used to render the same basic system and hardware adaptable to a wide range of applications, systems, conversions and relationships between input signals and output signals (count values).
It may be noted that several DACs (equal to the number of segments) may be utilized to provide fine A/D conversion for each channel once the segment is identified. For example, if the DAC output signal is divided into six segments, then six DACs may be provided in common to all the thirty-two channels, such that each of the DACs is dedicated to a single segment. Moreover, in such case, the gain and offset values for the respective segments may be pre-defined for the segment, and the system will apply the same automatically while performing the fine A/D conversion.
Referring generally to FIG. 9 , a graphical illustration 116 of the segmented linear-polynomial path followed by the DAC output signal is shown. As illustrated, after every C counts, the DAC output signal assumes a linear segment that conforms to the linear-polynomial path 64 . Non-optimal gain values provided during transformation of the base ramp 66 to the desired segment may result in dead bands. Similarly, variation in non-ideal implementation of offset value may result in dead bands. Such effects may provide erroneous digital output of the charge value Q in 40 . However, sufficient overlap 118 between segments may be provided to avoid dead zones caused by capacitor mismatches, offset errors, and other chip processing imperfections.
FIG. 10 is a flowchart illustrating the digital signal conversion process 120 . As illustrated in process 120 , a coarse A/D conversion is performed by the ARC 30 (block 122 ). The coarse A/D conversion may be utilized to determine the segment information (block 124 ). The segment information comprises the segment in which the digital equivalent of the input signal (e.g., charge value Q in ) 40 lies. Once the segment is determined, the digital signal conversion process 120 proceeds with performing a fine A/D conversion to determine the digital equivalent of the input signal (e.g., charge value Q in ) 40 (block 126 ).
The teachings of the present techniques may be implemented in systems where A/D conversion of a plurality of analog values is performed via a single DAC. Such systems may include digital X-ray systems, digital cameras, as well as other applications outside the imaging field. The teachings of the present techniques enable faster signal conversion. Moreover, advantages of the techniques include increased dynamic range with faster rates of conversion at lower power consumption, appropriate signal conditioning prior to conversion, optimized noise performance, and self test capability without reliance on external stimulus for providing precise amounts of charge to validate the system. Dynamically changing the bandwidth during a scan may allow obtain faster settling times and lower noise effective bandwidth.
While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
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A system and a method for converting an analog signal to a digital signal are provided. The technique involves receiving a sampled analog signal, and selecting one of a plurality of segments of a segmented relation between DAC output values and desired ADC input values. Desired gain and offset values are applied to the DAC output values or to the sampled analog signal based upon the selected segment. The sampled analog signal is converted to a digital signal based upon the desired gain and offset values.
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BACKGROUND OF THE INVENTION
This invention relates to the use of amphiphiles for permanently improving the dye compatibility of polyolefin-based moldings, fibers and films.
In many cases, the surface of plastic products has to be provided with three-dimensional, color or other effects which either can only be produced in completely, if at all, during the forming process for technical reasons or can only be inelegantly produced for economic reasons.
This applies, for example, to the dyeing and printing of the surfaces of polyolefin-based moldings, fibers and films. On account of their non-polar character, high molecular weight hydrocarbons, such as polyethylene or polypropylene, have a low surface tension (typically of the order of 20 to 30×10 −5 Ncm −1 . The adhesion of printing inks and dyes to their surface is correspondingly weak (typically below 0.5 Nmm −2 ).
It is known from the prior art that the compatibility of plastic surfaces with can be improved, for example, by oxidative aftertreatment processes, such as corona or plasma treatment. In processes such as these, the surface of the plastic is oxidized or chemically modified in the presence of gases and discharges, so that certain surface properties of the plastic can be modified. However, apart from their high energy consumption, processes such as these always involve an additional step and lead to ozone emissions in the manufacture of plastic parts.
Chemical pretreatment processes, including for example treatment with fluorine or chlorine gas, with chromosulfuric acid or fluorosulfonic acid, etc., have also been known for some time.
In addition, special substances which were applied to the surface of the plastic to make the problematical dyeability of polyolefins more favorable were known from the earlier literature.
Thus, even U.S. Pat. No. 3,284,428 points out the dyes adhere very poorly to polyolefin fibers because the polyolefins have an inert surface. It is also pointed out that although polypropylene, for example, can be dyed, the dye absorption rate is far too low for industrial technical requirements. U.S. Pat. No. 3,284,428 proposes the use of nickel derivatives of special diamines to solve this problem.
U.S. Pat. No. 3,424,716 describes polyolefins to which ternary mixtures of nickel compounds, sulfo compounds and n-octylphenyl salicylate are added as additives in order to improve the dyeability and stability of the polyolefins.
EP-B-372 890 describes polyolefin- or polyester-based fibers with a lubricant applied to their surface. This lubricant comprises a mixture of (1) fatty acid diethanolamide, (2) a polyether-modified silicone, (3) a sorbitan fatty acid ester and (4) a metal salt of an alkyl sulfonate. Components (1) to (4) are present in special quantity ratios. According to page 3, lines 20 to 26, the mixture of components (1) to (4) is applied to the surface. The technique by which the mixture containing the four components is applied to the surface of fibers is described in detail on page 4, lines 6 to 9. The application techniques mentioned include a) the use of rollers, b) spraying and c) immersion. Accordingly, the process according to EP-B-372 890 is a process in which a mixture of components (1) to (4) is applied to the surface of polyolefin moldings in an additional processing step. Accordingly, the expression “applied to the fiber surface” used in claim 1 of EP-B-372 890 may be clearly interpreted by the expert to mean that any adhesion involved is loose and temporary, for example in the form of relatively weak adhesion forces, and cannot in any way to be considered to represent permanent anchorage.
Even the more recent literature (both patent documents and scientific publications) that the dyeability of polyolefins is extremely problematical. For example, EP-B-595 408 describes a process for improving the surface compatibility properties of polypropylene which comprises heat-treating polypropylene together with at least one olefin compound polybrominated at an aromatic ring in the absence of free radical initiators.
U.S. Pat. No. 5,045,387 describes the treatment of polyolefin-based fibers or films in which special polyalkoxylated polydimethyl siloxanes or alkoxylated ricinoleic acid derivatives are applied to the surface.
In a fairly recent Article, J. Akrman and J. Prikryl investigate the dyeing behavior of polypropylene fibers (cf. Journal of Applied Polymer Science 1996, Vol. 62, pages 235-245). The authors of this Article point out that the causes behind the poor dyeability of polypropylene have been known for some time and lie in the fact that the material has high crystallinity and an extremely non-polar aliphatic structure which does not contain any reactive sites. The authors also point out that although additives containing basic nitrogen are known from the prior art, no seriously commercial product which satisfactorily solves the dyeability problems is available to the expert despite the intensive research efforts in this field. The authors then report—on the basis of their own studies—that a polypropylene fiber dyeable in acidic medium can be obtained by adding a special high molecular weight additive containing basic nitrogen on a rigid polymer chain to the polymer before it is extruded.
In view of the very widely used traditional chemical aftertreatment processes, such as corona and plasma treatment, it is known to the expert that no exact statements can be made as to the various processes involved. However, it has been established that oxidative surface changes occur and result in the formation of certain “active centers”. However, their concentration generally decreases with time so that the pretreatment effect also is only in evidence for a certain time, generally not more than 72 hours (cf. for example, Klaus Stoeckert (Editor), “Veredein von Kunststoff-Oberflächen”, Munich 1974, page 137).
One feature common to all the known processes is that, in general, the desired surface effects are only temporarily present.
EP-B-616 622 relates to extrudable compostable polymer compositions comprising an extrudable thermoplastic polymer, copolymer or mixtures thereof containing a degradation-promoting system of an auto-oxidative component and a transition metal. The auto-oxidative system comprises a fatty acid, a substituted fatty acid or derivatives or mixtures thereof, the fatty acid having 10 to 22 carbon atoms and containing at least 0.1% by weight of unsaturated compounds and at least 0.1% by weight of free acid. The transition metal is present in the composition in the form of a salt in a quantity of 5 to 500 ppm and is selected from the group consisting of cobalt, manganese, copper, cerium, vanadium and iron. The composition is said to be oxidatively degradable to a brittle material in the form of a film around 100 microns thick over a period of 14 days at 60° C. and at a relative air humidity of at least 80%.
DESCRIPTION OF THE INVENTION
The problem addressed by the present invention was to provide auxiliaries with which the dye compatibility of polyolefin-based moldings, fibers and films could be lastingly and permanently improved.
There are no restrictions to the expression “dyes” as used in the context of the present invention. In principle, therefore, any natural and/or synthetic dyes familiar to the expert and, more particularly, the dyes traditionally used in the dyeing of textiles may be used for the purposes of the present invention. Of particular importance in this regard are the synthetic dyes which are normally divided into the following groups: basic dyes (also known as cationic dyes), mordant dyes, direct dyes (also known as substantive dyes), dispersion dyes, development dyes, oxidation dyes, color lakes, vat dyes, leuco vat dye esters, metal complex dyes, pigments, reactive dyes and acid dyes (cf. for example, Ullmanns Encyclopädie der technischen Chemie, 4th Edition, Vol. 11, Chapter entitled “Farbstoffe, synthetische”, more particularly pages 138-139). All these dyes are specifically included in the scope of the present invention. Printing inks are also specifically regarded as dyes in the context of the present invention.
The present invention relates to the use of amphiphiles for permanently improving the dye compatibility of polyolefin-based moldings, fibers and films, characterized in that a mixture containing
a) predominantly one or more polyolefins,
b) 0.01 to 10% by weight, based on the polyolefins, of one or more migratable amphiphiles (additives I) and
c) 0.01 to 1000 ppm of one or more transition metal compounds (II)—metal content of the transition metal compounds (II) based on the polyolefins—
is subjected in the usual way to molding by extrusion, calendering, injection molding and the like at temperatures in the range from 180 to 320° C.
The additives according to the invention are also referred to hereinafter as additives (I). They are amphiphilic compounds. An amphiphile is understood in common usage to be a compound which combines hydrophilic and hydrophobic molecule parts. In other words, the molecular structure of amphiphiles contains as it were a “combination” of a suitable oleophilic basic molecule based on a hydrocarbon which contains one or more substituents of high polarity. The substituents of high polarity are formed in known manner by hetero atom-containing molecule constituents, particular significance being attributed in this regard to the hetero atoms oxygen, nitrogen and/or halogen for forming the functional group(s) of high polarity.
The use of the amphiphiles in accordance with the invention ensures that dyes are able permanently to adhere to or in the plastic without any additional pretreatment. Dye compatibility values once established remain intact for long periods or occasionally even increase in the event of continuing storage. It is specifically pointed out that, basically, the dyes adhere directly to or in the plastic, but not because they are present for example in an applied layer of paint or the like.
By adhesion “to or in the plastic” is meant that, although on the one hand the dyes adhere in the region of the plastic surface to which the migratable amphiphilic additives at least partly pass in the course of the molding process, on the other hand dyes can also diffuse into the interior of the plastic where they come into contact—in the sense of adhesion—with the additives present there.
The mixture containing components a), b) and c) is used by traditional molding techniques well-known to the expert, such as extrusion, calendering, injection molding and the like. In a preferred embodiment of the present invention, the melt of the mixture containing components a), b) and c) comes into contact with oxygen, more especially atmospheric oxygen, in the course of the molding process. In the case of extrusion, for example, this happens when the melt leaves the extruder through the extrusion die. The preferred embodiment mentioned above enables—optionally catalytically assisted—oxidative processes, for example oxidatively induced crosslinking—and hence ultimately immobilization—of olefinically unsaturated molecule constituents of the additives (I) to form relatively high molecular weight compounds, oxidatively induced oxidation of activated methylene groups which are present in the immediate neighborhood of the polar groups of the amphiphiles (I) and other oxidative reactions and secondary reactions to take place. (Atmospheric) oxygen can act on the one hand on the surface itself and, on the other hand, even in the interior of the plastic, especially in zones near the surface—to which it is capable of diffusing.
The additives (I) suitable for use in accordance with the present invention have relatively low molecular weights, a pre-requisite for reasonably rapid migration. An upper limit to the molecular weight of suitable internal additives (I) is at about 5,000 D (dalton), preferably at values of at most about 3,000 D and more preferably at maximum values of about 1,000 D. The expression of molecular weight in “daltons” is known to be the definition of the absolute molecular weight. Accordingly, by comparison with the polyolefins with their molecular weights of several million, the additives (I) are comparatively low molecular weight compounds. The lower limit to the molecular weight of these internal additives (I) is at about 50 to 100 D, preferably at 150 to 180 D and more preferably at around 200 to 300 D.
The use of the amphiphiles in accordance with the invention guarantees the compatibility of dyes subsequently applied with the polyolefin surface with virtually no time limit. The expression “with virtually no time limit” applies both to the time interval between production of the particular polyolefin-based molding and its surface dyeing in a separate process step and to the time interval between production of the dyed product and its practical application.
The preferred additives (I) according to the invention are amphiphiles of which the hydrophobic molecule parts at least partly contain olefinically unsaturated functions which are particularly readily accessible to radical-induced crosslinking reactions in the vicinity of the plastic surface. Preferred additives (I) are those which, in the unreacted state, have iodine values of at least about 10, preferably of at least about 30 to 40 and more preferably of at least about 45 to 50. The choice of the method by which the iodine value is determined is basically of minor importance. In the context of the present invention, however, reference is specifically made to the methods developed by Hanus and Wijs, which have long been part of Section C-V of the “DGF-Einheitsmethoden”, and to the equivalent method developed by Fiebig (cf. Fat Sci. Technol. 1991, No. 1, pages 13-19).
As will be shown in more detail hereinafter, both monoolefinically unsaturated hydrocarbon radicals and polyolefinically unsaturated hydrocarbon radicals may be provided in the additives (I) used in accordance with the invention. Combinations of several corresponding compounds are also important auxiliaries for the use according to the invention. The iodine values of the additives (I) used may assume values above 80 to 90 and, more particularly, values above 100. Highly unsaturated additive components with iodine values of up to about 200 or even higher, for example in the range from 120 to 170, are auxiliaries in the context of the use according to the invention.
In the three-dimensional structure of their hydrocarbon radical, these internal additives (I) may be both straight-chained and branched and/or may have a cyclic structure.
Basically, suitable substituents of high polarity are functional groups which are distinguished in particular by a content of hetero atoms and preferably by a content of O, N and/or halogen. The expression “functional group” is used in its most general sense in the context of the present invention and is understood to apply to groups of atoms which have a characteristic reactivity and which contain one or more hetero atoms. Accordingly, this definition encompasses for example OH groups (simple atomic groups) or N-containing heterocycles (more complex atomic groups), but not C═C-double bonds (no hetero atom) per se, unless they are present in addition to the hetero atoms in more complex atomic groups. Groups from the following classes are mentioned purely by way of example: carboxyl, hydroxyl, amino, oxazoline, imidazoline, epoxide and/or isocyanate groups and/or derivatives thereof. The group of such derivatives includes, for example, ester groups, ether groups, amide groups/alkanolamine and/or alkanolamide groups.
A very important class of substituents of high polarity in the context of the present invention are N-containing heterocycles and/or derivatives thereof, for example pyridazine, pyrimidine, pyrazine, pyridine, azane and azinane groups. Thiazole, thiazolane, thiazolidine, pyrrole, azolane, azolidine, pyrazole and isooxazole groups are particularly suitable, imidazole, imidazoline, diazolidine, oxazoline, oxazole, oxazolidine and oxazolidane groups being most particularly suitable.
A particularly preferred class of additives (I) are compounds which, on the one hand, contain one or more olefinically unsaturated functions in the hydrophobic part of the molecule and, on the other hand, extremely polar functions, such as oxazoline, imidazoline, sulfonate, phosphonate or carboxyl groups (or salts thereof), in the hydrophilic part of the molecule.
Certain individually selected additives of the type mentioned in the foregoing and mixtures of several corresponding auxiliaries may be used as the additive (I). By suitably selecting the substituents of high polarity in the particular auxiliaries of this class of additives used, the dye compatibility to which the end product is to be adjusted can be influenced in a predetermined manner. However, mixtures of the type in question here are also corresponding mixtures which, so far as their functional group is concerned, can be assigned to a sub-class, i.e. for example contain carboxyl groups as substituents of high polarity, but contain different basic structures in their hydrocarbon molecule. It is known that corresponding mixtures are obtained in particular when mixtures of the type in question based on natural materials are used. For example, olefinically unsaturated fatty acid mixtures of vegetable and/or animal origin or derivatives thereof can form valuable additives of the additive (I) type in the context of the teaching according to the invention.
As known per se to the expert, different improvements in dye compatibility can be expected according to the particular groups of high polarity present. Relevant specialist knowledge may be applied in this regard.
Another possibility of varying the internal additives (I) according to the invention lies in the number of functional substituents of high polarity in the particular basic hydrocarbon skeleton. Even one substituent of high polarity can lead to the permanent and at the same time marked increase in dye compatibility required, especially after adaptation of the type and quantity of functional groups available. In addition, however, it has been found that the presence of two or more such substituents of high polarity in the particular molecule of the additive (I) can be an important additional feature for increasing dye compatibility. Reference is made here purely by way of example to the class of so-called dimer fatty acids. Dimer fatty acids are known among experts to be carboxylic acids obtainable by oligomerization of unsaturated carboxylic acids, generally fatty acids, such as oleic acid, linoleic acid, erucic acid and the like. The oligomerization is normally carried out at elevated temperature in the presence of a catalyst, for example of alumina. The products obtained are mixtures of various subtonics in which the dimerization products predominate. However, small amounts of higher oligomers, especially trimer fatty acids, are also present. Dimer fatty acids also contain monomers or monofunctional fatty acids from their production. Dimer fatty acids are commercially available products and are marketed in various compositions and qualities. In the same way as dimer fatty acids, trimer fatty acids are oligomerization products of unsaturated fatty acids in which the percentage content of trimers in the product predominates. Dimer and trimer fatty acids have olefinic double bonds which make them capable of reactive solidification in the vicinity of the polyolefin surface.
Dialkanolamines containing at least partly olefinically unsaturated hydrocarbon radicals or dialkanolamides of unsaturated fatty acids are extremely effective dye compatibility improvers in the context of the teaching according to the present invention. This applies in particular to the corresponding diethanol derivatives. This class includes, for example, oleic acid diethanolamide and linoleic acid diethanolamide. Specifically included in this connection are technical products known to the expert, including the secondary components normally occurring therein. Examples of such products are “Comperlan OD” (technical oleic acid diethanolamide) and “Comperlan F” (technical linoleic acid diethanolamide), both commercial products of Henkel KGaA. However, such compounds as sorbitan monoesters with, in particular, ethylenically unsaturated fatty acids also lead to optimal results in the context of the teaching according to the invention.
The migration rate to be expected from the molecular structure of the particular additives (I) used may be one of the factors which determines the quantity of additives (I) to be used in each individual case. Lower limits to the size of the additions of additive (I) to the polyolefin are about 0.01% by weight and, more particularly, about 0.1% by weight. In general, it will be advisable to use at least about 0.2 to 0.8% by weight (based on the polyolefins). Optimum dye compatibility values for the particular representatives of this class of substances used in each individual case as the additive (I) are generally achieved in the range from about 0.3 to 5% by weight and, more particularly, in the range from 0.4 to about 1% by weight.
As already mentioned, the optimum dye compatibility to be adjusted is understandably determined by the chemical nature and by the possible interaction of the substituents of high polarity and optionally reactivity in the additive (I). The choice of additive (I) to be used in each individual case is determined by the particular stresses likely to be applied in the end product to the strength of the bond between the polyolefin and the dye applied.
The combination of the teaching according to the invention which leads to high dye compatibility values with technologies known per se for improving dye compatibility on polyolefin surfaces falls within the scope of the teaching according to the invention. Thus, both mechanical and chemical and/or physical surface treatments of the outer polyolefin surface may be combined with the dye compatibility modifications according to the invention. However, this is generally not necessary.
As already mentioned, the additives (I) are used in combination with transition metal compounds (II) during the molding of the polyolefins. The quantity of transition metal compound (II)—metal content of the transition metal compound (II) based on the polyolefins—is in the range from 0.1 to 1000 ppm. Basically, there are no particular restrictions in regard to the nature of the transition metal compounds (II). In principle, therefore, any transition metal compounds known to the expert may be used for the purposes of the teaching according to the invention. In one embodiment, transition metal salts, preferably salts based on organic acids containing 8 to 22 carbon atoms, are used as the transition metal compounds (II). In another embodiment, the transition metals are selected from the group consisting of lead, nickel, zirconium, chromium, titanium and tin. In another embodiment, the transition metal compounds are used in a quantity of less than 5 ppm—metal content of the transition metal compound (II) based on the polyolefins. Instead of or in addition to the metals just mentioned, cobalt, copper, iron, vanadium, cerium and magnesium, for example, may also be used.
If desired, other compounds known to the expert as catalysts for oxidative processes may be used in addition to the compulsory transition metal compounds (II) mentioned.
In one preferred embodiment, the ratio by weight of the additives (I) to the metal content of transition metal compounds (II) is adjusted to a value of 10:0.1 to 10:10 −7 , preferably to a value of 10:0.02 to 10:10 −6 and more preferably to a value of 10:0.01 to 10:10 −5 .
In the light of the teaching of EP-B-616 622 cited earlier on, the following observations may be made:
The teaching of the present invention on the one hand ensures that the improved and permanent dye compatibility required is achieved and, on the other hand, that it is achieved without any adverse effect on other material parameters.
In one preferred embodiment, the transition metal compounds (II) are used in combination with additives (I) selected from the class of diethanolamides of unsaturated fatty acids. As already mentioned, the diethanolamides are preferably used as technical products.
According to the invention, the amphiphilic additives (I) are used in the course of routine molding processes, such as extrusion, calendering, injection molding and the like. It may be desirable to use components a), b) and c) in the form of a mixture prepared in advance. Other typical auxiliaries which have generally been successful in the molding of plastics and which are known to the expert, for example slip agents, antistatic agents, lubricants, release agents, UV stabilizers, antioxidants, fillers, fire retardants, mold release agents, nucleating agents and antiblocking agents, may also be separately made up and added during the final mixing of the end products. However, it may also be desirable, for example where extrusion is applied, to introduce components b) and/or c) and/or other additives either completely or partly into the polyolefin melt itself in the extruder, so that the mixture of components a), b) and c)—and optionally other auxiliaries—is not present from the outset as a made-up product, but is formed in the extruder itself. A technique such as this is appropriate, for example, when the additives (I) to be added to the polymer melt are present in liquid form and are easier to inject than to make up in advance.
It may even be desirable, although not necessary for obtaining the effect according to the invention, to undertake a conventional corona or plasma treatment after the use of components a) to c) in accordance with the invention.
Basically, any known ethylene- or propylene-based polymers and copolymers may be used as the basic oleophilic polyolefin material.
Mixtures of pure polyolefins with copolymers are also suitable in principle providing the additives (I) retain their ability to migrate in accordance with the invention and hence to collect at the surfaces of solids. Polymers particularly suitable for the purposes of the teaching according to the invention are listed below: poly(ethylenes), such as HDPE (high-density polyethylene), LDPE (low-density polyethylene), VLDPE (very-low-density polyethylene), LLDPE (linear low-density polyethylene), MDPE (medium-density polyethylene), UHMPE (ultrahigh molecular polyethylene), VPE (crosslinked polyethylene), HPPE (high-pressure polyethylene); isotactic polypropylene; syndiotactic polypropylene; Metallocen-catalyzed polypropylene, high-impact polypropylene, random copolymers based on ethylene and propylene, block copolymers based on ethylene and propylene; EPM (poly[ethylene-co-propylene]); EPDM (poly[ethylene-co-propylene-co-conjugated diene]).
Other suitable polymers are: poly(styrene); poly(methylstyrene); poly(oxymethylene); Metallocen-catalyzed α-olefin or cycloolefin copolymers, such as norbornene/ethylene copolymers; perfluorinated polyolefins, polyvinyl chloride, acrylonitrile/butadiene/styrene copolymers (ABS), styrene/butadiene/styrene or styrene/isoprene/styrene copolymers (SIS or SBS); copolymers containing at least 80% ethylene and/or styrene and less than 20% monomers, such as vinyl acetate, acrylates, methacrylates, acrylic acid, acrylonitrile, vinyl chloride. Examples of such polymers are: poly(ethylene-co-ethyl acrylate), poly(ethylene-co-vinyl acetate), poly(ethylene-co-vinyl chloride), poly(styrene-co-acrylonitrile). Also suitable are graft copolymers and polymer blends, i.e. mixtures of polymers in which the above-mentioned polymers inter alia are present, for example polymer blends based on polyethylene and polypropylene.
Homopolymers and copolymers based on ethylene and propylene are particularly preferred for the purposes of the present invention. In one embodiment of the present invention, therefore, polyethylene on its own is used as the polyolefin; in another embodiment, polypropylene on its own is used as the polyolefin and, in a further embodiment, ethylene/propylene copolymers are used as the polyolefin.
The surface-modified polyolefin-based moldings and films obtained by the process according to the invention can be printed and dyed by any of the relevant methods known to the expert. Traditional acidic, basic or reactive wool or cotton dyes are preferably used for dyeing.
The present invention also relates to a process for the production of dyed and/or printed polyolefin-based moldings, fibers and films, characterized in that a mixture containing
a) predominantly one or more polyolefins,
b) 0.01 to 10% by weight, based on the polyolefins, of one or more migratable amphiphiles (additives I) and
c) 0.01 to 1000 ppm of one or more transition metal compounds (II)—metal content of the transition metal compounds (II) based on the polyolefins,
is conventionally molded by extrusion, calendering, injection molding and the like at temperatures of 180 to 320° C. and the resulting polyolefin-based moldings, fibers and films with improved dye compatibility are then printed and/or dyed by conventional methods.
The following Examples are intended to illustrate the invention without limiting it in any way.
EXAMPLE
1. Materials Used
1.1. Polyolefin
In all the tests, a granular polypropylene (“Hostalen PPH 2150”, a product of Hoechst AG) was used as the high molecular weight polyolefin.
1.2. Additives (I)
Soya oxazoline: oxazoline of soya fatty acids (technical quality) (“Loxamid VEP 8514”, a product of Henkel KGaA, Düsseldorf)
Ricinol oxazoline: oxazoline of castor oil fatty acid (technical quality) (“Loxamid VEP 8513”, a product of Henkel KGaA, Düsseldorf)
Comperlan F: linoleic acid diethanolamide, technical quality (“Comperlan F”, a product of Henkel KGaA, Düsseldorf)
Edenor HTiCT: selectively hydrogenated tallow fatty acid (“Edenor HTiCT”, a product of Henkel KGaA, Düsseldorf)
1.3. Transition Metal Compounds (II)
Pb-C8: lead-2-ethylhexanoate (lead salt of 2-ethylhexanoic acid)
Ni-acac: nickel acetyl acetonate
Cu-sol: mixture containing 62% copper(II) salts of branched C 6-19 fatty acids and Cu(II) naphthenate and 9% C 3-24 fatty acids and 35% by weight naphtha (“Cu-Soligen”, a product of Borchers GmbH)
1.4. Other Substances
Dye 1 commercial acid dye (“Supracen Rot 3B 200%”, a product of Bayer AG)
Dye 2 commercial reactive dye (“Levafix Brillantrot E-4BA”, a product of Bayer AG
Dye 3 commercial basic dye (“Astrazonrot 6B”, a product of Bayer AG)
2. Production of Surface-modified Polypropylene by the Process According to the Invention
In order to test the dye compatibility properties of surface-modified polypropylene, polypropylene was initially produced in tape form by mixing 600 g of polypropylene granules with 9.0 g (=1.5%) of additive (I) and 0.38 g of transition metal compound (II). The particular additive (I) and transition metal compound (II) used are shown in Tables 1 to 3 below. The mixtures were introduced through a hopper into an extruder. A Brabender DSK 42/7 twin-screw extruder (Brabender OHG, Duisberg) was used.
As well-known to the expert, an extruder is a machine for processing plastics in which both powder-form and granular thermoplastics can be continuously mixed and plasticized.
Beneath the feed hopper, there is a contra-rotating twin screw longitudinally divided into three heating zones in addition to a water-cooling system which is intended to prevent premature melting of the granules or powder. The temperature of the heating zones and the rotational speed of the twin screws can be controlled through a data-processing Plast-Corder PL 2000 which is connected to the extruder via a PC interface.
To produce the polypropylene tapes, the following temperatures were adjusted: heating zone I 250° C., heating zone II 270° C., heating zone III 290° C., the three heating zones being air-cooled to keep the temperatures constant.
The polypropylene granules (including the particular additive I and the transition metal compound II) were automatically taken into the extruder by the contra-rotating twin screws and transported along the screw. The rotational speed was 25 r.p.m. This guaranteed a relatively long residence time in the extruder and hence thorough compounding and homogenization. The resulting homogeneous and substantially bubble-free mixture finally entered a nozzle which represents a fourth heating zone. The temperature of the nozzle was 300° C., i.e. the particular mixture left the extruder at that temperature.
After leaving the nozzle, the hot mixture flowed onto a conveyor belt of which the speed was adjusted so that a smooth and uniformly thick and wide tape was formed on cooling in air. In the tests described here, the speed was adjusted so that the polypropylene tape was about 35 mm wide and about 0.35 mm thick. Square test specimens were die-cut from this material and used for the dyeing tests described hereinafter.
Test specimens of pure polypropylene were used for comparison purposes. They were produced by the extrusion technique just described, except that polypropylene granules on their own, i.e. with no additive I or transition metal compound II added, were used. The test results based on this material are identified in Tables 1 to 3 by the abbreviation “Comp.” In the first column.
3. Dyeing Tests with Acid Dye
3.1. Preparation of the Dyeing Solution A
Beginning at 50° C., Supracen Rot (dye “Dye 1”) was added to 1 liter of water in such a quantity that the concentration of the dye was 1.5%. 1.5 g of sodium sulfate calc. was then added, a pH value of 2 to 3.5 was adjusted with 85% formic acid and the whole was heated to boiling temperature at a rate of about 2° C. per minute. The dyeing solution thus prepared was used to test the dye compatibility of polypropylene test specimens.
3.2. Dyeing and Evaluation
Untreated polypropylene test specimens and polypropylene test specimens surface-modified in accordance with the invention were first stored for 1 to 7 days at 20 to 60° C. and then immersed for 60 minutes in the dyeing solution prepared in accordance with 3.1, the boiling temperature being maintained. The test specimens were then removed from the bath and rinsed with water first for 5 minutes at 50° C. and then for another 5 minutes at 20° C. The dyeing results were visually evaluated by a panel of examiners using a “school marking system”. The individual values (“marks”) have the following meanings: 1=very good, 2=good, 3=satisfactory, 4=adequate, 5=poor, 6=inadequate. The value “1” corresponds to the mark awarded in the corresponding dyeing of cotton while the value “6” corresponds to the mark awarded in the dyeing of untreated polypropylene.
The test results are set out in Table 1 below. All the results are average values from five tests.
TABLE 1
Dyeing tests with acid dye (dyeing solution A)
Transition
metal
compound
Storage
Result
No.
Additive (I)
II
Days
° C.
Dye
(mark)
Comp.
None
None
1
20
Dye 1
6
Comp.
None
None
6
20
Dye 1
6
Comp.
None
None
1
60
Dye 1
6
Comp.
None
None
6
60
Dye 1
6
B1
Soya oxazoline
Pb-C8
2
20
Dye 1
1
B2
Soya oxazoline
Pb-C8
7
60
Dye 1
1
B3
Soya oxazoline
Niacac
3
20
Dye 1
1
B4
Soya oxazoline
Niacac
7
60
Dye 1
1
B5
Soya oxazoline
Cu-sol
2
20
Dye 1
1
B5
Soya oxazoline
Cu-sol
7
60
Dye 1
1
B6
Ricinol oxazoline
Pb-C8
2
20
Dye 1
2
B7
Ricinol oxazoline
Pb-C8
7
60
Dye 1
2
B8
Ricinol oxazoline
Niacac
3
20
Dye 1
2
B9
Ricinol oxazoline
Niacac
7
60
Dye 1
2
B10
Ricinol oxazoline
Cu-sol
2
20
Dye 1
2
B11
Ricinol oxazoline
Cu-sol
7
60
Dye 1
1
B12
Comperlan F
Cu-sol
1
20
Dye 1
3
B13
Comperlan F
Cu-sol
6
60
Dye 1
2
B14
Comperlan F
Pb-C8
6
60
Dye 1
3
B15
Comperlan F
Niacac
6
60
Dye 1
3
B16
Edenor HTiCT
Cu-sol
1
20
Dye 1
3
B17
Edenor HTiCT
Cu-Sol
6
60
Dye 1
4
B18
Edenor HTiCT
Pb-C8
1
20
Dye 1
3
B19
Edenor HTiCT
Pb-C8
6
60
Dye 1
4
4. Dyeing Tests with Reactive Rye
4.1. Preparation of the Dyeing Solution B
Beginning at 25° C., 50 g of sodium sulfate calc. were added to 1 liter of water. After 5 minutes, 5 g of sodium bicarbonate were added, after another 5 minutes 5 g of soda were added and, after another 5 minutes, Levafix Brillantrot E-4BA (dye “Dye 2”) was added in such a quantity that the concentration of the dye was 1.5%. The solution was then heated to 60° C. at a rate of about 2° C. per minute. The dyeing solution thus prepared was used to test the dye compatibility of polypropylene test specimens.
4.2. Dyeing and Evaluation
Untreated polypropylene test specimens and polypropylene test specimens surface-modified in accordance with the invention were first stored for 1 to 8 days at 20 to 60° C. and then immersed for 45 minutes in the dyeing solution prepared in accordance with 4.1, the boiling temperature being maintained. The test specimens were then removed from the bath and rinsed with water first for 5 minutes at 50° C. and then for another 5 minutes at 20° C. The dyeing results were visually evaluated by a panel of examiners using a “school marking system”. The individual values (“marks”) have the following meanings: 1=very good, 2=good, 3=satisfactory, 4=adequate, 5=poor, 6=inadequate. The value “1” corresponds to the mark awarded in the corresponding dyeing of cotton while the value “6” corresponds to the mark awarded in the dyeing of untreated polypropylene.
The test results are set out in Table 2 below. All the results are average values from five tests.
TABLE 2
Dyeing tests with reactive dye (dyeing solution B)
Transition
metal
compound
Storage
Result
No.
Additive (I)
II
Days
° C.
Dye
(mark)
Comp.
None
None
1
20
Dye 2
6
Comp.
None
None
6
20
Dye 2
6
Comp.
None
None
1
60
Dye 2
6
Comp.
None
None
6
60
Dye 2
6
B20
Soya oxazoline
Pb-C8
8
60
Dye 2
2
B21
Soya oxazoline
Niacac
8
60
Dye 2
3
B22
Soya oxazoline
Cu-sol
8
60
Dye 2
2
B24
Ricinol oxazoline
Pb-C8
8
60
Dye 2
2
B25
Ricinol oxazoline
Niacac
8
60
Dye 2
2
B26
Ricinol oxazoline
Cu-sol
8
60
Dye 2
2
5. Dyeing Tests with Basic Dye
5.1. Preparation of Dyeing Solution C
Astrazonrot 6B (dye “Dye 3”) was made into a paste by stirring with 60% acetic acid at 20° C. The two components were used in a quantity which, after subsequent addition to the aqueous matrix, produced a concentration of 1.5% of each component, based on the aqueous matrix.
Beginning at 50° C., 100 g of sodium sulfate was first added, followed after 5 minutes by the dye made into a paste with acetic acid. The whole was then heated to boiling temperature at a rate of about 2° C. per minute. The dyeing solution thus prepared was used to test the dye compatibility of polypropylene test specimens.
5.2. Dyeing and Evaluation
Untreated polypropylene test specimens and polypropylene test specimens surface-modified in accordance with the invention were first stored for 1 to 8 days at 20 to 60° C. and then immersed for 60 minutes in the dyeing solution prepared in accordance with 5.1, the boiling temperature being maintained. The test specimens were then removed from the bath and rinsed with water first for 5 minutes at 50° C. and then for another 5 minutes at 20° C. The dyeing results were visually evaluated by a panel of examiners using a “school marking system”. The individual values (“marks”) have the following meanings: 1=very good, 2=good, 3=satisfactory, 4=adequate, 5=poor, 6=inadequate. The value “1” corresponds to the mark awarded in the corresponding dyeing of cotton while the value “6” corresponds to the mark awarded in the dyeing of untreated polypropylene.
The test results are set out in Table 3 below. All the results are average values from five tests.
TABLE 3
Dyeing tests with basic dye (dyeing solution C)
Transition
metal
compound
Storage
Result
No.
Additive (I)
II
Days
° C.
Dye
(mark)
Comp.
None
None
1
20
Dye 3
6
Comp.
None
None
6
20
Dye 3
6
Comp.
None
None
1
60
Dye 3
6
Comp.
None
None
6
60
Dye 3
6
B27
Soya oxazoline
Pb-C8
3
20
Dye 3
3
B28
Soya oxazoline
Pb-C8
8
60
Dye 3
2
B29
Soya oxazoline
Niacac
3
20
Dye 3
3
B30
Soya oxazoline
Niacac
8
60
Dye 3
2
B31
Soya oxazoline
Cu-sol
3
20
Dye 3
3
B32
Soya oxazoline
Cu-sol
8
60
Dye 3
2
B33
Ricinol oxazoline
Pb-C8
8
60
Dye 3
2
B34
Ricinol oxazoline
Niacac
8
60
Dye 3
2
B35
Ricinol oxazoline
Cu-sol
3
20
Dye 3
3
B36
Ricinol oxazoline
Cu-sol
8
60
Dye 3
2
B37
Comperlan F
Cu-sol
7
60
Dye 3
3
B38
Edenor HTiCT
Cu-sol
2
20
Dye 3
3
B39
Edenor HTiCT
Cu-sol
7
60
Dye 3
4
B40
Edenor HTiCT
Pb-C8
2
20
Dye 3
3
B41
Edenor HTiCT
Pb-C8
7
60
Dye 3
4
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A polyolefin composition having enhanced dyeing capabilities containing: (a) a polyolefin; (b) from 0.01 to 10% by weight, based on the weight of the polyolefin in, of a migratable amphiphile, excluding phenolic and sulfur-containing stabilizers and n-octyl phenyl salicylate; and (c) from 0.01 to 1000 ppm of a transition metal, based on the weight of the polyolefin.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a bowling assist device, and more particularly, to an apparatus for spotting the path of a bowling ball.
2. Description of Related Art
There have been several attempts to provide assistance to bowlers in improving their aim. One such attempt is described in U.S. Pat. No. 3,105,685 entitled "Bowling Target" issued Oct. 1, 1963 to Jahn which discloses the utilization of a pair of target strips hanging over the lane at a point along the bowling alley. The target strips are adjusted so that the bowler is to roll the ball between the strips in order to mark a particular predefined path. The target strips may be moved to any desired position over the alleys. A disadvantage of the device disclosed in Jahn is that the target strips must constantly be adjusted if the bowlers want to aim for different bowling pins. This disadvantage would significantly increase the amount of time needed to play a game.
Another attempt to provide a device which improves a bowler's aim is disclosed in U.S. Pat. No. 3,473,804 entitled "Bowling Trainer" issued Oct. 21, 1969 to Pecora. Pecora discloses the utilization of a second pair of target strips behind a first pair in order to provide a pair of spaced targets through which the ball is to roll. The disadvantage of Pecora is the same as that of Jahn U.S. Pat. No. 3,105,685, i.e., the bowlers must constantly readjust the targets if the bowlers desire to aim for different bowling pin locations.
Another attempt to provide a system that aids bowlers in improving their aim is described in U.S. Pat. No. 2,990,177 entitled "Illuminated Inserts For Spot Bowling" issued Jun. 27, 1961 to Hutchinson which discloses the utilization of illuminated inserts, i.e., electric inserts, which may be individually lit in the alley. A disadvantage of Hutchinson is that the alley bed must be configured to receive the illuminated inserts, i.e., recesses must be formed in the alley bed to accept the translucent plastic material. This is an expensive process which owners of bowling alleys might not be willing to undertake. Additionally, the circuit comprising the switches, electric lights and corresponding wiring is complex and is expensive to manufacture. Furthermore, the electric lights will frequently burn out and have to be replaced. Hence, the maintenance of such a system can be expensive in the situation where a bowling facility has many alleys which utilize this system.
Bearing in mind the problems and deficiencies of the prior art, it is therefore an object of the present invention to provide a new and improved apparatus to spot the path of a bowling ball which can be easily transported and assembled.
It is another object of the present invention to provide a new and improved apparatus to spot the path of a bowling ball which enables the user of the apparatus to aim for any one particular path without having to make adjustments or readjustments to the apparatus.
It is yet another object of the present invention to provide a new and improved apparatus to spot the path of a bowling ball that utilizes a plurality of target panels, each of which indicating a corresponding travel path of a bowling ball.
It is another object of the prevent invention to provide a new and improved apparatus to spot the path of a bowling ball which aids sight impaired bowlers in identifying a desired travel path of the bowling ball.
It is a further object of the present invention to provide a new and improved apparatus to spot the path of a bowling ball that is light in weight and of very simple construction.
It is yet another object of the present invention to provide a new and improved apparatus to spot the path of a bowling ball which is relatively inexpensive to manufacture.
SUMMARY OF THE INVENTION
The above and other objects, which will be apparent to those skilled in the art, are achieved in the present invention which is directed to an aiming apparatus for a bowling alley comprising an elongated member, means for supporting the elongated member in a substantially horizontal position above and across the bowling alley, the elongated member being substantially perpendicular to the axis of the bowling alley, and a plurality of independently hanging target panels rotatably attached to the elongated member in a manner such that the target panels are uniformly spaced across the full width of the bowling alley, each of the target panels indicating a corresponding travel path of a bowling ball, the elongated member being positioned above the bowling alley in a manner such that the bowling ball contacts and deflects the bottom portion of an individual one of the targets so as to mark the path of the bowling ball.
BRIEF DESCRIPTION OF THE DRAWINGS
For a full understanding of the invention, reference should be made to the following description taken in connection with the accompanying drawings in which:
FIG. 1 is a front elevational view of the aiming apparatus of the present invention.
FIG. 2 is a side elevational view taken along line 2--2 in FIG. 1.
FIG. 3 is a close-up front elevational view of an individual target panel utilized by the aiming apparatus of the present invention.
FIG. 4 is a side elevational view taken along line 4--4 of FIG. 3.
FIG. 5 is a top plan view of a bowling alley equipped with the aiming apparatus of the present invention.
FIG. 6 is a front elevational view of a mounting plate which can be utilized with the aiming apparatus of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, aiming apparatus 1 of the present invention comprises generally of horizontal support bar 8, vertical support members 4a, 4b, and transverse members or feet 2a, 2b. Velcro strips 14a, 14b are placed on the bottom surface of each member 2a, 2b, respectively so as to contact corresponding velcro strips (not shown) positioned on lane or alley separators 16a, 16b, respectively. Each velcro strip 14a, 14b (14b') is about 2 inches wide and 2 inches long. The utilization of the velcro strips in this instance adds stability to apparatus 1 and prevents the apparatus from sliding or falling off alley or lane separators 16a, 16b. T-shaped members 3a and 3b are fixed to members 2a and 2b, respectively. Transverse members 2a, 2b have a length of about 24 inches. The bottom ends of vertical support members 4a and 4b are disposed within top openings (not shown) of T-shaped members 3a and 3b, respectively. Vertical support members 4a, 4b have a height of about 20 inches. Horizontal support bar 8 has each end thereof disposed within a corresponding bore of tubular members 6a and 6b. In a preferred embodiment, support bar 8 is fabricated from steel tubing and is about 1/2 inch in diameter and about 66 inches in length. Preferably, support bar 8 is positioned at a height of about 18 inches above the bowling alley. Tubular members 6a and 6b are removably mounted to vertical support members 4a and 4b, respectively, via cylindrical inserts 5a and 5b, respectively. Inserts 5a, 5b are disposed within corresponding bores in the upper portions of vertical support members 4a, 4b, respectively. Tubular members 6a, 6b are fabricated from plastic or polyvinyl chloride (p.v.c.) and are about 2 inches in diameter and about 11 inches in length.
Spring member 18a is interposed between cylindrical insert 5a and transverse member 2a. Spring member 18b is interposed between tubular member 6a and transverse member 2a. Similarly, spring member 18c is interposed between cylindrical insert 5b and transverse member 2b. Spring member 18d is interposed between cylindrical insert 5b and transverse member 2b. Each spring member 18a-d has each end thereof fastened to a corresponding eye-hook 19a-h. Spring members 18a-d add structural support to the entire aiming apparatus.
Vertical support members 4a, 4b are provided with a plurality of longitudinally spaced openings which are capable of receiving inserts 5a, 5b, respectively, so as to allow the height of horizontal support bar 8 to be varied within the range from about 15 inches to about 18 inches, depending on the accuracy desired by the bowlers. Smaller size spring members 18a-d may be utilized when support bar 8 is at a minimum height above the bowling alley.
Target panels 10a-g are rotatably and slidably attached to horizontal support bar 8 and are uniformly spaced across the full width of bowling alley 22. Referring to FIGS. 3 and 4, upper portion 12 of each target panel (shown as 10) is curved so as to form groove 12a. Tubular member 9 is frictionally inserted into groove 12a and has an inner diameter that is slightly larger than the outer diameter of horizontal support bar 8 so as to facilitate rotation of each target panel 10a-g about support bar 8. In a preferred embodiment, each tubular member 9 is fabricated from p.v.c. tubing, has a length of 51/4 inches and an outer diameter of ˜ inch. The larger inner diameter of each tubular member 9 also allows the user of apparatus 1 to slidably mount each target panel on support bar 8 during assembly of the apparatus. Hence, each target panel 10a-g can move axially and rotatably upon support bar 8. Each target panel 10a-g is fabricated from 1/8 inch thick plexiglass, and is about 5 inches wide at upper portion 12, and tapers to a width of about 21/2 inches at lower portion 11. Thus, each target panel is sufficiently light in weight so as to not significantly alter the velocity of the bowling ball. Each target 10a-g is about 12 inches in length from upper portion 12 to lower portion 11. Tubular members 6a, 6b keep each target panel 10a-g positioned over its corresponding section of alley 22 and prevent each target panel from axially moving away from its corresponding section. The bottom portion 11a-g of each target panel 10a-g is covered with a thin rubber layer or shim 13 to absorb the impact of the contact between the bowling ball and the target panel and to prevent deflection of the bowling ball as it passes through aiming apparatus 1. Shim 13, if utilized, can be glued or taped to bottom portion 11a-g of each target panel 10a-g, respectively. Preferably, rubber shim 13 is about two (2) inches in length. Each target panel 10a-g is a different color so as to aid the bowler in quick identification of the area to which he or she must direct the bowling ball. Additionally, target panels having different geometric shapes can also be utilized.
Referring to FIG. 5, aiming apparatus 1 is positioned over alley 22 in a manner such that transverse members 2a, 2b are longitudinally positioned upon lane separators 16a, 16b, respectively, and horizontal support bar 8 is substantially perpendicular to the axis of alley 22 (see also FIG. 2). Each target panel 10a-g corresponds to a path on which the bowler may desire to have his or her ball roll. For instance, if the bowler desires to knock down pin 24j, he or she might throw the ball so that it will contact target 10g. However, the bowlers may use targets 10a-g in any manner so as to improve their game. For instance, if a bowler knows that he or she utilizes a "curve" in his or her toss, he or she may aim for target 10g so as to hit pin 24a. Furthermore, if a bowler desires to concentrate on directing the bowling ball to a specific path, the bowler may assemble aiming apparatus 1 so as to utilize only one of the target panels which may be slidably adjusted so as to designate or spot a specific path.
In an alternate embodiment, transverse members 2a and 2b and spring members 18a-d may be replaced by mounting plates 25 (see FIG. 6) which are attached rigidly to bowling alley lane separators 16a and 16b. Each mounting plate has an opening 26 to receive the bottom end of a corresponding vertical support member 4a, 4b. Each mounting plate also has a plurality of apertures 28 for receiving fasteners, i.e., screws, nails, etc. which are utilized to attach the mounting plate to the lane separator. Base 30 of mounting plate 25 is substantially flat and has a length of about 3 inches. The height of the mounting plate (designated by the letter "H"), between top portion 32 and bottom surface 30a, may be from about 1 inch to about 2 inches. In a preferred embodiment, mounting plate 25 is fabricated from steel.
Aiming apparatus 1 enhances a bowler's concentration and facilitates identification of the proper path on which to direct the bowling ball in order to contact specific bowling pins. The apparatus of the present invention also facilitates instructing younger bowlers, e.g., children who do not yet have a grasp on the fundamentals of the game of bowling. The aiming apparatus of the present invention also provides visual aids to the bowlers who are sight impaired since the bright colors of the target panels facilitate quick identification of a desired path. The lightweight and simplicity of the construction of apparatus 1 facilitates portability of the apparatus. The apparatus can be assembled and disassembled with ease.
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 constructions 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 drawings shall be interpreted as illustrative and not in a limiting sense.
While the invention has been illustrated and described in what are considered to be the most practical and preferred embodiments, it will be recognized that many variations are possible and come within the scope thereof, the appended claims therefore being entitled to a full range of equivalents.
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An aiming apparatus for a bowling alley comprising an elongated member, means for supporting the elongated member in a substantially horizontal position above and across the bowling alley, the elongated member being substantially perpendicular to the axis of the bowling alley, and a plurality of independently hanging target panels rotatably attached to the elongated member in a manner such that the target panels are uniformly spaced across the full width of the bowling alley, each of said target panels indicating a corresponding travel path of a bowling ball, said elongated member being positioned above the bowling alley in a manner such that the bowling ball contacts and deflects the bottom portion of an individual one of the targets so as to mark the path of the bowling ball.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of the Korean Patent Application No. 10-2007-0099411, filed on Oct. 2, 2007, which is hereby incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a mobile terminal, and more particularly, to a mobile terminal and method of controlling the same. Although the present invention is suitable for a wide scope of applications, it is particularly suitable for configuring a display screen to enhance user's convenience.
2. Discussion of the Related Art
A mobile terminal is a device which may be configured to perform various functions. Examples of such functions include data and voice communications, capturing images and video via a camera, recording audio, playing music files via a speaker system, and displaying images and video on a display. Some terminals include additional functionality which supports game playing, while other terminals are configured as multimedia players. More recently, mobile terminals have been configured to receive broadcast and multicast signals which permit viewing of content such as videos and television programs.
Efforts are ongoing to support and increase the functionality of mobile terminals. Such efforts include software and hardware improvements, as well as changes and improvements in the structural components which form the mobile terminal.
Recently, various terminals equipped with touchscreens, via which various commands can be inputted, have been introduced.
Hence, it is necessary to discuss how to facilitate a user to input various commands with a prescribed configuration of a display screen or a touchscreen.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a mobile terminal, computer program product and method for controlling the same that substantially obviate one or more problems due to limitations and disadvantages of the related art.
An object of the present invention is to provide a mobile terminal, computer program product and method for controlling the same, by which a terminal user is enabled to input specific commands to the mobile terminal with minimum effort in a manner of configuring a display screen with consideration of enhanced user's convenience.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, a mobile terminal according to the present invention includes a display unit, a wireless communication unit for an internet access, a user input unit for receiving an input from a user, and a control unit configured to display both a text input box and an indicator indicating a selected one among at least two functions of the text input box on a standby image of the display unit.
In another aspect of the present invention, a method of controlling a mobile terminal includes displaying a text input box on a standby image, and allocating at least two functions to the text input box.
It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings:
FIG. 1 is a block diagram of a mobile terminal in accordance with an embodiment of the present invention;
FIG. 2 is a perspective view of a front side of a mobile terminal according to an embodiment of the present invention;
FIG. 3 is a rear view of the mobile terminal shown in FIG. 2 ;
FIG. 4 is a block diagram of a CDMA wireless communication system operable with the mobile terminal of FIGS. 1 to 3 ;
FIG. 5 is a flowchart for a method of controlling a mobile terminal according to a first embodiment of the present invention;
FIG. 6 is a diagram of a display screen on which a method of controlling a mobile terminal according to a first embodiment of the present invention is implemented;
FIG. 7 is a flowchart for a method of controlling a mobile terminal according to a second embodiment of the present invention;
FIG. 8 is a diagram of a display screen on which a method of controlling a mobile terminal according to a second embodiment of the present invention is implemented;
FIG. 9 is a diagram of a display screen on which a method of controlling a mobile terminal according to a third embodiment of the present invention is implemented;
FIGS. 10 to 14 are diagrams of a display screen on which a method of controlling a mobile terminal according to a fourth embodiment of the present invention is implemented; and
FIG. 15 is a diagram of a display screen on which a method of controlling a mobile terminal according to a fifth embodiment of the present invention is implemented.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. It is to be understood by those of ordinary skill in this technological field that other embodiments may be utilized, and structural, electrical, as well as procedural changes may be made without departing from the scope of the present invention. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
In the following description, suffixes ‘module’, ‘unit’ and ‘part’ for elements are given to facilitate the preparation of this disclosure only. So, significant meanings or roles are not given to the suffixes themselves. Hence, it is understood that the ‘module’, ‘unit’ and ‘part’ can be used together.
FIG. 1 is a block diagram of mobile terminal 100 in accordance with an embodiment of the present invention. The mobile terminal may be implemented using a variety of different types of terminals. Examples of such terminals include mobile as well as non-mobile terminals, such as mobile phones, user equipment, smart phones, computers, digital broadcast terminals, personal digital assistants, portable multimedia players (PMP) and navigators. By way of non-limiting example only, further description will be with regard to a mobile terminal. However, such teachings apply equally to other types of terminals. FIG. 1 shows the mobile terminal 100 having various components, but it is understood that implementing all of the illustrated components is not a requirement. Greater or fewer components may alternatively be implemented.
FIG. 1 shows a wireless communication unit 110 configured with several commonly implemented components. For instance, the wireless communication unit 110 typically includes one or more components which permits wireless communication between the mobile terminal 100 and a wireless communication system or network within which the mobile terminal is located.
The broadcast receiving module 111 receives a broadcast signal and/or broadcast associated information from an external broadcast managing entity via a broadcast channel. The broadcast channel may include a satellite channel and a terrestrial channel. The broadcast managing entity refers generally to a system which transmits a broadcast signal and/or broadcast associated information. Examples of broadcast associated information include information associated with a broadcast channel, a broadcast program, a broadcast service provider, etc. For instance, broadcast associated information may include an electronic program guide (EPG) of digital multimedia broadcasting (DMB) and electronic service guide (ESG) of digital video broadcast-handheld (DVB-H).
The broadcast signal may be implemented as a TV broadcast signal, a radio broadcast signal, and a data broadcast signal, among others. If desired, the broadcast signal may further include a broadcast signal combined with a TV or radio broadcast signal.
The broadcast receiving module 111 may be configured to receive broadcast signals transmitted from various types of broadcast systems. By nonlimiting example, such broadcasting systems include digital multimedia broadcasting-terrestrial (DMB-T), digital multimedia broadcasting-satellite (DMB-S), digital video broadcast-handheld (DVB-H), the data broadcasting system known as media forward link only (MediaFLO®) and integrated services digital broadcast-terrestrial (ISDB-T). Receiving of multicast signals is also possible. If desired, data received by the broadcast receiving module 111 may be stored in a suitable device, such as memory 160 .
The mobile communication module 112 transmits/receives wireless signals to/from one or more network entities (e.g., base station, Node-B). Such signals may represent audio, video, multimedia, control signaling, and data, among others.
The wireless internet module 113 supports Internet access for the mobile terminal. This module may be internally or externally coupled to the terminal. Suitable technologies for wireless internet may include, but are not limited to, WLAN (Wireless LAN) (Wi-Fi), Wibro (Wireless broadband), Wimax (World Interoperability for Microwave Access), HSDPA (High Speed Downlink Packet Access).
The short-range communication module 114 facilitates relatively short-range communications. Suitable technologies for short-range communication my include, but are not limited to, radio frequency identification (RFID), infrared data association (IrDA), ultra-wideband (UWB), as well at the networking technologies commonly referred to as Bluetooth and ZigBee, to name a few.
Position-location module 115 identifies or otherwise obtains the location of the mobile terminal. If desired, this module may be implemented using global positioning system (GPS) components which cooperate with associated satellites, network components, and combinations thereof.
Audio/video (A/V) input unit 120 is configured to provide audio or video signal input to the mobile terminal. As shown, the A/V input unit 120 includes a camera 121 and a microphone 122 . The camera receives and processes image frames of still pictures or video.
The microphone 122 receives an external audio signal while the portable device is in a particular mode, such as phone call mode, recording mode and voice recognition. This audio signal is processed and converted into digital data. The portable device, and in particular, A/V input unit 120 , typically includes assorted noise removing algorithms to remove noise generated in the course of receiving the external audio signal. Data generated by the A/V input unit 120 may be stored in memory 160 , utilized by output unit 150 , or transmitted via one or more modules of communication unit 110 . If desired, two or more microphones and/or cameras may be used.
The user input unit 130 generates input data responsive to user manipulation of an associated input device or devices. Examples of such devices include a keypad, a dome switch, a touchpad (e.g., static pressure/capacitance), a jog wheel and a jog switch. A specific example is one in which the user input unit 130 is configured as a touchpad in cooperation with a touchscreen display (which will be described in more detail below).
The sensing unit 140 provides status measurements of various aspects of the mobile terminal. For instance, the sensing unit may detect an open/close status of the mobile terminal, relative positioning of components (e.g., a display and keypad) of the mobile terminal, a change of position of the mobile terminal or a component of the mobile terminal, a presence or absence of user contact with the mobile terminal, orientation or acceleration/deceleration of the mobile terminal. As an example, consider the mobile terminal 100 being configured as a slide-type mobile terminal. In this configuration, the sensing unit 140 may sense whether a sliding portion of the mobile terminal is open or closed. Other examples include the sensing unit 140 sensing the presence or absence of power provided by the power supply 190 , the presence or absence of a coupling or other connection between the interface unit 170 and an external device.
The interface unit 170 is often implemented to couple the mobile terminal with external devices. Typical external devices include wired/wireless headphones, external chargers, power supplies, storage devices configured to store data (e.g., audio, video, pictures, etc.), earphones, and microphones, among others. The interface unit 170 may be configured using a wired/wireless data port, a card socket (e.g., for coupling to a memory card, subscriber identity module (SIM) card, user identity module (UIM) card, removable user identity module (RUIM) card), audio input/output ports and video input/output ports.
The output unit 150 generally includes various components which support the output requirements of the mobile terminal. Display 151 is typically implemented to visually display information associated with the mobile terminal 100 . For instance, if the mobile terminal is operating in a phone call mode, the display will generally provide a user interface or graphical user interface which includes information associated with placing, conducting, and terminating a phone call. As another example, if the mobile terminal 100 is in a video call mode or a photographing mode, the display 151 may additionally or alternatively display images which are associated with these modes.
One particular implementation includes the display 151 configured as a touch screen working in cooperation with an input device, such as a touchpad. This configuration permits the display to function both as an output device and an input device.
The display 151 may be implemented using known display technologies including, for example, a liquid crystal display (LCD), a thin film transistor-liquid crystal display (TFT-LCD), an organic light-emitting diode display (OLED), a flexible display and a three-dimensional display. The mobile terminal may include one or more of such displays. An example of a two-display embodiment is one in which one display is configured as an internal display (viewable when the terminal is in an opened position) and a second display configured as an external display (viewable in both the open and closed positions).
FIG. 1 further shows output unit 150 having an audio output module 152 which supports the audio output requirements of the mobile terminal 100 . The audio output module is often implemented using one or more speakers, buzzers, other audio producing devices, and combinations thereof. The audio output module functions in various modes including call-receiving mode, call-placing mode, recording mode, voice recognition mode and broadcast reception mode. During operation, the audio output module 152 outputs audio relating to a particular function (e.g., call received, message received, and errors).
The output unit 150 is further shown having an alarm 153 , which is commonly used to signal or otherwise identify the occurrence of a particular event associated with the mobile terminal. Typical events include call received, message received and user input received. An example of such output includes the providing of tactile sensations (e.g., vibration) to a user. For instance, the alarm 153 may be configured to vibrate responsive to the mobile terminal receiving a call or message. As another example, vibration is provided by alarm 153 responsive to receiving user input at the mobile terminal, thus providing a tactile feedback mechanism. It is understood that the various output provided by the components of output unit 150 may be separately performed, or such output may be performed using any combination of such components.
The memory 160 is generally used to store various types of data to support the processing, control, and storage requirements of the mobile terminal. Examples of such data include program instructions for applications operating on the mobile terminal, contact data, phonebook data, messages, pictures, video, etc. The memory 160 shown in FIG. 1 may be implemented using any type (or combination) of suitable volatile and non-volatile memory or storage devices including random access memory (RAM), static random access memory (SRAM), electrically erasable programmable read-only memory (EEPROM), erasable programmable read-only memory (EPROM), programmable read-only memory (PROM), read-only memory (ROM), magnetic memory, flash memory, magnetic or optical disk, card-type memory, or other similar memory or data storage device.
The controller 180 typically controls the overall operations of the mobile terminal. For instance, the controller performs the control and processing associated with voice calls, data communications, instant message communication, video calls, camera operations and recording operations. If desired, the controller may include a multimedia module 181 which provides multimedia playback. The multimedia module may be configured as part of the controller 180 , or this module may be implemented as a separate component.
The power supply 190 provides power required by the various components for the portable device. The provided power may be internal power, external power, or combinations thereof.
Various embodiments described herein may be implemented in a computer-readable medium using, for example, computer software, hardware, or some combination thereof. For a hardware implementation, the embodiments described herein may be implemented within one or more application specific integrated circuits (ASICs), digital signal processors (DSPs), digital signal processing devices (DSPDs), programmable logic devices (PLDs), field programmable gate arrays (FPGAs), processors, controllers, micro-controllers, microprocessors, other electronic units designed to perform the functions described herein, or a selective combination thereof. In some cases, such embodiments are implemented by controller 180 .
For a software implementation, the embodiments described herein may be implemented with separate software modules, such as procedures and functions, each of which perform one or more of the functions and operations described herein. The software codes can be implemented with a software application written in any suitable programming language and may be stored in memory (for example, memory 160 ), and executed by a controller or processor (for example, controller 180 ).
Mobile terminal 100 may be implemented in a variety of different configurations. Examples of such configurations include folder-type, slide-type, bar-type, rotational-type, swing-type and combinations thereof. For clarity, further disclosure will primarily relate to a slide-type mobile terminal. However such teachings apply equally to other types of terminals.
FIG. 2 is a perspective view of a front side of a mobile terminal according to an embodiment of the present invention. In FIG. 2 , the mobile terminal 100 is shown having a first body 200 configured to slideably cooperate with a second body 205 . The user input unit (described in FIG. 1 ) may include a first input unit such as the touchpad and function keys 210 , a second input unit such as keypad 215 and a third input unit such as side keys 245 . The function keys 210 are associated with first body 200 , and the keypad 215 is associated with second body 205 . The keypad includes various keys (e.g., numbers, characters, and symbols) to enable a user to place a call, prepare a text or multimedia message, and otherwise operate the mobile terminal.
The first body 200 slides relative to second body 205 between open and closed positions. In a closed position, the first body is positioned over the second body in such a manner that the keypad 215 is substantially or completely obscured by the first body 200 . In the open position, user access to the keypad 215 , as well as the display 151 and function keys 210 , is possible. The function keys are convenient to a user for entering commands such as start, stop and scroll.
The mobile terminal 100 is operable in either a standby mode (e.g., able to receive a call or message, receive and respond to network control signaling), or an active call mode. Typically, the mobile terminal 100 functions in a standby mode when in the closed position, and an active mode when in the open position, This mode configuration may be changed as required or desired.
The first body 200 is shown formed from a first case 220 and a second case 225 , and the second body 205 is shown formed from a first case 230 and a second case 235 . The first and second cases are usually formed from a suitably ridge material such as injection molded plastic, or formed using metallic material such as stainless steel (STS) and titanium (Ti).
If desired, one or more intermediate cases may be provided between the first and second cases of one or both of the first and second bodies 200 , 205 . The first and second bodies 200 , 205 are typically sized to receive electronic components necessary to support operation of the mobile terminal 100 .
The first body 200 is shown having a camera 121 and audio output unit 152 , which is configured as a speaker, positioned relative to the display 151 . If desired, the camera 121 may be constructed in such a manner that it can be selectively positioned (e.g., rotated, swiveled, etc.) relative to first body 200 .
The function keys 210 are positioned adjacent to a lower side of the display 151 . The display 151 is shown implemented as an LCD or OLED. Recall that the display may also be configured as a touchscreen having an underlying touchpad which generates signals responsive to user contact (e.g., finger, stylus, etc.) with the touchscreen.
Second body 205 is shown having a microphone 122 positioned adjacent to keypad 215 , and side keys 245 , which are one type of a user input unit, positioned along the side of second body 205 . Preferably, the side keys 245 may be configured as hot keys, such that the side keys are associated with a particular function of the mobile terminal. An interface unit 170 is shown positioned adjacent to the side keys 245 , and a power supply 190 in a form of a battery is located on a lower portion of the second body 205 .
FIG. 3 is a rear view of the mobile terminal shown in FIG. 2 . FIG. 3 shows the second body 205 having a camera 121 , and an associated flash 250 and mirror 255 . The flash operates in conjunction with the camera 121 of the second body. The mirror 255 is useful for assisting a user to position camera 121 in a self-portrait mode. The camera 121 of the second body faces a direction which is opposite to a direction faced by camera 121 of the first body 200 ( FIG. 2 ). Each of the cameras 121 of the first and second bodies may have the same or different capabilities.
In an embodiment, the camera of the first body 200 operates with a relatively lower resolution than the camera of the second body 205 . Such an arrangement works well during a video conference, for example, in which reverse link bandwidth capabilities may be limited. The relatively higher resolution of the camera of the second body 205 ( FIG. 3 ) is useful for obtaining higher quality pictures for later use or for communicating to others.
The second body 205 also includes an audio output module 152 configured as a speaker, and which is located on an upper side of the second body. If desired, the audio output modules of the first and second bodies 200 , 205 , may cooperate to provide stereo output. Moreover, either or both of these audio output modules may be configured to operate as a speakerphone.
A broadcast signal receiving antenna 260 is shown located at an upper end of the second body 205 . Antenna 260 functions in cooperation with the broadcast receiving module 111 ( FIG. 1 ). If desired, the antenna 260 may be fixed or configured to retract into the second body 205 . The rear side of the first body 200 includes slide module 265 , which slideably couples with a corresponding slide module located on the front side of the second body 205 .
It is understood that the illustrated arrangement of the various components of the first and second bodies 200 , 205 , may be modified as required or desired. In general, some or all of the components of one body may alternatively be implemented on the other body. In addition, the location and relative positioning of such components are not critical to many embodiments, and as such, the components may be positioned at locations which differ from those shown by the representative figures.
The mobile terminal 100 of FIGS. 1-3 may be configured to operate within a communication system which transmits data via frames or packets, including both wireless and wireline communication systems, and satellite-based communication systems. Such communication systems utilize different air interfaces and/or physical layers.
Examples of such air interfaces utilized by the communication systems include example, frequency division multiple access (FDMA), time division multiple access (TDMA), code division multiple access (CDMA), and universal mobile telecommunications system (UMTS), the long term evolution (LTE) of the UMTS, and the global system for mobile communications (GSM). By way of non-limiting example only, further description will relate to a CDMA communication system, but such teachings apply equally to other system types.
Referring now to FIG. 4 , a CDMA wireless communication system is shown having a plurality of mobile terminals 100 , a plurality of base stations 270 , base station controllers (BSCs) 275 , and a mobile switching center (MSC) 280 . The MSC 280 is configured to interface with a conventional public switch telephone network (PSTN) 290 . The MSC 280 is also configured to interface with the BSCs 275 . The BSCs 275 are coupled to the base stations 270 via backhaul lines. The backhaul lines may be configured in accordance with any of several known interfaces including, for example, E1/T1, ATM, IP, PPP, Frame Relay, HDSL, ADSL, or xDSL. It is to be understood that the system may include more than two BSCs 275 .
Each base station 270 may include one or more sectors, each sector having an omnidirectional antenna or an antenna pointed in a particular direction radially away from the base station 270 . Alternatively, each sector may include two antennas for diversity reception. Each base station 270 may be configured to support a plurality of frequency assignments, with each frequency assignment having a particular spectrum (e.g., 1.25 MHz, 5 MHz).
The intersection of a sector and frequency assignment may be referred to as a CDMA channel. The base stations 270 may also be referred to as base station transceiver subsystems (BTSs). In some cases, the term “base station” may be used to refer collectively to a BSC 275 , and one or more base stations 270 . The base stations may also be denoted “cell sites.” Alternatively, individual sectors of a given base station 270 may be referred to as cell sites.
A terrestrial digital multimedia broadcasting (DMB) transmitter 295 is shown broadcasting to portable terminals 100 operating within the system. The broadcast receiving module 111 ( FIG. 1 ) of the portable terminal is typically configured to receive broadcast signals transmitted by the DMB transmitter 295 . Similar arrangements may be implemented for other types of broadcast and multicast signaling (as discussed above).
FIG. 4 further depicts several global positioning system (GPS) satellites 300 . Such satellites facilitate locating the position of some or all of the portable terminals 100 . Two satellites are depicted, but it is understood that useful positioning information may be obtained with greater or fewer satellites. The position-location module 115 ( FIG. 1 ) of the portable terminal 100 is typically configured to cooperate with the satellites 300 to obtain desired position information. It is to be appreciated that other types of position detection technology, (i.e., location technology that may be used in addition to or instead of GPS location technology) may alternatively be implemented. If desired, some or all of the GPS satellites 300 may alternatively or additionally be configured to provide satellite DMB transmissions.
During typical operation of the wireless communication system, the base stations 270 receive sets of reverse-link signals from various mobile terminals 100 . The mobile terminals 100 are engaging in calls, messaging, and other communications. Each reverse-link signal received by a given base station 270 is processed within that base station. The resulting data is forwarded to an associated BSC 275 . The BSC provides call resource allocation and mobility management functionality including the orchestration of soft handoffs between base stations 270 . The BSCs 275 also route the received data to the MSC 280 , which provides additional routing services for interfacing with the PSTN 290 . Similarly, the PSTN interfaces with the MSC 280 , and the MSC interfaces with the BSCs 275 , which in turn control the base stations 270 to transmit sets of forward-link signals to the mobile terminals 100 .
In the following description, a controlling method implemented in the above-configured will be explained per an embodiment. It is to be understood that each of the following embodiments can be implemented independently or that the present invention may be performed using any combination of such embodiments.
In the following description, it is assumed that the mobile terminal includes the slider type terminal including the first and second bodies. In particular, the first body 200 is a main body and the second body 205 is a slider that slides on the main body. And, it is also to be understood that the present invention is applicable to but not limited to a folder type terminal, a swing type terminal and the like as well as the slider type terminal.
First Embodiment
A method of controlling a mobile terminal according to a first embodiment of the present invention is explained with reference to FIG. 5 and FIG. 6 as follows.
FIG. 5 is a flowchart for a method of controlling a mobile terminal according to a first embodiment of the present invention, and FIG. 6 is a diagram of a display screen on which a method of controlling a mobile terminal according to a first embodiment of the present invention is implemented.
Referring to ( 6 - 1 ) of FIG. 6 , a standby image is displayed on a touchscreen 400 of the mobile terminal 100 . And, a text input box 410 is displayed on the standby image [S 51 ]. A standby image is an image displayed when the device is in a standby state (e.g., awaiting a user input).
The text input box 410 is usable for at least two functions. Details of the first and second functions will be explained later in this disclosure.
An indicator 420 indicating which one of the first and second functions is used for the text input box 410 is displayed on the standby image [S 52 ].
In case that the display module 151 of the mobile terminal 100 does not include a touchscreen, it is able to configure the first and second functions, as shown in ( 6 - 1 ) and ( 6 - 2 ) of FIG. 6 , to be mutually switched each other via a corresponding key manipulation (e.g., soft key manipulation) of the user input unit [S 53 , S 54 ].
In case that the display module 151 of the mobile terminal 100 is configured to operate as a touchscreen in a manner of constructing a mutual layer structure with the touchpad, it is able to configure the first and second functions, as shown in ( 6 - 1 ) and ( 6 - 4 ) of FIG. 6 , to be mutually switched to each other by having the indicator 420 touched (e.g., long touch). In this case, the indicator 420 plays a role as a toggle switch type selector to select either the first function or the second function [S 53 , S 54 ].
In the following description, it is assumed that the display module 151 operates as a touchscreen.
In ( 6 - 1 ) of FIG. 6 , depicted is an example that the text input box 410 is in progress of the first function, e.g., a search function (e.g., a Google™ search function).
For the search function, a terminal user selects the text input box 410 , for example by touching the text input box 410 .
Subsequently, a prescribed search word, as shown in ( 6 - 2 ) of FIG. 6 , is inputted to the text input box 410 via the user input unit 130 . It can be considered that when the text input box 410 is selected, a virtual keypad is created on the touchscreen, and the search word is inputted via the created virtual keypad.
After the search word has been inputted, if a command for executing a search for the search word is inputted, a result of the search corresponding to the search word, as shown in ( 6 - 3 ) of FIG. 6 , is displayed.
The execution command for the search can be carried out by a corresponding key manipulation (e.g., soft key manipulation) of the user input unit or by a touch of the indicator (e.g., short touch).
Meanwhile, a case of attempting to use the text input box 410 for the second function, e.g., an internet address input function (e.g., internet URL (uniform resource locator) input function) is explained as follows.
On the touchscreen 400 shown in ( 6 - 1 ) of FIG. 6 , a terminal user makes a long touch to the indicator 420 . If so, the text input box is switched for the second function. The indicator 420 , as shown in ( 6 - 4 ) of FIG. 6 , indicates that the text input box 410 is usable for the internet URL input function.
Subsequently, a prescribed internet URL, as shown in ( 6 - 5 ) of FIG. 6 , is inputted to the text input box 410 via the user input unit 130 . It can be considered that when the text input box 410 is selected, a virtual keypad is created on the touchscreen, and the internet URL is inputted via the created virtual keypad.
After completion of the internet URL input, if a command for executing an entry to the internet URL is inputted, a webpage, as shown in ( 6 - 6 ) of FIG. 6 , corresponding to the internet URL is displayed.
The command for the entry to the internet URL can be carried out via a corresponding key manipulation (e.g., soft key manipulation) of the user input unit 130 or a touch (e.g., short touch) of the indicator 420 .
The above-explained first and second functions are not limited to the search function and the internet URL input function, respectively. For the first and second functions, two functions can be selected from the group consisting of a first preset website search function, a second preset website search function, an internet address input function, a calculator function, and a file search function within a terminal.
In addition to the previously described embodiments, it is possible for the controller to be configured to distinguish between at least two input pattern types input into the text box, and to automatically select one of the at least two different information access functions based upon a distinguished pattern type. If pattern ambiguous, the controller is further configured to display a option selection screen (e.g, a pop-up window, a drop-down box, a dialog box or another option selection screen).
In addition, whereas the previous description describes the use of a standby image, it is not necessary that the text input box and the indicator to be displayed on a standby image. In such a case, the text input box and the indicator may be displayed on a blank (colored or not) screen.
Also, the indicator need not be a text icon as shown in the figures. In options not shown in the figures, the indicator may be one of a color of the text box, a location of the text box within the display, or a non-text image. For example, a red text box may correspond to a URL entry box, whereas a yellow text box may correspond to a phonebook or web search. Also, a box displayed on a top of the screen may correspond to a URL entry box, whereas a box displayed on a top of the screen may correspond to a phonebook or web search. Also, a displayed first symbol (e.g., a globe) correspond to a URL entry box, whereas a displayed second symbol (e.g., a phone) may correspond to a phonebook search.
Second Embodiment
A method of controlling a mobile terminal according to a second embodiment of the present invention is explained with reference to FIG. 7 and FIG. 8 as follows.
FIG. 7 is a flowchart for a method of controlling a mobile terminal according to a second embodiment of the present invention, and FIG. 8 is a diagram of a display screen on which a method of controlling a mobile terminal according to a second embodiment of the present invention is implemented.
Referring to ( 8 - 1 ) of FIG. 8 , a text input box 410 for a search function is presented in a standby image displayed on the touchscreen 400 [S 71 ]. And, an indicator 420 indicating that the text input box 410 is used for search is displayed together with the text input box 410 .
While the mobile terminal 100 is in a closed position, a real keypad for a text input of the user input unit 130 is not externally exposed. So, the real keypad may be in a deactivated mode [S 72 ].
If the text input box 410 is selected, a virtual keypad 433 , as shown in ( 8 - 2 ) of FIG. 8 , is created on the touchscreen [S 73 , S 74 ]. Hence, a terminal user is able to input a search word via the created virtual keypad.
Optionally, it is able to configure the created virtual keypad to automatically disappear from the touchscreen if the real keypad of the user input unit is in an active mode (e.g., the real keypad is externally exposed since the mobile terminal is in an open position).
Referring to ( 8 - 3 ) of FIG. 8 , the text input box 410 for an internet address input function is presented on a standby image displayed on the touchscreen 400 . And, an indicator 420 indicating that the text input box 410 is used for the internet address input function is displayed together with the text input box 410 .
If the text input box 410 is selected and the real keypad, as shown in ( 8 - 4 ) of FIG. 8 , becomes deactivated, a virtual keypad 435 is created on the touchscreen 400 .
The virtual keypad 435 shown in ( 8 - 4 ) of FIG. 8 needs not to be identical to the virtual keypad 435 shown in ( 8 - 2 ) of FIG. 8 . Namely, the device is able to configure the created virtual keypads to differ at least in part from each other to be most suitable for each of the functions used for the text input box, respectively.
For instance, the virtual keypad 435 shown in ( 8 - 4 ) of FIG. 8 can be provided with such a key button facilitating an internet address input as ‘www’, ‘com’ and the like.
Third Embodiment
In the first embodiment of the present invention, a single text input box is presented in the standby image and the text input box is usable for two functions. The present invention is further applicable to the case that the text input box is usable for at least three functions. This is explained as a third embodiment of the present invention with reference to FIG. 9 .
FIG. 9 is a diagram of a display screen on which a method of controlling a mobile terminal according to a third embodiment of the present invention is implemented.
Referring to ( 9 - 1 ) of FIG. 9 , a text input box 410 is presented in a standby image displayed on the display screen 400 of the mobile terminal 100 . And, an indicator 420 indicating a function for which the text input box 410 will be used is displayed on the display screen 400 together with the text input box 410 . In ( 9 - 1 ) of FIG. 9 , the indicator 420 indicates that the text input box 410 is usable for a first function (e.g., a first preset website search function).
If a long touch is made to the indicator 420 or if a corresponding key manipulation is carried out on the user input unit 140 , the indicator 420 , as shown in ( 9 - 2 ) of FIG. 9 , indicates that the text input box 410 is usable for a second function (e.g., a second preset website search function).
Similarly, whenever a long touch is made to the indicator 420 or each time a corresponding key manipulation is carried out on the user input unit 140 , the indicator 420 , as shown in ( 9 - 3 )/( 9 - 4 ) of FIG. 9 , indicates that the text input box 410 is us usable for a third/fourth function. In this case, a third function may include an internet address input function and a fourth function may include a file search function within a terminal.
So, by making a long touch to the indicator 420 or performing a corresponding key manipulation on the user input unit 130 until a necessary function is assigned to the text input box 410 , a terminal user is able to change a function of the text input box.
Referring to ( 9 - 4 ) of FIG. 9 , if the text input box 410 is double touched for example, it may be able to display a list 415 of texts recently inputted to the text input box 410 .
And, it may able to preset the number of functions used for the text input box 410 via a menu manipulation of the mobile terminal.
Fourth Embodiment
In the above description, a function to be used for the text input box 410 is changed if the indicator 420 is just touched. The present invention enables the function to be changed in various ways. This example is explained as a fourth embodiment of the present invention with reference to FIGS. 10 to 14 .
FIGS. 10 to 14 are diagrams of a display screen on which a method of controlling a mobile terminal according to a fourth embodiment of the present invention is implemented.
Like the descriptions of the first to third embodiments of the present invention, FIG. 10 shows that a text input box 410 and an indicator 440 are displayed. Yet, the indicator 440 shown in FIG. 10 is configured in a slide switch type different from the former indicator 420 of the first to third embodiments.
Referring to ( 10 - 1 ) of FIG. 10 , the indicator 440 indicates that a function used for the text input box is a Google search function for example.
If a slide switch within the indicator 440 is touched and dragged left, a function for the text input box, as shown in ( 10 - 2 ) of FIG. 10 , is changed into an internet address input function. And, the indicator 440 indicates that the text input box is usable for an internet address input.
FIG. 11 shows that the text input box 410 itself is used as a slider switch.
Referring to ( 11 - 1 ) of FIG. 11 , a portion 451 of the indicator is displayed right to the text input box 410 . The portion 451 of the indicator indicates that the text input box 410 is usable in association with Google search.
If the text input box 410 itself is touched and dragged right, the text input box 410 , as shown in ( 11 - 2 ) of FIG. 11 , covers the portion 451 of the indicator and moves to expose a different portion 453 of the indicator.
The different portion 453 of the exposed indicator indicates that the text input box 410 undergoes a function change to be usable in association with an internet URL input.
Referring to ( 12 - 1 ) or ( 12 - 3 ) of FIG. 12 , the indicator 440 shown in FIG. 10 is provided within the text input box 410 shown in FIG. 10 , whereby both of the indicator 440 and the text input box 410 can be built in one body. So, if a text is inputted to the text input box 410 , it is able to configure the indicator 440 , as shown in ( 12 - 2 ) or ( 12 - 4 ) of FIG. 12 , to disappear. This can be easily understood from the description of FIG. 10 without additional explanation. So, details will be omitted in the following description for clarity. Alternatively, it is able to modify the configuration in a manner that both of the indicator 440 and the text input box 410 to be built in one body by providing the indicator 440 shown in FIG. 6 within the text input box 410 shown in FIG. 6 .
Referring to ( 13 - 1 ) or ( 13 - 3 ) of FIG. 13 , a text input filed 410 and a plurality of indicators 451 , 453 and 455 respectively indicating functions of the text input field are simultaneously presented in a standby image displayed on a screen. One of a plurality of the indicators is displayed to be visually discriminated from the rest of the indicators. So, a terminal is facilitated to recognize that the text input filed 410 is usable for the function corresponding to the visually discriminated indicator. The terminal user views a plurality of the indicators at a glance, thereby understanding the functions usable for the text input field intuitively.
FIG. 14 shows that at least two text input boxes 413 and 415 usable for different function are presented in a standby image displayed on a screen of the mobile terminal.
Referring to FIG. 14 , an execution icon 460 is provided next to the text input boxes 413 and 415 to give a command for executing the function relevant to a text inputted to the corresponding text input box 413 / 415 .
Fifth Embodiment
In the above description, the text input box and the indicator corresponding to the text input box are presented in the standby image displayed on the screen. And, it is able to further configure the present invention in a manner that the text input box and the corresponding indicator are implemented on a web browser. This is explained as a fifth embodiment of the present invention with reference to FIG. 15 .
FIG. 15 is a diagram of a display screen on which a method of controlling a mobile terminal according to a fifth embodiment of the present invention is implemented.
Referring to ( 15 - 1 ) of FIG. 15 , a web browser for an internet access is displayed on a display screen 400 of the mobile terminal 100 .
And, a text input box 410 and a corresponding indicator 420 , which are as good as those of the first to fourth embodiments of the present invention, are displayed on the web browser.
Hence, a terminal user enables the web browser to display a webpage of a specific internet URL by inputting the specific internet URL to the text input box 410 in the state shown in ( 15 - 1 ) of FIG. 15 [cf. ( 6 - 6 ) of FIG. 6 ].
Meanwhile, the terminal user makes a long touch to the indicator 420 for example, thereby enabling the text input box, as shown in ( 15 - 2 ) of FIG. 15 , to operate as a search text input box of a specific search engine (e.g., Google).
Hence, if the terminal user inputs a specific search word text to the text input box shown in ( 15 - 2 ) of FIG. 15 regardless of what kind of webpage the web browser displays, the web browser displays a result from searching with the search word text in the specific search engine [cf. ( 6 - 3 ) of FIG. 6 ].
Accordingly, the present invention provides the following effects or advantages.
First of all, according to the present invention, a text input box usable for at least two functions is displayed on a standby image of a mobile terminal or a web browser. Hence, a terminal user is able to directly input a specific text to the text input box on the standby image or web browser in accordance with a specific function.
Secondly, according to the present invention, a text input box and a virtual keypad matching a function of the text input box are displayed on a standby image of a mobile terminal or a web browser. Hence, a terminal user is facilitated to input a specific text to the text input box using the virtual keypad.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the inventions. For instance, the above-described methods can be implemented in a program recorded medium as computer-readable codes. The computer-readable media include all kinds of recording devices in which data readable by a computer system are stored. The computer-readable media include ROM, RAM, CD-ROM, magnetic tapes, floppy discs, optical data storage devices, and the like for example and also include carrier-wave type implementations (e.g., transmission via Internet). And, the computer can include the control unit 180 of the terminal. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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A mobile terminal, computer program product, and method for controlling the same are disclosed, by which a terminal user is enabled to input specific commands to the mobile terminal with minimum effort in a manner of configuring a display screen with consideration of enhanced user's convenience. The present invention includes a display unit, a wireless communication unit for an internet access, a user input unit for receiving an input from a user, and a control unit controlling both a text input box and an indicator indicating one selected from the group consisting of at least two functions of the text input box to be displayed on a standby image of the display unit.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to circuits for processing video signals and more particularly to circuits for improving the television picture quality of a standard broadcast television signals such as NTSC signals.
2. Description of the Prior Art
Efforts are constantly being made to improve television picture quality. Many different picture "enhancers" have been developed, with varying degrees of success. Most enhancers have various problems associated with them, primarily in terms of distortion of the picture.
Television systems having increased resolution are commonly referred to as high definition television (HDTV). Such systems generally fall into three categories. The first category includes NTSC-type systems with evolutionary improvements which give the appearance of higher resolution. For example, various interference effects can be greatly reduced by the use of advanced "comb" filters and by using a digital framestore to eliminate the standard "interlaced" scanning method. A second category retains the 525-line and 4:3 aspect ratio of NSTC TV but employs non-NSTC encoding and requires a wider bandwidth. A third category is completely incompatible with NTSC-type systems and typically includes at least double the number of scan lines as are used in NTSC systems. The major problems associated with the second and third categories of HDTV are partial or complete incompatibility with the standard NTSC system, with resultant high costs associated with changing over to a new system. Therefore, it is desirable to provide some means of increasing picture resolution while maintaining the use of the standard NTSC format.
Circuits for improving television picture quality are disclosed in U.S. Pat. No. 3,859,544 to Nero, U.S. Pat. No. 3,935,384 to Jirka, U.S. Pat. No. 3,938,181 to Avins, U.S. Pat. No. 4,030,121 to Faroudja, U.S. Pat. No. 4,074,308 to Gibson, U.S. Pat. No. 4,268,864 to Green, and U.S. Pat. No. 4,402,006 to Karlock. In the Nero patent, a delay circuit is disclosed for delaying luminance information with respect to chroma information. In addition, a "crispness" circuit is discussed in which preshoot and overshoot in the luminance circuit is provided. In Kurka, a circuit for modulating scan velocity is disclosed to improve picture quality. Avins discloses a circuit in which the bandwidth of the luminance signal is controlled as a function of the amplitude of chrominance information. Faroudja discloses a video crispener in which video signals are differentiated twice and added to the original signal in order to give the appearance of increased bandwidth. In Gibson, a delay line is employed in which a plurality of delayed signals are combined in a controlled fashion in order to accentuate high frequency portions of a video luminance signal. Green discloses an enhancement system in which a fraction of a composite detail signal representative of amplitude variations of the video signal is subjected to processing and added to the delayed video signal to provide a picture with reduced noise while maintaining detail. Karlock discloses an enhancer in which picture detail is enhanced by suppressing large transitions in a video signal and adding the suppressed signal to a main video signal.
SUMMARY OF THE INVENTION
The present invention is directed to a system for substantially improving the picture quality of a standard NTSC system. Broadly, the invention is directed to a system for shifting a video signal, accentuating the luminance and hue of the shifted video signal at the interface between low luminance and high luminance portions of the signal and combining the shifted and accentuated signal with the original video signal. In a preferred embodiment of the invention, a video signal is divided into first and second video signals. The second video signal is shifted in phase with respect to the first video signal by a relatively small amount and is amplified and recombined with the first video signal. The amplification of the shifted second video signal is controlled as a function of the slope of the signal so that the luminance and hue of the shifted signal will be accentuated at steep transitions from low luminance to high luminance. The result of the shifting and selective amplification of the second video signal and remixing with the original signal is a television picture having substantially improved clarity and a distinct impression of depth in the picture.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described with reference to the accompanying drawings, wherein:
FIG. 1 is a block diagram of an analog version of the present invention;
FIG. 2 is a schematic diagram of the phase shift/accentuate circuitry of FIG. 1;
FIG. 3 is a timing diagram showing video signals produced by the present invention; and
FIG. 4 is a schematic diagram of the system of FIG. 1;
FIG. 5 is a block diagram of a digital embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The following description is of the best presently contemplated mode of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention. The scope of the invention is best determined by reference to the appended claims.
Referring to FIG. 1, the present invention operates to modify a composite video signal delivered at an input 10. The modification circuitry may be located at any point in the recording/transmission/reproduction chain. The video signal is supplied to a first amplifier 12 and a second amplifier 14. The output of the amplifier 14 is provided to phase shift/accentuate circuitry 16 which causes the video signal to be selectively shifted and accentuated as a function of its rise time. The modified video signal is recombined with the unmodified output of the amplifier 12 by means of a mixer 18 to provide the final video signal for reproduction.
The fundamental operation of the invention will be described with reference to FIGS. 2 and 3. FIG. 2 illustrates the general configuration of the phase shift/accentuate circuitry 16 of FIG. 1. The purpose of this circuitry is to modify the composite video signal from the amplifier 14 so that the interface from low to high luminance levels will be accentuated as a function of the rise time of the video signal. In addition, the circuit operates to shift the phase of the video signal as a function of its rise time. The video signal from the amplifier 14 is applied to a first RC network which includes a resistor 20 and capacitor 22. The capacitively coupled signal is applied to a first transistor 24 through a resistor 26. A bias is applied to the base of the transistor 24 via a resistor 25. The output at the emitter of the transistor 24 is the output signal for the circuit 16. In operation, the capacitively coupled video signal will drive the transistor 24, with the result being an output which is shifted with respect to the original video signal. The degree of shift is dependent upon the time constant of the RC network. Typically, the RC network will have a very short time constant and the phase shift of the video signal will be quite small. This is illustrated in FIG. 3. The video input signal at the input 10 is illustrated by a waveform 28. Because of the capacitive coupling, the input to the base of the transistor 24 will be shifted with respect to the signal 28, as indicated at 30 in FIG. 3. The degree of shift will be dependent upon the rise time of the video signal 28, with signals having a steep slope as indicated at 28a resulting in a greater shift than signals having a lesser slope as indicated at 28b and 28c. For the portions 28b and 28c, (i.e., low frequency signals) the output of the RC network will closely follow the input signal.
Thus, the video signal will be shifted in proportion to its rise time. In addition, the circuit of FIG. 2 operates to control the gain of the transistor 24, also as a function of the rise time of the video signal. The gain of the transistor 24 is controlled by a second transistor 32. By turning on the transistor 32, a portion of the input signal 30 will be shunted away from the base of the transistor 24, thus reducing the drive to the transistor 24. This gain control is achieved as a function of the rise time of the video signal. The video signal from the amplifier 14 is applied to a second RC network consisting of the resistor 20 and a capacitor 34, and the capacitively coupled signal is applied to the base of the transistor 32 via a resistor 36. As the video signal increases, the drive to the transistor 32 will increase, thus reducing the drive to the transistor 24. The gain of the circuit is thus controlled as a function of the magnitude of the video signal.
The accentuating operation of the circuit 16 is achieved by the operation of the second RC network to control the drive to the transistor 32. The value of the capacitor 34 is greater than that of the capacitor 22, with the result being that the time constant of the second RC network is greater than that of the first RC network. The second RC network will thus shift the video input signal to a greater extent than will the first RC network. This is indicated at 38 in FIG. 3. When the video signal has a steep slope, as at 28a, the signal 38 will lag behind the video signal by a greater extent than the signal 30. This signal 38 is applied to the base of the transistor 32. Since its rise time is relatively slow, the drive to the transistor 32 will initially be quite small. As a result, almost the entire signal 30 will be applied to the base of the transistor 24, with the result being that the output of the transistor 24 will closely track the signal 30. As the magnitude of the signal 38 increases, the transistor 32 will turn on and shunt away an increasing portion of the signal 30 from the base of the transistor 24. The output of the transistor 24 will thus cease to track the signal 30, as indicated at 40a in FIG. 3. The output of the transistor 24 will reach a peak at point 40b, where the signal 30 is at its maximum and the drive to the transistor 32 is at a middle level. As the signal 38 increases, the transistor 32 will progressively shunt away more of the drive to the transistor 24, thus causing its output to reduce as indicated at 40c. For the signal 28b, the lag between the signals 30 and 38 will result in a similar output signal 42. For the signal 28c which does not have a steep slope, the signal 38 will closely track the signal 30, with the result being that the input to the transistor 24 will be progressively and evenly shunted away by the transistor 32. The resulting output of the transistor 24, indicated at 44, will not be accentuated as with the steeper signals.
Thus, the circuit shown in FIG. 2 provides a video output signal (40, 42, 44) in which the interface from low to high luminance portions will be accentuated depending on the slope of the video signal. In addition, the video signal will be phase shifted with respect to the original signal. It should be noted that the accentuation of the interface between high and low luminance portions of the signal will be much more pronounced at transitions from low to high luminance rather than from high to low luminance. When the signal is changing from high luminance to low luminance, the gain of the system begins at a minimum and the reduction in the output of the transistor 24 is achieved as a result of the reduction in the magnitude of the video signal rather than in the gain of the transistor.
The shifted and accentuated signal provided by the circuit of FIG. 2 is mixed with the unmodified video signal at the mixer 18 in order to provide the final video output. The effect is the reproduction of the unmodified video signal in combination with the shifted and accentuated signal. The resulting image seen on a television screen appears to have depth and much higher resolution than an unmodified picture. It is to be noted that the circuit provides improvements both in contrast and hue since it operates on the composite video signal.
A preferred embodiment for the analog circuit of the present invention is shown in FIG. 4. In this figure, various elements which correspond to FIGS. 1 and 2 are similarly labeled. Video signals enter the circuit at a BNC connector 50. The video signal is fed to the amplifier 12 which includes an integrated circuit amplifier 52 and the amplifier 14 which includes an integrated circuit amplifier 54. A terminating resistor 56 helps to match the input impedance of the circuit to a standard 75 ohm transmission line. Potentiometers 58 and 60 control the input impedance to the IC's 52 and 54, respectively, as well as controlling the magnitude of the signal to the IC's. Potentiometers 62 and 64 control the level and phase of feedback signals to the positive input of the IC's 52 and 54, while capacitors 66 and 68 provide AC coupling for the feedback signals. The potentiometer and capacitor network provides control of the high frequency component of the video signal (burst) and stabilizes the IC's when changes in input impedance and gain are made.
Resistors 70, 72, and 74, 76 control the DC offset null of the IC's. In addition, this network helps control the tint of the picture by causing chroma phase changes. A feedback loop made up of potentiometer 78 and capacitor 80 and potentiometer 82 and capacitor 84 provides a means of controlling the gain of the IC's. The capacitors 80 and 84 are present to inhibit excessive ringing. Capacitors 86 and 88 provide compensation to the first stage of the IC's to allow high frequency operation without oscillation.
The output of the IC 52 is coupled to the noninverting input of an IC 90 via a potentiometer 92. Various circuit elements associated with the IC 90 perform the same function as similar elements associated with the IC's 52 and 54. The IC 90 provides the mixing and accentuating function for the circuit. The output of the IC 54 is provided to the second stage compensation inputs of the IC 90 via the potentiometer 20 and the capacitors 22 and 34. The potentiometer 20 and capacitors 22 and 34 form the RC networks which provide the necessary delay in the video signal from the amplifier 14. The desired accentuation of the video signal from the amplifier 14 is accomplished within the IC 90, as is the mixing with the unmodified video signal. In the present embodiment of the invention, the IC 90 is a Fairchild model uA715 high speed amplifier and the capacitors 22 and 34 are coupled to the second stage compensation inputs (pins 7 and 10 of a ten pin package). In the present embodiment of the invention, the capacitors 22 and 34 have values of 220 pf and 33 nf, respectively. The circuitry shown in FIG. 2 is a part of the IC 90. The output of the IC 90 is the mixed output of the unmodified and modified video signals and is provided to drive a television receiver.
The present invention may also be implemented in a digital format. Such a system is illustrated in FIG. 5. In this system, the composite video signal is applied to a buffer 100 and is converted to a digital value by an analog-to-digital converter 102. The analog video signals are sampled once every 62.5 nanoseconds, or at four times the video rate. The analog-to-digital converter used in the present embodiment is a high speed device having 8 bits of resolution. The sampling of the video signal is done under the control of a control logic section 104 which includes a reference clock and read only memory circuits to provide the desired timing control signals.
The output of the analog-to-digital converter is applied to a digital delay circuit 106, the output of which is provided to an arithmetic logic unit 108. The delay circuit is operated under control of the logic 104. The output of the analog-to-digital converter is also applied directly to the arithmetic logic unit 108. The arithmetic logic unit sums the eight-bit signals and provides a ten-bit binary output. This is accomplished by using the carry and propagate outputs of the arithmetic logic unit in order to provide a logarithmic sum which corresponds to the amplification accomplished in the analog embodiment of the invention.
The output of the arithmetic logic unit 108 is applied to a register 110, the contents of which are converted to an analog value by a digital-to-analog converter 112. The output of the converter 112 is supplied to a buffer 114 and is mixed with the original, unmodified video signal by a mixer 116.
The digital embodiment of the invention operates identically to the analog embodiment described above, but is more complex and expensive to implement. Therefore, the analog embodiment is presently preferred.
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A video processor receives a video signal and shifts and accentuates the signal in order to increase the apparent depth and resolution of the signal. The circuit operates to accentuate the interface between low luminance and high luminance portions of a video signal as a function of the slope of the video signal. The accentuated signal is also shifted by a slight amount and is then recombined with the original unmodified video signal. The result is substantially improved picture quality with the use of a minimal number of components.
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This is a Divisional of U.S. patent application Ser. No. 10/143,955, filed May 14, 2002, now U.S. Pat. No. 6,865,963 which claims priority to Japanese Patent Application Serial No. 2001-146282, filed May 16, 2001, Japanese Patent Application Serial No. 2001-193845, filed Jun. 27, 2001, Japanese Patent Application Serial No. 2002-050708, filed Feb. 27, 2002 and Japanese Patent Application Serial No. 2002-0050744, filed Feb. 27, 2002, which are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus and method for lubricating a feed mechanism of a forming machine. Description of the
2. Related Art
Conventionally, in a forming machine, such as an injection molding machine, resin heated and melted in a heating cylinder is injected into a cavity of a mold apparatus under high pressure so that the cavity is filled with the molten resin. The molten resin is then cooled and solidified within the cavity so as to produce a molded article.
The mold apparatus consists of a stationary mold and a movable mold. A mold clamping apparatus for advancing and retracting the movable mold is provided so as to bring the movable mold into contact with the stationary mold and separate the same from the stationary mold, to thereby effect mold closing, mold clamping, and mold opening.
The mold clamping apparatus has a toggle mechanism for advancing and retracting the movable mold. The toggle mechanism is operated through drive of a drive source, such as an electric motor or a servomotor, disposed at a drive section.
FIG. 1 is a sectional view of a drive section of a conventional mold clamping apparatus.
In FIG. 1 , reference numeral 51 denotes a servomotor serving as a drive source. The servomotor 51 is attached to an unillustrated stationary member, such as a toggle support, and has a rotary shaft 52 . The front end (right-hand end in FIG. 1 ) of the rotary shaft 52 is coupled to the rear end (left-hand end in FIG. 1 ) of a ball-screw shaft 56 via a coupling 53 . A key groove is formed on each of the outer circumferential surface of the rotary shaft 52 , the outer circumferential surface of the ball-screw shaft 56 , and the inner circumferential surface of the coupling 53 ; and keys 54 are fitted into the key grooves. Thus, rotation of the rotary shaft 52 is transmitted to the ball-screw shaft 56 via the coupling 53 .
The ball-screw shaft 56 is rotatably supported by bearings 57 accommodated within a bearing housing 58 , which is attached to the unillustrated stationary member, such as a toggle support. The outer rings of the bearings 57 are retained by means of a plate 59 attached to the bearing housing 58 . The ball-screw shaft 56 is fixedly attached to the inner rings of the bearings 57 by means of a nut 60 , so that the ball-screw shaft 56 cannot move along the axial direction.
A screw groove is formed on the outer circumference of the ball-screw shaft 56 over substantially the entire length thereof, and the ball-screw shaft 56 is in screw-engagement with a ball-screw nut 61 . The ball-screw shaft 56 and the ball-screw nut 61 constitute a ball-screw-type feed mechanism. The ball-screw nut 61 is attached to a cross head 62 of a toggle mechanism, which is slidable along guide bars 63 .
Therefore, when the servomotor 51 is operated, rotation of the rotary shaft 52 is transmitted to the ball-screw shaft 56 , and the ball-screw nut 61 in screw-engagement with the ball-screw shaft 56 moves along the axis of the ball-screw shaft 56 . As a result, the cross head 62 is moved leftward and rightward in FIG. 1 . When the cross head 62 is advanced (moved rightward in FIG. 1 ), the toggle mechanism extends so as to advance an unillustrated movable platen, to thereby perform mold closing and mold clamping. When the cross head 62 is retracted (moved leftward in FIG. 1 ), the toggle mechanism contracts so as to retract the movable platen, to thereby perform mold opening.
Since large torque is required to effect mold closing, mold clamping, and mold opening, heavy load acts on a ball screw that is constituted by the ball-screw shaft 56 and the ball-screw nut 61 . In view of this, grease serving as a lubricant is supplied to the ball screw in order to enable smooth movement of the ball screw serving as a feed mechanism and prevent wear of the ball screw to thereby prolong the service life of the ball screw.
However, in the conventional ball screw serving as a feed mechanism, since grease is used for lubrication, maintaining a uniform film of lubricant at the contact surfaces between the balls and the screw is difficult. Consequently, lubrication conditions at respective portions of the ball screw become uneven. In particular, when the stroke of movement of the ball-screw shaft relative to the ball-screw nut is short, the grease is pushed out from the contact surfaces between the balls and the screw, and therefore, maintaining the lubricant film is difficult. As a result, there arises a variation in service life among the respective portions of the ball screw, thereby shortening the overall service life of the ball screw.
When the supply rate of grease is set greater than a required rate in order to guarantee that grease is distributed sufficiently to respective portions of the ball screw, consumption of grease increases. In general, grease is expensive, and therefore, the increased consumption of grease renders maintenance cost of the forming machine extremely high. Further, when the supply rate of grease is increased, excessive grease overflows, scatters, and contaminates the forming machine and an area surrounding the forming machine.
Further, when the ball screw is used for a long period of time, iron particles generated due to wear contaminate grease. If lubrication is performed by use of grease containing iron particles, contact surfaces are abraded by the iron particles. Therefore, grease containing iron particles must be discharged as soon as possible. However, when the supply rate of grease is increased in order to discharge grease containing iron particles as soon as possible, grease is discharged from the ball screw at a high rate, resulting in increased maintenance cost and contamination of the forming machine and an area surrounding the forming machine, as described above.
Moreover, since grasping the progress of wear of the ball screw is difficult, the service life of the ball screw cannot be predicted accurately. Therefore, in some cases the ball screw is used even after its service life has been reached. As a result, the feed mechanism of the forming machine operates erratically, whereby the accuracy of formed products decreases, and other components of the forming machine are affected adversely. Meanwhile, when the ball-screw shaft and the ball-screw nut are replaced prematurely in order to avoid use of the ball screw beyond its service life, the maintenance cost of the forming machine increases.
In view of the foregoing, there has been proposed a method for measuring the amount of iron contained in grease adhering to the ball-screw shaft and the ball-screw nut and predicting the service life of the ball screw. However, this method requires stopping a forming machine so as to collect grease adhering to the ball-screw shaft and the ball-screw nut. When the frequency of operation of collecting grease is increased in order to improve prediction accuracy, the total stoppage time of the forming machine increases, and the productivity of the forming machine decreases. Meanwhile, the frequency of operation of collecting grease is decreased in order to shorten the total stoppage time of the forming machine, prediction accuracy deteriorates.
SUMMARY OF THE INVENTION
An object of the present invention is to solve the above-mentioned problems in conventional techniques and to provide an apparatus and method for lubricating a feed mechanism of a forming machine which can maintain uniform film of lubrication oil on contact surfaces of respective portions of the feed mechanism to thereby prolong service lives of the respective portions of the feed mechanism, reduce maintenance cost, prevent contamination of the forming machine and an area surrounding the forming machine, and prevent wear of the contact surfaces.
Another object of the present invention is to provide an apparatus and method for lubricating a feed mechanism of a forming machine which can detect the amount of iron contained in lubrication oil and control the forming machine properly on the basis of the detected amount of iron.
In order to achieve the above objects, the present invention provides an apparatus for lubricating a feed mechanism of a forming machine, comprising a conversion mechanism for converting rotational motion to rectilinear motion or converting rectilinear motion to rotational motion; and a lubrication oil circulation pipe for supplying lubrication oil to the conversion mechanism and collecting the supplied lubrication oil.
This simple configuration enables maintenance of a uniform film of lubrication oil on contact surfaces of respective portions of the feed mechanism, to thereby prolong the service lives of the respective portions of the feed mechanism.
Preferably, the conversion mechanism includes a screw shaft having a spiral groove; a screw nut having a spiral groove of the same pitch as that of the spiral groove of the screw shaft; and a power transmission member disposed between the spiral groove of the screw shaft and the spiral groove of the screw nut and adapted to transmit power between the screw shaft and the screw nut.
In this case, no friction is produced between the screw shaft and the screw nut, and thus, power is transmitted smoothly. Therefore, rotational motion of one of the screw shaft and the screw nut is efficiently converted to rectilinear motion of the other of the screw shaft and the screw nut.
Preferably, the power transmission member is a group of balls or rollers.
In this case, since a sufficient quantity of lubrication oil is supplied to the peripheral surfaces of the balls or rollers, a lubrication oil film does not break, and therefore, the contact surfaces of the respective portions of the feed mechanism do not wear.
Preferably, the lubrication apparatus further comprises a storage member for storing lubrication oil in an amount such that at least a portion of the screw shaft is immersed in the lubrication oil.
In this case, since a sufficient quantity of lubrication oil is supplied to the peripheral surface of the screw shaft, a lubrication oil film does not break, and therefore, the contact surfaces of the respective portions of the feed mechanism do not wear.
Preferably, the storage member covers at least a portion of the screw shaft to an extent such that the portion is immersed in the lubrication oil.
Alternatively, the lubrication apparatus further comprises a storage member for storing lubrication oil in an amount such that at least a lower portion of a return tube of the screw nut is immersed in the lubrication oil.
Preferably, the storage member covers at least the return tube of the screw nut to an extent such that the return tube is immersed in the lubrication oil.
Preferably, the lubrication apparatus includes filter means disposed in the lubrication oil circulation pipe and adapted to remove impurities contained in the lubrication oil.
In this case, since impurities, such as iron particles and dust, contained in the lubrication oil are removed by the filter means, the contact surfaces of the feed mechanism are not worn away by the impurities, such as iron particles and dust, contained in the lubrication oil.
Preferably, the lubrication apparatus includes a cooling unit disposed in the lubrication oil circulation pipe and adapted to cool the lubrication oil 35 .
In this case, since the respective portions of the feed mechanism are cooled by means of cooled lubrication oil, wear of the feed mechanism can be prevented.
Preferably, the lubrication apparatus includes an iron-content measurement unit disposed in the lubrication oil circulation pipe and adapted to measure iron content of the lubrication oil.
In this case, since the service life of the feed mechanism can be grasped in advance, the feed mechanism can be exchanged with a new one at proper timing.
Preferably, the lubrication apparatus includes control means for controlling the forming machine on the basis of the iron content measured by the iron-content measurement unit.
Preferably, the control means calculates a service life of the conversion mechanism on the basis of the measured iron content.
Preferably, the control means produces a warning for prompting exchange of the lubrication oil or the conversion mechanism when the measured iron content exceeds a predetermined level.
In this case, the timing for exchanging the lubrication oil or the feed mechanism can be grasped reliably.
The present invention provides a method for lubricating a feed mechanism of a forming machine, comprising supplying lubrication oil to a conversion mechanism for converting rotational motion to rectilinear motion or converting rectilinear motion to rotational motion; and collecting the supplied lubrication oil.
This method enables smooth and efficient conversion of rotational motion to rectilinear motion.
Preferably, the conversion mechanism transmits power by means of a screw shaft having a spiral groove; a screw nut having a spiral groove of the same pitch as that of the spiral groove of the screw shaft; and a power transmission member disposed between the spiral groove of the screw shaft and the spiral groove of the screw nut.
In this case, no friction is produced between the screw shaft and the screw nut, and thus, power is transmitted smoothly. Therefore, rotational motion of one of the screw shaft and the screw nut is efficiently converted to rectilinear motion of the other of the screw shaft and the screw nut.
Preferably, the power transmission member is a group of balls or rollers.
In this case, since a sufficient quantity of lubrication oil is supplied to the peripheral surfaces of the balls or rollers, a lubrication oil film does not break, and therefore, the contact surfaces of the respective portions of the feed mechanism do not wear.
Preferably, at least a portion of the screw shaft is immersed in the lubrication oil.
Preferably, at least a portion of the screw shaft is covered by a storage member to an extent such that the portion is immersed in the lubrication oil.
Alternatively, at least a lower portion of a return tube of the screw nut is immersed in the lubrication oil.
Preferably, at least a portion of the return tube of the screw nut is covered by storage member to an extent such that the portion is immersed in the lubrication oil.
Preferably, impurities contained in the lubrication oil are removed by filter means disposed in the lubrication oil circulation pipe.
In this case, since impurities, such as iron particles and dust, contained in the lubrication oil are removed by the filter means, the contact surfaces of the feed mechanism are not worn away by the impurities, such as iron particles and dust, contained in the lubrication oil.
Preferably, the lubrication oil is cooled by a cooling unit disposed in the lubrication oil circulation pipe.
In this case, since the respective portions of the feed mechanism are cooled by means of cooled lubrication oil, wear of the feed mechanism can be prevented.
Preferably, iron content of the lubrication oil is measured by use of an iron-content measurement unit disposed in the lubrication oil circulation pipe.
Preferably, the forming machine is controlled by use of control means and on the basis of the iron content measured by the iron-content measurement unit.
Preferably, the service life of the conversion mechanism is calculated by use of the control means and on the basis of the measured iron content.
Preferably, the control means produces a warning for prompting exchange of the lubrication oil or the conversion mechanism when the measured iron content exceeds a predetermined level.
BRIEF DESCRIPTION OF DRAWINGS
The structure and features of the apparatus and method for lubricating a feed mechanism of a forming machine according to the present invention will be readily appreciated as the same becomes better understood by reference to the drawings, in which:
FIG. 1 is a cross-sectional view of a drive section of a conventional mold clamping apparatus;
FIG. 2 is a schematic view of a mold clamping apparatus of an injection molding machine according to a first embodiment of the present invention;
FIG. 3 is a cross-sectional view of a lubrication apparatus for a feed mechanism according to the first embodiment of the present invention;
FIG. 4 is a cross-sectional view showing a first example structure of the feed mechanism according to the first embodiment of the present invention;
FIG. 5 is a cross-sectional view showing a second example structure of the feed mechanism according to the first embodiment of the present invention;
FIG. 6 is a schematic view showing a third example structure of the feed mechanism according to the first embodiment of the present invention;
FIG. 7 is a cross-sectional view showing a fourth example structure of the feed mechanism according to the first embodiment of the present invention;
FIG. 8 is a cross-sectional view as viewed in the direction of arrow A in FIG. 3 ;
FIG. 9 is a cross-sectional view of a lubrication apparatus for a feed mechanism according to a second embodiment of the present invention;
FIG. 10 is a cross-sectional view as viewed in the direction of arrow B in FIG. 9 ;
FIG. 11 is a partial cross-sectional view showing the lubrication conditions of the feed mechanism according to the second embodiment of the present invention;
FIG. 12 is a cross-sectional view as viewed in the direction of arrow A in FIG. 3 showing a third embodiment of the present invention;
FIG. 13 is a cross-sectional view as viewed in the direction of arrow B in FIG. 9 showing the third embodiment of the present invention; and
FIG. 14 is a diagram showing the configuration of an iron-content measurement unit used in the third embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Embodiments of the present invention will next be described in detail with reference to the drawings. Although the apparatus and method for lubricating a feed mechanism of a forming machine according to the present invention can be applied to various forming machines, such as extrusion molding machines, laminators, transfer molding machines, die casting machines, and IJ encapsulation presses, here, a case in which the present invention is applied to an injection molding machine will be described.
FIG. 2 is a schematic view of a mold clamping apparatus of an injection molding machine according to a first embodiment of the present invention.
In FIG. 2 , reference numeral 15 denotes a frame; 13 denotes a stationary platen, which is fixed to the frame 15 ; 23 denotes a toggle support, serving as a base plate, which is movably disposed on the frame 15 and is separated a predetermined distance from the stationary platen 13 ; 14 denotes tie bars which are disposed to extend between the stationary platen 13 and the toggle support 23 ; and 12 denotes a movable platen which is disposed to face the stationary platen 13 and is reciprocatable (can be moved leftward and rightward in FIG. 2 ) along the tie bars 14 . An unillustrated stationary mold is attached to a surface of the stationary platen 13 , which surface faces the movable platen 12 . An unillustrated movable mold is attached to a surface of the movable platen 12 , which surface faces the stationary platen 13 .
A dive unit 10 is attached to the rear end (left-hand end in FIG. 2 ) of the movable platen 12 . The drive unit 10 includes a motor 11 serving as a drive source and adapted to advance and retract (move leftward and rightward in FIG. 2 ) an ejector rod 24 , which is a member to be moved. The advancement and retraction of the ejector rod 24 causes advancement and retraction motions of an unillustrated ejector pin which projects into the cavity of the movable mold of the mold apparatus, to thereby eject a molded product. The motor 11 may be any type of motor; however, a servomotor is preferably used as the motor 11 .
A toggle mechanism 18 is disposed between the movable platen 12 and the toggle support 23 . A drive unit 10 ′ serving as a drive means for mold clamping operation of the injection molding machine is attached to the rear end (left-hand end in FIG. 2 ) of the toggle support 23 . The drive unit 10 ′ includes a motor 11 ′ serving as a drive source and adapted to advance and retract a cross head 17 , which is a member to be moved, to thereby operate the toggle mechanism 18 . Thus, the movable platen 12 is advanced (moved rightward in FIG. 2 ) to thereby perform mold closing. Further, a clamping force, which is the product of a thrust force generated by the motor 11 ′ and a toggle magnification ratio, is generated in order to perform mold clamping with the clamping force. In the present embodiment, the clamping force is generated through operation of the toggle mechanism 18 . However, the thrust force generated by the motor 11 ′ can be transmitted directly to the movable platen 12 as a clamping force, without use of the toggle mechanism 18 .
The toggle mechanism 18 includes toggle levers 21 swingably supported by the cross head 17 ; toggle levers 22 swingably supported by the toggle support 23 ; and toggle arms 16 swingably supported by the movable platen 12 . The toggle levers 21 are linked with the toggle levers 22 . The toggle levers 22 are linked with the toggle arms 16 .
Next, a lubrication apparatus for a feed mechanism of the drive unit 10 will be described.
FIG. 4 is a cross-sectional view showing a first example structure of the feed mechanism according to the first embodiment of the present invention; FIG. 5 is a cross-sectional view showing a second example structure of the feed mechanism according to the first embodiment of the present invention; FIG. 6 is a cross-sectional view showing a third example structure of the feed mechanism according to the first embodiment of the present invention; and FIG. 7 is a cross-sectional view showing a fourth example structure of the feed mechanism according to the first embodiment of the present invention.
In FIG. 4 , reference numeral 25 denotes a screw nut, and 26 denotes a screw shaft. The screw shaft 26 and the screw nut 25 have spiral grooves, respectively, which are formed at the same pitch. A plurality of balls 29 a , collectively serving as a power transmission member, are disposed between the spiral groove of the screw shaft 26 and the spiral groove of the screw nut 25 . A return tube 25 a is attached to the screw nut 25 by means of a return-tube attachment member 25 b . This configuration enables the balls 29 a to circulate, while rolling, through the space between the spiral groove of the screw shaft 26 and the spiral groove of the screw nut 25 , as well as through the interior of the return tube 25 a.
In the feed mechanism, the plurality of balls 29 a transmit power between the screw shaft 26 and the screw nut 25 , while rolling. Therefore, no friction is generated between the screw shaft 26 and the screw nut 25 , and power is smoothly transmitted therebetween. Therefore, rotational motion of the screw shaft 26 is efficiently converted to rectilinear motion of the screw nut 25 . Alternatively, rotational motion of the screw nut 25 is efficiently converted to rectilinear motion of the screw shaft 26 .
In the present embodiment, the power transmission member may be rollers. In this case, as shown in FIG. 5 , a plurality of rollers 29 b , collectively serving as a power transmission member, are disposed between the spiral groove of the screw shaft 26 and the spiral groove of the screw nut 25 . Notably, the spiral groove of the screw shaft 26 and the spiral groove of the screw nut 25 have the same pitch. In this case, two return tubes 25 a - 1 and 25 a - 2 are provided. Rollers 29 b which pass through the return tube 25 a - 1 and rollers 29 b which pass through the return tube 25 a - 2 are inclined in opposite directions. Notably, rollers 29 b inclined in one direction and rollers 29 b inclined in the opposite direction may be disposed alternately, as shown in FIG. 6 .
In this case, the direction of inclination of the rollers 29 b is determined in consideration of the axial direction in which the feed mechanism receives a load. Thus, the feed mechanism can bear a heavier load, and can efficiently convert rotational motion to rectilinear motion.
In the present embodiment, the power transmission member may be a planetary roller. In this case, as shown in FIG. 7 , a plurality of planetary rollers 29 c , collectively serving as a power transmission member, are disposed between the spiral groove of the screw shaft 26 and a spiral groove formed on a screw-groove formation member 25 c of the screw nut 25 . Notably, the spiral groove of the screw shaft 26 and the spiral groove of the screw-groove formation member 25 c of the screw nut 25 have the same pitch. Further, a spiral thread is formed on the perimeter of each of the planetary rollers 29 c at the same pitch as the spiral grooves. The spiral threads of the planetary rollers 29 c are in screw-engagement with the spiral groove of the screw shaft 26 and the spiral groove of the screw-groove formation member 25 c of the screw nut 25 . Notably, the screw nut 25 and the screw-groove formation member 25 c may be formed as a single member.
The planetary rollers 29 c are disposed around the screw shaft 26 in such manner that the center axes of the planetary rollers 29 c become parallel to the axis of the screw shaft 26 . The opposite ends of the planetary rollers 29 c are rotatably supported by guide rings 25 d secured to the screw-groove formation member 25 c . This configuration enables the planetary rollers 29 c to transmit power between the screw shaft 26 and the screw nut 25 while rotating.
In this case, since the backlash between the screw shaft 26 and the planetary rollers 22 c and the backlash between the screw-groove formation member 25 c and the planetary rollers 29 c are extremely small, rotational motion can be converted to rectilinear motion with high accuracy.
In the present embodiment, the feed mechanism may have any one of the above-described configurations. Here, a case in which balls are used as the power transmission member will be described.
FIG. 3 is a cross-sectional view of a lubrication apparatus for the feed mechanism according to the first embodiment of the present invention; and FIG. 8 is a cross-sectional view as viewed in the direction of arrow A in FIG. 3 .
In FIG. 3 , the screw nut 25 of the feed mechanism is fixed to a nut support member 31 by use of, for example, bolts.
The nut support member 31 may be a stationary member such as the toggle support 23 , or a movable member such as the cross head 17 . The screw shaft 26 , which has a spiral groove on the perimeter thereof, is in screw-engagement with the screw nut 25 . The right-hand end (in FIG. 3 ) of the screw shaft 26 is connected directly, or indirectly, to an unillustrated drive source, such as the above-described motor 11 . The screw shaft 26 is rotated by the drive source.
A portion of the screw shaft 26 in which no groove is formed is attached to a screw-shaft support member 41 via bearings 42 . The screw shaft 26 has an integrally formed flange portion 26 a . The screw shaft 26 is fixed to the inner rings of the bearings 42 by means of the flange portion 26 a and a fixing member 43 , such as a lock nut, fixed to the screw shaft 26 . Thus, the screw shaft 26 and the screw-shaft support member 41 are coupled to each other in such a manner that they can rotate relative to each other but cannot move relative to each other along the axial direction.
When rotation of the screw-shaft support member 41 is prohibited by a member such as a guide member, only the reciprocative motion; i.e., axial rectilinear motion, of the screw shaft 26 is transmitted to the screw-shaft support member 41 .
When relative rotation occurs between the screw nut 25 and the screw shaft 26 , the screw nut 25 axially moves relative to the screw shaft 26 . Therefore, when the nut support member 31 is a stationary member, the screw-shaft support member 41 is a movable member such as the cross head 17 ; and when the nut support member 31 is a movable member, the screw-shaft support member 41 is a stationary member such as the toggle support 23 .
A nut cover member 32 (storage member) for covering the perimeter of the screw nut 25 is fixed to the nut support member 31 by use of, for example, bolts. The nut cover member 32 assumes a cylindrical shape and has an open end and a closed bottom, which has a circular hole formed therein. The open end of the nut cover member 32 is attached to the nut support member 31 . The screw shaft 26 passes through the circular hole formed in the bottom wall.
A first seal member 36 such as a packing is disposed between the nut cover member 32 and the nut support member 31 in order to establish a fluid-tight condition to thereby prevent leakage of lubrication oil 35 . Further, a second seal member 37 such as an oil seal is disposed between the inner circumferential surface of the circular hole and the outer circumferential surface of the screw shaft 26 in order to establish a fluid-tight condition to thereby prevent leakage of the lubrication oil 35 . An oil pan 44 is attached to a side surface (left side surface in FIG. 3 ) of the screw-shaft support member 41 , which surface faces the screw nut 25 , and extends to a point below the nut cover member 32 . Therefore, when the lubrication oil 35 leaks from the clearance between the inner circumferential surface of the circular hole and the outer circumferential surface of the screw shaft 26 , the leaked lubrication oil 35 is received by the oil pan 44 without dripping further downward.
A screw-shaft cover member 33 (storage member) is attached to the side of the nut support member 31 opposite the nut cover member 32 by use of, for example, bolts. The screw-shaft cover member 33 covers the perimeter of an end portion of the screw shaft 26 which projects from the screw nut 25 toward the side opposite the nut cover member 32 . The screw-shaft cover member 33 assumes a cylindrical shape and has an open end and a closed end; i.e., a closed bottom. The open end of the screw-shaft cover member 33 is attached to the nut support member 31 . A first seal member 36 such as a packing is disposed between the screw-shaft cover member 33 and the nut support member 31 in order to establish a fluid-tight condition to thereby prevent leakage of the lubrication oil 35 .
As shown in FIG. 8 , a lubrication oil supply pipe 34 and a lubrication oil discharge pipe 38 , serving as a lubrication oil circulation pipe, and an air bleeder pipe 39 are connected to the screw-shaft cover member 33 . One end of the lubrication oil supply pipe 34 is connected to a top portion of the screw-shaft cover member 33 , and the other end of the lubrication oil supply pipe 34 is connected to a lubrication oil supply pump 47 . A suction pipe 45 , serving as a lubrication oil circulation pipe, is attached to the lubrication oil supply pump 47 , and filter means 46 is attached to the lower end of the suction pipe 45 . The lubrication oil 35 , which the lubrication oil supply pump 47 pumps from a lubrication oil tank 49 via the suction pipe 45 and the filter means 46 , is supplied to the interior of the screw-shaft cover member 33 via the lubrication oil supply pipe 34 . The lubrication oil supply pump 47 is driven by a pump drive source 48 such as an electric motor.
As shown in FIG. 8 , one end of the lubrication oil discharge pipe 38 is connected to a lower side portion of the screw-shaft cover member 33 , and the other end of the lubrication oil discharge pipe 38 is connected to the lubrication oil tank 49 . By virtue of this configuration, the quantity of the lubrication oil 35 stored inside the screw-shaft cover member 33 is controlled in such a manner that the oil level does not exceed the point at which the lubrication oil discharge pipe 38 is connected to the screw-shaft cover member 33 . As a result, only a bottom portion of the screw shaft 26 is immersed in the lubrication oil 35 . As shown in FIG. 8 , one end of the air bleeder pipe 39 is connected to a upper side portion of the screw-shaft cover member 33 , and the other end of the air bleeder pipe 39 is connected to the vicinity of the lubrication oil tank 49 . The air bleeder pipe 39 introduces air into the interior of the sealed screw-shaft cover member 33 to thereby enable the lubrication oil 35 to be discharged smoothly from the lubrication oil discharge pipe 38 .
The filter means 46 attached to the lower end of the suction pipe 45 is immersed in the lubrication oil 35 stored in the lubrication oil tank 49 . When the lubrication oil supply pump 47 pumps the lubrication oil 35 from the lubrication oil tank 49 , the lubrication oil 35 is caused to pass through the filter means 46 . Therefore, impurities such as iron particles and dust contained in the lubrication oil 35 are filtered out. Preferably, the filter means 46 is removably attached to the suction pipe 45 . Further, preferably, the filter means 46 has a filtering material, such as filter paper or wire mesh; i.e., a filter element in a removable form such as a cassette. In this case, the filter element can be exchanged with ease when a large quantity of impurities such as iron particles and dust have accumulated in the filter element due to use over a long period of time.
Next, operation of the lubrication apparatus having the above-described configuration will be described.
When the motor 11 serving as a drive source is operated, the screw shaft 26 is rotated. Since the screw shaft 26 is in screw-engagement with the screw nut 25 fixedly attached to the nut support member 31 , upon rotation of the screw shaft 26 , the screw shaft 26 and the screw nut 25 move (i.e., advance or retract) relative to each other in the axial direction. Notably, whether the screw shaft 26 and the screw nut 25 advance or retract relative to each other is determined by the direction of the screw thread and the rotational direction of the screw shaft 26 .
As result, the screw-shaft support member 41 and the nut support member 31 move relative to each other in the axial direction. For example, when the nut support member 31 is a stationary member such as the toggle support 23 and the screw-shaft support member 41 is a movable member such as the cross head 17 , the screw-shaft support member 41 is advanced or retracted along the axis of the screw shaft 26 .
As described above, the lubrication oil 35 is stored within the screw-shaft cover member 33 ; and, as shown in FIGS. 3 and 8 , the oil level is set slightly higher than the lowest point of the screw shaft 26 . In other words, a lower portion of the screw shaft 26 is immersed in the lubrication oil 35 . Therefore, when the screw shaft 26 rotates, the lubrication oil 35 comes to cover the entire surface of the portion of the screw shaft 26 located within the screw-shaft cover member 33 . In addition, the lubrication oil 35 flows along the spiral groove formed on the perimeter of the screw shaft 26 and enters the space between the screw nut 25 and the screw shaft 26 . Since the screw shaft 26 axially moves relative to the screw nut 25 and the screw-shaft cover member 33 , the lubrication oil 35 is sufficiently supplied to the inner circumferential surface (i.e., the spiral groove) of the screw nut 25 and a portion of the screw shaft 26 which projects rightward from the screw nut 25 in FIG. 3 .
By virtue of sufficient supply of the lubrication oil 35 , a film of the lubrication oil 35 is formed on the surface of the spiral groove of the screw shaft 26 , the surfaces of the balls 29 a held within the screw nut 25 , and the surface of the spiral groove of the screw nut 25 , thereby improving the lubrication conditions at the ball screw portion. As a result, the movement of the ball screw becomes smooth, and wear of the ball screw can be prevented, whereby the service life of the ball screw can be prolonged.
A portion of the lubrication oil 35 flows along the spiral groove formed on the perimeter of the screw shaft 26 to thereby move rightward in FIG. 3 beyond the screw nut 25 . However, since the second seal member 37 such as an oil seal is disposed between the inner circumferential surface of the circular hole of the nut cover member 32 and the outer circumferential surface of the screw shaft 26 , the lubrication oil 35 hardly leaks to the outside of the nut cover member 32 . Even when the lubrication oil 35 leaks outside along the spiral groove of the screw shaft 26 , the lubrication oil 35 leaks in a very small amount; i.e. oozes out. Since such an oozing portion of the lubrication oil 35 is received by the oil pan 44 , the lubrication oil 35 does not drip down.
The pump drive source 48 is operated periodically in order to drive the lubrication oil supply pump 47 . As a result, the lubrication oil 35 stored in the lubrication oil tank 49 is pumped via the filter means 46 and the suction pipe 45 and is supplied to the interior of the screw-shaft cover member 33 via the lubrication oil supply pipe 34 . Thus, the oil level within the screw-shaft cover member 33 rises, and an excessive portion of the lubrication oil 35 is discharged from the lubrication oil discharge pipe 38 and is caused to return to the lubrication oil tank 49 . When the lubrication oil 35 is caused to circulate in the above-described manner, impurities, such as iron particles and dust, contained in the portion of the lubrication oil 35 stored in the screw-shaft cover member 33 are removed by the filter means 46 , thereby cleaning the lubrication oil 35 .
The operation for driving the lubrication oil supply pump 47 by operating the pump drive source 48 may be performed, for example, once every week, once every day, or once every hour. Alternatively, the lubrication oil supply pump 47 may be operated continuously in order to circulate the lubrication oil 35 at all times. The filter element, which may be loaded with impurities such as iron particles and dust, may be replaced at predetermined time intervals or whenever the operation time of the injection molding machine reaches a predetermined time.
When the feed mechanism is used over a long period of time due to long-term operation of the injection molding machine, the lubrication oil 35 may contain impurities, such as iron particles and dust, which are generated due to wear of the ball screw. If lubrication is performed by use of the lubrication oil 35 containing impurities, such as iron particles and dust, the contact surfaces may be worn away by the impurities. Therefore, the impurities, such as iron particles and dust, must be removed from the lubrication oil 35 . In the present embodiment, the lubrication oil 35 is circulated periodically or continuously in order to remove impurities, such as iron particles and dust, from the lubrication oil 35 by use of the filter means 46 . Therefore, the contact surfaces of the feed mechanism are not worn away by the impurities, such as iron particles and dust.
Notably, since the quality of the lubrication oil 35 deteriorates with heat or with time, the lubrication oil 35 is desirably exchanged with fresh lubrication oil 35 at predetermined time intervals.
The feed mechanism is cooled by means of the lubrication oil 35 . Therefore, when the feed mechanism generates excessive heat due to severe use conditions, the heat generation of the feed mechanism can be suppressed through an increase in the quantity of the lubrication oil 35 stored in the screw-shaft cover member 33 or an increase in the circulation rate of the lubrication oil 35 .
Wear of the feed mechanism can be prevented through employment of a cooling unit which is disposed in the lubrication oil supply pipe 34 in order to cool the lubrication oil 35 to thereby cool the screw shaft 26 , the return tube 25 a , and the balls 29 a . Further, the lubrication oil 35 stored in the lubrication oil tank 49 may be cooled through employment of a cooling unit connected to the lubrication oil tank 49 .
As described above, in the present embodiment, the perimeters of the screw shaft 26 and the screw nut 25 are covered by the nut cover member 32 and the screw-shaft cover member 33 , respectively; and the lubrication oil 35 is stored in the screw-shaft cover member 33 in an amount such that a lower portion of the screw shaft 26 is immersed in the lubrication oil 35 to thereby lubricate the feed mechanism by means of the lubrication oil 35 .
Accordingly, a uniform film of the lubrication oil 35 can be maintained on the contact surfaces of the screw shaft 26 and the screw nut 25 through which they come into contact with the balls 29 a serving as the power transmission member. Thus, the service lives of the respective portions of the feed mechanism can be extended. Further, the respective portions of the feed mechanism are cooled by the lubrication oil 35 . Therefore, wear of the respective portions of the feed mechanism can be prevented in order to extend the service life of the feed mechanism.
Further, impurities, such as iron particles and dust, contained in the lubrication oil 35 are removed by use of the filter means 46 , whereby the lubrication oil 35 is cleaned. Therefore, wear of the respective portions of the feed mechanism due to impurities, such as iron particles and dust, can be prevented in order to extend the service life of the feed mechanism.
Next, a second embodiment of the present invention will be described. Repeated descriptions of structural features and operation which are the same as those of the first embodiment will be omitted.
FIG. 9 is a cross-sectional view of a lubrication apparatus for a feed mechanism according to the second embodiment of the present invention; FIG. 10 is a cross-sectional view as viewed in the direction of arrow B in FIG. 9 ; and FIG. 11 is a partial cross-sectional view showing the lubrication conditions of the feed mechanism according to the second embodiment of the present invention.
As shown in FIG. 10 , in the present embodiment, the lubrication oil supply pipe 34 and the lubrication oil discharge pipe 38 are connected not to the screw-shaft cover member 33 but to the nut cover member 32 . One end of the lubrication oil supply pipe 34 is connected to a top portion of the nut cover member 32 , and the other end of the lubrication oil supply pipe 34 is connected to the lubrication oil supply pump 47 . The lubrication oil 35 , which the lubrication oil supply pump 47 pumps from the lubrication oil tank 49 via the suction pipe 45 and the filter means 46 , is supplied to the interior of the nut cover member 32 via the lubrication oil supply pipe 34 . Although the air bleeder pipe 39 is omitted, the air bleeder pipe 39 may be provided in a manner similar to that in the first embodiment.
As shown in FIG. 10 , one end of the lubrication oil discharge pipe 38 is connected to a lower side portion of the nut cover member 32 , and the other end of the lubrication oil discharge pipe 38 is connected to the lubrication oil tank 49 . By virtue of this configuration, the quantity of the lubrication oil 35 stored inside the nut cover member 32 is controlled in such a manner that the oil level does not exceed the point where the lubrication oil discharge pipe 38 is connected to the nut cover member 32 .
In the present embodiment, the screw nut 25 is attached to the nut support member 31 in such a manner that the return tube 25 a is located on the lower side of the screw nut 25 , and, as shown in FIG. 11 , the oil level is set such that a lower portion of the return tube 25 a is immersed in the lubrication oil 35 . One or a plurality of fine holes (not shown) are formed in the return tube 25 a . Therefore, the lubrication oil 35 is supplied to the interior of the return tube 25 a via the hole(s), so that the surfaces of the balls 29 a are covered with the lubrication oil 35 . Further, since the lubrication oil 35 is supplied to the balls 29 a , which circulate along the spiral grooves of the screw shaft 26 and the screw nut 25 , an oil film is formed on the surfaces of the spiral grooves.
Further, as shown in FIG. 9 , the oil level of the lubrication oil 35 is set such that the oil level does not reach the height of the second seal member 37 , disposed between the inner circumferential surface of the circular hole of the nut cover member 32 and the outer circumferential surface of the screw shaft 26 . Therefore, the lubrication oil 35 hardly leaks from the clearance between the inner circumferential surface of the circular hole and the outer circumferential surface of the screw shaft 26 . Moreover, an oil pan 44 is attached to a side surface (left side surface in FIG. 9 ) of the screw-shaft support member 41 , which surface faces the screw nut 25 , and extends to a point below the nut cover member 32 . Therefore, when the lubrication oil 35 leaks from the clearance between the inner circumferential surface of the circular hole and the outer circumferential surface of the screw shaft 26 , the leaked lubrication oil 35 is received by the oil pan 44 without dripping further downward.
Notably, a cooling unit may be disposed in the lubrication oil supply pipe 34 in order to cool the lubrication oil 35 to thereby cool the screw shaft 26 , the return tube 25 a , and the balls 29 a for the purpose of preventing wear of the feed mechanism. Further, the lubrication oil 35 stored in the lubrication oil tank 49 may be cooled through employment of a cooling unit connected to the lubrication oil tank 49 .
As described above, in the present embodiment, the perimeters of the screw shaft 26 and the screw nut 25 are covered by the nut cover member 32 and the screw-shaft cover member 33 , respectively; and the lubrication oil 35 is stored in the nut cover member 32 in an amount such that a lower portion of the return tube 25 a is immersed in the lubrication oil 35 , which is thus supplied to the interior of the return tube 25 a.
Since the surfaces of the balls 29 a , serving as the power transmission member, are covered with the lubrication oil 35 , a uniform film of the lubrication oil 35 can be maintained on the contact surfaces of the screw shaft 26 and the screw nut 25 through which they come into contact with the balls 29 a . Thus, the service life of the feed mechanism can be extended.
Next, a third embodiment of the present invention will be described. Repeated descriptions of structural features and operation which are the same as those of the first and second embodiments will be omitted.
FIG. 12 is a cross-sectional view as viewed in the direction of arrow A in FIG. 3 showing the third embodiment of the present invention; and FIG. 13 is a cross-sectional view as viewed in the direction of arrow B in FIG. 9 showing the third embodiment of the present invention.
In the present embodiment, an iron-content measurement unit 71 for measuring quantity of iron contained in the lubrication oil 35 is disposed in the lubrication oil supply pipe 34 . In the present embodiment, the lubrication oil supply pipe 34 and the lubrication oil discharge pipe 38 may be connected to the screw-shaft cover member 33 , as shown in FIG. 12 , or to the nut cover member 32 , as shown in FIG. 13 . Further, the iron-content measurement unit 71 may be disposed in the lubrication oil discharge pipe 38 .
The iron-content measurement unit 71 is communicatably connected to a controller 72 , which serves as control means for controlling the operation of the molding machine, and transmits to the controller 72 a measurement signal indicative of a measured iron content. The controller 72 displays the measured iron content; calculates the service life of the feed mechanism on the basis of the iron content and displays the same; and, when the iron content is in excess of a preset value, warns an operator that the service life of the feed mechanism has been reached.
Next, the configuration of the iron-content measurement unit 71 will be described in detail.
FIG. 14 is a diagram showing the configuration of the iron-content measurement unit used in the third embodiment of the present invention.
In FIG. 14 , reference numeral 74 denotes a first excitation coil, which is disposed in such a manner that the lubrication oil supply pipe 34 passes through the center thereof. Reference numeral 75 denotes a second excitation coil, which is disposed to face the first excitation coil 74 . However, the lubrication oil supply pipe 34 does not pass through the center of the second excitation coil 75 . A detection coil 77 is disposed at the midpoint between the first excitation coil 74 and the second excitation coil 75 . The first excitation coil 74 and the second excitation coil 75 have the same configuration and are excited by the same current output from an oscillation circuit 76 . Therefore, the first excitation coil 74 and the second excitation coil 75 generate magnetic fields of the same intensity in the same direction.
Therefore, at the midpoint between the first excitation coil 74 and the second excitation coil 75 , the magnetic field generated by the first excitation coil 74 and that generated by the second excitation coil 75 are cancelled out, so that no electromotive force is induced; i.e., no voltage is generated in the detection coil 77 disposed at the midpoint.
However, when the lubrication oil 35 flowing inside the lubrication oil supply pipe 34 , which passes through the center of the first excitation coil 74 , contains iron particles 73 , the intensity of the magnetic field formed by the first excitation coil 74 increases, upsetting the balance of magnetic fields at the midpoint. Therefore, an electromotive force or voltage is generated in the detection coil 77 . The thus-generated voltage is amplified by means of an amplification circuit 78 and is sent to the controller 72 as a measurement signal. Since the amplitude of the voltage changes in proportion to the quantity of the iron particles 73 contained in the lubrication oil 35 , the quantity of the iron particles 73 can be measured on the basis of the amplitude of the measurement signal.
When the lubrication oil 35 circulates, the iron particles 73 contained in the portion of the lubrication oil 35 located inside the screw-shaft cover member 33 circulate together with the lubrication oil 35 . Therefore, the quantity of the iron particles 73 contained in the lubrication oil 35 can be measured by use of the iron-content measurement unit 71 disposed in the lubrication oil supply pipe 34 . Notably, the quantity of the iron particles 73 may be measured at all times, or intermittently at intervals corresponding to a frequency at which the lubrication oil supply pump 47 is operated.
When the iron-content measurement unit 71 is operated, the oscillation circuit 76 starts its operation, whereby magnetic fields are generated by the first excitation coil 74 and the second excitation coil 75 . When the lubrication oil 35 contains no iron particles 73 , the magnetic field generated by the first excitation coil 74 and that generated by the second excitation coil 75 have the same intensity, so that no voltage is generated in the detection coil 77 . However, when the lubrication oil 35 flowing inside the lubrication oil supply pipe 34 contains iron particles 73 , the intensity of the magnetic field generated by the first excitation coil 74 increases, so that a voltage is generated in the detection coil 77 . Since the intensity of the magnetic field generated by the first excitation coil 74 increases in proportion to the quantity of the iron particles 73 , the amplitude of the voltage generated by the detection coil 77 also increases in proportion to the quantity of the iron particles 73 . Therefore, the quantity of the iron particles 73 can be measured on the basis of the voltage generated by the detection coil 77 .
When the measurement signal is sent from the iron-content measurement unit 71 to the controller 72 , the controller 72 calculates the service life of the feed mechanism. When the quantity of the iron particles 73 contained in the lubrication oil 35 is in excess of a preset value, the controller 72 provides a warning to the operator. For example, when the iron content of the lubrication oil 35 has exceeded 0.1%, the controller 72 warns the operator to change the lubrication oil 35 ; and when the iron content of the lubrication oil 35 has exceeded 1.0%, the controller 72 warns the operator to change the feed mechanism, while commenting that the degree of wear of the feed mechanism has reached the allowable limit. The above-described values and contents of warning may be changed freely.
The controller may be configured to continuously display the iron content on a display or meter of the controller. Further, the controller may be configured to stop the molding machine when the controller determines that the feed mechanism has come into an anomalous condition due to excessively high iron content. Alternatively, the controller may be configured to display a predicted service life of the feed mechanism by means of a message reporting, for example, that one month remains before the time for exchange, or that the feed mechanism must be exchanged within one week. In this case, the operator can grasp the timing for exchange, and therefor can make complete preparation for exchange of the feed mechanism.
As described above, in the present embodiment, the iron content of the lubrication oil 35 is measured by use of the iron-content measurement unit 71 ; and the controller 72 calculates the service life of the feed mechanism on the basis of the measured iron content and warns the operator to replace the lubrication oil 35 or the feed mechanism. Therefore, the service life of the feed mechanism can be predicted accurately, thereby enabling replacement of components at proper timings.
In the above-described embodiments, a horizontal-type injection molding machine in which the movable platen moves in the horizontal direction has been described. However, the apparatus and method for lubricating a feed mechanism of a forming machine can be applied to a vertical-type injection molding machine in which the movable platen moves in the vertical direction. Further, the apparatus and method for lubricating a feed mechanism of a forming machine according to the present invention can be applied not only to injection molding machines, but also to other forming machines, such as die casting machines and IJ encapsulation presses.
The present invention is not limited to the above-described embodiments. Numerous modifications and variations of the present invention are possible in light of the spirit of the present invention, and they are not excluded from the scope of the present invention.
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A lubrication apparatus that lubricates mechanism of a molding machine. The lubrication apparatus includes a tank for collecting lubrication oil therein, and a lubrication oil supply route for supplying lubrication oil from the tank.
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The present application is a continuation of U.S. patent application Ser. No. 12/582,387, filed on Oct. 20, 2009, and entitled, “Correlating Call Log Files Using Voice Prints,” which is incorporated herein by reference.
BACKGROUND
The present disclosure relates to the field of telecommunications, and specifically to the management of calls to call networks. Still more particularly, the present disclosure relates to logging and storing log files related to calls made to call networks.
SUMMARY
According to one embodiment of the present invention, a processor-implemented method, system, and/or computer program product retrieves a voice print of a caller to a call network. A processor generates a first voice print, a second voice print, and a third voice print of a caller who makes a call to a call network. The first voice print is generated by a telecom router switch in the call network, the second voice print is generated by a telecom software system in the call network, and the third voice print is generated by a contact center agent in the call network. The first voice print, the second voice print, and the third voice print are consolidated into a consolidated voice print that comprises an original version of the first voice print, the second voice print, and the third voice print. A request for a requested voice print of the caller is received. The request includes a time of the call, a phone number of the caller, and/or a name of the caller. The processor retrieves the requested voice print from first voice print, the second voice print, and the third voice print in the consolidated voice print, and sends it to the requester.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 depicts an exemplary computer in which all or some elements of the present disclosure may be implemented;
FIG. 2 illustrates prior-art steps taken to log a call into a telecommunication network;
FIG. 3 depicts appending a caller's voice print to a call's log file in the telecommunication network in order to create a single correlated log file for the call;
FIG. 4 illustrates a system manager utilizing the single correlated log file when requesting information about the call; and
FIG. 5 is a high-level flow-chart of exemplary steps taken to utilize a caller's voice print to identify and correlate calling log data for a call to a network.
DETAILED DESCRIPTION
As will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a system, method or computer program product. Accordingly, aspects of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects of the present invention may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon.
Any combination of one or more computer readable medium(s) may be utilized. The computer readable medium may be a computer readable signal medium or a computer readable storage medium. A computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
A computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electro-magnetic, optical, or any suitable combination thereof. A computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device.
Program code embodied on a computer readable medium may be transmitted using any appropriate medium, including, but not limited to, wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.
Computer program code for carrying out operations for aspects of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
Aspects of the present invention are described below with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.
The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
With reference now to the figures, and in particular to FIG. 1 , there is depicted a block diagram of an exemplary computer 102 , which may be utilized by the present invention. Note that some or all of the exemplary architecture, including both depicted hardware and software, shown for and within computer 102 may be utilized by software deploying server 150 and/or caller system 152 , as well as the telecom router switch 306 , telecom software system 314 , contact center agent 320 , and system administrator 400 shown in FIG. 4 .
Computer 102 includes a processor unit 104 that is coupled to a system bus 106 . Processor unit 104 may utilize one or more processors, each of which has one or more processor cores. A video adapter 108 , which drives/supports a display 110 , is also coupled to system bus 106 . In one embodiment, a switch 107 couples the video adapter 108 to the system bus 106 . Alternatively, the switch 107 may couple the video adapter 108 to the display 110 . In either embodiment, the switch 107 is a switch, preferably mechanical, that allows the display 110 to be coupled to the system bus 106 , and thus to be functional only upon execution of instructions (e.g., voice print correlation and call routing program VPCCRP 148 described below) that support the processes described herein.
System bus 106 is coupled via a bus bridge 112 to an input/output (I/O) bus 114 . An I/O interface 116 is coupled to I/O bus 114 . I/O interface 116 affords communication with various I/O devices, including a keyboard 118 , a mouse 120 , a media tray 122 (which may include storage devices such as CD-ROM drives, multi-media interfaces, etc.), a printer 124 , and (if a VHDL chip 137 is not utilized in a manner described below), external USB port(s) 126 . While the format of the ports connected to I/O interface 116 may be any known to those skilled in the art of computer architecture, in a preferred embodiment some or all of these ports are universal serial bus (USB) ports.
As depicted, computer 102 is able to communicate with a software deploying server 150 via network 128 using a network interface 130 . Network 128 may be an external network such as the Internet, or an internal network such as an Ethernet or a virtual private network (VPN).
A hard drive interface 132 is also coupled to system bus 106 . Hard drive interface 132 interfaces with a hard drive 134 . In a preferred embodiment, hard drive 134 populates a system memory 136 , which is also coupled to system bus 106 . System memory is defined as a lowest level of volatile memory in computer 102 . This volatile memory includes additional higher levels of volatile memory (not shown), including, but not limited to, cache memory, registers and buffers. Data that populates system memory 136 includes computer 102 's operating system (OS) 138 and application programs 144 .
OS 138 includes a shell 140 , for providing transparent user access to resources such as application programs 144 . Generally, shell 140 is a program that provides an interpreter and an interface between the user and the operating system. More specifically, shell 140 executes commands that are entered into a command line user interface or from a file. Thus, shell 140 , also called a command processor, is generally the highest level of the operating system software hierarchy and serves as a command interpreter. The shell provides a system prompt, interprets commands entered by keyboard, mouse, or other user input media, and sends the interpreted command(s) to the appropriate lower levels of the operating system (e.g., a kernel 142 ) for processing. Note that while shell 140 is a text-based, line-oriented user interface, the present invention will equally well support other user interface modes, such as graphical, voice, gestural, etc.
As depicted, OS 138 also includes kernel 142 , which includes lower levels of functionality for OS 138 , including providing essential services required by other parts of OS 138 and application programs 144 , including memory management, process and task management, disk management, and mouse and keyboard management.
Application programs 144 include a renderer, shown in exemplary manner as a browser 146 . Browser 146 includes program modules and instructions enabling a world wide web (WWW) client (i.e., computer 102 ) to send and receive network messages to the Internet using hypertext transfer protocol (HTTP) messaging, thus enabling communication with software deploying server 150 and other described computer systems.
Application programs 144 in computer 102 's system memory (as well as software deploying server 150 's system memory) also include a voice print correlation and call routing program (VPCCRP) 148 . VPCCRP 148 includes code for implementing the processes described below, including those described in FIGS. 3-5 . In one embodiment, computer 102 is able to download VPCCRP 148 from software deploying server 150 , including in an on-demand basis. Note further that, in one embodiment of the present invention, software deploying server 150 performs all of the functions associated with the present invention (including execution of VPCCRP 148 ), thus freeing computer 102 from having to use its own internal computing resources to execute VPCCRP 148 .
Also stored in system memory 136 is a VHDL (VHSIC hardware description language) program 139 . VHDL is an exemplary design-entry language for field programmable gate arrays (FPGAs), application specific integrated circuits (ASICs), and other similar electronic devices. In one embodiment, execution of instructions from VPCCRP 148 causes VHDL program 139 to configure VHDL chip 137 , which may be an FPGA, ASIC, etc.
In another embodiment of the present invention, execution of instructions from VPCCRP 148 results in a utilization of VHDL program 139 to program a VHDL emulation chip 151 . VHDL emulation chip 151 may incorporate a similar architecture as described above for VHDL chip 137 . Once VPCCRP 148 and VHDL program 139 program VHDL emulation chip 151 , VHDL emulation chip 151 performs, as hardware, some or all functions described by one or more executions of some or all of the instructions found in VPCCRP 148 . That is, the VHDL emulation chip 151 is a hardware emulation of some or all of the software instructions found in VPCCRP 148 . In one embodiment, VHDL emulation chip 151 is a programmable read only memory (PROM) that, once burned in accordance with instructions from VPCCRP 148 and VHDL program 139 , is permanently transformed into a new circuitry that performs the functions needed to perform the process described below in FIGS. 3-5 .
The hardware elements depicted in computer 102 are not intended to be exhaustive, but rather are representative to highlight essential components required by the present invention. For instance, computer 102 may include alternate memory storage devices such as magnetic cassettes, digital versatile disks (DVDs), Bernoulli cartridges, and the like. These and other variations are intended to be within the spirit and scope of the present invention.
With reference now to FIG. 2 , a prior art telecommunication network 200 is presented. Assume that a caller 202 has placed a call 204 to the telecommunication network 200 , which may be a contact center network, a call center network, or any other network designed to handle phone calls from multiple customers, clients, users, etc., and to direct them to a person, software or other agent, in accordance with the nature of their call. The call 204 is first received by a telecom router switch 206 , which identifies the time and date of the call 204 while the call 204 is being handled by the telecommunication network 200 . This information is logged into a log 208 , and is then passed on to and stored in a central logging system 210 as a telecom router switch log file 212 . The call 204 is then passed on to a telecom software system 214 , which may be an interactive voice response (IVR) system or any other software system designed to pass the call to the appropriate resource within telecommunication network 200 . Telecom software system 214 generates a telecom software system log file, which identifies the telephone number of the caller 202 . This telecom software system log file is stored in a local log 216 , and then passed on to and stored in the central logging system 210 as a telecom software system log file 218 . Finally, the call 204 is passed on to a contact center agent 220 , which is software and/or a person that identifies the name of the caller. The contact center agent 220 stores this name information as a contact center agent log file in a local log 222 , and then passes it on for storage in the central logging system 210 as a contact center agent log file 224 . As depicted, the telecom router switch log file 212 , the telecom software system log file 218 , and the contact center agent log file 224 are all separate files with no common identifiers. Thus, there is no way to know that these three log files are for the same call 204 .
With reference now to FIG. 3 , an improved and novel telecommunication network 300 is depicted. Telecommunication network 300 may be a contact center network, a call center network, or any other network designed to handle phone calls from multiple customers, clients, users, etc., and to direct them to a person, software or other agent, in accordance with the nature of their call. A call 304 from a caller 302 is first received by a telecom router switch 306 , which identifies the time and date of the call 304 while the call 304 is being handled by the telecommunication network 300 . Within telecom router switch 306 is voice print logic, shown as a conversational biometric distributor and authenticator (CDBA) 309 a . CDBA 309 a is able to take a voice print of caller 304 . This voice print can be created by prompting the caller to state his name, any baseline word or phrase, or any other word or phrase. This voice print is digitized into a numeric value and appended to the telecom router switch log file 212 , which was described in FIG. 2 , to generate a correlated telecom router switch log file 330 , which is stored in the local log 308 and then passed on to the central logging system 310 .
The call 304 is then passed on to a telecom software system 314 , which may be an interactive voice response (IVR) system or any other software system designed to pass the call to the appropriate resource within telecommunication network 300 . Telecom software system 314 generates a telecom software system log file, which identifies the telephone number of the caller 302 , and then appends the voice print, which was generated earlier by telecom router switch 306 , to generate a correlated telecom software system log file 340 . This correlated telecom software system log file 340 is stored in a local log 316 , and is then passed on to and stored in the central logging system 310 . Finally, the call 304 is passed on to a contact center agent 320 , which is software and/or a person that identifies the name of the caller and stores this name information along with the voice print in a local log 322 as a correlated contact center agent log file 350 . The contact center agent 320 stores this correlated contact center agent log file 350 in a local log 322 , and then passes it on for storage in the central logging system 310 . The central logging system 310 utilizes the voice print found in all three log files to locate the consolidated files ( 330 , 340 , 350 ) in order to generate a single correlated log file 311 for the call 304 that contains the information in these consolidated files ( 330 , 340 , 350 ).
Note that while the voice print is described as being generated by the CDBA 309 a in the telecom router switch 306 , in one embodiment voice prints can be generated by CDBA 309 b in telecom software system 314 and by CDBA 309 c in contact center agent 320 . These multiple voice prints thus provide additional voice print data, which can be consolidated into a single voice print by the central logging system 310 . This consolidated single voice print is able to identify the voice prints generated by all of the CDBAs 309 a - c , thus providing means for identifying all of the three correlated call logs, while allowing each of the three correlated call logs to maintain their own unique voice prints.
With reference now to FIG. 4 , assume that a user of a computer depicted as system administrator 400 desires to perform an analysis of calls received at the telecommunication network 300 . The user of system administrator 400 needs only to know information about when the call 304 was processed, the phone number of the caller 302 , or the name of the caller 302 . By knowing any of these three items, the system administrator 400 is able to retrieve all three sets of data, since they are now consolidated and correlated into the single correlated log file 311 . Thus, the system administrator 400 can send a request to retrieve the caller's call log (step 402 ) using any of the three data elements (caller's name, phone number, or date/time of call). In one embodiment, only the voice print is returned to the system administrator (step 404 ). The system administrator 400 can then use this voice print (voice signature) to request all logs (step 406 ) that have this voice print appended to the log (as described above). The central logging system 310 can then return the single correlated log file 311 , as shown in step 408 .
With reference now to FIG. 5 , a high-level flow chart of exemplary steps taken to correlate log files in a call network is presented. After initiator block 502 , a call network (e.g., a contact center network) receives a call from a caller (block 504 ). A voice print of the caller is generated (block 506 ), and is appended to the telecom router switch log file (to generate a correlated telecom router switch log file), the telecom software system log file (to generate a correlated telecom software system log file), and the contact center agent log file (to generate a correlated contact center agent log file) as described above. These three voice print-augmented correlated log files are then consolidated into a single correlated log file for the call (block 508 ). The single correlated log file for the call is stored in a central logging system (block 510 ), which provides the single correlated log file to any requester (block 512 ), such as a system auditor, a system manager, etc. The process ends at terminator block 514 .
The flowchart and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present disclosure. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of various embodiments of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
Note further that any methods described in the present disclosure may be implemented through the use of a VHDL (VHSIC Hardware Description Language) program and a VHDL chip. VHDL is an exemplary design-entry language for Field Programmable Gate Arrays (FPGAs), Application Specific Integrated Circuits (ASICs), and other similar electronic devices. Thus, any software-implemented method described herein may be emulated by a hardware-based VHDL program, which is then applied to a VHDL chip, such as a FPGA.
Having thus described embodiments of the invention of the present application in detail and by reference to illustrative embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.
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A processor-implemented method, system, and/or computer program product retrieves a voice print of a caller to a call network. A processor generates a first voice print, a second voice print, and a third voice print of a caller who makes a call to a call network. The first voice print, the second voice print, and the third voice print are consolidated into a consolidated voice print. In response to a request for a particular voice print, the requested voice print is selectively retrieved from first voice print, the second voice print, and the third voice print in the consolidated voice print, and then sent to the requester.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a national phase entry under 35 U.S.C. §371 of International Application No. PCT/EP2013/066603, filed Aug. 8, 2013, which claims the benefit of German Application Nos. 10 2013 105 365.3, filed May 24, 2013 and 10 2012 214 730.6, filed Aug. 20, 2012. The entire contents of each of the foregoing patent applications are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method for measuring the deflection of a fuel element can of a fuel element of a boiling water reactor.
2. Background and Relevant Art
In a fuel element of a boiling water reactor, the fuel rods are arranged within a fuel element can. In the course of their operation, depending on their position in the core, the fuel elements and, accordingly, the fuel element cans can experience a deflection which, in the worst possible case, can lead to sluggishness of the control elements or to problems during a fuel element change. In order to be able to assess whether, where and with which rotational orientation a fuel element or a fuel element can may continue to be used in the core, it is therefore necessary to determine the deflection of the fuel element cans.
BRIEF SUMMARY OF THE INVENTION
The invention is therefore based on the object of specifying a method for measuring the deflection of a fuel element can of a fuel element of a boiling water reactor which can be carried out simply and with little expenditure of time.
The stated object is achieved, according to the invention, by a method having the features of patent claim 1 . In the method for measuring the deflection of a fuel element can of a fuel element of a boiling water reactor, an image of the fuel element can is recorded with a camera and is evaluated photogrammetrically, comprising the following method steps:
a) the fuel element can is positioned in a flooded basin,
b) the camera is positioned above the fuel element can and offset laterally with respect to the fuel element can in such a way that
b1) its optical axis is oriented at an acute angle to an ideal central longitudinal axis of the fuel element can, and that b2) its image plane is oriented parallel to a front edge of the fuel element can, and that b3) both of the front edges of the fuel element can that face the camera are depicted in the image,
c) in the image recorded by the camera, the image positions of the corner points of the front edges oriented parallel to the image plane and facing the camera are measured,
d) from a known length and width of the fuel element can, the image positions of the corner points of the front edges and the known image width of the camera, either the position of a section line in the image in which an intermediate plane perpendicular to the ideal central longitudinal axis and predefined with respect to its axial position intersects the side surface of the fuel element can that faces the camera is calculated, or the axial position of this section line is calculated from the position of a predefined section line in the image,
e) the section line is inserted into the image and the image positions of the corner points of the fuel element can that are located on this section line are measured,
f) from the image positions of the corner points, the image position of the center of a line connecting the corner points and running parallel to the front edges is determined,
g) with the aid of the known width of the fuel element can and of the known imaging scale of the camera in this section line, by using the measured image position of this center, the deviation of the latter from the ideal central longitudinal axis is calculated.
By means of this procedure, it is possible to measure the whole of the fuel element can, of which the length (distance between two corner points located on the front ends of a longitudinal edge) and width are known, by recording a single image, without the lateral and vertical distance of the camera from the fuel element can and the angle between the ideal central longitudinal axis of the fuel element and the optical axis of the camera having to be known for this purpose.
In the following, the term “ideal central longitudinal axis” is to be understood to mean a straight connecting line which connects the centers of the front edges (upper and lower) of the fuel element can that are located on the same side wall.
Image width of the camera designates the distance between the center of an imaginary thin lens and the image plane which has the same imaging scale as that used in the, generally multi-lens, camera objective, account additionally being taken of the different refractive indices of the medium located within the camera housing (usually air) and of the water surrounding the camera.
Although, in principle, it is already known from US 2011/0182393 A1 to measure the deflection and torsion of a fuel element of a pressurized water reactor with a photogrammetric method, the method explained therein is not suitable for measuring the deflection of a fuel element can, since the latter contains no structural elements visible from outside to which an exact axial position can be assigned. The method known from this document allows for an assignment of the deviations of the position of a structural element in the area of a spacer that are respectively measured in the image from an ideal straight line extending in the longitudinal direction of the fuel element solely by means of the position of the spacer that is visible in the image. In the case of a fuel element of which the fuel rods are surrounded by a fuel element can, or in the case of a fuel element can that is not filled, the horizontal planes respectively chosen for the measurement of the deviation cannot readily be assigned to an actual axial position.
The invention is based on the idea that, even without the presence of structural elements of which the axial position is known and which can be segmented in the image, and without exact knowledge of the relative position between camera and box-shaped fuel element can, it is possible, with the aid of simple basic equations of geometric optics, merely by using the known length and width of the fuel element can, the image positions of the corner points of the front edges and, accordingly, the image width of the front edges and the known image width of the camera in relation to each section line or section plane extending at right angles to the ideal central longitudinal axis, by measuring the width of the imaged fuel element can of the side surface facing the camera in this section plane, to determine the axial position thereof. To this end, either a calculation is made of the position of a section line in the image in which an intermediate plane which is perpendicular to the ideal central longitudinal axis, of which the axial position is predefined and which intersects the flat side of the fuel element can that faces the camera, or, by using the position of a predefined section line in the image, its actual axial position is calculated. Accordingly, from the positions of the corner points in the image that lie on this section line, it is possible to determine in which axial position which deviation of the real central longitudinal axis from the ideal central longitudinal axis is present.
In order to obtain the most complete statement about the course of the deflection of the fuel element can over the entire length of the fuel element can, the image position of the center is preferably measured for a multiplicity of intermediate planes, and the course of a center line connecting the centers and the deviation of said center line from the ideal central longitudinal axis is calculated.
On the one hand, measurement of the fuel element can is possible when the latter is empty, i.e. after the retaining structure fixing the fuel rods has been removed therefrom. On the other hand, the fuel element can may also be measured on the complete fuel element. In the latter case, a particularly simple procedure is achieved when the fuel element is positioned hanging freely in the basin during the performance of the method, since in this case it does not have to be uncoupled from the loading machine used to transport the fuel element into the measuring station.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to explain the invention further, reference is made to the exemplary embodiment illustrated in the figures, in which:
FIG. 1 shows a schematic image, in which the arrangement of the camera and the fuel element during the performance of the photogrammetric measurement according to the invention is illustrated in a side view,
FIG. 2 shows a plan view of the rear side of a deflected fuel element, facing away from the camera, likewise in a schematic basic image,
FIG. 3 shows an image of the fuel element can recorded by the camera, likewise in a simplified illustration.
DETAILED DESCRIPTION
According to FIG. 1 , a camera 2 provided for the photogrammetric measurement of the fuel element can is mounted such that it can be displaced horizontally (x-axis) and vertically (z-axis) on a frame 5 arranged on the edge of a flooded basin 4 and such that it can be pivoted about an axis extending at right angles to the drawing plane and at right angles to the x and z axis, as illustrated by a double arrow 6 . The image plane E of the camera 2 extends at right angles to the drawing plane, so that the angle β between the z axis and image plane E can be changed in the (drawing) plane spanned by the y and z axis.
A fuel element 8 of a boiling water nuclear reactor hanging freely from the gripper of a fuel element loading machine 7 is positioned in the image field of the camera 2 , the fuel element being illustrated in simplified form in the figure only in the shape of the fuel element can 10 surrounding the fuel rods. The basin 4 is flooded, so that camera 2 and fuel element 8 are located under the water surface 9 .
The camera 2 is located at a distance s and a height h offset laterally with respect to or above the upper front edge 12 of the fuel element 8 or fuel element can 10 that faces the camera 2 . In this case, the statements about distance and height refer to the point at which the optical axis A of the camera 2 intersects the outer surface of the objective lens system. Camera 2 and fuel element 8 or fuel element can 10 are positioned relative to each other in such a way that the optical axis A of the camera 2 extends at an acute angle α to an ideal central longitudinal axis 14 of the fuel element 8 . In other words: the camera 2 is offset laterally with respect to the fuel element can, i.e. arranged at a distance from the central longitudinal axis 14 . The fuel element 8 or the fuel element can 10 is aligned in such a way that the image plane E of the camera 2 is oriented parallel to the front edge 12 of the fuel element can 10 . The fuel element 8 is preferably additionally positioned such that the corner points of the front edge 12 in the image are approximately at the same distance from the lateral image edge, so that an ideal central longitudinal axis 14 connecting the image positions of the centers of the upper front edge 12 and the lower front edge 18 extends through the center of the image. Camera 2 and fuel element 8 are additionally positioned relative to each other such that, in the image recorded by the camera 2 , both the upper and the lower front edge 12 and 18 are depicted.
From the known image width of the camera 2 and the known length L and width B of the fuel element can 10 , it is now possible to determine a deflection of the fuel element in a plane perpendicular to the drawing plane solely from the course of the lateral longitudinal edges 20 of the fuel element can 10 that face the camera 2 , by applying simple trigonometric formulas and without any knowledge of the angle β, of the lateral distance s or of the vertical spacing h.
The optical axis A of the camera 2 intersects the plane spanned by the front edges 12 , 18 and oriented at right angles to the drawing plane, which also coincides sufficiently accurately with the side surface of the fuel element can 10 that faces the camera 2 , in the case of a rearward curved fuel element can (to the right in FIG. 1 ), at a point C. The latter is located at a distance d o and d u from the front edges 12 and 18 , respectively. l o and l u designate the distances of the front edges 12 and 18 from a point D at which the optical axis A intersects the center of the objective lens of the camera 2 , considered simply as a thin lens.
Also drawn in FIG. 1 is a section plane Z i which extends at right angles to the central longitudinal axis and to the drawing plane and which is located at a distance d i from the upper front edge of the fuel element can 10 .
FIG. 2 shows the arrangement illustrated in FIG. 1 in a plan view of the rear side of the fuel element can 10 , facing away from the camera 2 , the gripper of the fuel element loading machine not being illustrated for reasons of clarity. Likewise, the lateral deflection of the fuel element can 10 is illustrated exaggerated.
By using FIG. 3 , the procedure during the measurement of the deflection will be explained in more detail. In the image field 16 of the camera, the fuel element can 10 is depicted perspectively, it being possible to see that both the upper front edge 12 and the lower front edge 18 extend parallel to the x axis of an xy coordinate system spanned by the image field 16 of the camera. As a result of the acute-angled oblique orientation of the optical axis A of the camera relative to the ideal central longitudinal axis 14 , the lower front edge 18 is significantly shorter than the upper front edge 12 . Moreover, camera and fuel element can 10 are aligned in such a way that the image center, i.e. the point at which the optical axis A intersects the image plane, is located on the ideal central longitudinal axis 14 . This central longitudinal axis is defined in the image by the connecting line between the centers M o , M u of the imaged front edges 12 , 18 .
By using the known dimensions L, B of the fuel element can 10 , the known image width b of the camera, the image positions PL 0 , PR 0 , PL N , PR N of the front corner points 12 R, 12 L, 18 R, 18 L are used to calculate the distances d o , d u and the distances l o , l u ( FIG. 1 ), so that the position and alignment of the camera relative to the fuel element can 10 and, accordingly, the geometric imaging relationships are known. From the image coordinates of each image point on the side surface of the fuel element can 10 that faces the camera, it is then possible to calculate the position of the object point associated with this image point in the plane spanned by the side surface of the fuel element can 10 that faces the camera.
In a next step, a plurality of intermediate planes Z i on the real fuel element can, of which the distance d i ( FIG. 1 ) from the upper front edge 12 is known in each case, are then selected. With the aid of the imaging properties of the camera, which are now known, for these selected intermediate planes Z i section lines S i which would result if the intermediate planes Z i were to intersect a side surface of the fuel element can 10 that would be flat toward the camera are then displayed in the image recorded from the fuel element can 10 . Then, the image positions PL i and PR i of the corner points at which the section line S i in the image intersects the imaged longitudinal edges of the fuel element can 10 are measured. Even in the case of a fuel element can 10 that is curved convexly or concavely, seen from the camera, said image positions coincide with sufficient accuracy with the image positions of the corner points that are actually located in these intermediate planes Z i .
This is carried out for a plurality of intermediate planes Z i and section lines S i , only one further intermediate plane Z i+1 and the associated image positions PL i+1 and PR i+1 of the corner points being inserted into the figure for reasons of clarity. The image position M i of the center located between the image positions PL i and PR i of the corner points are then calculated for each intermediate plane Z i . In the case of a fuel element can 10 that has not been deflected, these centers all lie on the ideal central longitudinal axis 14 .
As an alternative to the procedure outlined above, it is also possible firstly for a section line S i extending parallel to the front edges 12 , 18 , for which the actual axial position thereof (distance d i ) is subsequently determined, to be displayed in the figure. It is important that the actual axial position of the section line S i is known.
In FIG. 3 , the longitudinal edges 20 of a curved fuel element can 10 are now shown dashed. In this case, the image positions BPL i and BPR i are displaced to the left. Accordingly, the image position BM i at the center of the line defined by these corner points BPL i and BPR i is also displaced to the left. If this is carried out for a multiplicity of intermediate planes Z i and section lines S i , it is possible in this way, because of the known imaging relationships, for the course of the real central longitudinal axis 14 to be calculated from the measured image positions BM i , BM i+1 of these centers.
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A method for measuring the deflection of a fuel element can for a fuel element of a boiling water reactor involves taking an image of the fuel element can with a camera and evaluating the image using photogrammetry. By means of the method, it is possible to determine the deflection of a fuel element can by taking a single image, even in the absence of external structural features recognizable in the image, and without knowledge of the relative position between the camera and the fuel element can.
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TECHNICAL FIELD
The present invention relates to a complex rare-earths doped optical waveguide. In particular, the complex rare-earths doped optical waveguide in accordance with an embodiment of the present invention is for modifying emission spectrum of erbium that is able to significantly enhance optical gain from shorter wavelength than 1530 nm.
BACKGROUND OF THE INVENTION
Wavelength division multiplexing method has been studied as a core technology for satisfying increasing demand in the area of optical communication networks. Likewise, optical amplifiers with broadband gain are needed.
Currently, gain wavelength of erbium doped silica optical amplifier is fixed over 1530 nm. Also, in order to amplify other wavelength regions, optical gain is obtained at ˜1300 nm, ˜1470 nm, and ˜1650 nm by employing praseodymium (Pr) ion and thulium (Tm) ion, respectively.
Erbium ion is an efficient gain medium. Since erbium results in a conspicuous gain when configured to optical fiber amplifiers regardless of host compositions of the optical fibers, many studies have been performed to obtain gain at shorter wavelength than 1530 nm by employing erbium ion.
When erbium ion dopes a crystal or a glass, it is excited by light or electricity and as a result, fluorescent emission in 1460˜1650 nm is evident, which is from 4 I 13/2 → 4 I 15/2 transition.
Gain wavelength of conventional erbium doped optical fiber amplifiers is between 1530 nm and 1600 nm and it is difficult for conventional erbium doped optical fiber amplifiers to obtain gain at wavelength shorter than 1530 nm. It is because that the emission cross-section of 4 I 13/2 → 4 I 15/2 transition is small at wavelength shorter than 1530 nm.
Generally, spectral lineshape of a gain spectrum is similar to shape of the amplified spontaneous emission spectrum, it is difficult for conventional erbium doped optical fiber amplifiers to obtain gain at wavelength shorter than 1530 nm.
SUMMARY OF THE INVENTION
A complex rare-earths doped optical waveguide is provided. The complex rare-earths doped optical waveguide in accordance with an embodiment of the present invention includes clad and core. The core is doped with erbium (Er) ion. The interior or exterior region of the core is doped with at least one of complex rare-earth ions. The interior and (or) the exterior region of the core, where the rare-earth ion (s) dope (s), is at a certain distance apart from the erbium-doped region.
Preferably, the complex rare-earth ion is thulium (Tm), terbium (Tb), dysprosium (Dy), or neodymium (Nd).
Preferably, erbium (Er) is doped within certain length from center of the core.
Preferably, the interior and (or) exterior of the core is doped with at least one complex rare-earth ion.
Preferably, a layer doped with at least one complex rare-earth ion wraps the erbium-doped layer of the core.
Preferably, distance between the erbium doped layer and the complex rare-earths doped layer is farther than 20 nm.
A complex rare-earths doped optical waveguide is provided. The. complex rare-earths doped optical waveguide in accordance with an embodiment of the present invention includes clad and core. In the whole region or in a fraction of the core are doped combination of erbium (Er) ion and ytterbium (Yb) ion. A layer, a certain distance apart from the erbium/ytterbium-doped layer is introduced and the layer is doped with at least one complex rare-earth ion.
Preferably, the complex rare-earth ion is thulium (Tm), terbium (Tb), dysprosium (Dy), or neodymium (Nd).
Preferably, erbium (Er) and ytterbium (Yb) are codoped in the core.
Preferably, the internal or the surface of the core is doped with at least one complex rare-earths ion.
Preferably, the internal or the surface of the core is wrapped by at least one complex rare-earths ion.
Preferably, distance between the erbium (Er) and ytterbium (Yb) codoped layer and the complex rare-earths doped layer is farther than 20 nm.
A complex rare-earths doped optical waveguide is provided. The complex rare-earths doped optical waveguide in accordance with an embodiment of the present invention includes clad and core. The core is doped with erbium (Er) ion and part of the clad is doped with at least one complex rare-earths ion.
Preferably, the complex rare-earths ion is thulium (Tm), terbium (Tb), dysprosium (Dy), or neodymium (Nd).
A complex rare-earths doped optical waveguide is provided. The complex rare-earths doped optical waveguide in accordance with an embodiment of the present invention includes clad and core. The core is doped with combination of erbium (Er) ion and ytterbium (Yb) ion and part of the clad is doped with at least one complex rare-earths ion. A complex rare-earths doped layer is introduced apart a certain distance from the core, in the clad region.
Preferably, the complex rare-earths ion is thulium (Tm), terbium (Tb), dysprosium (Dy), or neodymium (Nd).
BRIEF DESCRIPTION OF THE DRAWINGS
The embodiments of the present invention will be explained with reference to the accompanying drawings, in which:
FIG. 1 is a graph illustrating energy level of erbium (Er), thulium (Tm), terbium (Tb), dysprosium (Dy), and neodymium (Nd);
FIG. 2 is a cross sectional view illustrating complex rare-earths doped optical fiber in accordence with an embodiment of the present invention; and
FIG. 3 is across sectional view illustrating complex rare-earths doped optical waveguide in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Generally, there are two ways of energy transfer between rare-earth ions. One is radiative energy transfer and the other is nonradiative energy transfer.
Nonradiative energy transfer actively happens when the distance between ions is close, that is, when the ions are doped together. Mainly, the energy transfer is caused by electric dipole-dipole effect and the magnitude of the interaction is proportional to minus sixth power of the distance between ions. On the other hand, in radiative energy transfer, the emitted fluorescence is transferred as a form of photon and then is absorbed. The magnitude of the interaction is proportional to minus second power of the distance between ions. Therefore, as the distance between ions increases, influence of nonradiative energy transfer decreases rapidly and influence of radiative energy transfer increases.
One common feature of the two energy transfers is that transferred energy is always same. That is, there exists energy resonance. In case of nonradiative energy transfer, fluorescent lifetime of corresponding energy level decreases, even though shape of fluorescent emission spectrum is not changed at all. In case of radiative energy transfer, fluorescent lifetime of corresponding energy level is not changed and observed fluorescent emission spectrum depends upon the absorption lineshape of ion that absorbs energy. Therefore, in order to change lineshape of the emitted spectrum without decreasing fluorescent lifetime of erbium ion, nonradiative energy transfer needs to be suppressed and only radiative energy transfer should be activated. By this reason, the layer in which erbium is added, should be separated by a certain distance from the layer in which ions interested in this invention are added. In detail, since the distance in which nonradiative energy transfer actively happens is tens of nm, the distance of separation has to be larger than the tens of nm.
In an embodiment of the present invention, even though distance between the erbium doped layer and the layer doped with rare-earth ion of interest is designed as 200 nm, the purpose of the present invention was accomplished with the distance from 20 nm on the basis of experiment.
Also, in addition to the case in which the erbium doped layer and the layer in which rare-earth ion is added, same effect was achieved with the case erbium is doped at all area of the core and rare-earth ion doped layer is made in the clad.
Following examples illustrate how to suppress amplified spontaneous emission.
First, Sakamoto et al. published '35-dB gain Tm-doped ZBLYAN fiber amplifier operating at 1.65 μm at IEEE Photonics Technology Letters, 8(3), 349˜351 in 1996. In the experiment performed, the core is doped by thulium (Tm) and the clad is doped by terbium (Tb). As a result, center of fluorescent emission spectrum of thulium (Tm) was shifted from 1800 nm to 1650 nm. That is, when thulium (Tm) was added, 35 dB gain was achieved with terbium (Tb) at 1650 nm band. This implies that gain at 1650 nm band is improved by suppressing amplified spontaneous emission at 1800 nm band.
Second, band pass filters may be applied to suppress amplified spontaneous emission at unwanted wavelength. According to experiments, 35 dB gain was achieved by employing an erbium doped silica optical fiber amplifier with an optical band pass fiber-type filter, which selectively passes wavelength between 1500 nm and 1525 nm. This means there is 20 dB gain improvement in comparison with the case in which band pass filters are not utilized. The filters only suppress amplified spontaneous emission that has been accumulated before the filters, which means filters themselves cannot prevent amplified spontaneous emission power before it.
On the other hand, if rare-earth doped layer that absorbs wavelengths over 1530 nm is implemented around the core, fluorescence is absorbed constantly throughout the optical fiber and amplified spontaneous emission is efficiently prevented. Lasing effect is usually occurred at a wavelength where stimulated emission cross-section is at its maximum value. In the embodiment of this invention, such a lasing effect can also be avoided and even though pump power increases, gain is not saturated.
By the way, there are a few requirements for rare-earth ion that absorbs wavelengths longer than 1530 nm. First, the rare-earth ion should employ energy level that represents ground state absorption at wavelengths longer than 1530 nm. Second, the rare-earth ion should be able to emit the absorbed energy as a form of multiphonon relaxation mechanism. Third, the rare-earth ion should absorb as small as possible at 980 nm range and 1480 nm range.
FIG. 1 is a graph illustrating energy level of erbium (Er), thulium (Tm), terbium (Tb), dysprosium (Dy), and neodymium (Nd). The rare-earths ions illustrated in FIG. 1 follow the basic purpose of the present invention.
FIG. 2 is a cross sectional view illustrating complex rare-earths doped optical fiber in accordance with an embodiment of the present invention. FIG. 3 is a cross sectional view illustrating complex rare-earths doped optical waveguide in accordance with an embodiment of the present invention.
Following conditions should be considered for a part in which rare-earth ions absorbing wavelengths longer than 1530 nm are added.
First, in case of rare-earths ions that absorbs small at wavelengths shorter than 1530 nm and at wavelength of 980 nm, erbium ion is added at the center of the core and the rare-earths ions should be added inside of the core which is separated from the added layer at least 20 nm. FIG. 2 illustrates the structure of the optical fiber with such condition.
The advantages of the optical fiber shown in FIG. 2 are as follows. First, erbium ion is able to absorb excitation light efficiently. Second, since rare-earth doped layer is located in the core, spontaneous emission is efficiently suppressed. Third, the optical fiber may be utilized for multi-mode optical fibers as well as single-mode optical fibers.
Even though erbium ion may be added alone, erbium and ytterbium are combined and added together for improved performance.
Second, it is a case when added rare-earths ions have large absorption at 980 nm band, usually adopted as excitation wavelength for erbium doped optical fiber amplifiers or lasers. However, these rare-earth ions are able to suppress excitation light loss of 980 nm by adjusting distance between core layer and rare-earths layer. It is based upon the fact mode field diameter increases as wavelength gets longer. That is, 1530 nm wavelength is more related to the clad than 980 nm wavelength. Therefore, the distance between the core layer and the absorption rare-earths layer maybe calculated in consideration with core radius and numerical aperture of optical fibers. That is, cutoff wavelength of the optical fiber is shorter than 980 nm. Wavelength bandwidth and amplification wavelength bandwidth are all single mode conditions. In each wavelength, the portion propagated throughout the clad is described as (1−η) and η represents confinement factor. Following equation 1 describes η mathematically. η = 1 - exp [ - ( a w ) 2 ] [ Equation 1 ]
a: radius of core
w: mode radius of core, radius until mode intensity passing the core decreases to 1/e 2
Following equation 2 illustrates mode radius 2.
w=a(0.46+1.145V λ −1.5 +2.036 λ −6 ) [Equation 2]V λ : normalized frequency at wavelength λ,
2
π
aNA
λ
.
Explanation in detail regarding equation 1 and equation 2 is described at ‘Closed-form expressions for the gain in three- and four- level laser fibers’, IEEE Journal of Quantum Electronics, “M. J. Digonnet”.
Now, relative fraction of ion propagating through the clad at 980 wavelength bandwidth and 1530 wavelength bandwidth is obtained and on the basis of the branching ratio, 980 nm bandwidth should be formed with a certain distance to make sure not overlapping with absorption rare-earths ion layer. In addition, absorption cross-section of doped rare-earths at 980 nm and over 1530 nm should be considered. It is because that absorption rate at each wavelength is proportional to (absorption cross-section)×(1−η). Therefore, when an optical fiber in accordance with an embodiment of the present invention is manufactured, various factors should be considered to determine doped layer of rare-earths ion.
The content of the present invention may be applied to an optical waveguide as well as optical fiber and an embodiment of the case is illustrated at FIG. 3 .
Shape of doped rare-earths layer shouldn't have to be circular shape in case of optical fibers. Likewise, in case of flat optical waveguides, shape of doped rare-earths layer shouldn't have to be similar to the shape of the core. However, the distance between erbium ion of the core and codoping rare-earths ion of the clad should be far enough for not having nonradiative energy transfer and close enough for having radiative energy transfer. That is, when light over 1530 nm advances to the core with single mode, mode field diameter has to be overlapped with codoping rare-earths ion layer.
The amount of added rare-earths ion may be determined by following standard. First, when absorption rare-earths ion is added to the core, the amount of absorption rare-earths ion is proportional to the amount of erbium and inverse proportional to confinement factor of light over 1530 nm. That is, the amount of added rare-earths ion is proportional to density of erbium ion ×1/η. Second, when absorption rare-earths ion is added to the clad, the amount of added rare-earths ion is proportional to density of erbium ion ×1/(1−η). Exact proportional constant is determined through experiments. If the amount of absorption rare-earths ion increases, gain may decrease because absorption at signal wavelength may increase. Therefore, maximum amount of absorption rare-earths ion is determined.
As stated above, in an embodiment of the present invention, an optical waveguide is provided, in which erbium is added to the core and rare-earths ions such as thorium.(Tm), terbium (Tb), dysprosium (Dy), and neodymium (Nd) are added to a part of the clad together or alone. Therefore, an embodiment of the present invention accomplishes gain at wavelengths shorter than ones from which conventional erbium doped amplifiers or lasers accomplish gain.
Although representative embodiments of the present invention have been disclosed for illustrative purpose, those who are skilled in the art will appreciate that various modifications, additions and substitutions are possible without departing from the scope and spirit of the present invention as defined in the accompanying claims.
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The present invention relates to a complex rare-earths doped optical waveguide. In particular, the complex rare-earths doped optical waveguide in accordance with an embodiment of the present invention is for modifying emission spectrum of erbium that is able to obtain gain from shorter wavelength than 1530 nm. A complex rare-earths doped optical wavelength is provided. The complex rare-earths doped optical waveguide in accordence with an embodiment of the present invention includes clad and core. The core is doped with erbium (Er) ion. The internal or surface of the core is doped with at least one complex rare-earth ions. The internal and the surface of the core is distanced by certain length from center of the core.
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This is a continuation of co-pending application Ser. No. 07/229,983, filed on Aug. 9, 1988, now abandoned.
TECHNICAL FIELD OF THE INVENTION
The present invention relates in general to the field of scoops or dippers for use in serving frozen comestibles, and more particularly to an ice cream dipper that is electrically heated to facilitate the scooping and serving of ice cream.
BACKGROUND ART
Many frozen comestibles, such as ice cream, sherbert, or the like, are stored in containers in bulk form, and must be scooped out for consumption.
The removing of frozen comestibles from the storage containers is often made difficult because many forms of such food items must be maintained in a frozen state in order to be most desirable. Often, the requirements of freezing are such that the food item is quite hard and difficult to remove. While this may be an onerous task at home, if it is too time consuming and difficult, a store specializing in such food may lose business or be economically disadvantaged if the servers cannot remove the food quickly and easily from the storage containers.
For this reason, there have been many various designs proposed for easing the removal of frozen comestibles, such as ice cream, from the bulk storage containers. For the most part, such serving devices comprise a scoop-shaped bowl portion of semispherical configuration which is adapted to bite into the mass of the frozen comestible as the head of the device is forced into and through that comestible by manipulation of a handle portion connected to the head. The comestible forms a ball within the head and this ball can be dispensed accordingly.
Due to the difficulty in scooping and dispensing many highly frozen comestibles, many such scoop designs have been proposed. One common design includes an electrical resistance heating element in the scoop. This heating element is connected to a source of power, and serves to heat the scoop to melt the comestible sufficiently so as to ease the removal of that food from the bulk storage container and the dispensing thereof to a cone, dish or the like.
In the past, such electrically heated scoops have had disadvantages which have hindered the commercial acceptance thereof. Primary among such disadvantages is the cumbersome nature of such electrically heated scoops. These scoops are often heavy and may be difficult to manipulate, thereby making them undesirable for use by a server who must use the scoop many times a day. Furthermore, due to the design of presently available scoops, many electrical control elements, such as thermostats, and the like, are required thereby exacerbating the disadvantages thereof.
Accordingly, there is need for a scoop adapted for serving frozen comestibles and Which is electrically heated but is designed to be effective Without being cumbersome.
OBJECTS OF THE INVENTION
It is a main object of the present invention to provide an electrically heated frozen comestible scoop or dipper that is easy to manipulate and use.
It is another object of the present invention to provide an electrically heated frozen comestible scoop or dipper that is designed to make the most efficient and effective use of the electrically provided heat.
It is another object of the present invention to provide an electrically heated frozen comestible scoop or dipper that includes an electrical resistance heating element located and adapted to heat only those surfaces of the scoop bowl portion that are necessary for the efficient dispensing of the comestible.
It is a specific object of the present invention to provide an electrically heated frozen comestible scoop or dipper that includes an electrical resistance heating element that has portions thereof located to heat the exact portions of the comestible that are necessary to provide a smooth scooping and dispensing operation.
SUMMARY OF THE INVENTION
These and other objects are accomplished by providing a dipper or scoop bowl portion with an electrical heating element that includes portions located closer to the inner surface of the bowl than to the outer surface, and other portions that are located closer to the outer surface of that bowl than to the inner surface, and still other portions that are located approximately midway between the inner and outer surfaces of the scoop bowl. The portions of the bowl are selected according to the needs and requirements of an efficient scooping and dispensing process. The heating element also includes a portion located immediately adjacent to that portion of the bowl that will serve as the leading lip of the bowl when it is initially forced into the stored comestible during a serving process. The leading lip portion of the bowl can be selected to be that portion that will be the leading lip for either a right-handed person or a left-handed person.
In effect, the bowl of the scoop or dipper embodying the present invention is divided into portions according to the functions which that bowl must accomplish during a serving procedure.
Thus, initially, the leading lip of the scoop contacts the frozen comestible when that comestible is in its most highly frozen condition, and it is this leading lip that is most highly heated by the heating element of the present scoop. Next, due to the dipping and scooping motion of the procedure, a portion of the bowl outer surface contacts the comestible in its most frozen condition, and it is this portion of the bowl of the present device that is heated to a greater degree than the inner surface of the bowl that contacts only that comestible that has already been removed from the bulk. The next portion of the scooping motion begins to move the comestible into position for dispensing, and the electrical resistance heating element of the present scoop is located and positioned to most effectively carry out this function by positioning the heating element close to, the middle of the scoop thickness between the inner surface and outer surfaces of the scoop to maintain the comestible ball outer surface in condition to be easily dispensed. The next portion of the scooping and dispensing process requires the comestible to be dispensed off of the scoop bowl. Accordingly, the heating element of the present scoop has a portion located in the trailing portion of the bowl that is located closer to the outer surface to merely maintain the comestible in condition for dispensing and does not add sufficient heat to the comestible to melt it further.
In this manner, only those portions of the bowl that are required to effect an efficient serving process need to be heated, and the other portions thereof need not be over-heated. Thus, there is no need to provide heating element portions in those areas of the scoop that are not contributing to the scooping and dispensing process. Eliminating unnecessary portions of the heating element concomitantly eliminates unnecessary weight and control thereby making the scoop much easier to manipulate and handle than prior scoops.
DESCRIPTION OF THE FIGURES
Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention.
The drawings constitute a part of the present invention and illustrate various objects and features thereof.
FIG. 1 is a perspective view of the frozen comestible scoop or dipper embodying the present invention.
FIG. 2 is a perspective view showing the heating element positioned in the bowl portion of the scoop of the present invention.
FIG. 3 is a view taken along line 3--3 of FIG. 2.
FIG. 4 is a view taken along line 4--4 of FIG. 2 and schematically illustrates the location of the heating element with respect to the thickness of the scoop as measured between the inner and outer surfaces thereof at this location of the scoop.
FIG. 5 is a view taken along line 5--5 of FIG. 2 and schematically illustrates the location of the heating element with respect to the thickness of the scoop at this location of the scoop.
FIG. 6 is a view taken along line 6--6 of FIG. 2 and schematically illustrates the location of the heating element with respect to the thickness of the scoop at this location of the scoop.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention which may be embodied in various firms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
Shown in FIG. 1 is a dipper 10 suitable for the scooping and serving of frozen comestibles, such as ice cream, sherbert, or the like from a bulk storage container to dishes, cones, cups or the like.
The dipper 10 includes a handle portion 12 which is sized and shaped to be held and manipulated to execute the removal of the comestible from a bulk storage container and the dispensing thereof to a cone or a dish or the like. The handle includes a bore (not shown) defined axially therethrough, and an electrical cord 14 extends through that bore and to a power source (not shown) for a purpose that will be evident from the ensuing discussion. The cord 14 is shown as including a plug 16 on one end thereof for connection to a suitable outlet, but could be connected to a battery pack or other suitable power source. The cord can also include a storage means, indicated in FIG. 1 by the reference numeral 18. Such storage means can include means for retracting and storing the cord as needed. An example of such a storage means is the retractable cable devices shown in Patents such as U.S. Pat. No. 4,653,833.
The dipper 10 further includes a scoop portion 20 which is hemispherical in shape and is connected to the handle portion to be manipulated thereby. The scoop portion 20 includes a body 22 having a peripheral rim 24, an inner surface 26 and an outer surface 28. The scoop portion is shaped to form a ball of the frozen comestible being removed from a bulk storage container, with the inner surface 26 being adapted to contact the outer surface of such ball and the outer surface 28 of the scoop being adapted to contact the comestible remaining in the storage container during the scooping and dispensing process.
In effecting a scooping and dispensing procedure, the scoop bowl is manipulated to have a portion of the rim 24 initially contact the bulk item, and such rim portion will be designated hereinafter as the leading lip portion, with the diametrically opposite portion of the rim being designated as the trailing portion. Such leading lip is indicated in FIG. 1 as 30R and 30L. The leading lip 30R will be the leading lip for a right-handed scoop operator, and the leading lip 30L will be the leading lip for a left-handed operator.
The scoop bowl portion 20 is formed of heat conducting material, such as metal or the like, and is heated by a heating means to make the scooping, transporting and dispensing of the frozen comestible easy and efficient.
The heating means is shown in FIG. 2, and the positions of the various component portions thereof with respect to the thickness of the scoop body as measured between the inner surface 26 and the outer surface 28 are best shown in FIGS. 2-6, and reference is now made to those figures, it being noted that the heating means is shown only schematically in the interest of clarity of drawing. The heating means is indicated in FIG. 2 by the reference indicator 40 and includes a continuous and monolithic electrical resistance heating element 42. The element 42 includes a plurality of portions embedded in the scoop bowl body 28 to be spaced and located within the bowl to heat specific portions of the scoop as dictated by the scooping and dispensing procedure whereby the most efficient amount of heat is needed, and no portion of the scoop is overheated or underheated.
Thus, as is shown in FIGS. 2 and 3, the heating element 42 includes a first portion 44 located immediately adjacent to and extending coincidentally with the leading lip 30R to heat such lip sufficiently for the initial entry of the scoop into the bulk food to initiate the scooping and dispensing process. The first portion 44 can also be located adjacent to the edge 30L, but is not shown for the sake of brevity.
As is shown in FIGS. 2 and 4, the heating element also includes a second portion 45 that is designed to assist the separation of the food from the bulk in the container. This heating element portion 45 is thus located closely adjacent to the first portion 44 and is positioned to be closer to the outer surface 28 than to the inner surface 26 since the outer surface will still be in contact with the bulk material in the storage container.
The element 42 also includes a third portion 46 located adjacent to that portion of the scoop bowl that will contact the food after it has been separated from the bulk in the container and is located in the bowl for transportation from the container to the point of dispensing. As is best shown in FIGS. 2 and 5, the third portion 46 is embedded in the bowl material to be positioned approximately midway between the inner surface 26 and the outer surface 28 to heat these two surfaces to about the same degree. This will assist the separation of the ball of food from the bulk and will prevent that food from sticking to the scoop during transit without unduly heating the ball itself so that the food can be served at a desired temperature. The element third portion 46 extends from adjacent to the second portion to near the trailing portion of the rim as indicated in FIG. 2.
After the food is transported to the location for dispensing, the primary function of the device 10 is to efficiently dispense the food from the bowl to the dish, cone or the like. Accordingly, the element 40 includes a fourth portion 50 that is embedded in the bowl material adjacent to the rim portion located opposite to the leading lip, and functions as a trailing lip portion 52. The fourth portion 50 is located to be slightly closer to the inner surface 26 than to the outer surface since the outer surface has no effective contact with the food at this point in the process and thus need not be heated or temperature controlled and the inner surface merely has to be maintained at a temperature that keeps the food from sticking to the inner surface 26 of the scoop.
If the scoop 10 is tipped in the same direction for dispensing as it is in the initial filling, the first 44 and the second portion 45 will not interfere with the dispensing process as these portions are still embedded in the material far enough to ensure that the food will not be overheated during the dispensing process, and the third portion 46 will still function as just discussed.
Of course, the just-discussed portions will be similar for the case of a left-handed device, and the orientation, location and positioning thereof will be evident to one skilled in the art from the above discussion. Accordingly, such left-handed device Will not be described, but is intended to come within the scope of the present disclosure.
It is to be understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown.
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A frozen foot server includes a handle portion and a scoop portion and has an electrical heating element embedded in the scoop portion. The heating element includes a plurality of portions that are each positioned in the scoop portion to heat special areas of the inner and the outer surface of that scoop portion according to the particular portion of the scooping, transporting and dispensing process being carried out. The heating element can be positioned according to whether the server will be operated by a right-handed operator or by a left-handed operator.
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RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/820,639, filed Jul. 28, 2006, entitled VASCULAR ACCESS DEVICE VOLUME DISPLACEMENT, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present disclosure relates to the displacement of volume in medical devices such as vascular access devices to provide infusion or other therapy to patients. Infusion therapy is one of the most common health care procedures. Hospitalized, home care, and other patients receive fluids, pharmaceuticals, and blood products via a vascular access device inserted into the vascular system. Infusion therapy may be used to treat an infection, provide anesthesia or analgesia, provide nutritional support, treat cancerous growths, maintain blood pressure and heart rhythm, or many other clinically significant uses.
Infusion therapy is facilitated by vascular access devices located outside the vascular system of a patient (extravascular devices). Extravascular devices that may access a patient's peripheral or central vasculature, either directly or indirectly, include closed access devices, such as the BD Q-SYTE™ closed Luer access device of Becton, Dickinson and Company; syringes; split access devices; catheters; and intravenous (IV) fluid chambers. A vascular access device may be indwelling for short term (days), moderate term (weeks), or long term (months to years). A vascular access device may be used for continuous infusion therapy or for intermittent therapy.
A common vascular access device is a plastic catheter that is inserted into a patient's vein. The catheter length may vary from a few centimeters for peripheral access to many centimeters for central access. The catheter may be inserted transcutaneously or may be surgically implanted beneath the patient's skin. The catheter, or any other extravascular device attached thereto, may have a single lumen or multiple lumens for infusion of many fluids simultaneously.
The proximal end of a vascular access device commonly includes a Luer adapter to which other medical devices may be attached. For example, an administration set may be attached to a vascular access device at one end and an IV bag at the other. The administration set is a fluid conduit for the continuous infusion of fluids and pharmaceuticals. Commonly, an TV access device is a vascular access device that may be attached to another vascular access device, closes or seals the vascular access device, and allows for intermittent infusion or injection of fluids and pharmaceuticals. An IV access device may comprise a housing and a septum for closing the system. The septum may be opened with a blunt cannula or a male Luer of a medical device.
Complications associated with infusion therapy may cause significant morbidity and even mortality. One significant complication is catheter related blood stream infection (CRBSI). An estimate of 250,000-400,000 cases of central venous catheter (CVC) associated BSIs occur annually in US hospitals. Attributable mortality is an estimated 12%-25% for each infection and a cost to the health care system of $25,000-$56,000 per episode.
Vascular access device infection resulting in CRBSIs may be caused by pathogens entering the fluid flow path from refluxed or displaced blood subsequent to catheter insertion. Studies have shown the risk of CRBSI increases with catheter indwelling periods. This may be due, at least in part, to the reflux or displacement of blood from the vascular system of a patient to an extravascular device, such as the catheter. When contaminated, pathogens adhere to the vascular access device, colonize, and form a biofilm. The biofilm is resistant to most biocidal agents and provides a replenishing source for pathogens to enter a patient's bloodstream and cause a BSI.
Certain extravascular devices can operate with each other to form a continuous, extravascular system that provides fluid access to the vascular system, yet is entirely sealed from the external surrounding environment. Such a sealed system limits or supposedly prevents unwanted bacteria from entering from the external surrounding environment through the extravascular devices to the vascular system of a patient.
However, a sealed system of extravascular devices (extravascular system) may function as a closed or sealed vacuum, capable of drawing blood, and consequently a culture for infection, into the extravascular system. As devices are twisted off or otherwise removed from the extravascular system, the volume of the extravascular system is sometimes slightly increased. Because extravascular systems are often less elastic than a patient's vascular system, when the volume of the extravascular system is increased, the volume of a patient's vascular system is decreased under a vacuum pressure from the extravascular system. When the volume of the vascular system decreases, blood flows or is sucked from the vascular system to the extravascular system. Further, as pressure in the extravascular system decreases below the vascular pressure of a patient, either as a result of a change in volume in the extravascular system or another event, blood will flow from the vascular system to the extravascular system.
As recognized in conjunction with the present invention, even a temporary presence of blood within an extravascular system can cause future operational challenges for that extravascular system. For example, blood that clots in the end of a catheter of an extravascular system can block future fluid flow between the extravascular system and a vascular system. If drugs and other fluid substances are forced through the extravascular system causing the blood clot to dislodge from the extravascular system, the blood clot will enter the vascular system causing a dangerous embolism within the patient. Finally, as discussed above, even the rapid entry and exit of blood into the catheter tip of an extravascular system will leave a residue of protein, bacteria, and other pathogens on the inner wall of the catheter. This residue may become a breeding ground for bacteria to grow, and after a given period of time, will cause the formation of a harmful biofilm that is difficult to remove or bypass during extravascular system operation.
Therefore, a need exists for systems and methods that avoid or limit the reflux or displacement of blood from a patient's vascular system into an extravascular system that is connected to the patient's vascular system.
BRIEF SUMMARY OF THE INVENTION
The present invention has been developed in response to problems and needs in the art that have not yet been fully resolved by currently available extravascular systems, devices, and methods. Thus, these developed systems, devices, and methods provide an extravascular system that may be connected to a patient's vascular system and will limit or prevent the flow, reflux, or displacement of blood from the vascular system to the extravascular system.
A medical device may include a vascular access device with an access port having a septum and a slit. The slit is formed on the inner surface of the body of the septum. The access port may receive an access device that is separate from the vascular access device through the slit of the septum. A pivoting member in communication with the access port pivots when the port is accessed by an access device.
The pivoting member may be one of the following types of devices: a T-bone shaped rigid structure, a T-bone shaped rigid structure on the outer surface of the septum, an L-shaped rigid structure, a gate held under the tension of a torsion spring, a rib, a wedge, a split wedge, a four-bar mechanism, a semi-rigid or rigid buckling member, a rigid member displaced by a disturbed air pressure chamber, a rigid member displaced by a disturbed pressure sensitive chemical, and/or a spring finger. The pivoting member may articulate upon a bistable spring, a torsion spring, or other spring or tension creating member. The pivoting member may form a curved or other structure.
A method of employing the medical device may be used to control the volume displacement within a chamber of the medical device. The method may include decreasing the volume of a chamber of an extravascular system by inserting a substance having a mass into the chamber, pivoting a structure within the extravascular system, and increasing the volume of the chamber simultaneously and commensurately with the mass of the substance inserted into the chamber. The substance may be either a fluid or a mechanical structure of a medical device, such as the tip of a syringe.
These and other features and advantages of the present invention may be incorporated into certain embodiments of the invention and will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter. The present invention does not require that all the advantageous features and all the advantages described herein be incorporated into every embodiment of the invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
In order that the manner in which the above-recited and other features and advantages of the invention are obtained will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. These drawings depict only typical embodiments of the invention and are not therefore to be considered to limit the scope of the invention.
FIG. 1 is a perspective view of an extravascular system connected to the vascular system of a patient.
FIG. 2 is a cross section view of a vascular access device with pivoting T-bone members.
FIG. 3 is a cross section view of the vascular access device of FIG. 2 taken along lines 3 - 3
FIG. 4 is a cross section view of the vascular access device of FIG. 2 shown with the tip of a separate device inserted.
FIG. 5 is a cross section view of the vascular access device of FIG. 4 taken along lines 5 - 5 .
FIG. 6 is a cross section view of a vascular access device having an alternative embodiment of a pivoting member.
FIG. 7 is a cross section view of a vascular access device having a further embodiment of a pivoting member.
FIG. 8 is a partial cross section view of a vascular access device with an external pivoting member.
FIG. 9 is a cross section view of a vascular access device with a bistable spring pivoting member
FIG. 10 is a partial cross section view of the vascular access device of FIG. 9 with the bistable spring pivoting member actuated in an open position.
FIG. 11 is a partial cross section view of a vascular access device with a rigid pivoting member.
FIG. 12 is a partial cross section view of the vascular access device of FIG. 11 with the tip of a separate device inserted.
FIG. 13 is a partial cross section view of a vascular access device with a rigid pivoting member.
FIG. 14 is a partial cross section view of the vascular access device of FIG. 13 with the tip of a separate device inserted.
FIG. 15 is a partial cross section view of a vascular access device and closed spring loaded valve.
FIG. 16 is a partial cross section view of the vascular access device of FIG. 15 with the spring loaded valve open.
FIG. 17 is a partial cross section view of a vascular access device with a spring loaded valve.
FIG. 18 is a partial cross section view of a vascular access device having a rigid member.
FIG. 19 is a partial cross section view of the vascular access device of FIG. 18 with the tip of a separate device inserted.
FIG. 20 is a partial cross section view of a vascular access device and a rotational clip.
FIG. 20A is a partial cross section view of the vascular access device illustrated in FIG. 20 with a separate device inserted.
FIG. 21 is a perspective view of a vascular access device.
FIG. 22 is a perspective view of a vascular access device including the septum with a reservoir.
FIG. 23 is a perspective view of an annular member with spring fingers.
FIG. 24 is a cross section view of a vascular access device with a collapsed reservoir.
FIG. 25 is a cross section view of the vascular access device of FIG. 24 showing the reservoir full.
FIG. 26 is a partial cross section view of a vascular access device with a split wedge.
FIG. 27 is a partial cross section view of the vascular access device of FIG. 26 with the split wedge in open position.
FIG. 28 is a partial cross section view of a vascular access device with two curved pivoting members.
FIG. 29 is a partial cross section view of the vascular access device of FIG. 28 the tip of a separate device inserted.
FIG. 30 is a partial cross section view of a vascular access device with a four-bar mechanism.
FIG. 31 is a partial cross section view of the vascular access device of FIG. 30 with the tip of a separate device inserted.
FIG. 32 is a cross section view of a vascular access device with a rigid member.
DETAILED DESCRIPTION OF THE INVENTION
The presently preferred embodiments of the present invention will be best understood by reference to the drawings, wherein like reference numbers indicate identical or functionally similar elements. It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description, as represented in the figures, is not intended to limit the scope of the invention as claimed, but is merely representative of presently preferred embodiments of the invention.
Referring now to FIG. 1 , a vascular access device (also referred to as an extravascular device, intravenous access device, and/or access port) 10 is used to introduce a substance via a catheter 12 across the skin 14 and into a blood vessel 16 of a patient 18 . The vascular access device 10 includes a body 20 with a lumen and a septum 22 placed within the lumen. The septum 22 has a slit 24 through which a separate extravascular device 26 , such as a syringe, may introduce a substance into the vascular access device 10 .
The device 10 also includes a member (discussed with reference to the figures below) capable of creating a volume within the vascular access device 10 and/or the extravascular system 28 to which the vascular access device 10 is connected. The member capable of creating this volume creates the volume when a tip 30 of the separate device 26 is inserted into the vascular access device 10 through the slit 24 of the septum 22 . Normally, when the tip 30 is inserted into the device 10 , the volume of the extravascular system 28 is decreased, causing fluid to flow from the system 28 into the blood vessel 16 . Conversely, under normal conditions, when the tip 30 is removed from the device 10 , the volume of the extravascular system 28 is increased, causing blood to flow from the blood vessel 16 into the system 28 by entering through the end 32 of the catheter 12 .
As mentioned throughout this description, even a temporary presence of blood within an extravascular system 28 can cause future operational challenges for that extravascular system 28 . These problems may include blood clots, fluid flow barriers, embolisms, and the production of harmful biofilm. Thus, the devices disclosed herein are provided to avoid reflux or drawback of blood from the blood vessel 16 into the catheter 12 . The devices may include a member capable of creating a volume when the separate device 26 is inserted into the vascular access device 10 and will permit the created volume to decrease to its original size. When the volume decreases to its original size, the decrease in volume will offset any volume displaced such that upon removal of the separate access device 26 . The volume offset will either result in no net displacement of fluid between the system 28 and the vessel 16 or will result in fluid being forced distally from the vascular access device 10 or other medical device toward the vascular system of a patient. This further avoids creation of a vacuum or a pressure differential between the system 28 and the vessel 16 that would cause blood to flow or be sucked from the blood vessel 16 into the catheter 12 .
Referring now to FIG. 2 , a vascular access device 10 includes at least one rigid, pivoting member 34 within the wall of the septum 22 . The pivoting member 34 is rigid in relation to the materials of its surrounding environment. In this embodiment, the septum 22 is formed of silastic or other pliable, elastic material. Thus, the pivoting member 34 may be formed of hardened rubber, plastic, metal, alloy, or other relatively rigid material. The pivoting member 34 is shaped as a T-bone structure with a first end 36 of the top of the “T” extending towards the slit 24 of the septum. A second end 38 of the top of the “T” extends towards the edge of the body 20 of the vascular access device 10 . The base 40 of the “T” extends into a separation of an outer chamber 42 and an interior chamber 44 of the device 10 .
FIG. 3 is a cross-section view of the vascular access device 10 of FIG. 2 taken along lines 3 - 3 . Device 10 includes the base 40 of the “T” of the pivoting member 34 embedded within a silastic material. This silastic material is an extension of the septum 22 and has been manufactured, extruded, molded, heat-treated, or otherwise formed to include at least one fold 46 along its cross section. The fold 46 remains until a separate device 26 is placed within the slit 24 of the septum 22 causing the rigid member 34 to open. When the rigid member 34 opens, the base members 40 move from a first resting position shown in FIG. 3 to a second opened position to be shown in FIG. 5 . When the base members 40 are moved from a first resting position to a second opened position, the at least one fold 46 straightens causing the volume of the outer chamber 42 to decrease and the volume of the interior chamber 44 to increase.
Referring now to FIG. 4 , a vascular access device 10 of FIG. 2 is shown with the tip 30 of the separate device 26 inserted within the septum 22 . As the tip 30 is inserted into the septum, the walls of the septum begin to move downward and outward in a direction 48 . As the walls of the septum 22 are moved in a direction 48 under the influence of the tip 30 , rigid members 34 pivot outward causing the first ends 36 to move downward and the base members 40 to move outward towards the body 20 of the vascular access device 10 .
The first ends 36 move downward, away from the direction of the advancing tip 30 as the second ends 38 pivot against a fulcrum 50 placed within the body 20 of the vascular access device 10 . As the base members 40 are moved outwards towards the body 20 of the device 10 , the volume of the outer chamber 42 decreases while the volume of the interior chamber 44 increases. At least one channel 52 may need to be placed within the body 20 of the vascular access device 10 in order to permit the air within the outer chamber 42 to escape the outer chamber 42 when the base members 40 are moved into the space of the outer chamber 42 . The at least one channel 52 will permit the volume of the outer chamber 42 to decrease without any pressure buildup that would require an increase in insertion force during tip 30 insertion.
FIG. 5 is a cross-section taken along lines 5 - 5 of FIG. 4 . The vascular access device 10 includes the base member 40 extended towards the body 20 of the vascular access device 10 . With the base members 40 extended, the silastic material no longer includes at least one fold 46 . Rather the folds 46 , as show in FIG. 3 , have been extended to form a straight section of the silastic member such that the volume of the outer chamber 42 has been decreased and the volume of the interior chamber 44 has been increased.
When the tip 30 of a separate device 26 is removed from the slit 24 of the septum 22 , the rigid member 34 closes under the force of the formed silastic material that is an extension of the septum 22 . As mentioned earlier with reference to FIG. 3 , the silastic material has been manufactured or otherwise formed to include at least one fold ( FIG. 3 ) along its cross-section. These folds 46 exist when the silastic material is in its resting position. Thus, when the silastic material is stretched as shown in FIG. 5 , once the tip 30 of the separate device 26 is removed, the natural force of the formed silastic material will cause the silastic material to return to its original position as shown in FIG. 3 . When the formed silastic material returns to its original position, the base members 40 will likewise return to its original position causing the volume of the outer chamber 42 to increase while the volume of the interior chamber 44 decreases. This decrease of volume within the interior chamber 44 will result in either no net volume displacement within the interior chamber 44 or will result in a volume that is displaced from the interior chamber 44 downstream through the extravascular system 28 and into the vascular system of a patient.
Referring now to FIG. 6 , a vascular access device 210 includes at least one rigid, pivoting member 234 within the wall of the septum 222 . The pivoting member 234 is rigid in relation to the materials of its surrounding environment. As with embodiments previously discussed, the septum 222 is formed of silastic or other pliable, elastic material. Thus, the pivoting member 234 may be formed of hardened rubber, plastic, metal, alloy, or other relatively rigid material. The L-shaped member may be encased in the silastic as illustrated in FIG. 6 , or may be bonded or attached to the silastic by means well known to those of skill in the art.
In this embodiment, the pivoting member 234 is shaped as an L-shaped structure with a first end 236 of the top of the “L” extending towards the slit 224 of the septum. The base 240 of the “L” extends downwardly along the channel through the septum 210 . Thus, when a separate extravascular device 26 is inserted into the septum, the rigid L-shaped pivoting member 234 causes the channel 238 through the septum to increase in volume. When the extravascular device 26 is removed and the channel 238 returns to its original configuration, the volume within the channel 238 is reduce, thus preventing blood or other fluid from being drawn up into the extravascular system 28 .
FIG. 7 illustrates an alternative embodiment of the device in which the L-shape pivoting member 234 is replaced by a rigid wedge member 250 . Wedge member 250 can be made of rigid plastic or other similar materials. Once again, wedge member 250 provides sufficient rigidity to cause the channel 230 to expand in volume as a separate extravascular device 26 is inserted into the device 210 . Thus, when the extravascular device 26 is removed, the volume decreases to its original state, preventing blood or other fluids from being drawn into the extravascular system 28 .
Referring now to FIG. 8 , a partial cross-section view of a vascular access device 10 shows a rigid, folding member 54 located on the external surface of a silastic septum 56 . The silastic septum 56 includes a knob 58 on its exterior surface to which the pivoting member 54 is attached. The pivoting member 54 also includes an elbow 60 housed within a fulcrum 62 of the body 20 of the vascular access device 10 . The elbow 60 houses a flap 64 that extends from the body 20 of the septum 56 . In use, when a separate device 26 is placed within the slit 24 of the septum 56 , the body 20 of the septum 56 is biased downward and outward in a direction 48 , causing the knob 58 and/or any portion of the entire structure of the pivoting member 54 to bias downward and outward in the direction 48 . As the pivoting member 54 pivots in the direction 48 , the volume of the interior chamber 44 is increased while the volume of the outer chamber is decreased.
Referring now to FIG. 9 , a vascular access device 10 includes a rigid, pivoting member 66 embedded within the material of a silastic septum 22 . The pivoting member 66 includes a bistable spring 68 along the top of the “T” of the pivoting member 66 .
FIG. 10 is a partial cross section view of the device 10 of FIG. 9 . As illustrated in FIG. 10 , the bistable spring 68 of the pivoting member 66 is a beam that snaps open after a predetermined amount of pressure has been applied to the bistable spring 68 . In use, as the tip 30 of a separate device 26 is advanced through the slit 24 of the septum 22 , the septum 22 begins to open in an outward direction causing pressure to build upon the bistable spring 68 . After a given amount of pressure has been placed on the bistable spring 68 , the beam of the bistable spring 68 will snap open causing the pivoting member 66 to pivot upon a fulcrum 70 of the body 20 , which in turn causes the base 72 of the pivoting member 66 to move downward and outward in a direction 48 . When the base member 72 of the pivoting member 66 moves toward the body 20 , the volume of the interior chamber 44 is increased and the volume of the outer chamber 42 is decreased.
A bistable spring may be used with any of the above illustrated embodiments or with any of a number of the following embodiments described throughout this detailed description. The properties of the bistable spring may preferably be employed when a rapid increase in volume within an interior chamber is desired when a separate device 26 is introduced into the vascular access device 10 . Similarly, the properties of the bistable spring may also preferably be employed when a rapid decrease in volume of an interior chamber is desired upon retraction and/or removal of a separate device 26 from the vascular access device 10 .
In some embodiments, a gradual increase in volume of an interior chamber may be desired as a separate device is gradually inserted into the slit of the septum of the device. In these embodiments, as the separate device is gradually inserted, the opening of the septum decreases the volume of the interior chamber, while the opening of a rigid member simultaneously increases the volume of the interior chamber, offsetting the decrease of volume caused by the insertion of the separate device. In this manner, during the initial entry of the separate device into the septum, all the way through full engagement and full removal of the separate device from the septum, there will be no net change in volume of the interior chamber. Thus, with no net change in volume of the interior chamber during use of the vascular access device, any potential displacement of fluid into and out of a patient's vascular system is avoided.
Referring now to FIG. 11 , a vascular access device 10 includes at least one rigid member 74 in the shape of a wedge placed below the slit 24 of a septum 22 when the device 10 is in a resting state.
Referring now to FIG. 12 , when the tip 30 of a separate device 26 is inserted into the septum 22 , the rigid members 74 are biased downward and outward in a direction 48 causing an increase in volume within an interior chamber 44 . The increased volume of interior chamber 44 is illustrated as volume 76 . The rigid members 74 may be embedded, or surrounded, by an elastic material, such as silastic. The silastic may be attached at an elbow 78 of the silastic to a fulcrum 80 of the body 20 of the vascular access device 10 . A lower portion 82 of the elastic material will stretch to enable the rigid member 74 to create the additional volume 76 when the tip 30 is inserted into the septum 22 .
Referring now to FIG. 13 , a vascular access device 10 includes a rigid member 84 such as a rigid rib having a structure that is continuous with a silastic or other elastic septum 22 and an elastomer 86 . The elastomer 86 is attached to the base of the rib 84 while the septum 22 is attached to the head of the rib 84 . The rib or rigid member 84 may also be embedded or otherwise attached to a continuous elastomer as illustrated throughout the embodiments of this detailed description. As mentioned earlier, one end of the elastomer 86 is attached to the rib 84 , while the other end of the elastomer is fixed at a point 88 within the vascular access device 10 . Because the elastomer 86 is fixed at a point 88 and attached to the base of the rib 84 , when the rib 84 pivots, causing the elastomer 86 to stretch, the elastomer 86 will not be dislodged from its fixed point 88 .
Referring now to FIG. 14 , the vascular access device 10 of FIG. 13 shows the tip 30 of an external device 26 inserted within the septum 22 . As the tip 30 advances through the septum 22 , the rigid members 84 pivot upon an elbow 90 that communicates with a fulcrum 92 of the body 20 of the vascular access device 10 . When the rigid members 84 pivot, the base of the rigid members 84 moves in an outward direction 94 stretching the elastomer 86 and creating an increased amount of volume 96 within the interior chamber 44 . When the tip 30 of the external device 26 is removed from the septum 22 , the pivoting members 84 return to their original resting position as shown in FIG. 13 , causing the elastomers 86 to return to their original position and the volume gained 96 to be decreased to an original volume of the interior chamber 44 . A similar decrease in volume occurs with reference to FIGS. 11 and 12 when the tip 30 is removed from the device 10 of that particular embodiment.
Referring now to FIG. 15 , a vascular access device 10 includes a septum 98 that is sealed by a rigid, pivoting member 100 which pivots on a torsion type spring 102 . The tension of the spring 102 biases the pivoting member 100 in a clockwise direction 104 . In its resting state, the pivoting member 100 seals the septum 98 in a closed position.
Referring now to FIG. 16 , the vascular access device 10 of FIG. 15 is shown with the tip 30 of a separate device 26 inserted into the septum 98 . The tip 30 is shown discharging a fluid 106 towards the pivoting member 100 . The force of the fluid 106 and/or the force of the mechanical insertion of the tip 30 against a lower wing 108 of the pivoting member 100 causes the pivoting member 100 to rotate in a counter clockwise direction against the tension of the torsion spring 102 . When the pivoting member 100 rotates counter clockwise, the lower wing 108 extends into the interior chamber 44 and the upper wing 110 of the pivoting member 100 retracts into a cavity within the wall of the septum 98 to create an increased volume 112 . After the fluid 106 has been fully discharged into the interior chamber 44 and the rate of flow has decreased and/or after the tip 30 is removed, the tension of the torsion spring 102 will cause the pivoting member 100 to rotate again clockwise to a position that seals the septum 98 as shown in FIG. 15 . Once sealed, the pivoting member 100 prevents any backflow of fluid 106 into the septum chamber where the tip 30 is inserted.
Referring now to FIG. 17 , a vascular access device 10 includes a septum 112 and a pivoting member 114 placed under tension of a torsion spring 116 . When fluid is infused and/or the tip 30 of a separate device 26 is inserted into the septum 112 , the pivoting member 114 rotates counter clockwise against the clockwise tension of the torsion spring 116 . When the pivoting member 114 rotates counter clockwise, a lower wing 118 moves into an interior chamber 44 to decrease the volume of the interior chamber 44 . Simultaneously, an upper wing 120 is retracted from the interior chamber 44 into a recess of the septum 112 to create a larger volume 122 within the interior chamber 44 .
Thus, the vascular access device 10 of FIG. 17 is an alternate embodiment to the vascular access device of FIGS. 15 and 16 which creates more volume than the volume that is used or depleted when the tip 30 accesses the device 10 . The increased volume 122 is possible because the upper wing 120 is longer than the lower wing 118 , and when the pivoting member 114 rotates counter clockwise a greater amount of volume is created than the amount of volume that is depleted.
The embodiments shown in FIGS. 15 through 17 thus reveal a pivoting member that creates a larger volume within an interior chamber 44 when the pivoting member is activated by the insertion of the tip 30 of a separate, external device 26 . Preferably, the length of the various wings and the tension placed on the torsion spring of the pivoting member of the embodiments of FIG. 15 through 17 , may be adjusted to ultimately produce a mechanically activated valve that avoids any reflux or displacement of fluid. In this manner, the tip 30 of a separate device 26 may be inserted into the vascular access device 10 , fluid may be discharged, and a patient may be treated without the operation of the extravascular system ever resulting in fluid traveling upstream, i.e., from a patient's vascular system to a catheter of the extravascular system.
Referring now to FIG. 18 , a vascular access device 10 includes an elastomeric septum 124 with a rigid spring and pivoting member 126 embedded in the base 128 of the septum 124 . The base 128 of the septum 124 rests upon a fulcrum or pivot point 130 . The device 10 also includes a channel 132 located between the pivot point and the body 20 of the device 10 .
Referring now to FIG. 19 , the vascular access device 10 of FIG. 18 is shown with the tip 30 of a separate device 26 inserted into the septum 124 . With the tip 30 fully inserted into the septum 124 , the rigid spring member 126 is forced to bend or otherwise buckle in order to create a cavity 134 in which fluid is stored. The fluid enters the created cavity 134 through the flow channel 132 as the rigid spring member 126 is bent in an upward arched shape. As the tip 30 is removed from the septum 124 , the pressure placed on the spring member 126 is removed causing the spring member 126 to return to its original position as shown in FIG. 18 . When the spring member 126 returns to its original position, the cavity 134 disappears as the fluid that was once stored within the cavity 134 travels through the flow channel 132 and into the interior chamber 44 .
Thus, the embodiment described with reference to FIGS. 18 and 19 includes a spring member which gradually increases the overall volume of the interior chamber 44 as a tip 30 of a separate device 26 is inserted into the septum 124 of a vascular access device 10 . The spring member 126 may, in other embodiments, take any form, shape, or size. For example, in one embodiment, the spring member may be a bistable spring as mentioned earlier. When actuated by a Luer or other tip 30 of an external or separate device 26 , a bistable spring member will rapidly change shape, or otherwise buckle, in order to create or increase the overall volume of the interior chamber 44 . Subsequently, when the tip 30 of a device 10 is removed, the bistable spring will rapidly resume its posture to its original position, causing the chamber beneath it to collapse and the overall volume of the interior chamber 44 to decrease.
Referring now to FIG. 20 , a septum 136 of a vascular access device 10 includes a knob 138 attached to a metal clip 140 that rotates or otherwise pivots upon a pin 142 . FIG. 20 shows a vascular access device 10 that is not yet engaged or is disengaged with a separate device 26 . FIG. 20A shows the vascular access device 10 as engaged with a separate device 26 . In FIG. 20A the tip 30 of the separate device 26 is fully inserted into the septum 136 causing the metal clip 140 to rotate in a counter clockwise direction 144 around the pin 142 . The counter clockwise rotation of the metal clip 140 causes the metal clip 140 to raise the knob 138 , thus creating an increased volume 146 within an interior chamber 44 . When the separate device 26 is later removed, the metal clip 140 which is placed on a pre-loaded spring, restores the base, or diaphragm, 148 of the septum 136 to its original position. When the base 148 is returned to its original position, the internal fluid volume of the interior chamber 44 is decreased, causing fluid to flow from the extravascular system (to which the device 10 and separate device 26 are attached) to the vascular system of a patient.
Referring now collectively to FIGS. 21 through 23 , a vascular access device 10 includes a septum 150 with a slit 152 and at least one clearance slot 154 through which at least one spring finger 156 may articulate. The septum 150 includes a reservoir 158 at its base. An annular structure 160 may include at least one spring finger 156 . The annular structure 160 includes a lumen through which the septum 150 may be placed.
Referring now to FIG. 24 , a cross-section of the vascular access device 10 of FIG. 21 is shown engaged with the septum 150 of FIG. 22 and the annular member 160 of FIG. 23 . The combination of the body 20 of the vascular access device 10 , the septum 150 , and the annular member 160 is shown in resting position, prior to access by the tip 30 of a separate device 26 . In its resting state, the spring fingers 156 of the annular member 160 force the septum 150 closed, which in turn causes the reservoir 158 to be compressed. When the reservoir 158 is compressed, an interior chamber 44 has a relatively smaller internal volume.
Referring now to FIG. 25 , the vascular access device 10 of FIG. 24 is shown fully engaged with the separate device 26 such that the tip 30 is fully inserted into the septum 150 . Upon full insertion, the tip 30 causes the spring fingers 156 to separate outwards through the clearance slots 154 which are shown in FIG. 21 . With the spring fingers 156 extending outwards through the clearance slots 154 , the base or bottom of the septum 150 has more room to expand just above the reservoir 158 . When the base of the septum 150 expands just above the reservoir 158 , the reservoir also expands causing an increased amount of volume within the interior chamber 44 . Subsequently, when the tip 30 is removed from the device 10 , the spring fingers 156 will move inwardly from the clearance slots 154 towards the septum 150 , causing the septum 150 to close the body of the septum 150 to compress upon the reservoir 158 and the reservoir to collapse to its original starting position as shown in FIG. 24 . This action of moving the reservoir 158 from a decompressed to a compressed state will cause the internal volume of the interior chamber 44 to decrease, which in turn causes fluid to flow from the interior chamber 44 through the extravascular system and into the vascular system of a patient. This flow of fluid will prevent any unwanted reflux of blood or other fluid from a patient's vascular system into the extravascular system.
Referring now to FIG. 26 , a vascular access device 10 includes a body 20 and an elastomeric slit septum 162 . A split wedge 164 resides within a lower chamber 44 of the septum 162 . The split wedge is capable of separating its bottom angled surface when coerced by the tip 30 of a separate device 26 against a rigid base member 166 that resides beneath the split wedge 164 . Referring now to FIG. 27 , the vascular access device 10 of FIG. 26 is shown with the tip 30 of a separate device 26 fully engaged within the septum 162 . When the tip 30 places force upon the top surface 168 of the split wedge 164 , the bottom angled surfaces 170 of the split wedge 164 are pressed against the surface of the rigid structure 166 , causing the split wedge 164 to separate. When the split wedge 164 separates, the elastic walls of the septum 162 also separate causing the internal volume of the interior chamber 44 to increase. The internal volume of the interior chamber 44 increases both between the legs of the split wedge 164 and on the sides of the rigid structure 166 .
Referring now to FIG. 28 , a vascular access device 10 includes a septum 172 with a slit 174 and at least one curved, rigid, pivoting member 176 . The pivoting members 176 are fixed to a pivot point 178 against the body 20 of the vascular access device 10 .
Referring now to FIG. 29 , the vascular access device 10 of FIG. 28 is shown with the tip 30 of a separate device 26 fully engaged with the septum 172 . When the tip 30 is fully inserted into the slit 174 , the pivoting members 176 that are embedded within the septum 172 are forced outward against the walls of the body 20 of the device 10 . In their outward position, the pivoting curved members 176 open to increase the amount of internal volume within the interior chamber 44 beneath the closure of the septum 172 . The space 180 that is created during tip 30 insertion is later eliminated when the tip 30 is removed from the device 10 . As this volume is eliminated, the fluid residing therein is forced from the extravascular system toward the vascular system of a patient.
Referring now to FIG. 30 , the vascular access device 10 includes a septum 22 and a four-bar mechanism 182 that is separate and resides on an exterior surface of and in communication with the septum 22 . The four-bar mechanism 182 is anchored to the outer wall of the body 20 of the device 10 .
Referring now to FIG. 31 , the vascular access device 10 of FIG. 30 is shown with the tip 30 of a separate device 26 inserted into the septum 22 . With normal slit septums that do not include a four-bar mechanism as that shown in FIGS. 30 and 31 , when a tip 30 is inserted into a slit septum, only that portion of the septum that is in direct contact with the tip is biased open with a minimal amount of material of the septum 22 in front of the end of the tip 30 . However, the four-bar mechanism 182 of FIG. 31 permits the septum 22 to open along its entire length when the tip 30 is initially inserted into the top portion of the septum 22 . As the four-bar mechanism 182 opens the entire length of the septum 22 , a volume 184 is created within the septum 22 as the tip 30 is initially advanced. The increased volume 184 is added to the volume beneath it in the extravascular system, and when the tip 30 is removed from the device 10 , the four-bar mechanism 182 collapses causing the volume 184 to be eliminated. When the volume 184 is eliminated, fluid is expelled from that volume through the extravascular system and into the vascular system of a patient.
Referring now to FIG. 32 , a vascular access device 10 includes a septum 22 and a rigid member 186 capable of being displaced by an air pressure chamber 188 that may be disturbed when the tip 30 of a separate device 26 is inserted into the septum 22 . The rigid member 186 may be a bistable spring capable of flexing in alternating directions under the influence of opposing force exerted upon the body of the spring.
As the tip 30 is inserted into the septum 22 , an upper chamber 190 decreases in size, forcing air through a channel 192 in the septum 22 , to an air pressure chamber 188 neighboring the rigid member 186 . As the pressure within a neighboring chamber 188 increases, the bistable spring of the rigid member 186 will flex in a direction 194 into an expansion chamber 196 . As the rigid member 186 flexes in a direction 194 , the vacuum existing in the neighboring chamber 188 will pull an internal wall 198 in the direction 194 , causing the volume of an interior chamber 44 to increase.
As the tip 30 is retracted from the septum 22 , the upper chamber 190 will increase in size, pulling air from air pressure chamber 188 through the channel 192 into the upper chamber 190 . As the pressure within the air pressure chamber 188 decreases, the bistable spring of the rigid member 186 will flex in a direction opposite direction 194 to return to its original position, causing the internal wall 198 to also return to its original position, and causing the volume of the interior chamber 44 to decrease to its original volume prior to tip 30 insertion. The stress placed upon the bistable spring is such that only minimal force or pressure is required to engage the bistable spring in either direction.
The present invention may be embodied in other specific forms without departing from its structures, methods, or other essential characteristics as broadly described herein and claimed hereinafter. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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A medical device includes a vascular access device with an access port having a septum and a slit. The slit is formed on the inner surface of the body of the septum where the access port receives an access device that is separate from the vascular access device through the slit of the septum. A pivoting member in communication with the access port pivots when the port is accessed by an access device. The medical device may be used to control the volume displacement of a chamber within the medical device by decreasing the volume of the chamber by inserting a substance having a mass into the chamber, pivoting a structure associated with the chamber, and increasing the volume of the chamber simultaneously and commensurately with the mass of the substance inserted into the chamber.
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RELATED APPLICATION
This application claims priority of U.S. Provisional Application Ser. No. 60/116,799 filed Jan. 21, 1999.
FIELD OF THE INVENTION
The subject invention generally relates to the field of detecting halitosis or bad breath and, more particularly, to an improved method for measuring the concentration of sulfides within the mouth of a subject to determine the presence and extent of halitosis activity.
BACKGROUND OF THE INVENTION
Halitosis, commonly known as bad breath, is a common concern for many people. The most common source of halitosis is thought to be the tongue. Gram negative, anaerobic bacteria are prone to proliferate in the papilla structure at the posterior or rear of the tongue. The papilla form a multitude of niches or irregularities which are favored breeding grounds for the anaerobic bacteria as they simulate non-oxygenated micro environments. The anaerobic bacteria break down specific components such as amino acids found in the saliva generating or producing sulfur containing metabolic by-products. These sulfur containing by-products are volatile and have been implicated as the major cause of odor and/or halitosis. It is interesting to note that these same bacteria which are associated with the causation of halitosis are often the same bacteria considered as the etiological agent for periodontal disease.
The detection and diagnosis of halitosis has traditionally involved self-monitoring which is typically accomplished by breathing into one's own hand and then sniffing the trapped contents or a person suspecting that they have halitosis can utilize another person to sample their breath and render a subjective diagnosis.
Devices or monitors for the detection of halitosis are known in the art. U.S. Pat. No. 4,823,803, to Nakamura, issued Apr. 25, 1989, discloses a device for testing human exhalation for halitosis. Other prior art devices are known for analyzing a subject's breath for volatile sulfur emissions.
U.S. Pat. No. 5,275,161, hereby incorporated by reference, assigned to the same assignee as the subject invention, discloses a method and apparatus for electro-chemically detecting and quantifying sulfide levels in gingival sulci to determine the presence and extent of gingivitis and periodontal disease in a subject. The method disclosed therein employs a probe which is inserted into the sulcus and which includes a miniature sulfide measuring electrode and a reference electrode. U.S. Pat. No. 5,628,312 also assigned to the same assignee as the subject invention, discloses a probe for diagnosing periodontal disease by the concentration of sulfides present which includes a sulfide responsive measuring electrode and a reference electrode joined by a salt bridge to assure electrical continuity between the sulfide responsive electrode and the reference electrode.
Accordingly, it would be advantageous and desirable to have a method for diagnosing the presence and extent of halitosis activity on the surface of a subject's tongue by measuring the concentration of sulfides thereon.
SUMMARY OF THE INVENTION
There is disclosed a method for diagnosing the presence and extent of halitosis activity in a subject by measuring the concentration of sulfides present on the surface of the subject's tongue. The method includes the step of assaying fluid disposed on the surface of the tongue for the concentration of sulfides therein.
There is also disclosed a method for diagnosing the presence and extent of halitosis activity in the mouth of a subject by measuring the concentration of sulfides present on the surface of the subject's tongue including the steps of providing a sulfide responsive probe. A preferred probe includes a housing having a tip configured to probe the surface of the tongue, a measuring electrode and a reference electrode operative to establish an electrical potential therebetween when the tip is contacted with a sulfide containing fluid wherein the electrical potential generated is proportional to the concentration of sulfides in the fluid.
There is also disclosed a method for diagnosing the presence and extent of halitosis activity on the surface of a subject's tongue by measuring the concentration of sulfides thereon including the steps of providing a dual electrode probe having a sulfide-responsive measuring electrode and a reference electrode, providing a voltage indicator for generating a data readout reflective of the strength of the electrical potential between the sulfide-responsive measuring electrode and the reference electrode, and electrically connecting the sulfide-responsive measurement electrode and the reference electrode to the voltage indicator. The probe is then positioned in contact with the surface of the subject's tongue such that both electrodes are in contact with the surface of the tongue and the fluid disposed thereon wherein the fluid bridges the electrodes to cause a potential between the sulfide-responsive measurement electrode and the reference electrode, whereby the magnitude of the potential corresponds to the concentration of the sulfides in the fluid. The method further includes the steps of reading the data readout provided by the voltage indicator which is indicative of the concentration of sulfides on the surface of the tongue and comparing the data readout with a predetermined standard to determine the extent of halitosis.
BRIEF DESCRIPTION OF THE DRAWINGS
The following detailed description is best understood with reference to the following drawings in which:
FIG. 1 is a depiction of a probe structured in accordance with the present invention;
FIG. 2 is an enlarged, cross-sectional view of a portion of the probe of FIG. 1;
FIG. 3 is an enlarged, cross-sectional view of a portion of the probe of FIG. 1;
FIG. 4 is a graph depicting sulfide levels on the surface of a subject's tongue treated with artificial saliva;
FIG. 5 is a graph depicting sulfide levels on the surface of a subject's tongue treated with 0.12% chlorhexidine;
FIG. 6 is a graph depicting sulfide levels on the surface of a subject's tongue treated “back to back” with a first commercially available product and a second commercially available product;
FIG. 7 is a graph depicting sulfide levels on the surface of a subject's tongue treated with a third commercially available product; and
FIG. 8 is a graph depicting sulfide levels on the surface of a subject's tongue treated with a fourth commercially available product.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is directed to a halitosis probe for measuring the sulfide concentration of fluids disposed in the mouth or oral cavity, specifically on the surface of the tongue. Suitable probes include those disclosed in either U.S. Pat. No. 5,275,161 and/or U.S. Pat. No. 5,628,312 both incorporated herein by reference. Referring to FIGS. 1 and 2, a typical probe structure 20 in accordance with the principles of the present invention is shown. The probe 20 includes a housing 22 which can be disposable having a dimension and shape configured to contact or probe various regions of the surface of the tongue and also which contains a sulfide-responsive sensing electrode 24 . The probe 20 further includes a reference electrode 26 supported by the housing 22 or by an optional disposable second housing portion 23 . Referring to FIGS. 1 and 3, the reference electrode 26 is immersed within a salt pellet 28 to control the chemical environment. The reference electrode 26 is kept in electrical contact with the sulfide-responsive sensing electrode 24 through a salt bridge 30 . An aperture 25 is disposed within the probe assembly 20 to provide direct electrical contact to the salt bridge when hydrated.
As shown in U.S. Pat. Nos. 5,275,161 and/or 5,268,312, the sulfide-responsive measuring electrode 24 and the reference electrode 26 are connected to respective, electrically conductive leads 38 . The leads 38 are in electrical communication with an electro-chemical analyzer 40 which may operationally include a sound generator 42 in communication therewith.
In operation, the probe 20 is disposed so that a tip portion 32 thereof is in contact with the fluid layer disposed on the subject's tongue so that the sulfide-responsive electrode 24 contacts the fluid. The reference electrode 26 is also in electrical communication with the fluid, via the salt bridge 30 . An electrical potential is developed between the sulfide-responsive electrode 24 and the reference electrode 26 and this electrical potential is proportional to the sulfide concentration in the fluid. The electro- 163 chemical analyzer is operative to sense the potential between the electrodes 24 , 26 and to provide a display which is directly indicative of, or correlatable with, sulfide concentration. Since, in some instances, it is difficult for a practitioner to observe a visual display while properly positioning the probe 20 on the tongue, the sound generator 42 may be utilized in combination with the electro-chemical analyzer 40 . The sound generator 42 produces an audible signal which is indicative of the potential generated between the electrodes 24 , 26 .
Referring to FIG. 2, the sulfide-responsive measuring electrode 24 is most preferably fabricated from a material which undergoes an electro-chemical reactivation with the sulfide ion. One particularly preferred material comprises silver sulfide and, accordingly, the electrode 24 may be simply comprised of a fine sulfided silver wire 34 with an insulator 35 disposed therebetween. In other instances, the electrode 24 may comprise a wire, such as a stainless steel wire, coated with silver. Other metals reactive with sulfide may be similarly employed, for example, antimony.
The reference electrode 26 is disposed in an electro-chemical relationship with the sulfide-responsive electrode 24 and must be employed in order to provide a potential indicative of a sulfide ion concentration.
In a preferred embodiment, the reference electrode 26 is disposed in the probe 20 . One particularly preferred reference electrode 26 comprises a silver-silver chloride electrode, typically provided by disposing a chloride coating on a silver wire 34 . In some instances, the chloride coating will be disposed to cover a substantial length of the wire, and in other instances, the wire will be insulated along substantially all of its length and will have a body of silver chloride disposed so as to cover a free end of the wire. All such configurations may be employed in the practice of the present invention.
The reference electrode 26 is disposed within the pellet 28 of a salt, such as potassium chloride. The pellet 28 of potassium chloride can be partially covered by the material of the housing 22 , and preferably has a major portion of its free surface covered by a moisture impervious material, such as a layer of epoxy resin.
In accordance with another feature of the present invention, as shown in FIG. 3, there is provided a hydration layer 36 on the probe 20 , in the region of the reference electrode 26 , sulfide-responsive electrode 24 and salt bridge 30 . The hydration layer 36 comprises a smooth, open structured, over-coated layer which assures the maintenance of hydrated conditions between the electrodes 24 , 26 and salt bridge 30 and allows for wider tolerances in the fabrication of the salt bridge 30 . A number of different materials may be utilized for the hydration layer 36 . One preferred material involves cellulose acetate. Other embodiments of the hydration layer 36 may similarly be prepared from a variety of polymers such as cellulose acetate-butyrate, vinyls and the like.
In use, once the probe 20 is hydrated, the probe 20 is ready for insertion into the mouth of the subject and for contact with the surface of the subject's tongue. The probe 20 is inserted so that it comes into contact with the fluid layer overlying the tongue. The electrolytes within the fluid layer will cause an electrical potential to develop between the electrodes 24 , 26 , the magnitude of which corresponds to the concentration of sulfide in the fluid.
After measurement of the tongue, a portion of or all of the probe 20 may be discarded as the probe 20 is preferably made of or constructed of disposable materials.
While one particular configuration of the probe 20 has been illustrated, it will be appreciated that in accordance with the principles disclosed herein, other configurations may be implemented.
The present invention can be utilized to record localized measurements of sulfide concentrations on the surface of the tongue for day-to-day variations, variations within a single day, for the effect of normal activities (eating, drinking), and for the effective treatment modalities, such as mouthwashes, as illustrated in the examples set forth below. Additionally, as sulfide concentrations are not necessarily uniform over the entire surface of the tongue, the probe of the present invention can be utilized to detect points and/or regions of the surface of the tongue which may be “hot spots” where sulfide production is located or unusually high.
EXAMPLES
The following examples are presented in order to demonstrate the utility of the present invention.
EXAMPLE 1
Example 1 demonstrates the ineffectiveness of an artificial saliva product for altering the sulfide concentrations on the surface of a tongue of a subject. Referring to FIG. 4, the sulfide concentrations taken over time are displayed as a function of signal strength in millivolts.
Baseline data was obtained from the tongue of an experimental subject. Five measurements from the surface of the tongue including rear center, rear left, rear right, left side, and right side were obtained. One measurement from underneath the tongue was also obtained. The measurements were then repeated immediately following the subject's rinsing for thirty seconds with a commercially available artificial saliva product. The subject then brushed their tongue with a toothbrush dipped into the artificial saliva product and the six measurements were immediately taken again. Five hours after the initial rinse with the artificial saliva product, the six measurements were again repeated.
The data obtained in this example demonstrate the uniformity and repeatability of sulfide measurements obtained utilizing the probe of the present invention. The artificial saliva product, as expected, had no effect on the sulfide concentrations measured on the surface of the subject's tongue.
EXAMPLE 2
In this example, the effectiveness of the bactericide chlorhexidine for the reduction of sulfide levels on the surface of a subject's tongue was analyzed. It was predicted that chlorhexidine would be effective in the reduction of sulfide levels on the surface of the tongue as it is known that chlorhexidine is retained by oral tissue.
As in Example 1, measurements of the sulfide levels on the surface of the tongue and from the underside of the tongue were obtained utilizing the probe of the subject invention.
Referring to FIG. 5, the results of the chlorhexidine experiment are shown. Baseline data was obtained from the surface of the tongue and from underneath the tongue as described in Example 1. The measurements were then repeated immediately following a thirty second rinse of the subject's tongue in 0.12% chlorhexidine. The subject then brushed their tongue with a toothbrush which had been dipped into the 0.12% chlorhexidine solution. As shown in FIG. 5, two of the five measurements from the surface of the tongue are reduced significantly. After a one hour and twenty minute time delay following the initial chlorhexidine rinse, the measurements were repeated and four of the five measurements from the surface of the tongue were reduced considerably. The fifth measurement had also been significantly reduced. After a four hour delay following the initial chlorhexidine rinse, the six measurements were repeated. Four of the five measurements from the surface of the tongue were found to be lower than those recorded at the one hour and twenty minute time point. The fifth measurement was higher than that recorded at the one hour and twenty minute interval but was considerably lower than the initial measurement.
The data obtained in this example was found to be consistent with the documented modality or action of chlorhexidine. That is, there is no immediate reduction in sulfide concentration; however, after the passage of a period of time, the retained chlorhexidine residue destroys contacted bacteria thus shutting down the production of sulfides by the bacteria. As the time progresses, more and more bacteria are destroyed at some sites while at other sites the bacteria is able to proliferate once again. This example demonstrates the utility of the probe of the present invention in obtaining sulfide concentrations which are correlatable to the action of a known bactericide.
EXAMPLE 3
In Example 3, a first and a second commonly available commercial oral hygiene product were administered in a “back-to-back” fashion. Referring to FIG. 6, the data obtained in this example are illustrated. As in Example 1, measurements of the concentration of sulfides on the surface of the tongue and underneath the tongue were obtained utilizing a probe in accordance with the present invention. A baseline was established by obtaining five measurements of the surface of the subject's tongue and one measurement from underneath the subject's tongue. Immediately thereafter, the subject brushed and rinsed with the first product and then the six measurements were immediately obtained. Then, following a twenty minute time period, the six measurements were repeated. Then, the subject rinsed with the second product for thirty seconds and the six measurements were taken. Three of the five measurements of the sulfide concentration were found to be significantly lower with the other two being slightly reduced. The subject then brushed with the second product and the measurements were again repeated. All measurements on the surface of the tongue were significantly reduced. After a period of four hours from the initial brush and rinse with the first product, four of the five measurements from the surface of the tongue remained significantly lowered while one of the measurements had increased to the level seen immediately after the rinse with the second product.
Based on this “back-to-back” comparison, the first product was found to be ineffective for reducing the sulfide concentrations on the surface of the subject's tongue, the second product was found to have an immediate effect which could be increased by mechanically manipulating the surface of the tongue by brushing. After 4 hours, there was evidence that bacterial generation of sulfides were recurring.
EXAMPLE 4
In this example, another product comprising a third commonly available commercial oral hygiene product was tested as shown in FIG. 7 . Measurements were obtained as in Example 1. A baseline was established by taking five measurements of the sulfide concentration from the surface of the subject's tongue. One measurement was taken from underneath the tongue. The subject then rinsed with the product, and the six measurements were repeated thirty seconds thereafter. All five surface measurements indicated a significant lowering of the sulfide concentrations. The subject then brushed with a toothbrush which had been dipped in the product and the measurements were immediately repeated thereafter. Very little additional reduction of sulfide concentration was found. Five hours after the initial rinse, the measurements were repeated. Two of the five surface measurements were found to remain very low. The remaining three of the five signals had begun to increase approaching the initial baseline values.
The product tested appears to produce an immediate significant reduction of sulfide production. Some of the sulfide production areas were kept sulfide free for more than five hours. Other areas were found to again produce sulfide within this time interval.
EXAMPLE 5
In this example, a product comprising a fourth commonly available commercial oral hygiene product was tested for its ability to lower sulfide concentrations on the surface of a subject's tongue as shown in FIG. 8 . Measurements were taken as described for the previous examples utilizing a probe in accordance with the present invention. A baseline measurement was obtained and thereafter the subject rinsed twice with the product. Thirty seconds after the second rinse, the six measurements were immediately taken. It was found that all five surface sulfide concentrations had been considerably reduced. Five hours after the rinse, the measurements were repeated and all five of the surface sulfide concentration measurements indicated that all five sulfide concentration measurements were considerably reduced.
The product tested in this example demonstrated an immediate and significant reduction of sulfide production. Even five hours after the initial treatment, sulfide production remained very low and sulfide production had not been reestablished.
The foregoing examples demonstrate the ability of the probe of the present invention to be utilized for obtaining measurements of the sulfide levels on the surface of the tongue. These measurements can be used for the diagnosis of halitosis and to assess the effectiveness of treatments for halitosis.
In view of the teachings presented herein, other modifications and variations of the present inventions will be readily apparent to those of skill in the art. The foregoing drawings, discussion, and description are illustrative of some embodiments of the present invention, but are not meant to be limitations on the practice thereof. It is the following claims, including all equivalents, which define the scope of the invention.
Any patents or publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. These patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
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A method and apparatus for diagnosing the presence and extent of halitosis activity are disclosed. A method includes assaying for the presence of sulfides on the surface of a subject's tongue in order to determine the concentrations of sulfides in the fluids.
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CROSS-REFERENCE TO A RELATED APPLIACTION
[0001] The invention described and claimed hereinbelow is also described in U.S. Provisional Application Ser. No.: 60/716,581 filed Sep. 13, 2005. It is also described in German Patent Application No. 10 2005 027 521.1 filed on Jun. 14, 2005, whose subject matter is incorporated here by reference, and which provides the basis for a claim of priority of invention under 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION
[0002] The invention relates to a wall system, particularly for exhibition booths, having a plurality of intrinsically rigid wall elements.
[0003] One such wall system is already known from European Patent Disclosure EP 0 890 982 B1. In this wall system, adjacent wall elements are joined together by a tongue-and-groove joint and are secured to one another by coupling elements in the upper and lower corner regions of the wall elements.
SUMMARY OF THE INVENTION
[0004] The object of the present invention is to propose a wall system whose wall elements are structurally constructed even more simply and can be joined together more quickly than the wall elements of the prior art.
[0005] This object is attained according to the invention with a wall system of the type defined at the outset, by providing that the wall elements can be joined together magnetically at their face ends.
[0006] As a result of the magnetic joining of the wall elements, additional fastening means, which would have to be inserted in a separate work step after the wall elements have been pushed together, can be dispensed with. The wall system of the invention can furthermore be constructed completely without tools from the individual wall elements. Thus not only is a faster construction of a wall made up of a plurality of wall elements possible, but the individual wall elements can also be designed structurally more simply.
[0007] The magnetic joining of the wall elements can be done in various ways. In a preferred embodiment, each of the wall elements is provided on one of its face ends with at least one permanent magnet or at least one steel plate and likewise on the opposed face end, at the same level, with at least one permanent magnet or at least one steel plate. Both the at least one permanent magnet and the at least one steel plate can be let into the face ends of the wall elements.
[0008] The magnet has one north pole and one south pole, and the steel plate joins the two poles, and as a result the two wall elements are securely held against one another. If the magnets and steel plates are let into the face end, then after the magnetic fixation, the wall elements rest flush against one another. The wall elements may be equipped with at least one magnet on one face end and with at least one steel plate on the opposite face end, or they may have solely permanent magnets or solely steel plates.
[0009] For simpler assembly, that is, for automatic lateral centering and for absorbing transverse forces, the wall elements may also be connectable to one another via a tongue-and-groove joint.
[0010] A further facilitation of assembly by means of automatic heightwise centering can be attained if the wall elements, on their face ends, can furthermore be joined together via at least one (preferably two) centering bolts, which engage at least one centering sleeve of the next wall element. However, the centering bolts and the centering sleeves serve not only for heightwise centering but also for stabilizing the wall, since by way of them, forces acting laterally on the wall can also be absorbed.
[0011] Preferably, each of the wall elements can be provided, on both vertical face ends, with at least one centering sleeve which has a thread into which one end, provided with a thread, of a centering bolt can be screwed and into which the other end of the centering bolt, without a thread, can be inserted. Thus all the wall elements can initially be equipped with centering sleeves. As needed, then centering bolts can be inserted into the centering sleeves into the left and/or the right face end. Free centering sleeves serve to receive centering bolts of the next wall element in succession.
[0012] So that intrinsically angled walls can also be produced, the wall system can have corner profiles of polygonal cross section, and one wall element can be fixed magnetically and/or mechanically to at least two at a time of the outsides of the corner profiles.
[0013] The corner profiles and the wall elements can also be capable of being joined together via at least one centering bolt, which engages a centering sleeve. It is advantageous if the at least one centering bolt is disposed on the corner profile. In this way, even with a relatively small cross section of the corner profiles, wall elements can be secured to all of the outer sides of the corner profiles. The centering bolts and centering sleeves again serve the purpose of height centering and of additionally stabilizing the joint.
[0014] In an alternative embodiment, the corner profile and the wall elements can be connectable to one another via a centering bolt with a head that is offset from its basic body; the centering bolt can be introduced into an oblong slot with a widened region for receiving the head, so that the head engages the oblong slot from behind.
[0015] To make it possible to attach a further wall element, perpendicular to a first wall element at any arbitrary point on one of the front sides of the first wall element, connection profiles of rectangular cross section may be provided, which are fixable to the upper and lower face ends of the first wall element and on whose outer side the second wall element is magnetically fixable. Once again, the second wall element and the connection profile can be connectable via at least one centering bolt, which engages a centering sleeve. The outer side of the connection profile extends parallel to the front side of the first wall element and can be secured in any arbitrary position on the front side by its being fastened on the upper and lower face ends of the first wall element. A second wall element secured to the connection profile is thus oriented perpendicular to the first wall element and subdivides the front side of that wall element.
[0016] In a manner known per se, feet to stand on can be capable of being screwed into the lower face end of the wall elements. These feet make it possible for the wall to stand up more securely and can serve to compensate for unevenness of the floor, if they are adjustable in height.
[0017] The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 , a front view of a wall element in accordance with the present invention;
[0019] FIG. 2 , a section through the wall element of FIG. 1 taken along the line II-II in accordance with the present invention;
[0020] FIG. 3 , a detail, partly in section, of the upper connection region of two wall elements in accordance with the present invention;
[0021] FIG. 4 , a detail, partly in section, of the upper connection region between one corner profile and one wall element in accordance with the present invention;
[0022] FIG. 5 , a cross section through the corner profile of FIG. 4 in accordance with the present invention;
[0023] FIG. 6 , a detail, partly in section, of the upper connection region between a second corner profile and a wall element in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] FIG. 1 shows a wall element 10 , which in its interior has a frame, shown in dashed lines, that comprises two vertical frame legs 11 , 12 and one upper frame leg 13 and one lower frame leg 14 . As shown in the sectional view in FIG. 2 , taken along the line II-II, the frame legs 11 through 14 are covered, toward the front sides 17 , 18 of the wall element 10 , by cover plates 15 , 16 . Between the frame legs 11 , 12 , the space between the cover plates 15 , 16 is filled up by a honeycomb structure 19 , for instance of cardboard. By means of this construction, although it is not compulsory, the wall element 10 is especially lightweight. Grooves 22 , 23 are provided in the frame legs 11 , 12 on the vertical face ends 20 , 21 of the wall element 10 ; they serve to receive suitably shaped springs on the face ends of the adjacent wall elements.
[0025] The actual fixation of two adjacent wall elements 10 , 10 ′ is effected magnetically, however, as FIG. 3 shows. A permanent magnet 24 is let into the vertical frame leg 12 of the left wall element 10 . At the same height as the permanent magnet 24 , the vertical frame leg 11 ′ of the right wall element 10 ′ has a steel plate 25 .
[0026] For height centering and for additional lateral stabilization, both wall elements 10 , 10 ′ are provided with centering sleeves 26 . The centering sleeves 26 have a threaded region 26 . 1 . In the case of the wall element 10 , this threaded region 26 . 1 of the centering sleeve 26 serves for screwing in a centering bolt 27 , whose free end is introduced into the centering sleeve 26 of the wall element 10 ′. However, the centering bolt 27 could equally well be screwed into the sleeve 26 of the wall element 10 ′. Thus the wall elements 10 , 10 ′ may be designed identically with respect to the centering sleeves 26 .
[0027] The connection shown, by means of a magnet 24 and a steel disk 25 as well as by means of centering sleeves 26 and centering bolts 27 , is repeated in a practical way at least in the lower corner region of the connection of the two wall elements 10 , 10 ′, which is not shown here; as a result, great stability of the joint is attained. To join the wall elements 10 , 10 ′, merely pushing them together suffices. Undoing the connection of the wall elements 10 , 10 ′ is also done simply by pulling them apart.
[0028] FIG. 4 shows the connection between one wall element 10 and a corner profile 30 . The corner profile 30 , as FIG. 5 shows, has a square cross section. Thus wall elements 10 can be connected to each of the outer sides 31 , 32 , 33 , 34 of the corner profile 30 . The connection is again made magnetically, and the corner profile 30 is provided with steel plates 25 , while the wall elements have magnets 24 . In addition, here as well the connection is stabilized by means of a centering bolt 27 , which engages a centering sleeve 26 on the wall element 10 .
[0029] If the corner profile 30 has a correspondingly differently shaped polygonal cross section, then connections of wall elements at an angle other than 90° are also possible.
[0030] FIG. 6 shows an alternative connection between a wall element 10 and a corner profile 30 ′, the latter having an oblong slot 29 with a widened region 29 . 1 , preferably on each of its sides. The head 28 , offset from a basic body 27 . 1 ′, of a centering bolt 27 ′ can be introduced into the widened region 29 . 1 . Next, the corner profile 30 ′ is moved downward, so that the head 28 engages the narrow part of the oblong slot 29 from behind and thus secures the connection.
[0031] This purely mechanical connection between the corner profile 30 ′ and the wall element 10 is very stable, and preferably a second centering bolt and oblong slot connection is provided in the lower region of the corner profile 30 ′ and of the wall element 10 . To facilitate assembly when connecting a plurality of wall elements 10 to the corner profile 30 ′, the widened regions 29 . 1 of the oblong slots 29 may be located on the other sides of the profile 30 ′, outside the narrow region.
[0032] It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
[0033] While the invention has been illustrated and described as embodied in a wall system, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
[0034] Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
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A wall system has a plurality of intrinsically rigid wall elements, wherein the wall elements have face ends and are magnetically joinable to one another at the face ends.
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[0001] This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 60/951,891, entitled “VISION SYSTEM AND METHOD THEREOF,” filed Jul. 25, 2007, which is expressly incorporated by reference herein.
BACKGROUND
[0002] The present disclosure relates to a system and method for detecting and correcting defects in an automated production system. More specifically, embodiments of the present invention relate to a system and method for automatically detecting and correcting manufacturing defects in plastic bags.
[0003] Plastic bags are typically made from a web or roll of folded plastic film. Seams are applied to the film to form the bag which is separable by a perforation. Typically, the two seams are space a distance (illustratively about an inch) apart. The perforation is then cut between the seams. During manufacturing of the bags the location of the perforation cut can drift to the right or left (relative to the direction of the moving plastic) toward or away from the seams. This causes the perforation to be too close or too far from the seams.
[0004] It would be beneficial to provide a system for correcting this drift during the manufacturing process so the perforation is located in the proper position relative to the seam.
SUMMARY
[0005] The present disclosure describes a system for monitoring and correcting the position of a perforation during manufacture of plastic bags and the like. The location of the perforation relative to the seam is constantly monitored with certain deviations causing an alert. When needed, the system includes a correction mechanism that moves the perforation blade to the proper location.
[0006] An embodiment of the present disclosure provides a system for detecting and correcting defects. The illustrative system comprises a data file, wherein manufacturing specifications are stored, a production line, at least one device configured to provide treatment to goods on the production line, at least one sensor configured to capture data from goods passing on the production line, a computer system configured to receive, store, process, and send data, a controller operatively connected to the computer system and configured to send feedback, and an actuator operatively connected to the controller and configured to receive feedback from the controller.
[0007] Illustrative embodiments of the present disclosure relate to a method for detecting and correcting defects and may comprise providing a data file, providing a production line, transporting goods upon the production line, providing at least one sensor, capturing data from the goods with the sensor, communicating the data from the sensor to a computer system, detecting a defect whereby a reference data is compared to the data captured by the sensor, transmitting an output signal to a controller; processing output signals via the controller, generating corrective production specifications, communicating feedback production specifications from the controller to a actuator, and adjusting production specifications via the actuator, wherein the adjustments correct the detected defect.
[0008] Other embodiments of the present disclosure provide a system for detecting and correcting plastic bag manufacturing defects which may comprise a data file, a processing line, a heat welding device operatively connected to the processing line, a perforating device operatively connected to the processing line, at least one sensor configured to gather input from goods passing on the production line, a computer system in communication with the sensor, configured to store a reference and compare an image with said reference, a programmable logic controller operatively connected to the computer, wherein feedback is generated, and a perforation servomechanism operatively connected to the programmable logic controller.
[0009] Another embodiment of the present disclosure comprises a system or apparatus of monitoring and adjusting the location of a perforation during production of a plastic sheet. The system comprises a monitor that captures an image of the perforation cut into the plastic sheet; a computer that processes the image and determines whether the perforation is located in a desired position; and a controller that moves the a perforation blade if the computer determined that the perforation was not in the desired position.
[0010] The above and other embodiments may further comprise: the plastic sheet being a web of a plurality of folded plastic bags; the plastic sheet having a seal located adjacent and spaced apart from the perforation, the monitor capturing an image of the perforation and the seal, the computer determining whether the perforation is located in a desired position relative to the seal, and the controller moving the position of the perforation blade relative to the seal if the computer determined that the perforation was not in the desired position; the monitor being a camera; the camera capturing an image that is transmitted to the computer which includes a reference image that the image is compared to determine whether the perforation is located in the desired position; the controller including a programmable logic controller that receives corrective data from the computer moves the perforation blade if the perforation was not in the desired position; the controller being in communication with a perforation servomechanism that receives commands from the controller to move the perforation blade; movement of the perforation blade ensuring that subsequent perforations in the plastic sheet are in the desired position; the computer issuing a deadband to the controller if the perforation is located in the desired position.
[0011] Another illustrative embodiment is a method of monitoring and adjusting the location of a perforation during production of a plastic sheet. This method comprises the steps of: moving a length of the plastic sheet along a conveyor; monitoring the plastic sheet by capturing an image of the perforation cut into the plastic sheet; processing the image to determine whether the perforation is located in a desired position; and moving the a perforation blade if determined that the perforation was not in the desired position.
[0012] The above and other embodiments may further comprise the steps of: moving the plastic sheet which is a web of a plurality of folded plastic bags; providing a seal adjacent to and space apart from the perforation; capturing an image of the perforation and the seal, determining whether the perforation is located in a desired position relative to the seal, and moving the perforation blade relative to the seal if determined that the perforation was not in the desired position; providing a camera to monitor the plastic sheet; capturing an image that is transmitted to a computer which includes a reference image that is compared to the image to determine whether the perforation is located in the desired position; moving the perforation blade with the assistance of a programmable logic controller that receives corrective data from the computer when the perforation is not located in the desired position; providing a perforation servomechanism that receives commands from a controller for moving the perforation blade; moving the perforation blade to ensure that subsequent perforations in the plastic sheet are in the desired position; and sending a deadband if the perforation is located in the desired position.
[0013] Another embodiment includes a method of detecting two variables that are introduced at different points in the process relating to the art of bag making machinery, particularly to rotary bag making machines. The first variable is a heat welding device used to double seal two layers of plastic film together at about 1-inch paralleled seals illustratively perpendicular to the direction of a web path. A second variable can be introduced as a perforating device to perforate the plastic between the adjacent seals. Defects are related to process variables which affect the quality of the product. Quality Control Imaging and pattern recognition algorithms are applied. Once inspection of the variables has been performed, an output signal is used to effect a control action at the rotary bag machine. This method illustratively includes a) an image snapshot capturing the two variables introduced into the process as in claim 1 ; b) an image-capturing device monitors, records and reacts to a preset template of conditions given via computer program, wherein if the variables that pass before the capturing device deviate from the template and the preset measurements are recognized, the system or user is notified of the discrepancy; c) a perforation detector signal used to fire and rest the capturing device, wherein the signal is in close proximity of the capturing device which helps to stabilize the image at high production speeds; d) when a deviation is detected on a captured image, immediate feed back is sent for process corrections creating a closed loop control; e) depending on direction of deviation (upstream, downstream), one of two signals are sent to correct the registered error; f) a deadband control is utilized to eliminate oscillation in the process when no action is required, wherein a no alarm condition exists when the measured process enters the deadband range.
[0014] Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments exemplifying the best mode of carrying out the disclosure as presently perceived.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The detailed description particularly refers to the accompanying figures in which:
[0016] FIG. 1 is a block diagram of a computer system according to an embodiment of the this disclosure;
[0017] FIG. 2 is another illustrative system according to an embodiment of the this disclosure;
[0018] FIG. 3 is a flow chart of a monitoring system according to an embodiment of the this disclosure;
[0019] FIGS. 4 a and 4 b are images of plastic sheeting with target boxes which generally define an area or characteristic of interest;
[0020] FIG. 5 is a flow chart of a detection system according to an embodiment of the this disclosure;
[0021] FIG. 6 is a flow chart of a corrective system in accordance with one embodiment of the present invention; and
[0022] FIG. 7 is a flow chart of a method of detecting and correcting defects according to an embodiment of the disclosure.
DETAILED DESCRIPTION
[0023] A block diagram of a computer system 100 according to an embodiment of the present disclosure is shown in FIG. 1 . Computer system 100 generally comprises a computer 102 . Computer 102 illustratively comprises a processor 104 , a memory 110 , various support circuits 108 , an input/output (“I/O”) interface 106 , and a storage system 111 . Processor 104 may include one or more microprocessors. Support circuits 108 for processor 104 may include conventional cache, power supplies, clock circuits, data registers, I/O interfaces, and the like. I/O interface 106 may be directly coupled to memory 110 or coupled through processor 104 . Additionally, I/O interface 106 may be configured for communication with input devices 107 and/or output devices 109 , such as network devices, various storage devices, mouse, keyboard, displays, and the like. Storage system 111 may comprise any type of block-based storage device or devices, such as a disk drive system.
[0024] Memory 110 stores processor-executable instructions and data that may be executed by and used by the processor 104 . These processor-executable instructions may comprise hardware, firmware, software, and the like, or combinations thereof. Modules having processor-executable instructions that are stored in the memory 110 may include a capture module 112 . Computer 102 may be programmed within an operating system 113 , which may include OS/2, Java Virtual Machine, Linux, Solaris, Unix, HPUX, AIX, Windows, MacOS, among other platforms. At least a portion of operating system 113 may be stored in the memory 110 . Memory 110 may include one or more of the following: random access memory, read only memory, magnetoresistive read/write memory, optical read/write memory, cache memory, magnetic read/write memory, and the like.
[0025] A diagram of system 202 is shown in FIG. 2 . System 202 generally comprises a monitoring system 204 , a detection system 206 , and a corrective system 208 . System 202 may further include a conveyor belt system 210 , a heat welding device 212 , a perforating device 214 , a sensor 216 , the computer system 100 , a programmable logic controller 220 , and a corrective mechanism 222 .
[0026] System 202 may include an underlying conveyor system 210 being advanced in a production direction, along an extending path, by draw rollers 224 . Omitted for clarity is a complete production line whereby raw materials require sequential steps to render a finished product. This production line is known to those skilled in the art.
[0027] System 202 may also include treatment tools that modify goods. In one embodiment, the system may include a heat welding device 212 . In another embodiment, the system may include a perforating device 214 . In yet another embodiment, the system may include both a heat welding device and a perforating device. The heat welding device 212 is used to double seal two layers of plastic film together at illustratively, one inch paralleled seals perpendicular to the direction of the underlying belt movement. It is appreciated that other sealing configurations may be used. Similarly, perforating device 214 may include a perforation blade or equivalent that is used to perforate the plastic between the adjacent seals. It is understood that a variety of different tools may treat the material as it passes through the production line. For example, tools may provide treatments such as resizing, shaping, cutting and pressing.
[0028] Monitoring system 204 includes at least one sensor 216 . This sensor 216 may be positioned on the conveyor belt system illustratively after the goods receive treatment and before the end of the conveyor belt system. Sensor 216 is configured to capture quality control data from goods advancing on the conveyor belt system. Based on the speed at which goods advance, the sensor may be able to capture data at a high rate of speed. In one illustrative embodiment, sensor 216 may comprise a digital or analog camera that captures images on white or black film. Camera specifications may include, but not limited to, ⅓″ VGA CCD Imager, active pixels 656×494, 5.79 (H)×4.89 (V) active area (mm), 100 frames per second (“fps”) @ 40 MHz, and a minimum illumination of 1.0 lux at 100 fps. Optionally, the sensor may include electric eye sensors, infrared sensors, motion sensors, temperature sensors, vision cameras, and ultraviolet and other visible spectrum light sensors. Alternative embodiments of this disclosure may comprise an analog-to-digital component designed for digitizing analog signals.
[0029] The detection system 206 may include computer system 100 . (See also FIG. 1 .) Illustratively, computer system 100 is located in close proximity to the sensor to reduce the transfer time. This close proximity configuration may be implemented when data is being captured at high production speeds. Computer system 100 is in communication with the senor through any viable communication medium, such as a serial cable, wireless, Ethernet, Universal Serial Bus (“USB”), or the like, for example.
[0030] Corrective system 208 may comprise a programmable logic controller (“PLC”) 220 and a corrective mechanism 222 . PLC 220 is a digital computer used for automation of industrial processes, such as control of machinery on factory assembly lines. Unlike general-purpose computers, PLC 220 is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. The input/output arrangement may be built into a simple PLC, or the PLC may have external I/O modules attached to a computer network that plugs into the PLC. Programs to control machine operation are typically stored in battery-backed or non-volatile memory.
[0031] Optionally, PLC 220 and computer system 100 may be combined into one unit. In other words, the functionality of both the computer system and the PLC may be conducted by one computer system. Organizationally, as known to those skilled in the art, the computer system and the programmable logic controller may further be installed in the same location through a rack installation, or similar configuration.
[0032] Corrective mechanism 222 may comprise a mechanism to correct defects generated by the production line. PLC 220 is connected to an electro servo drive which moves or controls the perforation blade. The actuator is usually a physical mechanism, but also may refer to an artificial intelligent agent. In one embodiment, the corrective mechanism may comprise a perforation servomechanism (“servo”). The servo is optimally connected to the production line and, more specifically, to tools that provide treatment to the raw materials or products. For example, the servo can be connected to perforating device 214 such that adjustments may be made when plastic bag seals do not meet specification.
[0033] A block diagram of a monitor system 204 is shown in FIG. 3 . System 204 comprises data files 302 and at least one sensor 216 . Data files 302 hold data related to plastic bag manufacturing such as bag size, camera settings, and perforation settings. Specific parameters 306 are utilized to determine the monitoring requirements on a per-job basis. Moreover, data files 302 enable an operator to load a manufacturing run, along with all the customized manufacturing parameters by selecting a specific data file associated with the run. In one illustrative embodiment, sensor 216 may be configured to monitor plastic bag perforations. In another illustrative embodiment, sensor 216 may be configured to monitor plastic bag seals.
[0034] In operation, sensors 216 may be configured to focus on a particular characteristic of the goods. Specifically, a data file or operator may configure a target box whereby sensor 216 focuses on the particular area or characteristic of the plastic sheets. As shown in FIGS. 4 a and b, an image 404 (see also FIG. 5 ) is taken of plastic sheeting 320 . A target box 322 which generally defines an area or characteristic of interest is superimposed on image 404 . In this case, target box 322 maintains a fixed distance 329 from perforation 324 . A seam 326 is located inside target box 322 . (Seam 327 is located on the opposite side of perforation 324 .) In an illustrative embodiment, if seam 326 is too close to either the left side 328 or right side 330 of target box 322 , then a corrective function is engaged to adjust the perforation blade.
[0035] As shown in FIG. 4 b, once the perforation blade is moved, seam 326 moves back toward the center of target box 322 . As more bags pass under sensor 216 and are photographed, seam 326 should stay close to the center of target box 322 . If, however, perforation 324 drifts (target box 322 stays the same distance from perforation 324 ), seam 326 will drift as well. Once this drift is detected, corrective measures will once again be initiated.
[0036] To accomplish all of this, approximately 1 to 100,000 data points in the image are read. Some embodiments may utilize as many data points as capable and sustainable. A flow chart of a detection system 206 is shown in FIG. 4 . After sensor 216 captures quality control data, the data may transmit to computer system 100 . Computer system 100 , as described above, may process a computer readable medium having instructions to load a stored reference 402 , to compare with the quality control data. In control systems and used herein, the desired output of a system is called the reference. The computer readable medium may further include quality control imaging and pattern recognition algorithms. In one embodiment, the computer system may store the reference data, which is also called a template or target parameter. The computer readable medium may load a reference 402 and compare it against the recently captured image 404 from sensor 216 .
[0037] In operation, detection system 206 may provide a number of different detection methods. In one embodiment, a defect 406 may be detected by pixel counting whereby the number of light or dark pixels of the reference is compared with the captured image pixels. Additional embodiments may further comprise blob discovery whereby an image is inspected for discrete blobs of connected pixels as image landmarks. In yet another embodiment, defect detection 406 may comprise template matching whereby images are compared by finding, matching, and/or counting specific patterns. In still another embodiment, system 400 may comprise any combination of the above defect detection methods.
[0038] After determining defect 406 exists, computer system 100 may generate an output to PLC 220 . Illustratively, the location of the perforation with respect to defects corresponds to a specific output. For instance (and as discussed with respect to FIGS. 4 a and b ), a perforation to the left 408 may correspond to output 1 at 414 , while a perforation to the right 410 may correspond to output 2 at 416 . In an illustrative embodiment, an alarm may sound when a product defect is detected at 406 . These alarms may include visual and audio alarms to an operator, or any form of an electronic alarm. Examples of electronic alarms may include email, pager, instant message, pop-up, report generation, or the like. In an additional embodiment, the notification can be a series of lights such as green, yellow and red. If the light is green, the perforation is within an optimum tolerance and no adjustment is needed. If red, correction may be needed such as shifting the perforation blade illustratively to the left to get the perforation back within the optimum tolerance. If the light is yellow, correction may also be needed but now the perforation blade may need to be shifted the other way to get the perforation back within the optimum tolerance.
[0039] A flow chart of corrective system 208 is shown in FIG. 5 . Computer system 100 sends a defect output 502 to PLC 220 . Illustratively, PLC 220 includes communication ports such as 9-Pin RS232, RS485, Ethernet, and the like. Communication protocols used may include Modbus, DF1, and other communication network protocols. By employing these communication capabilities, the PLC is able to receive notification from the computer system.
[0040] In control theory, a closed-loop, also called a feedback control system, uses feedback to control states or outputs of a dynamical system. In operation, process inputs have an effect on the process outputs, which is measured with sensors and processed by the controller, wherein the result is used as input to the process, closing the loop. Embodiments of the present invention may provide a controller comprising a closed-loop architecture. Optionally, the system may comprise a closed-loop and open loop control simultaneously, wherein the open-loop control is termed feedforward and serves to further improve reference tracking performance.
[0041] After PLC 220 receives defect 503 output from computer system 100 , it processes the particular output at 504 . Processing may include determining what corrective actions need to be taken. Corrective parameters are then sent at 506 . Illustratively, programming gives an output signal to control overshooting when correcting the defect. The output and/or notification may be in any form capable of conveying corrective parameters to an actuator.
[0042] PLC 220 further comprises a deadband, which is an area of a signal range or band where no action occurs (the system is dead). When no defects are detected, computer system 100 does not send an output so PLC 220 takes no corrective actions. Most commonly, deadband is used in voltage regulators, thermostats, and alarms. The purpose for deadband is to prevent oscillation or repeated activation-deactivation cycles (called “hunting” in proportional control systems).
[0043] The actuator receives corrective parameters 508 from PLC 220 . In an illustrative embodiment, the perforation servo serves as the actuator. Based on the parameters received, the perforation servo may adjust production to correct the position of the perforation blade at 510 . Illustratively, receiving a corrective parameter may cause the perforation servo to initiate a correction sequence that adjusts the perforation blade so no more seal defects occur. It is understood to those in the art, however, that any device that may provide control of a desired operation through the use of feedback may serve as an actuator.
[0044] A flow chart of a method of detecting and corrective defects is shown in FIG. 6 . The method 2 is described with respect to the system 202 disclosed in FIG. 2 . Illustratively, production output includes providing a data file at 602 that may comprise a plastic bag that has been heat sealed and perforated. Optionally, the production output may comprise any goods, product, or material subjected to a quality assurance process.
[0045] At step 604 , the method captures data of the production output. As discussed in more detail above, there are a variety of methods to capture data. The method used to capture data will depend on a number of factors, including cost, the subject matter, and accuracy. In one embodiment, an image may be captured with a photographic device using white film. Illustratively, an image may be captured with a photographic device using black film, or even digitally using no film. The capturing device focuses on a particular area or feature, and adjusts itself ensuring it captures that particular area or feature.
[0046] At step 606 , the computer system loads a stored reference from its memory. This reference may comprise the target parameter for determining if a defect exists. Illustratively, the stored reference may comprise an image of a plastic bag with a seal and perforation within a target box. Optionally, the step of loading a stored reference 608 may utilize other computer systems and/or network topologies.
[0047] At step 610 , the method detects if a defect exists. To accomplish this step, the reference is compared with the captured data. Illustratively, the detection may occur using an application programmed to focus on the alignment of a seal. In addition, the application may focus on the perforation to determine if there is a defect. This detection comprises a pixel examination of images and attempting to develop conclusions with assistance of knowledge bases and features such as pattern recognition engines, and the like. Optionally, systems may be programmed to perform tasks such as counting objects on a conveyor, reading serial numbers, and searching for surface defects. When no defect is determined, the method may be completed, such that no corrective action takes place (deadband). Alternatively, if a defect is detected, the method performs other steps.
[0048] Step 612 comprises sending an output to a controller. The format for sending an output may comprise analog, digital, audio, visual, or the like. Illustratively, a computer system may send an output to PLC 220 . Optionally, if the computer system and the PLC functionality are combined within one unit, sending an output to a controller would comprise internal computer system communication.
[0049] At 614 , an actuator, or the like, receives feedback from the PLC and may provide adjustments at 616 to mechanisms within the system. A perforation servomechanism where, depending on the feedback, adjustments to the perforating device are made to correct misaligned perforations. Another illustrative embodiment includes a heat welding device being adjusted by the servomechanism.
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A system or apparatus of monitoring and adjusting the location of a perforation cut during production of a plastic sheet.
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The present application claims the benefit of U.S. provisional application No. 60/403,472, filed Aug. 15, 2002, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the surgical treatment of isolated articular chondral defects and, more specifically, to methods and instruments for replacement of articular cartilage in the knee using grafts harvested from a synthetic tissue specimen.
2. Description of the Related Art
Methods and apparatus for surgical treatment of isolated articular chondral defects by autograft and allograft transplantation are known. See, for example, U.S. Pat. Nos. 5,919,196, 6,591,581, and 6,592,588, having common assignment with the present application.
Various synthetic biomaterials are known. One of these, Salubria™, is an elastic biomaterial sold by Salumedica of Atlanta, Ga. Salubria™ is a poly (vinyl) alcohol hydrogel composition which is similar to human tissue in its mechanical and physical properties. See U.S. Pat. Nos. 5,981,826; 6,231,605; and published Application No. U.S. 2001/0029399, the disclosures of which are incorporated herein by reference.
The Salubria™ organic polymer-based material is highly biocompatible and hydrophilic (water loving); it contains water in similar proportions to human tissue. Although Salubria is soft and compliant like human tissue, it has proven to be exceptionally wear resistant and strong, making it an ideal implant material.
Salubria™ can withstand millions of loading cycles, yet it is soft enough to match the compliance of normal biological tissue. These properties allow Salubria™ to be molded into anatomic shapes and sterilized, making it usefuil for orthopedic applications.
It would be advantageous to have methods and systems for utilizing synthetic grafts in the repair of isolated chondral defects.
SUMMARY OF THE INVENTION
The present invention provides methods and apparatus for repair of isolated chondral defects using a synthetic substance, preferably a synthetic osteochondral graft material, such as Salubria™. The procedure can be utilized, for example, to anatomically re-establish a structural load-bearing surface to a damaged load bearing surface of the femoral condyle using implants harvested from synthetic anatomical specimens. Partial and full-thickness osteochondral lesions, 1.5-3.5 centimeters in diameter, are particularly amenable to treatment according to the methods of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a surgical step of sizing a lesion according to the present invention;
FIG. 2 illustrates a surgical step of marking an articular surface according to the present invention;
FIG.3 illustrates a surgical step of drilling a guide pin into bone according to the present invention;
FIG. 4 illustrates a surgical step of marking a synthetic hemi-condyle according to the present invention;
FIG. 5 illustrates a surgical step of scoring peripheral cartilage according to the present invention;
FIG. 6 illustrates a surgical step of boring into bone to form a recipient socket site according to the present invention;
FIG. 7 illustrates a surgical step of securing the synthetic hemi-condyle in a workstation according to the present invention;
FIG. 8 illustrates a surgical step of harvesting a core from the synthetic hemi-condyle secured in the workstation according to the present invention;
FIG. 9 illustrates a surgical step of transferring depth measurements to the core according to the present invention;
FIG. 10 illustrates a surgical step of cutting the harvested core to length according to the present invention;
FIG. 11 illustrates a surgical step of dilating the recipient socket site according to the present invention;
FIG. 12 . illustrates a surgical step of placement of the harvested core into the recipient socket using a delivery tube according to the present invention; and
FIG. 13 illustrates a complete core implant according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the present invention, a synthetic tissue specimen, such as an entire artificial distal femur, condyle, or hemi-condyle is created from synthetic biomaterial, such as Salubria™, and is delivered to a surgeon along with a set of surgical socket-forming and donor graft harvesting instrumentation. The tissue specimen is formed to closely approximate the anatomical tissue being repaired. The surgeon uses the instrumentation to fashion donor graft from the tissue specimen for osteochondral repair. The procedure is described below, with reference to the accompanying drawings.
Referring first to FIG. 1 , following standard pre-operative examination and diagnostic studies confirming the size and extent of the lesion 2 on an articular surface of femoral condyle 3 , a standard para-patellar arthrotomy is carried out to expose the defect. Cannulated sizers 4 in various diameters are selected to estimate and approximate coverage of the lesion 2 . Sizers 4 preferably are provided in 15, 18, 20, 25, 30, and 35 mm sizes.
Referring to FIG. 2 , once the appropriate size for the recipient socket is determined, a marker 5 is used to form a circumferential mark 6 on the condyle 3 around the cylinder of sizer 4 . As shown in FIG. 3 , a guide pin 8 is drilled through the sizer 4 past the lesion 2 and into bone. The sizer 4 is removed and a reference mark 10 is placed in a superior 12:00 o'clock position. See FIG. 3 .
Referring to FIG. 4 , markings are placed on a synthetic hemi-condyle 11 using the sizer 4 which was previously utilized to establish the recipient defect size and mark the condyle 3 . The sizer 4 is placed over the synthetic hemi-condyle 11 and is used to circumferentially mark 12 the surface of the hemi-condyle 11 in an area corresponding to that of the lesion 2 on the damaged articular surface of condyle 3 . The sizer is removed and a reference mark 13 is placed in a superior 12:00 o'clock position on the inside of the circle mark 12 on the hemi-condyle 11 .
Referring to FIG. 5 , the sizer is replaced with an appropriately sized recipient harvester 14 . The peripheral cartilage on the condylar surface is scored to the underlying subchondral bone. Scoring the peripheral cartilage obviates ancillary damage to the undamaged, peripheral articular surface. The harvester 14 is removed, leaving the guide pin 8 in place.
Referring to FIG. 6 , a cannulated calibrated recipient counterbore 16 is secured to the drill and placed over the drill pin 8 . Recipient socket 17 ( FIG. 9 ) is drilled into the lesion 2 and subchondral bone to a depth of 8 to 10 mm. Bleeding subchondral surfaces should be confirmed.
Preparation of the donor graft is described with reference to FIGS. 7-10 . Referring to FIG. 7 , donor condyle 11 is secured in a workstation 18 . As shown in FIG. 8 , a workstation bushing 20 of corresponding size is placed into a top housing 21 over the donor hemi-condyle 11 and set to the exact angle necessary to match the recipient's contour. The housing 21 is fastened securely.
A calibrated donor harvester 22 is connected to a drill and passed through the bushing 20 into the proximal graft housing 21 and rested upon the surface of the donor condyle 11 . The harvester 22 is drilled through the entirety of the donor hemi-condyle 11 . The harvester 22 is removed from the graft housing, securely holding the corresponding cylindrical donor graft core 24 , which can be visualized through slot 25 . Donor graft 24 is extracted gently from the harvester 22 so as not to disturb the articular surface or underlying subchondral bone.
Referring to FIG. 9 , a depth measurement guide 26 is used to measure the recipient depth in four quadrants: north, south, east and west. The depth measurements. are transferred to the synthetic graft core 24 , which is appropriately measured and marked 27 by referencing the four quadrant depths recorded from the recipient socket 17 that was created.
Referring to FIG. 10 , the donor graft 24 is secured in holding forceps 28 and trimmed by a reciprocating saw 30 to achieve the appropriate press fit accommodation of the recipient socket depth. The donor graft 24 is positioned with the articular surface inferior to cut.
Referring to FIG. 11 , a calibrated dilator 32 is inserted into the recipient socket site 17 to achieve a one half mm socket dilation. The end of the dilator is lightly tapped with a mallet. Dilation will also smooth the recipient socket surfaces.
Referring to FIG. 12 , once the precise depth of the donor plug (matching the recipient socket) is obtained, the donor plug 24 is line to line fitted with reference to the marks 10 and 13 into the recipient socket. Cancellous graft is inserted into the bed prior to insertion of the donor plug, if necessary. The donor graft 24 is inserted into a slotted, transparent, calibrated delivery tube 29 for insertion into the recipient socket 17 . A tamp corresponding to the graft's size is positioned against the plug. Gentle taps are recommended for seating the graft 24 into the socket 17 . Referring to FIG. 13 , the plug 24 is implanted until all edges are flush with the surrounding cartilage rim.
In situations necessary for plug removal, a graft retriever may be secured into the plug to facilitate extraction. At the conclusion of the procedure, the wound is closed in a routine fashion. Sterile dressing and a protective brace are applied during the initial wound-healing phase. Ambulation with the use of crutches and weight-bearing allowances are determined based on the size and the extent of the weight-bearing lesion reconstructed.
Although the present invention has been described in connection with preferred embodiments, many modifications and variations will become apparent to those skilled in the art.
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A method and apparatus for repairing isolated chondral defects using synthetic implants. Lesions in articular tissue are corrected by forming a recipient socket in the tissue. A donor graft of a size corresponding to the recipient socket is harvested from a synthetic specimen made of a synthetic tissue material, such as poly (vinyl) alcohol hydrogel. The donor graft is implanted into the recipient socket.
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BACKGROUND OF THE INVENTION
The present invention relates generally to electronic controls and more particularly to fast-response feedback-stabilized control circuits.
A control circuit such as a direct current amplifier receives an input signal and amplifies it to provide an output signal which is used, for example, to regulate a physical process by means of an electromechanical transducer. Such an amplifier may take the form of a differential amplifier which provides an output signal having a magnitude determined by any difference between a first input signal indicative of a desired state of the process and a second input signal indicative of the actual state of the process. In response to the output signal, the transducer regulates the process so as to cause the actual state of the process to approach the desired state.
It is sometimes required that the physical process commence precisely at a certain moment, for example to enable the duration of the process to be accurately controlled or to synchronize the commencement of the process with an external event. Under such circumstances an enabling input signal, which may be generated either manually or by automatic means such as a computer, is used to start and stop the process. When it is desired that the process commence, this enabling input signal is applied to the amplifier and causes the amplifier to provide the output signal.
An example of a physical process which is controlled in the above-described manner is the rate of mass flow of a fluid. A fluid mass flow controller has a sensor which measures the rate of mass flow of a fluid and provides a "mass flow" signal indicative of the measured rate of mass flow. An externally-generated "set point" signal indicates a desired rate of mass flow. When an enabling input signal indicates that the fluid should start flowing, a differential amplifier provides an output signal indicative of any difference between the mass flow and set point signals. An electromechanical transducer--specifically, a solenoid valve--opens in response to the valve signal to permit the fluid to begin flowing. The valve opens more or less according to the magnitude of the valve signal to increase or decrease the rate of mass flow of the fluid so as to minimize any difference between the mass flow and set point signals and thereby cause the actual rate of mass flow to approach the desired rate.
A feedback network having reactive components such as capacitors is commonly used in conjunction with a direct current amplifier, the network and the amplifier together defining a control loop, for example to prevent oscillation, to improve stability, to provide a desired input impedance, or the like. However, these reactive components are characterized by a time constant which results in a finite delay between the time the enabling input signal is provided and the time the amplifier is able to provide the output signal. For example, in a fluid mass flow controller of the kind described above, the amplifier includes an associated feedback network. This circuit is characterized by a delay, or response, time which must elapse between the time the enabling input signal arrives and the time the amplifier is able to provide the valve signal which causes the valve to open and initiate the flow.
Although the response time which is characteristic of an amplifier having reactive control loop components may be of little significance if the actual time at which the process commences is not critical, it is of great importance in those applications in which the moment at which the process commences must be accurately controlled. This is especially true when only a relatively small change in the magnitude of the process is desired because it often takes longer for the control loop to respond to a small input signal than to a large one. Accordingly, there is a need for a way to minimize this response time in electronic control circuits.
SUMMARY OF THE INVENTION
The present invention provides a fast response control circuit characterized by bias means which applies a bias signal to a control loop having reactive components and thereby minimizes the response time of the circuit. With essentially no delay, a control circuit according to the invention provides an output signal in response to an enabling input signal so as to permit precise regulation and control of the commencement time of a physical process.
A fast response control circuit according to the invention includes amplifier means, responsive to an enabling input signal to provide an output signal having a magnitude determined by a variable input signal; a feedback network in feedback relationship with the amplifier means and and defining therewith a control loop characterized by a response time; and bias means, in electrical communication with the control loop, operative to apply a bias signal to the control loop to reduce the response time. In one embodiment the amplifier means comprises a differential amplifier, the magnitude of the output signal being determined by any difference between first and second variable input signals.
The control loop typically includes a reactive component such as a capacitor, and the bias signal is applied to change the level of charge on the capacitor. The bias signal "pre-changes" the capacitor as closely as possible to an expected steady state charge level which the capacitor is expected to reach as the output signal reaches its steady state value. Thus, when the enabling input signal arrives the response time of the control loop is much shorter than it would have been had the capacitor not been pre-charged, and accordingly the output signal is able to reach its final value more rapidly.
In some applications the expected steady state charge level of the capacitor is dependent on the value of the variable input signal. Accordingly, in such embodiments the magnitude of the bias signal is determined by the input signal (or by one of the two variable input signals if a differential amplifier is being used) so as to pre-charge the capacitor as closely as possible to its expected steady state charge level. In other applications the expected steady state charge level is nearly independent of the variable input signal, and in such embodiments the magnitude of the bias signal is determined independently of the input signal.
Interrupt means preferably interrupts the communication between the bias means and the control loop when the enabling input signal is received so as to prevent the bias signal from interfering with normal circuit operation during the time the circuit is enabled.
One embodiment includes delay means to delay application of the variable input signal to the amplifier means for a short time after arrival of the enabling input signal, for example to improve stability.
In a preferred embodiment the invention is advantageously applied to minimize the response time of a fluid mass flow controller of the kind having means to provide a mass flow signal indicative of a measured rate of mass flow of a fluid, means to receive a set point signal indicative of a desired rate of mass flow of the fluid, means to receive an enabling input signal to start the flow of the fluid, amplifier means responsive to the enabling input signal to provide an output signal indicative of any difference between the mass flow and set point signals, a feedback network in feedback relationship with the amplifier means and and defining therewith a control loop characterized by a response time required for the output signal to attain a magnitude indicative of said difference, and valve means responsive to the output signal to change the rate of mass flow of the fluid to minimize said difference. Bias means applies a bias signal to the control loop when the fluid is not flowing, and, when the enabling input signal commands the fluid flow to start, the valve opens virtually instantaneously.
Other aspects and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a block diagram of a fast response control circuit according to the invention;
FIG. 1B is a block diagram of a fast response control circuit which is similar to that depicted in FIG. 1A except that the bias means receives an input from a power source instead of from an input terminal;
FIG. 1C is a block diagram of a fast response control circuit which is similar to that depicted in FIG. 1A except that the amplifier is a differential amplifier having two inputs instead of one;
FIG. 1D is a detail of the amplifier block of FIG. 1C;
FIG. 2 is a schematic diagram of a preferred embodiment of the circuit shown in FIG. 1C;
FIG. 3 is a partial section view of an improved fluid mass flow controller embodying the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in the drawings for purposes of illustration, the invention is embodied in a novel fast response control circuit. A conventional control circuit such as a direct current amplifier having a feedback network is characterized by a finite response time to provide an output signal in response to an enabling input signal. However, such a circuit is inadequate for applications requiring that an output signal be provided immediately upon command.
In accordance with the invention, a fast response control circuit having a control loop includes means to bias the control loop. When an enabling input signal arrives, this bias on the control loop allows the circuit to respond with essentially no delay. By means of a control circuit according to the invention it is possible to achieve virtually instantaneous initiation of a physical process, for example the flow of a fluid, on command and at a precisely determined rate.
A fast response control circuit according to the invention, as shown illustratively in block diagram form in FIG. 1A, comprises a differential amplifier means 11 responsive to an enabling input signal as received at an enabling input terminal 13 to provide an output signal at an output terminal 15 having a magnitude determined by an variable input signal as received at an input terminal 17; a feedback network 19 in feedback relationship with the amplifier means 11 and defining therewith a control loop characterized by a response time; and bias means 21 in electrical communication with the control loop 19 and operative to apply a bias signal to the control loop 19 and thereby to reduce the response time.
The bias means 21 receives the variable input signal from the input terminal 17 and the magitude of the bias signal is accordingly determined by the input signal. In an alternate embodiment as shown in FIG. 1B, the bias means 21 instead receives a potential from a power source 22 or the like, and the magnitude of the bias signal is accordingly independent of the input signal.
Interrupt means 23 receives the enabling input signal from the enable terminal 13. The interrupt means 23 is responsive to the enabling input signal to interrupt the communication between the bias means 21 and the feedback network 19 when the enabling input signal is received, thereby preventing the bias signal from interfering with normal operation of the control loop during the time the circuit is enabled.
Delay means 25 receives the variable and enabling input signals from the terminals 17 and 13, respectively, and in turn provides the variable input signal to the amplifier means 11. The delay means 25 delays application of the variable input signal to the amplifier means 11, for example to improve stability. If such delay is not desired, the delay means 25 is omitted.
In a preferred embodiment of the invention, differential amplifier means such as a differential amplifier 27 and a PNP output transistor 29 as shown in FIG. 1D (corresponding generally with the amplifier means 11 of the embodiment shown in FIG. 1A) provides an output signal having a magnitude determined by any difference between a first variable input signal and a second variable input signal, as shown in block diagram form in FIG. 1C and schematically in FIG. 2.
A negative input of the amplifier 27 receives the first variable input signal from a "set point" terminal 17A through a resistor 33 and a positive input of the amplifier 27 receives the second variable input signal from a "mass flow" terminal 17B through a resistor 37. (The inputs 17A and 17B correspond generally with the input terminal 17 of the embodiment shown in FIG. 1A). The amplifier 27 provides a differential signal having a magnitude determined by the difference between these two input signals. A base of the transistor 29 is connected to a terminal 38 of the amplifier 27 through a resistor 39 to receive this differential signal. The output signal is provided at a collector of the transistor 29.
A capacitor 41 is connected between the output and the negative input of the amplifier 27. A resistor 43 and a capacitor 45 in series with each other are connected in parallel with the resistor 37.
A resistor 47 is connected from the collector of the transistor 37 to a first terminal of a capacitor 49 and a second terminal of the capacitor 49 is connected to the positive input of the amplifier 27. The resistor 47 and capacitor 49 together define a feedback network (corresponding generally with the feedback network 19 of the embodiment shown in FIG. 1A in feedback relationship with the amplifier 27 and the transistor 39.
A bias amplifier 51 (corresponding generally with the bias means 21 of the embodiment shown in FIG. 1A) has a negative input which receives the first input signal from the terminal 17A through a resistor 53 and a positive input which is connected to ground. A resistor 55 is connected between the negative input and an output of the amplifier 51. The output of the amplifier 51 is connected through a resistor 57 to a first terminal of a variable resistor 59. A resistor 61 is connected between the first terminal of the variable resistor 59 and ground. A second terminal of the variable resistor 59 is connected to an anode of a diode 63, and a cathode of the diode 63 is connected to the first terminal of the capacitor 49 to apply the bias signal to change the level of charge on the capacitor 49.
A base of a PNP transistor 65 is connected to an anode of a Zener diode 67. A cathode of the diode 67 is connected to an anode of a diode 69. A cathode of the diode 69 is connected to the enabling input terminal 13 to receive the enabling input signal. An emitter of the transistor 65 is connected to ground. A collector of the transistor 65 is connected to the base of the transistor 29 to apply the enabling input signal to the transistor 29 and thereby enable the transistor 29 to provide the output signal.
The anode of the diode 67 is connected to a first terminal of a resistor 73. A second terminal of the resistor 73 is connected to a negative power supply line designated as "V-". The cathode of the diode 67 is connected to a cathode of a diode 75, and an anode of the diode 75 is connected through a resistor 77 to a positive power supply line designated as "V-".
A base of an NPN transistor 79 is connected to the base of the transistor 65. An emitter of the transistor 79 is connected to ground. A collector of the transistor 79 is connected to a base of a PNP transistor 81 and through a resistor 83 to V+.
An emitter of the transistor 81 is connected to ground through a resistor 85 and to V+ through a resistor 87. A collector of the transistor 81 is connected to a base of an NPN transistor 89 and to V- through a resistor 91. An emitter of the transistor 89 is connected to V-. A collector of the transistor 89 is connected to the anode of the diode 63. The transistors 81 and 89 and their associated components (corresponding generally with the interrupt means 23 of the embodiment shown in FIG. 1) interrupt the communication between the bias amplifier 51 and the capacitor 49 by applying a negative voltage to the anode of the diode 63 when the enabling input signal is present, thereby preventing the bias signal provided by the amplifier 51 from interfering with normal operation of the feedback network 19 defined by the capacitor 49 and the resistor 47.
The collector of the transistor 79 is also connected to a base of a field effect transistor ("FET") 93 through a resistor 95. The base of the FET 93 is connected to V- through a resistor 97. A drain of the FET 93 is connected to ground. A source of the FET 93 is connected through a resistor 99 to an anode of a diode 101, to a cathode of a diode 103, to a first terminal of a capacitor 105, and through a resistor 107 to the negative input of the amplifier 27. A cathode of the diode 101 is connected to V+. An anode of the diode 103, and a second terminal of the capacitor 105, are connected to ground. The FET 93 and its associated components (corresponding generally with the delay means 25 of the embodiment shown in FIG. 1A) serve to delay application of the set point signal to the negative input of the amplifier 27 for a brief time after arrival of the enabling input signal.
Electrical power is provided from a power supply (not shown) having a positive output connected to V+ at a terminal 109, a negative output connected to V- at a terminal 111, and a common return connected to ground at a terminal 113.
The collector of the transistor 29 is connected to the output terminal 15. The emitter of the transistor 29 is connected to a return terminal 117, to an anode of a diode 119, to a cathode of a diode 121, and to ground through a capacitor 123. A cathode of the diode 119 and an anode of the diode 121 are connected to ground.
A load, to be discussed in more detail hereafter, is connected from the terminal 15 to a negative terminal of a load power supply (not shown). A positive terminal of this power supply is connected to the terminal 117 and preferably to ground as well. The diodes 119 and 112 and the capacitor 123 serve to hold the emitter of the transistor 29 near ground potential in case of the external ground connection is inadequate. An anode of a surge prevention diode 125 is connected to the negative terminal of the load power supply and a cathode thereof is connected to the terminal 15.
The operation of the circuit will now be explained. In this discussion, the expression "turned off" with reference to a transistor means that the transistor is biased so that collector current does not flow, and the expression "turned on" means that the transistor is biased so that the flow of collector current is enabled.
First and second variable input signals and an enabling input signal are furnished to the terminals 17A, 17B and 13, respectively, from an external source. Initially the enabling input signal has a logic LO level, indicating that an output signal is not desired. This logic LO level at terminal 71 effectively grounds the cathode of the diode 69.
When the cathode of the diode 69 is grounded, the Zener diode 67 is reverse biased and a negative potential according to the Zener value of the diode 67 is developed at the anode of the diode 67 and applied to the bases of the transistors 65 and 79, turning the transistor 65 on and the transistor 79 off.
When the transistor 65 is turned on, its collector, and the base of the transistor 29 which is connected to said collector, are effectively connected to ground. This keeps the transistor 29 turned off and prevents any output signal from being provided by the transistor 29.
When the transistor 79 is turned off, no collector current flows through the resistor 83 and hence the collector of the transistor 79 remains at a positive potential near that of V+. This turns on the field effect transistor ("FET") 93, thereby effectively connecting the first terminal of the capacitor 105 to ground and diverting the first variable input signal from the negative input of the amplifier 27.
When the collector of the transistor 79 is at a positive potential as just described, the base of the transistor 81, which is connected to said collector, is brought to a potential which is positive with respect to the emitter of the transistor 81 and consequently the transistor 81 is turned off. When the transistor 81 is turned off, no base current can flow in the base circuit of the transistor 89 and it too is turned off. This in turn enables any bias signal potential developed at the output of the bias amplifier 51 to be applied to the first terminal of the capacitor 49 through the diode 63.
The amplifier 51 develops at its output a bias signal according to the magnitude of the first variable input signal and this bias signal is applied to the capacitor 49 to change the level of the charge on the capacitor 49.
When an output signal is desired, the enabling input signal assumes a logic HI level, thereby turning off the transistor 65 and turning on the transistor 79. When the transistor 65 is turned off, the base of the transistor 29 is no longer grounded and hence the transistor 29 is able to provide an output signal.
When the transistor 79 is turned on, its collector goes to a potential near grounded, turning off the FET 93 and turning on the transistor 81. When the FET 93 is turned off, it presents a very high impedance between its source and its drain, thereby ungrounding the first terminal of the capacitor 105 and enabling the negative input of the amplifier 27 to receive the first variable input signal. The capacitor 105 and the resistor 33 together serve to delay application of the first input signal to the amplifier 27 according to the characteristic response time of the amplifier 27 to improve stability and performance at times when the bias is not being applied to the capacitor 49.
More particularly, the capacitor 105 and the resistor 33 determine a time constant which governs the rate at which the amplifier 27 responds to any change in the first input signal. This time constant, and a time constant determined by the capacitor 49 and the resistor 37, are selected to optimize performance, as will be further explained in a succeeding paragraph.
The diodes 103 and 101 protect the amplifier 27 against any abnormally large values assumed by the first input signal.
When the transistor 81 turns on, the transistor 89 also turns on, reverse biasing the diode 63 and thereby blocking any bias signal developed by the amplifier 51 from reaching the capacitor 49.
As previously discussed, when the enabling input signal was at the LO level the transistor 29 was turned off, and since no current could flow in its collector circuit the collector assumed a negative potential equal to the potential provided by the load power supply. In the absence of the bias signal from the amplifier 51, the capacitor 49 would have charged to this potential. The presence of this charge on the capacitor 49 would have delayed the output signal after the enabling input signal went to the HI level until the capacitor 49 could discharge according to a time constant established by the values of the capacitor 49 and the resistor 37. It is this delay due to the discharge time of the capacitor 49 which is referred to as the "response time" of the control loop and which limits the rapidity with which the output signal can be provided when the enabling input signal goes HI.
The bias applied to the capacitor 49 by the amplifier 51 prevents the capacitor 49 from accummulating this charge during the time the enabling input signal is at the LO level and thus, when the enabling input signal goes HI, the transistor 29 is able to provided the output signal without any need to wait for the capacitor 49 to discharge. In this way any delay between the enabling input signal going HI and the providing of the output signal is minimized.
The delay in providing the output signal in response to the enabling input signal is particularly troublesome when only a small output signal is to be provided. This is because the current available to discharge the capacitor 49 is minimal under these circumstances. Thus, although an amplifier according to the invention provides an output signal of any magnitude in a minimum time, the benefits of biasing the capacitor 49 are most apparent in those situations where an output signal having a relationship small magnitude is desired.
In a preferred embodiment, a fast response control circuit according to the invention is utilized to improve the response time of a fluid mass flow controller (designated generally as 129) as shown in FIG. 3. The controller 129 has a sensor tube 131 to measure the rate of mass flow of a fluid through a flow path 133 defined within a conduit 135. Means such as an electronic device 137 provides a mass flow signal indicative of the measured rate of mass flow of the fluid.
The controller 129 includes a circuit of the kind shown in FIG. 2. In particular, the controller 129 includes means such as the terminal 17A to receive a set point signal indicative of a desired rate of flow of the fluid, means such as the terminal 13 to receive an enabling input signal to start the flow of the fluid, amplifier means such as the amplifier 27 and the transistor 29 responsive to the enabling input signal to provide an output signal indicative of any difference between the mass flow and set point signals, and a feedback network such as the capacitor 49 and the resistor 47 in feedback relationship with the amplifier means and defining therewith a control loop characterized by a response time required for the output signal to attain a magnitude indicative of said difference.
Valve means such as a solenoid valve 139 is disposed in the fluid flow path 133 to regulate the rate of mass flow of the fluid. The valve 139 is connected as the load of the amplifier between the terminal 15 (see FIG. 2) and the negative terminal of the load power supply. The valve 139 responds to the output signal to change the rate of mass flow of the fluid and thereby to minimize any difference between the mass flow signal and the set point signal.
Bias means such as the bias amplifier 51 is provided and functions as described previously to change the charge level on the capacitor 49 during the time the fluid is not flowing and thereby to reduce the response time of the control loop.
When the fluid is flowing, any change in the rate of mass flow is detected in the sensor tube 131 and results in a change in the mass flow signal. The time constant determined by the capacitor 49 and the resistor 37 governs the time it takes the amplifier to respond to such changes in the mass flow signal. Similarly, the time constant determined by the capacitor 105 and the resistor 33 governs the time it takes the amplifier to respond to changes in the set point signal. These time constants are selected with reference to each other and with reference to physical parameters of the mass flow controller so as to provide a stable, smoothly responding system which regulates the rate of mass flow of the fluiid according to the desired rate as indicated by the set point signal.
From the foregoing it will be appreciated that a fast response control circuit according to the invention provides an output signal with minimum delay in response to an enabling input signal. Precise control of the time of commencement of a physical process which is regulated by the output signal can be achieved. A fluid mass flow controller according to the invention responds with minimum delay to an enabling input signal to cause the flow of a fluid to commence precisely upon command at any desired flow rate.
Although certain specific embodiments of the invention have been described and illustrated, the invention is not to be limited to the specific forms or arrangements of parts so described and illustrated, and various modifications and changes can be made without departing from the scope and spirit of the invention. Within the scope of the appended claims, therefore, the invention may be practiced otherwise than as specifically described and illustrated.
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A fast response control circuit for providing an output signal in miminum time after receiving an enabling input signal. The control circuit includes an amplifier which provides an output signal having a magnitude determined by a variable input signal when the enabling input signal indicates that an output signal is desired. A feedback network and the amplifier together define a control loop which has a characteristic response time. When the enable signal is absent, a bias control biases a reactive component in the control loop so as to minimize this response time. The circuit is adapted for use in a fluid mass flow controller to provide rapid response to an enabling input signal, particularly when a very low fluid flow rate is desired.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to German Application No. DE 10 2006 039 809.2, filed Aug. 25, 2006, and German Application No. DE 10 2007 030 445.7, filed Jun. 29, 2007, both of which are expressly incorporated by reference in their entirety as part of the present disclosure.
BACKGROUND
[0002] The invention relates to an actuator for a motor vehicle, more specifically for a motor vehicle seat, according to the preamble of patent claim 1 . Such an actuator has been known from WO 03/068551 A1 and also from U.S. Pat. No. 3,617,021 A and from WO 86/06036. Additionally, the reader is referred to U.S. Pat. No. 6,073,893 A and to U.S. Pat. No. 6,322,146 B1.
[0003] The disadvantage of such actuators is that a certain clearance between spindle nut and spindle is unavoidable. This clearance is noticeable in practical use, for example during a change in the drive direction. Attempts have been made to make actuators of the type mentioned herein above having zero clearance. The reader is referred for example to the document EP 588 812 B1 which describes a spindle drive the spindle of which is motor rotated. It proposes two separate spindle nuts one of which fits against the left thread collars of the spindle thread and the other against the right thread collars of the spindle thread.
[0004] The invention aims at indicating an implementation of an actuator that is easy to realize in terms of construction and that comprises a zero clearance interaction, more specifically a zero clearance adjustable interaction, between the spindle nut and the spindle.
SUMMARY
[0005] The object is solved by providing an actuator for a motor vehicle including an electric motor having an output shaft, a gearbox that is connected to the output shaft and includes a spindle nut, and a spindle that engages the spindle nut. The spindle nut comprises a main portion and at least one axial socket. The axial socket: (a) is solidly connected to the main portion, (b) comprises an internal thread cooperating with the spindle and (c) is configured to be radially elastic. The actuator further includes an elastic element that fits against the axial socket and pushes the internal thread thereof into engagement with the spindle. In one aspect, the axial socket is integral with the main portion.
[0006] In accordance with the invention, there is provided at least one axial socket, one axial socket being preferably associated with the two axial ends of the spindle nut. The axial socket is preferably made integral with the spindle nut. The spindle nut may be made from metal and/or from plastic material.
[0007] The invention allows for a simple solution for zero clearance cooperation between the spindle nut and the spindle. In the region of the at least one axial socket, the elastic element urges the internal thread of the socket so far into the thread turns of the spindle that the flanks fit against each other on either side and that a zero clearance fit is achieved.
[0008] Generally speaking, what is achieved is that the functions of the spindle nut are distributed. The main portion absorbs the crash forces, the at least one axial socket is responsible for the zero clearance fit. The afore the applies in essence, for the axial socket also contributes to a certain extent to absorbing crash forces, although significantly less than the main portion.
[0009] The axial socket is preferably at least twice as elastically deformable in the radial direction as the main portion under the action of a radial force K.
[0010] In a preferred configuration, the at least one axial socket is solidly connected to the main portion. When made from plastic, the two are injection-molded together or made together in another way, when made from metal, the axial socket preferably has at least one slot for it to be sufficiently elastically deformable. In principle, such type slots are also suited for other materials and configurations of the axial socket.
[0011] The elastic element urges the axial socket into engagement with the thread of the spindle. This is how the zero clearance fit is achieved. The elastic element acts preferably over the entire circumference. It is sufficient that the axial socket is urged at one point so far into the thread turns of the spindle that a zero clearance fit is achieved there.
[0012] Preferably, the internal thread of the axial socket is made in one work step together with the inner thread of the main portion. Preferably, the two threads are disposed continuously one behind the other and are continuous.
[0013] Preferably, the axial socket has a smaller outer diameter than the main portion, more specifically an outer diameter amounting at the most to only about 80%, preferably only about 50% thereof. Between the axial socket and the main portion there is preferably located a step that may be used for accommodating a bearing, more specifically a ball bearing.
[0014] The spindle nut preferably has a toothed external surface feature that is provided only in the main portion and not on the axial socket. It is thereby preferred that the external surface feature is a worm wheel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Other features and advantages will become more apparent upon reviewing the appended claims and the following non restrictive description of embodiments of the invention, given by way of example only with reference to the drawing. In the drawing:
[0016] FIG. 1 shows a perspective illustration of a partially sectioned actuator of the invention;
[0017] FIG. 2 shows a perspective illustration of a combination of spindle and spindle nut similar to the configuration shown in FIG. 1 , but now with recesses;
[0018] FIG. 3 shows a top view of a combination shown in FIG. 2 ; and
[0019] FIG. 4 shows an axial sectional view taken along section line IV-IV in FIG. 3 .
DETAILED DESCRIPTION
[0020] FIG. 1 shows a first exemplary embodiment and illustrates an electric motor 20 having an output shaft 22 . A worm 24 , which meshes a worm wheel 26 , is non-rotatably connected thereto. This worm wheel 26 is part of a spindle nut 28 that engages a spindle 30 . In operation, the spindle 30 is not rotated by the electric motor 20 . The described parts 24 through 30 form a two-stage gearing comprising a worm gearing and a spindle gearing mechanism. The arrangement described is state of the art.
[0021] The spindle nut 30 has a main portion 32 that carries the worm wheel 26 on its circumference. Insofar, the spindle nut 28 does not differ from prior art. Still, there is a difference which is that there is provided an axial socket 34 on either of the two axial ends of the main portion 32 , the socket having an outer diameter that is significantly smaller than that of the main portion 32 . The axial socket 34 is solidly connected to the main portion 32 ; in the concrete embodiment according to FIG. 1 , it is integral with the main portion 32 . As can be seen from FIG. 4 , which also applies to FIG. 1 , the main portion has in a known way an inner thread 36 that engages with the thread of the spindle 30 . The axial sockets 34 each have an internal thread 38 that also cooperates with the spindle 30 and engages with the thread turns thereof. The axial sockets 34 are configured to be elastic in the radial direction, meaning they can be pushed more or less onto the spindle 30 . An elastic element 40 in the form of a ring-shaped spring is provided, the elastic element forming a surrounding grip around the respective associated axial socket 34 , as can be seen from the FIGS. 2 through 4 showing the second exemplary embodiment as well as from FIG. 1 . This elastic element 40 abuts the axial socket 34 and pushes at least a partial portion of this axial socket 34 in such a manner against the spindle that the internal thread 38 engages the thread turns of the spindle 32 with, as far as possible, zero clearance. It forms an almost entirely surrounding grip around the axial socket 34 and also encircles the spindle 30 .
[0022] The parts 24 through 28 , and in parts the spindle 30 , are disposed in a gear housing 42 that is shown in a partial sectional view in FIG. 1 . It has opposite openings 44 for passage of the spindle 30 . In the portion of these openings 44 there are affixed protective parts 46 which partially enclose the spindle 30 , with very little clearance but freely, and protect it from dirt. They have a cylindrical inner wall with an inner diameter that corresponds to the diameter of the addendum circle of the spindle 30 plus one to three tenths of a millimeter. At need, the protective part 46 is provided on its inner wall with a cleaning device, e.g., flocked with fibers.
[0023] As can be seen from FIG. 1 , outside of the protective parts 46 there are unprotected portions 48 , 50 where the spindle 30 is freely accessible and also freely visible in FIG. 1 . The axial length of each unprotected portion 48 , 50 is smaller than the axial length of the protective parts 46 . The arrangement is chosen such that the position of the spindle 30 shown in FIG. 1 is the central position. If the electric motor 20 is actuated in one direction of rotation, it transports the spindle 30 in one direction, it being hypothesized that it transports it leftward pursuant to arrow 52 in FIG. 1 . This movement is only possible up to the point at which a fastening portion 54 , which is solidly connected to the spindle 30 , strikes the free end of the neighboring protective part 46 . In this condition, the unprotected portion 48 has migrated inside the protective part 46 , as it can be seen from FIG. 1 , but it has not come into contact with the spindle nut 28 .
[0024] If the direction of rotation of the electric motor 20 is reversed, the same processes occur in the other direction, now a holding portion 56 , which is also connected to the spindle 30 , abuts the end of the left protective part 46 so that the movement is stopped. In this condition as well, the portion 50 , which is unprotected in FIG. 1 , has not been displaced far enough to come into contact with the spindle nut 28 . Accordingly, the spindle nut 28 generally comes only into contact with protected thread portions. These protected portions cannot be contaminated with dust, dirt or other particles and remain clean. In particular motor vehicles that are used for a longer period of time are known to have their openly accessible gear parts increasingly contaminated. This only occurs with the unprotected portions 48 , 50 which are irrelevant for the functioning of the actuator.
[0025] As shown in FIG. 1 , the two protective parts 46 are retained in the position shown by a bracket 58 that is substantially configured in a U shape and forms a surrounding grip around the top of the gear housing 42 . For this purpose, they have a groove 60 for lateral arms of the elastic bracket 58 made from wire to engage.
[0026] The second exemplary embodiment shown in the FIGS. 2 through 4 is not shown completely, these figures only showing the combination of spindle nut 28 and spindle 30 as well as the protective parts 46 that are illustrated in FIG. 4 . The difference from the first exemplary embodiment is that the axial socket 34 now has a recess 62 that may also be configured to be a slot, a bight portion, a hole or a notch. The radial elasticity of the axial socket 34 is increased as a result thereof. It is possible to make the spindle nut 28 from metal, at least in parts from metal.
[0027] As shown in particular in FIG. 4 , the axial socket 34 is quite thin, in any case significantly thinner than the main portion 32 . There, there is sufficient resistant material between the thread turns of the spindle 30 and the worm wheel 26 . In this portion, the spindle nut is configured like a prior art spindle nut 28 , meaning it can absorb crash forces. In the two axial sockets 34 , which are built according to the same principle, the wall is quite thin, it ranges from 1 through 3 mm, and appropriate measures have been further taken, for example material chosen, recess 62 provided and so on, for the axial sockets 34 to be at least partially sufficiently deformable for their internal thread 38 to completely mesh the thread turns of the spindle 30 without allowing axial clearance to occur. The threads have oblique flanks, e.g. trapezoidal engagement.
[0028] In the configuration shown in the FIGS. 2 through 4 , the thread of the spindle nut 28 is continuous and made in the same work step, more specifically during injection molding. In FIG. 1 , the two protective parts 46 are built substantially according to the same principle and have more specifically the same axial length. The axial length corresponds to about 65% of the axial length of the spindle nut 28 and ranges from 40 to about 80% of this axial length.
[0029] As shown in the FIGS. 2 through 4 in particular, the axial socket 34 has a cylindrical intermediate piece 63 commencing at the main portion 32 and an outer portion 66 extending outward therefrom. It is this outer portion 66 that performs the function of compensating for the clearance. The intermediate piece 63 is slightly thicker than the outer portion 66 . The intermediate piece 63 is in particular suited for receiving a bearing 64 that abuts the gear housing 42 .
[0030] As shown in FIG. 4 , each protective part 46 has an abutment surface 68 by which it contacts the gear housing. This abutment surface is limited either by a cylinder the cylinder axis of which passes through the centre of the spindle nut 28 and extends either parallel to the output shaft 22 or perpendicularly to the output shaft or by a ball the centre of which is in the center of the spindle nut 28 . Partially cylindrical outer surfaces or ball surfaces configured accordingly and mating the abutment surfaces 68 are provided on the gear housing 22 . Together with the protective parts 46 , the spindle 30 can be pivoted about this cylinder axis or about the center of the ball within a certain pivot range.
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An actuator for a motor vehicle with an electric motor having an output shaft, a gearbox that is connected to the output shaft that includes a spindle nut, and a spindle that engages the spindle nut. The spindle nut comprises one main portion and at least one axial socket. The axial socket: (a) is solidly connected to the main portion, more specifically is integral with the main portion, (b) comprises an internal thread cooperating with the spindle and (c) is configured to be radially elastic. An elastic element is provided which fits against the axial socket and pushes the internal thread thereof into engagement with the spindle.
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BACKGROUND OF THE INVENTION
[0001] This invention generally relates to a fuel stabilization system for an energy conversion device, and more particularly to a fuel stabilization system including several fuel deoxygenators for removing dissolved oxygen from a fuel.
[0002] Hydrocarbon fuels typically include some amount of dissolved oxygen due to exposure to air during transport or storage. Dissolved oxygen within the fuel limits the temperature to which the fuel may be heated due to the formation of insoluble products referred to as “coke”. The formation of coke deposits is dependent on the amount of dissolved oxygen present within the fuel. Reducing the amount of dissolved oxygen within the fuel decreases the rate of coke deposition and increases the maximum sustainable temperature of the fuel.
[0003] U.S. Pat. Nos. 6,315,815, and 6,709,432 assigned to Applicant, discloses devices for removing dissolved oxygen using a selective gas-permeable membrane disposed within the fuel system. As fuel passes along the permeable membrane, oxygen molecules in the fuel diffuse out of the fuel across the gas-permeable membrane. An oxygen partial pressure differential across the permeable membrane drives oxygen from the fuel, which is unaffected and passes over the membrane.
[0004] The more dissolved oxygen that can be removed from the fuel, the greater the fuel temperature before coke deposits form, thereby increasing the practical temperatures to which fuel can be heated prior for combustion to improve operating efficiencies. Disadvantageously, the size of a fuel deoxygenator increases proportionably with the requirements for removing oxygen. An increase in oxygen removal from 90% to 99% may require nearly a doubling of deoxygenator size. Further, as operational requirements change, so may the required oxygen removal rate. A single fuel deoxygenator may not adjust readily or be scalable to accommodate variations in oxygen removal requirements.
[0005] Accordingly, it is desirable to develop a fuel stabilization system that removes dissolved oxygen to allow increased fuel temperatures, and that is scaleable to accommodate changing oxygen removal requirements.
SUMMARY OF THE INVENTION
[0006] An example fuel stabilization system according to this invention includes several fuel deoxygenators operating in concert to remove dissolved oxygen from a hydrocarbon fuel.
[0007] An example fuel stabilization system according to this invention includes a plurality of fuel deoxygenating devices that are arranged in parallel. Hydrocarbon fuel flows in substantially equal portions through each of the plurality of fuel deoxygenating devices. Each of the fuel deoxygenating devices removes a portion of dissolved oxygen from the hydrocarbon fuel, which then exits the fuel stabilization system with a substantially increased temperature capacity.
[0008] Another example fuel stabilization system according to this invention includes a plurality of fuel deoxygenators arranged in series. Each of the fuel deoxygenators removes progressively additional amounts of dissolved oxygen. An initial fuel deoxygenator operates at a temperature well below that at which coke and other insoluble byproducts are formed. A second fuel deoxygenator operates at an elevated temperature due to the initial removal of some portion of dissolved oxygen from the fuel. Several fuel deoxygenators in series remove additional amounts of dissolved oxygen and can operate at increasingly elevated temperature that provide increased oxygen removal efficiencies.
[0009] The modular approach to using a plurality of fuel deoxygenating devices instead of merely using one deoxygenating device provides many advantages. Those advantages include the ability to troubleshoot and replace a specific deoxygenator that may not be operating as desired. Further, the use of fuel deoxygenating devices in series or parallel allows for each device to be operated at different temperatures and thereby provide the hydrocarbon fuel with different usable cooling capacities that can be tailored to specific systems requirements. Finally, spreading the deoxygenation function among several independent fuel stabilization modules may also provide an advantage relative to overall system reliability and functionality, as the failure of one unit would not represent a complete loss of deoxygenation functionality but rather would only impact a portion of the overall system capability.
[0010] Accordingly, the fuel stabilization system according to this invention increases and optimizes the efficiency of dissolved oxygen removal from a fuel providing significant system benefits.
[0011] These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a schematic illustration of an example fuel stabilization system according to this invention.
[0013] FIG. 2 is a schematic illustration of another example fuel stabilization system according to this invention.
[0014] FIG. 3 is a schematic illustration of yet another example fuel stabilization system according to this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] Referring to FIG. 1 , a fuel stabilization system 10 is schematically illustrated and includes a fuel tank 12 or other fuel source that provides fuel by way of a fuel pump 14 to an engine 15 . A fuel stabilization assembly 16 removes dissolved oxygen from within the fuel. The fuel stabilization assembly 16 includes a plurality of deoxygenators 18 , 20 , 22 , 24 , 26 . The example fuel stabilization assembly 16 includes five deoxygenators 18 , 20 , 22 , 24 and 26 , arranged in a parallel configuration.
[0016] The parallel configuration provides a substantially uniform pressure drop across the fuel stabilization assembly 16 . Each of the fuel deoxygenators 18 , 20 , 22 , 24 and 26 , provides an identical or very similar drop in fuel pressure. In some instances a single large deoxygenator can cause an undesirable drop in fuel pressure that is compensated for by other system devices such as the pump 14 . However, the use of the plurality of parallel configured deoxygenators 18 , 20 , 22 , 24 and 26 may reduce requirements for adapting to pressure drops as compared to the use of a single larger fuel deoxygenator without sacrificing the amount of dissolved oxygen removes from the fuel.
[0017] Each of the fuel deoxygenators 18 , 20 , 22 , 24 and 26 , removes a portion of dissolved oxygen from the fuel and exhausts the removed oxygen overboard as is indicated at 30 . The temperature of incoming fuel is within desirable limits that do not encourage the generation of insoluble materials in the presence of dissolved oxygen. Fuel leaving the fuel stabilization assembly 16 includes a reduced amount of dissolved oxygen and therefore can be heated to increased temperatures. A heat transfer device 32 provides for the transfer and heating of the fuel. The heat transfer device 32 may be of any configuration known to a worker skilled in the art. Increased temperature capability of the fuel provides for increased engine efficiencies. The increased temperature capacity of the fuel can thereby be utilized as a heat sink to absorb heat from other systems. Further, increasing the temperature of the fuel can improve combustion by speeding vaporization of the fuel.
[0018] Referring to FIG. 2 another example fuel stabilization system according to this invention is generally indicated at 40 and includes a fuel stabilization assembly 45 having a plurality of deoxygenating devices 44 , 46 , 48 , 50 , arranged in series. The series arrangement provides for a sequential and proportional removal of dissolved oxygen from the fuel. A first portion 41 of dissolved oxygen is removed from the hydrocarbon fuel in the first deoxygenator 44 . A second portion 43 is then removed by the second deoxygenator 46 , a third portion 47 removed by the third deoxygenator 48 , and a forth portion 49 is removed by the fourth deoxygenator 50 . The subsequent removal of additional amounts of dissolved oxygen from the hydrocarbon fuel provides for the use of deoxygenators of differing sizes and capacities along with operating each deoxygenator 44 , 46 , 48 and 50 at different temperatures to optimize the removal of dissolved oxygen.
[0019] A hydrocarbon fuel 28 entering the first deoxygenator 44 must be at a temperature below that temperature that may cause an undesirable formation of insoluble materials. However, subsequent deoxygenators such as the second deoxygenator 46 can operate at temperatures above that temperature at which the first deoxygenator 44 must operate due to the removal of the first portion 41 of dissolved oxygen. Accordingly, subsequently aligned fuel deoxygenators can operate at progressively greater and greater temperatures due to the ever decreasing amount of dissolved oxygen contained within the hydrocarbon fuel removed by a previous deoxygenator.
[0020] Hydrocarbon fuel exiting the fuel stabilization assembly 45 is then introduced into the heat transfer device 32 . As appreciated, the heat transfer device 32 can be of any configuration known to a worker skilled in this art. Further, the heat transfer device 32 may transfer heat from another system requiring cooling to utilize the increased cooling capacity of the hydrocarbon fuel. Additionally, the heat transfer device 32 may heat the fuel to a level to aid vaporization and thereby combustion of the hydrocarbon fuel once it reaches the combustion device disposed within the engine 15 .
[0021] Referring to FIG. 3 , another example fuel stabilization system 60 includes a first deoxygenator 64 and a second deoxygenator 68 . The first deoxygenator 64 operates to remove a first portion of dissolved oxygen 65 from the hydrocarbon fuel 28 . The modular approach of configuring the first deoxygenator 64 and the second deoxygenator 68 provides for the utilization of different size deoxygenators. Varying the size and performance of cascaded deoxygenators between a low temperature operational device and a high temperature device provides packaging and operational benefits. Increasing the fuel temperature entering a deoxygenator increases its performance due to enhanced oxygen diffusivity and solubility at higher temperature.
[0022] The modular approach of this invention can capture the benefit of fuel heating optimally, since for a single deoxygenator the inlet temperature is for example limited to a range of between 250° F. and 325° F. Accordingly, the modular configuration of the fuel stabilization system 60 provides that each successive deoxygenator may have an ever increasing inlet temperature due to the level of deoxygenation that is being accomplished at the previous deoxygenator.
[0023] In FIG. 3 the fuel 28 leaves the pump 14 at a first temperature 72 . Once the fuel 28 exits the first heat transfer device 62 , it is at a temperature 74 . The temperature 74 must be within a limited temperature range that does not cause the formation of an unmanageable amount of insoluble materials due to coking. At this point, the temperature 74 must be maintained within a level that accommodates the increased level of oxygen within the hydrocarbon fuel. After the fuel has flowed through the first deoxygenator 64 and the first portion of oxygen 65 has been removed, the temperature can be raised to a temperature indicated at 76 that is higher that the temperature 74 .
[0024] The hydrocarbon fuel 28 temperature can then further be raised within a second heat transfer device 66 to a fourth temperature 78 that is higher than the fuel temperature of the fuel 28 that first entered the first deoxygenator 64 . The second deoxygenator 68 removes a second portion of oxygen 69 and operates at a higher temperature than the first deoxygenator 64 because of the decreased amount of dissolved oxygen that had been previously removed by the first deoxygenator 64 . The fuel exiting the second deoxygenator 68 is at a temperature 80 that can again be further elevated in temperature to a final temperature 82 .
[0025] The hydrocarbon fuel temperature is elevated from the temperature 80 to the temperature 82 by a third heat transfer device 70 . Although, two deoxygenators 64 , 68 are shown in series, additional fuel deoxygenators and heat transfer devices can be arranged to optimally and successively provide for increased fuel temperatures of the hydrocarbon fuel due to the successive decrease in dissolved oxygen within that hydrocarbon fuel.
[0026] The example fuel stabilization systems of this invention provide deoxygenation of hydrocarbon fuel using a variety of configurations including series and parallel orientations of a plurality of fuel deoxygenators to lower the dissolved oxygen content within a hydrocarbon fuel. The lowering of dissolved oxygen within the hydrocarbon fuel enables fuel temperatures to reach as high as between 800° F. and 900° F. This increases the heat sink capacity of the fuel, which in turn can provide improved system and engine efficiencies.
[0027] Although a preferred embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.
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A fuel stabilization system includes a first deoxygenator and a second deoxygenator both for removing dissolved oxygen from a hydrocarbon fuel. The first and second deoxygenators are arranged in parallel or series to sequentially remove a portion of dissolved oxygen from the hydrocarbon fuel. The arrangement of several deoxygenators for a single fuel stream improves removal of dissolved oxygen and provides for scalability of the fuel system to meet application specific demands. The arrangement also provides for the preservation of partial system functionality in the event of the failure of one of the deoxygenator modules.
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This application claims the benefit of U.S. Provisional Application 60/101,001, filed Sep. 18, 1998.
BACKGROUND OF THE INVENTION
1. Related Applications
This work is an extension of work previously described in U.S. Pat. No. 5,630,410, in which H 2 -metabolizing microbes were introduced into the intestines of rats breathing H 2 in a hyperbaric chamber. The purpose of the previous invention was to remove some of the H 2 dissolved in the tissues of the rats in order to reduce their risk of decompression sickness following the exposure to an atmosphere containing high pressures of H 2 . The compositions of this invention are related to the compositions of co-pending application Ser. No. 08/852,207, which application, in turn, is a division of U.S. Pat. No. 5,630,410.
2. Field of the Invention
This invention relates to a method for relieving abdominal pains under normal atmospheric conditions caused by hydrogen (H 2 ) gas trapped in the large intestine. More particularly, this invention relates to a process of treating symptoms of irritable bowel syndrome or spastic colon or excessive flatulence or other gastrointestinal distress by assisting in the removal of H 2 trapped in the large intestine. This assistance is accomplished by supplying the intestine with an artificial excess amount of microbes that metabolize H 2 , converting some of the H 2 to water and other substances. This product and method supplement and accelerate the removal of H 2 from the large intestine that occurs spontaneously with normal intestinal microbial fermentation and motility, thereby relieving the symptoms of the disease.
3. Description of the Prior Art
Previously, one of the inventors developed and patented a method of “Accelerated Gas Removal From Divers' Tissue Utilizing Gas Metabolizing Bacteria”, U.S. Pat. No. 5,630,410. From this research, the inventors developed the concept of adapting the process to medical treatments for the symptoms of diseases or conditions that cause an excess of hydrogen (H 2 ) in the large intestine or bowel.
As stated in Harrison's “Principles of Internal Medicine” Twelfth Edition, Volume I at page 259 (1991), flatulence is a normal occurrence in humans and in animals. In humans, it is often caused by the fermentation in the gut of indigestible polysaccharides and oligosaccharides of food humans eat. Patents such as U.S. Pat. No. 4,376,128 and 5,773,427 sought to defeat flatulence by enzyme treatments either before or after consumption. Others have proposed different combinations of bacteria to re-establish normal gut flora. Chaleil et al. (Ann. Pharm. Fr. 46(2): 133-137, 1988) addressed the subject of a potential link between Methanobrevibacter smithii and encephalopathy, and concluded that this link was not present. They were concerned that bismuth salts given to patients as a pharmacological agent could place these patients in jeopardy of encephalopathy if M. smithii in the intestinal flora allowed a retention and concentration of bismuth within the patient's brain and other tissues. The work of Chaleil et al. is not relevant to the use of M. smithii described by us for the removal of H 2 from the intestines of people suffering from Irritable Bowel Syndrome, nor is the instant invention relevant to encephalopathy or bismuth metabolism by M. smithii. The only link between this work and that of Chaleil et al. is the coincidental interest in M. smithii as a normal constituent of the human intestinal flora. The intent of this prior art is to re-establish normal flora concentration.
Brody (U.S. Pat. No. 5,443,826, 1995) relates to the removal of a significant quantity of the intestinal flora of patients suffering from complications induced by an abnormal, pathogenic flora. Brody then proposes to replace the abnormal flora with cultures of normal flora in their usual relative concentrations, to reestablish intestinal normalcy and promote general patient health. The instant invention differs from that of Brody by adding a significant surplus of only one microbial constituent of the intestinal flora, for example M. smithii. The instant goal is not to establish a normal flora, but to establish an exceptional concentration of a single purpose flora for a purpose not anticipated by Brody or any others, namely to remove H 2 from the intestines of people suffering from excess intestinal production of H 2 and thereby relieve the symptoms. Brody's invention is not relevant to H 2 removal, nor does our invention call for the loss of any pathogenic intestinal flora. The only link between our work and that of Brody is the coincidental interest in M. smithii as a normal constituent of the human intestinal flora.
With irritable bowel syndrome, some people experience abdominal pains caused by gas trapped in the large intestine. In many cases, a large fraction of this gas is H 2 , which is generated in the large intestine as an end product of the metabolism by certain species of bacteria. These bacteria are an established part of the intestinal flora of most people, but the amount of H 2 they make can vary widely among individuals, and between diets. Many people also harbor microbes that consume this H 2 to form several possible end products. The purpose of this invention is to treat the problem of excess intestinal H 2 by using a natural approach: by introducing more of the natural intestinal microbes that consume the H 2 .
In healthy humans with a healthy gut and diverse and nutritionally adequate diet, digestive enzymes in the mouth, stomach, or small intestine break down much of the food ingested, and the digested nutrients are absorbed. The healthy large intestine (colon) houses a large number of microbial species that metabolize the nutrients that are not fully absorbed higher in the digestive tract. Some microbes ferment the complex poly- and oligosaccharides for which humans have no digestive enzymes, for example the cellulose and hemicellulose of plant cell walls, the stachyose in beans and the trehalose in mushrooms. In some individuals, certain digestive enzymes are missing or defective and food products that are absorbed by most people in the small intestine reach the large intestine in unusually large quantities; lactase deficiency leading to colonic lactose fermentation is one example.
A complex community of different species of microbes accomplishes colonic fermentation. The microbes metabolize the material entering the large intestine to a variety of end products including water, acetic, propionic and butyric acids, and the gases H 2 and carbon dioxide (CO 2 ). In some individuals and in ruminant animals, methane (CH 4 ) is produced. Microbes that produce methane consume H 2 as part of the metabolic pathway. Accumulation of large quantities of H 2 in the colon occurs when the H 2 -producing microbes generate amounts of H 2 far in excess of the amounts that can be metabolized by the H 2 -consuming microbes. Normal mammalian physiological mechanisms cannot remove the excess H 2 rapidly enough through flatulence, causing excessive pressure.
Some people harbor large concentrations of a methane-producing organism, Methanobrevibacter smithii. It reduces carbon dioxide with H 2 to produce methane and water:
4H 2 +CO 2 →CH 4 +2H 2 O (Eq. 1)
This process uses four volumes of H 2 to produce one volume of methane and two volumes of water, and can significantly reduce the gas pressure caused by production of H 2 in the colon. About 20% of the colonic gas is absorbed through the intestinal wall, into the bloodstream, and expired in the breath. The rest of the gases exit the body as flatus.
In many people, Methanobrevibacter smithii concentrations in the colon are too low to account for significant consumption of H 2 . Instead of microbial species that produce methane (Eq. 1), these people harbor colonic microbes that use H 2 to reduce carbon dioxide to acetic acid (CH 3 COOH) and water.
4H 2 +2CO 2 →CH 3 COOH+2H 2 O (Eq. 2)
An example of a microbe that is common in mammalian colons and is capable of such a consumption of H 2 is Acetitomaculum spp. About 98% of the acetic and other acids produced in colonic fermentation are absorbed and used by host body tissues as a source of energy or carbon. The rest of the acids exit the body in fecal material.
The painful buildup of H 2 gas in the large intestine is caused by such conditions or circumstances as the simultaneous effects of excessive food substrates reaching the intestine, a superabundance of H 2 -producing bacteria, and inadequate concentrations of H 2 -consuming microbes in the colonic microbial community. This problem is known in medicine under the general name of irritable bowel syndrome, or spastic colon, and is one of the most frequently occurring gastrointestinal disorders. Various techniques are used to reduce the symptoms. These techniques include modification of diet (to reduce dietary intake of the polysaccharides being malabsorbed), ingestion of charcoal (to absorb some of the gas), and dosing with simethicone (to disperse gas bubbles and prevent formation of large gas pockets). These remedies have variable degrees of success.
Attempts have been made to control “stomach gas” in ruminants with various pills. The literature suggests, among many treatment agents, adding polymers, U.S. Pat. No. 5 , 494 , 660 , actaplanin factor H, U.S. Pat. No. 4,558,036, or amidinureas, U.S. Pat. No. 4,285,972.
There remains a need for an efficient and safe method to reduce H 2 emissions and relieve gastric stress in both humans and animals.
SUMMARY OF THE INVENTION
Accordingly, an object of this invention is to provide a method to increase the rate of removal of gaseous H 2 from the intestines of people and animals suffering from an excessive accumulation of H 2 in the colon.
Another object of the invention is a method of relieving gastric distress caused by excess hydrogen in the gut.
An additional object of the invention is to encapsulate a form of non-toxic, microbe capable of reducing hydrogen in the gut to a lower volume of end-product that can be metabolized or expelled.
These and additional objects of the invention are accomplished by introducing, collectively or singly, into the large intestine high concentrations of H 2 consuming microbes. The introduction of H 2 metabolizing microbes into the colons of people suffering from intestinal gas pains is intended to relieve the symptom and is not intended as a treatment of the underlying cause. These microbes will convert some of the H 2 to water, methane, acetic acid, or other end products having less volume than hydrogen, thereby decreasing gas pressure and flatus.
The microbes are delivered in a manner that will protect their metabolic activity after oral ingestion and passage through the stomach to a release point further down the gut so that the H 2 consuming ability of the microbes will be maintained at the site of excess H 2 production in the large intestine. Any one of several means of packaging and delivery, including enteric-coated capsules, are available.
More specifically, this invention relates to the development of microbes or microbial supplements that, when delivered orally to the intestine of people or animals suffering from intestinal gas pains caused by H 2 , metabolize the H 2 to other compounds such as water, methane or acetic acid. In addition, this invention relates to the product that delivers the microbes to the intestine.
Other objects, advantages and novel features will be apparent to those that are familiar with the art upon reading the following detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention will be readily obtained by reference to the following Description of the Preferred Embodiments and the accompanying drawings in which like numerals in different figures represent the same structures or elements. The representation in each of the figures is diagrammatic and no attempt is made to indicate actual scales or precise ratios. Proportional relationships are shown as approximations.
FIG. 1 is a graph of the methane release rate from 5 rats with Methanobrevibacter smithii introduced into their intestines. While the rats were breathing a gas mixture that did not contain any H 2 (2% O 2 , balance helium at 11 atm total pressure), they made detectable but small quantities of methane. This was because of a supply of H 2 from native bacteria in the intestine that produce H 2 . The rats then breathed increasing quantities of H 2 , which were supplied at elevated environmental pressures to drive a significant volume of H 2 into the intestine. Methanobrevibacter smithii converted increasing amounts of H 2 to methane. This demonstrates that M. smithii can respond to volumes of H 2 in the intestine in great excess of normal physiological values, as in the disease state of irritable bowel syndrome.
FIG. 2 is a graph of the methane release rate from 4 rats while breathing air at normal atmospheric pressures. Without treatment, rats make undetectable quantities of methane. With Methanobrevibacter smithii placed in their large intestines, the rats make significantly more methane. This demonstrates that when these microbes are delivered artificially to the intestine, the microbes can metabolize H 2 produced by the native microbial flora of the intestine.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention relates to the finding that H 2 can be removed from the intestines of animals by supplementing their intestinal microbial flora with H 2 -metabolizing microbes.
In general, any H 2 -metabolizing microbes that are not toxic and that can be isolated from the intestinal tract of humans or other mammals are useful for this invention. It is impossible to name all microbes meeting these criteria because new species are being isolated almost daily. Preferred microbes are not toxic in an animal's gut and will reduce hydrogen to methane, acetic acid and the like. Illustrative methane-producing microbes (Eq. 1) operable in this invention are Methanobrevibacter smithii, Methanobrevibacter ruminantium, Methanobacterium formicicum, Methanomicrobium mobile, Anaerovibrio lipolytica, and Wolinella succinogenes. The precise identity of the human colonic microbial species responsible for the reduction of carbon dioxide to acetic acid and water (Eq. 2) is not presently known, though there is likely to be more than one organism responsible. Members of the genus Acetitomaculum and the strains CS1Van and CS7H are examples of acetic acid producing microbes isolated from bovine rumens and human feces.
A key objective of the invention is to deliver the microbes in a viable state to the large intestine. Intestinal delivery can be accomplished via anal insertion (for a laboratory animal), but the preferred route is by oral ingestion in the form of a delayed-release capsule.
The preparation of delayed-release capsules that do not dissolve or release contents in the stomach is well known. Such capsules are described in U.S. Pat. Nos. 5,650,170; 5,424,289; 5,417,682; 5,178,866; 4,627,851; 4,904,474; & 5,536,507. Alza Corp., of Palo Alto, Calif. produces enteric coatings in which an enteric-coated outer shell does not dissolve in the acid of the stomach but does dissolve in the mildly alkaline conditions of the intestine. Water permeating through a semipermeable inner capsule causes the capsule to separate, releasing the material packed inside. The time of separation, and therefore location in the transit through the digestive tract, can be precisely controlled by the rate of water imbibition through the semipermeable portion of the capsule. Other patents describing the methods for targeting delivery to the intestine are U.S. Pat. No. 4,079,125; U.S. Pat. No. 4,800,083; U.S. Pat. No. 5,415,864; and U.S. Pat. No. 5,356,625.
The microbes must be capable of returning to active metabolism upon release. The microbes can be included in a slow-release capsule in a number of possible forms; for example, as a freeze-dried product, as a cell paste preparation or in a gel formation. Exact dosages of microbes will vary with the activity of the microbes and the amount of gas per day that needs to be eliminated.
In the preferred embodiment, the person suffering from intestinal H 2 takes one or more capsules, tablets, or other form of packaging or non-packaged delivery of the preparation. The preparation contains a calculated dosage of microbes. In the preferred form, the microbes are in a freeze-dried encapsulation. The packaging must pass through the stomach and small intestine unharmed. The packaging begins to dissolve in the small intestine and is fully hydrated and operational on, or shortly after, arrival in the large intestine. This invention demonstrates that live, H 2 -metabolizing microbes placed in the large intestines of rats do indeed eliminate H 2 present in the rats' intestines. Of course, when no longer needed, the microbes die for lack of H 2 and are disposed of in normal fecal matter.
Having described the invention, the following examples are given to illustrate specific applications of the invention including the best mode now known to perform the invention. These specific examples are not intended to limit the scope of the invention described in this application.
EXAMPLE 1
Experimental Model for Demonstrating Intestinal H 2 Metabolism
Two milliliters of a concentrated culture of Methanobrevibacter smithii in a bicarbonate buffer (with an in vitro activity of 50 μmol H 2 uptake per minute) were injected into the caecum (anterior end of the large intestine) of rats, via a cannula introduced from the rectum. The animals (n=5) were then placed in a box. The box was pressurized with 11 atm of a gas mixture containing helium and oxygen (0.2 atm O 2 ), but no H 2 . A stream of gas passed through the box to a gas chromatograph in order to measure any methane released by the rats. As shown in FIG. 1, significant quantities of methane were detectable. Production of methane could only be caused by metabolism of H 2 by M. smithii in the intestines, with endogenous bacteria the only source of the H 2 . This is assured by finding no methane release from rats that had not been injected with M. smithii, since the strain of rats we were using have no native methane-producing intestinal microbes, but they are known to have native H 2 -producing bacteria.
To test the capacity of M. smithii to consume more H 2 than the amounts generated by the endogenous H 2 -producing bacteria in these healthy rats, we replaced the helium in the animals' box with H 2 . Hydrogen was introduced first at a total pressure of 11 atm, and then to a final pressure of 23.7 atm (including 0.2 atm O 2 ). The high pressure of H 2 was intended to mimic an extreme disease case. As the rats breathed more H 2 , the production of methane increased (FIG. 1 ). This demonstrated that H 2 had diffused into the intestine down a partial pressure gradient, and was being consumed by M. smithii. When we subsequently removed the H 2 from the animals' box and replaced it with helium again, the release rate of methane fell. Thus we are confident that microbes can be delivered viably to the intestines, and that these microbes can consume far more H 2 than the amounts released by the endogenous colonic H 2 -producing bacteria.
This experiment was successfully completed six more times, with 5 rats per experiment; results were qualitatively similar to those shown in FIG. 1 . Animals with M. smithii in their intestines make methane even when no H 2 is present in the breathing mixture, because the M. smithii metabolize H 2 in the intestine released by endogenous H 2 -producing bacteria, as illustrated in FIG. 2 . Animals with M. smithii make even more methane when H 2 is introduced into the breathing mixture, demonstrating that the capacity of these microbes to metabolize H 2 extends well beyond the H 2 supply rate from endogenous H 2 -producing bacteria in healthy animals. Animals that did not have M. smithii injected into their intestines do not make detectable methane under these experimental conditions, either with or without H 2 in their breathing mixture, because methane-producing bacteria are not native to the intestinal flora of this strain of rats. When lower activities of M. smithii were used than that described above, smaller volumes of methane were released per unit time .
EXAMPLE 2
To confirm that reactions at one atmosphere act the same as reactions under high-pressure conditions, the following test was conducted. Four untreated Sprague-Dawley rats were placed in a box that was ventilated with air. A sample of the air leaving the box was analyzed by gas chromatography for its methane content. No methane beyond the trace (ca. 4 ppm) normally found in air was detected. This is as expected because the Sprague-Dawley strain of rats does not usually have methanogenic organisms native to its intestinal flora. The four rats then had cultures of M. smithii (2 ml volume, 52 μmol CH 4 /min activity per rat) injected surgically into their caeca. Within minutes, the rate of release of methane became easily detectable and continued to increase over the next hour. This indicated that the cultures of M. smithii were metabolizing H 2 produced in the caeca of the rats by native H 2 -producing bacterial species. Thus, our approach of delivering live M. smithii or other methanogenic cultures of microbes to the large intestine in order to convert H 2 to CH 4 is successful under normal 1 atm conditions.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
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Some people suffer from pains in the abdomen that are due to excessive H 2 gas produced in the intestine. In this invention, microbes that metabolize H 2 are introduced into the intestine in order to accelerate the removal of the H 2 . The microbes are selected from species that are native to the large intestine of humans or other mammals, and are non-toxic. The end products are either non-gaseous, or significantly smaller volumes of gas than the original H 2 . The delivery of the microbes is accomplished by any one of several means, with packaging of the microbes in enteric coatings for oral ingestion as a preferred means.
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SCOPE OF THE INVENTION
[0001] The object of the invention is a permanent magnet unit for an electrical machine according to the preamble part of Claim 1 , a method for installing magnet units to an electrical machine according to the preamble part of Claim 6 , and a rotor for an electrical machine, excited by permanent magnet units, according to the preamble part of Claim 7 .
PRIOR ART
[0002] A permanent magnet is a component manufactured from a magnetically hard material and able to retain its magnetism permanently after magnetization. Permanent magnets are manufactured, for example, from an AlNiCo mixture that includes aluminum, nickel, cobalt and steel, or from ceramic materials or rare earth metals.
[0003] The industrial applications of permanent magnet motors have increased rapidly, particularly in the over-500 kW range. Permanent magnet motors have high efficiency, power density and reliability. Unlike a squirrel cage motor, for example, the properties of permanent magnet motors do not deteriorate when the rotation speed is low. Therefore, permanent magnet motors are well suited for the gearless drives used in, for example, windmills, electric trains and paper machines.
[0004] Rotating electrical machines have high rotating speeds, which results in major centrifugal forces affecting the rotor and the permanent magnets attached to the rotor. This sets requirements for precision of installation of the permanent magnets, and the durability of the fastenings and locking of the magnets.
[0005] The axial positioning of the magnets is also important, for example for rotors with a radial cooling system. In such systems, coolant flows into the rotor along axial channels and is then distributed into radial channels inside the rotor. If permanent magnets are not correctly positioned and reliably fastened, they may block a radial coolant channel and lead to an unwanted temperature increase inside the rotor.
[0006] A traditional way of fixing the permanent magnets to a rotor is to wrap the magnets individually in felt and then install them into the rotor, after which the rotor is immersed in resin. Another way of fastening the permanent magnets to the outer circumference of the rotor is to wrap resinified fiberglass tape around the rotor and permanent magnets. The resin used as a fixing agent is hardened by heating the rotor and permanent magnets in an oven.
[0007] The oven treatment required to harden the resin constitutes a problem for these traditional fastening methods. The oven temperature must be monitored so that it does not rise above the maximum temperature allowed for permanent magnets. During resinification it must also be ensured that the correct amount of resin is used at all necessary locations to ensure the permanence of the fastening of the permanent magnets.
[0008] Structural fragility and the sensitivity of any surface treatment add to the difficulties encountered during the handling and installation of permanent magnets. For example, the surface treatment of a permanent magnet is easily scratched, after which the magnet may begin to crumble or corrode.
DESCRIPTION OF INVENTION
[0009] The purpose of the present invention is to create a permanent magnet unit for an electrical machine, a method to install permanent magnet units in an electrical machine, and an electrical machine rotor excited by permanent magnet units. In order to achieve this, the invention is characterized by the features specified in the characteristics sections of Claims 1 , 6 and 7 . Some other preferred embodiments of the invention have the characteristics specified in the dependent claims.
[0010] In a permanent magnet unit according to the invention, designed for an electrical machine comprising a stator and rotor, at least one permanent magnet is enclosed in a non-magnetic enclosure. The enclosure has means for connecting it to at least one other substantially similar enclosure containing a permanent magnet.
[0011] In a method according to the invention to install permanent magnet units in an electrical machine, the electrical machine comprises a stator and a rotor. The rotor rotates around its shaft. The method involves at least two permanent magnet units to be installed, each of which comprising at least one permanent magnet enclosed in a non-magnetic enclosure. The enclosed permanent magnet is magnetized, and the enclosure has means for connecting it to at least one other substantially similar enclosure containing a permanent magnet. In the method, the first permanent magnet unit is installed from the rotor end into an installation channel parallel to the rotor axis, and the second permanent magnet unit is installed into the installation channel after the first permanent magnet unit in the direction of the rotor axis. The second permanent magnet unit is pushed against the first permanent magnet unit, and the permanent magnet units engage with each other using the brackets on the enclosures.
[0012] The rotor of the electrical machine according to the invention is excited with permanent magnets. The rotor rotates around its rotation axis and comprises at least a frame and permanent magnets. At least one permanent magnet is enclosed in a non-magnetic enclosure, and the enclosed permanent magnet is magnetized. The enclosure has means for connecting it to at least one other substantially similar enclosure containing a permanent magnet, the other enclosed permanent magnet constituting a permanent magnet unit. At least two permanent magnet units are placed inside an installation channel formed inside the rotor frame one after another in the direction of the rotor axis and the permanent magnet units are connected to each other, At the ends of the installation channel, there are supports that prevent the permanent magnets from moving in the direction of rotor axis.
[0013] The enclosure protects the permanent magnet during handling and installation, helping to avoid scratching and damaging of the permanent magnet's surface, for example. If the enclosure of the permanent magnet unit is fully closed, such as an insert molded enclosure, raw, i.e. not surface-treated, magnets may be used as permanent magnets. However, commercial permanent magnets are usually phosphated as a basic surface treatment. A hermetically sealed, airtight enclosure, manufactured from non-breathing plastic that will not absorb water, for example, will protect the permanent magnet in difficult conditions.
[0014] Enclosed permanent magnets are easier to manufacture than unenclosed magnets, as defects of form are allowed for an enclosed magnet. Traditionally, permanent magnets are manufactured by sintering and then honed to precise dimensions. Typical dimensional accuracy is in decimals of a millimeter. When the permanent magnet is enclosed, ±0.1 . . . 0.5 mm is an adequate dimensional accuracy. When manufacturing the enclosure with the insert molding method, in which an insert consisting of one or more permanent magnets is placed inside the plastic mold before casting and the plastic encases the insert, even more dimensional inaccuracy is allowed, as plastic will fill any gaps.
[0015] A permanent magnet unit consisting of, for example, one permanent magnet is easier to manufacture and handle than a single large permanent magnet. The equipment needed to magnetize a permanent magnet in a permanent magnet unit, for example, is considerably simpler and available to a larger group of manufacturers than the equipment needed to magnetize a permanent magnet which is, for example, three times as large. According to an embodiment of the invention, the permanent magnet is magnetized when enclosed, which increases safety at work at the manufacturing stage.
[0016] According to an embodiment of the invention, the permanent magnet unit has a feature that helps find the correct orientation when installing the unit into the rotor. Permanent magnets are magnetized, for example, in the direction of the rotor radius. A ridge or bevel can be formed, for example on the top or bottom surface of the permanent magnet unit's enclosure. When the permanent magnet unit is installed, the ridge or bevel will collapse and lock the unit in place. Another option is to add a color mark to the permanent magnet unit's enclosure, indicating the polarity.
[0017] No resinification or oven treatment is necessary to fix the permanent magnets in place in the method for installing permanent magnet units in an electrical machine. The installation of the permanent magnets can be carried out at factory temperature. The positioning of the permanent magnets is easy, as the shape of the permanent magnet unit corresponds to the shape of the installation channel. The location of the permanent magnet in the installation channel will be correct, as the permanent magnet units are located within a fixed distance of each other.
[0018] The permanent magnet units installed in the installation channel inside the rotor are embedded in the rotor and have a good tolerance for centrifugal forces when the rotor rotates, for example, at more than 2,000 rpm.
[0019] The solution according to the invention is also advantageous in situations in which the permanent magnets are demagnetized in the rotor of an electrical machine. The solution according to the invention facilitates easy replacement of permanent magnets in the rotor. Permanent magnet units are installed through an opening at the rotor end one after another in an axial direction into a channel or rotor groove within the rotor, parallel to the axis of the rotor. Permanent magnet units can be removed from the rotor by removing the support or lock preventing their axial movement at the other end of the rotor and pushing the permanent magnet unit in the opening at the other end of the rotor, making the interconnected permanent magnet units slide in the channel through the rotor to the other end, where they can be pulled out.
[0020] Alternatively, the axial-direction lock can be opened at one end of the installation channel, and the permanent magnet units can then be pulled out from that end of the rotor. The interconnected permanent magnet units form a chain, enabling the removal of all permanent magnet units from the rotor by pulling from the first permanent magnet unit in the chain. Permanent magnet units can be detached from each other by opening the clamps one at a time.
[0021] With the solution according to the invention, possible permanent magnet installation errors can be efficiently found and fixed. When incorrect orientation of the permanent magnet unit installed in the rotor is suspected, this can be checked without damaging the rotor by sliding the permanent magnet units out from the rotor.
[0022] The solution according to the invention is also advantageous for eliminating the power decrease due to aging of the permanent magnets. The solution according to the invention facilitates easier replacement of permanent magnets within the rotor, making it possible to replace old permanent magnet units, for example in connection with maintenance work.
[0023] If electrical magnets were fixed in place with resin, the rotor would have to be heated in an oven in a temperature of over 300° C. to remove the magnets from the rotor. This would destroy all permanent magnets in the rotor and they would need to be replaced.
[0024] When the solution according to the invention is used, not all the rotor's permanent magnets need to be replaced. Instead, only the desired number of permanent magnet units will be replaced. Replacement of permanent magnet units can be carried out at factory temperature without oven treatment. The rotor does not need to be transported long distances to be repaired. Instead, local repair facilities can be used.
[0025] A preferred embodiment of the invention is a rotor with a radial cooling system. The coolant flows into the rotor along axial channels and is then distributed into radial channels inside the rotor. Depending on the cooling solution, cooling air is conducted into the rotor from one or both ends of the rotor. In the radial channels, cooling air flows toward the rotor circumference and further toward the electrical machine's air gap. Rotor core sections consist of thin packed sheets and radial channels are formed between the rotor core sections by separating the core sections with spacers in the axial direction. In a rotor with a radial cooling system, permanent magnet units are installed in the installation channel so that the end of the permanent magnet unit is flush against the rotor end plate at the other end of the rotor. When the distance between two permanent magnet units connected to each other is substantially the same as the width of a radial cooling channel of the rotor, the permanent magnet unit is placed at the rotor core and the connection brackets of the permanent magnet unit are placed at the radial ducts. The opening through which the permanent magnet units were inserted are closed, or the other end plate of the rotor is fixed in place to cover the opening and to lock the permanent magnet units in place in the axial direction.
[0026] If the pole of the electrical machine is wide, its mechanical strength can be increased by dividing it into several sections. According to a preferred embodiment, at least two installation channels exist in the pole of the electrical machine in this case.
[0027] The arrangement according to the invention is preferable, for example, for wind generators, which typically operate in difficult weather conditions and a corrosive atmosphere. The required rotation speed range of wind power generators is large. Gusty winds may increase the wind velocity quickly, resulting in a rapid increase in the effect of centrifugal force on the rotor and the permanent magnets attached to it. When the load leaves the network, the rotation speed of the rotor may quickly rise to 75-100% of the nominal speed.
FIGURES
[0028] In the following, the invention will be described in more detail with the help of certain embodiments by referring to the enclosed drawings, where
[0029] FIG. 1 illustrates two interconnected permanent magnet units;
[0030] FIG. 2 illustrates two interconnected permanent magnet units, one of which is shown without the top part of the enclosure;
[0031] FIG. 3 illustrates a permanent magnet unit with the bottom part of the enclosure of another permanent magnet unit connected to it;
[0032] FIG. 4 illustrates a partial cross-section in the axial direction of a rotor according to the invention; and
[0033] FIG. 5 illustrates a cross-section A-A perpendicular to the shaft from FIG. 4 .
DETAILED DESCRIPTION
[0034] FIG. 1 illustrates two permanent magnet units 1 a and b for an electrical machine. The plastic enclosure 3 consists of two components 3 a - c , the top and bottom parts, both manufactured with the same mold, FIGS. 1-3 . Symmetrical enclosure components are advantageous in terms of manufacturing techniques, as different tools for different parts are not required. A phosphated permanent magnet 2 has been enclosed by installing it into the bottom part 3 c of a two-part plastic enclosure 3 , FIG. 2 , and then installing the top part of the plastic enclosure. Enclosure components 3 a - c have brackets ( 4 a and 4 b ) to connect the top and bottom components to each other after the permanent magnet ( 2 ) has been installed. The mating surface 8 of the top and bottom components of the enclosure is sealed, for example with glue or a sealing agent, to create a completely sealed enclosure.
[0035] The permanent magnet 2 does not need to be glued to the plastic enclosure 3 , as the back 7 and sides 6 a - d of the enclosure have been dimensioned to correspond to the back and sides of the permanent magnet. The surface area and shape of the back 7 of the enclosure 3 substantially correspond to the surface area and shape of the back of the permanent magnet 2 . The enclosure 3 supports the permanent magnet 2 rendering it immobile in the lateral, axial and vertical directions. As the enclosure 3 must have some free play, the inner surface of the enclosure 3 may have various guides, such as ridges or bevels that will give when installing the permanent magnet and then lock the permanent magnet in place in the enclosure.
[0036] Enclosure components 3 a - c have brackets 5 a, b on the outer surfaces, fastening permanent magnet units to each other. Three pairs of brackets 5 a, b have been placed on both long sides 6 a, b of the rectangular permanent magnet unit in FIGS. 1-3 . Fastening of the permanent magnet units to each other at the minimum of two points is preferred, in order to make them more robust. The permanent magnet units 1 a, b are locked together by brackets 5 a, b at the ends and the middle of the long sides. The brackets 5 a, b engage and lock when the two permanent magnet units 1 a, b are pushed together. When the permanent magnet unit 1 a, b has been installed into the rotor, the brackets 5 a, b are located in the permanent magnet unit sides that are transverse to the axial direction of the rotor.
[0037] Permanent magnet units can be fastened together with brackets inside the rotor installation channel or, if desired, before the permanent magnet units are installed into the rotor.
[0038] At the outmost permanent magnet unit end in the axial direction of the rotor, the ends of the brackets 5 a, b define the distance from the rotor end plate and act as support elements in the axial direction of the rotor.
[0039] The permanent magnet unit enclosure can also be manufactured using the insert molding method. For example, two or three permanent magnets are placed inside the mold, and the plastic constituting the enclosure is then cast so that it adheres to the magnets. The enclosure will be completely sealed, and no connection brackets or sealing at the mating surfaces of components are required.
[0040] If the rotor is a closed rotor, where the thin sheets in the rotor core are flush with each other, it is preferred that the fixed distance between two permanent magnet units fastened together is kept short. In this case, the brackets of the permanent magnet unit are placed on the permanent magnet unit sides parallel to the rotor axis. When the permanent magnet units are then connected together, only the distance created by the enclosure walls remains between the permanent magnets, and the adjacent sides of permanent magnet units are flush with each other.
[0041] Brackets can also be placed, for example, on the permanent magnet unit sides that are transverse to the axial direction of the rotor, so that when two permanent magnet units are connected together, the brackets of the first permanent magnet unit penetrate inside the second permanent magnet unit. The adjacent sides of the permanent magnet units will then be flush with each other. The space required by the penetrating brackets of the second permanent magnet unit can be created on the permanent magnet unit sides parallel to the rotor axis, for example, by making the sides thicker.
[0042] When using permanent magnet units to excite a rotor with a radial cooling system, the distance between two permanent magnet units 1 a , 1 b is dimensioned to be substantially equal to the width of a radial cooling duct of the rotor. This ensures that the permanent magnet unit will not block the coolant flow in the rotor air duct, as only the permanent magnet unit brackets will be located at the air duct.
[0043] FIG. 4 is a partial cross-section of the rotor ( 40 ) of an eight-pole synchronous machine according to the invention. FIG. 5 is the cross-section A-A from FIG. 4 . The rotor core ( 41 ) fitted on a shaft ( 42 ) is manufactured from magnetically conductive sheets. The rotor consists of four core sections in the axial direction, separated by radial air duct 43 between the sheets. The coolant air cooling the rotor flows through the air duct in the radial direction towards the outer circumference of the rotor in a well-known way. The rotor core has channels 44 parallel to the rotor axis to lighten the structure and to allow the coolant air to flow through the rotor. Rotor poles with two permanent magnet unit chains embedded inside the core have been formed at the outer circumference of the rotor. The permanent magnet units have been fitted inside the installation channels 45 extending throughout the rotor's length parallel to the longitudinal axis of the rotor. The permanent magnet units 1 c - g comply with the illustrations in FIGS. 1-3 . In the circumferential direction of the rotor, the permanent magnet units are separated by a narrow core strip 46 . Similarly, there is a core strip 47 between both permanent magnet units and the pole edge. The core strips 46 , 47 support the outmost part of the rotor pole and the permanent magnet units against centrifugal forces.
[0044] Permanent magnet units 1 c - g are installed in place by pushing them into the openings 52 at the end of the rotor 40 . The end 50 of the permanent magnet unit 1 c is flush against the rotor end plate 51 at the other end of the rotor. As a result, the permanent magnet 2 inside the permanent magnet unit is located at the rotor core 41 . The brackets 5 c - f in the chain consisting of permanent magnet units 1 c - g are located at the radial ducts 43 . The brackets 5 g of permanent magnet unit 1 g closest to the installation opening 52 are flush against the end plate. The permanent magnet unit installation opening 52 will be closed, or the other end plate of the rotor will be fixed in place to cover the opening and to lock the permanent magnet units in place in the axial direction. It is not necessary to fasten the permanent magnet units to the rotor, as the installation channel and the end plates will lock them in place in relation to the rotor.
[0045] The figures illustrate an substantially rectangular, flat permanent magnet unit. The permanent magnet unit may also be a non-right-angled parallelogram.
[0046] The permanent magnet unit may also be outwardly arched to follow the curve of the rotor circumference. In this case, the top and bottom components of the permanent magnet unit will not have the same shape.
[0047] The invention has been described above with the help of certain embodiments. However, the description should not be considered as limiting the scope of patent protection; the embodiments of the invention may vary within the scope of the following claims.
[0048] Parts List:
[0049] 1 a - g permanent magnet unit; 2 permanent magnet; 3 enclosure; 3 a, b top component of the enclosure; 3 c bottom component of the enclosure; 4 a, b closing bracket; 5 a - g connection bracket; 6 a - d side of the enclosure; 7 back of the enclosure; 8 mating surface; 40 rotor; 41 rotor core; 42 shaft; 43 air duct; 44 opening; 45 installation channel; 46 , 47 core strip; 50 end of the permanent magnet unit; 51 end plate; 52 opening; s distance.
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In a permanent magnet unit according to the invention, designed for an electrical machine comprising a stator and rotor, at least one permanent magnet ( 2 ) is enclosed in a non-magnetic enclosure ( 3 ). The enclosure has means ( 5 a, 5 b ) for connecting it to at least one other substantially similar enclosure ( 3 ) containing a permanent magnet.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119 to provisional application Ser. No. 62/026,951, filed Jul. 21, 2014, herein incorporated by reference in its entirety.
GRANT REFERENCE
[0002] This invention was made with government support under Contract No. 2008-51180-19561, awarded by the United States Department of Agriculture and under Hatch Act Project Nos. PEN04547 and PEN04282, awarded by the United States Department of Agriculture/NIFA. The Government has certain rights in the invention.
FIELD OF THE INVENTION
[0003] The present invention relates to selective automated blossom thinning More specifically, but not exclusively, the present invention relates to a selective automated blossom thinner, system and method.
BACKGROUND OF THE INVENTION
[0004] The specialty crop production industry is a cornerstone of the U.S. agricultural economy. Since the turn of the twenty-first century, specialty crop production has accounted for over 41.2 percent of U.S. cropland value of production. Producers and handlers of fruits, tree nuts, vegetables, melons, potatoes, and nursery crops comprise the multi-faceted specialty crop production industry. At the forefront of this industry is tree fruit production, which accounts for 35.3 percent of U.S. specialty crop consumption per capita and generated nearly 15 billion dollars in annual revenue in 2010 alone. These tree fruit crops are some of the most labor intensive crops to produce. The variable production labor overhead includes the pruning, thinning and harvesting processes. The blossom thinning or green fruit thinning has been in practice for hundreds of years; it is a complex, time sensitive procedure, which reduces fruit branch loading, resulting in a higher quality, larger sized product.
[0005] Too many blossoms and/or fruits per tree can result in small fruit size, poor quality, and breakage of limbs. Traditionally, this process has been accomplished by hand or manual labor. However, a variety of chemical and mechanized thinning methods have been explored to reduce labor requirements. However, chemical thinning techniques have been proven unsafe and caustic in particular fruits, such as peaches, and is not an option for growers. Conversely, mechanical thinning and/or mechanized thinning studies have shown improved production efficiency while maintaining canopy integrity.
SUMMARY OF THE INVENTION
[0006] Therefore, it is a primary object, feature, and/or advantage of the invention to continue to improve upon the state of art for mechanized fruit thinning.
[0007] Another object, feature, and/or advantage of the present invention is to selectively remove blossoms and immature fruit based on branch length, blossom size, distance from trunk, and other like optimization parameters.
[0008] A still further object, feature, and/or advantage of the present invention is to employ heuristic blossom thinning methods that will result in ideally loaded branches for optimization of product growth.
[0009] One other object, feature, and/or advantage of the present invention is to develop a selective, fully automated, mechanized thinning system for fruit blossoms, such as peach blossoms.
[0010] Another object, feature, and/or advantage of the present invention is to visualize the tree fruit canopy, discriminate targets, mechanically reach the canopy from a stable platform and remove unwanted targets.
[0011] One or more of these and/or other objects, features or advantages of the present invention will become apparent from the specification and claims that follow.
[0012] The present invention provides selective automated blossom thinning More specifically, but not exclusively, the present invention relates to a selective automated blossom thinner, system and method.
[0013] One exemplary embodiment provides a selective automated blossom thinning system. The system can include a robotic arm having proximal and distal portions articulable relative to each other by one or more interconnected members. An end-effector can be included at the distal portion of the robotic arm. The end-effector can have one or more fruit blossom thinning elements movable between open and closed positions for receiving and removing selected fruit blossoms. At least one input to a control on the arm from an acquisition device can be used to position the end-effector proximate one or more fruit blossoms, which can be heuristically selected by a computer-executed algorithm for removal from a plurality of fruit blossoms.
[0014] Another embodiment provides a selective automated blossom thinner. The blossom thinner can include a pair of opposing blossom thinning elements. A carriage of the blossom thinner can have a linear transversal assembly and an element actuator assembly. In a first position of the carriage the pair of opposing blossom thinning elements are in at least partial contacting engagement. In a second position of the carriage the pair of opposing blossom thinning elements are separated. A robotic arm can be operably connected to the carriage.
[0015] Yet another embodiment provides an automated method for blossom thinning. In one aspect, blossom thinning elements can be mounted on a carriage with a linear transversal assembly and element actuator assembly. A location of one or more blossoms can be heuristically approximated. Actuating the linear transversal assembly can move blossom thinning elements between open and closed positions for receiving one or more blossoms. Selected one or more fruit blossoms can be removed with the element actuator assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Illustrated embodiments of the present invention are described in detail below with reference to the attached drawing figures, which are incorporated by reference herein, and where:
[0017] FIG. 1 is a pictorial representation of an overview in accordance with an illustrative embodiment;
[0018] FIG. 2 is a pictorial representation of a tree structure in accordance with an illustrative embodiment;
[0019] FIG. 3 is a pictorial representation of a flow chart of methodology for automated selective blossom thinning;
[0020] FIG. 4 is a pictorial representation of Picture and SolidWorks 3-D renderings of an M-16iL robotic arm;
[0021] FIG. 5 is a pictorial representation of an M-16iL robotic arm electrical wiring;
[0022] FIG. 6 is a pictorial representation of a robotic arm projected onto the 0 frame;
[0023] FIG. 7 is a pictorial representation of a robotic arm projected on a 2D plane;
[0024] FIG. 8 is a pictorial representation of blossom pixels in R, a predefined range on its depth line is projected into frames L and T;
[0025] FIG. 9 is a pictorial representation of a Boolean operator subroutine schematic;
[0026] FIG. 10 is a pictorial representation of a heuristic thinning algorithm schematic;
[0027] FIG. 11 is a pictorial representation of an applied point load to 90 degree blossom and resulting force balance equation;
[0028] FIG. 12 is a pictorial representation of an applied load to 90 degree blossom and resulting force balance;
[0029] FIG. 13 is a pictorial representation of an M-16iL robotic arm (FANUC, 2000);
[0030] FIG. 14 is a pictorial representation of a quarter-scale robotic arm workspace schematic top view;
[0031] FIG. 15 is a pictorial representation of a joint servomotor schematic;
[0032] FIG. 16 is a pictorial representation of a robotic arm link parameters schematic;
[0033] FIG. 17 is a pictorial representation of a preliminary end-effector testing and designs;
[0034] FIG. 18 is a perspective and exploded view of an end-effector housing;
[0035] FIG. 19 is a pictorial representation of an end-effector brush translation schematic;
[0036] FIG. 20 is a pictorial representation of an end-effector translation assembly schematic;
[0037] FIG. 21 is a pictorial representation of end-effector drive roller schematic;
[0038] FIG. 22 is a pictorial representation of an end-effector prototype;
[0039] FIG. 23 is a pictorial representation of a vision system setup;
[0040] FIG. 24 is a pictorial representation of a heuristic thinning experimental setup;
[0041] FIG. 25 is a pictorial representation of a Normal Force blossom removal graph (vertical);
[0042] FIG. 26 is a pictorial representation of a Normal Force blossom removal graph (horizontal);
[0043] FIG. 27 is a pictorial representation of a Tangential Force blossom removal graph;
[0044] FIG. 28 is a pictorial representation of a kinematic positioning scatter plot (position 1);
[0045] FIG. 29 is a pictorial representation of a kinematic positioning scatter plot (position 2);
[0046] FIG. 30 is a pictorial representation of a kinematic positioning scatter plot (position 3);
[0047] FIG. 31 is a pictorial representation of a kinematic positioning scatter plot (position 4);
[0048] FIG. 32 is a pictorial representation of a kinematic positioning scatter plot (position 1-4);
[0049] FIG. 33 is a pictorial representation of a normal distribution curve for kinematic positioning test (position 1-4, 120 trials);
[0050] FIG. 34 is a pictorial representation of a vector magnitude plot for kinematic positioning test (position 1);
[0051] FIG. 35 is a pictorial representation of an end-effector placement plot (position 1);
[0052] FIG. 36 is a pictorial representation of an end-effector placement plot (position 2);
[0053] FIG. 37 is a pictorial representation of an end-effector placement plot (position 3);
[0054] FIG. 38 is a pictorial representation of an end-effector placement plot (position 1-4);
[0055] FIG. 39 is a pictorial representation of a heuristic thinning sample trace;
[0056] FIG. 40 is a pictorial representation of a heuristic thinning blossom position chart;
[0057] FIG. 41 is a pictorial representation of a heuristic thinning example; and
[0058] FIG. 42 is a pictorial representation of a kinematic software flowchart.
[0059] FIG. 43 is a perspective view of a robot and end effector device according to some aspects of the invention.
[0060] Various embodiments of the invention will be described in detail with reference to the drawings, wherein like reference numerals represent like parts throughout the several views. Reference to various embodiments does not limit the scope of the invention. Figures represented herein are not limitations to the various embodiments according to the invention and are presented for exemplary illustration of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0061] According to at least some aspects, selective automated blossom thinning can consist of: vision acquisition hardware, kinematic targeting and heuristic programming, a robotic arm and a pomologically designed end-effector. This system is shown in FIG. 1 .
[0062] A methodology can be employed to investigate automated selective blossom thinning using robotic controlled end-effectors with a 3-D vision target acquisition system for various fruit tree scaffold types, such as the open vase tree shown in FIG. 2 . Other scaffold types such as KAC-V and Y-trained tree systems are contemplated. A study of such an investigation can be divided into two phases: the design, fabrication and integration phase and the experimental and statistical analysis phase ( FIG. 3 ).
[0063] According to at least some aspects of a system for selectively thinning blossoms, an industrial grade robotic arm ( FIG. 3 ) can be used. The Figure shows the use of an FANUC M-16iL, which is a double-jointed robotic arm, with six axes of rotation. The M-16iL was designed primarily for repetitive industrial tasks. However, an automation process for the selective automated thinning of blossoms requires a programmable robotic unit and/or robotic controller which would accept ‘real time’ Cartesian coordinate data for transversal paths about a chosen target area. The M-16iL robotic arm does not have this capability. Therefore, two different methods can be implemented for circumventing the robotic arm's motors and motor controller signals.
[0064] The first method includes replacing the existing motor controllers with new programmable controllers; wherein the real time transversal data can be fed directly to the motors ( FIG. 4 ). The second method includes a reverse engineering breakout method; which is where the pendant controller signal is replaced with customized transversal software. Note, the pendant controller is the physical input control for the robotic arm motor controllers. Nonetheless, both methods require replacement of the motors and motor controllers (encoders). These methods can be rather costly. Therefore, some aspects of the invention may be directed to design and construct a quarter-scale version of the M-16iL robotic arm. This will be discussed herein.
[0065] In order to create an effective thinning system, the design can be divided into four parts. One proposed system consisted of a vision targeting system, algorithm design, robotic arm and end-effector. Thus, a part of the invention includes a design of the quarter-scale robotic arm and blossom thinning end-effector. Hardware designs can be based upon peach orchard field requirements. The quarter-scale arm 10 (see, e.g. FIG. 43 ) can be designed to match the FANUC M-16il industrial robotic arm. The end-effector 100 (see, e.g., FIG. 22 ) can be designed to be applicable in a full-scale environment at the quarter-scale payload of the robotic arm 10 .
[0066] Furthermore, the robotic arm can be considered to be animatronic or mechanical in nature. For example, when animatronic, the arm may be an autonomous system or used with an autonomous vehicle that positions the arm at or near a tree. The vision system and algorithm then determine how the arm is to be used to selectively remove shoots from a branch. As the arm includes a heuristic computing system, it will be able to track the branches cleaned such that it can send a signal the carrier vehicle to move to a next tree, where the system is repeated.
[0067] However, the robotic arm could also be mechanical in nature. As will be explained, an end effector 100 is included with the arm 10 to remove the shoots from a branch. The end effector can include spinning brush members to effectively remove the shoots. The robotic arm could be an exoskeleton-like device wherein a human user operates the arm to position the arm at or near a branch of a tree. The user could then operate the arm to position the end effector near a shoot to be removed. Activation of the arm, such as via a trigger, linkage, pulley, or the like, could cause the end effector to operate, such as by spinning one or more brush members, such that the shoot(s) is removed from the branch. The user would move from branch to branch and tree to tree to efficiently and easily remove the unwanted shoots.
[0068] Still further, the invention contemplates hybrid arms that may be partially mechanical and partially animatronical. For example, the thinning device could be at least partially manipulated by a user to either position or activate the arm and/or end effector to remove shoots from a branch, while doing some of the movements on its own.
[0069] As shown in FIG. 3 , phase two of one example includes all experimental testing of the selective fruit thinning system. All experimental testing can be performed in a laboratory environment. According to one example, there were five separate case studies conducted on the thinning system. First the positioning of the robotic arm was evaluated with and without the end-effector. Next, the blossom force tests were performed using the end-effector, a high-speed camera, and Saturn peach blossoms artificially bloomed in a growth chamber. Finally, the spatial heuristics were observed with and without the aid of the vision system. Testing the thinning heuristics of the system with the vision targeting activated concluded the data acquisition portion of phase two ( FIG. 3 ). Note the final test series included all parts of the automated thinning system.
[0070] All data collected in phase two was quantitative. This data was then analyzed using vector, force, and statistically analyses techniques.
Inverse Kinematic Algorithm
[0071] The inverse kinematic algorithm can then be programmed for the quarter-scale robotic arm 10 . The quarter-scale design is an all revolute joint manipulator and is categorized as an articulated robotic arm with a spherical wrist. The algorithm calculates each of the robotic arm joint's variables (angular velocities and accelerations) based on positions (Cartesian coordinates x-y-z) within the robotic arm workspace. The joint variables can be expressed as a 3 by 1 position vector O ef =(O 6 0 ) with a 3 by 3 orientation matrix R ef =(R 6 0 ). Finding solutions to this problem can be difficult. However, solutions to a six revolute joint robotic arm with the last three joints configured as a spherical wrist can be found by a strategy called kinematics decoupling. The kinematic decoupling approach divides the equation into two smaller parts, an inverse kinematic position solution and an inverse orientation kinematic solution. The complete joint variables solutions are listed in equations 1 through 7. Note, d's, a's and c's are set parameters of the robotic arm. Equation seven is listed here as the position of the wrist center O c and is used to combine the two derivations. Note, d 3 is a link length parameter on the robotic arm, where subscripts refer to links unless noted as otherwise.
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r
32
,
-
r
31
)
or
atan
2
(
-
r
32
,
r
31
)
(
6
)
o
c
=
[
x
c
y
c
z
c
]
=
o
ef
-
d
3
R
[
0
0
1
]
(
7
)
[0072] When calculating the inverse kinematic equations it is common for solutions not to be unique, meaning valid inputs may have four solutions, two solutions, or infinitely many solutions. The four solution case is the most frequent, where there are two possible θ 3 with two θ 2 , two θ 4 , two θ 6 , and four θ 5 . The potential combinations are enumerated in Table 1.1.
[0000]
TABLE 1.1
Potential combinations of possible joint variable table
Joint Variable
(Num. of
θ 1
θ 2
θ 3
θ 4
θ 5
θ 6
candidates)
(1)
(2)
(2)
(2)
(4)
(2)
Solution
1
I
I
I
I
I
I
2
I
I
I
I
II
I
3
I
II
II
II
III
II
4
I
II
II
II
IV
II
[0073] The non-unique issue can be partially alleviated by setting the operating range of the joints' variables (axis servo motors). Limiting the range of motion for the servo motors eliminates possible candidates and allows for convergence to a single solution. See Table 1.2 for joint operating ranges.
[0000]
TABLE 1.2
Joint servo motors operating limit table
Joint
1
2
3
4
5
6
Upper limit
135°
99°
90°
150°
91°
150°
Lower limit
−135°
−45°
−99°
−150°
−91°
−150°
[0074] The geometric approach (inverse position kinematics) can be used to solve the first three joint variables, which can be characterized as an elbow of a robotic arm. By projecting the robotic arm onto a 2D plane, which are the x o -y o plane and the x o -z o plane in a three dimensional (3D) space, the problem becomes a simple trigonometry exercise, see FIG. 8 .
[0075] In FIG. 6 , the x, axis and the projection of the robotic arm on the x o -y o plane has an angle θ 1 . See Equation (2) for θ 1 equation. Using the equation (8), θ 1 becomes a unique solution for joint 1 .
[0000] θ 1 =a tan 2( y c ,x c ) (8)
[0076] Looking back at the robotic arm projected onto the 2D plane simplifies the problem ( FIG. 7 ). The two joints can be solved by applying the law of cosine, see equations (9) through (12).
[0000]
r
=
x
c
2
+
y
c
2
-
a
1
and
z
c
-
d
1
,
cos
(
π
-
θ
3
)
=
a
2
2
+
d
4
2
-
(
r
2
+
s
2
)
2
a
2
d
4
(
9
)
cos
θ
3
=
(
r
2
-
s
2
)
-
a
2
2
-
d
4
2
2
a
2
d
4
≡
D
(
10
)
θ
3
=
atan
2
(
±
1
-
D
2
,
D
)
(
11
)
θ
2
=
atan
2
(
s
,
r
)
-
atan
2
(
a
3
s
3
,
a
2
+
d
4
c
3
)
(
12
)
[0077] Angles θ 1 , θ 2 , and θ 3 of the robotic arm now have solutions and inverse orientation kinematics can be used to solve for the remaining joint variables. The first three joint variables can be represented in the form of a rotation matrix R 3 0 and transfer the reference frame from o 0 x 0 y 0 z 0 to o 3 x 3 y 3 z 3 which is the frame of the wrist center. Since R (input) and R 3 0 are both known, the R 6 0 rotational matrix can be solved, see Equations (13) and (14). The R 6 3 rotational matrix, Equation (15), is identical to a specific form of rotation called Euler angle transformation.
[0000] R=R 0 6 =R 3 0 R 6 3 (13)
[0000] R 6 3 =( R 3 0 ) −1 R =( R 3 0 ) T R =known values (14)
[0000] Besides, R 6 3 can be represented by θ 4 , θ 5 , and θ 6 as
[0000]
R
6
3
=
[
c
4
c
5
c
6
-
s
4
s
6
-
c
4
c
5
s
6
-
s
4
c
6
c
4
s
5
s
4
c
5
c
6
+
c
4
s
6
-
s
4
c
3
s
6
+
c
4
c
6
s
4
s
5
-
s
5
c
6
s
5
s
6
c
5
]
=
expression
in
θ
4
,
θ
5
,
and
θ
6
(
15
)
R
6
3
=
[
-
c
4
c
6
-
s
4
s
6
-
c
4
s
6
-
s
4
c
6
0
-
s
4
c
6
+
c
4
s
6
-
s
4
s
6
+
c
4
c
6
0
0
0
-
1
]
=
[
-
c
4
-
6
-
s
4
-
6
0
-
s
4
-
6
c
4
-
6
0
0
0
-
1
]
(
16
)
[0000] And the solution is
[0000] θ 4 −θ 6 =a tan(− r 12 ,−r 11 )
[0000] The default value of θ 4 is 180°.
[0078] Although the sum of the rotational matrix R 6 3 can be determined, there can be infinitely many combinations of θ 4 and θ 6 . To address this issue, θ 4 is set to 180° in the kinematic control software, (Equation (16)). The kinematic control software of the robotic arm was written in MATLAB® version 7.11 (R2010b) using the Symbolic Math Toolbox™ version 5.5 (R2010b).
[0079] The vision system uses a correlation-based stereo vision approach to 3D blossom mapping for automated thinning of peach blossoms on perpendicular “V” architecture trees ( FIG. 2 ). The vision algorithm was developed for utilizing trinocular stereo with low complexity that dynamically selects camera pairs and triplets for triangulation. The five part step by step process for blossom mapping is listed below.
[0080] [1] Calibrate the cameras.
[0081] [2] Capture synchronized nighttime views of peach trees using flash illumination.
[0082] [3] Perform window correlation in depth space.
[0083] [4] Apply error correction based upon a selection of certainty measures or validation metrics.
[0084] [5] Deliver the 3D blossom point cloud to the heuristic algorithm.
Vision System Algorithm
[0085] Traditional stereo vision literature focuses on epipolar geometry and reducing the reconstruction to mere disparity estimation between different views. This global optimization approaches become computationally complex with increasing resolution and the functional assumption does not apply to the scene in this work, where all the blossoms have the same color, even across depth discontinuities. An alternative and more computationally efficient technique to global surface optimization is to use a strong rejection of false matches using an uncertainty measure.
[0086] Therefore, windows correlation was selected for this application because it is highly suitable for real-time parallel processing, and avoids warping problems from extrinsic rectification. Consequently, the algorithm uses the depth discourse rather than the disparity discourse. This means for each point in a reference frame, the depth is estimated instead of the disparity. Rather than performing projection of each depth layer, a line is given by minimum and maximum depth. The line is bent if lens distortion is present. Modern machine vision cameras are capable of delivering lens distortion compensated images.
[0087] A fixed window size of 7000 pixels for each window trial may be selected for this work. Blossoms are segmented by thresholding the red color channel in each of the three views. Results have shown that this is an efficient means of identifying the blossoms on the proximal limb of the perpendicular “V” architecture trees. The objective is then reduced to finding the correspondences between blossom pixels from one image to another. Where R, L and T are the intensity images of the reference frame right, left and top cameras, respectively ( FIG. 8 ).
[0088] Binocular camera pairs have been defined as R-L and R-T, while the trinocular triangulation have been defined as R-L-T. The core of this method is the sum of squared differences (SSD) and Symmetric Multiple Windows (SMW), (Equation (17)).
[0000]
D
I
1
I
2
(
x
,
y
,
k
)
=
arg
min
(
i
,
j
)
∈
S
∑
(
a
,
b
)
∈
W
k
(
I
1
(
x
+
a
,
y
+
b
)
-
I
2
(
i
+
a
,
j
+
b
)
)
2
(
17
)
[0089] The essence of this equation is that a correspondence within the search space, S, is tested using a number of windows, Wk, of equal size, but centered differently around (x, y) and (i, j). Five windows can be used: centered and off-centered in the corners such that matching at depth discontinuities is improved. Therefore, the best match is found at the minimum dissimilarity measured by SSD in the correlation window. D I1I2 forms an image pair, e.g., DTR is the map between the Top and Right images. The equation in FIG. 8 selects the correspondence (i, j) in alternative frames for the Kth window. Sometimes it is beneficial to triangulate through all three frames to get the 3D point, other times it is better to treat the three cameras as two independent camera pairs. Consequently, the algorithm has the ability to adapt to using either binocular pairs or the trinocular set for triangulation.
[0090] The uncertainty equation, (Equation (19)) is defined as the variation in correspondences found by the multiple windows tested and used to find the one with minimum SSD in Equation (17). For the sake of simplicity, the (i, j) correspondences in D I1I2 (x, y, z) are referred to as ik and jk found in Equations (18) and (19).
[0000]
i
^
=
1
5
∑
k
i
k
j
^
=
1
5
∑
k
j
k
(
18
)
c
(
x
,
y
)
=
1
5
∑
k
(
i
k
-
i
^
)
2
+
(
j
k
-
j
^
)
2
(
19
)
[0091] Where c is the uncertainty at a given pixel (x, y), based on the corresponding (ik, jk) for each of the five windows and their means. Correspondence maps and uncertainty maps are generated for R-L and R-T pairs in all images. Once a blossom window match is found, it is crosschecked for right-left and left-right for consistency. All matches with a c above a prescribed threshold (certainty threshold) are invalidated. The remaining validated corresponding points are triangulated into 3D points.
[0000] Peach ( Prunus persica (L.) Batsch) Crop Load Management Practice Background for Thinning Heuristics
[0092] Horticulturalist goals for blossom thinning management are to reduce the competition between developing fruits and to reduce hand thinning labor. Peach is a high value crop, so the risk of over-thinning should be minimized. Additional factors, such as low bud health, lack of pollination, and adverse weather can also reduce fruit set. In common practice there may be 10 or more flowers present for every fruit that is desired, the percentage of flowers that ultimately set fruit is usually less than 100%. For these reasons, crop load management practices typically leave a smaller surplus, while drastically reducing the number of flowers.
[0093] While there may be some flowers present on older wood, the greatest numbers of viable peach flowers occur on the previous season's shoots. So the primary target for selective thinning is to address the flower density on one-year-old shoots. Another goal of managing crop load through thinning is to leave space between the fruits so that fruits are not touching one another. This reduces the risk of insect damage, which often occurs where two fruits touch one another. Spacing fruits out may prevent misshapen fruit, and enhances red coloration of mature fruits through uniform exposure to sunlight. If the final diameter of the remaining fruits at harvest is to be 8 cm (3.14 in), then it follows that this should be the minimum linear distance between fruits on a peach shoot.
[0094] The initial step in cropload management in modern peach orchard systems is to reduce cropping potential by thinning out the number of fruiting shoots and eliminating those shoots that are too short or too long. The length of fruiting shoots present at blossom thinning should fall between 20 cm to 60 cm (7.87 in to 23.6 in). The most recent approach used in green fruit hand thinning is to identify three classes of shoot fruit carrying capacity, based on length. Shoots 20 cm-30 cm (7.87 in-11.8 in). Length can support two peach fruits, those 31 cm-46 cm (11.9 in-18.1 in) in length can support three peach fruits, and those 47-60 cm (18.2 in-23.6 in) in length, four peach fruits. This crop load management thinning practice can be surmised as follows:
[0095] 1. Shoots 20 cm-30 cm (7.87 in-11.8 in)
[0096] All flowers in the basal 5 cm (1.96 in) of shoot length should be removed, as fruits in this section are often crowded by the proximity of the supporting structural limb (scaffold). Two flowers would then be left in the next 6 cm-11 cm (1.97 in-4.33 in), and then all flowers removed for a distance of 8 cm (3.14 in), with two more flowers left between 19 cm-24 cm (7.48 in-9.44 in). Any more distal flowers would be removed from 25 cm-30 cm (9.5 in-11.8 in) shoots, completing this smallest shoot class.
[0097] 2. Shoots 31 cm-46 cm (11.9 in-18.1 in)
[0098] If the shoot is 31-46 cm in length, then the thinning would begin the same as the shorter class. Two flowers would then be left between 32 cm to 37 cm (12.6 in to 14.5 in). Then all flowers more distal than 38 cm (14.96 in) removed.
[0099] 3. Shoots 47-60 cm
[0100] If the shoot is >46 cm (18.1 in) in length, the thinning would begin the same as the middle class. Two flowers would then be left between 45 cm and 50 cm (17.7 in-19.7 in). Then all flowers more distal than 51 cm (19.8 in) removed.
Heuristic Algorithm
[0101] The hand thinning process for peaches typically involves removing the blossoms in a spatial pattern based on the blossom density of each select cultivar. This spatial pattern is based on the grower's experience and peach ( Prunus persica (L.) Batsch) crop load management practices. The Saturn variety cultivar was selected for one study. This cultivar was used as the standard species for programming of the heuristic algorithm. Note, for other peach cultivars the algorithm can be adjusted to meet the blossom density thinning needs of each unique blossom cluster patterns.
[0102] In order to correctly thin each branch, the blossom position matrix input from the vision system is filtered through a heuristic identity subroutine that added a Boolean operator to each blossom 3D position. This true false binary addition to each coordinate set, confirmed the beginning of each branch ( FIG. 9 ).
[0103] After the origin of each branch has been established the spatial thinning algorithm creates removal zones based on the length of the branch. The length is calculated by vector addition from the origin to the last point on the branch (last false Boolean response or 0). Once the length of the branch is known, the removal zone pattern selects blossoms from the origin to the first 5 cm (1.96 in) along the averaged vector for removal. The algorithm then skips the next vector averaged 5 cm (1.96 in) and targets the next 8 cm (3.15 in) for complete removal. From this point on the algorithm follows a 5 cm (1.96 in) skip, to 8 cm (3.15 in) target pattern; targeting all blossoms within the 8 cm (3.15 in) window for removal until the end of the branch ( FIG. 10 ).
[0104] After the removal zones have been established, the target blossom coordinates are placed in a target array. The algorithm then targets blossoms in the previously skipped 5 cm (1.96 in) regions, called the growth zone. The algorithm selects all blossom in this 5 cm (1.96 in) region except the furthest blossom pairs from the center of the vector averaged 5 cm (1.96 in) regions ( FIG. 10 ). If the growth zones do not contain two blossom pairs, the algorithm will take the closest blossom pairs to either side in the removal zone out of the target array. The selected blossoms from the growth zone are then added to the target array. Once the target array has been filled with the branch's removal coordinates, a kinematic command series of subroutines run the robotic arm and end-effector to the positions for removal.
Blossom Removal (Force Study)
[0105] The typical hand removal method used in blossom thinning is the club method. The club method has many variations but the technique behind the blossom removal is the same. A rubber hose attached to a wooden handle or plastic bat is used to knock off unwanted blossoms. A skilled worker will concentrate their swings (force) perpendicular to the growth pattern of the blossom. This method has been mechanically duplicated with ropes and plastic chords, as seen with the Darwin String Thinner. In general the blossom branch configuration can be viewed as a single fixed support and/or cantilever beam system.
[0106] A cantilever beam is one in which one end is built into a wall or in this case a branch, where the built-in end cannot move transversely or rotate. Reactions, such as the internal shear or failure mode for the beam can be obtained from a free-body diagram and applying the equations of equilibrium. The force required to detach a blossom and/or create a shearing failure mode can be calculated using Newton's Second Law of motion, F=ma. Note, Biological systems are continually changing during the bloom or growth season making the ability to find a constant difficult. Young's Modulus and other pertinent material properties of peach blossoms for varying degrees of growth has not been cataloged to date. Thus, an empirical investigation was chosen over a computational study.
[0107] Two separate case studies were conducted with two different applied loads. The first approach investigated was an applied load at a single point. This approach would simulate a force applied to the blossom from a single strike and/or perpendicular pushing motion. Using the coordinate frame from the center of the point force, gives an applied load in the normal direction. The normal force required to detach the blossom can be calculated using the equation of motion. Summing the forces applied to the length of the blossom and calculating the time in conjunction with the applied linear velocity results the force used for detachment as shown in FIG. 11 . Note, a constant mass is assumed for this calculation.
[0108] The second approach examined was a tangential force applied to the length of the blossom. This second technique allowed for the mimicking of an angular velocity or sweeping motion over the length of the blossom as shown in FIG. 12 . The tangential force required to detach the blossom with an applied angular velocity can be calculated using the equation of motion. Summing the forces applied to the length of the blossom and calculating the time in conjunction with the applied rotational speed, revolutions per minute (RPM), results the force used for detachment. Using the coordinate frame from the center of rotation gives an applied force in the tangential direction. Note, uniform circular motion is assumed for this calculation.
[0109] One branch blossom interface system is a bud protruding 90° perpendicular to the branch. However, a biological system always presents challenges. In this case the buds or blossom formations grow randomly with varying angles from the branch. In order to overcome this dilemma a statistical analysis will be performed averaging a sample size equal to or above the normal distribution.
Experimental Design
[0110] An experimental setup for the various kinematic, heuristic, and applied force tests conducted can be used according to various aspects of the invention.
[0111] All experimental testing for the exemplary example described herein was performed at an Automation and Mechatronics Laboratory (AML). The AML facility is a 6.09 m by 4.87 m (20 ft by 16 ft) room which houses three separate test stations. The test stations can be setup to run various small-scaled experiments. Each test station has a primary computer for mechatronics control, algorithm programming, data acquisition tasks and/or advanced diagnostics. Separate cable and power access ports are also available at each test station for secondary equipment.
[0112] Test station one is 3.65 m by 0.76 m (12 ft by 2.5 ft) sectional laboratory countertop. The CPU, cameras, robotic arm, and test plate were aligned from left to right. The position of the components changed based on testing phase requirements.
Quarter-Scale Robotic Arm Hardware
[0113] A robotic arm prototype was designed and built for the study described in the present example. The robotic arm design was modeled after the industrial grade FANUC M-16iL robotic arm. The FANUC M-16iL is a double-jointed robotic arm, with six axes of rotation. The robotic arm offers a longitudinal 330° rotation, 1605 mm (5.26 ft) workspace, with an 1813 mm (5.94 ft) extended reach ( FIGS. 4.2 and 4 . 3 ). The six axes of rotations or joints are revolute and controlled by servomotor encoder combinations; see Table 4.1 for servomotors details. The M-16iL can handle payloads up to 10 kg (22 lbs).
[0000]
TABLE 4.1
M-16iL robotic arm motor specifications table
Specs
Axis 1
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
Model
AM9/3000
Model
AM9/3000
Model
A2/3000
Model
A1/3000
Model
B0.5/3000
Model
B0.5/3000
Output
18000
Output
18000
Output
5000
Output
3000
Output
200
Output
200
(Watts)
(Watts)
(Watts)
(Watts)
(Watts)
(Watts)
Volt (V)
161
Volt (V)
161
Volt (V)
129
Volt (V)
90
Volt (V)
49
Volt (V)
49
Amp (A)
6.8
Amp (A)
6.8
Amp (A)
2.4
Amp (A)
2.3
Amp (A)
2.8
Amp (A)
2.8
Freq (Hz)
200
Freq (Hz)
200
Freq (Hz)
200
Freq (Hz)
200
Freq (Hz)
200
Freq (Hz)
200
Speed
3000
Speed
3000
Speed
3000
Speed
3000
Speed
3000
Speed
3000
(1/Min)
(1/Min)
(1/Min)
(1/Min)
(1/Min)
(1/Min)
3 Phase
3 Phase
3 Phase
3 Phase
3 Phase
3 Phase
Stall Torque
9
Stall
9
Stall
2
Stall
1
Stall
0.65
Stall
0.65
(Nm)
Torque
Torque
Torque
Torque
Torque
(Nm)
(Nm)
(Nm)
(Nm)
(Nm)
@ AMP
10
@ AMP
10
@ AMP
3
@ AMP
2.3
@ AMP
2.8
@ AMP
2.8
Stall Torque
6.64
Stall
6.64
Stall
1.48
Stall
0.74
Stall
0.48
Stall
0.48
(ft * lb)
Torque
Torque
Torque
Torque
Torque
(ft * lb)
(ft * lb)
(ft * lb)
(ft * lb)
(ft * lb)
[0114] The robotic arm prototype was constructed out of an aluminum alloy 6011 (AA6011). The quarter-scale model has a longitudinal 270° rotation, 344.4 mm (1.13 ft) workspace, with and a maximum payload of 2.5 kg (5.5 lbs). The longitudinal degrees of rotation and workspace are approximately 18% and 14% percent lower, respectively, than the calculated quarter-scale values. The rotation of the quarter-scale model was reduced for simplification of the kinematic programming. The workspace was scaled down due to the torque limitations of the robotic servomotors. The revolute joints on the prototype were actuated by ROBOTIS servomotors ( FIG. 15 ). The ROBOTIS motors were connected in a daisy chain formation using a RS-485 network bus controller. See Table 4.2 for ROBOTIS servomotors details
[0000]
TABLE 4.2
Quarter-scale robotic arm motor specifications table (ROBOTIS, 2007)
RX-28
RX-64
EX-106+
Model
(Visit Product Page)
(Visit Product Page)
(Visit Product Page)
Stall Torque @ Max Voltage
3.7N · m (37.7 kg-cm)
6.3N · m (54 kg-cm)
10.9N· m (111 kg-cm)
Speed (RPM)
85
64
91
Nominal Operating Voltage
12-18.5 v
12-18.5 v
12-18.5 v
Stall Current Draw
1.9 A
2.6 A
7 A
Dimensions
35.6 × 50.6 × 35.5 mm
40.2 × 61.1 × 41 mm
40.2 × 65.1 × 46 mm
Weight
72 g
126 g
154 g
Resolution
0.29°
0.29°
0.29°
Operating Angle
300
300
251
Gear Reduction
193:1
200:1
184:1
Geartrain Material
Hardened Steel
Hardened Steel
Hardened Steel
Onboard CPU
ATMega8 (ATMEGA8-
ATMega8 (ATMEGA8-
ATMega8 (ATMEGA8-
16AU @ 16 MHZ, 8
16AU @ 16 MHZ, 8
16AU @ 16 MHZ, 8
Bit)
Bit)
Bit)
Position Sensor
Potentiometer
Potentiometer
Magnetic Encoder
Com Protocol
TTL
RS-485
RS-485
Com Speed
1 mbps
1 mbps
1 mbps
Compliance/PID
Compliance
Compliance
Compliance
[0115] As per the M-16iL design, the quarter-scale prototype can be a 6-DOF all-revolute-joint robotic arm, which is categorized as an articulated manipulator with a spherical wrist. The Denavit-Hartenberg (DH) convention is applied for describing reference frames for joints. Figure Table 4.3 provides all the DH parameters of the prototype. The zero position or default position for the robotic arm is a vertically fully extended gesture.
[0000]
TABLE 4.3
Robotic arm DH parameters table
Denavit-Hartenberg Table
i
a i-1
α i-1
d i
θ i
1
a 1
90
d 1
θ 1
2
a 2
0
0
θ 2
3
a 3
−90
0
θ 3
4
0
90
0
θ 4
5
0
−90
0
θ 5
6
0
0
d 6
θ 6
*The D-H Table variable parameter values can be found below.
[0000]
Variable Parameters
a 1
1.35
[cm]
d 1
11.40
[cm]
a 2
17.75
[cm]
d 6
6.40
[cm]
a 3
10.25
[cm]
[0116] Variables a and d in Table 4.3 represent the lengths of each respective link. While α and θ represent the angles of the common normal and new to old link respectively. Each row of Table 4.3 represents a system of linear equations, or the homogeneous transformation Ai, which can be broken into four basic transformations (Equation (20)). Note different references may have their own methods for carrying out the four transformations. Thus, the final product can look different, although they carry the same information.
[0000]
A
i
(
θ
i
)
=
Rot
z
,
θ
i
Trans
z
,
d
j
Trans
y
,
a
i
Rot
x
,
α
i
=
[
c
θ
i
-
s
θ
i
0
0
s
θ
i
c
θ
i
0
0
0
0
1
0
0
0
0
1
]
[
1
0
0
0
0
1
0
0
0
0
1
d
i
0
0
0
1
]
[
1
0
0
a
i
0
1
0
0
0
0
1
0
0
0
0
1
]
[
1
0
0
0
0
c
α
i
-
s
α
i
0
0
s
α
i
c
α
i
0
0
0
0
1
]
=
[
c
θ
i
-
s
θ
i
c
α
i
s
θ
i
s
α
i
a
i
c
θ
i
s
θ
i
c
θ
i
c
α
i
-
c
θ
i
s
α
i
a
i
s
θ
i
0
s
α
i
c
α
i
d
i
0
0
0
1
]
=
[
R
i
t
i
3
×
3
3
<
1
0
0
0
1
]
(
20
)
[0117] The general form of transformation matrix T j i , which represents frame j (or coordinate system j) with respect to frame i can be represents as seen in Equation (21).
[0000]
T
j
i
=
{
A
i
-
1
A
i
+
2
…
A
j
-
1
A
j
if
i
<
j
I
if
i
=
j
(
T
i
j
)
-
1
if
i
>
j
(
21
)
[0118] By multiplying and solving the A i series, the final transformation matrix T 0 6 can be found in Equation (22). This T 0 6 matrix transforms the coordinates from the world frame (frame 1st) to the tool frame (frame 6th).
[0000]
6
0
T
=
(
r
11
r
21
r
31
p
x
r
12
r
22
r
32
p
y
r
13
r
23
r
33
p
z
0
0
0
1
)
(
22
)
[0119] Where,
r 11 =−c 4 (c 5 s 1 s 4 +s 23 (c 1 s 5 )−c 1 c 2 c 1 c 3 c 5 +c 1 c 3 c 1 c 4 c 5 )−s 6 (c 4 s 1 −c 1 c 2 c 3 c 4 −c 1 s 2 s 3 s 4 ) r 21 =s 6 (c 1 c 4 −s 1 s 4 (c 2 c 3 +s 2 s 3 ))−c 6 (s 1 (s 23 s 5 −c 2 c 3 c 4 c 5 +c 4 c 5 s 2 s 3 )−c 1 c 5 s 4 ) r 31 =s 6 (c 123 c 46 −s 15 +s 23 (c 1 c 4 c 6 −s 4 s 6 ) r 12 =s 6 (c 5 s 1 s 4 +s 23 c 1 (s 5 −c 2 c 3 c 4 c 5 +c 2 c 3 s 2 s 3 )−c 6 (c 4 s 1 +c 1 c 2 c 3 s 4 −c 1 s 2 s 2 s 4 ) r 22 =s 6 (s 23 s 1 s 5 −c 5 (c 1 s 4 −c 2 c 3 c 3 s 1 +c 1 s 1 s 2 s 0 ))+c 6 (c 1 c 3 −c 2 c 3 s 1 s 3 +s 1 s 2 s 3 s 4 ) r 32 −−s 23 (c 6 s 1 +c 1 c 3 s 0 )−c 23 s 5 s 6 r 13 =s 1 s 2 s 3 −s 23 c 1 c 5 −c 1 c 4 s 3 (c 2 c 3 +s 3 ) r 23 =s 1 (c 4 s 2 s 3 s 5 −s 23 c 5 −c 2 c 3 c 4 s 5 )+c 1 s 4 s 5 r 33 =c 23 c 5 −s 23 c 4 s 5 p x =c 1 (a 1 +a 2 c 2 +a 3 (c 2 c 3 +s 2 s 3 ))+d 6 (c 1 c 4 s 2 s 3 s 5 −c 1 c 2 c 3 c 4 s 5 −s 1 s 4 s 0 −s 23 c 1 c 3 ) p y =s 1 (a 1 +a 2 c 2 +a 3 (c 2 s 1 +s 2 s 3 ))+d 6 (c 1 s 1 s 2 s 3 s 5 −c 2 c 3 c 4 s 1 s 5 −c 1 s 4 s 5 −s 23 c 5 s 5 ) p z =d 1 +a 2 s 2 +a 3 (c 2 s 3 +c 3 s 2 )+d 6 (c 32 c 5 −s 23 c 3 s 5 )
And,
s i =sin θ i c i =cos θ i s ij =sin(θ i +θ j ) c ij =cos(θ i +θ j )
Robotic End-Effector
[0137] The objective of the end-effector design is to remove target peach buds and/or blossoms from a branch consistently with minimal maintenance. A variety of potential blossom removing end-effector designs were considered for the study described in the present example, including air blasts, laser beams, water jets, and mechanical methods. Each of these methods are considered to be variations to the type of end effector to be used with the robotic arm machine 10 . However, for purposes of experimentation, a process of elimination approach was used in the end effector design consideration. A mechanical design simplified the problem to a force application. Two mechanical designs include a hand gripper and brush design. However, these are not meant to be limiting, and any mechanical setup capable of performing the tasks needed should be considered to be part of the invention. The brush design chosen is shown generally in FIG. 22 . The brush design offers two means of force application, a normal blunt force and axial spinning force. The hand gripper offers a blunt normal force. The preliminary end-effector design was based on functionality and requirements for a full-scale robotic arm payload. An initial design comprised two 5.08 cm (2 in) diameter 25.4 cm (10 in) and 20.32 cm (8 in) longitudinally long counter rotating brushes that open and closed at an angle from a fixed point ( FIG. 17 ). The end-effector brushes and linear actuated movement can be pneumatically powered and, as shown in the figure, weighed approximately 4.08 kg (9.0 lbs).
[0138] The end effector design can be divided into three parts; the linear actuation of the brushes, the power assembly for brush rotation, and the housing for the design. The payload restrictions for the end-effector design were 2.5 kg (5.5 lbs). The housing for the end-effector has been constructed out of an aluminum alloy 6011 (AA6011). However, other rigid metals, composites, plastics, and the like can be used. The end-effector housing was designed to attach directly to the six axis servomotor or the end of link d6, shown on FIG. 16 . The housing was 13.3 cm (5.25 in) long 12.57 cm (4.95 in) wide with mounts for a power assembly and two servo motors. FIG. 18 shows views of the end-effector housing 200 . As will be understood, the housing includes a top plate 201 having a slot 202 that will allow brushes 101 , 102 to pass through and also move in a linear manner. The housing 200 also includes a side plate 203 and a bottom plate 204 . Additional components of the housing 200 can include a railing mount and stiffener supports for adding support to the housing 200 .
[0139] The linear open and close transverse motion of the brushes is a servo motor, rail, and carriage design. While it is imagined that the end effector can be a swinging gate (angular displacement) brush delivery system of the preliminary design, the exemplary version as shown includes brushes 101 , 102 transverse linearly in one plane ( FIG. 19 ). The angular displacement of the servo motor can be converted to a linear translation. The angular displacement and brush rotation are actuated by ROBOTIS RX-28 servomotors. A displacement arm 103 can be attached to the servomotor 108 with two links 104 , 105 connected to carriages 106 , 107 on a rail system. Each link 104 , 105 is positioned at an angle of 45°, as the servo motor 108 displaces in a clockwise (CW) direction, the angle of the links increase creating a linear translation on the rail.
[0140] The diameter thickness of a fruit bearing peach shoot is approximately 0.317 cm (0.125 in) to 0.635 cm (0.250 in). Thus, the spacing for the linear motion brushes 101 , 102 when open has been designed at a width of 1.9 cm (0.75 in) for safe branch transversal. At 0° (displacement arm completely vertical) the carriages are centered and the brushes are closed, at 31° (CW) the carriages transverse the brushes to the open position ( FIG. 20 ). The carriages carried two bearings with a free spinning drive shaft that attached to the brushes.
[0141] When the brushes close on a selected blossom target, two 2.54 cm (1.0 in) neoprene idler roller wheels 110 connect to a neoprene 3.17 cm (1.25 in) driver roller 109 powered by the second servo motor 115 , mounted parallel to the wheel set. When engaged, the drive roller 109 spins the idler rollers 110 along with the brushes 101 , 102 that are attached to aluminum free spinning rollers 110 ( FIG. 21 ). The free spinning roller design allows for a non-engaged brush to simply roll over branches and/or blossoms without applying a tangential or normal force. A perspective view of an end effector 100 with associated components can be seen in FIG. 22 .
[0142] A view of the robotic arm 10 with the end effector 100 positioned thereon is shown in FIG. 43 . The arm 10 is on a base 50 , which includes a motor (not shown) mounted thereto. The base motor provides rotational movement to arm 100 and therefore, the arm can be understood to be rotatably and/or pivotably connected to the base 50 . The base 50 can be generally any shape or size capable of supporting the arm 10 . Furthermore, the base 50 may be connected to a vehicle or portion of a vehicle. Still further, it is contemplated that the base be replaced with an exoskeleton-like member that can be manipulated by a user to provide mechanical manipulation and/or activation of the arm 10 and/or end effector 100 to aid in the thinning of blossoms at a selected location.
[0143] Connected to the base 50 is a waist assembly 55 including a motor mount 56 and motors 57 , 58 . Extending from the waist assembly 55 is a lower link 12 that extends from the waist assembly 55 to an elbow assembly 20 . The motors 57 , 58 provide for rotational movement to the lower link 12 , which extends and retracts the arm 10 . The lower link 12 is a rigid member comprising steel, plastics, composites, or the like, and provides length to the arm 10 . When the arm 10 is mechanical in nature, linkages, electrical connections, or the like can be included with the lower link to transfer an electrical or mechanical activation at the base 50 to the upper or distal components of the arm 10 . The link 12 is pivotably connected to both the waist assembly 55 and the elbow assembly 20 .
[0144] The elbow 20 is an assembly including a mount member 21 housing three motors 22 . The motors 22 can provide varying movement to the upper or distal components of the arm 10 . For example, the outer motors are pivotably connected to an upper end of the lower link 12 and provide rotational movement about said connection. The middle motor is rotatably and/or pivotably connected to a rail member 23 extending distally from the elbow 20 , and provides rotational movement to the components extending therefrom. The rail member 23 extends outward from the mount 21 . Connected to the elbow 20 is a wrist assembly 30 . The wrist assembly 30 includes a first motor 31 and a second motor 32 . The second motor 32 is pivotably connected to a wrist link 33 so as to provide pivoting movement from the motor 32 to the link 33 . A portion of the wrist link 33 is sandwiched between the first motor 31 and the lower plate 204 of the housing 200 for mounting the end effector 100 . Therefore, the motor 31 provides rotational movement to the housing 200 and end effector 100 attached thereto.
[0145] The end effector has been previously shown and described, and works with the arm 10 to selectively thin blossoms on a tree. Therefore, as is understood, the links of the arm are driven to extend, retract, and/or rotate to position the end effector 100 at a location to selectively thin blossoms from a branch.
[0146] Furthermore, as mentioned, the arm 10 can include mechanical components and/or a joystick or other direction input as well as an end effector activator. The direction input can be a joystick that is manipulated by a user to position the end effector at a location. An activator, such as a trigger or other mechanism, can be included to activate the end effector by the user to remove the blossoms from the branch as the user decides, making the arm 100 more of a hand-held device.
[0147] The motors, as disclosed elsewhere in the present disclosure, can be servo motors or other types of motors. Still other variations obvious to those skilled in the art are to be considered a part of the invention. This can include more or less motors, linkages, pulleys, lighting systems, and the like.
Example
Robotic Arm Stand, Test Plate and Test Rods
[0148] The robotic arm 10 was tested by placing on a stand to mimic a vehicle in the orchard and increase the workspace range. The quarter-scale arm was elevated 22.86 cm (9 in) from ground on a platform constructed of 2.19 cm (0.865 in) thick 4130 alloy steel. The base plate is 22.86 cm (9 in) length by 15.24 cm (6 in) width and the top plate is 10.16 cm (4 in) length by 12.7 cm (5 in) width supported by eight 0.317 cm (0.125 in) 4130 steel square tubing. The platform was attached to a test plate for experimental study at test station 1 .
[0149] The experimental test plate was a 101.6 cm (40.0 in) length 64.7 cm (25.5 in) width 1.27 cm (0.50 in) thickness 4130 steel plate. The robotic arm 10 and stand was centered in width and attached to the first 22.86 cm (9 in) length 7 of the test plate. At 17.78 cm (7.0 in) length from the robotic arm stand base is a column of seventeen 2.19 cm (0.865 in) threaded holes evenly spaced 3.81 cm (1.50 in) width apart. The threaded hole pattern was repeated at 7.62 cm (3 in) intervals on the test plate length, for a total of nine rows. The Cartesian coordinate convention for the test plate and robotic arm is as follows.
[0150] x direction—Positive length of the test plate, (0 being the zero position of the robot)
[0151] y direction—Width of the plate, (0 being the middle of the test plate, − right)
[0152] z direction—Height from the plate, (0 being the surface of the plate, + up)
[0153] The experimental test plate has 153 2.19 cm (0.865 in) threaded holes for mounting of test equipment in the robotic arm workspace. Threaded rods 2.19 cm (0.865 in) in diameter were used to create branch like structures at various lengths and heights on the test plate. Target rods were created and placed at various locations for testing. The target rods were 0.865 in diameter and were signified by white, yellow and red tape. The center of the white was the target position with the median of the yellow 2.54 cm (1.0 in) in either longitudinal direction representing the first standard deviation. The yellow and red tape's longitudinal length medians indicated the first and second standard deviation respectively.
[0154] An INSTRON model No. 4444 Universal Testing machine (Instron, Norwood, Mass.) was used for the blossom removal force study. A 2.54 cm (1.0 in) nylon brush was attached to the crosshead of the INSTRON. The brush was used to apply a normal point force to the blossom. The INSTRON brush crosshead configuration had a total vertical travel of 500 mm (19.7 in) and a vertical test space of 658 mm (25.9 in). The INSTRON has a vertical test speed of 0-1000 mm/min (0-40 in/min) and a load range of 0-2000 N (0-450 lbf), with an accuracy to the nearest tenth of a kilogram/pound force. Samples were taken at a test speed of 127 mm/min (5 in/min). The INSTRON Series 4400 control panel software was used for data acquisition. The vertical transversal, time and force data were recorded and stored in Excel spreadsheets.
[0155] A Sony HDR-CX110 Digital HD Video Camera Recorder was used to capture the tangential blossom force test. The blossom removal images were recorded at 29.97 frames per second (fps) with a resolution of 640×360 pixels. The shutter speed was automatically set to 1/30 for an average record time of 48 s. The camera was placed underneath a peach branch at a 45 degree angle parallel to the blossom. The camera was fixed and mounted to the main test plate. The camera was triggered by the remote and was connected to a PC for image collection.
[0156] The Conviron GR series growth chamber was used to bloom the peach blossom cultivars used in this study. The GR growth chamber is a walk-in controlled environment unit. The chamber offers low to moderate level light intensities using multiple light canopies. The airflow design directs air downward toward the floor and then redirects the returning air upward between the plants and through the lamp canopies. The chamber also offers humidity and temperature control in conjunction with cyclic automated lighting patterns.
[0157] The peach cultivars shoots were harvested. The chamber's temperature and humidity were set at 27° C. (80.6° F.) and 80% with the lights cycling 12 hours on and 12 hours off. The peach blossom cultivars buds showed signs of pink formations within 72 hours and bloomed within 6 days in the chamber.
[0158] The vision system is a correlation-based stereo vision design used to map the blossoms in 3D space.
[0159] The stereo vision system was mounted on a flatbed trailer pulled between the tree rows by an orchard tractor ( FIG. 23 ). Three digital color cameras (model D200 with AF Nikkor 20 mm lens, NIKON Company, Japan) were mounted in a trinocular “L” configuration with the cameras spaced at 0.8 m (2.62 ft) apart. This baseline gives a theoretical accuracy of 5 mm (0.196 in) at the distance of the far blossoms. The “L” setup is chosen because the cameras form two different baselines, which make occluding shoots less likely to obstruct the view in both camera pairs, especially those aligned with one baseline. The plane of the trinocular “L” is positioned perpendicular to the “V” and inclined 45° from horizontal to allow full view of the proximal limb of the “V” that inclines into the same row containing the stereo vision system, and is approximately 3 m (9.84 ft) away. With this configuration, the trees are in the field of view, switching to 16 mm (0.629 in) lenses to view taller trees, if necessary.
[0160] The stereo images (each 2592×3872 pixels, 24 bit color) were acquired at night using high intensity flash illumination (model Porty EHT 1200, Hensel Studiotechnik GmbH & Co., Germany). Nighttime flash illumination is advantageous because it synchronizes the image acquisition, eliminating any image blurring due to light scattering, and provides a simple and effective method of segmenting the blossoms on the proximal limb from the remaining tree canopy and from the blossoms on the distal limb or on other trees in the background. After each digital stereo image triplet is acquired, the ground truth 3D locations of a set of blossoms from several shoots on the proximal limb were determined using a total station (model 55-305R, CST/Berger, Watseka, Ill.) equipped with a targeting blaser. The total station, of the quality used in this research, has a resolution of <lmm (0.04 in) in the fronto-planar plane and 3 mm (0.11 in) in depth with repeatability determined experimentally to be +/−1 mm (0.04 in).
Experimental Test Conditions—Blossom Force Test
[0161] For this example, the normal and tangential forces required to remove a peach blossom from a branch were examined. Both tests used a 2.54 cm (1.0 in) nylon test brush for loading. The normal force test used a point loading approach while the tangential force test employed a centripetal force. The centripetal and point normal force tests were performed on the Saturn and Loring cultivar respectively. Each blossom set was artificially bloomed in the Conviron growth chamber prior to testing.
[0162] The Instron crosshead brush configuration was used to conduct the normal force blossom removal tests. The blossoms shoots were fixed horizontally and vertically. The blossoms were also tested in the bud and full blossom phase (Table 4.4).
[0000]
TABLE 4.4
Blossom removal normal force case study chart
Number
Blossom
Blos-
Average
Run
of
Shoot
som
Force
Standard
No.
Date
Trials
Configuration
Stage
(lbf)
Deviation
LP01
40209
8
Hor
Bloom
0.11
0.052
LP02
40209
10
Hor
Bud
0.09
0.025
LP03
40209
10
Vert
Bloom
0.13
0.026
LP04
40209
8
Vert
Bud
0.07
0.019
LP05
41009
16
Hor
Bud
0.12
0.054
LP06
41009
10
Vert
Bud
0.16
0.050
LP07
41009
14
Vert
Bud
0.16
0.074
LP08
41309
10
Hor
Bloom
0.11
0.037
LP09
41309
12
Vert
Bloom
0.13
0.040
[0163] The top side of a thinning brush was placed on the surface of the Loring peach cultivar blossom. In the horizontal position, the shoot was attached to a wooden surface with the blossom free-floating above a 3.8 cm (1.5 in) wide rectangular cavity, creating a dynamic flexure test. In the vertical position, the shoot was clamped at the base and the free-floating blossom was positioned under the brush.
[0164] The Instron vertical test speed was fixed at a constant rate of 127 mm/min (5 in/min) for this study. The speed was set at this rate to capture the detachment of the blossom. The brush bristles were placed on the surface of the blossom as the Instron loaded the blossom. The time, linear deflection, and force were recorded until detachment of the blossom occurred. Note, the normal force tests were conducted prior to the beginning of this study by Benjamin Kemmerer a graduate student in Agricultural and Biological Engineering at The Pennsylvania State University. The normal force test information and results presented in this investigation were not previously published and were intended for this study.
[0165] The end-effector 100 provided the centripetal motion for the tangential force test. The end-effector was attached vertically to the test board. A Saturn peach cultivar shoot was attached horizontally to a 0.95 cm (⅜ in) threaded rod fixed 16.51 cm (6.5 in) above the test board surface and through the target position of the end-effector brushes. A camera was placed underneath the rod at a 45 deg angle parallel to the shoot facing the end-effector. The tangent of the end-effector brush bristles was placed on the surface of the Saturn blossom.
[0166] The speed of the brushes was increased linearly until detachment of the blossom occurred. The actuation of the servo motor that controls the spinning action of the brushes was a binary voltage step function. The binary step voltage was converted to meters per second. The experiment was recorded at 27.9 frames per second. At each binary step, increase of voltage the time was noted by voice actuation and highlighted on the frame capture (check this sentence). The tangential force study consisted of 30 recorded tests. The repetitions were chosen to meet or exceed the standard normal distribution at a 95% confidence level.
Kinematic Robotic Arm Positioning Tests
[0167] For the kinematic positioning study, four 3D points were chosen within the robotic arm workspace. The four locations were represented with target position branches. The robotic arm kinematic software (see, for example, FIG. 42 ) was then programmed with the four 3D target coordinates. The testing algorithm placed the robotic arm at each position in a random order. The robotic arm paused at each target area for measurement. The robotic arm placement 3D distance from the target position was measured with a level and calipers. The target to actual position difference was then recorded in an Excel spreadsheet. The kinematic positioning test consisted of 120 repetitions. See Table 4.5 for the target positioning test matrix. The repetitions were chosen to meet or exceed the standard normal distribution at a 95% confidence level.
[0000]
TABLE 4.5
Kinematic position case study chart
Run
Number
Target Position (cm)
No.
Date
of Trials
x
y
z
KS01
May 2, 2013
30
30.94
−11.2
17
KS02
May 2, 2013
30
38.44
0
33
KS03
May 4, 2013
30
30.94
−22.75
53
KS04
Jun. 2, 2013
30
30
0
17
End-Effector Positioning Tests
[0168] For the end-effector positioning test, three target positions were chosen within the robotic arm workspace. The three locations were represented with target position branches. The robotic arm kinematic software was then programmed with the three target coordinates. The end-effector was set at 90°, placing the branch perpendicular to the brushes. The end-effector brushes were open at a distance of 1.905 cm (0.75 in) as the robotic arm moved into position. The robotic arm paused while the end-effector brushes closed on the target at each target area for measurement. The testing algorithm placed the robotic arm and end-effector at each position in a random order. The center of rotation of the end-effector brushes was measured from target with a level and calipers. The target to actual position difference was then recorded in an Excel spreadsheet. See Table 4.6 for end-effector placement test matrix. The end-effector positioning test consisted of 90 repetitions. The repetitions were chosen to meet or exceed the standard normal distribution at a 95% confidence level.
[0000]
TABLE 4.6
End-effector position case study chart
Number
Target Position (cm)
Branch
Run No.
Date
of Trials
x
y
z
Thickness (cm)
EES01
60413
30
50.8
−9.28
38
0.825
EES02
60513
30
50.8
−23
38
0.825
EES03
60613
30
30.94
−22.75
53
0.825
Heuristic Thinning Tests
[0169] The heuristic thinning test study was conducted in two parts. For one series of tests, the blossom coordinates were manually added to the heuristic algorithm. In the second series, the vision system automatically loaded the blossoms coordinates into the heuristic thinning algorithm.
[0170] The heuristic study consisted of a test branch being mounted at an x position of 50.8 cm (20 in) and a z position of 38 cm (15 in), and placed perpendicular to the front of the robotic arm. The test branch varied from 10 cm (3.93 in), 15 cm (5.90 in) and 20 cm (7.87 in) along the y axis. Three artificial blossoms were placed every 5 cm (1.96 in). The end-effector was set at 90°, placing the branch perpendicular to the brushes. The end-effector brushes were open at a distance of 1.905 cm (0.75 in) as the robotic arm moved into position and removed the blossom according to the spatial thinning algorithm. The blossom positions with and without blossoms were then counted and recorded in an Excel spreadsheet. See Table 4.7 for the heuristic thinning test matrix. The heuristic thinning test consisted of 60 repetitions. The repetitions were chosen to meet or exceed the standard normal distribution at a 95% confidence level.
[0000]
TABLE 4.7
Heuristic thinning case study chart
Run
Branch Length
Blossom
Number
No.
Date
(cm)
count
of Trials
HT01
Sep. 21, 2013
10
6
10
HT02
Sep. 23, 2013
15
9
10
HT03
Sep. 24, 2013
20
12
10
HTV04
Sep. 24, 2013
10
6
10
HTV05
Sep. 25, 2013
15
9
10
HTV06
Sep. 26, 2013
20
12
10
*note
HTV is with vision system
Experimental Results
[0171] Experimental results of selective blossom thinning according to at least one aspect of the invention are addressed in the proceeding sections.
Blossom Force Test Analysis
[0172] The normal and tangential force required to remove a peach blossom from a fruit-producing shoot was investigated. For the normal force test, Loring peach blossoms were forced into bloom and tested using an Instron force loader. The Instron was used to simulate the perpendicular force acting on a bud and/or blossom. The shoot and blossom combination was tested horizontally and vertically for blossom removal. The blossoms were also tested in the bud and full bloom stages. The force, time and distance of blossom elongation before failure were recorded. After 98 test runs, the observed average normal force needed to remove a blossom from a shoot was approximately 0.533 N (0.12 lbf), with a confidence level of 95% and a margin of error of +/−9.9%, giving a range of 0.44 N to 0.57 N (0.10 lbf-0.13 lbf). The largest recorded force value from each test trial was used to calculate the required averaged removal force. The y axis is the force in pound force and the x axis is the time duration in seconds of the sample.
[0173] The tangential force required to remove a peach blossom from a fruit-producing shoot was simulated using the dual brush end-effector prototype. The end-effector provided the centripetal motion for the tangential force acting on the blossom. The Saturn peach cultivar was selected for this test series. The tangent of the end-effector brush bristles was placed on the surface of the Saturn blossom and increased linearly until full detachment. The time and angular velocity were concurrently recorded. After 30 test runs, the average calculated tangential force required to remove a blossom from a shoot was approximately 0.62 N (0.14 lbf), with a confidence level of 95% and a margin of error of +/−18% giving a range of 0.49 N to 0.71 N (0.11 lbf-0.16 lbf). FIG. 25 shows a sample force graph calculated after testing. The y axis is the force in pound force and the x axis is the time duration in seconds of the sample.
[0174] The resultant of the blossom force test gives us a range of 0.44 N to 0.57 N (0.10 lbf-0.13 lbf) for the normal force and 0.49 N to 0.71 N (0.11-0.16 lbf) for the tangential force. The end-effector has a tangential force capability of 5.3 N (1.19 lbf) at the brush blossom interface. The robotic arm can deliver a torque >44 N (10 lbf) at the brush blossom interface. Thus, the robotic arm with end-effector can effectively remove peach buds and/or blossoms from a branch or shoot.
Kinematic Data Analysis
[0175] In this analysis, the precision and accuracy of the robotic arm placement was studied. The robotic arm's kinematic algorithm was programmed with four 3D target coordinates. The testing algorithm then placed the robotic arm at each position in a random order. The robotic arm placement 3D distance from each target position was measured and recorded. The kinematic positioning test consisted of 120 repetitions, 30 trials at each location. FIGS. 28 through 31 show the scatter plot for each position. The positions are represented in a 2D graphical form for simplification. The x and y axis of the graph are the y and z axis, respectively, of the robotic workspace. The x axis can be considered into the figure and is noted above each target. The highlighted dot on each figure represents the target location in 2D space. The dashed red line represents a 5% error band around the target. Each trial run was represented by a blue dot. FIG. 32 presents the complete kinematic positioning test.
[0176] For positions 1 to 4 , the resultant 120 test repetitions fell within the first standard deviation of the proposed+/−2.54 cm (1 in), ( FIG. 33 ). With a confidence level of 95% and a margin of error of +/−8.96%, the robotic arm has a consistent range of −1.26 cm (0.496 in) to +1.57 cm (0.618 in) vector magnitude per target location. As seen in FIG. 34 , the vector magnitude for each trial was well within the operating conditions set for the robotic arm. Therefore, the end-effector was attached to the robotic arm for further testing.
End-Effector Positioning Analysis
[0177] For the end-effector positioning test, three target positions were chosen within the robotic arm workspace. The robotic arm kinematic software was then programmed with the three target coordinates. The end-effector brushes were set at a 90° angle perpendicular to the branches. End-effector brushes were open at a distance of 1.905 cm (0.75 in) as the robotic arm moved into position. The testing algorithm placed the robotic arm and end-effector at each position in a random order. The center of rotation of the end-effector brushes was measured from target and recorded. The end-effector positioning test consisted of 30 trials at each location for a total of 90 repetitions. FIGS. 35 through 37 show the bar graph for each position. The positions are represented in a 2D graphical form for simplification. The x and y axis of the graph are the y and z axis respectively of the robotic workspace. The x axis can be considered into the figure and is noted above each target. The black bar on each figure represents the target location in 2D space. The dashed black line represents a 5% error band around the target. Each trial run was represented with a red bar.
[0178] For positions 1 to 3 the brushes reached the proposed+/−2.54 cm (1 in) target area 100% of the time. The deviation from target to the center of the brushes were within the first standard deviation with a confidence level of 95% and a margin of error of +1-10.33%, the end-effector brushes have a consistent range of −2.97 cm (−1.1 in) to +3.04 cm (+1.2 in) per target location. Note, it was observed that as the robotic arm and end effector transverses further in the +/−y direction, the brushes reached the target area at an angle. The angle had no effect on the target area and brush surface area or interface and was neglected. It was noted here for possible concerns and corrections to a larger scale model. The angle can be calculated and corrected in the kinematic software.
Heuristic Thinning Data Analysis
[0179] A major objective of this was to investigate selective thinning of peach blossoms. A selective spatial thinning heuristic algorithm was tested. The heuristic test consisted of a series of branches that varied in length from 10 cm (3.93 in), 15 cm (5.90 in) and 20 cm (7.87 in) along the y axis, with three artificial blossoms placed approximately every 5 cm (1.96 in). The end-effector was moved into position and removed the blossom according to the spatial thinning algorithm. The blossom positions with and without blossoms were then counted and recorded. The heuristic thinning test consisted of 10 trials per length for a total of 30 repetitions.
[0180] A Boolean, or true-false approach was used for the heuristic analysis. A blossom position is considered a true or 1 value; a position without a blossom is a false or 0 reading. Therefore, we can create a sample trace based on the spatial thinning parameters set for the Saturn variety peach blossom. As seen in FIG. 39 , the Saturn (5, 8, 5, 8 . . . ) general heuristic case gives us four growth areas on a maximum fruit-bearing branch of 60 cm. The test setup for the 20 cm (7.87 in) case can be seen FIG. 40 .
[0181] When the heuristic thinning sample trace from FIG. 39 is transposed on to FIG. 40 the resulting blossom values should be in or around the designated growth zones. If the resultant blossom values are not in the growth zones the two closet blossoms to either side of the zone should be kept ( FIG. 41 ). The Boolean analysis is a quantitative visual indication of selective thinning effectiveness.
[0182] An empirical formula was created in order to calculate the thinning heuristics. A percentage value was determined for each repetition (Equation (23)). The blossom thinning percentage BTP is a rating scale based on the length of shoot and blossom count. A 100% rating is a perfectly thinned peach shoot according to the spatial heuristics. A percentage greater than 100% is an over thinned shoot and a percentage lower than 100% is an under thinned branch.
[0000]
B
T
P
=
B
C
2
*
{
Z
}
(
0.714
*
x
)
×
100
%
(
23
)
Where
BTP—Blossom Thinning Percentage
BC—Visual blossom count after heuristic thinning
{Z}=(0.714*X) Z must be rounded to a Whole Number
X—Length of peach shoot in cm
[0188] For the heuristic thinning tests of 10 cm (3.93 in), 15 cm (5.90 in) and 20 cm (7.87 in) the end-effector successfully removed the unwanted blossom in each case. The BTP for each case was 100%.
[0189] The present invention is not to be limited to the particular embodiments described herein. In particular, the present invention contemplates numerous variations in the type of ways in which embodiments of the invention may be applied to selective automated blossom thinning. The foregoing description has been presented for purposes of illustration and description. It is not intended to be an exhaustive list or limit any of the disclosure to the precise forms disclosed. It is contemplated that other alternatives or exemplary aspects are considered included in the disclosure. The description is merely examples of embodiments, processes or methods of the invention. It is understood that any other modifications, substitutions, and/or additions may be made, which are within the intended spirit and scope of the disclosure. For the foregoing, it can be seen that the disclosure accomplishes at least all of the intended objectives.
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The invention relates to an end-effector device and automated selective thinning system. The system includes vision acquisition hardware, kinematic targeting and heuristic programming, a robotic arm, and a pomologically designed end-effector. The system is utilized to improve efficiency for the fruit-thinning process in a tree orchard, such as peach thinning By automating the mechanical process of fruit thinning, selective fruit-thinners can eliminate manual labor inputs and further enhance favorable blossom removal. Automation used in conjunction with a heuristic approach provides improvements to the system. The system may also be configured as a robotic arm or as a handheld system by including a battery and switching microcontroller with handle or wrist straps. Handheld thinning devices that are mechanical in nature may also be part of the system.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for producing an unsaturated alcohol, in which an unsaturated aldehyde is hydrogenated to give a corresponding unsaturated alcohol in the presence of a novel catalyst. In particular, the present invention relates to a process for producing an α, β-unsaturated alcohol, in which an unsaturated aidehyde is used as a starting material, and only the aidehyde group in the unsaturated aidehyde is selectively hydrogenated by hydrogen transfer reaction from an alcohol in the presence of a catalyst containing the specific metallic oxide as an active ingredient, while leaving the carbon-carbon double bond as it is, to give the corresponding α, β-unsaturated alcohol.
2. Description of the Prior Art
An unsaturated aidehyde has both a carbon-carbon double bond and a carbonyl group as functional groups in the same molecule. However, it is extremely difficult to selectively reduce only one of the functional groups. In particular, in the case of an α, β-unsaturated carbonyl compound in which a double bond and a carbonyl group have a conjugated relationship with each other, an alkenyl group hydrogenates more easier than the carbonyl group. Therefore, in such case, the by-products of hydrogenation, such as saturated aldehydes and saturated alcohols, or other various by-products of condensation reaction are produced, resulting in the greater difficulty in selective hydrogenation.
Various methods have been attempted to selectively hydrogenate the aldehyde group in α, β-unsaturated aldehydes, such as acrolein, while leaving the unsaturated bond as it is, and to produce the corresponding α, β-unsaturated alcohol in high yields.
Numerous direct hydrogenating methods have been proposed. For example, there is the long-standing method using noble metals of the platinum group as catalysts (W. F. Tuley, R. Adams, J. Am. Chem. Soc., 47, 3061 (1925)); methods using catalysts mainly composed of copper-cadmium (U.S. Pat. No. 2,763,696), silver-zinc (Japanese Patent Laid-open No. 47-13010) or silver-cadmium (Japanese Patent Laid-open No. 53-18506) as catalysts able to give relatively high yield; and improved methods thereof (Japanese Patent Laid-open Nos. 64-159054 and 64-1207041).
However, the catalysts used in these methods do not exhibit enough high selectivity for the hydrogenating reaction. In addition, many of such catalysts contain harmful compounds. Therefore, from a safety point of view, they have not been used in large amounts industrially.
On the other hand, methods taking the place of those above have also been attempted, in which unsaturated alcohols are synthesized by utilizing the hydrogen transfer reaction from alcohol as a hydrogen source.
For example, there have been proposed methods using catalysts, such as catalysts containing alkali metals and alkaline earth metals, e.g., magnesium oxide, calcium oxide and lithium oxide, as active ingredients (S. A. Ballard et. al, "Advances in Catalysis" Vol. IX, Academic Press, (1957)); and catalysts represented by the general formula:
MgaXbYcOd
(in which X represents boron, aluminum, silicon, yttrium, niobium, lanthanum, etc., Y represents an alkali metal and/or an alkaline earth metal other than magnesium, O represents oxygen, and a, b, c and d are atomic ratios of Mg, X, Y and O, respectively) (Japanese Patent Laid-open No. 62-30552).
In addition, other silver-based catalysts used in direct hydrogenation have also been proposed (Japanese Patent Publication No. 51-42042).
However, the catalysts used in above methods exhibit low activity and selectivity, and the activity changes with the passage of time. Therefore, it is difficult to say that such catalysts have reached to an industrial level of use.
SUMMARY OF THE INVENTION
In order to solve the above problems, the present inventors have carried out a wide range of research concerning catalysts used for the production of unsaturated alcohols, in which an unsaturated aldehyde and an alcohol are supplied simultaneously to the catalyst layer, where hydrogen atom of the alcohol is donated to the unsaturated aldehyde to prepare an unsaturated alcohol.
As a result, the present inventors have surprisingly found that the catalysts containing at least one oxide selected from the group consisting of oxides of yttrium, lanthanum, praseodymium, neodymium and samarium as the main active ingredient, not only exhibit high activity and selectivity but also have a long life span against the reaction for the selective production of unsaturated alcohols. This result has led to the present invention.
That is, the present invention relates to a process for producing an unsaturated alcohol from an unsaturated aldehyde by using a hydrogen transfer reaction from an alcohol, which is characterized by using a catalyst that contains at least one oxide selected from the group consisting of oxides of yttrium, lanthanum, praseodymium, neodymium and samarium, as a main active ingredient, and further contains at least one oxide selected from the group consisting of oxides of manganese, calcium, strontium, chromium, magnesium, iron, cobalt, nickel, copper, zinc, zirconium, silver, cadmium, barium, cerium, lead, bismuth, boron, vanadium and tin.
DETAILED DESCRIPTION OF THE INVENTION
The main active ingredient and the supplementary active ingredient constituting the catalyst of the present invention are at least one element selected from the group consisting of yttrium, lanthanum, praseodymium, neodymium and samarium.
The catalyst of the present invention can contain at least one element selected from the group consisting of manganese, calcium, strontium, chromium, magnesium, iron, cobalt, nickel, copper, zinc, zirconium, silver, cadmium, barium, cerium, lead, bismuth, boron, vanadium and tin, as a supplementary ingredient.
In particular, catalysts containing yttrium as a main active ingredient and cobalt, zinc and/or manganese as a supplementary ingredient can give a preferable effect on the selectivity of the reaction and contribute to the improvement in yield of the objective products.
The form of such ingredients is preferably a soluble compound which can be converted into an oxide by hydrolysis or the following calcining process. Examples of such a compound include salts of inorganic or organic acids such as nitrates, sulfates, acetates, various kinds of halides, etc., and metallic organic compounds such as complex salts, chelate compounds, alkoxides, etc.
Preparation of Catalyst
The method for preparing the catalyst is not particularly limited, and any conventional method can be applied, so long as the method satisfies the requirement that the above active ingredients finally take the form of an oxide in which the ingredients are fully dispersed, such as impregnation methods, precipitation methods, coprecipitation methods, etc.
Also, any methods or steps for including the active ingredients in the catalysts can be applied arbitrarily, so long as the objects and the effects of the present invention are not substantially impaired.
For example, impregnation methods can be applied in which a precursor of a soluble active ingredient is impregnated in a pre-molded conventional porous carrier particles or fine powder, such as aluminum oxide, titanium oxide and zirconium oxide, followed by drying and calcining, to give a catalyst; and precipitation methods in which an active ingredient is precipitated from the aqueous solution of a salt of an active ingredient. In the latter method, the resulting catalyst precipitation can be used as it is, or by molding or calcining, or can be used by further supporting it on an appropriate carrier such as silica, alumina, etc.
At least one of the elements selected from the group consisting of yttrium, lanthanum, praseodymium, neodymium and samarium, constitutes the main ingredient of the catalyst of the present invention. The amount of such element to be used is within the range of 3 to 99.9 wt %, preferably 10 to 99.5 wt % of the total catalyst.
The active ingredient compound to be used is not necessarily in a pure form, and may be a so-called mixed rare earth elements which is a mixture of various kinds of rare earth elements so-called the mixed rare earth elements, and contains yttrium, etc. as a main component.
The supplementary active ingredients can be added in an arbitrary amount, so far as the amount is less than 50% of the main active ingredients.
The form of "catalyst" according to the present invention may be powdery or molded. Examples of the molded form are pillar-like, tablet, particulate, granular and plate forms.
The catalysts thus obtained have excellent properties in that high activity and high selectivity are maintained in the selective hydrogenating reaction of unsaturated aldehyde into unsaturated alcohols, even in long-duration continuous reactions.
Unsaturated aldehydes
In the present invention, as mentioned above, an unsaturated aldehyde is selectively hydrogenated to produce the corresponding unsaturated alcohol.
As the unsaturated aldehyde to be used in the present invention, there can be employed acrolein, methacrolein, crotonaldehyde, methyl vinyl ketone, cinnamaldehyde, and so on. In particular, the use of acrolein gives the most remarkable effect of the present invention.
Alcohols
The alcohol to be used as a hydrogen source in the present invention can be arbitrarily selected from primary and secondary alcohols, such as methanol, ethanol, isopropanol, 1-propanol, 1-butanol, 2-butanol, benzyl alcohol, isobutyl alcohol and cyclohexanol, by considering the availability, cost, the added value of the by-produced aldehyde and ketone, and so on.
Hydrogenating Reaction
The reaction in the method of the present invention can be carried out either in liquid phase or in vapor phase. In such reaction, the contact method can be appropriately selected from conventional known methods. For example, in the liquid phase reaction, a continuous or batchwise suspended bed method using a powdery catalyst can be employed. In the vapor phase method, not only the conventional fixed bed method, but also a fluidized bed method and a moving bed method can be employed.
In order to impart the characteristics of the present invention more effectively, the following reaction conditions are recommended:
The reaction temperature to be employed may be somewhat varied depending on the kinds of starting unsaturated aldehydes and alcohols, and so on, but is within the range of 100° to 500° C., preferably 200° to 400° C. When the temperature is lower than 100° C., the reaction rate of the unsaturated aldehyde is too low, which is not practical. On the other hand, when the temperature is greater than 500° C., the side reactions such as decomposition increase, resulting in a lowering of the selectivity of unsaturated alcohol, which is not desirable.
It is preferable that the molar ratio of alcohol/aldehyde be within the range of 0.1 to 20 and the flow rate (L.H.S.V) within the range of 0.01 to 1 hr -1 (based on aldehyde).
In the reaction, the starting materials consisting of unsaturated aldehydes and alcohols can be supplied to the catalyst layer as is, or as mixed gases in which said starting materials are diluted with adequate diluents, such as nitrogen, steam, hydrogen, etc., if necessary.
Although the reaction pressure is not particularly critical, it is preferably within the range of atmospheric pressure to 50 kg/cm 2 in the gas phase reaction, and 10 to 100 kg/cm 2 in the liquid phase reaction.
As mentioned above, according to the present invention, there can be provided an epochmaking method for producing unsaturated alcohols using novel catalysts that do not contain the harmful substances such as cadmium, contained in conventional known catalysts and which show an extremely small lowering of activity with the passage of time and have high activity and selectivity in the reaction for producing unsaturated alcohols by hydrogenated reaction of unsaturated aldehydes.
EXAMPLES
The present invention will be illustrated in more detail by the following examples.
EXAMPLE 1
Preparation of Catalysts
An aqueous solution prepared by dissolving Y(NO 3 ) 3 .6H 2 O in 250 ml of pure water at 40° C., was added to 500 ml of an aqueous solution containing ammonium carbonate as a precipitant at 40° C. The resulting precipitate was filtered off, washed with pure water sufficiently, and then dried, followed by calcining at 600° C. for 2 hours.
To the resulting calcined powder, an adequate amount of pure water was added, to give a slurry. Then, the slurry was heat-kneaded to give a clayey material, and the resultant was subjected to extrusion molding, to give tablets with dimensions of 3φ×5 mm. After drying, the tablets were further calcined at 600° C. for 3 hours. The resultant was named Catalyst 1.
Other catalysts were prepared in the same manner as above, except that La(NO 3 ) 3 .6H 2 O, Pr(NO 3 ) 3 .6H 2 O, Nd(NO 3 ) 3 .6H 2 O, Sm(NO 3 ) 3 .6H 2 O, Mg(NO 3 ) 3 .6H 2 O and Ce(NO 3 ) 3 .6H 2 O were used instead of Y(NO 3 ) 3 .6H 2 O as a starting material. The resulting catalysts were named Catalysts 2 to 5, Comparative Catalyst 1 (MgO) and Comparative catalyst 2 (Ce 2 O 3 ), respectively.
The amounts of starting nitrates and ammonium carbonate to be used in the above preparation of these catalysts, are shown in Table 1 below.
TABLE 1______________________________________ ammonium Starting nitrate carbonateCatalyst Chemical formula weight (g) weight (g)______________________________________Catalyst 1 Y(NO.sub.3).sub.3.6H.sub.2 O 101.8 60.6Catalyst 2 La(NO.sub.3).sub.3.6H.sub.2 O 79.7 42.0Catalyst 3 Pr(NO.sub.3).sub.3.6H.sub.2 O 79.1 41.5Catalyst 4 Nd(NO.sub.3).sub.3.6H.sub.2 O 78.2 40.7Catalyst 5 Sm(NO.sub.3).sub.3.6H.sub.2 O 76.5 39.3Catalyst 6 Y(NO.sub.3).sub.3.6H.sub.2 O 33.9 40.4 Sm(NO.sub.3).sub.3.6H.sub.2 O 39.3Catalyst 7 Y(NO.sub.3).sub.3.6H.sub.2 O 41.4 49.3 Pr(NO.sub.3).sub.3.6H.sub.2 O 47.0Catalyst 8 Y(NO.sub.3).sub.3.6H.sub.2 O 58.3 52.1 Nd(NO.sub.3).sub.3.6H.sub.2 O 33.4Catalyst 9 Y(NO.sub.3).sub.3.6H.sub.2 O 79.0 56.5 La(NO.sub.3).sub.3.6H.sub.2 O 17.9Catalyst 10 Y(NO.sub.3).sub.3.6H.sub.2 O 31.3 46.3 Sm(NO.sub.3).sub.3.6H.sub.2 O 36.1 Pr(NO.sub.3).sub.3.6H.sub.2 O 17.7Catalyst 11 Sm(NO.sub.3).sub.3 .6H.sub.2 O 39.3 40.4 Pr(NO.sub.3).sub.3.6H.sub.2 O 38.5Catalyst 12 Sm(NO.sub.3).sub.3.6H.sub.2 O 64.1 39.5 Nd(NO.sub.3).sub.3.6H.sub.2 O 12.6Comparative Mg(NO.sub.3).sub.3.6H.sub.2 O 190.8 169.8catalyst 1Comparative Ce(NO.sub.3).sub.3.6H.sub.2 O 79.4 41.7catalyst 2______________________________________
In 100 ml of pure water, 25 g of magnesium hydroxide and 0.6 g of boron oxide were suspended, and heated at 90° C. while being stirred sufficiently, until achieving a clayey substance. The resultant was molded into tablets (3φ×5 mm). After drying, the tablets were calcined at 600° C. for 2 hours, to give Comparative Catalyst 3 (Mg:B (atomic ratio)=100:4).
Synthesise of Unsaturated Alcohols
In a SUS reaction tube (inner diameter:16 mm) charged with 10 cc of the individual catalysts prepared in the above procedures, a mixture of acrolein and secondary butanol in a molar ratio of 1:5 was continuously supplied at 0.10 hr -1 of L.H.S.V. (based on acrolein), followed by reacting at 300° C. for 10 hours at atmospheric pressure. The reaction products were analyzed using gas chromatography. The results are shown in Table 2 below.
TABLE 2__________________________________________________________________________ Compara. Compara. Compara.Catalyst No. Catalyst 1 Catalyst 2 Catalyst 3 Catalyst 4 Catalyst 5 Catalyst 1 Catalyst 2 Catalyst 3Component Y.sub.2 O.sub.3 La.sub.2 O.sub.3 Pr.sub.2 O.sub.3 Nd.sub.2 O.sub.3 Sm.sub.2 O.sub.3 MgO Ce.sub.2 O.sub.3 Mg--B--O__________________________________________________________________________Acrolein 26.5 24.6 27.8 24.7 28.1 23.9 19.1 23.8conversion (%)Selectivity (mol %)allyl alcohol 88.5 79.3 83.8 80.6 84.1 74.2 46.4 76.9propionic aldehyde 7.3 11.8 11.0 11.0 8.4 11.3 32.2 9.7n-propanol 0.4 0.1 0.6 0.1 0.4 1.1 0.1 0.7other by-products 3.8 8.8 4.6 8.3 7.1 13.4 21.3 12.7__________________________________________________________________________
EXAMPLE 2
Catalysts 6 to 12 were prepared in the same manner as Example 1, except that mixed aqueous solution of nitrates of Y, La, Pr, Nd and Sm were used instead of Y(NO 3 ) 3 .6H 2 O.
Using these catalysts, the same reaction as Example 1 was carried out. The compositions of the prepared catalysts and the analytical results of the reaction productions are shown in Table 3.
The amounts of starting nitrates and ammonium carbonate to be used in the preparation of Catalysts 6 to 12 are shown in Table 1 above.
TABLE 3__________________________________________________________________________ Catalyst 10 Catalyst 6 Catalyst 7 Catalyst 8 Catalyst 9 Y.sub.2 O.sub.3 Catalyst 11 Catalyst 12Catalyst No. Y.sub.2 O.sub.3 Y.sub.2 O.sub.3 Y.sub.2 O.sub.3 Y.sub.2 O.sub.3 Sm.sub.2 O.sub.3 Sm.sub.2 O.sub.3 Sm.sub.2 O.sub.3Component Sm.sub.2 O.sub.3 Pr.sub.2 O.sub.3 Nd.sub.2 O.sub.3 La.sub.2 O.sub.3 Pr.sub.2 O.sub.3 Pr.sub.2 O.sub.3 Nd.sub.2 O.sub.3__________________________________________________________________________Composition 1:1 1:1 1:0.5 1:0.2 1:1:0.5 1:1 1:0.2(atomic ratio)Acrolein 28.5 27.7 25.5 26.3 30.3 28.3 28.3conversion (%)Selectivity (mol %)allyl alcohol 85.5 87.5 82.8 85.0 86.5 83.0 81.5propionic aldehyde 8.0 8.7 10.1 9.8 7.7 9.2 10.2n-propanol 0.3 0.6 0.2 0.5 0.3 0.4 0.2other by-products 6.2 3.2 6.9 4.7 5.5 7.4 8.1__________________________________________________________________________
EXAMPLE 3
Using Catalyst 1 and Comparative Catalyst 1, long-duration continuous reactions were carried out in the same manner as Example 1, except that the reaction temperature were changed with the passage of reaction time. The results are shown in Table 4 below.
TABLE 4__________________________________________________________________________ Selectivity (mol. %)Reaction Reaction Acrolein allyl propionic other by-temp. (°C.) time (hr) conversion (%) alcohol aldehyde n-propanol products__________________________________________________________________________Catalyst No. Catalyst 1Component Y.sub.2 O.sub.3300 4 39.0 86.3 7.8 0.6 5.3 10 26.5 88.5 7.3 0.4 3.8330 12 63.8 84.5 6.2 2.5 6.8 50 50.2 85.8 7.4 1.7 5.1340 54 67.9 85.1 6.5 3.3 5.1 200 -- -- -- -- -- 1000 67.2 84.6 7.3 3.5 4.6__________________________________________________________________________Catalyst No. Comparative catalyst 1Component MgO300 4 48.0 73.5 10.7 2.1 13.7 10 23.9 74.2 11.3 1.1 13.4330 12 54.3 67.8 13.6 3.0 15.6 50 34.0 68.5 14.5 2.2 14.8340 54 52.6 61.6 17.4 5.5 15.5 200 45.9 58.7 21.8 4.5 15.0 1000 -- -- -- -- --__________________________________________________________________________
EXAMPLE 4
Catalysts 13-29, 33-49 and 53-56 were prepared in the same manner as Example 1, except that mixed aqueous solution of nitrates of Y, Sm, Mg, Ca, St, Cr, Mn, Fe, Co, Ni, Cu, Zn, Zr, Ag, Cd, Ba, Ce, Pb Bi and Sn were used instead of Y(NO 3 ) 3 .6H 2 O as a starting material, with ammonium bicarbonate as a precipitant.
Using these catalysts, the same reaction as Example 1 was carried out. The compositions of the prepared catalysts and the analytical results of the reaction products are shown in Tables 5, 6 and 7.
EXAMPLE 5
An aqueous solution prepared by dissolving Y(NO 3 ) 3 .6H 2 O or Sm(NO 3 ) 3 .6H 2 O in 250 ml of pure water at 40° C. was added to 500 ml of an aqueous solution containing ammonium bicarbonate, followed by reacting at 40° C. The resulting precipitate was filtered off, washed with pure water sufficiently, added to a solution prepared by dissolving or dispersing boron oxide, ammonium methavanadate or tin oxide while being stirred sufficiently, and then dried, followed by calcining at 600° C. for 2 hours.
Using the resulting calcined powder, Catalysts 30-32 and 50-52 were prepared in the same manner as Example 1.
Using these catalysts, the same reaction as Example 1 was carried out. The compositions of the prepared catalysts and the analytical results of the reaction products are shown in Tables 5 and 6.
TABLE 5______________________________________Cat- Added Acrolein Selectivity (mol. %)alystelement conver- allyl propionic n-pro- other by-No. *1 sion (%) alcohol aldehyde panol products______________________________________13 Mg 24.0 87.9 8.8 0 3.314 Ca 25.1 86.2 10.3 0.3 3.215 Sr 23.8 86.8 9.3 0.3 3.616 Cr 20.3 87.9 8.8 0 3.317 Mn 31.1 90.6 6.6 0.3 2.518 Fe 22.1 85.9 11.0 0.7 2.419 Co 31.1 90.2 7.6 0.2 2.020 Ni 28.5 86.5 11.6 0.5 1.421 Cu 22.6 88.2 9.8 0 2.022 Zn 18.5 90.1 7.5 0.3 2.123 Zr 21.2 88.2 8.5 0 3.324 Ag 20.1 88.5 9.0 0.3 2.225 Cd 21.6 88.0 8.7 0 3.326 Ba 26.2 86.1 9.0 0.5 4.427 Ce 20.1 88.1 8.6 0 3.328 Pb 37.7 86.3 8.0 1.2 4.529 Bi 24.1 88.8 8.8 0 2.430 B 26.5 86.5 8.9 0.2 4.431 V 27.9 87.0 9.9 0.9 2.232 Sn 25.3 86.0 11.0 0.2 2.8______________________________________ *1: Catalyst composition (atomic ratio) yttrium (Y):added element = 10:1
TABLE 6______________________________________Cat- Added Acrolein Selectivity (mol. %)alystelement conver- allyl propionic n-pro- other by-No. *2 sion (%) alcohol aldehyde panol products______________________________________33 Mg 22.8 86.9 8.2 1.0 3.934 Ca 24.2 84.6 10.5 1.0 3.935 Sr 25.1 84.8 10.4 0.9 3.936 Cr 26.8 85.3 9.8 1.0 3.937 Mn 26.6 85.8 9.4 1.0 3.838 Fe 16.2 84.2 10.0 1.9 3.939 Co 30.6 84.6 10.3 1.3 3.840 Ni 27.7 85.6 9.4 1.1 3.941 Cu 29.0 85.1 10.0 1.1 3.842 Zn 28.2 85.4 9.8 1.0 3.843 Zr 23.3 85.2 10.1 0.9 3.844 Ag 25.2 85.8 9.6 0.7 3.945 Cd 20.7 84.5 10.0 1.6 3.946 Ba 24.7 85.0 9.7 1.4 3.947 Ce 21.8 85.6 9.6 1.0 3.848 Pb 40.0 84.5 8.6 2.1 4.849 Bi 26.0 85.1 9.8 1.3 3.850 B 27.6 85.6 9.9 0.9 3.651 V 26.9 85.7 9.3 1.3 3.752 Sn 23.2 84.4 10.1 1.6 3.9______________________________________ *2: Catalyst composition (atomic ratio) samarium (Sm):added element = 10:
TABLE 7______________________________________Catalyst Component Acrolein Selectivity (%)No. composition conversion (%) allyl alcohol______________________________________53 Y Ca Cu 27.5 87.1 (10) (0.5) (0.5)54 Sm Cd Mn 25.2 85.7 (10) (0.2) (0.2)55 Y Zn 20.0 89.3 (1) (1)56 Y Co 35.3 89.5 (1) (1)______________________________________ The number in () represents an atomic ratio of each element.
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This invention relates to a process for producing α, β-unsaturated alcohol, which uses unsaturated aldehyde as a starting material, and in which only the aldehyde group in the unsaturated aldehyde is selectively hydrogenated by hydrogen transfer reaction, while the carbon-carbon double bond is left as it is. The method is characterized by using a catalyst which contains at least one oxide selected from the group consisting of oxides of yttrium, lanthanum, praseodymium, neodymium and samarium, as a main active ingredient. The catalysts exhibit high activity and selectivity, as well as a long life span.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of international patent application no. PCT/DE2006/001544, filed Sep. 2, 2006 designating the United States of America, and published in German on Mar. 22, 2007 as WO 2007/031052, the entire disclosure of which is incorporated herein by reference. Priority is claimed based on Federal Republic of Germany patent application nos. DE 10 2005 043 766.4, filed Sep. 13, 2005, and DE 10 2006 007 388.6, filed Feb. 17, 2007.
BACKGROUND OF THE INVENTION
The invention relates to a hollow shaft, which has external profilings for torque transmission at its two ends, e.g., splines, wedge-shaped teeth, polygonal profiles or the like, such that the shaft sections therebetween have a smaller diameter than the profilings.
Hollow shafts of this type can be used to drive units such as oil pumps, where, for space reasons, the center section is thinner than the toothed ends.
One proposed method to produce such shafts was to form them as a single part using cold extrusion. In this case, however, one of the profilings would have to be re-expanded after the forming of the hollow shaft section. Such expansions can only be done in special, highly complex tools and require a substantial amount of additional work thereafter. This would have caused substantial additional costs.
SUMMARY OF THE INVENTION
It was therefore an object of the present invention to provide a hollow shaft of the above-described type, which is distinguished by its particularly simple, cost-effective and rapid manufacture and high precision.
A further object was to provide methods for its cost-effective, rapid and precise production.
According to the invention, these objects are achieved by a shaft assemblable or assembled from two components, one of which comprises the hollow shaft section and the one profile as well as an external torque-transmitting slip joint on the shaft side opposite the profile, and the other of which is a sleeve-like component having the second profile and an internal torque-transmitting profile of a slip joint.
It is advantageous if the hollow-shaft-type section, the profilings and the one profile of the slip joint of the one component and/or the other component are formed from a solid blank using cold extrusion.
It can be advantageous if an interference fit is provided between the internal and external profiles of the slip joint to prevent the sleeve from falling off the shaft-like section after mounting during transport, handling or assembly.
If the two profilings provided on the shaft ends have different diameters, it is advantageous if the smaller profiling is provided on the sleeve-like component and the larger profiling is integrally formed with the tubular section.
To produce the hollow shaft section with a torque-transmitting profiling, such as an external spline profile, which is formed at its one end and has a larger diameter than the shaft diameter, and a torque-transmitting external profile of a slip joint provided on the opposite shaft end, it is advantageous to provide at least some of the process steps listed below:
a) cutting a material blank from bar stock to length, b) a first cupping to form a cup-like hollow region with a solid extension, such that the cup region corresponds at least approximately to the inside and the outside diameter of the profile section, c) a second cupping to lengthen the hollow region from the extension using cold extrusion, d) perforating the cup's bottom, e) tube extrusion to begin to form the hollow shaft body using cold extrusion, f) a first reduction of the diameter and the wall thickness and lengthening of the hollow shaft section produced in step e) and forming a neck portion that is thicker than the outside hollow shaft diameter adjoining the region intended to form the profiling, using cold extrusion, g) a second reduction starting at least approximately from the annular neck portion and lengthening of the hollow shaft section produced in step f) using cold extrusion, h) final pressing by cold extrusion of the profile region to form the external teeth by inserting a mandrel into the internal contour of the profile region with the same diameter, such that an annular die surrounding the mandrel penetrates the end face of the end region and thereby displaces material into the counterteeth of a die placed around the region intended to form the teeth, thereby forming an axial projection, i) optionally and simultaneously with step h), producing the external profile of the slip joint in the region of the hollow shaft opposite the profile region using cold extrusion, and j) removing the projection by turning.
To produce the bushing with the external profiling and an internal profile of a slip joint, at least some of the process steps listed below can be particularly advantageous:
a) cutting a material blank from bar stock to length, b) cupping and simultaneously forming the internal profile of the slip joint, preferably to the finished profile dimension, using cold extrusion, c) perforating the cup's bottom, d) turning the outside diameter, e) producing the external profile using cold extrusion by inserting a mandrel with a profile corresponding to the internal profile of the slip joint into the internal profile, such that an annular die surrounding the mandrel penetrates the end face opposite the perforated bottom and thereby displaces material into the counterteeth of a die previously placed around the region intended to form the external profile, thereby forming an axial projection, and f) turning the bushing height to the finished dimensions and thereby removing the axial projection.
For the further production of a hollow shaft at least three of the steps listed below can be particularly advantageous, either before or after mounting or pressing the sleeve onto the shaft via the slip joint:
a) turning the portion within the profile region formed integrally with the shaft profile to form a bearing seat, b) forming a recess in the outer end region of the profile, c) forming a chamfer at the beginning of the internal contour in the region of the profile, and d) forming an undercut in the end region of the cylindrical internal contour in the region of the profile.
It can be advantageous to carry out a heat treatment or surface treatment, particularly soft annealing, between some of the process steps to resoften the material whose structure was hardened by cold forming in the previous steps, e.g., when producing the hollow shaft body with the first profile formed onto it, between steps b) and c), d) and e), e) and f), f) and g), and g) and h), or, when producing the sleeve, between steps d) and e).
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in further detail hereinafter with reference to illustrative embodiments depicted in the accompanying drawing figures in which:
FIG. 1 shows a hollow shaft according to the invention or a hollow shaft produced using a method according to the invention;
FIG. 2 is a schematic depiction of a blank or workpiece produced by sawing or cutting stock material;
FIG. 3 is a schematic representation of the workpiece after a first cupping step;
FIG. 4 is a schematic representation of the workpiece after a second cupping step;
FIG. 5 is a schematic representation of the workpiece after a bottom perforating step;
FIG. 6 is a schematic representation of the workpiece after a hollow flow pressing or tube extrusion step;
FIG. 7 is a schematic representation of the workpiece after a first size reduction and lengthening step;
FIG. 8 is a schematic representation of the workpiece after a second diameter reduction step;
FIG. 9 is a schematic representation of the workpiece after a final pressing step;
FIG. 10 is an enlarged detail view of the area X of FIG. 9 ;
FIG. 11 is a cross sectional view of the workpiece taken along line XI-XI of FIG. 9 ;
FIG. 12 is a schematic representation of the workpiece after a length turning step;
FIG. 13 is a schematic depiction of another blank or workpiece produced by sawing or cutting stock material;
FIG. 14 is a schematic representation of the workpiece after a cupping step;
FIG. 15 is a top view of the workpiece in the direction of arrow XV of FIG. 14 ;
FIG. 16 is a schematic representation of the workpiece after a bottom perforating step;
FIG. 17 is a schematic representation of the workpiece after a first turning step;
FIG. 18 is a schematic representation of the workpiece after a tooth forming and reducing step; and
FIG. 19 is a schematic representation of the workpiece after a second turning step.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The oil pump shaft 1 shown in FIG. 1 is a hollow shaft and has external profilings at its ends in the form of shaft profilings or splines 2 , 3 . Between the two profile zones 2 , 3 is a tubular section 4 , which, at least in partial areas, has a smaller diameter than the profilings 2 , 3 .
In the present example, profile 3 and the tubular section 4 are formed integrally or as a single part. Sleeve 7 , which is provided with profile 2 , is mounted to the end of the shaft opposite profile 3 via a torque-transmitting slip joint 5 , 6 , which will be described in more detail below. The slip joint 5 , 6 is configured as an interference fit. The tubular section 4 and the profile section 3 integrally formed therewith as well as the sleeve 7 are produced by cold forming as described below, at least with respect to their functional areas.
FIG. 2 shows a blank or workpiece 8 cut to length from bar stock, in this case by sawing.
Using a cold extrusion process, a component 9 as shown in FIG. 3 is produced from this blank in a “first cupping” process step.
The sleeve-like part identified by 10 in FIG. 4 is produced by cold extrusion in a “second cupping” process step.
In a perforation process step, the bottom 11 (see FIG. 4 ) of the sleeve-like component 10 is removed to create a component 12 without a bottom as illustrated in FIG. 5 .
Then, in a tube extrusion or hollow flow pressing process step, material is essentially displaced from region 13 as shown in FIG. 5 to produce the hollow region 14 of component 15 as illustrated in FIG. 6 .
In the “first reduction” process step, the hollow shaft section 16 of component 17 illustrated in FIG. 7 is essentially produced from the region 14 shown in FIG. 6 . A neck portion 18 adjoining the region intended to create the profile 3 is also formed.
In a subsequent “second reduction” process step, the section identified as 16 in FIG. 7 is tapered by cold extrusion starting at least approximately from the neck-shaped portion 18 shown there, and the hollow shaft section 20 of a component 21 is produced as shown in FIG. 8 .
The component 22 shown in FIG. 9 is provided in a “final pressing” process step with the external profiling 3 . This external profiling 3 is clearly visible in FIG. 10 , which shows an enlarged detail X of FIG. 9 . In the same “final pressing” process step, profiling 5 , i.e., a polygon for a torque-transmitting slip joint can be formed at the ends of the hollow shaft section 23 opposite splines 3 . This detail is illustrated in an enlargement depicted in FIG. 11 , which shows a section taken along line XI-XI of FIG. 9 .
The profiling 3 is formed by placing a die “B”, which is provided with a counterprofiling, around the profile forming region identified by reference numeral 19 in FIG. 8 . A mandrel “A” is then inserted into the interior contour of region 19 and an annular die—a part of which, identified as 25 , is shown in FIG. 10 —is driven or forced against the end face 26 (see FIG. 8 ), penetrates region 19 and displaces material into the teeth of the die to form teeth 3 . In this process, a projection 27 is also formed, as may be seen particularly in FIG. 10 .
The projection 27 is removed by turning at line 28 in a “length turning” process step to form the hollow shaft as illustrated in FIG. 12 with its region 4 and the splined region 3 integrally provided thereon and with the external profile 6 of a slip joint as shown in FIG. 1 .
The sleeve 7 with external profile 2 and external profile 6 of a slip joint is produced as illustrated in FIGS. 13 to 19 .
In a sawing or cutting process step, a blank 30 is formed as illustrated in FIG. 13 .
A cup-shaped component 31 with a cylindrical region 32 and a bottom 33 as illustrated in FIG. 14 is produced in a cold extrusion “cupping” process step. The internal profile 5 of the torque-transmitting slip joint in the form of a polygon also is produced in the cold extrusion step illustrated in FIG. 14 .
The interal profiling 5 is clearly visible in FIG. 15 , which shows a top view in the direction of arrow XV-XV in FIG. 14 .
The bottom 33 (see FIG. 15 ) of the workpiece is partly removed in a “perforation” process step as illustrated in FIG. 16 .
In a “first turning” process step, the outside diameter 34 of the sleeve-like component 7 illustrated in FIG. 17 is turned.
In the “tooth forming and reducing” process step, the external profile 2 shown in FIG. 19 is produced in essentially the same manner as the process step for producing profile 3 illustrated in FIG. 9 .
In the process step in which sleeve 7 is provided with the toothed profile 2 shown in FIG. 19 , a mandrel corresponding to profiling 5 is again axially inserted into profile 5 and an annular die 35 drives against the end face 36 ( FIG. 18 ), such that material from the end face region is displaced by cold extrusion into the counterprofile of a die, which is provided with the countershape of profiling 2 and which is placed around the cylindrical outside diameter 34 . A projection 37 created in this process is removed in a “second turning” process step as illustrated in FIG. 19 .
Region 38 , which may serve as a bearing seat, can be formed by turning before, or even after, assembly of components 4 and 7 . A recess 39 is turned in the outer end region of profile 3 . Likewise, a chamfer 40 and an undercut 41 are turned at the end of the cylindrical region 38 .
The foregoing description and examples have been set forth merely to illustrate the invention and are not intended to be limiting. Since modifications of the described embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed broadly to include all variations within the scope of the appended claims and equivalents thereof.
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A method of producing a hollow shaft having first and second profilings provided for torque transmission at respective ends thereof, wherein a shaft section between the ends has a smaller diameter than at least one of the profilings, and the hollow shaft is assembled from hollow shaft and sleeve components joined via a torque-transmitting slip joint, in which the shaft and sleeve components are each formed from cut blanks by cupping, perforating. cold extrusion and turning steps, and the respective components are assembled to each other.
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FIELD OF THE INVENTION
The present invention relates to parabolic trough solar concentrators and, more particularly, to a parabolic concentrator with improved PV cell cooling with plus means to collect heat energy for beneficial use, structurally integrated radiator, and integrating aerodynamic elements for controlling wind induced forces while also providing stiffness.
DESCRIPTION OF THE PROBLEM
The cost of parabolic concentrators and all solar power systems in general is one of the paramount problems of widespread adoption of solar energy. Many systems have solved the basic implementation problems associated with parabolic concentrators. However, these systems have in general used discrete components for each base requirement, i.e. mirror, structure, cooling, etc, as opposed to a highly integrated structure. In order to capitalize on the potential cost savings of concentrating light the structural weight of parabolic concentrators must be reduced while maintaining stiffness and performance, which may only be achieved by utilizing a highly integrated structure such as a unibody structure. Additionally there is a question of light utilization; once the sunlight is concentrated, CPV systems typically convert the light via PV cell and dissipate the remaining heat. The proportion of sunlight converted to heat is approximately four times the amount converted to electricity. Concentrated photovoltaic and thermal (CPVT) systems need to be developed that can capture the otherwise wasted heat for beneficial use, thus altering the economics of solar. Traditionally, concentrated photovoltaic (CPV) systems use passive cooling for the PV cells; this is material intensive, uncontrollable, and eliminates the possibility of collecting the heat for beneficial use. With passive cooling, cell temperatures may get too hot and in some cases exceed acceptable operating limits, which reduces the efficiency and shortens cell life. Parabolic trough concentrators have a linear focus; typically the PV array is disposed at or near the focal point or focal line. Mostly standard techniques have been employed to build the small linear arrays for parabolic trough concentrators. Standard array tabbing techniques do not allow for ultra close cell spacing, i.e. less then 1 mm. Thus, a significant portion of light may fall between the cells and be unavailable for conversion, i.e. lost.
Another problem can arise due to the aerodynamics of parabolic troughs. Parabolic trough solar concentrators are wing like in cross section and therefore can produce undesirable forces (i.e., lift and torque) in high speed wind conditions. These forces may damage the trough or associated structures they are mounted on/to (e.g., the roof). Washing of parabolic troughs is traditionally accomplished by spraying water from a passing vehicle; this is time consuming, costly and wasteful of water. Most parabolic troughs are shipped from the factory in some state of disassembly and require significant assembly in the field before installation, increasing installation labor cost.
BACKGROUND OF THE STATE OF THE ART
Cooling is critical to the success of concentrator systems that focus light onto photovoltaic cell(s), otherwise known as Concentrated Photovoltaic (CPV). Cell cooling in these systems may be either passive or active. Most CPV systems currently rely on passive cooling. While passive cooling has obvious advantages, such as simplicity and reliability, it has the significant disadvantages of being material intensive and therefore costly as well as uncontrollable, and less effective than a typical active cooling system. Passive cooling heat sinks are typically Aluminum with high surface area that is required for natural convection heat transfer; this mass of Aluminum is a significant cost component for CPV systems. Further cooling elements usually only add weight to a system but do not significant increase the structural strength, if at all. Such compact passive heat sinks with high surface area benefit very little from radiation heat transfer to the environment. In addition, because CPV systems use passive cooling to dissipate the heat from the PV cells to the atmosphere, there is little or no possibility of collecting the heat for beneficial uses. Such as can be done with emerging Concentrated Photovoltaic & Thermal (CPVT), essentially a subclass of CPV, whereby the Photovoltaic (PV) cell is actively cooled and heat is captured in a liquid heat transfer medium for beneficial use or to be dissipated elsewhere.
Typical parabolic trough concentrated PV system use a single reflection to focus light onto the PV cells. This has the advantage of not incurring losses from a second or successive reflection. However, it has the disadvantage that during the tracking of the sunlight either some light must be lost or the PV cell will have some dark areas, or a combination of both. Additionally, with the dispersion of the concentrated light due to solar ray angle, imperfect specular reflection, as well as various tolerances, limit the maximum concentration. To avoid this problem it is necessary to reflect at least a portion of the light a second time.
In flat panel PV modules spacing between the PV cells is not of critical importance, thusly spacing of several millimeters is acceptable. However, in CPV systems, where great care and cost have been expended to collect the light to a narrow linear focus, cell spacing is important. The traditional methods of tabbing solar cells to form the module into a string technically works, but with the cost of lost concentrated light and thereby efficiency. A fraction of a millimeter, the minimum to provide electrical isolation, is optimal for a parabolic trough CPV cell array.
In the state of the art parabolic troughs and other such linear concentrators for CPV, the PV cell buss bars are exposed to the concentrated light. This directly reduces the efficiency by the proportion of area covered by the buss bar since the light is reflected away from the cell and/or converted into heat. To reduce or eliminate this loss the buss bars should be removed or protected from the concentrated light. In concentrator cells, the proportion of buss bar coverage to active cell area can be high, even 20% or more. A typical technique for this has been to use rear surface contacts only. However, this is a costly and largely unnecessary approach for many applications.
In the state of the art parabolic concentrators for both CPV and concentrated thermal applications, little or no attention has been paid to controlling, reducing, and/or minimizing the resultant forces of lift and torque due to high speed winds, i.e. in excess of 90 mph. In high speed wind conditions, a parabola may have very high lift, several thousands of pounds force depending on the trough size. In conjunction with lift, they may also develop high torque, sufficient to damage the structure or break the constraints holding it from turning. If aerodynamically unmodified troughs are placed on rooftops, significant damage may occur to the structure do to high speed winds.
In all environments, mirrored surfaces of parabolic troughs require cleaning at various periodicities. This is usually accomplished by spraying the mirrors with water from a vehicle with a water tank and spray apparatus, which drives by the parabola.
This invention is warranted by the shortcomings of other parabolic trough concentrators. Specifically, the following areas are poorly or have entirely not been addressed: aerodynamic issues; material intensity, which contributes to high cost; concentrated light utilization, only converting a minor portion of concentrated light to electricity for beneficial use and then throwing away the heat as opposed to collecting it for beneficial use also; using passive cooling, those few systems which use active cooling use centralized heat exchangers as opposed to each trough having its own built in radiator which is much more efficient in terms of parasitic cooling loads and is more cost effective than centralized cooling.
OBJECTS OF THE INVENTION
It is an object of the invention to improve the aerodynamic performance of parabolic trough concentrators.
It is another object of the invention to provide a means of reducing and balancing the resultant aerodynamic forces due to high winds.
It is another object of the invention to provide aerodynamic flow spoilers along the longitudinal edges.
It is another object of the invention to integrate aerodynamic flow spoiler elements to increase stiffness of parabolic trough structures.
It is another object of the invention to provide an aerodynamic element disposed below the vertex of the parabola parallel to the longitudinal axis.
It is another object of the invention to have aerodynamic elements work together to control aerodynamic forces resulting from high speed winds.
It is another object of the invention to increase the stiffness of parabolic trough structures.
It is another object of the invention to reduce the mass per unit area of parabolic trough concentrators.
It is another object of the invention to improve the cooling of PV cells in CPV applications.
It is another object of the invention to provide a liquid cooled receiver design.
It is another object of the invention to provide a means of mixing the heat exchange liquid in the receiver fluid channels such that there is low pressure drop and low parasitic power consumption for pumping,
It is another object of the invention to provide a means of providing increased heat transfer by continuously mixing the fluid flow, which disrupts the formation of a boundary layer.
It is another object of the invention to incorporate the radiator into the structure of the parabolic trough concentrator.
It is another object of the invention to improve the dissipation of heat, collected from cooling the PV cells, by a radiator which appreciably uses both convection and radiation heat transfer to the environment.
It is another object of the invention to improve the airflow through a radiator by using multiple tubes disposed periodically along the long axis of the back surface of the trough.
It is an object of the invention to in improve convection cooling by providing airflow passages disposed between the radiator and back shell components.
It is an object of the invention to provide vent holes to facilitate airflow in and/or out of the airflow passages.
It is another object of the invention to provide a means of distributing the heated liquid predominately evenly among the tubes of the radiator.
It is another object of the invention to provide a means of collecting heat, from heated PV cells, for beneficial use.
It is another object of the invention to provide a liquid cooled receiver design that can capture the heat from the PV cell for beneficial use or for removing the heat to the radiator.
It is another object of this invention to provide a means of replacing and/or upgrading the PV cells by exchanging the receiver or replacing the PV cells on the existing receiver.
It is another object of this invention to provide a means of changing and/or upgrading the receiver in the field.
It is another object of this invention to provide a means of manufacturing a receiver for CPV and/or CPVT applications.
It is another object of the invention to provide a means for supporting a receiver combined with a means for delivering heat exchange fluid to that receiver, in order to reduce light blockage and cost as well as to facilitate ease of installation.
It is another object of this invention to provide a means of connecting and securing a receiver to the supports.
It is another object of this invention to provide a pattern of concentration of light reflected from the main mirror to the receiver.
It is another object of this invention to provide a pattern of concentration of light reflected from the main mirror which exhibits a dual focal point for focusing onto a CPV receiver.
It is another object of this invention to provide secondary mirrors along both sided of the PV array as means for reflecting a portion of the solar rays a second time before they strike the surface of the PV cells or face of a thermal receiver.
It is another object of this invention to provide another secondary mirror displaced above the centerline of the PV array for reflecting an additional portion of the concentrated rays and redirecting them onto the face of the PV array or face of a thermal receiver.
It is another object of the invention to provide a PV cell layout, including buss bar location and sizing.
It is another object of the invention to provide means for evenly distributing the concentrated solar rays onto the face of the PV cells.
It is another object of the invention to provide alternative means for evenly distributing the concentrated solar rays onto the face of the PV cells.
It is another object of the invention to improve the utilization of concentrated solar rays by reducing blockage to the face of the solar cell, i.e. buss bar and thereby limiting losses.
It is another object of the invention to provide and aerodynamic shape to the receiver.
It is another object of the invention to provide a passage(s) in the receiver for wires, diodes etc.
It is another object of the invention to provide alternative means to electrically interconnecting solar cells in a string.
It is another object of the invention to provide decrease resistance in the electrically interconnect of solar cells, compared to state of the art tabbing.
It is another object of the invention to provide a means of close coupling (i.e. less than 1 mm) for solar PV cells in a string array.
It is another object of the invention to provide a convenient means of attaching diodes and/or wires to the cell electrical interconnect device.
It is another object of the invention to provide means for mounting solar tracking and alignment device in the receiver.
It is another object of the invention to increase the ease of and lower cost of maintenance by providing means for automated mirror washing.
It is another object of the invention to provide for easy and efficient shipping of the factory assembled parabolic trough concentrators; by allow the troughs to be packed in a nested fashion.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a parabolic trough solar concentrator typified by a highly integrated structure, whereby various, otherwise typically discrete, components are combined such that they work together to increase strength and performance while reducing weight.
This invention is a group of design features and elements intended to address the cost and performance of the state of the art parabolic trough. It is the general vision of the inventor that in order to be cost effective a solar energy concentrator system must reduce material intensity and improve performance. Therefore, a solar power module must be as materially efficient as possible. Concentrated PV offers the opportunity to use very small amounts of PV cells leaving open opportunity for entrepreneurs to design concentrator structures that minimize material structural weight and thereby cost. In order to reduce the weight and thereby the commodity cost of the materials required, the trough structure should be highly integrated to reduce cost and increase strength. By utilizing a highly integrated structure whereby various typically discrete components are combined such that they work together to form an integrated unibody structure, cost may be reduced and strength increased. For example, aerodynamic elements can be used to increase structural rigidity. Likewise, cooling elements, aka a radiator, can also be integrated into the structure to dissipate heat and increase stiffness, analogous to the concept of a unibody automobile. The aerodynamic features increase strength and reduce harmful and unwanted forces due to high wind speeds, thus making it stronger and reducing the required strength simultaneously.
Further, the present invention includes a liquid cooled receiver for active cooling for the PV cells. In conjunction with the liquid cooled receiver, each parabolic trough concentrator, for CPV applications, has its own radiator structurally integrated into the back side of the trough to dissipate the heat.
As an added bonus, locally dissipating the heat from cooling the PV cells reduces parasitic pumping losses as well as eliminating electric fans and a generally expensive central heat exchanger, and is an overall significant cost saving when implementing a parabolic trough CPV system.
Alternatively, as envisioned by this invention, the heat thus collected from the liquid cooled receiver can be collected for beneficial use. The cooling fluid once heated by passing through the receiver would be collected for use in water heating, building heating, driving an absorption chiller, or numerous other industrial processes. This is referred to as Concentrated PV and Thermal (CPTV).
As further explanation, the cooling elements, hereby called the radiator, should not merely function as cooling system, it should also function as a structural element, supplementing and/or replacing strength from other elements of the structure. When properly implemented, the radiator can offset its cost by reduce the cost of existing structure and by serving a dual role as both a cooling element and a structural component. This dual role, while not required by this patent, benefits to a great extent the economy of implementing solar power. In alternative configurations, the elements also do not need to be integrated into the unibody structure. This would still serve the purpose of controlling the aerodynamic forces but as a discrete add on component. In another alternative configuration, the radiator is not integrated into the unibody structure but is still distributed on the backside of the trough in order to dissipate the heat.
Another aspect of this invention is the secondary mirrors, called side mirrors and the apex mirror, incorporated into the receiver. They serve three important purposes: to redirect a portion of the concentrated light onto the solar cells, producing an even light distribution for the full range of motion between the trough and the direct solar rays; the side mirrors predominately hiding the bus bars of the solar cells from contact by concentrated light, thereby improving the utilization of the concentrated light by reducing losses; and the secondary mirrors allowing a greater degree of concentration by further focusing the already concentrated light.
Further elements of this invention include: a device for the close connection of solar cells to minimize the light lost in the gap between cells in an array; a means of mounting and aligning a solar tracking device; a means for automated washing of the mirror; trough design that permits efficient packing of the parabolic troughs for shipping; as well as techniques for manufacturing components; and other various complementary features.
BRIEF DESCRIPTION OF THE DRAWINGS
A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent, detailed description, in which:
FIG. 1 is a perspective view of a basic parabolic trough concentrator 10 without improvements, primary trough components are: mirror 11 ; and generic receiver supports 5 ; generic receiver 3 ; mounting and pivot points 12 ; and back shell 100 ; which is composed of back shell ribs 120 connected by back shell sheet 110 .
FIG. 2 is an exploded view of FIG. 1 .
FIG. 3 is an exploded perspective view of some main elements of an improved parabolic trough to be added to basic trough 10 . Radiator plenum 430 A&B at either end of the radiator 40 , anti-lift aero balance tube 20 , anti lift tube mount 210 , anti lift tube bracket 220 , 15 A&B are both aerodynamic spoiler and stiffener, mounting and pivot block 12 , back shell sheet 110 and back shell ribs 120 form the primary structural elements of the back shell 100 , generic receiver 3 and generic support 5 of FIG. 1 have been replace by elements of this invention 30 & 50 respectively, 30 an improved CPV receiver, 50 A&B are fluid riser and receiver supports located at opposite ends of the receiver.
FIG. 4 is a top perspective view of an improved parabolic trough concentrator. 10 is the overall basic body of a parabolic trough, 11 is a mirror, 51 A&B are simple receiver supports space in the midsection of the receiver, 18 are stabilizer wires for the receiver, a multitude of vent holes 105 can be seen spaced along a side rail 140 .
FIG. 5 is a bottom perspective view of an improved parabolic trough. This fully shows the coverage of radiator 40 , and anti-lift aero balance tube 20 .
FIG. 6 is an end view of an improved trough assembly.
FIG. 7 is detail A view from FIG. 6 , of a cross section of the aerodynamic spoiler and stiffener 15 . Shown are aerodynamic spoiler and stiffener 15 has two primary parts, lower lip 152 , which extends below the rim of the parabola and upper lip 151 which extents above the rim of the parabola, a side rail 140 , and mirror wash tube 16 .
FIG. 8 is a close up perspective view of a section of the radiator 40 , rows of louvers 410 and rows of parallel tubes 420 interspaced between louvers, which extend generally the length of the trough.
FIG. 8A is a perspective view of an alternative configuration for radiator 40 , rows of parallel tubes 420 A spaced periodically, which extend generally the length of the trough. The tubes 420 A spaced by means of spacers 450 . Tubes 420 A are terminated in the radiator plenum 430 at both ends of the trough.
FIG. 9 is a longitudinal cross section view of an improved trough showing cooling channels 130 bounded by back shell ribs 120 on two sides, a back sheet 110 , and a radiator 40 . Mirror 11 is shown for reference.
FIG. 10 is a section view of a fluid riser 50 attached to receiver by means of a fitting 520 , which is threaded onto nipple 522 , which is attached to receiver 30 , and sealed by means of an o-ring 521 , wire attachment ring 530 is provided for attachment of stabilizing wires 18 of FIG. 6 .
FIG. 11 is a perspective view of a CPV receiver 30 . Coolant fluid flow mixers 80 A&B, which are located in the internal receiver fluid channels, are revealed.
FIG. 12 is a section view of a concentrated photovoltaic receiver 30 , a general rounded aerodynamic shape of receiver can be seen. 60 is an encapsulated solar array mounted on the heat transfer wall of the receiver (aka receiver face), receiver fluid channels 310 A&B opposite solar array mounting face, chambers 320 A&B along either side of the solar array are passages for wires, 630 A&B are PV cell buss bars hidden from sunlight by small side mirrors 330 A&B. 340 is solar alignment channel for locating solar tracking device. 350 is the Apex mirror for secondary concentration.
FIG. 13 is a detail view B from FIG. 12 . It shows solar cell 620 with interconnect 611 attached to PV cell buss bar 630 A. 601 A&B are front and back encapsulation layers respectively.
FIG. 14 is a perspective view of a PV cell interconnects 611 and 612 connecting cells, anode to cathode of PV cells 620 in a string, PV cell 620 back side (non-sun facing side) is shown in this view, PV cell buss bars are not visible.
FIG. 15 is a top view of a PV cell interconnects 611 and 612 connecting cells, anode to cathode of PV cells 620 , PV cell 620 back side (non-sun facing side) is shown in this view, PV cell buss bars are not visible.
FIG. 16 is a section view along line c-c from FIG. 15 .
FIG. 17 is a detail view of D from FIG. 16 . This shows a close up of a cross section of an interconnect 611 as connected to a cell 620 with buss bar 630 A.
FIG. 18 is perspective views of a cell interconnects, oppositely folded 611 & 612 and unfolded 610 (i.e. as stamped blank) interconnect device. 606 A&B are tabs that are to be soldered to the PV cell anode and cathode. 608 is a small through hole stamped in interconnect for location of cell isolation rod.
FIG. 19 is an end view of overall general light concentration pattern for a cross section of the trough, with idealized parallel rays and perfect specular reflection from the main mirror 11 .
FIG. 19A is an end view of overall general light concentration pattern for a cross section of the trough, with non-parallel solar rays and imperfect specular reflection from the main mirror 11 .
FIG. 20 is a cross section close up, at the receiver, of the pattern of light concentration shown in FIG. 19 , it also shows a portion of the rays reflected by the side mirrors and the apex mirror. This is the concentration pattern of idealized parallel rays and perfect specular reflection.
FIG. 20A is also a cross section close up, at the receiver, of the pattern of light concentration shown in FIG. 19A , it also shows a portion of the rays reflected by the side mirrors and the apex mirror. This is the concentration patter of real solar rays and imperfect specular reflection.
FIG. 21 is a cross section close up, at the receiver, of the concentration pattern of parallel incoming rays with perfect specular reflection, when the trough is 0.075 degrees off center i.e. during solar tracking.
FIG. 21A is a cross section close up, at the receiver, of the concentration pattern of real incoming solar rays with imperfect specular reflection, when the trough is 0.075 degrees off center i.e. during solar tracking, i.e. the same as FIG. 21 but with non-idealized rays and imperfect reflection.
FIG. 22 is a cross section view of an alternative method of distributing and maintaining even distribution of concentrated light over the cell(s) using a single focal point pattern, the side mirror faces are perpendicular to the cell face.
FIG. 23 is a end view of a trough module with the air flow pattern for 60 m/s (134 mph).
FIG. 24 is a plan view of a nested stack of troughs for shipping.
For purposes of clarity and brevity, like elements and components will bear the same designations and numbering throughout the Figures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Whereas it is desirable to use parabolic troughs for concentrated solar for CPV and CPVT applications to reduce cost and increase efficiency, in general as compared to non-concentrated. It is necessary to improve on the cost and performance of the state of the art parabolic trough concentrator for both thermal and CPV applications.
This invention provides for improvements in the structure of parabolic troughs and the integration of components to increase strength and performance while reducing weight. This invention also provides for improvements in the focusing of light and the distribution of concentrated light over the face of the PV cells. The improvements of the present invention may be applied to many configurations of basic trough designs such as the those proposed in: U.S. patent application Ser. No. 12/365,549 Solar Trough and Receiver; U.S. Pat. No. 4,135,493 Parabolic Trough Solar Energy Collector Assembly; or WIPO publication number WO 2007/076578 A1.
Realization of the potential to capitalize on PV cell cost savings requires integrating the trough and ancillary structures in to a unibody structure, which reduces mass while maintaining and/or improving other performance attributes.
FIG. 1 shows a basic parabolic trough concentrator 10 . The primary structure is composed of: back shell sheet 110 stretching between back shell ribs 120 , which all together form a back shell 100 ; mounting and pivot block 12 at both ends; a mirror 11 (of glass, metal or other); general receiver support 5 at both ends of the trough; and a general receiver 3 . This is a basic functional parabolic trough concentrator 10 showing only some of the elements of the present invention. Many parabolic troughs with an analogous structure have been proposed, a few examples are cited in the aforementioned patent references. An essential advantage of this invention is the integrated nature of those elements along with the addition of new elements and features to reduce cost and improve structural performance.
FIG. 2 is an exploded view of FIG. 1 showing some basic elements of a parabolic trough concentrator 10 .
FIG. 3 shows a basic parabolic trough concentrator 10 with the addition of some of the major elements of this invention visible in an exploded view. Elements of this invention shown, with the basic parabolic trough concentrator 10 , include: combined aerodynamic spoiler and stiffener 15 A&B (A&B are identical); anti-lift aero balance tube 20 , which is mounted to anti lift tube mount 210 at the ends and center minimally, then clamped in place with anti lift tube bracket 220 at each mount; the cooling elements (detailed later) which are collectively a radiator 40 , with radiator plenum 430 A&B (A&B are identical), otherwise known as a header, at either end; integrated fluid riser and receiver support 50 A&B (A&B are identical); receiver central support 51 A&B (A&B are identical) are simple receiver supports space in the midsection of a receiver; receiver stabilizing wire 18 at each support; and CPV receiver 30 is a concentrated light receiver where the solar rays are intercepted for conversion alternatively a pure thermal receiver can be substituted without change to the trough structure.
FIG. 4 shows an improved parabolic trough concentrator with some of the aforementioned improvements of this invention integrated. Additionally, each longitudinal edge has a side rail 140 , which serves to strength and to cap back shell ribs 120 and back shell sheet 110 . Side rails 140 A&B (A&B are identical) can be seen in FIG. 4 & FIG. 6 . In CPV application where cooling is required side rail 140 also contains a multitude of vent holes 105 .
There are two variants for the heat gathered from cooling the PV cells. Variant one: the heat is dissipated in the radiator on the backside of the trough. The coolant fluid is then circulated to the next trough in a continuous loop of cooling PV cells then dumping the heat in the radiator. Variant two: the heated fluid from cooling the PV cells is gathered via a piping system, for beneficial use elsewhere. Thus in variant two the radiator, if installed, is not utilized or is utilized to dump only excess heat that could not be used for beneficial purposes.
FIG. 5 shows the back side of the improved parabolic trough concentrator, which reveals fully the coverage of radiator 40 and placement of anti-lift aero balance tube 20 . Radiator 40 has been structurally integrating as one element of a “Unibody” structure, which adds strength to an integrated trough and reduces overall weight by being able to make other structural elements lighter. Radiator 40 is fixed to back shell ribs 120 on the backside of a back shell 100 by means of spot welding or other bonding technique.
Air flow channels 130 , shown in FIG. 9 , are formed by an area bounded between back shell sheet 110 on one side, a radiator 40 on the opposite side and finally by back shell ribs 120 forming a basic cell in the cross section of FIG. 9 . These form multiple air flow channels 130 , which follow the curve of the back shell, for air to flow, which aids in cooling. Air flow is facilitated in air flow channels 130 by a multitude of vent holes 105 along both side rails 140 of a trough, providing an exit and/or entrance, depending on trough orientation, to facilitate airflow. In one embodiment, a radiator 40 is constructed from flat sheets of aluminum or steel with rows of louvers 410 stamped in and rows of parallel radiator tubes 420 interspaced between the louvers 410 , which can be seen in the detailed view of FIG. 8 . In an alternative embodiment, a radiator 40 is constructed from rows of parallel radiator tubes 420 A spaced (without a louvered sheet), which can be seen in FIG. 8A . By utilizing a radiator 40 so located, spread out over a large area on the back generally non-sun facing side of the trough, the cooling is enhanced by taking advantage of a large surface area which is exposed to the background environment, which will enhance thermal radiation heat transfer for cooling. Depending on the conditions, radiation heat transfer can account for up to 50% of the cooling capacity. This radiation heat transfer, in combination with natural convection from louver 410 and/or tubes 420 (A), greatly improves cooling performance compared to a passive heat transfer arrangement.
Fluid riser and receiver support 50 A, 50 B are each intended as both the receiver support structure and fluid supplies tubes to the receiver. Thus, two functions are combined into one physical element saving weight and cost as well as reducing the area of potential light blockage compared to two components. This approach applies to both CPV and thermal concentration applications. FIG. 10 is a cross section detailing a connection to a receiver 30 . The fluid riser is attached to a receiver by means of a threaded fitting 520 , which is threaded onto threaded nipple 522 , which is bonded to a receiver, and sealed by means of an o-ring 521 . Receiver wire attachment ring 530 is provided for attachment of receiver stabilizing wire 18 . Fluid riser and receiver support 50 A, 50 B is preferably made of Aluminum but can be any metal, plastic or composite material.
The heat transfer fluid passes into CPV receiver 30 from a fluid riser and receiver support 50 , then having passed through receiver and picked up heat, fluid then passes out of the receiver down another fluid riser and receiver support 50 on the other end. The thus heated fluid leaving the fluid riser and receiver support 50 is passed via a tube to a radiator plenum 430 , which traverses one end of the parabola along its curve. A radiator plenum 430 supplies fluid to radiator tubes 420 , which extend the entire length of the parabola and distribute a heat across the surface of a radiator 40 , cooled fluid is then collected by another identical radiator plenum 430 located on the opposite end of radiator 40 . The thus cooled fluid is then passed to the next trough in the string. Fluid flows at a generally equal rate through all radiator tubes 420 by means of employing equal and opposite pressure drops in the opposing radiator plenums 430 . This is accomplished by having the fluid enter the inlet plenum on one corner and exit the opposing plenum on the opposite corner. In so doing the fluid path and resistance along that path are the same for all paths. Therefore, flow is generally the same for each tube 420 . In an alternative configuration, a radiator 40 is not integrated into the main structure but is discretely attached to the backside of a trough structure. In another alternative, a radiator 40 is displaced from a trough structure and place close to the ground below the trough in a stationary position. In yet another alternative, a radiator 40 is not present and all fluid is collect to a central system where it can be used for beneficial purposes.
A parabolic trough would normally act as a wing in high speed wind conditions. However, the combination of aerodynamic elements, anti-lift aero balance tube 20 , and combined aerodynamic spoiler and stiffener 15 , work together to dramatically reduce lift and torque forces in very high wind conditions (e.g., hurricane/tornado). Such combination results in induced lift and torsion forces from high speed winds that are a small fraction of what they would be without the aerodynamic alterations. FIG. 23 shows a cross section of the module with the air flow pattern for 60 m/s (134 mph). In FIG. 23 , it can be observed how the air flow patterns are disrupted. The resultant lift forces on the trough are reduced by roughly 90% compared to the trough without balanced aerodynamic control elements.
Combined aerodynamic spoiler and stiffener 15 generally extends the length of a trough longitudinally on the outer edge on each side, as shown in FIGS. 4 and 6 . It has two primary functions: one is to work in combination with the anti-lift aero balance tube 20 to change the pattern of the wind flowing over the trough. The second is to further serve the purpose of adding stiffness to the trough, in another example of structural integration of traditionally non-structural elements.
Combined aerodynamic spoiler and stiffener 15 has two spoiler sub-elements: lower lip 152 , which extends below the rim of the parabola; and upper lip 151 , which extents above the rim of the parabola. In another minor purpose, upper lip 151 also serves to attach and hold a wash tube 16 , as shown in FIG. 7 . A further function is to provide a surface to stand the trough on its side during shipping. Aerodynamic spoiler and stiffener element 15 is preferably fabricated from steel, but may be of Aluminum or composite material. A roll forming process is the preferred fabrication technique but, alternatively, bending on a metal brake is possible.
Another aerodynamic control element, anti-lift aero balance tube 20 , is a generally circular tube that extends the length of a trough on the backside, below the vertex of the parabola. By sizing and correctly spacing anti-lift aero balance tube 20 away from the surface of the back shell 100 and/or radiator 40 , whichever is present, the anti-lift aero balance tube works in conjunction with the aerodynamic spoiler and stiffener element 15 to control lift and torque due to high winds. Anti-lift aero balance tube 20 is attached to and supported by the trough, preferably at three points but other supports may be acceptable. Preferably made of steel but can be Aluminum or other metal, plastic or composite material. Alternatively, the tube may have another cross section other than generally circular. Element 20 can also be used to increase cooling capacity by adding cooling lines, interiorly or exteriorly, to distribute heat over the surface, thereby dissipating additional heat. A general tubular structure in this general location has sometimes been used in past trough designs purely for structural reasons but not for aerodynamic reasons; such tube was often referred to as a “torque tube”. In this invention, tube 20 does not serve as a torque tube. In yet another alternative embodiment, the tube can have the additional purpose of integrated structural member to increase the flexural stiffness of the trough if needed.
Mirror wash tube 16 , shown in FIG. 7 , is provided for automated cleaning of the mirror 11 surface. Mirror wash tube 16 is preferably mounted to upper lip 151 of combined aerodynamic spoiler and stiffener 15 . Mirror wash tube 16 , which extends the general length of a trough, has a plurality of small holes evenly space along the length. These holes are oriented such that water or cleaning fluid jetted out under pressure will be directed onto the surface of a mirror 11 . When a trough is placed at some angle, the fluid jetted from mirror wash tube 16 will traverse across the width of mirror 11 and exit the other side of the trough, thus cleaning the entire surface of mirror 11 . Mirror wash tube 16 may be located along one or both sides of the trough. The tubes are preferably fabricated from aluminum or plastic.
This invention incorporates a CPV receiver 30 design for liquid cooling. The general cross section of CPV receiver 30 is shown in FIG. 12 . A primary objective of the liquid cooled CPV receiver 30 is to provide superior heat absorption into the coolant fluid (or heat transfer fluid) from the solar cells (i.e. for PV cell cooling). Coolant fluid is pumped through receiver fluid channels 310 A&B, which extend along the entire length of a receiver, shown in FIG. 12 as two channels joined but may be any number of channels. The fluid channels are collocated opposite a common wall, where the encapsulated PV array 60 is bonded on one side with the fluid channels 310 on the other side. A receiver also includes electrical wire channels 320 A&B, which extend the entire length of the receiver. Wire channels 320 A&B provide space for the solar cell interconnect, bypass diodes, wires and sensor leads, which may be needed for a PV array. CPV receiver 30 is preferably made of extruded Aluminum but can be any metal and formed by alternative process, such as roll forming or some combination of processes.
FIG. 13 illustrates detail B from FIG. 12 , showing PV cell 620 with PV cell interconnect 611 attached to PV cell buss bar 630 A. Not shown is 630 B on the opposite longitudinal edge of PV cell 620 , which has an identical configuration but with mirror interconnect 612 . 601 A&B are front and back array encapsulation layers, respectively.
This invention includes two small side mirrors 330 A&B (A&B are identical), located in a CPV receiver 30 shown in FIG. 12 . These small side mirrors 330 A&B serve to redirect a portion of the concentrated light onto the solar cells (i.e. increase the concentration factor and affect distribution of the concentrated light), producing a generally even light distribution as the trough tracks from side to side due to the relative motion between the sun's direct rays and the trough (distribution pattern detailed later).
FIG. 12 also shows an apex mirror 350 . The apex mirror 350 serves essentially the same purpose as side mirrors 330 , but for a different portion of the concentrated light. Further, in combination side mirrors 330 and apex mirror 350 concentrate the light further than is possible from the single focus of the main mirror. This in affect allows the utilization of smaller PV cells and consequently lower cost. With the addition of side mirrors 330 and apex mirror 350 the receiver has a much great acceptance angle for incoming light.
Additionally, in order to maximize the light which strikes a solar cell(s) and thus maximize electric and/or thermal power output, this invention utilizes the small side mirrors 330 A&B as a feature which hides a PV cell buss bar 630 A&B and associated interconnect 611 & 612 from the concentrated light, thus improving effective efficiency. The small side mirrors 330 A&B serve this second purpose of shading or “hiding” by redirecting concentrated light away from the PV cell buss bars 630 A&B. Thus creating hidden buss bars and preventing the light, which would have impacted the buss bars, from being lost. PV cell buss bars 630 and associated interconnects 611 & 612 extend longitudinally along the sides of the PV cell 620 , as illustrated in FIG. 14 & FIG. 15 . When a cell or an array of cells is mounted in the receiver, as shown in FIG. 12 and detail FIG. 13 , small side mirrors 330 cover PV cell buss bars 630 , minimizing the loss from light normally reflected by/from the buss bars and thus not absorbed by a PV cell 620 . Small side mirrors 330 A&B are intended to be attached to CPV receiver 30 after an encapsulated PV array 60 is bonded in place, this makes solar cell string mounting easier. Alternatively, small side mirrors 330 may be integral to the main body of a receiver and a PV cell array inserted from the end. The preferred method of fabrication is to extrude the small side mirrors 330 from aluminum, steel, plastic or composite material and then to laminate or deposit a mirror surface on the face. Alternatively, it is possible to manufacture small side mirrors 330 by machining process of milling the profile required from a solid piece of material of the same selection.
In order to get the best heat conduction into the fluid it is desirable that the fluid should be turbulent which breaks up the boundary layer, but it is also desirable to minimize the pumping power and pressure losses. Low pressure drop, and thus low relative pumping power, are generally inconsistent with producing turbulent flow. Therefore, this design incorporates flow mixers 80 A&B (A&B are identical), which are located in the receiver fluid channels 310 A&B. Flow mixers 80 cause the flow to swirl and mix, thereby generally eliminating the boundary layer, which improves heat transfer to the fluid. These flow mixers 80 cause relatively low pressure loss compared with high a Reynolds number associated with turbulent flow. FIG. 11 shows and perspective view of the receiver with internal flow mixers 80 revealed.
Further, this CPV receiver 30 design incorporates an aerodynamic shape for low coefficient of drag, where generally rounded sidewalls slope in at the top and at the bottom, which can be seen in cross section FIG. 12 . During high wind conditions, the drag force exerted on a receiver due to such winds can be significant. These forces would be transferred to a trough causing a torque on a trough and its tracking drive, potentially damaging other components. By designing a receiver with a low coefficient of aerodynamic drag, the forces can be greatly reduced.
All parabolic trough concentrators need to be aligned with the sun at least along the long axis of the trough. This invention includes an external longitudinal channel, called the receiver solar alignment channel 340 in FIG. 12 , which extends along the length of a receiver on the general sun facing side, opposite and parallel to the surface where an encapsulated solar array 60 is to be mounted. Receiver solar alignment channel 340 is to be used to align the trough with the sun. More precisely, receiver solar alignment channel 340 is for locating a solar alignment sensor and or solar tracking device.
In an alternative embodiment the features represented here for a CPV receivers, side mirrors, flow channels, flow mixers, aerodynamic shape, and alignment channel, can also be applied to thermal receivers for high temperature thermal applications, i.e. a receiver without PV cells for heat only.
In order to minimize losses, the cells in CPV applications need to be as closely connected as possible. This invention includes a device for interconnecting the solar cells by means of a PV cell interconnect 611 and mirror image PV cell interconnect 612 , which extend along the sides of a solar cell on opposite edges. This eliminates the need to use the traditional flexible tabs that usually extend between the cells, requiring a larger gap than desired here. Close spacing of solar cells 620 requires a different method from traditional interconnecting of cells in a string or array. PV cell interconnect 611 and mirror image PV cell interconnect 612 are intended to facilitate close spacing of solar cells 620 when connected in an array. Since a parabolic trough is a linear focus concentrator, the solar cells extend one next to the other in a line or linear array at or near the focal point, or more accurately along the focal line, as illustrated in FIG. 19 through FIG. 22 for PV array placement near the focal point. Installed PV cell interconnects are illustrated in FIG. 13 through FIG. 17 . FIG. 17 detail D of section C-C is essentially the same view as detail B in FIG. 13 , but only of a bare cell and interconnect without encapsulate and not mounted in a receiver. PV cell interconnects 611 & 612 have two tabs 606 A&B, which are generally symmetrical. These tabs are to be connected to the solar cell anode and cathode generally by means of soldering one tab is soldered to a solar cell buss bar 630 and the other is solder to the back of an adjacent cell. Interconnects are preferably made of Copper but they can be of any high conductive metal. Interconnects are preferably fabricated by means of first stamping from flat strips to produce the interconnect blank 610 , then folding a blank 610 in one direction to produce PV cell interconnect 611 and folding another blank 610 in the opposite direction to produce mirror image PV cell interconnect 612 . FIG. 18 illustrates the stamped blank 610 and the two oppositely folded interconnects 611 & 612 . Folding of interconnect blank 610 is preferably accomplish by roll forming but can also be by other process such as stamping etc. Interconnect blank 610 is folded so that connecting tabs 606 A & 606 B are on parallel planes but displaced by the thickness of the cell as shown in FIG. 17 detail D. A small hole 608 , shown in interconnect blank 610 , remains in interconnect 611 & 612 and is to provide means of inserting and holding a generally circular insulator intended to prevent adjacent cells from touching and thus electrically shorting. Interconnects have the added benefit that their overall resistance is lower than traditional tabs, because it can be made with a much greater cross section area than the traditional tabs used for connecting PV cells thus the resistive losses are reduced. FIG. 14 and FIG. 15 show how PV cells 620 are to be interconnected in a string using PV cell interconnects 611 & 612 . Additionally the PV cell interconnects 611 & 612 provide a convenient means of attaching wires and bypass diodes, either surface mount or axial lead, should they be required. There are many alternative configurations of the PV cell interconnect 611 & 612 but the base elements are that the device should connect the bus bar anode on one face of a cell to the cathode on the opposite face of and adjacent cell and so forth in series. In addition, it should not intercede between the cells but instead pass along the side to allow for minimum cell spacing.
To achieve the highest possible efficiency from the solar cell, light distribution should be maintained as near even as possible across the cell face. An aspect of this invention includes a method of evenly distributing concentrated light over the surface of the encapsulated PV array 60 . FIG. 19 shows the overall concentration pattern in neutral position for the full cross section of an improved parabolic trough with ideal parallel rays and perfect reflection. FIG. 19A shows the same except with non-ideal solar rays and imperfect specular reflection. As can be seen in FIG. 20 , close up of FIG. 19 , the concentration pattern in neutral position, rays from each half of a parabola, left and right, do not significantly cross each other before impacting a secondary mirror or PV array 60 , thus concentrated rays have a dual focus pattern and not a single focal point as in state of the art parabolic concentrators. Again FIG. 20A is the same as 20 but with non-idealize rays and imperfect reflection. This dual focus pattern generally leaves an area below a receiver 30 , and with the approximate width of the solar cell, open between a mirror 11 and a receiver 30 . This area is intended to accommodate the apex mirror and/or fluid riser and receiver support 50 A&B, which will have minimal light interference so located.
Further, this method includes maintaining generally even distribution of concentrated light over the surface of the encapsulated PV array 60 while tracking the sun, i.e. changes in relative position of the sun with regard to perfect alignment with the trough. FIG. 21 shows concentration pattern of idealize parallel rays and perfect specular reflection from the main mirror 11 , with a shifted alignment, specifically in the solar tracking position of 0.1 degrees off center. FIG. 21A is the same as FIG. 21 but the solar rays are non-parallel and with imperfect specular reflection from the main mirror 11 .
This invention includes alternative method of distributing and maintaining distribution of concentrated light over the cell(s) as shown in FIG. 22 , an alternative concentration pattern neutral position, whereby a higher percent of light is reflected from the sidewalls also achieving a generally even distribution pattern. This alternative has a more classic focal pattern with a single focal point where concentrated rays from the left and right halves cross. Rays crossing at a central point is both an advantage and disadvantage of this focusing method. This can be advantageous because it is a simpler pattern to produce and may be beneficial for thermal concentrators, which may benefit from a tight focus or require light to pass through a narrow aperture or smaller receiver tube. It also allows for greater acceptance angles while providing a generally even light distribution. The disadvantage is for CPV applications the central crossing of the rays can create a long shadow from supports, wires and hoses, (depending on sun angle), for a significant portion of the year. This shadow is highly disadvantageous for PV arrays, shadowing can severely limit or block output from an entire array. Bypass diodes can be used to address this problem somewhat but the net array output will be significantly lower. In this alternative, side mirrors are generally perpendicular to the cell face and receives a generally greater proportion of the concentrated rays on first impact.
For shipping efficiency, improved parabolic troughs of this invention are designed to be nested with a minimum of spacing to improve the efficiency of packaging multiple units, as illustrated in FIG. 24 . It is intended that troughs be shipped standing vertically, resting on one of the longitudinal ends by means of either a standard ISO container or box trailer. Efficient shipping allows trough units to be factory assembled with minimum field assembly required. Further, due to the reduced mass of a unibody construction and tight packing, shipping cost will be reduced.
Since other modifications and changes varied to fit particular operating requirements, and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention.
Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims.
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The invention includes a parabolic solar concentrator typified by a highly integrated structure whereby, mirror, aerodynamic elements, a shell structure, cooling elements and other elements have been integrated to form a unibody structure, which is both stiffer and lighter than traditional trough structures. The invention includes; aerodynamic features that greatly limit lift forces induced by high speed winds, a receiver with liquid cooling for better control of PV cell temperatures and which allows for the collection of the heat for beneficial use, accommodations for a solar tracker, and improvements in the focusing and distribution of light using secondary mirrors. The receiver incorporates specific details to improve heat transfer and reduce parasitic pumping loads and incorporates secondary mirrors to increase light acceptance angles. Automated mirror washing is addressed. In applications where the heat is un-utilized the integrated radiator is employed to dissipate the heat using both convection and radiation heat transfer.
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FIELD OF THE INVENTION
[0001] This invention relates in general to frozen confections and more particularly to a frozen confection that is nutritious and can be manufactured in a variety of healthy flavours.
BACKGROUND OF THE INVENTION
[0002] There is an ever increasing demand for food products that consumers consider to be healthy. This demand is especially evident in the confectionary sector where traditionally these products are full of sugar and additives resulting in a confection that has low nutritional value. In the frozen confectionary sector, traditionally the frozen confection can take the form of ice cream, frozen yogurt, ice milk, non-dairy frozen products like gelato and sorbet or combination products. The most popular are the products with dairy derived ingredients, typically ice cream and non-dairy products such as frozen ices or products based on frozen fruit juices.
[0003] Typically the methods used to manufacture frozen confections affects the types of frozen confections being produced. Frozen confections are typically prepared at a factory site using raw material that is then mixed with a liquid ingredient such as milk or cream. Frozen fruit mixes are typically supplied in a pureed form. All of these mixes have very limited shelf life and must be used within a relatively short prescribed time. In addition, all dairy products and fruit pureed ingredient mixes must be pasteurized in the factory to kill any bacteria that may have grown during shipment and storage of the mix. As such there is not only a need for a frozen confection having improved nutritional value and improved shelf stability, but also a need for an improved manufacturing process.
[0004] Prior art frozen confections have been devised to address the noted issues. For example, U.S. Pat. No. 6,395,314 issued on May 28, 2002 to Whalen et al. This patent relates to a process for forming a syrup product that is suitable for use as a non-dairy frozen confection. The non-dairy frozen confection exhibits selected sweetness, texture, and mouth feel characteristics while being devoid of exogenous sweeteners, stabilizers, emulsifiers, and proteins. The process includes blending a base formulation and water to form a slurry, the base formulation having a major amount of an oat material or waxy barley hybrid flour. The process also includes liquefying and saccharifying the slurry to produce the syrup product.
[0005] U.S. Pat. No. 5,989,598 and U.S. Pat. No. 5,723,162 which issued on Nov. 13, 1999 and Mar. 3, 1998 respectively to Whalen et al. relate to a process for forming a non-dairy frozen confection from an oat material or barley material. The non-dairy frozen confection exhibits selected sweetness, texture, and mouth feel characteristics while being devoid of exogenous sweeteners, stabilizers, emulsifiers, and proteins.
[0006] Zweben is the owner of U.S. Patent Application Publication No. 2006/0029709 which was published on Feb. 9, 2006. This patent relates to a frozen confection made from masticating frozen foodstuffs and such having no air entrapment (overrun); a homogeneous consistency; an increase in total sugar content as compared to the feed material; and a superior mouth feel. This frozen confection possesses an appearance and a mouth feel similar to soft-serve ice-cream without the use of air, dairy, fillers, creaming agents, preservatives, or additives of any sort. Upon processing, the frozen convection made from frozen fruit, vegetables, or foodstuffs shows a gain in natural sugars.
[0007] However to date formulae for frozen confections have not included a set of ingredients focused exclusively on healthy additives. In general frozen confections derive most of their nutritional content from the ingredients that are used to create the desired flavours and textures. For example, ice cream and soy products derive their protein content from the dairy and soy ingredients respectively, which in turn provide the desired taste and texture to the product.
[0008] Thus a frozen confection which has improved nutritional value, improved shelf life and has an improved manufacturing process is desirable.
SUMMARY OF THE INVENTION
[0009] An object of one aspect of the present invention is to provide an improved frozen confection having improved nutritional value and shelf stability as well as an improved method of manufacture.
[0010] In accordance with one aspect of the present invention there is provided a frozen confection that has improved nutritional value by having increased protein content made from a starting material of wet or dry flavouring and a wet or dried protein material where the wet or dried protein material is a maximum 75% of the total weight of the product
[0011] In accordance with one aspect of the present invention there is provided a frozen confection that has improved nutritional value by having increased protein content made from a starting material of wet or dried or powdered fruit and a wet or dried protein material where the dried or liquid protein material is a maximum 75% of the total weight of the product.
[0012] In accordance with another aspect of the present invention there is provided a frozen confection that has improved nutritional value by having increased omega essential fatty acids content and is made from a starting material of wet or dried flavouring and wet or dried omega essential fatty acids where the wet or dried omega essential fatty acids is a maximum 95% of the total weight of the product.
[0013] In accordance with another aspect of the present invention there is provided a frozen confection that has improved nutritional value by having increased omega essential fatty acids content and is made from a starting material of wet or dried or powdered fruit and wet or dried omega essential fatty acids where the wet or dried omega essential fatty acids is a maximum 95% of the total weight of the product.
[0014] In accordance with another aspect of the present invention there is provided a frozen confection that has improved nutritional value by having an increased value of energy rich ingredients and is made from a starting material of wet or dried flavouring and wet or dried ginseng and wet or dried guarana where the wet or dried ginseng is a maximum of 75% of the total weight of the product and the wet or dried guarana is a maximum of 75% of the total weight of the product.
[0015] In accordance with another aspect of the present invention there is provided a frozen confection that has improved nutritional value by having an increased value of energy rich ingredients and is made from a starting material of wet or dried or powdered fruit and wet or dried ginseng and wet or dried guarana where the wet or dried ginseng is a maximum of 75% of the total weight of the product and the wet or dried guarana is a maximum of 75% of the total weight of the product.
[0016] In accordance with another aspect of the present invention there is provided a frozen confection that has improved nutritional value by having an increased vitamin and mineral blend and is made from a starting material of wet or dried flavouring and wet or dried taurine where the wet or dried taurine is a maximum 75% of the total weight of the product.
[0017] In accordance with another aspect of the present invention there is provided a frozen confection that has improved nutritional value by having an increased vitamin and mineral blend and is made from a starting material of wet or dried or powdered fruit and wet or dried taurine where the wet or dried taurine is a maximum 75% of the total weight of the product.
[0018] In accordance with another aspect of the present invention there is a provided a method of manufacture of a frozen confection including blending a starting material of wet or dry flavouring and a wet or dried material that has increased nutritional value to create a dry pre-blend; reconstituting the dry pre-blend with a liquid; blending the liquid and the pre-blend creating a slurry; allowing the slurry to settle to remove air bubbles; forming the slurry into a desired format for a frozen confection; and freezing the slurry to a frozen state.
[0019] In accordance with another aspect of the present invention there is a provided a method of manufacture of a frozen confection including blending a starting material having a wet or dried or powdered fruit and a wet or dried material that has increased nutritional value to create a dry pre-blend; reconstituting the dry pre-blend with a liquid; blending the liquid and the pre-blend creating a slurry; allowing the slurry to settle to remove air bubbles; forming the slurry into a desired format for a frozen confection; and freezing the slurry to a frozen state.
[0020] Advantages of the present invention are: higher nutritional value than typical frozen confections such as ice cream or frozen juice pops, reduced manufacturing time, increased efficiency in manufacturing, no pasteurization of the frozen confection, increased shelf life, reduced costs for shipping and storage of product, reduction in production errors, and reduced possibility of contamination of product.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] The present invention will be described by way of examples wherein the percents in the description and drawings are in terms of weight:
EXAMPLE 1
[0022] In accordance with a preferred embodiment of the present invention there is provided a frozen confection that has improved nutritional value by having increased protein content made from a starting material of wet or dried or powdered fruit and a wet or dried protein material where the wet or dried protein powder is a maximum 75% of the total weight of the product. A frozen confection was produced in accordance with Table 1. More specifically a starting material was obtained by dry mixing the ingredients in Table 1 in the indicated proportions. Upon obtaining a dry-blend of the ingredients outlined in Table 1 the ingredients are reconstituted or re-hydrated and blended to form a solution or slurry. The solution is allowed to settle to remove or reduce the number of trapped air bubbles. The waiting period may be between zero to six hours. The solution may be slightly agitated prior to its being packed into a desired mold and frozen into a solid state. Table 2 describes the ingredients of an alternative flavour for a frozen confection having increased protein content.
[0000]
TABLE 1
Percentage
Percentage
of Weight
of
on total
Variance
Ingredient
Product
Allowable
Mango Protein
Citric Acid
1.85
45%
Anhydrous
Sugar Fine
34.7
25%
Granulated
Mango Powder
7.89
85%
Whey Isolate
55.52
75%
Yellow Color # 6
0.05
35%
100%
[0000]
TABLE 2
Percentage
Percentage
of
of
Variance
Ingredient
Weight
Allowable
Chocolate
Protein
Skim Milk
4.41
25%
Powder (med temp)
Sugar Fine
37.44
25%
Granulated
Cocoa Powder
5.29
85%
Whey Isolate
52.86
75%
100%
EXAMPLE 2
[0023] In accordance with another aspect of the present invention there is provided a frozen confection that has improved nutritional value by having increased omega essential fatty acids content and is made from a starting material of wet or dried or powdered fruit and wet or dried omega essential fatty acids where the wet or dried omega essential fatty acids is a maximum 95% of the total weight of the product. A frozen confection was produced in accordance with Table 3. More specifically a starting material was obtained by dry mixing the ingredients in Table 3 in the indicated proportions. Upon obtaining a dry-blend of the ingredients outlined in Table 3 the ingredients are reconstituted or re-hydrated and blended to form a solution or slurry. The solution is allowed to settle to remove or reduce the number of trapped air bubbles. The waiting period may be between zero to six hours. The solution may be slightly agitated prior to its being packed into a desired mold and frozen into a solid state. Table 4 describes the ingredients of an alternative flavour for a frozen confection having increased omega essential fatty acid content.
[0000]
TABLE 3
Percentage
Percentage
of Weight
of
on total
Variance
Ingredient
Product
Allowable
Choc/Banana
Omega
Skim Milk
1.57
50%
Powder (med Temp)
Sugar Fine
33.83
25%
Granulated
Cocoa Powder
6.27
85%
Whey Isolate
43.86
75%
Banana Powder
14.1
85%
Banana Flavor
0.38
85%
Omegas
900 mg
95%
[0000]
TABLE 4
Percentage
Percentage
of
of
Variance
Ingredient
Weight
Allowable
Mango/Papaya
Sugar Fine
31.69
25%
Granulated
Whey Isolate
56.04
75%
Citric Acid
0.25
45%
Anhydrous
Yellow Color # 6
0.04
35%
Mango Powder
7.49
85%
Papaya Flavor
4.49
85%
Omegas
900 mg
95%
EXAMPLE 3
[0024] In accordance with another aspect of the present invention there is provided a frozen confection that has improved nutritional value by having an increased value of energy rich ingredients and is made from a starting material of wet or dried or powdered fruit and wet or dried ginseng and wet or dried guarana where the wet or dried ginseng is a maximum of 75% of the total weight of the product and the wet or dried guarana is a maximum of 75% of the total weight of the product. A frozen confection was produced in accordance with Table 5. More specifically a starting material was obtained by dry mixing the ingredients in Table 5 in the indicated proportions. Upon obtaining a dry-blend of the ingredients outlined in Table 5 the ingredients are reconstituted or re-hydrated and blended to form a solution or slurry. The solution is allowed to settle to remove or reduce the number of trapped air bubbles. The waiting period may be between zero to six hours. The solution may be slightly agitated prior to its being packed into a desired mold and frozen into a solid state. Table 6 describes the ingredients of an alternative flavour for a frozen confection having increased energy values.
[0000]
TABLE 5
Percentage
Percentage
of Weight
of
on total
Variance
Ingredient
Product
Allowable
Raspberry/Strawberry
Energy
Guar Gum
0.06
75%
Carrageenan Premium
0.08
75%
Xanthum Gum
0.08
75%
Sugar Fine Granulated
75.61
25%
Citric Acid Anhydrous
0.76
45%
Ginsing 2%
0.15
75%
Guarana 22%
0.26
75%
Strawberry Powder
8.39
85%
Strawberry Flavor
0.57
85%
Raspberry Powder
6.99
85%
Raspberry Flavor
0.38
85%
Vanilla Flavor
0.30
85%
(artificial)
Allura/Red 40 Dye
0.04
35%
[0000]
TABLE 6
Pineapple/Tangerine
Energy
Guar Gum
0.08
75%
Carrageenan
0.08
75%
Premium
Xanthum Gum
0.08
75%
Sugar Fine
79.67
25%
Granulated
Citric Acid
1.60
45%
Anhydrous
Ginsing 2%
0.16
75%
Guarana 22%
0.28
75%
Tangerine
0.20
85%
4056-N Tangerine
3.79
85%
4052-N Pineapple
5.95
85%
Pineapple Flavor
1.20
85%
(artificial)
Color Yellow # 5
0.04
35%
EXAMPLE 4
[0025] In accordance with another aspect of the present invention there is provided a frozen confection that has improved nutritional value by having an increased vitamin and mineral blend and is made from a starting material of wet or dried or powdered fruit and wet or dried taurine where the wet or dried taurine is a maximum 75% of the total weight of the product. A frozen confection was produced in accordance with Table 7. More specifically a starting material was obtained by dry mixing the ingredients in Table 7 in the indicated proportions. Upon obtaining a dry-blend of the ingredients outlined in Table 7 the ingredients are reconstituted or re-hydrated and blended to form a solution or slurry. The solution is allowed to settle to remove or reduce the number of trapped air bubbles. The waiting period may be between zero to six hours. The solution may be slightly agitated prior to its being packed into a desired mold and frozen into a solid state. Other vitamins and minerals may be included in the formula to provide improved mineral and vitamin content. Such vitamins and minerals are the following by way of example only: vitamin C, B1, B2, B3, B6, folic acid (B9), B12, B5 (pantothenate), H (biotin), A, E, D3, K1, potassium iodide, cupric (sulfate anhydrous, picolinate, sulfate monohydrate, trioxide), selenomethionine, borax, zinc, calcium, magnesium, chromium, manganese, molybdenum, betacarotene, citrus bioflavonoids extract, iron, carotenes (e.g. lutein, lycopene), “near” Bvitamins (inositol, choline, PAPA), betaine hydrochloride, lecithin, and citrus bioflavinoids.
[0000]
TABLE 7
Percentage
Percentage
of Weight
of
on total
Variance
Ingredient
Product
Allowable
Vitamin/Mineral
Pre Blend
Taurine USP
54.053
75%
D-
35.062
Glucuronolactone
Caffeine
4.383
Anhydrous USP
Inositol
3.562
Niacinamide
1.400
Pyridoxine HCI
0.498
Calcium
0.441
Pantothenate
Vitamin B-12
0.397
(0.1%)
Riboflavin
0.114
Vitamin B-12
0.397
(0.1%)
Riboflavin
0.114
[0026] The method of manufacture of a frozen confection including blending a starting material having a dried or powdered fruit and a dried material that has increased nutritional value to create a dry pre-blend; reconstituting the dry pre-blend with a liquid; blending the liquid and the pre-blend creating a slurry; allowing the slurry to settle to remove air bubbles; forming a slurry into desired format for frozen confection; and freezing the slurry.
[0027] The frozen confections may be formed into a wide variety of formats such as bars, push pops, formed, soft serve, hand held, tubs having various sizes, cakes (shaped), cones, and cups by way of example only.
[0028] The method of manufacture is simplified by the nature of the ingredients used. Specifically the use of dried products such as dehydrated fruit powder for the dried flavouring and dried protein such as whey, omega essential fatty acids, ginseng, guarana and taurine for the dried material with increased nutritional value, allows for a dry pre-blend that can be easily packaged and stored. The method of manufacture and the resulting confections however may utilize any dry flavouring such as a dried fruit powder, or dry cocoa powder by way of example only. The flavouring may also be wet, such as a wet fruit puree, by way of example only, that is mixed with the other dry ingredients such as the dry protein powder.
[0029] The packaged dry pre-blend can be easily and cost effectively shipped as there is no liquid and has a much longer shelf-life since there is no liquid that can promote bacteria growth or requires refrigeration. The dry pre-blend can be shipped to a production facility where reconstitution or re-hydration of the dry pre-blend can occur with the addition of water, liquid sugar or sweetener. Upon reconstitution the solution or slurry is sheer blended to mix all the ingredients. The solution is then allowed to settle so that any air bubbles that have been trapped in the solution dissipate. The solution may sit for a maximum of six hours depending on the formulation. Once the solution has settled, depending on the formulation, it may be moved to a flavour additive tank with mild agitation so as to incorporate the flavour. The solution may then be moved to the forming process for the desired format of the frozen confection and then frozen into a solid state. Once frozen the confection may be packaged and stored at −20° C.
[0030] Throughout this method or process, there is no need for pasteurization of the ingredients. All of the dry ingredients used in the pre-blend have been pasteurized prior to dehydrating. By not having to pasteurize the solution or slurry, the process is simplified, is more timely, more energy efficient, less costly, and less chance of human error and therefore contamination of the frozen confection.
[0031] Other variations and modifications of the invention are possible. All such modifications or variations are believed to be within the sphere and scope of the invention as defined by the claims appended hereto.
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A frozen confection having improved nutritional value namely improved protein, omega essential fatty acids, energy and mineral and vitamin levels. An improved method of manufacture of a frozen confection that is simplified and does not require pasteurization thereby providing improved shelf life.
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This invention relates to supercharger systems for internal combustion engines. This is a Continuation-In Part application of Ser. No. 09/002,602 filed Jan. 5, 1998, now abandoned.
BACKGROUND OF THE INVENTION
Superchargers are air pumps or blowers in the intake system of an internal combustion engine for increasing the mass flow rate of air charge and consequent power output from a given engine size. Turbosuperchargers (normally called turbochargers) are engine exhaust gas turbine driven superchargers. When superchargers are driven mechanically from the shaft of the internal combustion engine, a speed increasing gear box or belt drive is needed. Such superchargers are limited to a relatively low rotating speed and are large in size. Paxon Blowers and Vortech Engineering Co. are marketing such superchargers. Fixed gear ratio superchargers suffer from two very undesirable features: 1) there is a sharp decrease in boost pressure at low engine RPM because boost pressure goes generally to the square of the speed of rotation, and 2) it is generally difficult to disconnect the supercharger from the engine when the supercharger is not needed.
Applicant was granted on Dec. 5, 1995 a patent (U.S. Pat. No. 5,471,965) on a very high speed radial inflow hydraulic turbine. FIG. 12 of that patent discloses the hydraulic turbine driven blower used in combination with a conventional turbocharger to supercharge an internal combustion engine. In that embodiment the output of the hydraulic driven compressor was input to the compressor of the conventional turbocharger. In all the embodiments shown in the '965 patent, the pump delivering high pressure hydraulic fluid to the hydraulic turbine was driven directly off the engine shaft. At high speeds when the exhaust driven turbosupercharger is fully capable of supplying sufficient compressed air to the engine, a bypass valve unloaded the hydraulic fluid pump but it continued to pump hydraulic fluid through the bypass valve which is a waste of engine horse power.
Another hybrid supercharger is disclosed in U.S. Pat. No. 4,285,200 issued to Byrne on Aug. 25, 1981. That patent disclosed a compressor driven by an exhaust driven turbine and a hydraulic driven turbine, the compressor and both turbines being on the same shaft. That turbine was an axial flow turbine and the turbine was driven with engine oil. With this design oil foaming can be a problem. U.S. Pat. No. 5,471,965 and U.S. Pat. No. 4,285,200 are incorporated herein by reference.
Many motor vehicles being produced at the time of the filing of this application utilize high pressure fluid to drive devices such as power steering equipment. These devices typically are designed for higher pressure hydraulic fluid than the preferred hydraulic fluid pressures needed for hydraulic fluid driven superchargers.
There is a great need for additional supercharging of present turbocharged diesel engines. In the low RPM range, the currently available turbocharging systems are not very effective in producing sufficient engine manifold pressure and power, required for satisfactory vehicle acceleration and exhaust smoke reduction. This applies especially to "stop and go" type services, such as city buses and trash collecting trucks. A thermodynamic cycle analysis of a typical truck turbodiesel engine shows that even with modest 2 to 3 psi supercharging applied in series to the inlet of the existing turbocharger compressor in the low engine RPM range, the existing turbocharger pressure ratio increases exponentially mainly due to a large increase in turbocharger turbine power.
What is needed, is a better supercharger system.
SUMMARY OF THE INVENTION
The present invention provides a supercharger system in which a hydraulic driven supercharger shares a hydraulic power system with at least one other hydraulic driven device. The system includes a very high speed radial inflow hydraulic turbine drive driving a compressor for supplying compressed air to an internal combustion engine. Pressurized hydraulic fluid for driving a supercharger hydraulic turbine is provided by a first pump driven by the engine shaft. A second pump provides a higher pressure hydraulic fluid flow for driving at least one other device, such as a power steering device. In a preferred embodiment, when the hydraulic turbine is not needed at high engine speed because sufficient air is provided by a turbosupercharger, a bypass valve is opened by a controller to unload the hydraulic pump and then the controller causes a clutch to decouple the supercharger hydraulic pump from the engine shaft. Each of several preferred embodiments utilize a plastic-metal turbine wheel in which the plastic portion of the wheel other than the blades is solidly anchored within a metal containing wheel. The superchargers provided by the present invention produce immediate response to engine demand for increased combustion air and will dramatically reduce smoke emission during low speed acceleration of bus and truck engines as well as greatly improve engine efficiency. In another preferred hybrid embodiment, the hydraulic turbine drive is mounted on the same shaft with an exhaust driven turbine, and both drive the a compressor providing compressed air to the engine. In a preferred embodiment a novel nozzle body is disclosed having an increased number of nozzles at angles such as to provide substantial exit hole overlapping at nozzle exits to produce an output increase of about 7 percent over similar prior art hydraulic turbine driven superchargers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional drawing showing a preferred embodiment of a very high speed turbine drive.
FIG. 2 is a drawing showing an exploded view of a prior art turbocharger.
FIGS. 3 and 4 are drawings showing views of the nozzle arrangement of the turbine drive shown in FIG. 1.
FIGS. 5 and 6 show an alternate arrangement similar to that shown in FIGS. 3 and 4.
FIGS. 7 and 8 show views of an all metal turbine wheel.
FIG. 9 shows blade dimensions.
FIG. 10 is a layout of a hydraulic system utilizing my novel turbine drive.
FIG. 11 is a modified version of FIG. 10.
FIG. 12 is a layout similar to FIG. 11 including a turbocharger.
FIG. 13 is a drawing of a hybrid supercharger.
FIG. 14 shows some details of the FIG. 13 system.
FIG. 15 shows a hydraulic turbine driven supercharger device using a hydraulic fluid system in common with a hydraulic driven power steering device.
FIG. 16 shows a novel nozzle body design.
FIG. 17 is a prospective view of the FIG. 16 nozzle body.
FIG. 18 is a drawing showing the detail dimensions of turbine blades used with the nozzle body shown in FIGS. 16 and 17.
FIG. 19 is a drawing showing the positions of the turbine blades on the turbine wheel.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Preferred embodiments of the present invention are described by reference to the drawings.
Turbine Drive
A prior art turbine drive is shown in FIGS. 1, 2, 3 and 4 which are extracted from U.S. Patent '965.
Turbine Wheel
Turbine 61 with a wheel of only 0.800 inch diameter is capable of generating 9.6 HP at 69,750 RPM, with pressure differentials of 930 psi and having the capability of operating at the fluid temperatures of 150 to 250 degrees Fahrenheit.
Turbine drive 8 includes turbine wheel 11 with 27 turbine blades 31 which are preferably formed in an injection molding process. The plastic is pressure injected into a mold containing a containing wheel 12 (which is a metal such as steel) forming an integral assembly of plastic turbine wheel 11, metal wheel 12 and plastic turbine blades 31. The metal containing wheel 12 is precisely centered into the turbocharger shaft 14 and held axially by self locking steel fastener 17. Compressive load generated by the self locking steel fastener 17 is sufficient to facilitate the torque transfer from the metal containing wheel 12 into the turbocharger shaft 14 under all anticipated torque loads, fluid temperatures and rotating speeds. During the normal operation the temperature of hydraulic oil is usually in the range of 150 to 250 degrees Fahrenheit which expands the metal containing wheel 12 axially slightly more than the self locking steel fastener 17 and the turbocharger shaft 14, thus increasing the compressive load in the metal containing wheel 12 and the torque transfer capability slightly above the cold assembly condition. The centrifugally and thermally induced stresses in the plastic turbine wheel 11 which is solidly anchored inside the metal containing wheel 12 are to a great extent being absorbed by the metal containing wheel 12. Blade dimensions are shown in FIG. 9. As indicated on FIG. 3 and FIG. 1, the plastic turbine blades 31 are of the radial inflow type with rounded leading edges to minimize the erosion tendency sometime caused by very high hydraulic oil velocity as combined with sharp, thin leading edges. The radial inflow type blading geometry allows, after the blades are cast, the plastic mold to be withdrawn axially out from the blades. The blades of the turbine wheel are preferably made of high strength thermoplastic material, Polysulfone which is pressure injected into a mold holding the steel portion of the wheel which together form an integral metal/plastic turbine wheel and blade. Vespell, a high temperature plastic made by DuPont, has also been successfully tested for this application.
Turbine Parts and Its Operation
Turbine discharge housing 22 is solidly bolted by six bolts 29 to the turbine inlet housing 21 which is solidly bolted by a series of bolts at 35 to the commercially supplied (T04 form Turbonetics) turbocharger housing 41. Turbine nozzle ring 18 preferably made from Vespel is held in a precise axial and radial position by the turbine inlet housing 21 and the turbine discharge housing 22. (Nozzle ring 18 could also be made from brass or any of several other similar metals.) Nozzle ring 18, inlet housing 21 and discharge housing 22 together define toroidal inlet cavity 32. The high oil pressure contained inside inlet cavity 32 is sealed by O-Ring 24 and O-Ring 25 which prevent any leakage from inlet cavity 32 to the discharge cavity 34 along the contact surfaces between turbine nozzle ring 18, turbine inlet housing 21 and turbine discharge housing 22. A substantial portion of the inside diameter of the turbine nozzle ring 18 is supported radially by matching diameters of turbine inlet housing 21 and turbine discharge housing 22 which restrain radial deformation of the turbine nozzle body 18 and to a great degree absorb inwardly compressive pressure generated by the high pressure hydraulic fluid contained inside inlet cavity 32. The axial dimension of the turbine nozzle ring 18 is precisely matched with the axially allowable space between turbine discharge housing 22 and turbine inlet housing 21. At normal operating temperatures the turbine nozzle ring 18 expands slightly more than the matching surfaces of turbine inlet housing 21 and turbine inlet housing 22 which essentially restrain the axial expansion of the turbine nozzle ring 18 and produces a moderate axial compressive stress in the turbine nozzle ring 18. Commercially supplied sliding seal ring 16 provides the oil seal between the commercially supplied turbocharger housing 41 and the turbocharger shaft 14. O-Ring 26 seals the relatively low oil pressure around the turbocharger shaft 14 from leaking to ambient. O-Ring 23 seals the high oil pressure contained in inlet cavity 32 from leaking to ambient.
As indicated in FIGS. 3 and 4, in this embodiment sixteen turbine nozzles 15 are drilled in a radial plane, through the turbine nozzle ring 18 at an angle of 11 degrees with the tangent to a circle of the plastic turbine blades 31 outer diameter. The center lines of the turbine nozzles 15 positioned in a radial plane cause high pressure hydraulic fluid to expand radially inward from the inlet cavity 32 through turbine nozzles 15 into the vaneless passage 19 and into the inlet of the plastic turbine blades 31 where the hydraulic fluid momentum is converted into shaft power by well known principles. FIG. 3 shows the plan view of the exit portion of the turbine nozzles 15 as viewed in the planes 3--3 in FIG. 4. FIG. 4 shows a section through the nozzle ring 18 along the plane 4--4 in FIG. 3 High hydrodynamics efficiency of nozzles 15 is attributed to the particular combination of round cross sectioned turbine nozzles 15 and the gradual change in the cross section of the flow area along the centerline axis of the individual turbine nozzles 15 as shown in FIG. 3. The sixteen turbine nozzles 15 are positioned close to each other within the turbine nozzle ring 18 so as to produce minimum wakes of low velocity fluid in the vaneless passage 19 and turbine blades 31. Such wakes are considered to be generally harmful to the turbine hydraulic efficiency. Such nozzle positioning as shown in FIG. 3 and 4 maximizes the percentage of the turbine blades radial flow area occupied by the high velocity fluid relatively to the radial flow area occupied by the wakes. Also, providing vaneless passage 19 permits each of nozzles 15 to be drilled without drilling into other nozzles.
During operation high pressure oil (preferably at about 900 psi) enters the turbine via inlet channel 27. It flows into inlet cavity 32 which supplies the oil flow to the 16 nozzle passages 15 which are contained within turbine nozzle ring 18. The oil flow accelerates through nozzle passages 15 converting pressure energy into kinetic energy which is then utilized to provide a driving force to the plastic turbine blades 31. Oil exits from the plastic turbine blades 31 into exit cavity 34 and is discharged at low pressure through exit channel 33.
Design Details--Three Models
The hydraulic turbine drive described herein will provide very substantial advantages in cost and performance, especially for high speed turbine drives in the 50,000 to 150,000 RPM and 5 to 25 horsepower ranges. I provide in the following table design details applicable to three preferred embodiments recommended for use as drives for motor vehicle superchargers.
______________________________________MODEL 1 2 3______________________________________Engine Power (HP) 140 220 300Turbonetics Compressor Model TO4B S3 TO60-1 TO67Compressor Pressure Ratio 1.52 1.52 1.52Hydraulic Turbine Power (HP) 9.6 14.8 19.5Hydraulic Turbine Pressure (PSIG) 930 1020 1130Hydraulic Turbine Flow (GPM) 23.5 32.0 38.0Hydraulic Turbine Efficiency 0.75 0.77 0.78Hydraulic Turbine Speed (RPM) 69,750 64,500 62,500Hydraulic Turbine Wheel Dia. (mm) 20 20 22Hydraulic Turbine Blade 1.55 1.58 1.65Height (mm)Number of Nozzles 8 8 12Nozzle Angle (DEG.) 11 11 11(measured from tangent)Rotor Blade Angle (DEG.) 28 28 28Number of Rotor Blades 27 27 30______________________________________
The above parameters are chosen for supercharging non-turbocharged engines. When supercharging similar size turbocharged engines the operating parameter requirements will be lowered appropriately using well known thermodynamic principals.
Alternate Turbine Arrangements
An alternate turbine arrangement is shown in FIGS. 5 and 6. This arrangement provides for better matching of the hydraulic turbine with different sizes of supercharging compressor wheels, without the necessity for changing basic turbine blades, tooling and nozzle tooling. FIG. 5 which represents section 5--5 in FIG. 6 shows the vaneless passage 19 having increased radial depth as compared to preferred embodiment shown in FIGS. 3 and 4. FIG. 6 which represents section 6--6 in FIG. 5 shows ring insert 39 forming conically slanted sidewall of vaneless passage 19, which decreases axial width of vaneless passage 19 with decreasing radius. The plastic turbine blades 31 are axially shorter, matching the width of the vaneless passage 19 at the exit of the vaneless passage 19. The change in vaneless passage 19 width affects mainly the radial velocity component of the free vortex flow that is predominant in the vaneless passage 19. Since the tangential velocity component is governed by the law of conservation of momentum, it is inversely proportional to the change in radius and is generally not affected by the change in the width of the vaneless passage 19. By changing the radial velocity component at different rate than the tangential velocity component, the angle of velocity exiting the vaneless passage 19 will change with different width of ring inserts 39 and will affect the turbine operating speed at the point of maximum turbine power, which is one of the objectives of this alternate embodiment. With decreased width of vaneless passage 19, the hydraulic fluid will expand partially through the nozzles 15 and partially through the vaneless passage 19, which will affect the turbine pressure vs flow characteristics, which is another objective of this alternative embodiment.
A solid metal wheel turbine is shown in FIGS. 7 and 8. My preferred metal is brass. The blades are machined. The wheel is more expensive than the metal-plastic wheel discussed above but service life could be considerably longer.
Drive for Supercharger
The turbine described in detail herein is designed for use with the compressor and bearing assembly portion of the TO4B turbocharger, sold by Turbonetics Incorporated, 650 Flinn Avenue, Unit 6, Moorpark, Calif. A drawing of this model is shown in FIG. 2. The dashed line in FIG. 2 encircles the parts not used in a preferred embodiment of the present invention. The parts I use are individually available from the Turbonetics catalogs.
Hydraulic Supercharging System
FIG. 10 shows a one-stage supercharger hydraulic system. This arrangement is similar to FIG. 10 in my U.S. Patent '965 except I have added controller 102 and clutch 103. In this preferred embodiment, engine 68 is a standard Mazda RX-7 rotary engine producing useful mechanical power. Hydraulic pump 81 is driven by engine 68 and the pump is pressurizing, at the rate of about 27 gallons per minute, hydraulic fluid to a pressure of approximately 1000 psi into line 82 which channels the hydraulic fluid to turbine drive 8 and via line 84 to bypass valve 83. Hydraulic pump 81 is a commercially available hydraulic pump such as Parker Model H77. Supercharger compressor wheel 62 is a standard commercially available TO-4 compressor which is driven by turbine wheel 61 as shown in FIG. 10.
Bypass valve 83 when open allows hydraulic fluid to bypass turbine 61 and unloads hydraulic pump 81. To prevent unnecessary wear and friction losses of pump 81, when the high pressure hydraulic fluid is not needed, it is desirable to mechanically disconnect pump 81 from engine 68. This is accomplished with clutch 103. Such clutch is commonly used in driving hydraulic pumps and is commercially available from suppliers such as Northern Hydraulic Co. with offices in Burnsville Minn. In order to increase the useful life of clutch 103, it is desirable to connect and disconnect the pump under minimum pump load whenever possible. For this reason, controller 102 preferably causes bypass valve 83 to open a fraction of a second before clutch 103 disengages pump 81. Also, controller 102 causes bypass valve to close a fraction of a second after clutch 103 engages. These precautions minimize wear on clutch 103.
Also there are other important functions which are provided by sequential activation and deactivation of bypass valve 83 and pump 81 via clutch 103. When pump 81 is disengaged, virtually no oil flows through any oil lines. However, it is important that forced lubrication through lines 94 and 86 be established prior to high speed rotation of turbine 61. Previously described sequential closing of bypass valve 83 allows for free oil flow to bypass turbine 61 and establish full lubrication via lines 94 and 86 prior to high speed rotation of turbine 61 caused by closing bypass valve 83. During disengagement of pump 81, the sequence is reversed in that bypass valve 83 opens first which allows turbine 61 to slow down prior to disengagement of pump 81 via clutch 103 which in turn causes the stopping of forced lubrication via lines 94 and 86.
Turbine discharge line 94 is connected to bypass valve discharge line 85. The amount of flow from turbine wheel 61 discharge is reduced by the bearing lubricant flow of approximately 1.5 GPM which flows through line 86. The combined flow from the bypass valve 83 discharge and turbine wheel 61 net discharge flow are forced to flow through throat 92 of venturi nozzle 93. Throat 92 diameter is sized to provide a drop in static pressure at the throat 92 location of about 60 psi. This location serves as the return point for the lubricant flow supplied to supercharger bearings via line 86. The bearings drain line 87 is connected to expansion tank 88 which provides for thermal expansion of the hydraulic fluid and as a degassing point for the hydraulic fluid. The expansion tank is further connected via line 91 to the throat of venturi 93. Bearing lubricant flow from line 91 joins at that point the combined turbine discharge and bypass valve discharge flows, flowing further through the diffuser section of venturi nozzle 93 where about 80 percent of the throat 92 dynamic head of 60 psi is recovered, thus raising the static pressure in line 96 to about 50 psi above throat of venturi 93 static pressure.
The hydraulic fluid flows from line 96 into oil cooler 97 where the heat losses are rejected. Hydraulic fluid flows further via line 98 back into hydraulic pump 81. Pressurized air flowing through line 64 is typically aftercooled in the air to air aftercooler 65 where large amount of heat of compression is rejected to ambient. Relatively cool pressurized air is further charged into engine 68. Line 71 is the engine exhaust pipe. Bearing oil discharge is directed to expansion tank 88. Expansion tank 88 is vented into supercharger discharge line 64 which pressurizes expansion tank 88 to supercharger discharge line pressure.
FIG. 11 shows a configuration where tank 88 is vented to the atmosphere.
A very important advantage of the present invention over direct drive superchargers is that the supercharger compressed air flow and pressure in the present system can be controlled independent of engine speed. This is simply done by adjusting the bypass flow through valve 83. This permits much higher power at low speeds for motor vehicles and permits easy compensation for altitude changes in airplane engines.
When multi-stage supercharging is desirable, such as in aircraft engine applications or in the case of high output engines, the expansion tank 88 can be vented into the discharge of the last stage supercharger. This will assure in the case of aircraft applications adequate hydraulic pump inlet pressurization even at higher altitudes. FIG. 12 shows such a case utilizing supercharger and turbocharger is series where line 89 is connected to the discharge line out of turbocharger 66. Second aftercooler 67 supplies cooled compressed air via line 75 into engine 68. Exhaust pipe 71 provides the turbine section of the turbocharger 66 with pressurized exhaust flow which after exiting turbocharger 66 turbine section flows further through line 73 to ambient or to another turbine or heat exchanger. Valve 72 provides for turbocharger 76 control to prevent overboosting engine 68.
The FIG. 11 configuration and the FIG. 12 configuration include the clutch and the controller discussed above with respect to the FIG. 10 configuration.
Single Shaft Hybrid Supercharger System
FIG. 13 shows a hybrid supercharger system 120 supercharging internal combustion engine 68 and FIG. 14 shows a portion of the system in greater detail. In this embodiment compressor wheel 62 is driven on a single shaft by engine exhaust turbine 51 and by hydraulic turbine 61. Engine exhaust is provided to turbine 51 by exhaust line 71 and hydraulic fluid is provided to hydraulic turbine 61 by hydraulic pump 81 driven by the engine shaft.
Engine Exhaust Turbine
Engine exhaust turbine 51 is a standard turbocharger turbine such as the turbine portion of the TO4B-V turbocharger. It is driven as stated above by engine exhaust from engine 68 through exhaust pipe 71 and the exhaust from the turbine is to the ambient.
Supercharger Compressor
Compressor 62 is a standard turbocharger compressor again such as the compressor portion of the TO4B-V turbocharger. The exhaust from compressor 62 is directed through line 64, air to air aftercooler 65, and line 70 into the intake manifold of engine 68.
Hydraulic Inflow Radial Turbine
Hydraulic turbine 61 in this embodiment shown in FIG. 14 is similar to the hydraulic inflow radial turbine described in FIG. 1. The FIG. 14 turbine is a turbine with a wheel of only 0.800 inch diameter with the capability of generating 9.6 HP at 69,750 RPM, with pressure differentials of 930 psi and having the capability of operating at the fluid temperatures of 150 to 250 degrees Fahrenheit. As shown in FIGS. 13 and 14 hydraulic turbine 16 is solidly coupled to shaft 53 and supported rotatably by bearings 52. On one end of shaft 53 turbine wheel 51 is attached and on the other end of shaft 53 compressor wheel 62 is attached. During engine operation engine exhaust drives turbine 51 is transferring power to compressor wheel 62 through shaft 53. When additional engine power is required high pressure hydraulic fluid is supplied via line 82 to turbine 61 which augments the power produced by turbine 51. This additional power increases the rotational speed of shaft 53 and compressor wheel 62 producing increased air flow which is supplied to engine 68 via line 64 aftercooler 65 and line 70.
Pump 81 driven by engine 68 through coupling 106 supplies high pressure fluid to hydraulic turbine 61 via line 82. Similarly as in FIG. 10 bypass valve 83 allows hydraulic fluid to bypass hydraulic turbine 61 thus unloading pump 81. Sequential action directed by a controller (similar to the one shown in FIG. 10 but not shown in FIG. 13) allows coupling 106 to be connected and disconnected with virtually no load. Hydraulic fluid is discharged from turbine 61 via line 94 and from bypass valve 83 via line 85 into joint line 96 returning the fluid to pump 81 via oil cooler 97 and line 98.
Pump 105 supplies hydraulic fluid to bearings 52 via line 86. Pump 105 has substantially smaller capacity and produces substantially lower pressure than pump 81. It can be driven directly by the shaft of engine 68 as shown in FIG. 12 or by a small electric or hydraulic motor. Hydraulic fluid supplied to bearings 52 drains into cavities 75 and 76 along with a relative small amount of air leaking through shaft seal 55 from compressor wheel 62 and a relatively small amount of exhaust gas leaking from turbine wheel 51 through shaft seal 56. Mixture of hydraulic fluid and gas bubbles is channeled further to venturi type jet pump vial line 87.
About 50 percent of the total hydraulic fluid flow of pump 105 is channeled to venturi type jet pump 101 via line 102 where it is used to jet pump the hydraulic fluid-gas mixture supplied by line 87. The hydraulic fluid-gas mixture is scavenged into hydraulic tank 88 via line 103. Gas phase is allowed to separate and vent outside tank 88 through breathing cap 89. Alternatively, this gas phase can be reintroduced back into the intake of compressor 62 through a line not shown and be further consumed by engine 68. Following gas separation in tank 88 hydraulic fluid is returned via line 91 to the main hydraulic flow returning via line 96 and further through oil cooler 97 and line 98 to pump 81 and pump 105. In this preferred embodiment pump 81 has a capacity of 22 GPM at a pressure of 1200 psi and pump 105 has a capacity of 2.0 GPM at a pressure of 80 psi.
Sharing Hydraulic Fluid Drive System
One potential disadvantage of a hydraulic fluid driven supercharger system is that it requires hydraulic fluid drive system. This potential disadvantage is minimized if the motor vehicle already has a hydraulic fluid drive system, such as for powering a power steering system. A combined system could be utilized for new or existing vehicles. However, often the pressure requirements for different hydraulic devices are different. For example, power steering pumps utilized for typical truck and bus applications require maximum oil pressures of 2000 to 2500 psi and oil flow rates of 2 to 4 gallons per minute. Maximum pressure for driving the hydraulic supercharger turbine is optimally 900 to 1400 psi at flow rates of 18 to 22 gallons per minute. A combined system dealing with these different requirements is shown in FIG. 15. The fluid for the supercharger turbine is provided by pump 81 and the fluid for the power steering is provided by pump 155. In this preferred embodiment both pumps are commercially available as a single body double pump Model G5-25-6 manufactured by John S. Barnes Corporation, Rockford, Ill. Both pumps are supplied with hydraulic fluid via line 98. Lines 158 channels the hydraulic flow from the power steering mechanism 156 via line 157. Line 158 channels the hydraulic flow from power steering mechanism into line 96 where it mixes with hydraulic fluid exiting venturi nozzle 93, further flows through oil cooler 97 and via line 98 back into pumps 81 and 155.
Improved Turbine Design
FIGS. 3 and 4 show a preferred nozzle body configuration which is described above. An alternate design is shown in FIGS. 16 through 19. In this alternate design the angle of the nozzle is changed slightly and the total nozzle flow area has remained approximately the same while the individual nozzle throat diameters have been decreased and the number of nozzle holes has been increased to the point where the nozzle exit holes are overlapping each other by about 22 percent of the peripheral length of each nozzle exit. FIG. 16 shows the 18 nozzles configuration in the preferred embodiment with nozzle angles of 13 degrees to the tangent on a diameter of 0.993 inch with a 0.044 inch individual nozzle throat diameter. FIG. 17 shows a perspective view of the nozzle body with individual nozzles overlapping each other by about 20 percent. FIGS. 18 and 19 show new improved turbine wheel blades configured for higher efficiency. More uniform distribution of nozzles flow and and nozzles flow angle around the turbine wheel periphery provides for a more uniform inlet flow angle into the rotating turbine blades which allows for a sharper turbine blades leading edges and lower blade losses without potential flow separation at the blade inlets. Combination of overlapping nozzles and the new turbine wheel blades as compared to nozzles shown in FIG. 3 and turbine blades shown in FIG. 9 has produced an approximately 7 percent increase in the overall efficiency of the supercharger. I have determined that exits holes overlaps of between about 20 to 25 percent provides best results. Of course separate pumps could be utilized and separate pumps would be preferred is a clutch is to be provided to disengage to pump supplying the supercharger as discussed above.
It should be understood that the specific form of the invention illustrated and described herein is intended to be representative only, as certain changes may be made therein without departing from the clear teachings of the disclosure. If a clutch is provided to disconnect pump 81 in the case of the hybrid supercharger embodiment, an alternative method of lubricating the supercharger bearings must be provided. Compressor units other than that of Turbonetics could be used for superchargers. Turbine wheels with diameters as low as 0.350 inch and as large as 2.0 inches could be utilized effectively under the teachings of this invention with the diameter of the nozzle exit surface slightly larger. The number of turbine blades could be increased or decreased within the range of about 18 to 40. With changes obvious to persons skilled in the art, the unit described above could be driven with other fluids such as water. Nozzle angles as small as 8 degrees and as large as 30 degrees could be used. The hydraulic system configurations shown in FIGS. 10, 11, 12, and 13 can be improved by employing a variable displacement piston pump, such as Vickers Model PVB15RSY-31-CM-11 in which case the bypass valve 83 could be eliminated. Alternately, a second bypass valve could be added in parallel with valve 83 in order to provide a better stepwise control of the hydraulic systems shown in FIGS. 10, 11, 12 and 13. Accordingly, reference should be made to the following appended claims in determining the full scope of the invention.
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A supercharger system in which an hydraulic driven supercharger shares an hydraulic power system with at least one other hydraulic driven device. The system includes a very high speed radial inflow hydraulic turbine drive driving a compressor for supplying compressed air to an internal combustion engine. Pressurized hydraulic fluid for driving a supercharger hydraulic turbine is provided by a first pump driven by the engine shaft. A second pump provides a higher pressure hydraulic fluid flow for driving at least one other device, such as a power steering device. In a preferred embodiment, when the hydraulic turbine is not needed at high engine speed because sufficient air is provided by a turbosupercharger, a bypass valve is opened by a controller to unload the hydraulic pump and then the controller causes a clutch to decouple the supercharger hydraulic pump from the engine shaft. Each of several preferred embodiments utilize a plastic-metal turbine wheel in which the plastic portion of the wheel other than the blades is solidly anchored within a metal containing wheel. The superchargers provided by the present invention produce immediate response to engine demand for increased combustion air and will dramatically reduce smoke emission during low speed acceleration of bus and truck engines as well as greatly improve engine efficiency. In another preferred hybrid embodiment, the hydraulic turbine drive is mounted on the same shaft with an exhaust driven turbine, and both drive the a compressor providing compressed air to the engine. In a preferred embodiment a novel nozzle body is disclosed having an increased number of nozzles at angles such as to provide substantial exit hole overlapping at nozzle exits to produce an increase of about 7 percent over similar prior art hydraulic turbine driven superchargers.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a gas burner and a warming apparatus (i.e. a warmer) having the burner for use in agriculture and stockbreeding, and more particularly to a burner having no tendency to exhibit backfiring and a warming apparatus for use in agriculture and stockbreeding which warms agricultural products, domestic animals or poultry by radiation heat radiated by heating radiation surfaces with the gas burner.
Illustrations of suitable use of the apparatus of this invention are brooders, poult cages, swine cages, dryers for tobacco and grains, and the like.
The present invention will be explained herein relative to brooders or poult cages as a non-limiting example.
2. Description of the Prior Art
Brooders and poult cages are known in the art and a poult cage heater is described in Japanese Utility Model Registration No. 921354. In brooders known in the art, almost all of the warming apparatuses use frameworks (or frames) having large surface areas as a radiation surface. The frames are heated with a burner and radiation heat radiated from the heated frames is utilized. However, a frame has a considerable weight and therefore, it is necessary to use a brooder having a strong ceiling so as to support the heavy warming apparatus. Further, a frame has a tendency to crack by the repetition of thermal stress and shock which are caused by rapid temperature changes. Such cracking of the frame often injures poults by dropping fragments of the frame thereon. Further, if a heated frame drops on tobacco or grains, it would result in a danger of fire.
I have noted the deficiencies of the framework-type warming apparatus and have studied for a long time to develop a light weight warming apparatus which has high heating efficiency and has no risk to cause cracking. It was known prior to the present invention that a warming apparatus may have a single radiator made of perforated metal plate. However, the warming apparatus having a single radiator made of a perforated metal plate shows insufficient heating efficiency and the heating efficiency itself varies in a wide range depending upon the regulation of the fuel gas flow rate by a thermostat. The reason for the wide variation of heating efficiency would be ascribed to the fact that by the regulation of the fuel gas flow rate, the shape and size of the flame are varied and the contact of the flame with the perforated plate changes significantly. Further the regulation of the fuel gas flow rate often causes local heating of the radiator and if a small flame is used, the flame cannot contact with the perforated plate.
Prior to the study to develop the present invention, I studied how to overcome the deficiencies mentioned above concerning a warming apparatus having a single radiator made of a perforated metal plate, and found that if radiators made of perforated metal plates are disposed adjacent each other and flame is to be located between the two radiators, heating efficiency is improved and the radiators are heated substantially uniformly independent of the fuel gas flow rate. I had found that by the use of the warming apparatus having dual radiators made of perforated metal plates, fuel consumption could be saved by around 20% even in full capacity operation, and could be saved by around 50% in a low capacity operation by throttling a fuel valve when compared with conventional warming apparatuses heretofore used. Based upon the findings described above, I proposed a warming apparatus having dual radiators made of perforated metal plates (Japanese Utility Model application No. 89245/1978; Japanese Utility Model Disclosure No. 10003/1980).
I prepared 50 units of warming apparatuses in accordance with Japanese Utility Model application No. 89245/1978 and they were tested in poultry yards. Unexpectedly, the results reported by the poultry yards were unfavorable. The poultry yards reported that the warming apparatuses often exhibit backfiring. The burners used in the warming apparatuses supplied for testing were burners of conventional type used successfully for a long time in conventional frame-work type warming apparatuses without receiving reports on backfiring.
SUMMARY OF THE INVENTION
From the above, I knew that if new type radiation surfaces are utilized in a warming apparatus, it would be necessary to change type and shape of the burner to be employed in the new warming apparatus so as to accommodate to the new type radiation surfaces. From long experiences in the manufacturing of burners and warming apparatuses, I have known the fact that to prevent backfiring it is helpful to use a flame pore of small diameter and to thicken the burner wall. Accordingly, I have tried the two procedures mentioned above with the warming apparatuses tested in poultry yards. However, no remarkable improvement could be obtained.
I have further continued the study on a procedure to avoid backfiring in the new warming apparatus, and found that when a burner having multiple tubular flame nozzles extending radially from the burner body is used, the new warming apparatuses tested in poultry yards could be used successfully without the problem of backfiring.
Accordingly, the first object of this invention is to provide a burner which can prevent the problem of backfiring. The second object of this invention is to provide a new warming apparatus which has no tendency to exhibit backfiring. The third object of this invention is to provide a warming apparatus of light weight, having high heating efficiency and having no risk of backfiring. Other objects of this invention will be obvious and will appear hereinafter.
As is apparent from the above, the burner of this invention was developed mainly to avoid backfiring in a warming apparatus having dual radiators made of perforated metal plates. However, of course, the burner of this invention is also effective in a conventional framework-type warming apparatus and can minimize the occurrence of backfiring in such warming apparatus. It can easily be understood by one skilled in the art that backfiring in poult cages and swine cages interferes with the growth of poults and swines, since they do not eat food when shocked by a sudden large sound and they become nervous. Further, a strong wind caused by the backfire often blows out a pilot flame and results in the outflow of fuel gas in the cage which would invite a risk of fire. Accordingly, the prevention of backfiring is an extremely important problem in a warming apparatus to be used in poult or swine cages.
Accordingly, the gist of this invention resides in a burner having multiple tubular flame nozzles extending or projecting radially from the burner body and a warming apparatus for use in agriculture and stockbreeding which comprises a burner having multiple tubular flame nozzles extending or projecting radially from the burner body, a first radiator made of a perforated metal plate and a second radiator made of a perforated metal plate, wherein the second radiator is positioned above the first radiator.
The reason why backfiring often occurs in a warming apparatus having dual radiators made of perforated metal plates, even if a burner having no tendency to cause backfiring in a conventional warming apparatus is used, is not yet fully understood but I think that probably, the reason therefor is as follows: In the warming apparatus having dual radiators, the temperature of the burner body rises to a higher level than the temperature found in a conventional framework-type warming apparatus, since in the warming apparatus having dual radiators, the heating efficiency is higher than that of a conventional warming apparatus and in the warming apparatus having dual radiators, radiation surfaces can be extended to a nearer position of the burner when compared with a conventional apparatus. Backfire of gas can only occur when the flame propagating velocity is higher than the velocity of the fuel gas supply. Even if the flame propagating velocity is higher than the velocity of the fuel gas supply, if the flame disappears in the flame nozzle or burner wall, backfiring cannot occur. It is considered that in a conventional warming apparatus, backfiring is prevented by a cooling effect of the burner wall, since in a conventional warming apparatus, the temperature of the burner wall is relatively low. Accordingly, in a conventional warming apparatus, even if a flame enters into the flame nozzle, the flame disappears in the nozzle by the cooling effect of the burner wall. The burner of this invention, i.e. a burner having multiple tubular flame nozzles extending radially from the burner body, is prepared in compliance with my thought above and the burner could completely prevent backfiring. The long tubular flame nozzles extending from the burner body can provide sufficient cooling effect to prevent backfire. From the above, it is apparent that to prevent backfire, the degree of cooling in the flame nozzle is important. In other words the ratio of the cross-sectional area of the gas path and the area of the surrounding surface thereof is important.
Accordingly, the cross-section of the tubular flame nozzle, hereinafter called flame pipe, is not necessarily limited to a circle and a flame pipe having a cross-section of an oval or a polygon can also be used without disadvantage. The length of the flame pipe is determined so as to give a sufficient cooling effect and the preferred range of the length is varied depending upon the diameter, temperature, etc. The length can be shortened when a flame pipe of small diameter and in low temperature is used. It is preferred that the internal diameter of the flame pipe is selected within a range from 1 mm to 4 mm and the length thereof is from 10 mm to 40 mm. When flame pipe having an internal diameter of higher than 4 mm is used, the risk of backfiring cannot be avoided completely and if a flame pipe having an internal diameter of less than 1 mm is used, the warming effect is insufficient due to the shortage of fuel gas supply. If the length is shorter than 10 mm, prevention of backfiring is insufficient and even if a flame pipe is extended more than 40 mm, no special merit can be obtained from such excess length.
In the warming apparatus of this invention, it is preferred to provide a heat interception plate between the burner and the radiators so as to maintain the burner at a relatively low temperature. Use of a heat interception plate is effective to shorten the length of the flame pipe and, therefore, allows the use of wider radiators (radiation surfaces). Further, the use of a heat interception plate is also effective to warm the outer side of the poult cage, since a part of the heat radiated from the radiation surfaces is reflected by the heat interception plate to the outer side of the cage. As stated before, in the warming apparatus of this invention, even if the supply of fuel gas is reduced, there is no fear of backfiring, and therefore, the flow rate of gas can be controlled in a proportional action by a throttle-valve which is actuated by a thermometer. Thus, by the use of the warming apparatus of this invention, temperature control can easily be accomplished.
In a conventional apparatus heretofore used, temperature control is conducted by the use of a snap valve, i.e. a kind of on-off valve, which is actuated by a thermostat and in a conventional warming apparatus, the use of a proportional action valve is avoided. The reason therefor is that in a conventional apparatus, if the rate of fuel supply is reduced, there is a risk of backfiring and the heating efficiency varies significantly depending upon the flow rate of the fuel gas.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a preferred embodiment of the warming apparatus of this invention;
FIG. 2 is a top plan view of the apparatus shown in FIG. 1; and
FIGS. 3 to FIG. 5 are simplified cross-sectional views of prior art warming apparatuses in which the left hand sides of the figures show a warming apparatus having dual radiators made of perforated metal plates specified in the present invention, and the right hand sides of the figures show a warming apparatus having single radiator made of a perforated metal plate.
DETAILED DESCRIPTION
Referring to FIG. 1, a frustoconical (shape of a frustrum of a cone) heat reflecting plate 4 enlarging upwardly is shown at the top of the figure. In the embodiment illustrated in FIG. 1, both ends, i.e. lower and upper ends, of the frustoconical heat reflecting plate 4 are not closed. The circular openings formed by the lower and upper ends of the frustoconical heat reflecting plate 4 are acting as a stack and assist the cooling of burner body 2 and flame pipe 3 by the circulation of air through the frustoconical space. Beneath the heat reflecting plate 4, a second radiator 6 made or a perforated metal plate having a frustoconical shape is provided. Further, beneath the second radiator 6, a first radiator 5 made of a perforated metal plate having a frustoconical shape is provided. Similar to the reflecting plate 4, the lower ends of the second radiator 6 and the first radiator 5 are not closed and form circular openings. It is preferred that the degree of inclination of the first radiator 5 is higher than that of the second radiator 6 and the first radiator 5 and the heat reflecting plate 4 are combined at the outer end thereof. Between the first radiator 5 and the second radiator 6, it is necessary to have some distance and the arrangement to provide two radiators so close to each other is undesirable. If the two radiators 5, 6 are arranged so closely, combustion of fuel will be interfered with an incomplete combustion will occur. Therefore, between the two radiators, it is preferred to provide a distance of about two times the widths of the flame.
In the figures, the cross-sections of the frustocones are shown as circles. However, it is obvious to a person skilled in the art that the cross-section of the frustocone can be a polygonal shape. The diameter of the lower end of frustoconical second radiator 6 is substantially the same as that of heat reflecting plate 4. The diameter of the lower end of frustoconical first radiator 5 is somewhat larger than those of the second radiator 6 and heat reflecting plate 4. Further, in the warming apparatus, a heat interception plate 7 is provided and the lower end of the heat reflecting plate 4 contacts the heat interception plate 7 just above its midsection. The heat interception plate 7 prevents heating of burner body 2 and flame pipes 3 by reflecting the heat radiated from the radiators and by accelerating air circulation through the cylindrical space as a stack. The second radiator 6 extends to the heat interception plate 7, but between the heat interception plate 7 and the first radiator 5, it is necessary to provide a substantial distance. The distance found between the plate 7 and the radiator 5 can provide a sufficient space to allow entering of secondary air. To obtain an excellent result, it is preferred to use perforated metal plate having a perforation density of from 15% to 60% as radiation surfaces. The radiators 5 and 6 should be made of a heat resisting metal and examples of suitable metals are SUS430 and SUS301.
In the figures, numeral 1 shows a gas nozzle and it is designed to induce primary air between burner body 2 and gas nozzle 1. Gas nozzle 1 receives fuel gas from line 12 which has a valve 11 therein. In the figures, the upper portion of burner body 2 is extended to form a disk-like shape and at the outer periphery of the disk, many tubular flame pipes 3 are provided radially as seen in FIG. 2. The heat interception plate 7 has many small holes 8. The number of the small holes 8 and the position thereof are determined so as to correspond to the number and the position of the flame pipes 3. The outer end of a flame pipe 3 is located in the small hole 8 of the heat interception plate 7. If the outer end of the flame pipe 3 projects outwardly of the heat interception plate 7, the extended portion of the flame pipe 3 will receive undesirable over heating. It is also undesirable that the outer end of the flame pipe 3 is located within the heat interception plate 7. The reason therefor is that in the arrangement mentioned above, if the relative position of the flame pipe 3 and heat interception plate 7 is changed by some causes, the flame contacts with the heat interception plate 7 which not only results in lowering of heating efficiency but also results in undesirable overheating of heat interception plate 7 and flame pipe 3. Accordingly, it is preferred to locate the outer end of the flame pipe 3 in the small hole 8 of heat interception plate 7. In the figures, numeral 9 shows a connector which connects the burner body 2 and the heat interception plate 7. Numeral 10 shows a guide which determines the position of the flame pipes 3. The guide 10 is located inside the heat interception plate 7 and concentric with it. The guide 10 has many small holes and the flame pipes 3 extend from the burner body 2 through the holes of guide 10. The position of flame pipes 3 is fixed thereby.
In the embodiment shown in the figures, the flame pipe 3 has following dimensions: Internal diameter 3 mm; External diameter 5 mm and Length 15 mm. The connection of the heat interception plate 7 and the heat reflecting plate 4 can be carried out in any suitable manner, such as by welding or bolting. In the embodiment shown in the figures, the outer end of flame pipe 3 is located between the first radiator 5 and the second radiator 6. Accordingly, the flame can extend through the space formed between the first and the second radiators.
As stated above, the warming apparatus of this invention has dual radiators made of perforated metal plates. As would be apparent from the prior art as shown in FIGS. 3-5, the use of dual radiators can minimize waving of the flame and provides a uniform heating of the radiators. In the warming apparatus of this invention, even if the flame is shortened, the contacts of the flame with the second radiator 6 are still effectively maintained and the heat radiated from the hot second radiator 6 can reach the bed of the cage directly or indirectly via the heating of the first radiator. If the second radiator 6 is made of a flat plate having no perforations, the result obtained thereby is essentially the same as that obtained by the use of a warming apparatus having a single radiator. The explanation for the difference of the results obtained by the use of single radiator and dual radiators is not yet clear to me, but it is my thought that the difference may arise from the following causes. By the use of a second radiator made of perforated metal plate, the contacts of the flame and the second radiator are improved and the perforations enhance the formation of small vortexes around the flame which improve the contacts between the fuel and secondary air. Naturally, sufficient contacts of fuel with an appropriate amount of air results in a high combustion temperature and may increase radiation of heat.
As heated above, the apparatus of this invention has no tendency of backfiring, even if the fuel supply is controlled by the use of a throttle-valve. Accordingly, in a brooder or a poult cage, when an actual temperature deviates from a set temperature, the deviation of temperature can be compensated by increasing or decreasing the fuel supply in proportion to the deviation of temperature by valve 11 in the fuel gas supply line 12. Thus, temperature control can be effected easily by the use of the burner and the warming apparatus of this invention. The fact mentioned above can give significant improvement in controlling of temperature when compared with the use of a conventional apparatus in which a throttle-valve cannot be used and an on-off valve can only be used to avoid a danger of backfiring. Accordingly, in a preferred embodiment, the burner or the warming apparatus of this invention is used in combination with a valve 11 (FIG. 1) workable with a proportional action, such as a throttle-valve. The term "proportional action" used herein means not only "proportional action" in a strict sense but also "proportional-integral action" and "proportional-integral-derivative action". The mechanism of these three kinds of controlling operations and the effects obtained thereby are well known in the art.
In the description above, the present invention is described relative to a warming apparatus for a poult cage, but it would be apparent to a person skilled in the art that the present invention can be used in other fields. For example, the burner and the warming apparatus of this invention can be used in a swine cage. In such case, however, it is preferred to use a somewhat smaller apparatus than those used in a poult cage.
From the explanations given above, the merits obtainable by the use of the burner and the warming apparatus of this invention can easily be understood by a person skilled in the art.
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A warming apparatus uses a gas burner which comprises a burner body and a plurality of tubular flame nozzles projecting radially from the burner body. The tubular nozzles have an internal diametr which ranges from about 1 mm to about 4 mm, and the projecting length of the tubular nozzles which extends from the burner body is within a range of from about 10 mm to about 40 mm. The nozzles have axially directed nozzle openings. The warming apparatus comprises the gas burner in combination with first and second radiators and a heat interception plate positioned between the burner body and the radiators.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application relates to and claims priority from U.S. Provisional Ser. No. 61/344,801 filed Oct. 13, 2010 and International Ser. No. PCT/US2011/056230 filed Oct. 13, 2011, the entire contents of each of which are incorporated herein by reference.
FIGURE SELECTED FOR PUBLICATION
FIG. 3
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to the field of piezoelectric crystals and piezoelectric crystal composites operating for high frequency (>20 MHz). More particularly, the present invention provides high frequency piezoelectric crystal composites for high resolution imagery for preferred use in industrial and medical ultrasound applications, and even more particularly to the methods of manufacturing the same.
Description of the Related Art
Conventionally, PMN-PT based piezoelectric single crystals have superior dielectric and piezoelectric properties compared to the traditional PZT ceramics. To more fully exploit the excellent properties of single crystals, crystal composites have been fabricated to improve the electromechanical coupling coefficient and thus transducer performance characteristics.
For ultrasound transducers, the operating frequency is inversely related to the thickness of the piezoelectric material. Thus, as the targeted operating frequency increases, the thickness of piezoelectric material decreases accordingly this induces operative and electro mechanical difficulties. On the other hand, an optimal aspect ratio has been attempted for the piezoelectric crystal pillars in order to maintain the high electromechanical coupling coefficient of piezoelectric composite. To accommodate the requirements in thickness and aspect ratio, the feature size of the piezoelectric material in the high frequency composite needs to be reduced to meet the optimal ratio.
One attempt has been provided for such medical applications of micromachined imaging transducers known generally from U.S. Pat. No. 7,622,853 (Rehrig et al., assigned to SciMed Life Systems, Inc.), the entire contents of which are incorporated herein by reference.
As noted in U.S. Pat. No. 7,622,853, a medial device is provided with a transducer assembly including a piezoelectric composite plate formed using photolithography micromachining. The particular steps in the '853 patent are noted therein. The '853 patent additionally notes the conventional challenges of micromachining poled PZT ceramics, but fails to adjust to the now appreciated challenges noted below and additionally includes the detrimental impacts of electric field and clamping effect on strain. There is now appreciated a need for further imagery resolution and sensitivity over a depth that cannot be achieved.
Finally, it is further recognized that a high frequency transducer is typically driven at a higher electrical field compared to a low frequency transducer.
Accordingly, there is a need for an improved high frequency piezoelectric crystal composite, optionally related devices, and further optionally methods for manufacturing the same.
Related publications include the following, the entire contents of each of which are incorporated herein fully by reference:
1. P. Han, W. Yan, J. Tian, X, Huang, H. Pan, “Cut directions for the optimization of piezoelectric coefficients of PMN-PT ferroelectric crystals”, Applied Physics Letters, volume 86, Number 5 (2005). 2. S. Wang, et al., “Deep Reactive Ion Etching of Lead Zirconate Titanate Using Sulfur hexafluoride Gas”, J. Am. Ceram. Soc., 82(5) 1339-1341, 1999. 3. A. M. Efremov, et al., “Etching Mechanism of Pb(Zr, Ti)O 3 Thin Films in Cl 2 /Ar Plasma”, Plasma Chemistry and Plasma Processing 2(1), pp. 13-29, March 2004. 4. S. Subasinghe, A. Goyal, S. Tadigadapa, “High aspect ratio plasma etching of bulk Lead Zirconate Titanate”, in Proc. SPIE—Int. Soc. Opt . Engr, edited by Mary-Ann Maher, Harold D. Stewart, and Jung-Chih Chiao (San Jose, Calif., 2006), pp. 61090D1-9.
ASPECTS AND SUMMARY OF THE INVENTION
In response, it is now recognized for the present invention that improved PMN-PT based piezoelectric crystal composites and for methods for manufacturing composite crystal elements required and are provided herein.
The present invention generally relates to high frequency piezoelectric crystal composites, devices, and method for manufacturing the same. In adaptive embodiments an improved imaging device, particularly a medical imaging device or a distance imaging device, for high frequency (>20 MHz) applications involving an imaging transducer assembly is coupled to a signal imagery processor. Additionally, the proposed invention presents a system for photolithography based micro-machined piezoelectric crystal composites and their uses resulting in improved performance parameters.
The present invention additionally relates to imagery devices, particularly medical devices and especially to improved medical imaging devices and systems that employ the proposed novel structures of crystal composite and composite crystal elements.
It is a further aspect of the present invention that the innovative fabrication approaches make the commercial production of crystal composite feasible and practical. The high frequency crystal composite (20 MHz to >100 MHz, and a thickness electro-mechanical coupling factor k t 0.65-0.90 can be used for medical ultrasound imaging and diagnosis with significantly improved performances. The high frequency crystal composite is especially applicable to use with skin, eye, intravascular, intracardiac, intracranial, intra-cavity or intra-luminal medical diagnosis devices. Such devices may be used in applications involving dermatology, ophthalmology, laparoscopy, intracardiac and intravascular ultrasound.
There is a further aspect of the invention that recognizes the use of crystal with a high coercive field (EC) when transducer excitation field is also high. In one alternative aspect of the present invention, ternary crystals Pb(In½Nb½)O3-Pb(Mg⅓Nb⅔)O3-PbTiO3 (PIN-PMN-PT) and other PMN-PT based crystals are recognized as having improved thermal and electrical properties than the binary PMN-PT crystal. As a consequence, an alternative embodiment of the invention employs a crystal composite based on these crystals which it is now recognized inherit the improved properties of the ternary crystals.
In one aspect of the particular invention there is provided a piezoelectric PMN-PT based crystal composites, having the crystal composition represented by the formula I: x*Pb(B′½B″½)O3-y*PbTiO3-(1-x-y)*Pb(Mg⅓Nb⅔)O3, where, x is defined as molar % 0.00 to 0.50; and y is defined as molar % 0.00 to 0.50, B′ represents Indium (In), Ytterbium (Yb), Scandium (Sc) or Iron (Fe), B″ represents Niobium (Nb) or Tantalum (Ta). Additionally, formula I be combined with additives Manganese (Mn) of up to 5% (wt %) and/or Cerium (Ce) of up to 10% (wt %) of a total batch weight.
In one aspect of the particular invention there is provided a piezoelectric PMN-PT based crystal composites, having the crystal composition represented by the formula II: x*ABO3-y*PbTiO3-(1-x-y)*Pb(Mg⅓Nb⅔)O3, where, x is defined as molar % 0.00 to 0.50; and y is defined as molar % 0.00 to 0.50, A represents Lead (Pb) or Bismuth (Bi), B represents Indium (In), Ytterbium (Yb), Iron (Fe), Zirconium (Zr), Scandium (Sc), Niobium (Nb), Tantalum (Ta), or a combination of the above elements. Additionally, formula II may be combined with additives Manganese (Mn) of up to 5% (wt %) and/or Cerium (Ce) of up to 10% (wt %) of a total batch weight.
In a further aspect of the invention piezoelectric crystal composites having formula I or II above are prepared by a method involving photolithograph based micromachining.
In a further aspect of the invention of the proposed invention as noted herein the composite posts proposed have an aspect ration of a post height (H) to an effective post width (W), H:W, of greater than 0.50, preferably greater than 1.0, and more preferably greater than 2.0
In a further aspect of the invention the proposed composite is a discontinuous hexagonal arrangement in a hybrid 1-3 configuration, and the piezoelectric crystal is (001) cut and poled in <001> direction.
In a further aspect of the invention, the proposed composite is a discontinuous hexagonal arrangement in a hybrid 1-3 configuration, and the piezoelectric crystal is (011) cut and poled in <011> direction, wherein polymeric fill lines extend in +/−32.5° (+/−2.5°) away from <10 1 > direction.
In a further aspect of the invention, the proposed composite is parallelogram hybrid 2-2/1-3 configuration, and the piezoelectric crystal is (011) cut and poled in <011> direction, wherein polymeric fill lines extend in +/−32.5° (+/−2.5°) away from <10 1 > direction.
The above and other aspects, features, systems, methods, and advantages of the present invention will become apparent to one with skill in the art upon study of the following description read in conjunction with the accompanying drawings, in which like reference numerals designate the same elements. It is intended that all such additional systems, methods, features, compositions, and details included within this description, be within the scope of the invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a process flow for a photolithography based micro machining process according to the present invention.
FIG. 2 is an illustrative schematic view of an imaging transducer arrangement operatively coupled with a digital transducer signal processor for operatively imaging the signals from the imaging transducer.
FIG. 3 is a 2-dimensional plot for calculated value of d 31 on (011) plane (the plane out of the paper) for a PMN-PT crystal. FIG. 3 indicates that the micro strain is fully zero in the directions +/−32.5° (see arrows) between curves. Calculated using formula d′ 31 =d 31 *Cos(θ)*Cos(θ)+d 32 *Sin(θ)*Sin(θ).
FIG. 4A is an illustrative perspective schematic of a hybrid 1-3 crystal composite for a transducer having a hexagonal structure, <001> cut, noting directional orientation and epoxy polymer and crystal designations with no impact on clamping direction due to <001> cut.
FIG. 4B it a top-view SEM image of a 1-3 crystal composite of FIG. 4A for a transducer having a hexagonal structure, <001> cut, thickness 30 μm, wherein the black lines are understood as kerfs filled with an epoxy polymer, in accordance with a preferred embodiment of the present invention.
FIG. 5A is an illustrative perspective schematic of a 1-3 crystal composite for a transducer having a hexagonal structure, <011> cut, noting directional orientation and epoxy polymer and crystal designations
FIG. 5B is a top-view SEM image of a hybrid 1-3 crystal composite of FIG. 5A for a transducer having a hexagonal structure, <011> cut, thickness 22 μm, wherein the black lines are kerfs filled with an epoxy polymer, in accordance with a preferred embodiment of the present invention.
FIG. 5C is an illustrative orientation drawing noting the kerf orientation at the identified 30°, and a clamping direction between 30° and 35°, and preferably +/−32.5° from the <10 1 > direction orientation for a hexagonal polygon arrangement as in FIGS. 5A and 5B .
FIG. 5D is an illustrative dimensioning guide regarding calculating effective post widths where not square, here, an average width is calculated from the diagonal widths and heights for aspect ratio considerations.
FIG. 6A is an illustrative perspective schematic of a 1-3 crystal composite for a transducer having a parallelogram (diamond) structure, to minimize the transverse clamping effect by the epoxy polymer filled kerfs, in accordance with a preferred embodiment of the present invention.
FIG. 6B is an illustrative plan view in (011) cut of a hybrid 1-3 crystal composite (of FIG. 6A ) for a higher coupling factor wherein the transverse epoxy polymer filled kerfs are made at +/−32.5° (+/−2.5°) are therefore strain free. The clamping effect direction is noted.
FIG. 7A is a schematic pattern drawing of the proposed hybrid 2-2/1-3 crystal composite of an (011) cut with the kerf filling line in the direction of +/−32.5° (+/−2.5°) relative to the <10 1 > direction.
FIG. 7B is a top-view SEM image of an (011) cut hybrid 2-2/1-3 crystal composite as in FIG. 7A , in accordance with a preferred embodiment of the present invention.
FIG. 7C is a perspective view of FIG. 7A showing a schematic pattern drawing of the proposed hybrid 2-2/1-3 crystal composite of an (011) cut with the kerf filling line in the direction of +/−32.5° (+/−2.5°) relative to the <10 1 > direction.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to embodiments of the invention. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps. The drawings are in simplified form and are not to precise scale. For purposes of convenience and clarity only, directional (up/down, etc.) or motional (forward/back, etc.) terms may be used with respect to the drawings. These and similar directional terms should not be construed to limit the scope of the invention in any manner.
As will be used herein the Miller Indices identifiers serve as vector representations for orientation of an atomic plane in a crystal lattice having three axes represented by a set of 3 integer numbers, for example such conventional identifiers as, for example <010> or <10 1 >, are used.
As will be further used herein, for example regarding the images of the present invention wherein polymeric (epoxy) regions are filled with a piezoelectrically non-active material, that the use of the phrase “kerf” is not limited to a region formed by a mechanical saw of any kind—instead the phrase “kerf” will be understood broadly by ones skilled in the art to represent the region between piezoelectric posts which receiving polymeric material, whether or not the actual region is formed by a saw, or by any other manufacturing process discussed herein.
Additionally, a description methodology (the M-N labeling convention) is used to describe the number of directions which each section of the piezoelectric material and polymeric material continuously extend, wherein M represents the number of continuous directions in which the piezoelectric (PMN-PT) material extends and N represents the number of directions in which the polymeric (epoxy) material continuously extends. While those of skill understand this convention, however as modified herein, the structures suggested herein have never been subjected to the M-N convention and therefore applicant requires a hybrid understanding wherein the directional extensions generally remain, but are discontinuous or interrupted, for example, by intersection with a cross directional polymeric material extending in a different and also discontinuous direction. In this manner, it will be understood that the (as later described) hexagonal structure involves discontinuous, interrupted, or hybrid polymeric (epoxy) material directions where the polymeric material direction is linear in only one direction along the length of the piezoelectric material itself and the other polymeric (epoxy) directions are interrupted-in-direction or discontinuous-in-direction by encountering piezoelectric material. One embodiment of the invention further has a structure the result of the piezoelectric material elements having discontinuous or interrupted side alignments with respective sides/edges of proximate piezoelectric material elements, so that sides/edges may not be coplanar (on the same plane) but may extend on parallel planes. Still a further embodiment of the invention does not contain simple regular unit elements ( FIGS. 7A-7C for example), and instead requires a still further hybridization of the M-N convention.
This invention relates to the 20 MHz to >100 MHz high frequency piezoelectric single crystal composites/composite crystal elements and the process for the preparation thereof. The novel high-coupling factor crystal composites can broadly replace the legacy materials such as piezoelectric ceramics, single crystal and traditional crystal composite for high frequency transducers.
Referring now to FIG. 1 a process flow for a photolithography based micro machining process 100 is discussed. In the first step 10 , a plate or block of piezoelectric single-crystal material (shown later), such as PMN-PT (Lead Magnesium Niobate-Lead Titanate) based crystals, such as binary solid solution PMN-PT and ternary solid solution PIN-PMN-PT (Lead Indium Niobate-Lead Magnesium Niobate-Lead Titanate) or PYbN-PMN-PT (Lead Ytterbium Niobate-Lead Magnesium Niobate-Lead Titanate) or these crystals above with dopants (Mn, Ce, Zr, Fe, Yb, In, Sc, Nb, Ta, and others). Such ternary crystals of the PMN-PT based piezoelectric crystals are now recognized as having improved thermal stability and increased coercive field that allows a higher driving electrical field.
The crystal composite and the composite crystal elements have novel structures and/or new crystallographic cut directions. The crystal composites can be fabricated by proprietary procedures including photolithography, deep reactive ion etching, fine mechanical finishing and electrode coating.
The plate (not shown) is preferably lapped on both sides and polished on one of the sides. The lapped and unpolished side can then be bonded to a glass carrier (not shown), which is bonded to a silicon, Si, wafer (not shown). The dimensions of the plate are in the range of ten (10) millimeters (“mm”)×ten (10) mm×0.20 mm-to-1.20 mm in thickness; however, the dimensions could be of any size.
The material of the plate is a single crystal with electroded faces oriented along the <001> or <011> crystallographic directions. As one of ordinary skill in the art would appreciate, a single crystal structure can desirably have a high piezoelectric coefficient (e.g., d 33 >2000 pC/N, d 33 >0.8, d 33 ′>0.7). The plate preferably has a dielectric constant in the range of approximately 4000 to >7700 and a dielectric loss of less than 0.01.
It will be recognized that the plate piezoelectric single crystal is a ternary crystal formed according to the following formulas I or II:
Formula I: x*Pb(B′½B″½)O3-y*PbTiO3-(1-x-y)*Pb(Mg⅓Nb⅔)O3, where, x is defined as molar % 0.00 to 0.50; and y is defined as molar % 0.00 to 0.50, B′ represents Indium (In), Ytterbium (Yb), Scandium (Sc) or Iron (Fe), B″ represents Niobium (Nb) or Tantalum (Ta). Additionally, formula I may be combined with additives Manganese (Mn) of up to 5% (wt %) and/or Cerium (Ce) of up to 10% (wt %) of a total batch weight.
Formula II: x*ABO3-y*PbTiO3-(1-x-y)*Pb(Mg⅓Nb⅔)O3, where, x is defined as molar % 0.00 to 0.50; and y is defined as molar % 0.00 to 0.50, A represents Lead (Pb) or Bismuth (Bi), B represents Indium (In), Ytterbium (Yb), Iron (Fe), Zirconium (Zr), Scandium (Sc), Niobium (Nb), Tantalum (Ta), or a combination of the above elements. Additionally, formula II may be combined with additives Manganese (Mn) of up to 5% (wt %) and/or Cerium (Ce) of up to 10% (wt %) of a total batch weight.
Several non-limited examples of formulae I and II are found in the following table. It will be recognized that any composition matching the formulae I or II is included herein by reference as a suitable composition.
Formula I
Formula II
Example 1
31% PIN-46.7%
15% BiScO-58.6% PMN-26.4% PT
PMN-20.8% PT
Example 2
15% PIN-53.7%
15% BiScO-57.6% PMN-
PMN-22.4% PT:8.9%
26.4% PT:1% Ce
Ce
Example 3
25% PYbN-45.7%
10% BiScO-58.6% PMN-
PMN-25% PT:2% Mn
26.4% PT:5% Mn
Example 4
10% PZrT-64%
7% BaTiOs-61% PMN-PT-32% PT
PMN-24% PT:3% Mn
In a second step 20 of photolithography a thin metal (Nickel) seed layer was applied and then in a step 30 a mask was prepared by spincoating a photoresist on top of the seed layer. The mask defines the desired shape and/or pattern of imaging element(s) within the piezoelectric composite material. After baking, UV exposure, and development, a patterned photoresist was obtained.
A Nickel mask of a predetermined thickness (here 10 microns, but can be any thickness from 1 to 30 microns) was electroplated thereon to have the inverse pattern of the mask of the photoresist, which was then stripped away using reactive ion etching. The use of hard or high molecular weight metals such as Ni and Pt, is desirable for selectivity to protect the covered underlying area of the plate from being later etched.
The etching process, such as reactive ion etching (“RIE”) is used as noted, but other etching processes can be used, such as wet-etching. In one preferred embodiment, chlorine, Cl 2 based RIE etching is used, which has an etching rate of approximately from less than 3 microns/hour to 12 microns/hour and can cause a substantially vertical etching profile (e.g., >89 degree). In the alternative, or in addition, to Cl 2 , sulfur hexafluoride, SF 6 , based etching can be used, which has similar etching properties to that of Cl 2 . The nickel, Ni, pattern protects the underlying portions of the plate covered by the pattern from the etching process.
In a step 40 the crystal parts with the patterned etched mask were located into an ICP-plasma unit for deep reactive ion etching (DIRE) using the preferred Cl 2 gas. As a result of step 40 , one or more deep posts of the type discussed later are formed in the plate with one or more kerfs bounding each respective post, etched in the uncovered portions of the plate. The one or more kerfs can have a width in the range of approximately from less than one (<1) to twelve (12) microns, and preferably from 1 to 10 microns in width.
The respective posts can have a width ranging from approximately 3 to 200 (or longer in length for the hybrid 2-2/1-3 configuration discussed herein) microns and have a height in the range of approximately less than five (<5) to more than seventy (>70) microns, such that in one embodiment, it is preferable to have an aspect ratio (post height/post width) of at least one to dampen the effect of lateral modes. For the dimensions of the plate described above, the etching process can last approximately six (6) to eight or eighteen (8 or 8) hours. After the etching step 40 , the plate is then rinsed with a solvent for cleaning.
In the next step 50 , the kerfs are filled with an epoxy, such as Epoxy 301 provided by Epo-Tek, although other epoxies may be employed without departing from the scope and spirit of the present invention. A vacuum (not shown) may be utilized to remove air bubbles and prevent any void within the kerfs. In the next step 60 , after the epoxy cures, the top portion of the plate and epoxy are lapped to a thickness of approximately 25 microns. In a step 70 , an electrode pattern is then applied to the plate to form the imaging transducer pattern. The electrode pattern is preferably comprised of gold (Au) and/or chromium (Cr). Moreover, as one of ordinary skill in the art would appreciate, electronic circuitry, such as imaging processing circuitry, (not shown) can be bonded to the electrodes (not shown). Further, the electrode pattern formed on the plate can define any pattern of imaging transducers, including an array, e.g., an imaging transducer at each post, or a single imaging transducer. An epoxy layer may be applied to the back of the plate.
In a further step 80 the plate is dimensioned suitably as desired and then poled at 50 VDC. In a step 90 key dielectric and piezoelectric properties are measured and calculated with suitable equipment, for example Agilent 4294A Precision Impedance Analyzer.
Imaging transducers having an operating frequency at above 20 MHz, e.g., to >100 MHz, can be developed using photolithography based micromachining, such as the process 100 described above. The higher frequency of operation increases the resolution and image depth of an imaging transducer. Furthermore, the bandwidth of the imaging transducer, particularly when single crystal PMN-PT is employed as the piezoelectric, can be close to 100%, compared to only 70 to 80% for <20 MHz transducers made with PZT ceramic.
The greater bandwidth improves the transducer's axial resolution, which increases the imaging depth. This is desirable for high frequency transducers, which have very limited imaging depth due the strong attenuation of high frequency ultrasound in tissue. When single crystal is used, these advantages can be achieved with sensitivities equivalent to or better than ceramic transducers. These high frequency transducers can be applied to a number of medical procedures including the imaging of the anterior region of an eye for monitoring surgical procedures such as cataract treatment by lens replacement and laser in situ keratomileusis (LASIK) and tumor detection (preferably up to sixty (60) MHz for fifty (50) .mu.m resolution); skin imaging for care of burn victims and melanoma detection (preferably twenty five (25) MHz for subcutaneous, fifty (50) MHz for dermis and one hundred plus (100+) MHz for epidermis); intra-articular imaging for detection of pre-arthritis conditions (preferably twenty five (25) to fifty (50) MHz); in-vivo mouse embryo imaging for medical research (preferably fifty (50) to sixty (60) MHz); Doppler ultrasound for determination of blood flow in vessels<one hundred (100) .mu.m in diameter (preferably twenty (20) to sixty (60) MHz); intracardiac and intravascular imaging (preferably ten (10) to fifty (50) MHz); and ultrasound guidance for the biopsy of tissue.
As an example of such a medical device, we refer not to FIG. 2 , wherein an exemplary medical treatment transducer device 200 includes an array (not shown) of transducers is joined with an exemplary array (not shown) of the proposed inventive piezoelectric posts (not shown) in a form (shown circularly) suitable for use in a catheter or guidewire of some type. An exemplary guidewire and signal conduit 220 transmit received imagery signals to a computerized processing and imaging system 230 for display of the received imaging signals. The conduit 220 may be formed in any conventional form operative for the purpose. For example it may be formed of polymer or metal construction and contain multiple signal or control wires to operatively join a treatment end with the imagery display comptroller.
The present inventors have determined that the PMN-PT based piezoelectric crystals usually use (001)-cut and poling <001> which gives the highest d 33 but the lateral clamping effect by the epoxy filled into kerfs cannot be avoided and his highly detrimental to performance for a variety of imaging systems and methods of use. We first use the hexagonal (“bee nest”) type hybrid shaped 1-3 type crystal composite. The advantage is significant in that the structure is mechanically much stronger and more stable than square-shaped pattern if the both piezo-effective volume is the same. It is much more practical/suitable for large scale fabrication.
Referring now to FIG. 3 , it was determined as particularly suitable the (011)-cut and poled PMN-PT based crystal for particularly high frequency transducers. The advantage is the lateral clamping effect by the epoxy in kerfs can be totally avoided if the kerf filling in the direction of +/−32.50° (+/−2.5°) is used in a direction away from the <10 1 > direction.
We have induced the formula (I) to calculate the d 31 by coordination rotation:
d′ 31 =d 31 *Cos(θ)*Cos(θ)+ d 32 *Sin(θ)*Sin(θ) (1)
From the 2-D plot of the d 31 , it is indicated that the micro strains are zero in the +/−32.50° directions away from the <10 1 > direction. It is a significant advantage that the lateral strain-free arrangement will greatly enhance the electromechanical coupling factor and broaden the bandwidth permissible in an ultrasound device.
Discussion of FIGS. 4A to 4B a schematic and SEM image of a hexagonal hybrid 1-3 crystal composite structure having an (001) cut. Here the ‘hybrid’ phrase is used for M-N configuration as for the first time discontinuous kerf lines are used and for the first time hexagonal crystal posts are used. As a result, this aspect of the invention is isotropic, and the field/clamping effect is substantially the same in any direction since the kerf is parallel to the poling direction. Perspective view FIG. 4A illustrates directional orientation and hybrid M-N arrangement for discontinuous or interrupted polymeric material arrangements. The SEM image of FIG. 4B is shown having a thickness of 30 microns. As noted, in view of the (001) cut and a poling at <001> direction, the clamping effect is substantially uniform in any direction (see illustrative arrows) and the reliability of the piezoelectric crystal composite is greatly enhanced since failure direction must be non-linear and the clamping effect is also not directionally dependent.
Referring now to FIGS. 5A and 5B a schematic and SEM image of a hexagonal hybrid 1-3 crystal composite structure having a completely new (011) cut. Perspective view FIG. 5A illustrates directional orientation and hybrid M-N arrangement for discontinuous or interrupted polymeric material arrangements. Here the ‘hybrid’ phrase is used for M-N configuration as for the first time discontinuous kerf lines are used and for the first time hexagonal crystal posts are used, particularly new with the (011) cut direction. The SEM image of FIG. 5B is shown having a thickness of 22 microns. As noted, in view of the (011) cut and a poling at <011> direction, the clamping direction is desirably 30-35° from <10 1 > direction, and preferably about 32.5° (+/−2.5°) from the <10 1 > direction. In this alternative embodiment, at least one kerf is guaranteed to be free of any clamping effect while the reliability of the piezoelectric crystal composite is greatly enhanced since failure direction must be non-linear.
Referring now to FIG. 5C a schematic illustrative orientation drawing noting the kerf orientation at the identified 30° from the <10 1 > direction for the hexagonal hybrid 1-3 configuration, and a clamping direction between 30° and 35°, and preferably +/−32.5° from the <10 1 > direction, as noted in FIGS. 5A and 5B . It will also be recognized that the same 30° understanding off a designated direction is suitable for FIGS. 4A and 4B albeit from a different (001) cut direction.
Referring now to FIG. 5D , is an illustrative dimensioning guide regarding calculating effective post widths where not square, as here in a hybrid 1-3 configuration. As noted, either a hexagonal or parallelogram configuration designates a single height of the piezoelectric crystal material and can be measured. Regarding each cross sectional view, there are multiple diagonals (either generally uniform as in the hexagon or non-uniform as in the parallelogram). On either configuration, multiple width measurements are taken and an average is calculated for determination of an aspect ratio (Height:Width) of preferably greater than 0.50, more preferably greater than 1.0, and more preferably greater than 1.5 or 2.0. However, each ideal ratio is dependent upon the other configurations, composition details, and device or method requirements. For example, one preferred alternative embodiment includes a specific ratio of less than 2. As a further detail, it will be noted (for example with the hybrid 2-2/1-3 configuration of FIGS. 7A to 7C , that such aspect ratios are no longer applicable. It will also be understood that typically a desired kerf width is between 1 micron to 10 microns.
As a result of preparing such composites according to the details herein throughout, a thickness electromechanical coupling factor k t of 0.65-0.90 is achieved.
Referring now to FIGS. 6A and 6B an alternative parallelogram hybrid 1-3 configuration is presented with an (011) cut and a <011> poling direction where the kerf lines run at 30-35° away from the <10 1 > cut, and preferably at 32.5°+/−2.5°. This configuration minimizes the transverse clamping effect by the epoxy filled into the kerfs between the parallelogram shaped crystal posts. Based upon this hybrid 1-3 configuration the composite crystal provides a high coupling factor, wherein the epoxy kerfs are transverse strain free. Here the ‘hybrid’ phrase is used for M-N configuration as for the first time continuous kerf lines are used in a parallelogram pattern with the kerf lines being 115° apart relative to a respective plane. This arrangement fully cancels the lateral clamping effect.
Referring now to FIGS. 7A to 7C . Here a schematic, SEM, and perspective view of a further discontinuous hybrid 2-2/1-3 configuration is provided with repeated units shown, wherein the crystal is (011) cut and <011> poled. As graphically illustrated, the kerf filling line direction is preferably 30-50° and more preferably 32.5° (+/−2.5°) away from the <10 1 > direction. As a result of this discontinuous hybrid 2-2/1-3 configuration the clamping direction (shown) has no negative impact on performance. It is noted that the white spaces in FIGS. 7A, 7C and the black spaces in FIG. 7B represent epoxy or polymeric material, and the bars represent piezoelectric material. It is noted that the transverse extension strain is negative parallel to the <011> direction and positive parallel to the <011> direction.
As noted herein with regards to FIGS. 7A to 7C , each individual unit member (shown) is a unique geometry for smooth packing while simultaneously allowing for allowing gas outwardly during epoxy infusion. Each unit member includes a central elongate web bar (shown) extending in a first direction from a first end to a second end. Respective bridge members or bridge portions (shown) extend perpendicularly from the elongate web bar on opposing sides (shown) and intermediate the respective first and second ends, forming a total of four bridge member parts, two on each side of the web bar (shown). Extending from each of the four bridge member parts are leg bars (shown), each leg bar parallel to the web bar and spaced therefrom by a kerf width. In this configuration, it is thus understood that the hybrid 2-2 configuration portion represents the parallel web bars and leg bars, each spaced by polymeric material, and the hybrid 1-3 configuration portion represents the interaction of the crossing bridge members and bridge member parts and the polymeric material cross-passages at the end of each leg bar. As a result, those skilled in the art will recognize the hybrid 2-2/1-3 configuration as fully understood in conjunction with the drawings.
It will be understood that the method of fabricating noted earlier may be used to fabricate one of more imaging transducers having any of the hybrid configurations with any composition shown herein without departing from the scope of the entire disclosure. It will be understood that the compositions may be used in any configuration.
It will be understood that an imaging device may be configured as discussed in FIG. 2 , and may be formed in any hybrid configuration in any composition shown herein without departing from the scope of the entire disclosure. It will be understood that the compositions may be used in any configuration.
It will be understood that the phrase hexagonal is a polygon with six edges or sides in a plan view, such that the hexagonal polygons of the type shown have six edges or sides and extend from an initial position.
It will be understood that there are many different kinds of quadrilateral (four sided) polygons, and all have several things in common: two opposing sides are coplanar, have two diagonals, and the sum of their four interior angles equals 360 degrees, however as noted herein, the phrase parallelogram used herein reflects two parallel pairs of opposite sides without right angles, and a rhombus is merely such a parallelogram with equal length sides (and may also be referred to as a ‘diamond’ pattern or an oblique rhombus) with understanding by those of skill in the art.
Having described at least one of the preferred embodiments of the present invention with reference to the accompanying drawings, it will be apparent to those skills that the invention is not limited to those precise embodiments, and that various modifications and variations can be made in the presently disclosed system without departing from the scope or spirit of the invention. Thus, it is intended that the present disclosure cover modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents. As a further example, each feature of one embodiment can be mixed and matched with other features shown in other embodiments, and similarly features may be added or removed such that the invention is recognized as not restricted except in view of the appended claims.
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The present invention generally relates to high frequency piezoelectric crystal composites, devices, and method for manufacturing the same. In adaptive embodiments an improved imaging device, particularly a medical imaging device or a distance imaging device, for high frequency (>20 MHz) applications involving an imaging transducer assembly is coupled to a signal imagery processor. Additionally, the proposed invention presents a system for photolithography based micro-machined piezoelectric crystal composites and their uses resulting in improved performance parameters.
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This is a divisional of application Ser. No. 962,453, filed Nov. 20, 1978, now U.S. Pat. No. 4,229,194.
This invention relates to improved apparatus and methods such as are disclosed in U.S. Pat. No. 4,081,249 (1978) for carrying out chemical conversions and for restoring the catalytic activity of solid particles used to promote chemical conversions. More particularly, the invention relates to such improved apparatus and methods for carrying out chemical conversions and for restoring the catalytic activity of solid particles used to promote such conversions wherein mixtures of solid particles and vapor require separation.
In many instances throughout process industries, chemical reactions occur which are promoted by relatively small, e.g., diameters ranging from about 10 microns to about 500 microns, catalyst particles, for example, in fluidized bed reactors. One process involving such catalyst particles is the catalytic cracking of higher boiling hydrocarbons to gasoline and other lower boiling components. This process is used extensively in the petroleum industry. Often, apparatus used for carrying out chemical conversion, e.g., cracking of a feedstock, reforming, e.g., hydrocarbon gas oil, involves a reaction zone where the relatively small catalyst particles and feedstock are contacted with chemical conversion, e.g., hydrocarbon cracking or reforming etc., conditions to form at least one chemical conversion product, e.g., hydrocarbons having a lower boiling point than the hydrocarbon feedstock and/or a higher octane rating. Often, while promoting the desired chemical conversion, the catalyst particles have deposited thereon material, e.g., carbon, coke and the like, which acts to reduce the catalytic activity of these particles. Apparatus which are used to restore the catalytic activity of such particles often include a regeneration zone where the deposit-containing solid particles are contacted with oxygen-containing vapor at conditions to combust at least a portion of such deposited material.
Operation of each of the systems referred to above involves the formation of a mixture of solid particles and vapor followed at some point in time with a separation of at least a portion of said particles from said mixture. Therefore, both the apparatus for carrying out chemical conversion and the apparatus for restoring the catalytic activity of the solid catalyst particles include at least one separation zone wherein the mixture of solid particles and vapor formed in either a reaction or a regeneration zone, respectively, are at least partially separated. Such separation zones often involve conventional cyclone precipitators.
However, processing solid catalyst particles through such cyclone precipitators causes some particle attrition. That is, the solid catalyst particles have a tendency to fall apart and/or form fines while being processed through a separation system, e.g., cyclone precipitator. The resulting particle "fines" are often of such a size that they cannot be retained to promote chemical conversion. Accordingly, it is advantageous to provide for reduced attrition of solid catalyst particles.
Therefore, one object of the present invention is to provide apparatus and methods for carrying out chemical conversions, e.g., cracking or reforming, of a feedstock, e.g., hydrocarbon, using solid catalyst particles wherein attrition of the particles is reduced.
Another object of the present invention is to provide apparatus and methods for restoring the catalytic, e.g., hydrocarbon cracking or reforming, activity of solid catalyst particles wherein attrition of the particles is reduced.
Another object of the present invention is to provide apparatus and methods for separating solid particles from a mixture of solid particles and vapor wherein the attrition of separated solid particles is reduced.
Other objects and advantages of the present invention will become apparent hereinafter.
In one embodiment, the present invention involves an improved apparatus for carrying out a chemical conversion of a feedstock. This apparatus includes a chemical reaction zone wherein the feedstock, e.g., a substantially hydrocarbon material, is contacted with solid particles capable of promoting chemical conversion, e.g., hydrocarbon cracking, at chemical conversion conditions to form at least one chemical conversion product and a mixture of solid particles and vapor, the major portion, preferably at least about 90%, by weight of the solid particles having diameters in the range from about 10 microns to about 500 microns, preferably from about 20 microns to about 200 microns; and at least one separation means in fluid communication with the reaction zone, wherein the mixture of solid particles and vapor is at least partially separated. The separation means comprises a chamber defined by an interior surface, which can be of a variety of shapes, with cylindrical being preferred; an inlet means to the chamber in fluid communication with both the reaction zone and the chamber to allow entry of a mixture of solid particles and vapor into the chamber, the inlet means being situated so that movement of the mixture wthin the chamber causes solid particles to preferentially move toward the interior surface; a particle outlet means from the chamber to allow at least a portion of the solid particles of the mixture to exit the chamber; and a fluid outlet means from the chamber to allow at least a portion of the vapor component of the mixture to exit from the chamber. In one embodiment, the present improvement involves an arresting means located in spaced relation to, and preferably attached to, the interior surface to slow the velocity of at least a portion of the solid particles as the solid particles preferentially move toward the interior surface, thereby inhibiting the attrition of the solid particles.
An improved method of chemical conversion, e.g., hydrocarbon cracking or reforming, utilizing such improved apparatus has also been discovered.
In an additional embodiment, the present invention involves an apparatus for restoring the catalytic activity of solid particles which have previously been used to promote chemical conversions, e.g., hydrocarbon cracking, and have deactivating carbonaceous material deposited thereon, the major portion, preferably at least about 90%, by weight of the solid particles having diameters in the range from about 10 microns to about 500 microns, preferably from about 20 microns to about 200 microns. This apparatus includes a regeneration zone wherein solid particles having deactivating deposits thereon are contacted with oxygen-containing vapor under conditions to combust at least a portion of the deposits and form a mixture of solid particles and vapor; and in fluid communication with the regeneration zone at least one separation means wherein at least a portion of the solid particles are separated from the mixture. The separation means comprises a chamber defined by an interior surface; an inlet means to the chamber in fluid communication with both the regeneration zone and the chamber to allow entry of the mixture into the chamber, the inlet means being situated so that movement of the mixture within the chamber causes solid particles to preferentially move toward the interior surface; a particle outlet means from the chamber to allow at least a portion of the solid particles of the mixture to exit from the chamber; and a fluid outlet means from the chamber to allow at least a portion of the vapor of the mixture to exit from the chamber. The present improvement provides for arresting means located in spaced relation to, and preferably attached to, the interior surface to slow the velocity of at least a portion of the solid particles as the solid particles preferentially move toward the interior surface, thereby inhibiting the attrition of the solid particles.
An improved method for restoring the catalytic activity of solid particles utilizing this improved apparatus has also been found.
Each of the arresting means described above preferably involves a zone, which is located in spaced relationship to the interior surface and which comprises at least two generally vertical and at least two generally horizontal vanes which extend a distance, more preferably a substantially equal distance, toward the central axis of the chamber. Thus, in a more preferred embodiment, the end of each of the vertical vanes away from the interior cylindrical surface is at a substantially equal distance from the central axis of the chamber. Into these zones at least a portion of the solid particles from the mixture of such particles and vapor preferentially move. Further, the vertical vanes are preferably positioned so that each vane overlaps at least one adjacent vane when viewed from the central axis of the chamber.
The generally vertical vanes can be inclined at a predetermined, more preferably at a substantially uniform angle, e.g., in the range of about 0° to about 50° out of 360°, relative to a central axis of the chamber. These inclined vertical vanes act to urge solid particles in the proximity of the interior, e.g., cylindrical, surface of the chamber downward and thus, provide improved separation, and improved inhibition of solid particle attrition.
Each of the generally vertical vanes is at an angle chosen so that these vanes are generally parallel to the path of those solid particles induced to move toward the surface of the interior walls, thereby reducing as much as possible any attrition between such particles and such vanes. This angle, in the range of about 10° to about 75° out of 360°, is preferably uniform and is between each vertical vane and a plane tangent to the interior surface of the peripheral wall along a line of apparent intersection (defined hereinafter in the section entitled Detailed Description of The Invention). In other words, the generally vertical vanes are preferably inclined, as shown in FIGS. 4 and 5, against the general direction of spiralling flow of the mixture of vapors and solid particles at such angles to minimize both attrition to the particles and any resistance to the flow of the vapors.
The generally horizontal vanes extend a distance, more preferably a substantially equal distance, toward the central axis of the chamber. It is to be noted that in a preferred embodiment, the ends of both the vertical and horizontal vanes are at a substantially equal distance from the central axis of the chamber, but can be at different distances therefrom without departing from the scope or intent of this invention. Each horizontal vane forms an acute angle opened toward the central axis of the chamber between itself and the horizontal direction of the chamber in the range of between about 0° to about 50°, preferably between about 0° to about 30° and still more preferably between about 5° to 20° out of 360°.
The preferred vertical and horizontal vanes are planar, however, curved vanes for either can be used. In the case of curved vertical vanes, the surface of curvature is selected to minimize both flow resistance and attrition due to collision between the solid particles and such vanes. In the case of curved horizontal vanes, the surface of curvature is selected to encourage movement of deposited solid particles thereon to move toward the nearest portion of the interior wall.
The relative sizes of the components of the present apparatus may be varied depending on the particular application involved. For example, the reaction zone and regeneration zone can each have a volume ranging from about 10 cubic feet or less to about 100,000 cubic feet or more, preferably from about 100 cubic feet to about 50,000 cubic feet. The chamber of the present separation means typically can have an inside diameter when cylindrical ranging from about 0.1 foot to about 10 feet or more, preferably from about 1 foot to about 7 feet, and a length ranging from about 0.5 foot to about 50 feet or more, preferably from about 5 feet to about 35 feet.
The apparatus of the present invention include at least one separation means. However, often the apparatus involves a plurality, more preferably from about 3 to about 15, of such separation means in direct fluid communication with either the reaction zone or the regeneration zone. "In fluid communication" as used herein refers to communication wherein a mixture of solid particles and vapor can flow from the reaction zone or regeneration zone into the separation means. This is in contrast to the situation wherein staged separators, e.g., two or more separation means in series, are employed. The second and following separation means, if any, in a series are in fluid communication with the reaction zone or regeneration zone only indirectly. However, the present improved separation means can advantageously be used as either the first and/or succeeding separation means in such a series.
The inlet means of the present separation means can involve a conduit in fluid communications with both the reaction zone, or regeneration zone, and the chamber. Although the conduit may empty into the chamber from any convenient angle, preferably this conduit empties either substantially parallel to the central axis of the chamber, e.g., top inlet to a chamber situated so that its central axis is substantially vertical, or substantially tangential to the interior surface of the chamber.
When entry to the chamber from the conduit is substantially parallel to the central axis, the inlet means, for example, can further comprise flow directing means which direct the flow of a solid particles and vapor mixture in the chamber so that at least a portion of the solid particles preferentially move toward a peripheral wall. In a preferred embodiment, the flow directing means involve a plurality of baffles situated, e.g., at mutually inclined angles, so that as the mixture of solid particles and vapor from the conduit passes these baffles, the mixture is caused to flow in a generally spiralling path through the chamber. The angle of incline between the partial baffles helps determine the magnitude of the tangential velocity component, all other variables being equal. All other variables being equal, the greater the angle of incline between the partial baffles (in other words, the more horizontal the baffles in a vertical chamber), the greater the tangential velocity component.
Improved separation of solid particles and vapor is achieved generally at increased tangential velocities. However, such increased velocities tend to increase particle attrition. Therefore, the present apparatus can also involve at least one velocity altering means which preferably provides for separation of a portion, preferably a major portion, of the solid particles at relatively low tangential velocities, e.g., before the mixture of solid particles and vapor pass the velocity altering means. Increased tangential velocities allow improved separation of the particles from the remaining mixture. The velocity altering means is located between the inlet and the bottom of the chamber.
The present separation means can include flow redirecting or altering means, preferably a pair of partial baffles in spaced relation, preferably attached, to the interior surface at a distance along the interior or peripheral surface, e.g., below the inlet means, to redirect the flow of the mixture of solid particles and vapor in the chamber in a generally spiralling fashion through the remainder of the chamber. Such flow redirecting can be employed in the present separation means regardless of the angle at which the solid particles and vapor mixture enters the chamber from the inlet means, even when the conduit of the inlet means empties substantially tangentially to the interior cylindrical surface of the chamber.
Although the present invention is useful in many chemical conversions and catalyst regenerations, the apparatus and methods of this invention find particular applicability in systems for the catalytic cracking of hydrocarbons and the regeneration of catalysts so employed. Such catalytic hydrocarbon cracking often involves converting, i.e., cracking, heavier or higher boiling hydrocarbons to gasoline and other lower boiling components, such as hexane, hexene, pentane, pentene, butane, butylene, propane, propylene, ethane, ethylene, methane and mixtures thereof. Often, the substantially hydrocarbon feedstock comprises a gas oil fraction, e.g., derived from petroleum, shale oil, tar sand oil, coal and the like. Such feedstock may comprise a mixture of straight run, e.g., virgin gas oil. Such gas oil fractions often boil primarily in the range from about 400° F. to about 1000° F. Other substantially hydrocarbon feedstocks, e.g., other high boiling or heavy fractions of petroleum, shale oil, tar sand oil, coal and the like, can be cracked using the apparatus and method of the present invention. Such substantially hydrocarbon feedstock often contain minor amounts of contaminants, e.g., sulfur, nitrogen and the like.
Hydrocarbon cracking conditions are well known and often include temperatures from about 850° F. to about 1100° F., preferably from about 900° F. to about 1050° F. Other reaction conditions usually include pressures of up to about 100 psig.; catalyst to oil ratios of from about 5 to 1 to about 25 to 1; and weight hourly space velocities (weight of catalyst/weight of hydrocarbon feedstock/hour) of from about 3 to about 60. These hydrocarbon cracking conditions are not critical to the present invention and can be varied depending, for example, on the feedstock and catalyst being used and the product wanted. The hydrocarbon cracking reaction is generally conducted in the essential absence of added free molecular hydrogen.
In addition, the catalytic hydrocarbon cracking system includes an apparatus for restoring the catalytic activity of catalyst particles previously used to promote hydrocarbon cracking. This apparatus involves a catalyst regeneration zone into which at least a portion of the catalyst from the cracking reaction zone is withdrawn. Such catalyst is contacted with free oxygen-containing gas in the regeneration zone to restore or maintain the activity of the catalyst by removing, e.g., by combusting, carbonaceous material deposited on the catalyst particles. The combustion gas temperature in the regeneration zone is generally from about 900° F. to about 1500° F., preferably from about 900° F. to about 1400° F. and more preferably from about 1100° F. to about 1300° F. At least a portion of the regenerated catalyst is often returned to the hydrocarbon cracking reaction zone.
The catalyst particles useful in the catalytic hydrocarbon cracking embodiment of the present invention can be any conventional catalyst capable of promoting hydrocarbon cracking at the conditions present in the reaction zone, i.e., hydrocarbon cracking conditions. Similarly, the catalytic activity of such particles is restored at the conditions present in the regeneration zone. Typical among these conventional catalysts are those which comprise alumina, silica, silica-alumina, at least one crystalline alumino-silicate having pore diameters of from about 8 A to about 15 A and mixtures thereof. Because of the increased economic incentive for maintaining the particle size of a zeolite-containing catalyst, it is preferred that the catalyst particles comprise from about 1% to about 50%, more preferably from about 5% to about 25%, by weight of at least one crystalline alumino-silicate having a pore diameter of from about 8 A to about 15 A. At least a portion of the alumina, silica, silica-alumina and crystalline alumino-silicate may be replaced by clays which are conventionally used in hydrocarbon cracking catalyst compositions. Typical examples of these clays include halloysite or dehydrated halloysite (kaolinite), montmorillonite, bentonite and mixtures thereof. These catalyst compositions can also contain minor amounts of other inorganic oxides such as magnesia, zirconia, etc. The compositions can also include minor amounts of conventional combustion promoters such as the rare earth metals, in particular, cerium. Such catalyst compositions are commercially available in the form of relatively small particles, e.g., having diameters in the range from about 10 microns to about 500 microns, preferably from about 20 microns to about 200 microns.
In general, and except as otherwise provided for herein, the apparatus of the present invention can be fabricated from any suitable material or combination of materials of construction. The material or materials of construction used for each component of the present apparatus dependent upon the particular application involved. Of course, the apparatus should be made of materials which are substantially unaffected either physically or chemically, except for normal wear and tear, by the conditions at which the apparatus are normally operated. In general, such material or materials should have no substantial detrimental effect on the feedstock being chemically converted, the chemical conversion product or products or the catalyst being employed.
These and other aspects and advantages of the present invention are set forth in the following detailed description and claims, particularly when considered in conjunction with the accompanying drawings in which like parts bear like reference numerals.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a simplified schematic view of a fluid bed catalytic hydrocarbon cracking reactor-regeneration system.
FIG. 2 is a partial side elevation view, with a portion of one peripheral wall cut away to disclose the interior.
FIG. 3 is an enlarged cross section view taken along line 3--3 of FIG. 2.
FIG. 4 is an enlarged cross sectional view taken along line 4--4 of FIG. 1.
FIG. 5 is an enlarged top view in cross section of a portion of the wall of FIG. 3.
FIG. 6 is an inside view of the portion of the wall shown in FIG. 5 but with left most vertical vane removed and portions of both a rear vane and horizontal vane removed.
FIG. 7 is an additional modification and alternate embodiment of a part of this invention disclosing a means for reducing turbulance in a dip leg or particle outlet means.
FIG. 8 is a cross-sectional view taken along line 8--8 of FIG. 7.
Referring now to the drawings, FIG. 1 shows a simplified schematic diagram of a catalytic hydrocarbon conversion reactor-regenerator system. Although the drawings and following description are directed particularly to catalytic hydrocarbon cracking, the present invention may be readily adapted to apparatus and methods for other chemical conversions and catalyst regenerations by those skilled in the art. In FIG. 1, reactor 10 provides the required space for catalytic hydrocarbon cracking to occur. Preheated hydrocarbon feedstock, e.g., petroleum derived gas oil, from line 12 is combined with catalyst particles, e.g., more than 90% by weight of such particles having diameters in the range from about 30 microns to about 100 microns, from line 14. The mixture of feedstock and catalyst flows through riser 16 (where a portion of the catalytic hydrocarbon cracking takes place) and through a diffuser means 17, e.g. a plate with holes, into reactor 10. The feedstock (and certain cracked products) form a "dense fluid bed" below level 18. The solid particles-vapor, e.g., cracked products and unreacted feedstock, mixture in reactor 10 above level 18 is in the form of a "lean fluid." This "lean fluid" enters first separator 20 tangentially through inlet 22. First separator 20 acts, as will be described in detail hereinafter, to separate a portion of the solid particles in the "lean fluid" from the remainder of the solid catalyst particles-vapor mixture, which is sent through line 24 to second separator 26. The separated solid particles from first separator 20 flow through first dip leg 28 to the "dense fluid bed" below level 18. The solid particles-vapor mixture in line 24 is conveyed to the top of second separator 26 which acts to further seperate solid particles from the vapor. Vapor from second separator 26 exits through line 30 and is sent to product processing, e.g., fractionation, other chemical reactions and the like, to produce a final saleable product. The vapor in line 30 may also require additional processing to remove any remaining solid particles, e.g., by conventional means well known in the art. The separated solid particles leave second separator 26 by second dip leg 32 which exits below level 18.
Solid particles are withdrawn from reactor 10 through stripper 34. Stripping gas, e.g., steam, from line 36 enters first stripper 34 and acts to strip hydrocarbon from the solid particles exiting reactor 10. The stripped solid catalyst particles from first stripper 34 flow through line 38, past valve 40, through line 42 and are combined with an oxygen-containing gas, e.g., air, from line 44. The mixture of solid catalyst particles, which have a carbonaceous deposit thereon that had formed in reactor 10, and oxygen-containing gas flow through pipe 46 through a diffusion means 45, e.g. a plate with holes, into regenerator 48 where at least a portion of the carbonaceous deposit on the solid catalyst particles is removed by combustion with the oxygen-containing gas. The "lean fluid" above the level 50 in regenerator 48 is a mixture of solid catalyst particles and vapor. This "lean fluid" enters separator 52 via top inlet 54, e.g. like that shown in FIG. 3. Separator 52 acts to separate solid catalyst particles, which exit separator 52 through third dip leg 56, from the vapor which exits separator 52 through outlet line 58. The vapor from line 58, which includes combustion flue gases, may be released to the atmosphere or further processed, for example, in an electrostatic precipitator, to remove any remaining solid particles.
Regenerated catalyst solid particles, i.e. catalyst particles which have had catalytic activity at least partially restored by removal of carbonaceous deposit, are removed from regenerator 48 through standpipe 57. As the solid catalyst particles flow through standpipe 57, fluidizing gas, e.g., steam, from line 60 enters standpipe 57, contacts the solid particles, thereby fluidizing the solid particles in standpipe 57 and acting to strip any remaining oxygen-containing gas from the solid particles. The thus fluidized and stripped solid catalyst particles flow from standpipe 57 through line 62, past valve 64 and into line 14. The solid catalyst particles from line 14 are combined with the hydrocarbon feedstock from line 12 and the cycle is repeated.
Separator 52 of FIG. 1 is shown in more detail in FIG. 2. Separator 52 comprises a top 63, a bottom 65 which, in this example, is in the form of a conical frustum 53, an inlet or top inlet means 54, an outlet means or a fluid outlet means 58, a plurality of zones 71, a hollow cylinder or a peripheral wall 80, and a particle outlet means which in FIGS. 1 and 2 is a dip leg 56. Chamber 61 of separator 52, is defined by a top 63, a bottom 65 and an interior surface 81 of peripheral wall 80. Inlet means 54 of FIG. 2 is axially oriented, but can be tangentially oriented as exemplified in FIG. 4 by tangential inlet 22. In FIG. 2, inlet means 54 comprises an opening between top 63 and outlet means 58. Surrounding and preferably attached to fluid outlet means 58 are baffles 13. Conical frustum 53 is one of many shapes that can be used for the bottom portion of cylindrical separator 52 as is well known in the art. Optionally, but preferably, one or more lower vanes 83 can be disposed within conical frustum 53 as shown in FIGS. 7 and 8. Spaced from the interior surface 81 of peripheral wall 80 is a plurality of zones 71 each of which zones 71 is defined by two generally vertical side vanes 70, a generally vertical rear vane 74, and two generally horizontal vanes 76.
Operation of separator 52 is as follows: a mixture of vapor and particles enters through inlet means 54 and is induced to flow in a downwardly directed counter-clockwise spiral by interaction with baffles 13. This spiral induces solid particles contained within the mixture to preferentially move toward peripheral surface 81 and eventually to enter zones 71 spaced therefrom. Zones 71 are arresting means which reduce the degree of attrition that would otherwise occur during separation of some of the particles from the mixture. Dotted lines shown in FIGS. 4 and 5 indicate that the spiral flow causes a portion of the particles of the mixture to enter zones 71. The particles upon entering zones 71 gradually slow down as a result of the cushion of air contained within zones 71 and thereby slow down before contacting generally vertical vane 74. The particles upon loosing momentum fall generally downward under the influence of gravity and any current flows present onto top surfaces of generally horizontal vanes 76. Particles thus separated from the mixture of particles and vapor move or slide along the top surfaces of vanes 76 and through gap 75 into the space 82 defined by generally vertical vanes 70, 74 and the interior surface 81 of peripheral wall 80. Ultimately, these particles enter conical frustum 53 where lower vanes 83 (shown in FIGS. 7 and 8) are disposed therewithin. The presence of vane 83 tends to slow or diminish any turbulence that can be present within conical frustum 53 so as to lessen any attrition that might otherwise arise with respect to material within dip leg 56.
The solid particles in dip leg 56 provide a vapor seal so that the vortex of vapor in hollow cylinder 80 is forced through outlet line 58.
Of course, apparatus similar to separator 20 and/or separator 26 may be used in series with or as a replacement for separator 52 to separate the solid catalyst particles-vapor mixture from regenerator 48. Other combinations of apparatus similar to separators 20, 26 and 52 can also be used in either reactor 10 and regenerator 48. All such combinations are within the scope of this invention. In addition, separator 20 can include a top inlet (rather than the tangential inlet 22 shown) and also include at least one pair of partial baffles to cause the solid particles-vapor mixture to flow in a generally spiralling fashion generally downward through a portion of the space defined by hollow cylinder 80. Other modifications regarding position of various components of the present apparatus are also within the scope of the present invention.
Although FIG. 1 illustrates a single series of separators, i.e., separators 20 and 26 in series, and a single separator, i.e., separator 52, conventional reaction zones and regeneration zones often include a plurality of separators or series of separators. For example, reactor 10 and/or regenerator 48 can contain from about 2 to about 12 series of separators each in parallel with one another wherein there are, for example, from 1 to about 3 separators in each series. Each of the individual separators in each of these series can be constructed similarily to separators 20, 26 or 52. In any event, apparatus and methods involving such plurality of separators or series of separators are within the scope of the present invention.
FIGS. 5 and 6 provide enlarged views of zones 71. One means for locating zones 71 in spaced relation to peripheral surface 81 are bolts 79, spacers 78, and nuts 77. Bolt 79 is an example of a means for attaching rear vane 74 to peripheral surface 81. Spacers 78 provide a means for spacing rear vane 74 from peripheral wall 81. Rear vanes 74 also are spaced above the generally horizontal vane 76 so as to provide a gap or space 75 shown in FIG. 6. Gap 75 is a space between the top surface of vane 76 and the bottom edge of vane 74. Generally, each horizontal vane 76 forms an angle between itself and the horizontal direction of chamber 61 of about 15°. This angle is open toward the central axis of chamber 61.
Generally horizontal vanes 76 are preferably tilted so that particles deposited on the top surfaces of each of vanes 76 will have a tendency to slide toward peripheral wall 81. Vertical side vanes 70 preferably approach peripheral wall 81 closely, e.g., to distance of about 1/16 to 1/2 inch so as to provide a dead space 82 defined by interior peripheral surface 81 and generally vertical vanes 70 and 74.
The orientation of vane 70 with respect to interior peripheral surface 81 can be discussed in terms of an angle defined by a vane 70 and a tangent plane to interior surface 81 of peripheral wall 80 along a line of intersection (hereinafter and in the claims referred to as a "line of apparent intersection") between vane 70 itself or any co-planar extention of vane 70 necessary to intersect surface 81. A top view of such a tangent plane is shown in FIGS. 3 and 5 by lines "T." The angle with sides "T" and vane 70 can be in the range of about 10° to about 75° out of 360°. The preferred range of this angle depends upon the diameter of the spinning vapor within the cyclone, the mass of the particles within said spinning vapor, the gas velocity, the distance of surface 81 away from the center of the vortex of the spinning vapor, and the maximum distance vane 70 extends away from surface 81. The angle is chosen so as to minimize as much as possible attrition due to collisions between vertical vanes 70 and particles which are induced to move towards peripheral surface 81 or generally vertical rear vane 74. It is important to note that the vertex of the angle is defined along a line of apparent intersection and that this line itself can be inclined at some angle with respect to the vertical or central axis of the apparatus so as to permit a less impeded flow of spiralling downward material.
Vanes 70, 74 and 76 can be joined along fold lines when cut from a flat sheet or can be welded or bonded together along intersecting edges by means well known and understood by a person skilled in the sheet metal working art. The method of manufacture of vanes 70, 74 and 76 and their method of attachment to interior peripheral surfaces or walls is not deemed to be part of this invention.
The previous description of this invention with respect to specific embodiments disclosed in FIGS. 1-8 are intended to clarify the invention by way of examples. Variations of these examples based upon the teachings of this specification are readily apparent to one of skill in the art and are intended to be within the scope of this invention.
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An improved apparatus for separating solid particles from vapor is disclosed which in one embodiment employs at least one zone defined by at least two generally vertical and at least two generally horizontal vanes and in another embodiment optionally employs at least one vane to inhibit turbulence in a lower portion of this apparatus to aid the settling of particles within a particle outlet means.
This apparatus is particularly suited to at least partially separating solid particles from a mixture of vapors and solid particles which arise either when restoring the catalytic activity of solid particles that had previously been used to promote a chemical conversion or when carrying out a chemical conversion, such as for example hydrocarbon cracking or reforming.
Improved methods employing such apparatus are also disclosed.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to the field of electrolysis prevention in pipelines, and more specifically to the prevention of galvanic corrosion in interconnected pipelines.
[0003] 2. Description of the Background
[0004] Electrolysis results in corrosion which is well known to damage interconnected pipes. The National Association of Corrosion Engineers estimates the cost of corrosion and corrosion protection to be in excess of $10 billion dollars per year. Blowouts of pressurized pipes continue to occur despite long term efforts to reduce and/or prevent corrosion due to electrolysis. In an effort to prevent the corrosion, different strategies have been employed in the past by those with skill in the art including employing coatings, chemical inhibitors, and cathodic protection. Another method is to coat anodic and cathodic metals with an epoxy or paint, or at minimum coating the anodic metal. This too can be problematic, because if the coated areas sustain damage, then the galvanic corrosion will occur nonetheless.
[0005] Various efforts to prevent electrolysis and/or corrosion is shown by the following background U.S. patents:
[0006] U.S. Pat. No. 6,080,293, issued Jun. 27, 2000, to T. Takeuchi et al., discloses an electrolytic test machine used for a corrosion resistance test for a test material comprised of a metal blank and a coating film. The electrolytic test machine is constructed so that an adverse influence, due to chlorine gas generated during a test, can be inhibited. The electrolytic test machine includes an electrolytic cell in which an aqueous solution of NaCl is stored so that a test material is immersed in the aqueous solution of NaCl. An electrode is immersed in the aqueous solution of NaCl. A DC power source supplies electric current between the electrode and the test material. A chlorine gas treating device collects chlorine gas which is generated with electrolysis of the aqueous solution of NaCl and which is released out of the aqueous solution of NaCl along with the aqueous solution of NaCl. The chlorine gas treating device includes a treating pipe line, a suction pump mounted on the treating pipe line, and a chlorine gas purifying member.
[0007] U.S. Pat. No. 4,037,810, issued Jul. 26, 1977, to H. Pate, discloses an improved pipe bracket and clamp for holding a pipe or conduit in a manner minimizing heat and sound transmission, preventing electrolysis or galvanic action and avoiding pipe rupture through thermal expansion and contraction. The clamp is preferably formed of a resilient synthetic resinous material in a unitary structure comprising a U-shaped body portion having a recess therein in which a toothed jaw portion is formed to receive and engage a pipe or conduit. A clamping portion is hingedly secured to the body portion by an integral flexible hinge and is adapted to fold about the hinge to enclose and engage the pipe or conduit in the recess by means of a corresponding toothed jaw portion formed on the clamping portion. A flange portion on the body portion includes an aperture which comes into alignment with a corresponding aperture in the clamping portion through which apertures a fastener may be received to clamp the pipe or conduit and secure it to a wall structure or the like. An alternate embodiment includes an integral cover structure for protecting the fastener from the adverse effects of corrosive or deleterious elements after the bracket is secured to the pipe or conduit.
[0008] U.S. Pat. No. 4,516,069, issued May 7, 1985, to D. Schmanski, discloses an electrolysis test station terminal support for use in connection with measurement of electrical properties of an underground pipe. The terminal support includes an elongated web structure formed of nonconductive plastic material and including at least one longitudinal rib integrally formed as part of the web structure. A hollow core is formed within the longitudinal rib and provides a housing for conductive wire to be concealed therein. An opening in the longitudinal rib provides access to the core to enable physical contact for measurement of electrical properties as conducted from the underground pipe through the wire into the terminal support.
[0009] U.S. Pat. No. 5,194,132, issued Mar. 16, 1993, to M. Hartmann, discloses an electrolysis apparatus for the production of chlorine, sodium hydroxide solution and hydrogen from aqueous alkali-metal halide solutions, which electrolysis apparatus comprises at least one electrolysis cell, anode and cathode, which are separated from one another by a partition, are disposed in a housing composed of two half-shells electrically separated by an insulating seal. The housing is provided with devices for supplying the electrolysis starting substances and for removing the electrolysis products, the latter comprising at least one discharge pipe which extends in the vertical direction in the interior of the half-shells, passes through the half-shell in the vicinity of the lower edge and extends up to the upper edge. The discharge pipe terminates in a separating chamber which is disposed in a stilling zone. The stilling zone is formed by a plate attached to the electrode and to the associated half-shell.
[0010] U.S. Pat. No. 6,276,726, issued Aug. 21, 2001, to R. Daspit, discloses a pipeline repair clamp partially or completely embracing the outer wall circumference of a pipe having a damaged area; a single or complementary semi-cylindrical clamp bodies having diametral engagement, the bodies having a semi-cylindrical bore contiguous to the pipe wall and with continuous seal grooves at its ends and sides, there being a metallic liner or dielectric coating said bore and terminating at the bottom of said grooves, a continuous gasket-compression seal carried in said grooves adapted to embrace said damaged area and seal with the pipe wall and at said liner-coating termination precluding electrolysis, and means forcefully drawing the clamp bodies onto the pipe wall.
[0011] The above discussed background efforts have not been found to solve the long-felt problems associated with corrosion and do not disclose the present invention. Accordingly, those of skill in the art will appreciate the present invention, which addresses the above and/or other problems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1A is an elevational view, partially in hidden lines, of pressurized metal pipeline flange connectors positioned adjacent each other prior to interconnection in accord with with one possible embodiment of the invention;
[0013] FIG. 1B is an elevational view of a Teflon gasket with a support member or plate inserted therein, which may be utilized in one possible embodiment of the present invention;
[0014] FIG. 1C is a front elevational view of a metal flange with circularly oriented apertures, which may be utilized in one possible embodiment of the present invention;
[0015] FIG. 1D is an insulated metal flange bolt which may be utilized in one possible embodiment of the present invention;
[0016] FIG. 2 is an enlarged elevational view, in cross section, of flange components for pressurized pipe which may be utilized in one possible embodiment of the present invention;
[0017] FIG. 3 is an elevational view, partially in cross section, of a pressurized pipe flange connection which may be utilized in one possible embodiment of the present invention;
[0018] FIG. 4 is an elevational view, partially in cross section, showing multiple sections of pressurized pipe, which are electrically insulated with respect to each other, which may be utilized in one possible embodiment of the present invention; and
[0019] FIG. 5 is an elevational view, in cross-section, showing an insulated threaded pressurized pipe connection in accord with one possible embodiment of the present invention.
DESCRIPTION OF EMBODIMENTS
[0020] Detailed descriptions of the preferred embodiment are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner. It is to be further understood that the drawings are not necessarily intended to be in scale or provide manufacturing level drawings but rather may be exaggerated and/or altered to more clearly show representative features of various embodiments of the invention.
[0021] Turning to the drawings, and in particular FIG.1A , FIG. 1B , FIG. 1C , and FIG. 1D , there are shown various components, which may be utilized in one possible embodiment of corrosion mitigation system 10 A for pressurized metal pipes 12 and 14 . For pressure containment purposes, pipes 12 and 14 are connected utilizing flanges 16 and 18 , which may be welded to pipes 12 and 14 . However, in FIG. 1A , the flanges are not yet connected together. The pipes and/or flanges may vary greatly in size. For example, flanges may range from below four inches to fifty or more inches in diameter. The pipes may also vary in size according to use. The pipes and interconnections are generally pressure rated with smaller diameter pipes sometimes in the 10,000 psi range or higher. Larger diameter pipes will have lower pressure ratings. The pressure ratings may range from 500 psi to 10,000 psi but can also vary above and below this range. Pipes such as pipes 14 and 16 may be coated externally and/or internally with one or more coats of insulative material and/or acid or corrosive resistant materials, and the like, depending on use. Pipes 14 and 16 may have an internal and/or insulative cylindrical or pipe-like layer of material, if desired.
[0022] Flange 17 is shown in a front elevational view in FIG. 1C , which is representative for flanges 16 and 18 . The flanges may comprise multiple openings, such as openings or bores 19 , which surround through bore 25 through flange, in a circular pattern.
[0023] In one possible embodiment, insulated fasteners are used in bores 19 , such as insulated metallic stud 15 , shown in FIG. 1D , having threads 21 . Insulated bolts, insulated nuts and/or washers, and the like, which may be utilized to secure the flanges together with significant torque applied thereto to control pressurized fluids such as liquids and gasses contained within the pipes. In one possible embodiment, insulated stud 15 may comprise a sleeve with insulation material such as Teflon or the like, with a tolerance of 0.1000 inches or less, if desired. If desired, studs or other fasteners comprised of insulative materials may be utilized but may require larger diameters than steel fasteners to provide the sufficient tightening force to maintain the pressurized ratings of the connectors.
[0024] Referring to FIG. 1B , Teflon gasket 20 with insert 22 may be cut or otherwise sized to fit to flange faces, such as flange face 27 . Through bore 23 of gasket 20 mates with bore 25 through flange 17 to allow material flow through the pipe line. In one possible embodiment, insert 22 may be steel, steel mesh, or the like. However, other types of inserts such as composite material and/or other hard materials may also be utilized. Other types of insulation materials besides Teflon® may also be utilized.
[0025] Teflon coated gaskets with steel inserts, which may be utilized in some embodiments of the invention, are commercially available for use with flanged connections for pipelines, under the name of Texalon™ gaskets. However, in another embodiment, other materials may be utilized for the soft sealing material such as rubber, rubber-like, elastomeric, and/or flexible sealing material. Other reinforcement materials, which may or may not utilize steel inserts within the gaskets, and/or other hard materials, carbon materials, composite materials, and/or the like may be utilized so long as they are suitable for the pressure rating of the flange connection.
[0026] Referring to FIG. 2 , there is shown an enlarged view, which shows details of one possible fastening arrangement for corrosion mitigation system 10 . In a possible embodiment, first flange 16 and second flange 18 are secured together by use of insulated sleeve 24 , metallic stud 26 , insulated washers 28 and 30 , back up metallic washers 35 and 37 , and metallic nuts 31 and 32 . Alternative insulated fastening means could be utilized such as insulated metallic bolts, non-metallic composite materials, or the like, when available which are suitably strong to secure the flange connection in a manner which maintains the seal at the desired pressure rating.
[0027] In one embodiment, insulated sleeve 24 is a pliable insulative material, such as Teflon® or other relatively soft or shrinkable material, which may be fitted, heat shrinked, or otherwise secured to otherwise metallic stud 26 . In another embodiment, insulated sleeve 24 could be a rigid material, such as Delrin®, inserted into first aperture 34 of first flange 16 and second aperture 36 of second flange 18 . In another embodiment, multiple layers of soft and/or hard insulative materials may be utilized as insulated sleeve. Alternatively insulative 24 sleeve may be baked on, sprayed on, or coated to stud 26 and/or may also comprise layers of insulative material and/or insulative coatings and/or layers of soft and/or hard insulative materials.
[0028] In one possible embodiment, flanges 16 and 18 may comprise one or more insulative coatings which is engaged by a pliable surface of insulative sleeve 24 . In another embodiment, insulative sleeve may comprise a hard insulative material and a softer pliable component which may engage the insulative coatings of internal surfaces of first aperture 34 . In another embodiment, various insulative layers of pliable and/or hard materials may be utilized. Soft insulative layers or other soft or pliable coatings may be provided on insulative sleeve 24 to engage insulative coating within the internal surfaces of aperture 34 .
[0029] As noted above, first flange 16 and second flange 18 may typically, but not necessarily, comprise a plurality of circular apertures 34 concentrically located around the flanges, such as bores 19 , shown in FIG. 1C . In one possible embodiment, insulated gasket 20 engages first flange 16 and second flange 18 and is circularly sized but with a radius smaller than circular apertures locations on the flanges so as to remain within the circle formed by the plurality of apertures. However, insulated gasket 20 may also comprise openings which mate to the aperture 34 , and/or mate to bores 19 , shown in FIG. 1C .
[0030] As discussed in some possible embodiments hereinbefore, insulated sleeve 24 is designed for snug fit around bolt 26 which is inserted through insulated sleeve 24 . Bolt 26 may be coated with insulative material prior to use of sleeve 24 . In this embodiment, insulated bolt or stud 26 has threads 21 on both ends which extend outwardly from first flange 16 and second flange 18 once properly inserted into insulated sleeve 24 . Insulated sleeve 24 may be fitted and cut to the size and length of flanges being used and may typically have tight clearance around metallic bolt or stud 26 .
[0031] Insulated washer 28 engages with first flange 16 , and is secured by metal washer 35 and nut 31 , which is tightened sufficiently to provide the sealed pressure rating of the pipe. Insulated washer material 28 may comprise one or more internal supports, such as steel or composite materials, if desired, separated by one or more insulative layers. If the flange is coated with insulative material, then insulated washer 28 may comprise a pliable surface component to engage the coating of the flange. Insulated washer 28 may comprise various layers and/or comprise multiple layers and/or coatings of pliable and/or hard insulative material. Insulated material should be of a thickness and radial size to place sufficient pressure on flange 16 to provide the pressure rating.
[0032] Accordingly, insulated washer 28 does not have to have the strength of steel but instead may comprise a larger radial size than is normally required when only metal washers/nuts are utilized to thereby, along with metal washer 35 , place sufficient force for the desired pressure rating on flanges 16 and 18 and flange gasket 20 . In other words, by utilizing an insulative material with a compression strength less than steel but with a larger radial size, sufficient pressure or force may be applied to flanges 16 and 18 . In another embodiment, other washer arrangements may be utilized. A similar arrangement of washers and nuts may utilize insulated washer 30 , metal washer 37 , and nut 32 to tighten second flange 18 with first flange 16 to the desired tightness required for the pressure rating of the pipe. This connection point can then withstand the pressurized fluids and/or gas that will often be transported by the pipeline.
[0033] As depicted in FIG. 2 , there is no metal to metal contact between first flange 16 and second flange 18 , which along with the pipes themselves is an area where galvanic corrosion is common in pipeline configurations. The use of insulated sleeve 24 , insulated washers 28 and 30 , and insulated gasket 20 , prevents electrical connections between the pipes and thereby can mitigate corrosion not only at the flanges but also including corrosion that may occur within the pipes.
[0034] FIG. 3 illustrates an elevational side view, partially in cross-section, of one possible embodiment of corrosion mitigation system 10 A, which shows a completed flange connection between the pipes. As discussed hereinbefore, a pipeline will consist of a plurality of metal pipes, such as metal pipe 12 and metal pipe 14 . As noted hereinbefore, the metal pipes may comprise other components or layers, such as interior tubular coatings and layers, which may or may not comprise metal. As discussed above, first flange 16 of metal pipe 12 is insulated from second flange 18 of adjacent metal pipe 14 by insulated gasket 20 which is preferably round or disc shaped with a center aperture therethrough approximately equal to the size of an open end of metal pipes 12 and 14 . Insulated gasket 20 is positioned between first flange 16 and second flange 18 to prevent any metal to metal contact between the metal pipes 12 and 14 , while not obstructing the free flow of fluids transported within the pipeline. Insulated gasket 20 can be used for metal pipe flanges ranging from 3″ to 50″.
[0035] As discussed above, insulated gasket 20 comprises insulative material and may, in one possible embodiment, comprise metal core 22 or other types of support material and/or may comprise insulative composite materials. In one possible embodiment, metal core 22 may comprise any of the following, including: perforated stainless steel, nickel iron chromium alloy, titanium, gold, platinum, graphite, or carbon. By utilizing insulated gasket 20 , electrolysis prevention system 10 provides a tight seal with structural support, without sacrificing the goal of electrolysis mitigation.
[0036] First flange 16 and second flange 18 are secured together by use of insulated sleeve 24 , bolt 26 , insulated washers 28 and 30 , and/or other metallic or non-metallic washers, and nuts 31 and 32 . This configuration allow for securing pipeline sections 12 and 14 without compromising electrolysis prevention where first flange 16 of metal pipe 12 and second flange 18 of metal pipe 14 connect. Electrolysis prevention system 10 is capable of electrically insulating a plurality of metal pipes from each other with a resistance greater than 100 kiloohms in free space, or in another embodiment greater than 1 megaohm in free dry space, and in another embodiment greater than 10 megaohms in free dry space. It will be appreciated that various insulative coatings and the like may typically be utilized on the exterior of the flange connections, which cover any spaces or air gaps, to further protect the flange connections and/or pipes from the elements. Coatings may be applied prior to and/or after assembly. Other coatings and/or materials may be utilized on the pipes. As discussed hereinbefore, coatings may be utilized within the apertures, on the surface of the bores, through which the fasteners are inserted. Sleeves 24 may be soft, hard, or multilayered with an outer relatively soft or pliable layer, such as Teflon®, for preventing damage thereto.
[0037] Turning to FIG. 4 , there is shown another view of electrolysis/corrosion mitigation system 10 A, depicting how the system prevents electrolysis in multiple sections of pipeline. The drawing shows metal pipes 12 , 14 , 42 , 46 , and/or any number of pipes. In one embodiment, each pipe is insulated from all other pipes by the insulated flange connection discussed hereinbefore.
[0038] In accord with methods of the present invention, during installation first flange 16 of metal pipe 12 is insulated from second flange 18 of adjacent metal pipe 14 by insulated gasket 20 . Insulated gasket 20 is positioned between first flange 16 and second flange 18 to prevent any metal to metal contact between the metal pipes 12 and 14 . In this embodiment, first flange 16 and second flange 18 are secured together by use of insulated sleeve 24 , bolt 26 , insulated washers 28 and 30 , additional washers, and/or nut 31 and 32 , as discussed hereinbefore. The process is repeated for metal pipe 14 and metal pipe 42 . As explained hereinbefore, bolt 26 is insulated utilizing and/or inserted through one or more insulated sleeves 24 which is secured on one end to first flange 16 of metal pipe 14 by insulated washer 28 and nut 31 . Insulated washer 30 and nut 32 secure bolt 26 on the opposite end to second flange 18 of metal pipe 15 . To be noted, by isolating the individual metal pipes, particularly where first flange 16 and second flange 18 connect to each other, the present invention prevents electrolysis and/or galvanic corrosion.
[0039] FIG. 5 represents an alternative embodiment of electrolysis prevention system 10 , the present embodiment being configured for interlocking pipelines. Metal pipe 50 has a female threaded end 58 while metal pipe 52 has male threaded member 56 . Insulated threaded gasket 54 is comprised of a non-conductive composite material in this embodiment, though other materials are readily available provided the provide sufficient electrical insulation, as discussed hereinbefore. Such materials may comprise composite materials or any other suitable insulative materials and/or the like. Furthermore, insulated gasket 54 may contain metal or composite material supports or core 57 to provide additional structural support for connection 60 , if desired. Such pipes may be utilized in various suitable environments including pipe lines, as production tubing in oil wells and/or the like. Insulated gasket 54 comprises mating threaded connectors and mates with male threaded member 56 and female threaded member 58 to form connection 60 and may also comprise coatings, lubricants, and the like. Connection 60 should be sufficient to withstand the force from the pressurized fluids and/or gases present within the pipeline. As discussed hereinbefore, insulated gasket 54 both connects and electrically isolates pipeline section 50 and pipeline section 52 simultaneously. As a result, the interconnected sections of pipeline can withstand the pressurized fluids and/or gases, while mitigating the chance of electrolysis by avoiding metal to metal contact Electrolysis prevention system 10 is capable of electrically insulating a plurality of metal pipes from each other with a resistance greater than 100 kilo Ohms in dry space, or in another embodiment greater than 1 Mega ohm if free dry space, and in another embodiment greater than 10 mega ohms in free dry space.
[0040] In summary, the present invention may be utilized to isolate sections of pipeline to prevent corrosion related to electrolysis. While the invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
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A corrosion mitigation system for use in a pressurized pipeline for carrying pressurized fluids utilizes a plurality of metal pipes to form a pressurized pipeline wherein each pipe comprises connectors on opposite ends. The connectors comprise metallic connector components. Insulative material components which mate to said metallic connector components at said connections between said plurality of metal pipes for insulating the connectors and which conforms to respective ends of said plurality of metal pipes while permitting sufficient connection force at said connections to prevent leakage of said pressurized fluids.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 11/743,420, filed on May 5, 2007, which claims the benefit of priority to U.S. Provisional Patent Application No. 60/796,747, filed on May 2, 2006. This application is also a continuation-in-part of U.S. patent application Ser. No. 11/743,486, filed on May 5, 2007, which claims the benefit of priority to U.S. Provisional Patent Application No. 60/797,007, filed on May 2, 2006. The entire content of each of the aforementioned patent applications is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. The Field of the Invention
[0003] Implementations of the present invention relate to equipment that facilitates the application of paint to various surfaces. More particularly, it relates to a tray for holding paint that has a handle formed in its bottom wall that facilitates holding of the tray in one hand.
[0004] 2. Description of the Prior Art
[0005] Commercially available paint trays are sold in many different sizes. Some of them are too big, bulky, or heavy to easily hold in one hand. Some of them are too small and flimsy. Others have inadequate roller handles, and users can not substitute better roller handles sold separately to get the desired paint application and finish on surfaces that are being painted. A further problem is that conventional paint trays can only be used in tray function uses.
[0006] Accordingly, there are a number of disadvantages in the art that can be addressed.
SUMMARY OF THE INVENTION
[0007] Implementations of the invention provide a paint tray that incorporates ergonomic principles.
[0008] Although there are many commercially available paint trays, few if any incorporate the art of ergonomics. The novel tray incorporates ergonomic principles and includes the following advantages.
[0009] The novel paint tray includes a stiffening rib in the shape of an “S” curve that facilitates comfortable and easy holding of the tray by users having hand sizes that range from very small to very large. The paint tray further includes a curved bottom rake that enables a user to smoothly roll a paint roller cover through it. The “S” curve stiffening rib runs the length of the tray and channels paint in the tray to prevent paint from sloshing out of the tray as the roller cover passes through it. Moreover, finger location indents are formed in the sides of the tray to enhance the user's grip. A protrusion on opposite sides of the tray bottom provides an additional surface for users to hold the tray with their fingers. A smaller well on one end of the tray may hold a paint roller cover attached to a paint roller handle while the paint roller handle rests in the water and paint exit spout preventing the roller handle from falling into the paint, in the tray during use.
[0010] More particularly, the novel paint tray has a leading end and a trailing end and includes an open-topped paint-retaining cavity defined by a pair of transversely opposed, longitudinally extending sidewalls, a pair of transversely disposed end walls, and an imperforate bottom wall. The transversely disposed end walls include a leading end wall having a first height and a trailing end wall having a second height. The open-topped paint-retaining cavity includes a main cavity that extends from the leading end of the paint tray to a preselected transverse line beyond the mid-point of the paint tray. The open-topped paint-retaining cavity also includes a secondary cavity that extends from the preselected transverse line to the trailing end wall. The bottom wall is arcuate along the extent of the main cavity so that the main cavity is deepest about mid-length of the main cavity. The bottom wall is straight and inclined downwardly along the extent of the secondary cavity from the preselected transverse line to a bottom edge of the trailing end wall.
[0011] A hollow stiffening rib has a gradual “S” shape, a longitudinal extent substantially equal to a longitudinal extent of the paint-retaining cavity, is formed integrally with the paint tray bottom wall, and is positioned about mid-width of the paint tray. The stiffening rib has a bottom wall disposed in a substantially horizontal plane when the paint tray is in a substantially level, functional position and the stiffening rib bottom wall is substantially coplanar with a lower edge of the trailing end wall. A first plurality of finger-receiving indentations is formed in a first sidewall of the paint tray and a second plurality of finger-receiving indentations is formed in a second sidewall of the paint tray. A user may therefore hold the paint tray in one hand by placing fingers of a first hand in the first plurality of finger-receiving indentations and a thumb of the first hand against the stiffening rib.
[0012] In the alternative, a user may hold the paint tray in one hand by placing a thumb of a first hand in a preselected finger-receiving indentation of the first plurality of fingerreceiving indentations and fingers of the first hand against the stiffening rib. Similarly, a user may hold the paint tray in one hand by placing fingers of a first hand in the second plurality of finger-receiving indentations and a thumb of the first hand against the stiffening rib or the user may hold the paint tray in one hand by placing a thumb of a first hand in a preselected finger-receiving indentation of the second plurality of finger-receiving indentations and fingers of the first hand against the stiffening rib.
[0013] A paint applicator roller has a transverse extent slightly less than a width of the open-topped paint retaining cavity and is disposed transversely in the main cavity about mid-length thereof. A transversely disposed axle extends from opposite ends of the paint applicator roller. Each of the longitudinally-extending sidewalls of the paint tray is adapted to rotatably engage an axle extending from the paint applicator roller.
[0014] A peripheral flange extends outwardly in a substantially horizontal plane from the longitudinally-extending sidewalls and the transversely disposed end walls. The peripheral flange is bent downwardly about ninety degrees at its outer edges to form longitudinally-extending and transversely disposed flange vertical walls. The flange vertical walls are bent at their respective lower edges about ninety degrees into a substantially horizontal plane.
[0015] A roller cover wash shield is adapted to engage the paint tray in covering relation to the open-topped paint-retaining cavity. A roller cover cleaning space is defined between the paint tray and the roller cover wash shield. The roller cover wash shield is adapted to accommodate a handle of a paint roller when the roller cover wash shield is engaged to the paint tray. The roller cover wash shield includes a first downwardly-opening main cavity defined by an arcuate top wall. The greatest height of the downwardly-opening main cavity is about mid-length of the downwardly-opening cavity. The downwardly-opening main cavity is positioned in open communication with the open-topped main cavity of the paint tray.
[0016] Accordingly, the two confronting cavities combine to form a single primary cavity, or roller cover cleaning space, that can accommodate a roller brush cover. The roller cover wash shield also includes a second downwardly-opening cavity defined by a tunnel-like section that accommodates a handle of a paint roller. The second downwardly-opening cavity is in open communication with the first downwardly-opening main cavity and hence with the primary cavity when the roller cover wash shield is in engagement with the paint tray.
[0017] A wand has a discharge nozzle and is in fluid communication with a source of water under pressure. A slot is formed in the top wall of the roller cover wash shield to admit the wand into the roller cover cleaning space. A paint roller cover having a handle is positioned in the roller cover cleaning space, with the handle accommodated within the tunnel-like section of the roller cover wash shield. Opening the source of water under pressure causes the roller cover to spin as water flows from the nozzle onto the roller cover. This cleans the roller cover. The roller cover wash shield and paint tray together provide a shield that confines the water and paint spray generated by such spinning to the confines of the primary cavity.
[0018] An important object of the invention is to provide a paint tray that can easily be held in one hand.
[0019] Another important object is to provide a paint tray having a main paint-retaining cavity and a secondary paint-retaining cavity.
[0020] Still another important object is to provide a roller cover wash shield that is releasably attachable to a paint tray so that a paint roller cover may be cleaned at the end of a job by using the paint tray and the roller cover wash shield as a unit.
[0021] These and other important objects, advantages, and features of the invention will become clear as this description proceeds.
[0022] The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts that will be exemplified in the description set forth hereinafter and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] For a fuller understanding of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:
[0024] FIG. 1 is a side elevational view of the novel “S” grip paint tray;
[0025] FIG. 2 is a top plan view of the novel tray;
[0026] FIG. 3 is a bottom plan view of the novel tray;
[0027] FIG. 4 is a side elevational view of the “S” grip tray with a wash shield attached;
[0028] FIG. 5 is a top plan view of the parts depicted in FIG. 4 ; and
[0029] FIG. 6 is an end view of the “S” grip tray with the wash shield attached.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] Referring now to FIGS. 1-3 , it will there be seen that an improved ergonomic paint tray that is comfortable and easy to hold with small or large hands is denoted as a whole by the reference numeral 10 . Paint tray 10 has a generally rectangular shape when viewed in plan and defines an open-top cavity for retaining paint therewithin. It includes longitudinally-extending upstanding sidewalls 12 a , 12 b , transversely extending upstanding end walls 14 a , 14 b and an imperforate bottom wall 16 formed integrally with the respective bottom edges of said sidewalls and end walls. The term “upstanding” may be interpreted as “vertical,” it being understood that the sidewalls and end walls are generally vertical when paint tray 10 has paint contained therein and is in its generally horizontal, functional position.
[0031] A thin, flat, horizontally disposed peripheral flange 18 is formed integrally with and extends outwardly from the respective upper edges of sidewalls 12 and end walls 14 . Peripheral flange 18 is bent downwardly by about ninety degrees (90°) at its outermost edge, thereby forming vertical flange sidewalls 18 a . Said vertical flange sidewalls 18 a are bent about ninety degrees (90°) outwardly so that they are disposed in a horizontal plane, thereby forming horizontal flange walls 18 b.
[0032] As best understood in connection with FIG. 1 , paint-retaining cavity 20 does not have a uniform depth. Defining the left end of tray 10 as the leading end and the right end thereof as the trailing end, it will be observed that leading end wall 14 a has a height extent less than that of trailing end wall 14 b . The leading end of bottom wall 16 begins at the lowermost end of leading trailing wall 14 a and is curved downwardly as at 16 a until it reaches a depth substantially equal to the height of trailing end wall 14 b , said maximum depth being denoted 16 b . Bottom wall 16 then curves gradually upwardly as at 16 c as it extends toward the trailing end of the paint tray until it reaches a depth about equal to the height of leading end wall 14 a . A transverse line that corresponds with that depth is denoted 16 d in FIG. 2 . Bottom wall 16 then has a linear section 16 e that extends downwardly at a roughly forty five degree (45°) angle to the lowermost edge of trailing end wall 14 b . Bottom wall 16 thus creates a main cavity 22 having a curved bottom wall and a trailing or secondary cavity 24 having an inclined bottom wall.
[0033] Hollow stiffening rib 26 is formed integrally with bottom wall 16 of tray 10 . Stiffening rib 26 is “S”-shaped and substantially extends the entire length of paint tray 10 in this preferred embodiment. However, an “S-shaped stiffening rib that extends less than the entire length of the tray is also within the scope of this invention, as is a stiffening rib that is straight or that has varying degrees of curvature. In this embodiment, the stiffening rib is discontinuous in the region 22 a where main paint-retaining cavity 22 is deepest. The longitudinal axis of symmetry of stiffening rib 26 is positioned substantially centrally of bottom wall 16 , equidistant from sidewalls 12 a , 12 b.
[0034] Stiffening rib 26 has a hollow structure and therefore creates an “S”-shaped secondary cavity 28 , depicted in the top plan view of FIG. 2 , having a depth greater than the depth of main paint-retaining cavity 22 for most of the extent of the tray, with the exception being a short distance where the depth of main cavity 22 reaches its greatest depth, i.e., at region 22 a where stiffening rib 26 is discontinuous.
[0035] A plurality of indentations, collectively denoted 30 , is formed in sidewalls 12 a , 12 b of paint tray 10 . These indentations are adapted to accommodate the fingers or fingertips of a user when the tray is held in one hand. More particularly, a user places a thumb against a first side of stiffening rib 26 that faces away from the sidewall 12 a or 12 b to be grasped, and places one or more fingers of the same hand in indentations 30 formed in said sidewall. For example, as perhaps best understood in connection with the bottom plan view of FIG. 3 , a user places a thumb on the lower side of stiffener rib 26 and the fingers in the indentations 30 formed in the sidewall at the top of said Fig. In the alternative, a user places a thumb on the top side of stiffener 26 and positions the fingers of the same hand in indentations 30 formed in the sidewall at the bottom of said figure.
[0036] Peripheral flange 18 is discontinuous at the leading end of tray 10 , as is vertical flange sidewall 18 a . Horizontal flange wall 18 b is not discontinuous but it is sloped downwardly at the discontinuity as at 18 c , as best depicted in FIG. 6 , to form a cradle for the handle of a paint roller, not depicted. This cradle enables a user to position a roller cover attached to a paint roller handle into trailing paint cavity 24 and rest the roller handle in the cradle area atop horizontal flange wall 18 c to keep the roller handle out of the paint in main paint-receiving cavity 22 when the user desires to set a paint roller down.
[0037] A button-shaped protrusion 32 a , 32 b is formed in each sidewall 12 a , 12 b , respectively, as best depicted in FIG. 2-4 . Each protrusion forms a concavity when viewed from the inside of main paint-retaining cavity 22 . An axle protruding from opposite ends of rotatable paint applicator wheel 34 is snapped into said concavities so that a user can apply paint onto the pad of a typical paint pad. Each axle spins about its axis of rotation when the paint applicator is rotated.
[0038] Roller cover wash shield 36 , depicted in FIGS. 4 and 5 , acts as a cover for paint tray 10 when said paint tray is converted into a washing housing that encloses a paint roller cover during cleaning Roller cover wash shield 36 includes thin, flat peripheral flange 38 that is horizontally disposed and adapted to overlie and abuttingly engage peripheral flange 18 of paint tray 10 . Peripheral flange 38 is bent downwardly about ninety degrees (90°) to form vertical flange sidewall 38 a that abuttingly engages vertical flange sidewall 18 a of paint tray 10 when peripheral flange 38 abuts peripheral flange 18 . Vertical flange sidewall 38 a is bent about ninety degrees (90°) in a horizontal plane and in an outward direction to form horizontal flange 38 b that overlies and abuttingly engages horizontal flange 18 b when roller cover wash shield 36 is engaged to paint tray 10 .
[0039] As best depicted in FIG. 4 , roller cover wash shield 36 includes vertical sidewalls 40 a , 40 b and vertical end walls 42 a , 42 b . The respective upper edges of vertical sidewalls 40 a , 40 b are curved as depicted and the peripheral edges of curved top wall 44 are formed integrally with the respective top edges of vertical sidewalls 40 a , 40 b and vertical end walls 42 a , 42 b . The curvature is substantially a mirror image of the curvature formed in bottom wall 16 of main paint-retaining cavity 22 , i.e., top wall 44 reaches its zenith in diametrically opposed relation to the point where bottom wall 16 reaches its nadir as at 16 b . Sidewalls 40 a , 40 b , end walls 42 a , 42 b , and top wall 44 collectively form the main part of roller cover wash shield 36 .
[0040] Horizontal flange 38 is also bent so that it forms a tunnel-shaped passageway 46 that is in open communication with the trailing end of roller cover wash shield 36 . Passageway 46 accommodates a paint roller handle.
[0041] Slot 48 is formed in top wall 44 of shield 36 and has a transverse part 48 a from opposite ends of which extend generally longitudinal slots 48 b , 48 b . The slots collectively form a generally square “U”-shaped flap. A user snaps roller cover wash shield 36 onto tray 10 so that a paint roller handle 47 is in passageway 46 and a paint roller cover 49 is positioned in an open space bounded at its bottom by tray 10 and at its top by shield 36 . A suitable wand is inserted through the flexible flap which is momentarily displaced as the wand is inserted through it and which closes under its inherent bias when the wand is properly inserted into said open space. Water under pressure is then sprayed from the wand onto the edge of the paint roller cover. The force of the water spins the roller cover and paint is removed therefrom by centrifugal force, as more fully disclosed in U.S. Pat. No. 5,797,410.
[0042] Novel tray 10 can also be used with better roller handles and covers so that a user may substitute such roller handles and covers as may be required for various jobs. For example, the paint tray having a roller handle wash shield attachment, disclosed in U.S. Pat. No. 5,797,410 may be used as a second shield half for cleaning roller covers. Paint tray 10 may also be used for packaging quality roller handles and roller covers so said paint tray, handles, and covers can be sold together.
[0043] It will be seen that the advantages set forth above, and those made apparent from the foregoing description, are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
[0044] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
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An open-topped paint tray includes an upwardly-opening paint-retaining cavity defined by a pair of sidewalls, a pair of end walls, and an imperforate bottom wall. The cavity includes a main cavity with an arcuate bottom wall and a secondary cavity having a straight, downwardly inclined bottom wall. A hollow stiffening rib having a gradual “S” shape is formed integrally with the paint tray bottom wall and enables a user to hold the paint tray in one hand. A roller cover wash shield releasably engages the paint tray and defines a downwardly-opening cavity that together with the upwardly-opening paint retaining cavity provides a primary cavity for cleaning a paint roller cover. A flap formed in the roller cover wash shield admits a wand having a nozzle that spins and cleans a paint roller cover, positioned within the primary cavity, with water under pressure.
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BACKGROUND ART
In many optical applications, modules are used to couple a light source to an optical fiber. The module may include one or more lenses that promote efficient coupling between the optical fiber and the light source. The light source may be formed of a succession of thin films on a semiconductor substrate, so as to define a Vertical Cavity Surface Emitting Laser (VCSEL). A VCSEL is a surface emitting laser. Another type of semiconductor laser used in telecommunications applications is referred to as an edge emitting laser, which may be further divided into subtypes that include Fabry Perot (FP) and Distributed Feedback (DFB) lasers.
Particularly within the field of data communications via optical signals, consistency with respect to certain optical properties is important in assuring proper operations. The power output (i.e., the light intensity) must remain above a predetermined level. The wavelength of the signal may also be significant. Various factors will cause changes in the optical properties. For example, a change in the temperature of the environment in which a laser diode resides will affect the laser emission wavelength. As another example, the bias current of the laser controls its output power. The aging of a laser diode also may affect its power output.
Techniques for monitoring and controlling properties of an output beam are known. FIG. 1 shows a prior art approach to monitoring and controlling an output beam of an edge emitting laser diode 10 . The diode is shown as being mounted on a substrate 12 . The laser diode emits an output beam 14 from a front facet 16 and emits a monitoring beam 18 from a rear facet 20 . The output beam may be directed through optics 22 , such as a lens which provides beam collimation. The beam is reflected by a 45 degree mirror 24 to an optical fiber 26 that has an optical axis perpendicular to the substrate 12 . The 45 degree mirror may be used for applications in which the desired orientation of the beam from an edge emitting laser is to be the same as the conventional output beam orientation of a module that uses VCSELs.
Within the path of the monitoring beam 18 from the rear facet 20 of the edge emitting laser 10 is a detector 28 that generates a signal indicative of power. Because there is a known ratio between the power of the output beam 14 and the power of the monitoring beam, the signal from the detector may be used to identify the output power to the fiber 26 . The electrical signal from the detector is directed to a controller 30 that is able to adjust the bias current of the laser 10 . Thus, the signal from the detector provides feedback for maintaining the laser in a constant output power state. While not shown, the controller may also receive a signal from a temperature sensor. Then, the controller may adjust operations of a thermo-electric cooling (TEC) device or a heating device.
While the monitoring and controlling techniques described with reference to FIG. 1 operate well for their intended purpose, there are concerns. For example, the known ratio of the power of the two beams 14 and 18 is less reliable with respect to maintaining the output power to the fiber 26 if the output beam 14 is manipulated in a manner different than the monitoring beam 18 . For example, in an Externally Modulated Laser (EML), the modulation which occurs for telecommunications or other applications does not affect the monitoring beam 18 . Thus, a feedback signal from the detector 28 will not show all fluctuations of output power to the fiber.
SUMMARY OF THE INVENTION
In accordance with the invention, a combination of reflection and diffraction is used to cause a monitoring beam portion to substantially retrace (subtend) angles followed by an input beam for which monitoring is of interest. An optical monitoring system includes a beam input that defines an input segment of a beam path. A reflection-inducing structure positioned along the input beam segment reflects light from the input beam segment to a reflected beam segment. A diffraction-inducing structure positioned along the reflected beam segment diffracts a minor portion of the light, so as to return to the reflection-inducing structure. The minor portion is again reflected and is directed to a detector which generates a signal indicative of an optical property of this diffracted and reflected beam portion. The major portion of the light energy is not reflected by the diffraction-inducing structure, but instead exits as the output beam.
In one embodiment, the optical monitoring system is formed as an optical module. A front side of the optical module includes a beam input and at least one beam monitor output. An internal mirror has a substantially 45 degree angle relative to the front side. The internal mirror is positioned to be impinged by a beam propagated through the beam input. A lid of the optical module is substantially transparent with respect to the beam, so as to enable passage of the output beam to an optical fiber or the like. However, a diffractor is disposed within the output path of the beam in order to reflect the minor portion, which again impinges the internal mirror. The diffractor in effect optically couples the diffracted portion to each beam monitor output via the reflection at the internal mirror. A detector may be aligned with each beam monitor output.
A method in accordance with the invention includes receiving the input beam, reflecting the input beam, transmitting a major portion of the reflected beam as an output signal and diffracting a minor portion such that a monitoring beam portion is directed rearwardly, reflecting the monitoring beam portion so as to subtend generally the same angle as the input beam, and detecting at least one optical property of the monitoring beam portion.
In a power monitoring application, a single detector, such as an edge detector, may be aligned with a single beam monitor output at the front side of the module. The detector generates a signal indicative of the intensity of the diffracted portion of the original input beam, which may be generated by an edge emitting laser mounted on a same substrate as the edge detector. The signal may be used to determine the intensity of the output beam and to provide feedback control to maintain a constant output power. Alternatively, in a wavelength-locking application, two detectors may be used. The first detector may monitor total power of the output beam as in the power monitoring application. A second detector is aligned with the second beam monitoring output at the front side of the module and is configured to generate a signal that is strongly dependent on wavelength. For example, a wavelength-specific filter may be positioned in the path to the second detector. The output of the second detector may be used to control the wavelength of the light source. As one possibility, the wavelength control may be provided by dynamically adjusting the temperature of a laser that is used as the light source. The relationship between temperature and the emitted wavelength of a laser is known. Thus, the wavelength and power of a laser can be controlled by adjustments to the temperature and bias current of the laser. For an edge emitting laser, the “feedback” is determined from the front facet emission, rather than from light emission from the rear facet of the edge emitting laser.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional representation of a prior art optical arrangement for monitoring and controlling power of a beam output.
FIG. 2 is a perspective view of a module in accordance with one embodiment of the invention.
FIG. 3 is a top view of the use of the present invention in a power monitoring application.
FIG. 4 is a top view of the use of the present invention in a wavelength-locking application.
FIG. 5 is a block diagram of components for enabling dynamic adjustments of optical properties of an output beam in accordance with the invention.
DETAILED DESCRIPTION
FIG. 2 shows one embodiment of an optical module 40 that enables feedback control of either or both of output power and emission wavelength (or other beam property), while retaining generally the same size requirements as a module without such a capability. Compactness is maintained by employing a combination of reflection and diffraction. In the embodiment shown in FIG. 2 , a front side 42 of the module includes a beam input 44 and a pair of beam monitor outputs 46 and 48 . Typically, the front “side” is not defined by structure, since even a transparent component would have an effect on beam propagation (i.e., refraction). Rather, the optical elements for directing and redirecting light define the positions of the input and the outputs. Moreover, the components of FIG. 2 may be only a subset of components of a more complete module, such as one that includes electrical components. The invention is considered to be well suited for use for a module that houses the components of FIG. 2 and the light source 12 , as well as a light source and at least one detector.
A light source, such as a laser, emits an input beam 50 that is collimated by a ball lens 52 . In other embodiments, the collimation is achieved using alternative means, such as other types of optical devices. The light source can be an edge emitting laser that is mounted on a substrate that supports the ball lens and other components of FIG. 2 . The input beam 50 then represents the emission from the front facet of the laser.
Following the collimation of the input beam 50 by the ball lens 52 , the light follows an input beam segment 54 of the path through the module 40 . A 45 degree mirror 56 is positioned such that the light is reflected upwardly to a reflected beam segment 58 of the path through the module.
The reflected beam segment 58 of the beam path passes through a lid structure 60 . For embodiments in which the 45 degree mirror 56 and lid are housed in common with other optical and electrical components of a more complete module, the lid may be easily held at a fixed but spaced-apart position relative to the mirror 56 . The lid structure is transparent to the wavelength of the light source, so as to allow an output beam 62 to exit at an output 64 of the module 40 . As one possibility, the lid structure may be a silicon substrate for beam wavelengths of longer than 1 μm. While not shown, a lens may be placed at the output 64 of the module. The lens may be used to focus the beam 62 onto an optical fiber or other element.
Within the beam path through the module 40 is a diffraction-inducing structure 66 , such as a diffraction grating. While the major portion of the input beam 50 propagates through the diffraction grating, a minor portion is directed rearwardly for a second reflection from the 45 degree mirror 56 . In the embodiment of FIG. 2 , first and second diffracted beam portions 68 and 70 are reflected by the mirror for exit via the beam monitoring outputs 46 and 48 , respectively. In other embodiments, a single diffracted beam portion is utilized for optical monitoring. Also in the embodiment of FIG. 2 , the 45 degree mirror is shown as a continuous structure. In other embodiments, the mirror may be segmented such that the input beam and the diffracted portions are directed to different segments.
Each diffracted beam portion 68 and 70 is reflected at an angle on the basis of Bragg's diffraction law. As is known to persons skilled in the art, the power of the reflected light depends upon the incident beam power and the design of the grating. When using a grating, more than one beam of diffracted light will be reflected, as shown in FIG. 2 . In the design of the grating, care should be taken to ensure that reflected power back to the laser is less than that which might affect operation of the laser. Lamellar gratings and blaze gratings are two of the available options.
FIG. 3 illustrates an embodiment for monitoring power. A laser 72 directs an input beam through the ball lens 52 , which provides beam collimation. The input beam may be emitted from a front facet of an edge emitting laser. The light travels along the input beam segment 54 of the beam path and is reflected by the 45 degree mirror 56 upwardly along a reflected beam segment 58 . As described with reference to FIG. 2 , the major portion of the beam provides the output, but a minor portion is reflected by the diffraction-inducing structure to provide the diffracted beam portion 68 shown in FIG. 3 . This beam portion is again reflected by the 45 degree mirror to the beam monitor output 46 . The axis of the beam monitor output is generally along the same horizontal plane as the axis of the input beam. That is, the axis is parallel to the base of the 45 degree mirror. The beam portion from the diffraction-inducing structure subtends the same angles as the original beam, but with the Bragg's diffraction angle. Therefore, a monitoring device, such as an edge detector 74 mounted on the same substrate as the mirror and the laser, can be aligned to collect the energy of the diffracted beam portion. The intensity of the diffracted beam portion is dependent upon the intensity of the input beam from the laser 72 . Therefore, the signal generated by the monitoring device can be used to control the laser so as to maintain a constant intensity. For example, the bias current of the laser may be dynamically adjusted on the basis of the signal from the monitoring device.
Because the input beam is collimated following passage through the ball lens 52 , the beam can undergo multiple reflections and can propagate along a long path without losing significant intensity. Only a small diffraction angle is required, so that a diffraction grating may have a long period, thereby easing manufacturing requirements. Additionally, because the beam monitor output 46 is generally parallel to the base of the mirror, an edge detector monitor 74 can be used.
While the diffraction-inducing structure for dividing the input beam has been described as being a diffraction grating, other approaches to partially reflecting the input beam may be used.
FIG. 4 shows another application of the invention. For each of the applications of FIGS. 3 and 4 , the illustrated optical and electrical components may be housed in a single module and can be mounted along a surface of a single substrate. In the application of FIG. 4 , wavelength locking is enabled. Both of the diffracted beam portions 68 and 70 of FIG. 2 are utilized. Thus, the beam along the reflected beam segment 58 is divided into the output beam and a pair of smaller intensity monitor beams 46 and 48 . The first monitoring device 74 operates in the same manner as described with reference to FIG. 3 . Thus, the total power emitted by the laser 72 may be monitored. The second beam monitor output 48 has an optical path that passes through a filter 76 before reaching a second monitoring device 78 . If the filter is wavelength-specific, the output of the second monitoring device will have an intensity that is strongly dependent on wavelength. The monitoring devices 74 and 78 may be edge detectors that generate signals that are responsive to changes in intensity. In this configuration, the output of the first edge detector is used to control total emitted power by dynamically adjusting the bias current of the laser 72 . The output of the second edge detector 78 is used to control the wavelength of the laser. As one possibility, wavelength control is achieved by dynamically adjusting the temperature of the laser. Since the emitted wavelength of the laser is varied by changes in the operating temperature, the emission wavelength can be locked by the combination of controlling laser output using the measurements by the first edge detector 74 and controlling laser temperature using the output of the second edge detector 78 .
FIG. 5 is a block diagram of components for implementing the invention of FIGS. 2 and 4 . The laser 72 provides an input beam to the optical module 40 . The combination of diffraction and reflection divides the input beam between an output to an output device (such as an optical fiber) and a pair of lower intensity beam monitor outputs. One beam monitor output is directed to a power detector, such as an edge detector, which generates signals indicative of laser output power. The signals from the detector 74 are used by a bias current controller 82 to maintain a constant intensity of the laser output. The second monitor beam is received by the wavelength detector 78 . As in FIG. 4 , a filter 76 may be used to ensure that the output of the detector 78 is strongly dependent upon an optical property at a specific wavelength. The output of the wavelength detector is used by a temperature controller 84 to regulate the temperature of the environment in which the laser resides. Therefore, the temperature can be adjusted to ensure that the wavelength of the laser emission is locked.
While the optical module 40 is shown as being separate from the laser 72 , and the detectors 74 and 78 , the components may be housed in common. Thus, the lid of the optical module may form a portion of a hermetical seal for the laser and the detectors. Signals generated by the detectors within the housing could be output to the controllers 82 and 84 . However, there are advantages to providing the controllers within the same housing, so that all of the components are integrated. Thus, with a heating element, such as a resistor within the housing, the environment in which the laser (e.g., an Externally Modulated Laser (EML)) resides may be easily controlled. Similarly, persons skilled in the art would readily recognize means for controlling the bias current of the laser. For an embodiment in which the laser is an EML, the light that is monitored is the light emission from the front facet and after the modulation, so that there is a greater accuracy than would be achieved by monitoring emission from the rear facet.
Where all of the components shown in FIG. 5 either define or are contained within a single housing, the housing can be compact as a result of the above-described combination of reflection and diffraction. In another embodiment, a single hermetically sealed housing is used for multiple channels. Thus, there is a separate laser for each channel, as well as a separate power detector 74 for each laser 72 . Moreover, separate temperature control is provided for each channel. Identically formed lasers will emit at substantially the same wavelength, but can be induced to emit at the different wavelengths of the various channels by individually setting the temperatures of the lasers. The different wavelengths/channels can then be combined and transmitted over a single fiber, so as to greatly increase the bandwidth of data transmission via the fiber.
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Compactness is preserved while enabling beam monitoring of optical properties of an output beam by employing a combination of reflection and diffraction. An input beam is reflected, divided using reflection/diffraction, and re-reflected. As a consequence, both a light source and one or more beam monitoring detectors may be disposed along a single side of an optical module. In one embodiment, an input beam is introduced from a first side of an optical module, is reflected by a 45 degree mirror, and is divided by a diffraction grating which redirects a minor portion of the beam energy back to the 45 degree mirror. Following the second reflection from the mirror, the returned portion of the beam is used to measure one or more optical properties.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 14/738,210, filed Jun. 12, 2015, which is a continuation of U.S. patent application Ser. No. 14,133,733, filed Dec. 19, 2013, which issued as U.S. Pat. No. 9,088,361 on Jul. 21, 2015 which is a continuation of U.S. patent application Ser. No. 12/884,483, filed Sep. 17, 2010, which issued as U.S. Pat. No. 8,639,124 on Jan. 28, 2014, which claims the benefit of U.S. Provisional Patent Application No. 61/243,819, filed Sep. 18, 2009; U.S. Provisional Patent Application No. 61/243,862, filed Sep. 18, 2009; and U.S. Provisional Patent Application No. 61/250,811, filed Oct. 12, 2009, the contents of all of which are incorporated by reference as if fully set forth herein.
BACKGROUND
[0002] Visible light communications (VLC) is a communications medium that uses visible light (e.g., light with wavelengths in the range of approximately 400 to 700 nanometers (nm) that may be seen with the naked human eye) to wirelessly transmit data (e.g., voice data, numerical data and image data). To transmit data using VLC, a visible light source, such as a fluorescent light bulb or a light emitting diode (LED), may be turned on and off or intensity modulated at a very high speed. A receiving device (e.g., a camera, a mobile telephone's imager or ambient light sensor) may receive the intensity modulated light and convert it into data that the receiving device may process for the user's use and/or enjoyment.
[0003] One major draw to VLC is the ubiquitous nature of visible light sources that may be used to transmit data to receiving devices. By way of example, lamps, consumer electronics which may include LED backlit displays and other LEDs, such as indicator lights and traffic signals, all include one or more visible light sources. Thus, visible light sources have the potential to wirelessly transmit data to a user located almost anywhere.
[0004] VLC may provide benefits such as freeing up limited radio frequency bandwidth for other uses since it does not require use of a radio frequency bandwidth. In addition, since light sources are already in place for other purposes (e.g., providing light and displaying television shows, movies and data), the light sources may be readily converted into transmitters by simply coupling them to control devices. However, one drawback to VLC is that VLC may interfere with dimming.
[0005] VLC may be used in a variety of applications, including but not limited to the categories listed in Table 1 below.
[0000]
TABLE 1
Application
Node
Definition
Examples
Infrastructure
Networked
VLAN, ATM
communications node
Machine
installed at a permanent
location
Mobile
Low mobility device,
PDA
may include fixed
devices
Vehicular
High mobility node
Automobile
associated with
transportation
applications
SUMMARY
[0006] A VLC device for lighting and data transmission is disclosed. The VLC device may comprise circuitry configured to receive a first stream of bits and determine a first switchpoint for transmitting the first stream of bits and first filler data. The VLC device may further comprise red, green, and blue (RGB) LEDs configured to transmit the first stream of bits and the first filler data in the visible light spectrum. The first filler data may begin to be transmitted at the first switchpoint. Similar to the first stream of bits, a second stream of bits may be received and transmitted by the RGB LEDs of the VLC device. In this way, a naked eye of a human may not detect flicker of the VLC device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] A more detailed understanding may be had from the following description, given by way of example in conjunction with the accompanying drawings wherein:
[0008] FIG. 1A is a system diagram of an example communications system in which one or more disclosed embodiments may be implemented;
[0009] FIG. 1B is a system diagram of an example wireless transmit/receive unit (WTRU) that may be used within the communications system illustrated in FIG. 1A ;
[0010] FIG. 2 shows an IEEE 802.15.7 network topology including communication interfaces;
[0011] FIG. 3 shows an IEEE 802.15 topology stack;
[0012] FIG. 4 is a block diagram of the VLC Physical data flow using one luminary;
[0013] FIG. 5 shows a multi-luminary architecture;
[0014] FIG. 6 shows a Walsh Code Tree for use in VLC;
[0015] FIG. 7 shows an example of a data duty cycle;
[0016] FIG. 8 shows examples of the average brightness of modulations;
[0017] FIG. 9 shows a relationship between the data duty cycle and a desired dimming or brightness level;
[0018] FIG. 10 shows an embodiment of VLC in the MAC architecture;
[0019] FIG. 11 shows a proposed MAC protocol data unit (PDU);
[0020] FIG. 12 shows MAC multiplexing and multiple access;
[0021] FIG. 13 is a flow diagram of the discovery procedure;
[0022] FIG. 14 is an example of VLC dimming controlled by MAC; and
[0023] FIG. 15 is a block diagram showing VLC including adaptation layer support.
DETAILED DESCRIPTION
[0024] FIG. 1A is a diagram of an example communications system 100 in which one or more disclosed embodiments may be implemented. The communications system 100 may be a multiple access system that provides content, such as voice, data, video, messaging, broadcast, etc., to multiple wireless users. The communications system 100 may enable multiple wireless users to access such content through the sharing of system resources, including wireless bandwidth. For example, the communications systems 100 may employ one or more channel access methods, such as code division multiple access (CDMA), time division multiple access (TDMA), frequency division multiple access (FDMA), orthogonal FDMA (OFDMA), single-carrier FDMA (SC-FDMA), and the like.
[0025] As shown in FIG. 1A , the communications system 100 may include wireless transmit/receive units (WTRUs) 102 a , 102 b , 102 c , 102 d , an access network (AN) or radio access network (RAN) 104 , a core network 106 , a public switched telephone network (PSTN) 108 , the Internet 110 , and other networks 112 , though it will be appreciated that the disclosed embodiments contemplate any number of WTRUs, base stations, networks, and/or network elements. Each of the WTRUs 102 a , 102 b , 102 c , 102 d may be any type of device configured to operate and/or communicate in a wireless environment. By way of example, the WTRUs 102 a , 102 b , 102 c , 102 d may be configured to transmit and/or receive wireless signals and may include user equipment (UE), a mobile station, a fixed or mobile subscriber unit, a pager, a cellular telephone, a personal digital assistant (PDA), a smartphone, a laptop, a netbook, a personal computer, a wireless sensor, a media transfer protocol (MTC) device, consumer electronics, and the like.
[0026] The communications systems 100 may also include a base station 114 a and a base station 114 b . Each of the base stations 114 a , 114 b may be any type of device configured to wirelessly interface with at least one of the WTRUs 102 a , 102 b , 102 c , 102 d to facilitate access to one or more communication networks, such as the core network 106 , the Internet 110 , and/or the networks 112 . By way of example, the base stations 114 a , 114 b may be a base transceiver station (BTS), a Node-B, an eNode B, a Home Node B, a Home eNode B, a site controller, an access point (AP), a wireless router, and the like. While the base stations 114 a , 114 b are each depicted as a single element, it will be appreciated that the base stations 114 a , 114 b may include any number of interconnected base stations and/or network elements.
[0027] The base station 114 a may be part of the RAN 104 , which may also include other base stations and/or network elements (not shown), such as a base station controller (BSC), a network controller or a radio network controller (RNC), relay nodes, etc. The base station 114 a and/or the base station 114 b may be configured to transmit and/or receive wireless signals within a particular geographic region, which may be referred to as a cell (not shown). The cell may further be divided into cell sectors. For example, the cell associated with the base station 114 a may be divided into three sectors. Thus, in one embodiment, the base station 114 a may include three transceivers, i.e., one for each sector of the cell. In another embodiment, the base station 114 a may employ multiple-input multiple output (MIMO) technology and, therefore, may utilize multiple transceivers for each sector of the cell.
[0028] The base stations 114 a , 114 b may communicate with one or more of the WTRUs 102 a , 102 b , 102 c , 102 d over an air interface 116 , which may be any suitable wireless communication link (e.g., radio frequency (RF), microwave, infrared (IR), ultraviolet (UV), visible light, etc.). The air interface 116 may be established using any suitable access technology or radio access technology (RAT).
[0029] More specifically, as noted above, the communications system 100 may be a multiple access system and may employ one or more channel access schemes, such as CDMA, TDMA, FDMA, OFDMA, SC-FDMA, and the like. For example, the base station 114 a in the RAN 104 and the WTRUs 102 a , 102 b , 102 c may implement a technology such as Universal Mobile Telecommunications System (UMTS) Terrestrial Radio Access (UTRA), which may establish the air interface 116 using wideband CDMA (WCDMA). WCDMA may include communication protocols such as High-Speed Packet Access (HSPA) and/or Evolved HSPA (HSPA+). HSPA may include High-Speed Downlink Packet Access (HSDPA) and/or High-Speed Uplink Packet Access (HSUPA).
[0030] In another embodiment, the base station 114 a and the WTRUs 102 a , 102 b , 102 c may implement a technology such as Evolved UMTS Terrestrial Radio Access (E-UTRA), which may establish the air interface 116 using Long Term Evolution (LTE) and/or LTE-Advanced (LTE-A).
[0031] In other embodiments, the base station 114 a and the WTRUs 102 a , 102 b , 102 c may implement technologies such as IEEE 802.16 (i.e., Worldwide Interoperability for Microwave Access (WiMAX)), CDMA2000, CDMA2000 1X, CDMA2000 EV-DO, Interim Standard 2000 (IS-2000), Interim Standard 95 (IS-95), Interim Standard 856 (IS-856), Global System for Mobile communications (GSM), Enhanced Data rates for GSM Evolution (EDGE), GSM EDGE (GERAN), and the like.
[0032] The base station 114 b in FIG. 1A may be a wireless router, Home Node B, Home eNode B, or access point, for example, and may utilize any suitable access technology or RAT for facilitating wireless connectivity in a localized area, such as a place of business, a home, a vehicle, a campus, and the like. In one embodiment, the base station 114 b and the WTRUs 102 c , 102 d may implement a technology such as IEEE 802.11 to establish a wireless local area network (WLAN). In another embodiment, the base station 114 b and the WTRUs 102 c , 102 d may implement a technology such as IEEE 802.15 to establish a wireless personal area network (WPAN). In yet another embodiment, the base station 114 b and the WTRUs 102 c , 102 d may utilize a cellular-based RAT (e.g., WCDMA, CDMA2000, GSM, LTE, LTE-A, etc.) to establish a picocell or femtocell. As shown in FIG. 1A , the base station 114 b may have a direct connection to the Internet 110 . Thus, the base station 114 b may not be required to access the Internet 110 via the core network 106 .
[0033] The RAN 104 may be in communication with the core network 106 , which may be any type of network configured to provide voice, data, applications, and/or voice over internet protocol (VoIP) services to one or more of the WTRUs 102 a , 102 b , 102 c , 102 d . For example, the core network 106 may provide call control, billing services, mobile location-based services, pre-paid calling, Internet connectivity, video distribution, etc., and/or perform high-level security functions, such as user authentication. Although not shown in FIG. 1A , it will be appreciated that the RAN 104 and/or the core network 106 may be in direct or indirect communication with other RANs that employ the same RAT as the RAN 104 or a different RAT. For example, in addition to being connected to the RAN 104 , which may be utilizing an E-UTRA radio technology, the core network 106 may also be in communication with another RAN (not shown) employing a GSM radio technology.
[0034] The core network 106 may also serve as a gateway for the WTRUs 102 a , 102 b , 102 c , 102 d to access the PSTN 108 , the Internet 110 , and/or other networks 112 . The PSTN 108 may include circuit-switched telephone networks that provide plain old telephone service (POTS). The Internet 110 may include a global system of interconnected computer networks and devices that use common communication protocols, such as the transmission control protocol (TCP), user datagram protocol (UDP) and the internet protocol (IP) in the TCP/IP internet protocol suite. The networks 112 may include wired or wireless communications networks owned and/or operated by other service providers. For example, the networks 112 may include another core network connected to one or more RANs, which may employ the same RAT as the RAN 104 or a different RAT.
[0035] Some or all of the WTRUs 102 a , 102 b , 102 c , 102 d in the communications system 100 may include multi-mode capabilities, i.e., the WTRUs 102 a , 102 b , 102 c , 102 d may include multiple transceivers for communicating with different wireless networks over different wireless links. For example, the WTRU 102 c shown in FIG. 1A may be configured to communicate with the base station 114 a , which may employ a cellular-based radio technology, and with the base station 114 b , which may employ an IEEE 802 radio technology.
[0036] FIG. 1B is a system diagram of an example WTRU 102 . As shown in FIG. 1B , the WTRU 102 may include a processor 118 , a transceiver 120 , a transmit/receive element 122 , a speaker/microphone 124 , a keypad 126 , a display/touchpad 128 , non-removable memory 106 , removable memory 132 , a power source 134 , a global positioning system (GPS) chipset 136 , and other peripherals 138 . It will be appreciated that the WTRU 102 may include any sub-combination of the foregoing elements while remaining consistent with an embodiment.
[0037] The processor 118 may be a general purpose processor, a special purpose processor, a conventional processor, a digital signal processor (DSP), a plurality of microprocessors, one or more microprocessors in association with a DSP core, a controller, a microcontroller, Application Specific Integrated Circuits (ASICs), Field Programmable Gate Array (FPGAs) circuits, any other type of integrated circuit (IC), a state machine, and the like. The processor 118 may perform signal coding, data processing, power control, input/output processing, and/or any other functionality that enables the WTRU 102 to operate in a wireless environment. The processor 118 may be coupled to the transceiver 120 , which may be coupled to the transmit/receive element 122 . While FIG. 1B depicts the processor 118 and the transceiver 120 as separate components, it will be appreciated that the processor 118 and the transceiver 120 may be integrated together in an electronic package or chip.
[0038] The transmit/receive element 122 may be configured to transmit signals to, or receive signals from, a base station (e.g., the base station 114 a ) over the air interface 116 . For example, in one embodiment, the transmit/receive element 122 may be an antenna configured to transmit and/or receive RF signals. In another embodiment, the transmit/receive element 122 may be an emitter/detector configured to transmit and/or receive IR, UV, or visible light signals, for example. In yet another embodiment, the transmit/receive element 122 may be configured to transmit and receive both RF and light signals. It will be appreciated that the transmit/receive element 122 may be configured to transmit and/or receive any combination of wireless signals.
[0039] In addition, although the transmit/receive element 122 is depicted in FIG. 1B as a single element, the WTRU 102 may include any number of transmit/receive elements 122 . More specifically, the WTRU 102 may employ MIMO technology. Thus, in one embodiment, the WTRU 102 may include two or more transmit/receive elements 122 (e.g., multiple antennas) for transmitting and receiving wireless signals over the air interface 116 .
[0040] The transceiver 120 may be configured to modulate the signals that are to be transmitted by the transmit/receive element 122 and to demodulate the signals that are received by the transmit/receive element 122 . As noted above, the WTRU 102 may have multi-mode capabilities. Thus, the transceiver 120 may include multiple transceivers for enabling the WTRU 102 to communicate via multiple RATs, such as UTRA and IEEE 802.11, for example.
[0041] The processor 118 of the WTRU 102 may be coupled to, and may receive user input data from, the speaker/microphone 124 , the keypad 126 , and/or the display/touchpad 128 (e.g., a liquid crystal display (LCD) display unit or organic light-emitting diode (OLED) display unit). The processor 118 may also output user data to the speaker/microphone 124 , the keypad 126 , and/or the display/touchpad 128 . In addition, the processor 118 may access information from, and store data in, any type of suitable memory, such as the non-removable memory 106 and/or the removable memory 132 . The non-removable memory 106 may include random-access memory (RAM), read-only memory (ROM), a hard disk, or any other type of memory storage device. The removable memory 132 may include a subscriber identity module (SIM) card, a memory stick, a secure digital (SD) memory card, and the like. In other embodiments, the processor 118 may access information from, and store data in, memory that is not physically located on the WTRU 102 , such as on a server or a home computer (not shown).
[0042] The processor 118 may receive power from the power source 134 , and may be configured to distribute and/or control the power to the other components in the WTRU 102 . The power source 134 may be any suitable device for powering the WTRU 102 . For example, the power source 134 may include one or more dry cell batteries (e.g., nickel-cadmium (NiCd), nickel-zinc (NiZn), nickel metal hydride (NiMH), lithium-ion (Li-ion), etc.), solar cells, fuel cells, and the like.
[0043] The processor 118 may also be coupled to the GPS chipset 136 , which may be configured to provide location information (e.g., longitude and latitude) regarding the current location of the WTRU 102 . In addition to, or in lieu of, the information from the GPS chipset 136 , the WTRU 102 may receive location information over the air interface 116 from a base station (e.g., base stations 114 a , 114 b ) and/or determine its location based on the timing of the signals being received from two or more nearby base stations. It will be appreciated that the WTRU 102 may acquire location information by way of any suitable location-determination method while remaining consistent with an embodiment.
[0044] The processor 118 may further be coupled to other peripherals 138 , which may include one or more software and/or hardware modules that provide additional features, functionality and/or wired or wireless connectivity. For example, the peripherals 138 may include an accelerometer, an e-compass, a satellite transceiver, a digital camera (for photographs or video), a universal serial bus (USB) port, a vibration device, a television transceiver, a hands free headset, a Bluetooth® module, a frequency modulated (FM) radio unit, a digital music player, a media player, a video game player module, an Internet browser, and the like.
[0045] FIG. 2 shows an IEEE 802.15.7 network topology including communication interfaces 200 . A core network (CN) 210 may be connected to an infrastructure node 225 via a Q interface 220 , using a technology including but not limited to power line communication (PLC) or Ethernet. The infrastructure node may be connected to a fixed, mobile or vehicle node 235 using an R x interface 230 , which may be a VLC link. An R x interface 230 may be an inter-luminary interference used for spatial multiplexing. The P interface 240 may indicate peer-to-peer (P2P) communication that may not include connectivity to a network.
[0046] VLC may be used with a variety of applications and topologies including P2P, infrastructure and simplex, wherein each topology may include a particular mode. An infrastructure topology may include an infrastructure mode that provides features for communications while maintaining illumination as a primary function of a LED source. Dimming may be implemented in this mode so that data throughput is maximized and multiplexing may be used to support multiple end users. In addition, interference from an unintended light source may be rejected in this mode. Also, the infrastructure node in this mode may be linked using an R x interface 230 .
[0047] In a P2P topology, a P2P mode may use spatial separation to limit interference from other VLC sources. Maximum data rate may be achieved in this mode by eliminating added signaling and physical layer redundancy. Also, the P2P node in this mode may be linked using a P interface 240 .
[0048] In addition to the P2P and infrastructure modes, VLC may utilize a simplex mode to allow visible light links to work as a complimentary wireless access technology with uni-directional support. This may allow visible light links to operate as a uni-directional broadcast channel. Also, retransmissions may be repeated a fixed number of times with no dependency on an external entity.
[0049] FIG. 3 shows an IEEE 802.15 topology stack 300 . Both the physical (PHY) 310 and MAC 320 layers are included. Above the MAC layer may exist logical link control (LLC) layers 330 . In simplex mode, medium access control (MAC) protocols may provide the receipt of control information including acknowledgments (ACK) and channel quality measurements from an external entity outside the MAC. Other LLC sublayers may also be included in the VLC architecture 340 .
[0050] FIG. 4 is a block diagram of VLC PHY data flow including separation and aggregation of bands of data using one luminary 400 . In FIG. 4 , a luminary 405 is used to show a single data flow in order to illustrate interference in a communications channel. A stream of bits x 1 , x 2 , x 3 , . . . x N 407 , used as an input vector of length N, are input into a PHY band separator 410 , where N is the size of the MAC protocol data unit (PDU). Bit padding of “0” is used to ensure the length of the vector is N, which is a multiple of M, where M is the total number of bands of data, or colors:
[0000]
N
′
=
M
⌈
N
M
⌉
.
Equation
[
1
]
[0000] The stream of bits 407 input into the band separator block 410 are denoted as x 1 , x 2 , x 3 , . . . x N . The band separator 410 aggregates the stream of bits across multiple bands of data 415 . The output of the band separator 410 are M bands of data, b m, 415 . Each band of data includes data bits that are mapped through the band separator. The mathematical representation of the mapping of data bits through the band separator may be determined by the following equations which show how input bits x are multiplexed into the bits b in each band:
[0000]
b
m
,
k
=
x
M
(
k
-
1
)
+
m
Equation
[
2
]
k
=
1
,
2
,
3
,
…
,
X
Equation
[
3
]
X
=
N
′
M
Equation
[
4
]
m
=
1
,
2
,
…
,
M
.
Equation
[
5
]
[0000] Where k is the channel number, X is the total number of channels, m is a band of data, and b m,k is the data.
[0051] To provide maximum capacity in infrastructure systems when multiple bands of light are used, the PHY separates and aggregates data through the band separator 410 . Each data symbol sent in parallel over the air interface is converted to a serial data stream, starting with the symbol at the lowest wavelength band to the highest wavelength band. In infrastructure topologies, support for multiple wavelengths or bands is provided. These bands may be associated with colors of the visible light spectrum and different wavelengths, where different wavelengths correspond to different colors of the visible light spectrum. When the bands are multiplexed together the overriding color is white light.
[0052] For each band in, the data b m,k is spread by a channelization code C(k,SF) at the channelization block 420 , which is specific to a luminary, where (SF) is the spreading factor of the code and k is the channel number:
[0000] 0≦ k≦SF− 1 Equation [6].
[0000] In other words, the (SF) is the number of luminaries at use, and k is the index of a particular luminary.
[0053] A scrambling code s m or line code may then be applied at the scrambling or line code block 425 to each band of data. Conversion to unipolar data may then occur at the direct current (DC) offset or unipolar conversion block 430 for each band of data. A DC offset or conversion to unipolar signaling may be necessary to provide consistency with on/off keying (OOK) of the LED light source.
[0054] In order to transmit data while maintaining brightness of the luminary, dimming is implemented. Dimming is performed at a dimming block 435 . A desired brightness level is received at the dimming block 435 . Based on the desired brightness level, a data duty cycle for transmission of data is determined. Filler luminance values are determined based on the received brightness level. Filler luminance values of either a “1” or a “0” are added to the data prior to conversion to light by the single or multi-band LED device 440 allowing for the alternation of data and light on the luminary.
[0055] Another aspect of the VLC network topology concerns PHY band separation and aggregation. For the infrastructure VLC, single-chip (band) based LEDs may be used for an energy efficient solution, while three-chip (band) (i.e., RGB) LEDs may provide increased data rate. In the case of RGB, white light is still desired for the primary function of illumination, meaning that all bands are active. Therefore, in the interest of maximizing data capacity, each band may be used by each luminary. Any band that remains active for the purpose of illumination, and does not carry data, may add to the system interference and lower overall capacity.
[0056] PHY multiplexing provides independent channels among multiple luminary sources (inter-luminary) so that multiple luminary sources may exist at the same time. PHY multiplexing allows the separation of signals from one luminary source to another. In infrastructure topologies, interference among luminary sources may be mitigated using code division multiplexing (CDM). Variable length spreading codes are defined where the spreading factor is equal to the reuse factor, or number of channels desirable within a geographic area.
[0057] FIG. 5 shows a multi-luminary architecture 500 . In FIG. 5 two data flows, or two luminaries 505 , 508 , are shown. A plurality of luminaries may exist at one time. A stream of bits x 1 , x 2 , x 3 , . . . x N 507 , 509 , for each luminary may be used as an input vector of length N and input into a PHY band separator 510 , 511 . Bit padding of “0” is employed to ensure the length of the vector is N, which is a multiple of M using Equation [1]. The output of the band separator 510 , 511 , may be M bands of data 515 , 516 , for each luminary 505 , 508 .
[0058] The channelization code, C(k,SF), is applied to each band of data at the channelization code block 520 , 521 . A scrambling or line code sm may then be applied to each band of data at the scrambling or line code block 525 , 526 . If there are more luminaries than spreading codes, then at least two luminaries may have the same spreading code. In this case, different scrambling codes may be used. At an input port or a receiver, there may be interference among the luminaries. However, the interference is reduced by the (SF). Interference may be mitigated by using CDM using Walsh codes and variable spreading based on a system reuse parameter. Conversion to unipolar data may occur at a DC offset or unipolar conversion block 530 , 531 , for each band of data.
[0059] Dimming may be performed at a dimming block 535 , 536 , for each band of data. A desired brightness level is received at each the dimming block 535 , 536 . Based on the desired brightness level, a data duty cycle for transmission of data is determined. Filler luminance values are based on the received brightness level. Filler luminance values of either a “1” or a “0” are added to the data prior to conversion to light by the single or multi-band LED device 540 , 541 before the bands are output to a transport channel 550 . The value of the filler luminance values or filler bits, b B, is determined from the equation:
[0000]
b
B
=
{
0
,
L
<
B
1
,
L
≥
B
.
Equation
[
7
]
[0000] Wherein B is the average brightness of a given modulation and L is the desired illumination level.
[0060] Data transmission and reception are performed using transport channels 550 provided by the VLC physical layer. There are two different types of transport channels according to their objectives and characteristics, the broadcast channel (BCH) and the shared traffic channel (STCH). The BCH is a downlink channel that broadcasts the current status of the system and cells to entire cells. The STCH is a channel used for user data transmission. Since this channel is shared by many users, data flow on this channel is managed by a scheduler and a medium access mechanism. The STCH is used for both uplink and downlink communications.
[0061] FIG. 6 shows a Walsh Code Tree for use in VLC. Walsh spreading codes are orthogonal. Accordingly, if luminaries are assigned different spreading codes and identical scrambling codes, and if they are transmitting synchronously, they may be separated by the receiver, and may not interfere with each other. This property may be used to solve the “near-far” problem commonly encountered in wireless transmission. The near-far problem is a condition in which a strong signal is captured by a receiver making it impossible for the receiver to detect a weaker signal. By using Walsh coding with synchronization, where the codes are orthogonal, the near far problem is reduced.
[0062] Walsh codes have a property such that the channelization code C(0,SF) is a pure DC offset while all other codes have no DC offset component. After scrambling, each code may result in a random DC offset component. Low-frequency ambient noise may still interfere with transmission, however, the impact is reduced by a factor of SF compared to using OOK.
[0063] FIG. 7 shows an example of a data duty cycle 700 . While VLCs may use indoor lighting, the primary function of indoor lighting is lighting while VLC is a secondary function. In order to maintain communications while changing the brightness of the lights, dimming is implemented. The brightness of the light corresponds to the portion of on/off periods of the light. When lights are turned off very quickly, the naked eye cannot detect the flicker. If the light is on more often than it is off, the light may appear brighter than if the light is off more often than on. The flow of data using VLC is mapped to the on time of the lights. In order to achieve a desired brightness and a maximum transmission level for data, a data duty cycle is implemented.
[0064] In FIG. 7 , over a time interval T 710 , a data duty cycle 720 is highest, meaning the maximum amount of data may be sent, when the average illumination level 730 is half of the maximum illumination level. For example, at 50% illumination level the data duty cycle operates at 100%. The data duty cycle is lowest, meaning the minimum amount of data is sent, when the brightness is highest or lowest. For example, when the average illumination level is at 100%, meaning the light is on, no data is transmitted and when the average illumination level is at 0%, meaning the light is off, no data is transmitted.
[0065] When the minimum amount of data is sent and brightness is at its highest, the LED filler luminance value is 1. A LED filler luminance value of 1 is equivalent to the LED being on, which may indicate that the lights are on. When the minimum amount of data is sent and brightness is at its lowest the LED filler is 0. A LED filler of 0 is equivalent to the LED being off, which may indicate that the lights are off. The average illumination level, L, over the time interval T, is a function of the data transmission duty cycle Y B and the LED filler level, when no data is transmitted.
[0066] The desired brightness of a light source may be controlled by varying or modulating the length of the duty cycle of an active data transmission. Dimming is used as a link power control for communications. When the average illumination level is less than 100% and more than 0%, data may be sent. When data is sent, the light is dimmed by a percentage.
[0067] When the average illumination level is above 50%, dimming allows the data duty cycle to increase, when the average illumination level is below 50%, further dimming forces the data duty cycle to decrease. Data transmission is at the highest rate when the average illumination level is at 50%. At the absolute maximum brightness level and in total darkness, no data transmission is possible.
[0068] When multiple luminaries are dimmed separately, they may have different data duty cycles. In order to minimize interference, phasing of the duty cycles of the multiple luminaries may be staggered. The phase of the duty cycles may be controlled by timing of the switchpoint alignment or phase signal in the dimming block 535 , 536 , that is input from the MAC.
[0069] Optimum performance in terms of interference is achieved when the data transmission in the duty cycles of the multiple luminaries have minimum overlap. This is achieved by either estimating or removing a filler bit. When a filler bit value is zero, there may not be interference to the data.
[0070] FIG. 8 shows an example of the relationship between the average brightness, B, of LEDs and different methods of modulating a transmission 800 . For example, data transmission may be determined by OOK or by Manchester modulation, where the average brightness during data transmission is 50% of the peak brightness. In another example, data transmission may be determined by 4 pulse-position modulation (4-PPM) where the average brightness during data transmission is 25% of the peak brightness.
[0071] FIG. 9 shows a relationship between the data duty cycle, Y B , and a desired dimming or brightness level. A provisional illumination level 910 that may be below the absolute maximum LED brightness allows for a minimum level of data transmission. Where L is the average illumination level desired by a user and B is the average brightness of a given modulation.
[0072] FIG. 10 shows an embodiment where VLC is present in the MAC architecture 1000 . The MAC subsystem interfaces with upper layers via control and data signaling. The MAC subsystem performs various functions including classification and distribution of control and traffic packets for interfacing with the upper layer, state management of the WTRUs, depending on the existence of data to be transmitted, packet scheduling, and downlink broadcasting for information delivery.
[0073] The MAC sublayer is responsible for access to the physical channels and is responsible for such tasks including but not limited to: (1) dimming control; (2) broadcast and common data; (3) packet scheduling; (4) employing time division multiplexing (TDM) for multiple access within a luminary; and (5) data framing including segmentation and assembly.
[0074] Several functional blocks are utilized in order to perform the above functions including but not limited to: (1) Reassembly/Deframing Block 1010 ; (2) State Management Block 1020 ; (3) Broadcasting/Common Control Block 1030 ; (4) Buffer Management Block 1040 ; (5) Transmission/Reception Control Block 1050 ; and (6) Packet Scheduling Block 1060 .
[0075] In FIG. 10 , the mobile equipment MAC is a subset of the infrastructure MAC. A dimming control 1070 is administered prior to packet scheduling 1060 . The dimming control 1070 includes a color quality index which is used to schedule and manage data flow. The MAC controls dimming by accepting a desired average illumination level, L, as a MAC input, and determining the duty cycle, γ B from the
[0000]
γ
B
=
{
L
B
,
L
<
B
1
1
-
B
(
1
-
L
)
,
L
≥
B
.
Equation
[
8
]
[0000] equation:
Where B is the average brightness of a given modulation. Both the data flow and the size of the data package are based on dimming and channel measurements 1065 including but not limited to the channel quality index (CQI), the color quality index and power level.
[0076] FIG. 11 shows a MAC protocol data unit (PDU) 1100 of size N PDU . The structure for the MAC PDU includes a preamble, a PHY header 1130 , a MAC header 1140 , a start of packet delimiter 1120 , a payload 1150 and an optional frame check sequence 1160 . The preamble 1110 may be used for receiver timing and synchronization. The size of the MAC PDU may be computed as:
[0000] N PDU =N F γ B α Equation [9]
[0000] where N F is the size of the physical layer data frame (including filler bits), γ B is the data duty cycle and α is the FEC code rate.
[0077] The MAC multiple access feature may be used within a luminary (intra-luminary) for the purpose of providing data service to multiple users under a luminary.
[0078] FIG. 12 shows an example of MAC multiplexing and multiple access. The MAC multiple access feature may be used within a luminary (intra-luminary), or infrastructure node 1210 , for providing data service to multiple end-user nodes 1230 , 1235 . MAC channelization may be done through logical channels which include broadcast channels 1220 , multicast channels 1240 and unicast channels 1225 . Broadcast channels may be used for system information. Unicast and multicast channels may be used for user or group data.
[0079] The logical channels may be related to the types and contents of data transferred over the air or radio interface. There may be different categories of data traffic mapped to the logical channels. The broadcast channel may be a downlink only channel that is used to broadcast capabilities of the infrastructure node and current status of the system to the entire luminary domain. The broadcast channel may be mapped to Broadcast Control Channel (BCH). The multicast channel may be a downlink only channel that is used to send common user-data transmissions to a subgroup of users. It may be mapped to a shared traffic channel (STCH). In addition, per-packet identification of the group may be made using a multicast MAC address. The unicast channel may be the point-to-point duplex channel between the infrastructure node and each of the end-user nodes. It may be used to carry user data transmissions and is mapped to the STCH.
[0080] FIG. 13 is a flow diagram of the discovery procedure 1300 . The discovery procedure encompasses the process by which an end-user discovers a luminary with which to associate. The discovery and association process begins with a newly turned on end-user device receiving beacons from all nearby infrastructure luminaries. Upon entering a luminary domain, a new device starts receiving on a configured channel. At periodic intervals, the luminary sends a beacon including capabilities on the broadcast channel 1310 .
[0081] A device receiving the beacon makes a decision based on the capabilities received. The device processes the capabilities received from the luminary infrastructure node. The capabilities include PHY capabilities, MAC capabilities, uni-directional traffic support, bi-directional traffic support, dimming support, and visibility support 1320 . The end-user device performs a selection algorithm to determine the luminary with which it would like to associate with based on the received capabilities, which may also include signal measurements and data rate requirements. The end-user device sends a request-to-associate to the selected luminary, thereby initiating the association process 1330 - 1350 . Once the luminary confirms that it has associated with the end-user, additional information is transmitted including resource allocation information, transmission (TX) and receiving (RX) information, CDMA parameters and bands available for use 1360 . The end-user may be able to exchange data with the luminary on the agreed upon channels 1370 .
[0082] FIG. 14 is a block diagram showing dimming controlled by MAC 1400 . The dimming signals are received from a higher level such as a light abstraction layer (LAL). The dimming signals are used to determine the duty cycle 1420 . The MAC determines the switchpoint based on the duty cycle γ B 1430 . The data is then output to the LED device 1440 .
[0083] FIG. 15 is a block diagram showing VLC including adaptation layer support 1500 . To perform infrastructure uplink on different radio access technologies (RAT), adaptation layer support is needed in the MAC. A management component 1560 features RAT availability, QoS mapping, control/data multiplexing options, and configurations. The management component 1560 transmits and receives information from the PHY layer 1565 .
[0084] The architecture includes the following layers that may be used in both uplink and downlink transmissions: an application layer 1510 , a middleware layer 1520 , a network protocol layer 1530 , an adaptation data layer 1540 , a first adaptor coupled to a first technology dependent MAC layer 1550 , a second adapter coupled to a second technology dependent MAC layer 1555 . While two adaptors are described in this example, the number of adaptors may be limited by the number of RATs supported by the device.
[0085] One of the difficulties with VLC is that the availability of an uplink and downlink are independent due to device restrictions. In some environments, high intensity visible light based downlink may be easily be provided from infrastructure lighting fixtures, while uplink is limited to the transmit power of a portable device and may need to be provided using spectrum other than visible light (e.g., RF).
[0086] Another feature of visible light is that the optical confinement of LED light may provide localized high bandwidth density. This may be leveraged by allowing spectrum aggregation and using multiple access technologies in a single direction. Visible light may operate as a complementary communication link between two devices using, for example, visible light communications in the downlink and infrared in the uplink, or by creating hybrid topologies performing control and data communication over different access technologies, or by creating a “hotspot” functionality with multiple access technologies co-working in each direction.
[0087] Although features and elements are described above in particular combinations, one of ordinary skill in the art will appreciate that each feature or element can be used alone or in any combination with the other features and elements. In addition, the methods described herein may be implemented in a computer program, software, or firmware incorporated in a computer-readable medium for execution by a computer or processor. Examples of computer-readable media include electronic signals (transmitted over wired or wireless connections) and computer-readable storage media. Examples of computer-readable storage media include, but are not limited to, a read only memory (ROM), a random access memory (RAM), a register, cache memory, semiconductor memory devices, magnetic media such as internal hard disks and removable disks, magneto-optical media, and optical media such as CD-ROM disks, and digital versatile disks (DVDs). A processor in association with software may be used to implement a radio frequency transceiver for use in a WTRU, UE, MTC device, terminal, base station, RNC, or any host computer.
|
A visible light communication (VLC) device for lighting and data transmission is disclosed. The VLC device may comprise circuitry configured to receive a first stream of bits and determine a first switchpoint for transmitting the first stream of bits and first filler data. The VLC device may further comprise red, green, and blue (RGB) light emitting diodes (LEDs) configured to transmit the first stream of bits and the first filler data in the visible light spectrum. The first filler data may begin to be transmitted at the first switchpoint. Similar to the first stream of bits, a second stream of bits may be received and transmitted by the RGB LEDs of the VLC device. In this way, a naked eye of a human may not detect flicker of the VLC device.
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BACKGROUND ART
[0001] 1. Field of the Invention
[0002] The invention relates to an electroluminescent film for emitting light. More particularly, the invention relates to an electroluminescent film for emitting light of varying wavelengths and a method for its production.
[0003] 2. Description of the Related Art
[0004] Electroluminescent films are generally two-dimensional illuminants that radiate light when subjected to electric current. The electroluminescent film has a base film in which fluorescing substances are present. As a rule, the fluorescing substance is a zinc sulfide (phosphor powder). The portion of the spectrum of the electromagnetic radiation, i.e., the hue of the light, radiated by the electroluminescent film depends on the doping of the fluorescing pigments. If the electroluminescent films must be prepared for differing hues of radiated light, production is worthwhile only for large quantities. Not all color locations or hues can be realized through varying doping of the phosphor powder. Also, the yield of the luminance is often only slight.
[0005] Electroluminescent films are also known in which the particular portion of the electromagnetic radiation spectrum is adjusted through the addition of fluorescing coloring agents into the phosphor paste. Thus, for example, the reflected light color (when the electroluminescent film is not switched on) can be pink, while the electroluminescent film radiates white when it is switched on. As a result of the added coloring agent, however, the reflected light color of the electroluminescent film, i.e., the hue of this film when it is not electrified, changes. Frequently, however, a neutral reflected light color is required in the switched-off state, so that the addition of fluorescing coloring agents is not possible. In addition, there is the problem of separation of the coloring agent within the phosphor paste so that the quality of the electroluminescent film is impaired. There is also the problem of UV resistance of the coloring agent or pigment.
[0006] The object of the invention is to configure the generic electroluminescent film and the method for producing it such that with simple production, all hues of the light to be radiated from the electroluminescent film can be set and a long useful light and high luminescence are ensured.
[0007] This object is solved in the generic electroluminescent film according to the invention with the characterizing features of claim 1 and in the generic method according to the invention with the characterizing features of claim 11 .
[0008] In the electroluminescent film according to the invention, the light, which as a rule has a hue, radiated from the base film passes through the color filter layer. With it, any desired color can be produced which is desired for the application of the electroluminescent film. Thus the electroluminescent film according to the invention by way of example has a useful life of around 10,000 hours with a green illuminating color and up to around 3,000 hours with a red illuminating color. In addition, the electroluminescent film according to the invention is characterized by a high luminance.
[0009] In the method according to the invention, the color filter layer is initially imprinted onto the carrier film. Following this, the unit composed of color filter layer and carrier film is attached to the base film.
[0010] Advantageously the color filter layer contains fluorescing pigments imbedded in a binding agent. The color filter layer thus forms a fluorescent filter with which the desired hue of the radiated light can be set. Depending of the desired color location, various fluorescing pigments are added to the binding agent.
[0011] The color filter layer preferably is provided on a carrier film so that the base film remains unchanged. The carrier film with the color filter layer is merely fastened onto it.
[0012] The carrier film advantageously is composed of polyester.
[0013] In order to achieve optimal protection of the electroluminescent film, it advantageously is backed.
[0014] The side of the carrier film next to the color filter layer is advantageously provided with a layer that determines the reflected light color of the electroluminescent film. Advantageously this layer consists of white fluorescent color. Then the electroluminescent film in switched-off condition has a neutral, whitish hue. It of course is possible to configure this layer such that the electroluminescent film in switched-off condition has a hue. In this case, fluorescing pigment particles are contained in this layer.
[0015] The fluorescing pigments advantageously are uniformly distributed in the color filter layer so that the light radiated from the electroluminescent film has a uniform luminance.
[0016] But it is also possible for the fluorescing pigments to arranged so as to be not uniformly distributed in the color filter layer. Then a gradient of light intensity can be set.
SUMMARY OF THE INVENTION
[0017] An electroluminescent film includes a base film through which an electric current is selectively passed. The base film emits radiant energy in the visible spectrum when the electric current is passed therethrough. A filter layer is fixedly secured to the base film and filters a portion of the radiant energy wherein only a portion of the radiant energy emitted by the base film passes through the filter layer to be visible to an observer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Advantages of the invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
[0019] FIG. 1 is a schematic sectional side view of an electroluminescent film according to the invention;
[0020] FIG. 2 is a schematic side view of various layers of the electroluminescent film; and
[0021] FIG. 3 is an exploded view the various layers of the electroluminescent film according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] The electroluminescent film forms a two-dimensional illuminant that depending on configuration can radiate light in varying hues. Such electroluminescent films are advantageously utilized in the automobile industry, for example in the interior of an automobile. Thus electroluminescent films can be used in the headliner, as marking lights at door handles and the like.
[0023] The electroluminescent film has a base film 1 that in switched-on condition radiates light of a specific color, for example green light. In the installed position, this base film 1 forms the back side of the electroluminescent film. On the one side 2 of base film 1 , there is a color filter 3 with which the desired hue of the light radiated from the electroluminescent film can be set. The color filter 3 is situated on the one side of a carrier film 4 that covers the color filter 3 . It contains fluorescing pigments 5 that are embedded in a binding agent 6 . The proportion of pigment 5 to binding agent 6 is selected depending on the desired color saturation.
[0024] The color filter 3 is applied to carrier film 4 in a printing process. The printer or developer can adapt the hue on site to the desires of the customer. As a result, it is possible to very quickly fulfill the desires of the customer with respect to the hue of the electrified electroluminescent film. During the printing process, it is possible to directly influence the hue. Since the printing process can be well controlled, the amount of scrap is very low in the production of this electroluminescent film: In the printing process, the color pigments can be optimally arranged. Thus, for example, a uniform coverage of the surface of carrier film 4 with fluorescing pigments 5 is possible. But color gradients can also be easily and reliably created in the printing process. Depending on the wishes of the customer, the color gradients can be extremely varied and/or have areas of translucence.
[0025] The color filter 3 can also be bonded to carrier film 4 through lamination. The carrier film 4 consists of a material that ensures an optimal bond with the fluorescing pigments 5 and/or the binding agent 6 . By way of example, the carrier film 4 may be fabricated from polyester. But, it can also consist of any other transparent material that ensures a bond of pigments 5 and binding agent 6 .
[0026] On the side facing the color filter 3 , the carrier film 4 is provided with a fluorescing layer 7 that is more or less highly pigmented. In the exemplary embodiment, this fluorescing layer 7 is configured white, i.e., achromatic so that the light escaping to the outside through the layer 7 is not changed in its hue. If no current is passing through the electroluminescent film, as a result of layer 7 it has a white hue on its outside. In this case, the so-called reflected light color of the of the electroluminescent film is white. The layer 7 advantageously is applied to the carrier film 4 in the screen printing process.
[0027] Depending on the type of application, the fluorescing layer 7 can of course have a hue. In this embodiment, the electroluminescent film in non-electrified state reflects a particular color. Examples of possible reflected colors include, but are not limited to, yellow, blue or orange hues. The electroluminescent film then of course will have a corresponding luminescent color. In the described exemplary embodiment, the achromatic, white fluorescent color of the layer 7 does not have any influence or has only a negligible influence on the hue of the electroluminescent film in electrified condition.
[0028] In order that the electroluminescent film be optimally protected and in particular that it also have a high degree of stability in the presence of moisture, it is coated with a moisture-impervious laminate (not shown) so that the electroluminescent film will have a long useful life even under harsh operating conditions.
[0029] The carrier film 4 with imprinted color filter 3 is fastened in known manner to the upper side 2 of base film 1 .
[0030] When electrified, the base film 1 emits light 8 corresponding to its hue ( FIG. 2 ), which light penetrates the color filter 3 . Corresponding to the fluorescing pigments 5 in the color filter 3 , the hue is changed after passing through the color filter 3 . Thus, the green hue of the light 8 originating from base film 1 can, by way of example, take on an orange hue after passing through the color filter 3 . Upon the light beams 9 passing through the carrier film 4 and layer 7 , the hue is not changed, so that the light in the hue determined by the color filter 3 emerges through the layer 7 .
[0031] In the color filter 3 , fluorescing particles of the most varied kinds can be provided such that all luminescent colors can be set. It is even possible to use fluorescing pigments of different colors within zones of color filter 3 so that light of different colors emerges through the layer 7 . By means of the printing process, the distribution of the variously colored fluorescing pigment 5 in the color filter 3 can be produced very precisely and in the most varied of forms. In addition, it is possible to provide a color filter 3 only in areas on carrier film 4 so that it does not cover the entire exterior side of the carrier film.
[0032] The color filter 3 absorbs a portion of the light 1 radiated by base film 1 and permits the remainder of the light to pass through as remainder light 9 .
[0033] All suitable pigments can be used as fluorescing pigments for the color filter 3 and the layer 7 . All suitable binding agents can be used to bind the pigments. However, they must not have any influence on the pigment quality.
[0034] Depending on the desired color density, the percentage of pigment and binding agent in the electroluminescent film is between around 10% and around 70%.
[0035] The invention has been described in an illustrative manner. It is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation.
[0036] Many modifications and variations of the invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the invention may be practiced other than as specifically described.
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An electroluminescent film includes a base film through which an electric current is selectively passed. The base film emits radiant energy in the visible spectrum when the electric current is passed therethrough. A filter layer is fixedly secured to the base film and filters a portion of the radiant energy wherein only a portion of the radiant energy emitted by the base film passes through the filter layer to be visible to an observer.
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PRIORITY
This application claims the benefit under 35 U.S.C. §119(a) of a Korean patent application filed in the Korean Intellectual Property Office on Mar. 8, 2011 and assigned Serial No. 10-2011-0020612, the entire disclosure of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a display device mounted on a portable terminal. More particularly, the present invention relates to a lighting device which facilitates reduction in the thickness of a backlighting device and a display device including the lighting device.
2. Description of the Related Art
Generally, the term “display device” refers to a device for presenting a screen with a provided image signal. The display device has been widely used in daily life for not only portable terminals, such as cellular phones, Portable Multimedia Players (PMPs), etc., but also electric appliances, such as navigation systems for vehicles, televisions (TVs), laundry machines, refrigerators, etc.
With the common use of a flat-panel display device such as a Liquid Crystal Display (LCD), the display device can now be mounted on a small-size device such as a portable terminal. Recently, a combination of a touch screen panel and a display device implements a virtual keypad on a screen in place of a physical keypad of the portable terminal.
Since the flat-panel display device cannot emit light itself, the display device visually presents a screen implemented through the display device with light provided from a separately installed light source. The flat-panel display device, at its early stages of development, displayed a simple character or symbol with combinations of black and white, such that lighting can be sufficiently provided by installing a point light source at a side of the display device.
Recently, however, as a television or a monitor for a computer, which uses a flat-panel display device, has been popularized and a multimedia service using a portable terminal is also rapidly increasing, there is a limitation in providing lighting for the flat-panel type display device with a point light source which has a large deviation in backlighting according to an installation position. As a result, effort has been exerted to provide lighting uniformly over the entire area of the display device by using a light guide plate or a sheet diffuser which converts a point light source into a surface light source. In addition, a reflection plate for efficient use of light generated from the light source is also mounted in the flat-panel type display device.
FIG. 1 is an exploded perspective view of a display device according to the related art. The display device 10 implements an image based on a provided image signal through a flat-panel display device 21 , and a backlighting device including a light source (not shown) provides lighting to allow a user to view the image implemented through the flat-panel display device 21 . The backlighting device includes a light guide plate 12 , a sheet diffuser 13 , and a prism sheet 14 which are disposed on a frame 11 , and the light source (not shown) is disposed on at least a side of the light guide plate 12 . A plurality of light sources may be installed in an actual product according to a size of the flat-panel display device 21 or the like.
The frame 11 may be provided to enclose a back surface and side surfaces of the flat-panel display device 21 while maintaining the shapes of the light guide plate 12 , the sheet diffuser 13 , and the prism sheet 14 .
The light guide plate 12 allows the light provided from the light source to be radiated over the entire area of the flat-panel display device 21 . In other words, a line light source radiated from the light source is converted into a surface light source through the light guide plate 12 .
The sheet diffuser 13 uniformly adjusts the light radiated from the light guide plate 12 toward the flat-panel display device 21 over the entire area of the flat-panel display device 21 . The light passing through the sheet diffuser 13 is refracted in various directions, thereby passing through the prism sheet 14 .
The prism sheet 14 converts side light, which passes through the sheet diffuser 13 and then goes in an inclined direction with respect to the flat-panel display device 21 , into front light. That is, the light passing through the prism sheet 14 enters the prism sheet 14 perpendicular to a surface of the flat-panel display device 21 .
The backlighting device described above is adhered to a back surface of the flat-panel display device 21 through a separate adhesive sheet (not shown).
The light radiated from the light guide plate 12 also goes to a back surface which does not face the flat-panel display device 21 , degrading lighting efficiency. Therefore, the backlighting device preferably includes a reflection plate 15 on the back surface of the light guide plate 12 .
The reflection plate 15 forms a reflection layer by depositing a metal component such as aluminum on a surface of a deposition film. In this case, since it is difficult to secure a sufficient refractive index only with a general metal component, deposition films on which reflection layers are formed are laminated and thermally compressed, after which thickness is reduced by a stretching process and a surface area is expanded, thus completing the reflection plate 15 . The completed reflection plate 15 is adhered to the back surface of the light guide plate 12 or the frame 11 through a separate adhesive tape 16 .
However, in the backlighting device of the related art, the reflection plate has disadvantages of a complex manufacturing process and a high possibility of a crack being generated in the reflection layer or the deposition film. Moreover, the reflection plate is manufactured by laminating the plurality of deposition films and then performing the stretching process, such that to dispose the reflection plate in an actual product, a separate cutting process and an adhering process using an adhesive tape are required. As a result, the assembly process of the reflection plate to the backlighting device as well as the manufacturing process of the reflection plate is cumbersome. Moreover, the thickness of the adhesive tape as well as the thickness of the reflection plate including the deposition films hinders reducing the thickness of the display device.
The above information is presented as background information only to assist with an understanding of the present disclosure. No determination has been made, and no assertion is made, as to whether any of the above might be applicable as Prior Art with regard to the present invention.
SUMMARY OF THE INVENTION
Aspects of the present invention are to address at least the above-mentioned problems and/or disadvantages and to provide at least the advantages described below. Accordingly, an aspect of the present invention is to provide a display device including a backlighting device, which contributes to simplifying a manufacturing process.
Another aspect of the present invention is to provide a display device including a backlighting device, which contributes to reducing the thickness of the display device, and thereby reducing the thickness of a portable terminal in which the display device is mounted.
According to an aspect of the present invention, a display device is provided. The device includes a display element for outputting an image according to a provided image signal, a frame disposed on a rear surface of the display element, and a reflection layer formed on the frame and positioned between the display device and the frame, the reflection layer being a coating layer formed using a paint including at least one of silver and aluminum.
The frame may be formed of a plate using a metal material or an injection-molded product.
The display device may further include a bottom primer layer interposed between the frame and the reflection layer, and in this case, the bottom primer layer may be formed using a paint including at least one of acryl, urethane, silicon, epoxy, styrene, polyester, and high polymer polyester.
The display device may further include an ultraviolet (UV)-curing layer interposed between the bottom primer layer and the reflection layer.
The display device may further include a top coating layer formed on the reflection layer and positioned between the display element and the reflection layer.
The display device may further include an anti-tarnish layer coated on a surface of the reflection layer.
The display device may further include a silicon particle layer formed on the reflection layer and positioned between the display element and the reflection layer.
The display device may further include a bottom primer layer interposed between the frame and the reflection layer, an ultraviolet (UV)-curing layer interposed between the bottom primer layer and the reflection layer, a top coating layer formed on the reflection layer and positioned between the display element and the reflection layer, and an anti-tarnish layer coated on a surface of the reflection layer, in which at least one of the bottom primer layer, the UV-curing layer, the top coating layer, and the anti-tarnish layer may be formed using a paint to which at least one of a pigment, a dye, and a quencher are added.
Meanwhile, it can be easily understood by those of ordinary skill in the art that the reflection layer may be applicable to not only the display device, but also a lighting device used in daily life, for example, indoor lighting, a street lamp, a vehicle's head lamp, etc.
When the backlighting device of the display device is configured, a conventional reflection plate where deposition films and a reflection layer made of a metal component are deposited is not required and a reflection layer may be formed on a frame by using a paint having at least one of silver and aluminum as its main components, thereby simplifying a manufacturing process. In other words, it is unnecessary to deposit the metal component onto the deposition films to form the reflection layer or to deposit and stretch the deposition films where the reflection layer is formed, thus simplifying the manufacturing process.
Furthermore, the reflection layer may be directly formed on the frame disposed on the rear surface of the display device, thereby removing a need for cutting or adhesion of the reflection plate and thus contributing to reduction of the thickness of the display device, and thereby contributing to reduction of the thickness of a device having the display device mounted thereon, such as a portable terminal, due to the deposition films or an adhesive tape.
In addition, the reflection layer whose manufacturing process is simplified and whose thickness is easy to reduce can be applied to indoor lighting, a street lamp, a vehicle's head lamp, and so forth, thereby reducing the manufacturing cost of a device or equipment for which lighting is used.
Other aspects, advantages, and salient features of the invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses exemplary embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features, and advantages of an exemplary embodiment of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is an exploded perspective view of a display device according to the related art; and
FIG. 2 is a cross-sectional view of a display device according to an exemplary embodiment of the present invention.
Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of exemplary embodiment of the invention as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope and spirit of the invention. In addition, descriptions of well-known functions and constructions will be omitted for clarity and conciseness.
The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention is provided for illustration purpose only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.
It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a component surface” includes reference to one or more of such surfaces.
FIG. 2 is a cross-sectional view of a display device according to an exemplary embodiment of the present invention. According to exemplary embodiments of the present invention, the display device shown in FIG. 1 may include additional and/or different components, or omit any number of the components shown in FIG. 1 . Similarly, the functionality of two or more components may be integrated into a single component.
Referring to FIG. 2 , a display device 100 according to an exemplary embodiment of the present invention includes a backlighting device in which a reflection layer 102 may be formed on a frame 101 disposed on a back surface of a display element 105 . The backlighting device may include a light guide plate, a sheet diffuser, a prism sheet, and so forth, but such a configuration can be easily understood by those of ordinary skill in the art and thus will not be described in detail herein.
The display element 105 , may be implemented with a flat-panel display element, and may be manufactured with various elements such as a Liquid Crystal Display (LCD) element, a Thin Film Transistor (TFT) LCD element, an Organic Light Emitting Diode (OLED) element, etc. Since the display element 105 generally cannot emit light by itself or cannot generate enough light to clearly implement a screen color, the display device 100 includes the separate backlighting device.
The backlighting device includes the frame 101 provided on the back surface of the display device 105 to enclose at least the back surface of the display device 105 , and the reflection layer 102 formed on a surface of the frame 101 .
The frame 101 provides a structure, although not shown, for installing a light source or a light guide plate of the backlighting device. The frame 101 may be coupled to the display element 105 to protect the display element 105 . The frame 101 may be manufactured by processing a plate using a metal material or manufactured with an injection-molded product. In other words, the frame 101 may be manufactured with a plate using a metal material such as iron, aluminum, magnesium, or the like, or with an injection-molded product using a synthetic resin material such as polycarbonate resin, ABS resin, natural rubber, or the like.
The reflection layer 102 includes a coating layer formed by coating a paint onto a surface of the frame 101 . The paint for the reflection layer 102 includes silver and aluminum as its main components, such that the surface of the frame 101 may be coated by spraying the paint onto the surface of the frame 101 , and the paint may be cured by thermal curing, thus completing the reflection layer 102 . The reflection layer 102 may be formed to have a thickness of at least 20 μm, thus securing a refractive index equal to or higher than that of a reflection plate of the related art. When the refection layer 102 is formed to have a thickness of 60-120 μm, its refractive index may be further improved and its durability may be improved.
Table 1 shows a comparison between a refractive index of a reflection plate of the related art having deposition films and a refractive index of a reflection layer according to an exemplary embodiment of the present invention. As can be seen in Table 1, the refractive index of the reflection layer according to the present exemplary embodiment of present invention may be equal to that of the reflection plate of the related art in a visible light spectrum.
TABLE 1
Visible Light Wavelength
400 mm
500 mm
600 mm
700 mm
Reflection Plate Having
89.4%
89.4%
96.6%
96.5%
Deposition Films
Reflection Layer
82.5%
96.0%
96.5%
97.4%
The frame 101 may be further formed with a bottom coating layer, a top coating layer 147 , an anti-tarnish layer 141 , a silicon particle layer 145 , and so forth to facilitate coating of the paint for the reflection layer 102 or to protect the reflection layer 102 .
The bottom coating layer may include a bottom primer layer 131 and an ultraviolet (UV)-curing layer 135 . The bottom primer layer 131 may be formed between the reflection layer 102 and the frame 101 , more specifically, on the surface of the frame 101 , and the UV-curing layer 135 may be formed on a surface of the bottom primer layer 131 to be positioned between the bottom primer layer 131 and the reflection layer 102 .
A surface treatment process for reinforcing affinity of the frame 101 with respect to the paint for the reflection layer 102 may be used to form the bottom primer layer 131 and the UV-curing layer 135 . The bottom primer layer 131 and the UV-curing layer 135 are formed by coating a paint including at least one of acryl, urethane, silicon, epoxy, styrene, polyester, and high polymer polyester at least once and are completed by thermally curing or UV-curing the coated paint.
The top coating layer 147 may be intended to protect the reflection layer 102 , and may be formed by coating a paint including at least one of acryl, urethane, silicon, epoxy, styrene, polyester, and high polymer polyester at least once and may be completed by thermally curing the coated paint. The top coating layer 147 may be formed on the reflection layer 102 , such that it may be positioned between the reflection layer 102 and the display element 105 .
The anti-tarnish layer 141 may prevent discoloration of the reflection layer 102 by preventing contamination or oxidation of silver (Ag) and aluminum (Al) which are the main components of the reflection layer 102 . To this end, the anti-tarnish layer 141 may be formed on the surface of the reflection layer 102 . The anti-tarnish layer 141 may be positioned between the reflection layer 102 and the top coating layer 147 .
The silicon particle layer 145 may be formed on the surface of the reflection layer 102 or the surface of the anti-tarnish layer 141 by applying or depositing a paint having silicon dioxide or silicon carbide as its main component. The silicon particle layer 145 suppresses damage of the reflection layer 102 such as a scratch on the surface of the reflection layer 102 and suppresses contamination of the surface of the reflection layer 102 due to a foreign substance or a worker's finger print. Moreover, the silicon particle layer 145 can be washed by water even when being contaminated by a foreign substance or a worker's finger print, such that the contamination substance can be easily removed therefrom. Although the silicon particle layer 145 may be formed on the surface of the reflection layer 102 or the surface of the anti-tarnish layer 141 in the present exemplary embodiment of the present invention, it may be formed on the surface of the top coating layer 147 .
When the bottom coating layer/the top coating layer 147 or the anti-tarnish layer 141 are formed, a pigment, a dye, a quencher, etc. may be added to the paint to minimize color distortion during reflection, refraction, and penetration of light emitted from a light source. Such addition may be intended to prevent a lighting color from distorting a color implemented by the display element 105 .
As mentioned previously, the backlighting device of the display device 100 may include a light guide plate and a sheet diffuser to convert a point light source into a surface light source and uniformly distribute light over the entire area of the display element 105 .
The thickness of the display device 100 structured as described above may be reduced by a minimum of 0.14 mm when compared to a display device including a reflection plate manufactured by depositing/stretching deposition films.
While the present invention has been shown and described with reference to certain 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 spirit and scope of the invention as defined by the appended claims and their equivalents.
For example, in a lighting device in which a reflector is installed behind a light source, such as indoor lighting using a fluorescent lamp or a Light Emitting Diode (LED), outdoor lighting such as a street lamp around a footpath or flood lighting around a road, or vehicle lighting such as a vehicle's headlamp, the reflection layer 102 may be formed. In this case, a frame positioned behind the light source may be manufactured with an injection-molded product or a metal material, and according to the manufacturing material, top/bottom coating layers, an anti-tarnish layer, a silicon particle layer, etc. may be formed to improve the durability of the reflection layer formed on the frame.
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A display device and a lighting device are provided. The display device includes a display element for outputting an image according to a provided image signal, a frame disposed on a rear surface of the display element, and a reflection layer formed on the frame and positioned between the display device and the frame, the reflection layer being a coating layer formed using a paint including at least one of silver and aluminum. When the backlighting device of the display device is configured, a reflection plate where deposition films and a reflection layer made of a metal component are deposited is not required and the reflection layer is formed on the frame by using a paint having at least one of silver and aluminum as its main components, thereby simplifying a manufacturing process, and contributing to reducing the thickness of the display device.
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CROSS-REFERENCE OF RELATED APPLICATIONS
Not Applicable
FEDERALLY SPONSORED RESEARCH
Not Applicable
SEQUENCE LISTING OR PROGRAM
Not Applicable
BACKGROUND OF INVENTION
1. Field
This invention relates to golf swing training, generally, a device used by a player to train for a game or sport using a tangible projectile, the invention specifically stretches the parts of the body used for the backswing and follow-thru, strengthens the muscles used for the downswing and is a teaching aid to correct many swing flaws.
2. Prior Art
Golf training through exercise is a comparatively new field for such an old game. Up until the last 20 years or so golfers generally avoided most physical training exercises for fear of losing their swing from physical body changes. As training techniques have progressed, golfers have worked more on physical fitness and golf specific muscles.
Although there have been some golf swing casualties in the professional ranks from body changes due to physical workouts, younger pros have achieved more promising results. Up until the present time, stretching and strengthening golf muscles has been achieved by improving overall physical fitness and using specific exercises for golf muscle groups.
Spending so much time exercising is a noble goal for those who have the time like the pros, but working amateurs with families cannot usually find the time. Many training aids have been developed that have not been widely accepted. Others, that have been widely sold, rarely fulfill their advertised claims. Some current exercise training products involve a belt around the torso with an elastic cord attached to the club handle. Although they claim to stretch and strengthen the golf swing, these products usually do the opposite. They provide resistance on the backswing and follow-thru where stretching is actually required and elastic pulling on the downswing where resistance is required.
Other golf training products that haven't made it to market include the use of pivotal resistance with the resistance mechanism in front of the golfer and some form of arm to rotate by the golfer for exercising the swing such as Lee and Leadbetter in U.S. Pat. No. 5,284,464 and Hundley in U.S. Pat. No. 5,242,344. These are very rigid devices for swing training and often resist backswing motion where pull is actually required. Also, a golfer's backswing and downswing is normally on different swing planes and swing circumferences have odd shapes that are not rigid. The prior devices do not accommodate such variations in golf swings and can create problems associated with undesirable swing alterations.
Other devices employ vertical resistance through pulleys, guides, weights and springs to offer resistance for a portion of the downswing such as Bickford in U.S. Pat. No. 3,966,203, Masters in U.S. Pat. No. 4,229,002 and Kim in U.S. Pat. No. 6,537,184. U.S. Pat. No. 6,537,184 offers some origin movement using a sliding pulley on a trolley connected to springs, but offers no real improvement over the other inventions, particularly since pulleys do not work on such angles, especially when resistance is decreased and increased. Also, the club never gets close to the top of the backswing and the club handle is pointed away from the golfer at the so-called top causing the wrists to start down without being cocked. Just like U.S. Pat. No. 3,955,203 and U.S. Pat. No. 4,229,002, U.S. Pat. No. 6,537,184 fails to solve the problem of providing resistance for the whole downswing or even accommodating the whole backswing and downswing. Of course stretching in these devices isn't even addressed.
Still other devices involve railed or guided golf swing planes, which force the golfer to swing on some predetermined swing path. Hurley in U.S. Pat. No. 5,072,942, Beckish in U.S. Pat. No. 4,071,251, and Higginson in U.S. Pat. No. 5,467,993 are examples of these types of devices. These path guides assume swings are or should be on one flat plane, which they normally are not, and there is no pull or resistance exercise provided.
The challenges of golf swing training equipment are many and result from real life factors such as that the golf swing is 3-dimensional; golfers' height, limb length, flexibility, swing type and other physical aspects make each swing different; a player's backswing is not on one plane and is rarely on the same plane as the downswing; and by exercising specific groups of muscles on different non-golf apparatus, the golf muscles do not always proportionately remain the same and coordination and feel can suffer.
OBJECTS OF THE INVENTION
Objects therefore of the present invention are:
(a) to provide adjustable pull or resistance to a golfer's swing to stretch both the entire backswing and follow-thru and to strengthen the muscles used for the downswing; (b) to provide a swing plane track with means for adjusting same to different swing diameters and heights; (c) to provide for an adjustable swing plane angle of said track accommodating very upright to very flat swing planes; (d) to provide a swing plane track that rotates so that the track follows the normal or natural swing path of the golfer and also to serve as a platform so that the golfer can work on changing his or her swing plane; (e) to provide for a lateral movement of said track for golfers who start their downswing with lateral movement; (f) to provide a training device that will teach golfers not to cast, release the club early, come over the top, swing from outside to in, or reverse weight shift; and (g) to provide a relatively compact golf swing training apparatus which can readily be used at home.
SUMMARY OF THE INVENTION
A golf swing training apparatus which stretches and strengthens the precise parts of the body used in the golf swing while providing a tool to make swing changes. The apparatus fully accommodates all variations of the entire backswing and downswing thru the hitting area and further provides pull during the backswing and follow-thru, and resistance during the downswing. These gainful aspects are attained thru the use of a swing guide track, provided with a swing pull-resistance mechanism, and which is mounted on a base in such a manner that the track follows the swing path of the golfer and is maneuverable by the golfer, consciously or unconsciously, to more precisely accord to special stylistic features of the golfers unique swing.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, it's objects and advantages will be understood further from the drawings herein and description of preferred embodiments, wherein:
FIG. 1 is a side perspective view of the present golf swing training apparatus.
FIG. 1A is a schematic of the overall curvature dimension of the swing guide track.
FIG. 2 is a perspective view of a portion of the swing track, drawn out of scale, with the wall sections broken away to show the pull-resistance connecting cords and the cord connecting cars.
FIG. 3 is a perspective view of a cord connecting car with connecting car eyelets.
FIG. 4 is a cross-section of a swing track with an end view of a cord connecting car mounted thereon as in FIG. 2 .
FIG. 5 shows a cross-section for the variation of the track's curved portions with a cord connecting car mounted thereon and with cord support rollers underneath the cord connecting car's wheels, and also connecting cord positions when the cars are not present.
FIG. 6 is a double swing bearing mount support structure connecting the swing track to an overhead beam of a base structure.
FIG. 7 is a rear perspective view of the invention showing the track plane adjustment mechanism with an attached weight support and also the track diameter adjustment mechanism connected to the lower portion of the swing guide track.
FIG. 7A shows the track diameter adjustment mechanism with cotter pin, cotter bolt and the diameter adjustment holes on the vertical member of the track plane adjustment mechanism.
FIG. 8 is a front view of the present apparatus shown in FIG. 1 .
FIG. 9 is a perspective view of duel pulleys mounted to the overhead beam of the base structure at the proximal end of the swing track and includes duel cords.
FIG. 10 shows the track roller sections and the placement of the roller sections on the swing track's curved portions over the track channel punch-outs.
FIG. 10A is a perspective view of a track roller section and the cord support rollers attached at the lower channel of the roller section.
FIG. 10B is a portion of a track roller section with the wall broken away to show the cord support rollers attached in the lower channel.
Drawings—Reference Numerals
12
Base Structure
14
Support Structure
16
Swing Guide Track
17
Curvature Dimension
18
Swing Plane
20
Track Follower (car)
22
Handle
24
Motion Resistance Structure
26
1 st Base Foot
28
2 nd Base Foot
30
Stanchion
32
Horizontal Beam
33
Stanchion Overlap
34
Upper Stanchion
36
Lower Stanchion
38
Stanchion Pin
40
Floor
43
Upper Bearing
44
Lower Bearing
46
Bearing Loop
48
Upper Bushing
50
Lower Bushing
52
1 st Track Channel Member
54
2 nd Track Channel Member
56
Track Cross Member
58
Lead Cord Connecting Car
60
2 nd Cord Connecting Car
61
Connecting Car Eyelet
62
Connecting Cords
64
Duel Cords
65
Car Stop Pin
66
Proximal Track End
68
1 st Track End Pulley
70
2 nd Track End Pulley
72
Duel Pulleys
74
Duel Weight Pulleys
76
Cord Fixture
78
Resistance Weights
79
Track Plane Adjustment Mechanism
80
Vertical Plane Adj. Member
82
Diagonal Plane Adj. Member
84
Horizontal Plane Adj. Member
86
Stabilizing Rod
87
Stabilizing arm
88
Weight Support
90
Diameter Adjustment Holes
91
Cotter Pin
92
Cotter Bolt
93
Track Diameter Adj. Mechanism
95
Track Roller Section
97
Cord Support Rollers
99
Channel Punch-outs
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings and with particular reference to the claims herein, a preferred embodiment of the present apparatus comprises a base structure generally designated 12 and a support structure 14 for attaching a generally upright swing guide track 16 to the base ( FIGS. 1 and 8 ). The track has an overall curvature of at least 90 degrees ( FIG. 1A ) within a swing plane 18 ( FIG. 8 ), wherein the base is stationary and wherein the support is flexible to allow the track limited freedom of motion relative to the base. The overall curvature dimension 17 ( FIG. 1A ) consists of three sides with preferred ranges of d 1 =60″ to 80″, d 2 =40″ to 60″, and d 3 =32″ to 42″.
A track follower 20 engages the track for movement there along throughout the curvature dimension 17 , and a handle 22 (most clearly in FIG. 2 and FIG. 3 ) is affixed to the follower for being gripped by a golfer for movement of the follower 20 by the golfer.
A motion resistance structure 24 ( FIG. 1 ) is connected to the base 12 and the follower 20 to provide a back force f 1 to forward motion M 1 of the handle 22 and the follower 20 through the curvature dimension 17 , whereby the golfer's swing muscles become strengthened against the back force, and said muscles become stretched with backward motion of the handle 22 by said back force, and whereby the swing thus becomes stronger and longer with regard to a desired trajectory.
Base 12 can of course be structurally varied widely depending on available space or the like and the base structure shown is well suited for a free standing compact training unit for home use. The base shown comprises of foot sections 26 and 28 ( FIGS. 1 and 8 ) rigidly affixed to a stanchion 30 which is affixed at the upper end to a generally horizontal beam 32 . Stanchion 30 preferably is formed in sections 34 and 36 wherein section 34 can slide upwardly at stanchion overlap 33 for adjusting the height of beam 32 above the floor 40 ( FIG. 1 ) and is affixed with the stanchion pin 38 . The stanchion 30 height adjustment of one section sliding and being affixed in place onto the other section can be provided in many ways.
Support 14 preferably comprises the dual bearing mount ( FIG. 6 ) wherein upper bearing 43 is attached to beam 32 and lower bearing 44 is attached to track 16 . Bearing loop 46 is pivotally mounted in upper bushing 48 and lower bushing 50 affixed to bearings 43 and 44 respectively. The bearing mount gives the desired universal type freedom of motion to the track whereby the golfer during the swing does not feel uncomfortably restrained.
The swing track structure can be widely varied but preferably comprises a pair of laterally spaced track channel members 52 and 54 attached to a track cross member 56 ( FIGS. 4 and 5 ).
The arrangement of the track follower 20 shown in FIG. 2 is a preferred one and comprises of dual cord connecting cars 58 and 60 connected together at connecting car eyelets 61 (also in FIG. 3 ) on the cord connecting cars by connector cords 62 , wherein the golf handle 22 is flexibly attached to the lead cord connecting car 58 ( FIG. 3 ). This arrangement gives a smooth ride of the cord connecting cars around the track 16 , however a single track follower 20 may alternatively be employed. Attachment of the golf handle 22 with a flexible tether line is preferred, allowing the golfer freedom to hold the handle in proximity to the track at address where the golfer feels most comfortable.
The motion resistance structure 24 comprises dual cords 64 slidably in channels 52 and 54 as shown in FIGS. 1 and 2 and mounted around duel track end pulleys 68 and 70 ( FIGS. 8 and 9 ) adjacent the proximal end 66 of the swing track 16 ( FIGS. 1 and 8 ). Duel pulleys 72 are similarly mounted at the other end of the beam 32 and cords 64 run the length thereof and also around hanging duel weight pulleys 74 and then are affixed at cord fixture 76 to the beam ( FIG. 1 ). Various sized resistance weights 78 can be hung from hanging duel weight pulleys 74 to vary the resistance or back force f 1 on the cords 64 leading back to the handle 22 .
The bottom of channels members 52 and 54 at both the top and lower curves of the swing track 16 are punched out at channel punch-outs 99 and covered with track roller sections 95 where the duel cords 64 would normally drag in the channels as shown in FIG. 10 . The top curve of said swing track is completely punched out up to 90 degrees and the lower curve is partially punched out as both curves are covered with track roller sections 95 ( FIG. 10 ). The cord support rollers 97 are affixed to the channel portion of the track roller sections 95 ( FIGS. 5 , 10 A and 10 B). The duel cords fall through the punched out portions of the track and onto the cord support rollers 97 (seen best in FIG. 5 ). The punched out portions of the swing track are narrower than the wheels on the cord connecting cars 58 and 60 shown in FIG. 5 .
A track plane adjustment mechanism, generally designated 79 ( FIGS. 1 , 7 and 8 ), comprises a generally triangular frame of members 80 , 82 , and 84 , affixed to the track 16 at the top half of d 2 ( FIG. 1A ) using vertical member 80 (seen best in FIG. 7 ) and having a weight support 88 on which weights can be placed to vary the angle of the track swing plane 18 ( FIG. 8 ) by pivoting the track on the support structure 14 .
At vertical segment d 2 of the overall swing track curvature dimension ( FIG. 1A ) the lower half of the track 16 is slidable into the top half of the track to adjust the swing track diameter. The lower track half is variously affixed at the track diameter adjustment mechanism 93 to the track plane adjustment mechanism 79 shown in FIG. 7 using the diameter adjustment holes 90 of vertical member 80 , a cotter bolt 92 and cotter pin 91 ( FIG. 7A ).
The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications will be effected with the spirit and scope of the invention.
Operation— FIGS. 1 , 1 A, 7 , 7 A, and 8
The settings that each golfer makes on the swing training apparatus are extremely important. No two people have the same swing so the settings will be only for that person. The settings would be duplicated each time the person uses the apparatus and would be easy to perform.
The height is set by adjusting the overlapping stanchion 30 sections 34 and 36 in FIG. 1 and affixing them with the stanchion pin 38 at stanchion overlap 33 so that the top of the swing track 16 is just higher than the golfer's hands at the top of the backswing. The diagonal 82 and horizontal 84 segments of the track plane adjustment mechanism 79 should be moved to the side of the swing track that the person intends to stand as shown in FIGS. 1 , 7 and 8 . Weights would be fastened on top of the weight support 88 until the swing track has achieved the desired swing plane angle 18 in FIG. 8 . The bearing unit support structure 14 in FIG. 1 allows the swing track to move to any swing plane 18 and to freely rotate to follow the golfer's swing and for a limited amount of lateral movement.
The desired swing diameter is set by adjusting the overlapping vertical portion of the swing track 16 in FIG. 7 (d 2 in FIG. 1A ), so that the golfer's hands are just above the lower horizontal swing track portion (d 3 in FIG. 1A ) at address. The golfer lines up the diameter adjustment holes 90 on the vertical plane adjustment segment 80 with the holes on the track diameter mechanism 93 and slides a cotter bolt 92 thru the holes. The bolt is secured by a cotter pin 91 as shown in FIGS. 7 and 7A . With resistance weights 78 shown in FIG. 1 in the down position, additional weight units can be added, with only 5 to 15 lbs. of weight being all that is usually needed.
An additional optional piece, a stabilizing rod 86 , may be wedged between the lower horizontal portion d 3 ( FIG. 1A ) of the swing track 16 and the horizontal plane adjustment segment 84 as shown in FIG. 7 . The stabilizing rod gives the swing-track a little more stability and more importantly puts the lower swing track d 3 in an inside-out position which may help golfer obtain a better swing path image even though the swing track will follow the golfer's swing path. When the stabilizing rod is utilized, a stabilizing arm 87 is attached to the top portion of diagonal member 82 and to the top of the swing track at d 1 to keep the track plane adjustment mechanism 79 perpendicular to the swing track 16 in FIG. 7 .
With resistance weights 78 in the down position, the golf handle 22 will be at the top horizontal swing track portion d 1 in FIG. 1A . The golfer now just pulls the golf handle down into the address position and the resistance weights are lifted up in the air. The golfer takes his/her normal stance so the golfer's hands on the backswing do not come in contact with the vertical portion d 2 in FIG. 1A of the swing track 16 . The golfer can now repeat the backswing, downswing and hitting area using his/her normal swing and working on parts of the swing that need stretching, strengthening or improved technique. The golf handle 22 can be pulled all the way past the end of the swing track 16 as the lead cord connecting car 58 will be halted by the car stop pin 65 in FIG. 2 . If the golfer starts the downswing with lateral movement, the swing track 16 will move laterally automatically, using the support structure 14 . The swing track will freely rotate during training to match the path of the golfer's swing.
If the golfer chooses to work on stretching the follow-thru of the swing, the horizontal 84 and diagonal 82 segments of the track plane adjustment mechanism 79 in FIGS. 1 , 7 and 8 , would be moved to the opposite side of the swing track 16 . The golfer would then switch sides and reverse address direction in order to let the weights pull or stretch the parts of the body used in the follow-thru.
CONCLUSION, RAMIFICATIONS AND SCOPE
The reader will see that the golf swing training apparatus solves the problem of how to accommodate the entire backswing, downswing and hitting area, providing consistent pull or resistance throughout a movable swing plane while the swing plane is in motion. Furthermore, the present invention has additional advantages in that it allows golfers to just perform their normal swing to stretch and strengthen the golf muscles;
it provides training in the minimum amount of time for maximum results; it allows older golfers to maintain, recapture or generally expand and strengthen their golf swings; it provides instant feedback for stretching, strengthening and making swing changes; it allows golfers to stretch and strengthen golf muscles in a proportionate manner so that coordination remains the same.
Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but rather as an illustration of the preferred embodiment of the invention. For example, the base structure could have 2 or 3 legs or even 4 legs such as most swing sets. The base could also be ceiling studs from which the swing track is hung. The track could be low friction tubing or have an I-beam cross-section shape or the channels could be affixed back-to-back with the connecting cars underneath. Variable motion resistance could be supplied by springs, bowed flexible material or a wound spring mechanism. Support structures allowing swing track motion might include universal joints, an axle and bearing, chain links or some other flexible material. The track plane adjustment mechanism could comprise of adjustable springs or counter weights hung by pulley attached to the base and track. The swing track could of course be shortened by excluding the lower horizontal portion—d 3 . To adjust the diameter of the swing track, telescopic elements could be employed or just a thumb screw to affix the slidable track sections. The base structure height adjustment could be performed with a side crank, jack, telescopic elements or inner strut and lock screw. Depending on such factors as the weight of the swing track or the size of the support structure, a bumper cushion may be affixed at the proximal end of the swing track to keep the track from moving too far upward during lateral movement, causing the track to hit the beam or the cords above the track.
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A golf swing training apparatus that stretches and strengthens the precise parts of the body used in the golf swing while providing a tool to make swing changes. The apparatus employs a swing guide track, which is mounted on a base in such a manner that the track follows the golfer's normal golf swing, accommodating any type of swing. The swing track is maneuverable by the golfer, consciously or unconsciously, to more precisely accord to the special stylistic features of the golfer's unique swing, and wherein a consistent pull or resistance is provided and is attached to a golf handle, which the golfer swings on a movable swing plane while the plane is in motion.
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This application is a continuation of application Ser. No. 08/073,071 filed Jun. 8, 1993 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a camera having a mid roll interrupt (MRI) function (function to rewind a film midway in use and reload it for further use).
2. Related Background Art
There is such a camera recently proposed for example in U.S. Pat. No. 4,864,332 that, in use of a film having a magnetic record portion, information, for example a date of year, month, and day, a shutter speed, an aperture value, etc., is written by a magnetic head in the magnetic record portion, and that the written information can be read with necessity or that the information such as ISO and the number of frames in film, which was originally written, can be read out. Regarding the details of recording method of magnetic information, WO 90-04204 discloses that ID's (identifications) different from each other are provided for respective information pieces in magnetic information, and WO 90-04225 does an example to put an end mark after data.
Also, U.S. Pat. No. 4,878,075 disclosed a camera using a film cartridge enclosing even the tip end of film, which permits mid-roll rewinding (midway unloading) of film and reloading of film cartridge for further use.
In the proposal in the patent, the film is provided with a magnetic record portion of a transparent magnetic layer. The camera has a magnetic head for writing information into the magnetic record portion or for reading information preliminarily recorded in the magnetic record portion. When a film cartridge which was rewound midway is reloaded, it is judged by either of the following methods whether each frame is exposed or unexposed.
(i) Specific information is recorded for a photographed (or exposed) frame. The specific information is used to as an exposed flag, which will be referred to as a DEP flag (Double Exposure Prevention encodement). The magnetic head reads presence or absence of DEP flag upon reloading of the cartridge. A frame with DEP flag is judged as an "exposed" frame.
(ii) Film information is preliminarily recorded on film. The camera produces a DEP flag by overwriting specific information on the initial information for each photographed frame or by simply erasing the initial film information. The magnetic head reads presence or absence of DEP flag upon reloading of the cartridge. A frame with DEP flag is judged as an "exposed" frame.
The above techniques are disclosed in the U.S. Patent.
The above U.S. Patent further discloses a sequence of from the film winding through the exposed frame detection to the unexposed frame positioning, executed upon reloading the cartridge.
Assignee of the present invention filed Japanese Patent Application No. 2-297828, which discloses an improvement of judging method of whether each frame is exposed or unexposed with the following technology. Information, e.g. ISO, the number of photographic frames, etc., is preliminarily recorded in a magnetic track on a film, and the camera is arranged to overwrite camera information on the original information after exposure of each frame. Further, the film has a set of film information pieces preliminarily written in a magnetic record portion of each frame. The camera is provided in its exposure state judging means with comparing means for comparing a predetermined number with the set number of film information pieces left as written in the magnetic record portion of a frame positioned by frame positioning means when the film cartridge storing a film midway used is reloaded, and with judging means for judging the frame to be an exposed frame when the comparing means presents a comparison result that the number of film information pieces is not more than the predetermined number, whereby a frame is judged to be exposed when the set number of film information pieces is not more than the predetermined number. (In such an arrangement, there is no possibility to judge an exposed frame as unexposed, though there is a possibility to judge an unexposed frame as exposed.)
The cameras enabling the midway unloading and reloading of film as described in the above conventional examples, however, had the following disadvantages: in case that a film was set and exposed in two cameras having different film winding methods (e.g., normal wind and prewind) and that the film is reloaded, unexposed frames cannot be in position or a correspondence would be lost between the taking order and the frame number on film, thereby making it difficult for a user to know the photographed order (exposure sequence) on the developed negative.
Further, it is not assumed in the above conventional examples that an error is caused in production of DEP flag for exposed frame or in writing the camera information. Since only a border is detected between an exposed frame and an unexposed frame, double exposure may occur not only in the frame but also in following frames starting from the error frame. Such double exposure cannot be prevented in the conventional examples, which was another disadvantage.
In addition, the conventional examples disclose no technique about display of information on how much a film loaded in the camera is exposed or unexposed, nor other information about film.
SUMMARY OF THE INVENTION
The present invention has been accomplished taking the above circumstances into account, and an object thereof is to provide a camera which can perform positioning of unexposed frame even when a film exposed midway in cameras different in film feed method is reloaded.
In one aspect of the invention, achieving the above object, control means is provided for such a control that when a film is loaded in a camera the film is successively fed out of a film cartridge; information recorded in a magnetic record portion of each frame is read out to judge whether the each frame is exposed or unexposed; a first unexposed frame on the leader end or side of film and a first exposed frame on the trailer side are searched; and in photography, exposure is started from the first unexposed frame on the leader side of film or from a frame next on the leader side to the first exposed frame on the trailer end or side.
In one aspect of the invention, achieving the above object, a calculation circuit is provided for calculating an exposure sequence for each of unexposed frames being to be successively exposed, based on the information of the first unexposed frame on the leader side and the information of the first exposed frame on the trailer side, which calculates the exposure sequence and an exposed frame number of each unexposed frame to record them in each frame upon photography, whereby a correspondence is set between the exposure sequence and the frame number.
In one aspect of the invention, achieving the above object, a camera is provided with a display of a total number of unexposed frames or numbers of unexposed frames, based on the information of the first unexposed frame on the leader side and the information of the first exposed frame on the trailer side.
In one aspect of the invention, achieving the above object, a camera is provided, which can judge whether erroneous writing is present in information for exposed frames, based on the judgement result of the judging circuit about whether each frame is unexposed or exposed.
The object of the present invention will be more apparent from the embodiments which will be described referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view to show the mechanical structure of a camera in the first embodiment of the present invention;
FIG. 2 is a circuit block diagram of the camera of the present invention;
FIG. 3, consisted of FIGS. 3A to 3D, is a flowchart to show an operation of a control circuit as shown in FIG. 2;
FIGS. 4A to 4E are drawings to show a display state in the present invention;
FIG. 5 is a perspective view to show the mechanical structure of a camera in the second embodiment of the present invention;
FIG. 6, consisted of FIGS. 6A to 6D, is a flowchart to show an operation of a control circuit in the second embodiment of the present invention;
FIG. 7, consisted of FIGS. 7A to 7C, is a flowchart to show an operation of a control circuit in the third embodiment of the present invention;
FIG. 8, consisted of FIGS. 8A to 8C, is a flowchart to show an operation of a control circuit in the fourth embodiment of the present invention;
FIG. 9, consisted of FIGS. 9A to 9D, is a flowchart to show an operation of a control circuit in the fifth embodiment of the present invention;
FIG. 10, consisted of FIGS. 10A to 10D, is a flowchart to show an operation of a control circuit in the sixth embodiment of the present invention;
FIG. 11, consisted of FIGS. 11A to 11D, is a flowchart to show an operation of a control circuit in the seventh embodiment of the present invention;
FIG. 12, consisted of FIGS. 12A to 12D, is a flowchart to show an operation of a control circuit in the eighth embodiment of the present invention;
FIG. 13, consisted of FIGS. 13A to 13D, is a flowchart to show an operation of a control circuit in the ninth embodiment of the present invention;
FIGS. 14A to 14D are drawings to illustrate a state of display in the embodiment of FIG. 13; and
FIG. 15, consisted of FIGS. 15A to 15D, is a flowchart to show an operation of a control circuit in the tenth embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 to FIG. 4E show the first embodiment according to the present invention.
FIG. 1 is a perspective view to show the main structure of the camera. In FIG. 1, reference numeral 1 designates a photographic lens, 2 a lens actuator for driving the photographic lens 1 and a lens encoder for generating a lens position signal, 3 a lens shutter, 4 a photometric sensor for automatic exposure (AE), 5 a lens for determining a sensitive angle of the photometric sensor 4, 6 a block containing a distance measuring sensor and a finder, 7 a photoreflector for detecting perforations P 1 , P 2 of a film F to generate a signal for setting a frame in film F in position, 8 a film feed motor located in a spool, 9 a gear train for speed reduction and for switch between winding and rewinding, and 10 a rewinding fork.
Capital letter C denotes a film cartridge storing the film, F the film provided with a magnetic record portion (magnetic track TR) on the base side, P 1 and P 2 the perforations corresponding to a photographic frame A, and H a magnetic head for writing information in the magnetic record portion TR on the film F or for reading the information out of the magnetic record portion. Numeral 11 represents a pad for pressing the film F against the magnetic head H, which has a recess for enhancing adherence between the film F and a head gap in the central portion. Numeral 12 denotes a pad position control mechanism for urging the pad 11 against the magnetic head under a certain pressure with the film F in between only during film feed. Numeral 16 designates a release button, 17 a switch (SW 1) for starting photometry and distance measurement, 18 a switch (SW 2) for starting a sequence of shutter opening and film feed, and 20 a rewind switch for midroll rewinding.
FIG. 2 is a circuit block diagram of the camera to show portions related to the present invention, and the same portions are denoted by the same numerals as in FIG. 1.
In FIG. 2, numeral 19 designates a back lid switch for detecting closure of a back lid, 21 an ID detection circuit for detecting ID sentinels in film information, 22 a head amp for the magnetic head H, 23 a buffer, 24 a decoder, 25 an encoder, 26 a buffer, 27 a control circuit composed mainly of a microcomputer for executing the sequence control of circuits, 28 a motor driver for driving the film feed motor 8, and 29 a display composed of a display circuit and a display device.
An operation of the control circuit 27 is now described with the flowcharts of FIGS. 3A to 3D. It is assumed that the camera in the present embodiment is of a so-called prewind type in which the film F is entirely wound once and then rewound one by one after each exposure. It is also assumed that the frame number on the film F is counted from the film cartridge side to increase in order, for example 1, 2, 3 . . . , and the frame number at the film leader end coincides with the maximum, which is opposite to the ordinary counting order. This order of frame number will be commonly employed in all the following embodiments.
When a film cartridge C is loaded in the camera and when the back lid is closed to turn on the back lid switch 19, the flow proceeds from Step 101 (abbreviated as S101 in FIG. 3A) to Step 102, where the film feed motor 8 is driven through the motor driver 28 to start winding the entire film F. Then at Step 103, on the way of film winding, the magnetic head H reads out the film information such as the film speed, the number of frames, and the type of film, which is recorded as a line of data characters starting with ID sentinels (information start signal) on the magnetic track TR of film F.
The thus read-out film information is amplified and converted from analog to digital by the head amp 22, the amplified signal is transferred to the buffer 23, and thereafter the signal is decoded by the decoder 24 to be transferred to the control circuit 27.
Also at this Step 103, the ID detection circuit 21 continues detecting ID sentinels of N bits (for example "10000000") in film information, and the control circuit 27 receives this detection output while counting.
At Step 104 the film information read at Step 103 is indicated on the display 29 (see FIG. 4A). In FIG. 4A reference numeral 30 represents a display device such as a liquid crystal display plate, 31 an indication of film speed, 32 an indication of number of frames in film, and 33 an indication of type of film. At Step 105 the control circuit 27 puts values of L=EXP+1, T=0, and N=EXP in internal registers. L represents the frame number of leader portion, EXP the number in film read at Step 103, T the frame number of trailer portion, and N a frame number of a frame located at camera aperture. Then the control circuit 27 detects a perforation detection signal from the photoreflector 7 (Step 106). Further, the indication of film information presently displayed is flashed to indicate that the film F is under feed (Step 107). A user of camera may identify by this change of indication that the film F is exposable for example on the 36th frame.
The number of ID sentinels of film information as described above is then compared with a predetermined number, for example 8, which is a threshold value to determine whether a frame is "exposed" or not. If a frame is judged as "exposed" (if ID sentinel number≦predetermined number), the flow goes to Step 109. Unless a frame is "exposed" (if ID sentinel number>predetermined number) the flow goes to Step 115 (Step 108). A plurality of ID sentinels each of N bits of film information are recorded for each frame, and a predetermined number out of the plurality of ID sentinels preliminarily recorded are erased upon exposure, whereby it may be judged in the above judgment step whether a frame is exposed or not. At Step 109 it is judged whether N=1. If N=1, all the frames are exposed and then the flow goes to Step 139. Unless N=1, an unexposed frame possibly exists in the film, and then the flow goes to Step 110.
Suppose frames on the leader end or side on film F were already exposed from the last frame on the leader side (for example the 36th frame) up to the N-th frame (for example the 21st frame). Then Steps 108-114 are carried out before N becomes 20. The respective steps are as follows. The value of N is put into L (Step 110). The feed of film F is continued in the direction to pull out the film F from the cartridge C (Step 111). The perforations of film F are next detected in the same manner as at Step 106 (Step 112). After that, the indication of film information presently displayed is flashed to indicate that the film is under feed, in the same manner as at Step 107 (Step 113). Since it is detected at Step 112 that the film F is fed by a frame in the pull out direction from the cartridge C, N is decreased by one (Step 114).
In contrast, if it is judged at Step 108 that the frame is not "exposed" (if ID sentinel number>predetermined number), the number of exposed frames on the leader side on film F is indicated (Step 115). In the above example the 36th frame to the 21st frame are exposed, and then L=21 and EXP=36. Thus, the exposed frames are between L and EXP, so that the indication is as shown in FIG. 4C as L=21 and EXP=36. In FIG. 4C numeral 34 represents an indication of shutter speed of camera, 35 an indication of aperture value of camera, and 37 an indication of exposed frames to show that the 21st-36th frames are exposed. Then, the feed of film F is continued in the direction to pull out the film F from the cartridge C in the same manner as at Step 111 (Step 116), and the perforations of film F are detected in the same manner at Step 106 or 112 (Step 117). The indication of exposed frames presently displayed is flashed to indicate that the film F is under feed (Step 118). The user of camera may identify by this change of indication that the camera is in feeding the film F. Then, since the film F is fed by a frame at Step 117, N is decreased by one in the same manner as at Step 114 (Step 119). After that, it is detected in the same manner as at Step 108 whether the frame with frame number N is exposed (Step 120). If it is unexposed, the flow returns through Step 124 to Step 116 to detect whether a next frame is exposed or unexposed. If the frame with frame number N is exposed, the flow goes to Step 121 to substitute N into the number T of exposed frames on the trailer end or side on film F (Step 121).
Supposing frames of from the frame number 9 to 1 on the film are exposed, Steps 116-120 are repeated before N becomes 9. When N=9, the frame is exposed and the flow goes to Step 121 to set T=9.
Since the above procedure determined the leader side exposed frame number L and the trailer side exposed frame number T, unexposed frames on film F are indicated (Step 122). Frames of from the (T+1)-th to the (L-1)-th are unexposed. In case that T=9 and L=21, the indication is as shown in FIG. 4D. In FIG. 4D reference numeral 38 represents an indication of unexposed frames to show that the 10th-20th frames are unexposed. After the unexposed frame indication, the film F is reversely fed in the direction to rewind it into the cartridge C (Step 123). Steps 124 and 125 are carried out if there is no exposed frame on the trailer side of film F. If N=1 at Step 124 after an exposed frame is not detected at Step 120, there is no exposed frame on the trailer side. Unless N=1, there is a possibility that an exposed frame exists on the trailer side. Then the flow returns to Step 116 (Step 124). At Step 125 unexposed frames are indicated in the same manner as at Step 122. Since T=0, unexposed frames are from 1 to L-1 (Step 125). When the film F is fed in the rewind direction into the cartridge C, it is detected in the same manner as at Step 106, 112, or 117 that the film F is fed by one frame (Step 126). Then the indication of unexposed frames presently displayed is flashed to indicate that the film F is under feed (Step 127). Since it is detected at Step 126 that the film F is fed by one frame; N is increased by one (Step 128), and then the flow goes to Step 144. An exposure sequence is then calculated for a frame currently located at the exposure position (Step 144). Since the first exposable frame on the cartridge side is N at present, the order of the frame to be exposed this time may be calculated with the numbers of exposed frames on the leader side and the trailer side as EXP+N-L+1=26. This value is put into K, the information of K is encoded, the encoded data is transferred to the buffer 26, and then the flow goes to Step 129. Calculating N-T and L-T-1, the number of usable frames on film F is indicated. N-T represents the number of frames exposed after the film is loaded this time (Step 129).
L-T-1 represents the number of unexposed frames at the time of the present loading of film F. For example, if N=10, T=9, and L=21, the indication is as shown in FIG. 4E. In FIG. 4B numeral 39 denotes usable frames. This indicates "MRI" which is an abbreviation of Mid Roll Interrupt and "1 of 11" which is the number of usable frames. After that, the feed motor 8 is stopped through the motor driver 28 to stop the feed of film F (Step 130). It is then detected whether the rewind switch 20 for mid-roll rewind is on (Step 131). If it is on, the flow goes to Step 140 to rewind the film F into the cartridge. If it is off, the flow goes to Step 132.
At Step 132 it is judged whether the switch SW 1 is on. If it is on, the operations of photometry and distance measurement are carried out. The data such as the shutter speed and the aperture value obtained in the photometric operation and the distance measurement operation is then converted into camera information, and the converted data is transferred to the encoder 25. The encoder 25 encodes the camera information transferred thereto, and the buffer 26 stores the camera information. Further, it is judged whether the switch SW 2 is on. If it is on, the conventional exposure operation is carried out. In detail, the control circuit 27 receives a lens position signal from the lens encoder 2b through the lens actuator 2a, and when the photographic lens 1 reaches a position corresponding to the distance information the control circuit 27 supplies a stop command to the lens actuator 2a to stop the drive of photographic lens 1, or the focus operation. Almost at the same time, the open and close operation of shutter 3 is carried out with an output of the photometric sensor 4 for a certain time (Step 132).
After the open and close operation of shutter 3, the film feed motor 8 feeds the film F into the cartridge C (Step 133).
The magnetic head H is driven to write on the magnetic track TR of film F the camera information stored in the buffer 26 through the head amp 22 during the film feed in the form of a series of data characters starting with ID sentinels of N bits (for example "00000000") different from the ID sentinels preliminarily recorded as film information (Step 134). The data stored in the buffer contains the exposure sequence information K, which is thus recorded for each frame. Upon detection of next perforations the writing of data at Step 134 is stopped (Step 135).
Then the usable frame indication is flashed to inform the user of camera that the next perforations are detected at Step 135 (Step 136). Since the perforations are detected at Step 135, the film F is fed by one frame and N is thus increased by one (Step 137). It is then detected whether N becomes equal to L, which represents the leader side exposed frame (Step 138). If N=L, all frames are exposed, and then the flow goes to Step 139. Unless N=L, there remains an unexposed frame, and the flow returns to Step 144 to carry out the exposure operation.
Since all frames are exposed at Step 139, an all-frames-exposed indication is given as shown in FIG. 4B. In FIG. 4B numeral 36 represents an indication of "ALL EXPOSED," that is, the all-frames-exposed indication.
After that, the motor 8 feeds the film F into the cartridge C (Step 140). The perforation detecting photoreflector 7 detects the state immediately before the film F is fully rewound into the cartridge C (Step 141), and after a certain time elapsed it is judged that the film F is stored in the cartridge C. The film feed motor 8 is stopped (Step 142). Then the indication on the indication plate 30 of display 29 is turned off (Step 143).
It should be noted, though not described above, that not only in the present embodiment but also in the following embodiments the pad 11 is urged against the magnetic head H by the pad position control mechanism 12 only during movement of film F to make the reading and writing of magnetic information certain.
FIGS. 5 to 6D are drawings to show the second embodiment of the present invention. The above embodiment showed the prewind camera, whereas the second embodiment shows a normal wind camera which starts the exposure of film F from the leader side of film F.
FIG. 5 corresponds to FIG. 1 and shows the normal wind camera different from the prewind camera in that the magnetic head H, the pad 11, and the pad position control mechanism 12 are disposed on the opposite side to the side in the prewind camera with respect to the camera aperture, because the film F is fed out of the cartridge C after exposure.
FIGS. 6A to 6D are flowcharts corresponding to those of FIGS. 3A to 3D, in which different steps from those in FIGS. 3A to 3D are marked with star ahead and in which the same steps as those in FIGS. 3A to 3D are denoted by the same step numbers but different steps by numerals of 200's.
The different steps from those in FIGS. 3A to 3D are now described.
The control circuit 27 puts L=EXP+1, T=0, and N=EXP-1 in the internal registers (Step 205).
They are different from the embodiment of FIGS. 1 to 3D due to the difference of position of magnetic head H. At Step 206 the perforations are detected twice. This is also because the position of magnetic head H is different from that in the prewind camera. Further, at Step 210 N+1 is substituted into L. This is again because of the difference of position of magnetic head H. Then at Step 221 N+1 is substituted into T. This is because of the difference of position of magnetic head H too. At Step 224 it is detected whether N=0. This is because it cannot be detected whether all frames on the trailer side of film F are exposed, before N is reduced down to 0 due to the position of magnetic head H. Further at Step 225 the film F is rewound until N becomes L-1, because the film F must be returned to the leader side in case of the normal wind camera after detection of exposed frames on the leader side and on the trailer side. Unless N=L-1 the flow returns to Step 126. If N=L-1 the flow goes to Step 244.
At Step 233 the film F is fed out of the cartridge C after exposure in case of the normal wind camera. Also at Step 237, since the perforations are detected at Step 135 and the film F is fed by one frame, N is decreased by one. At Step 238 it is detected whether N=T. If N=T all frames are exposed, and then the flow goes to Step 139. Unless N=T there remains an unexposed frame, and the flow returns to Step 129.
At Step 244 the exposure sequence K is calculated. Since the presently set frame is an unexposed frame closest to the leader portion, K=EXP+T+1-N. K is encoded and transferred to the buffer 26, and then the flow goes to Step 129.
FIGS. 7A to 7C are flowcharts to show the third embodiment of the present invention. In the present embodiment, the structure of camera is the same as that in FIGS. 1 and 2 except that the display 29 is omitted. An operation will be described with the flowcharts of FIGS. 7A to 7C, based on the operation of control circuit 27 as shown in FIG. 2. It is assumed in the present embodiment that the camera is of the so-called prewind type in which after the film F is entirely wound once up to the end the film is rewound one by one after exposure of each frame. It is also assumed that the frame number on film F sequentially increases from the film cartridge side as 1, 2, 3 . . . , and the end frame on the film leader side coincides with the maximum number, which is opposite to the ordinary order.
When the film cartridge C is loaded in the camera and the back lid is closed to turn on the back lid switch 19, the flow proceeds from Step 201 to Step 202, where the film feed motor 8 is driven through the motor driver 28 to start winding all the film F. At Step 203, during the winding of film, the magnetic head H reads the film information such as the film speed, the number of frames, and the type of film recorded in the magnetic track T of film F as a line of data characters starting with ID sentinels (information start signal).
This read film information is amplified and converted from analog to digital by the head amp 22, then transferred to the buffer 23, decoded by the decoder 24, and transferred to the control circuit 27.
At Step 203 the ID detection circuit 21 continues detecting ID sentinels of N bits (for example "10000000") of film information, and the control circuit 27 receives the detection output thereof while counting.
Then the control circuit 27 detects a perforation detection signal from the photoreflector 7 (Step 205).
Further, the number of ID sentinels of film information is compared with a predetermined number, for example 8, which is a threshold value to determine whether a frame is "exposed" or not. If it is judged that a frame is "exposed" (if ID sentinel number≦predetermined number), the flow goes to Step 207. If the frame is not "exposed" (if ID sentinel number>predetermined number), the flow goes to Step 212 (Step 206).
At Step 207 it is judged whether N=1. If N=1, all the frames are exposed and then the flow goes to Step 231. Unless N=1, there is a possibility that an unexposed frame exists, and then the flow goes to Step 208.
Since frames up to the N-th frame are exposed on the leader side on film F, the value of N is substituted into L (Step 208). Namely, a frame with frame number under execution of Step 208 is "exposed," so that the value of L becomes the frame number of the exposed frame. Thus, frames of from L to EXP are exposed.
Further, the feed of film F is continued in the direction to pull out the film F from the cartridge C (Step 209). At Step 210 the perforations of film F are detected in the same manner as at Step 205. When the perforations are detected at Step 210 to confirm that the film F is fed by one frame out of the cartridge C, N is reduced by one (Step 211). By the above procedure, all exposed frames on the leader side of film are fed, so that the smallest number N out of the frame numbers of exposed frames is input into L.
On the other hand, if an unexposed frame is detected at Step 206, the feed of film F is continued at Step 212 in the direction to pull the film F out of the cartridge C in the same manner as at Step 209. Then at Step 213 the perforations of film F are detected in the same manner as at Step 205 or 210.
After the film F is fed by one frame at Step 217 in the same manner as at Step 211, N is decreased by one (Step 214).
It is next detected in the same manner as at Step 206 whether the frame with frame number N is exposed. If it is unexposed then the flow returns through Step 220 to Step 212 to detect whether a next frame is exposed or unexposed. If the frame with frame number N is exposed then the flow goes to Step 216 (Step 215).
The frame number N of current exposed frame is subtracted from the leader side final exposed frame L to obtain the number of successive unexposed frames between them, and the number is compared with a predetermined number M. If the number is less than M, it is supposed that there is an accidental error in writing between L and N, and the flow goes to Step 217 for abnormal process. If the number is not less than M, it is supposed that the unexposed frames are correctly detected, and the flow goes to Step 218 for normal process (Step 216).
If an abnormal state is detected at Step 216, the frames detected as unexposed between L and N are ignored, and N is put into L (Step 217). After that, the flow returns through Step 220 to Step 212.
At Step 218 N is substituted into the frame number T of exposed frame on the trailer side on film F. T is the first frame number of exposed frame on the cartridge side, so that unexposed frames are (T+1) to (L-1).
The film is then rewound into the cartridge C (Step 219).
At above Step 220, if N=1, there is no exposed frame on the trailer side, and then the flow goes to Step 223.
At Step 221 it is detected in the same manner as at Step 105, 110, or 113 that the film F is rewound by one frame. Consequently, since the one frame feed of film F is detected, N is increased by one (Step 222).
After that, the feed motor 8 is stopped through the motor driver 28 to stop the feed of film F (Step 223). It is then detected whether the rewind switch 20 for mid-roll rewind is on (Step 224). If it is on, the flow goes to Step 231 to rewind the film F into the cartridge. If it is off then the flow goes to Step 225. At Step 225, similarly as in the operation of FIGS. 3A to 3D in the first embodiment, the film feed motor 8 feeds the film F into the cartridge C after the open and close operation of shutter 3 (Step 226).
Then, during the film feed, the magnetic head H is driven to write on the magnetic track T of film F the camera information stored in the buffer 26 through the head amp 22 in the form of a line of data characters starting with ID sentinels of N bits (for example "00000000") different from the ID sentinels of film information.
Then, the writing of data at Step 227 is stopped by detecting perforations (Step 228).
The perforations are detected at Step 228, which means that the film F is fed by one frame, and N is increased by one (Step 229). Further, it is detected whether N becomes equal to L, which is the exposed frame on the leader side (Step 230). If N=L, all frames are exposed and then the flow goes to Step 231. Unless N=L, there remains an unexposed frame and the flow returns to Step 223 to carry out the exposure operation.
If N=L the motor 8 feeds the film F into the cartridge C (Step 231). Then, the perforation detecting photoreflector 7 detects the state immediately before the film F is entirely rewound into the cartridge C; after a certain time elapsed it is determined that the film F is stored in the cartridge C (Step 232); and thereafter the film feed motor 8 is stopped (Step 233).
FIGS. 8A to 8C are flowcharts to show an operation of the fourth embodiment of the present invention. The third embodiment of FIGS. 7A to 7C showed the example of prewind camera, whereas the fourth embodiment of FIGS. 8A to 8C shows an example of normal wind camera in which the exposure of film F is started from the leader portion of film F. Accordingly, the present embodiment illustrates the operation of the camera of FIG. 5, which is different from the prewind camera of FIG. 1 in that the magnetic head H, the pad 11, and the pad position control mechanism 12 are disposed on the opposite side to the set positions thereof in the prewind camera, because the film F is fed out of the cartridge C after exposure in the normal wind camera. FIGS. 8A to 8C correspond to the flowcharts of FIGS. 7A to 7C, in which different steps from those in FIGS. 7A to 7C are marked with star ahead and in which the same steps are denoted by the same numerals as those in FIGS. 7A to 7C but different steps by numerals of 300's. The steps with the same step numbers as in FIGS. 7A to 7C are the same operations, and therefore are omitted to explain here. The different steps from those in FIGS. 7A to 7C will be described.
At Step 304 after the reading of film information the control circuit 27 puts L=EXP+1, T=0, and N=EXP-1 in the internal register. The substitution of N=EXP-1 is due to the positional difference of magnetic head H. Since the scan of magnetic information upon film pull out is carried out on a frame which is closer by one frame to the leader than in the prewind camera, that is, on N+1, the film must be fed up to the (EXP-1)-th frame to judge whether the frame with the number of EXP is exposed or unexposed. Therefore, the starting point of frame counter is set as EXP-1. This is different from the previous embodiment. At Step 305 two frames are fed for the same reason as at Step 304. At Step 308 N+1 is substituted into L. This is also because of the difference of position of magnetic head H. Similarly at following Steps 317 and 318 L=N+1 and T=N+1 are respectively set in the same manner as at Step 308. It is detected at Step 320 whether N=0. It cannot be detected whether all frames are exposed including frames on the trailer side of film F, before N is reduced down to 0 due to the position of magnetic head H. Also at Step 334 the rewind film F is continued before N becomes L-1, because the film F must be again fed to the leader side after the detection of exposed frames on the leader side and on the trailer side in the normal wind camera. Unless N=L-1, the flow returns to Step 221. If N=L-1 then the flow goes to Step 223 to stop the rewinding of film. At Step 326 the film F is pulled out of the cartridge C after exposure in the normal wind camera. Then at Step 329 N is decreased by one, since the perforations are detected at Step 228 to confirm the one frame feed of film F. It is detected at Step 330 whether N=T. If N=T, all frames are exposed, and then the flow goes to Step 231 to rewind the film. Unless N=T, there remains an unexposed frame, and then the flow returns to Step 223 to stop the film rewinding.
FIGS. 9A to 9D are drawings to show the fifth embodiment of the present invention. Since the structure of camera is the same as in the third embodiment (of FIGS. 1 and 2), the description thereof is omitted here.
It is assumed in the present embodiment that the camera is of the so-called prewind type in which the film F is entirely wound once and then rewound one by one after exposure of each frame. The present embodiment will be described in detail with the flowchart.
When the film cartridge C is loaded in the camera and the back lid is closed to turn on the back lid switch 19, the flow proceeds from Step 401 to Step 402, where the film feed motor 8 is driven through the motor driver 28 to start the winding of entire film F. At Step 403, during the film winding, the magnetic head H reads out the film information such as the film speed, the number of frames, and the type of film recorded on the magnetic track T of film F as a line of data characters starting with ID sentinels (information start signal).
The read film information is amplified and converted from analog to digital by the head amp 22, then transferred to the buffer 23, thereafter decoded by the decoder 24, and transferred to the control circuit 27.
Also at Step 403, the ID detection circuit 21 continues detecting ID sentinels of N bits (for example "10000000") of film information, and the control circuit 27 receives the detection output while counting.
At Step 404 the control circuit 27 puts values of L=EXP+1, T=0, N=EXP, K=0, P=0, and Q=0 in the internal registers. Here, L represents the leader frame number, EXP the number of frames in film read at Step 403, T the trailer frame number, and N the frame number of a frame at the exposable position. Also, K, P, and Q are pass counters for counting a pass number through the loop used in the following flow. The control circuit 27 then detects a perforation detection signal from the photoreflector (Step 405). When it is detected, the number of ID sentinels of film information is compared with a predetermined number, for example 8, which is a threshold value to determine whether a frame is "exposed" or not. If the frame is judged as "exposed" (if ID sentinel number≦predetermined number), the flow goes to Step 407. If the frame is not "exposed" (if ID sentinel number>predetermined number), the flow goes to Step 412 (Step 406). It is then judged at Step 407 whether N=1. If N=1, all the frames are exposed and then the flow goes to Step 446. Unless N=1, there is a possibility that an unexposed frame exists, and the flow goes to Step 408.
At Step 408 the value of N is put into L, because frames up to the N-th frame are exposed on the leader side on film F. Thus, the frames between L and EXP are exposed. After that, the feed of film F is continued in the direction to pull the film out of the cartridge C (Step 409). The perforations of film F are detected in the same manner as at Step 405 (Step 410). Then, N is decreased by one, since it is detected that the film F is fed by one frame out of the cartridge C at Step 410 (Step 411). By this operation, all exposed frames on the leader side are fed and the smallest frame number is recorded as L among the exposed frames on the leader side.
After the feed of all exposed frames on the leader side is completed by this operation and after an unexposed frame is detected, the feed of film F is continued in the direction to pull the film F out of the cartridge C in the same manner as at Step 409 (Step 412). The perforations of film F are then detected in the same manner as at Step 405 or 410 (Step 413). When they are detected, N is decreased by one in the same manner as at Step 411, because it is detected at Step 413 that the film is fed by one frame (Step 414).
If the value of register K is not less than 2, that is, if the number of pass times through the abnormal process loop indicated by the register K is not less than 2, the flow goes to Step 446 assuming that an abnormal accident which cannot be ignored happens in production of DEP flag or in overwriting of information in either of cameras in which the film F was used. In case that the value of K is 0 or 1, the abnormality is ignored and the flow goes to Step 416 as the normal process. In the above abnormal process, the first appearance of "mid-dropped" unexposed frames is ignored if the frames are less than M. At Step 416 it is detected whether the frame with frame number N is exposed in the same manner as at Step 406. If it is unexposed then the flow returns through Step 420 to Step 412 to detect whether a next frame is exposed or unexposed. If the frame with frame number N is exposed, the flow goes to Step 417.
At Step 417 the frame number N of current exposed frame is subtracted from the leader side final exposed frame L to obtain the number of successive unexposed frames between them, and the obtained number is compared with the predetermined number M. If the number is less than M, it is supposed that there is an accidental error caused in writing between L and N, and then the flow goes to Step 418 for abnormal process. If the number is not less than M, it is supposed that the unexposed frames are correctly detected, and the flow goes to Step 419 for normal process.
If L-N<M, that is, if an abnormal state is detected at Step 417, frames detected as unexposed frames between L and N are ignored, and N is substituted into L. Also, the counter K is increased by one to store the number of abnormal process executed. After that, the flow returns through Step 420 to Step 412.
At Step 419 N is put in the frame number register T of exposed frames on the trailer side on film F. Namely, when Step 419 is carried out, the largest frame number is input into T out of the exposed frames on the trailer side. Accordingly, frames between T+1 and L-1 are unexposed.
In case that the frame with frame number N is not exposed at Step 416, carried out at Step 420 is the process executed when there is no exposed frame on the trailer side of film F. In other words, unless the frame is exposed but N=1 at Step 420 there is no unexposed frame on the trailer side. In this case the flow goes to Step 438. On the other hand, after the largest frame number out of the exposed frames on the trailer side is input into T, the feed of film F is continued in the pull out direction (Step 421), and the one frame feed of film F is then detected by detecting the perforations in the same manner as at Step 405, 410, or 413 (Step 422). After it is detected at Step 422 that the film F is pulled out by one frame, N is decreased by one (Step 423). It is again judged whether the fed frame is exposed or unexposed (Step 424). If it is exposed, the flow goes to Step 425 as the normal process. If an unexposed frame is detected, the flow goes to Step 427 for abnormal process II, since L and T were already determined.
At Step 425 the flow returns to Step 421 unless N=1, in order to continue the above abnormality detection up to the film end. If N=1 then the flow goes to Step 426. The check is thus completed for all frames, and then the feed direction of film is reversed to start rewinding it into the cartridge (Step 426). Further at Step 427 the register Q is started counting up from 1 to store the number of processing times of the abnormality process II branched at Step 424. Then, the unexposed frame number N detected at Step 424 is put into the register P (Step 428).
The number of processing times of abnormal process II is next checked from the content of Q. If it is less than 2, the flow goes to Step 430 to check abnormality remedy. If it is not less than 2, the flow goes to Step 446 assuming that there was unignorable abnormality, similarly in the case that K is not less than 2 at Step 415.
At Step 430 the feed of film F is continued in the pull out direction. It is detected whether a frame is fed (Step 431), and if the one-frame feed is detected, the frame number register N is decreased by one (Step 432).
It is then judged whether the frame is exposed or unexposed (Step 433). After that, since the present step is reached if the abnormality process time is not more than once, the flow goes to Step 425 if the frame is detected as exposed, ignoring detected, unexposed frames in the abnormal process II. If an unexposed frame is detected, the flow goes to Step 234. Then, a number of successive unexposed frames is calculated by subtracting the current frame number from initial P of unexposed frame. This is compared with the predetermined number M (Step 234). If it is not less than M, there are two unexposed portions of not less than successive M frames in film F, so that the flow goes to Step 446, regarding it as unignorable abnormality. If it is less than M, the flow returns to Step 429, because the abnormality might be ignorable.
In the above abnormality process II the unignorable abnormality is a case that the abnormality times are not less than twice, that is, that two or more unexposed frame portions are detected on the trailer side after detection of exposed frame, or a case that M or more successive frames are abnormally unexposed.
If the above abnormality is not detected, the feed of film is started in the rewinding direction into the cartridge (Step 426), and thereafter it is detected whether a frame is fed (Step 435). When it is detected at Step 425 that a frame is fed, the frame number register N is increased by one (Step 436).
The frame number register N is then compared with (T+1) to check if the film is fed up to the initial unexposed frame T+1 on the trailer side (Step 437). Unless N is (T+1) then the flow returns to Step 425. If N is (T+1) then the flow goes to Step 438. The feed motor 8 is stopped through the motor driver 28 to stop the feed of film F (Step 438).
It is next detected whether the rewind switch 20 for mid-roll rewind is on (Step 439). If it is on then the flow goes to Step 447 to rewind the film F into the cartridge. If it is off then the flow goes to Step 440.
At Step 440 it is judged whether the switch SW 1 is on. If it is on, the operations of photometry and distance measurement are carried out. Subsequently, the data of shutter speed, aperture value, and so on obtained in the photometry and distance measurement operations is converted into camera information, and the converted data is transferred to the encoder 25.
The encoder 25 encodes the camera information transferred thereto, and the buffer 26 stores it. Further, it is judged whether the switch SW 2 is on. If it is on, the conventional exposure operation is carried out. In detail, the control circuit 27 receives a lens position signal from the lens encoder 2b through the lens actuator 2a, and gives a stop command to the lens actuator 2a to stop the drive of photographic lens 1, or the focus operation when the photographic lens 1 reaches the position corresponding to the distance information measured. Almost at the same time the open and close operation of shutter 3 is carried out with an output of photometric sensor 4 for a certain time. After completion of the open and close operation of shutter 3, the film feed motor 8 rewinds the film F into the cartridge C (Step 441). During the feed of film, the magnetic head H is driven to write on the magnetic track T of film F the camera information stored in the buffer 26 through the head amp 22 in the form of a line of data characters starting with ID sentinels of N bits (for example "00000000") different from the ID sentinels of film information. After that, when the perforations are detected (Step 443), the data writing is stopped at Step 442. N is increased by one, since the perforations are detected at Step 443 to confirm that the film F is fed by one frame (Step 444).
It is next detected whether N becomes equal to L, which is the exposed frame on the leader side (Step 445). If N=L, all frames are exposed, and then the flow goes to Step 446. Unless N=L, there remains an unexposed frame, and then the flow returns to Step 438 to stop the feed.
The perforation detecting photoreflector 7 detects the state immediately before the film F is fully rewound into the cartridge C (Step 447) and after a certain time elapsed it is determined that the film F is stored in the cartridge C. The film feed motor 8 is then stopped (Step 448).
Though not explained above, the pad 11 is urged against the magnetic head H by the pad position control mechanism 12 only during movement of film F to assure the reading and writing of magnetic information.
FIGS. 10A to 10D are drawings to show the sixth embodiment of the present invention. In the sixth embodiment the camera is so arranged to have the structure as shown in FIG. 5 with the control circuit excluding the display 29 in the block diagram of FIG. 2, and therefore the structure thereof is omitted to explain here. The present embodiment shows a normal wind camera in which exposure of film F is started from the leader side thereof, as in the fourth embodiment.
FIGS. 10A to 10D correspond to the flowcharts of FIGS. 9A to 9D. In FIGS. 10A to 10D steps having the same operations as in FIGS. 9A to 9D are given the same step numbers, and are omitted to explain here. Steps having different operations from those in FIGS. 9A to 9D are marked with star before step numbers. The difference is due to the following two reasons: (1) Since the position of magnetic head is located at the opposite side to that in the prewind camera with respect to the camera aperture, the scan of magnetic information for the frame N at the camera aperture is carried out with N+1 next thereto by one frame on the leader side during pull out of film; (2) The film feed direction upon photography is the film pull out direction. The different steps will be described below.
At Step 504 EXP-1 is put into the film frame register N, and at Step 505 feed of two frames is detected. At Step 507 it is detected whether the film is fed up to the 0th frame, and at Step 508 N+1 is put into L. At Step 518 N+1 is put into L. At Step 520 it is detected whether the film is fed up to the 0th frame. Further, at Step 525 it is detected whether the film is fed up to the 0th frame in the same manner as at 520. At Step 537 it is detected whether the film is fed to (L-1)-th frame. At Step 541 the film is fed in the pull out direction. At Step 545 the counter N is decreased by one. Then at Step 546 it is detected whether the film is fed to T-th frame.
Throughout the embodiments as described above, the judgment number M for determining whether abnormal or normal when unexposed frames are successively detected may be 1 in the strictest case, or 2, 3, 4, or more depending upon the provability of error operation of camera.
FIGS. 11A to 11D show the seventh embodiment of the present invention. Since the structure of camera of FIGS. 11A to 11D is the same as that in FIGS. 1 and 2, the description thereof is omitted.
An operation of control circuit 27 of FIG. 2 is described with the flowcharts of FIGS. 11A to 11D. It is assumed in the present embodiment that the camera is of the so-called prewind type in which the film is entirely wound once and rewound one by one after exposure of each frame.
When the film cartridge C is loaded in the camera and the back lid is closed to turn on the back lid switch 19, the flow proceeds from Step 601 to Step 602 to drive the film feed motor 8 through the motor driver 28 and to start winding of the entire film F. Then at Step 603, during the film winding, the magnetic head H reads the film information such as the film speed, the number of frames, and the type of film recorded on the magnetic track T of film F as a line of data characters starting with ID sentinels (information head signal).
The read film information is amplified and converted from analog to digital by the head amp 22, transferred to the buffer 23, thereafter decoded by the decoder 24, and then transferred to the control circuit 27.
Also at Step 603, the ID detection circuit 21 continues detecting ID sentinels of N bits (for example "10000000") of film information, and the control circuit 27 receives the detection output while counting.
At Step 604 the film information read at Step 603 is indicated on the display 29 as shown in FIG. 4A. In FIG. 4A numeral 30 represents a display device such as a liquid crystal display plate, 31 an indication of film speed, 32 an indication of number of frames in film, and 33 an indication of type of film. At Step 605 the control circuit 27 puts values of L=EXP+1, T=0, and N=EXP in the internal registers. Here, L denotes a leader portion frame number, EXP the number of frames in film read at Step 603, T a trailer portion frame number, and N a frame number at the camera aperture.
The control circuit 27 detects a perforation detection signal from the photoreflector 7 (Step 606). Then, in order to indicate that the film F is under feed, the indication of film information presently indicated is flashed (Step 607). This change of indication permits a user of camera to identify for example that the film F is exposable at the 36-th frame.
The number of ID sentinels of film information is compared with a predetermined number, for example 8, which is a threshold value to determine whether a frame is "exposed" or not, in the same manner as at Step 108 in FIG. 3B (Step 608). If the frame is judged as "exposed" (if ID sentinel number≦predetermined number), the flow goes to Step 609. If the frame is not "exposed" (if ID sentinel>predetermined number) then the flow goes to Step 615. In case that the frame is "exposed", it is judged whether N of exposable frame number is 1 (Step 609). If N=1, all frames are exposed, and then the flow goes to Step 639. Unless N=1, there is a possibility that an unexposed frame exists, and therefore the flow goes to Step 610. Since frames up to the N-th frame are exposed on the leader side on film F, the value of N is put into L (Step 610).
The feed of film F is continued in the direction to pull the film F out of the cartridge C (Step 611). Subsequently, perforations of film F are detected in the same manner as at Step 606 (Step 612). Once the perforations are detected, the indication of film information presently indicated is flashed in order to indicate that the film is under feed, in the same manner as at Step 607 (Step 613). Since it is detected at Step 612 that the film F is fed by one frame out of the cartridge C, N is decreased by one (Step 614). By above steps 608 to 614, the smallest frame number is detected out of frame numbers of exposed frames on the leader side of film.
At Step 615, indicated are the exposed frames on the leader side on film F, which were detected at the above steps. Exposed frames are from L to EXP. The indication is as shown in FIG. 4C as L=21 and EXP=36. In FIG. 4C numeral 34 represents an indication of shutter speed of camera, 35 an indication of aperture value of camera, and 37 an exposed frame indication to indicate that 21st to 36th frames are exposed. After the indication of exposed frames, the feed of film F is continued in the direction to pull the film F out of the cartridge C, in the same manner as at Step 611 (Step 616). After that, the perforations of film F are detected in the same manner as at Step 606 or 612 (Step 617). Once the perforations are detected, the exposed frame indication presently indicated is flashed in order to indicate that the film F is under feed (Step 618). The indication change permits the user of camera to identify that the film F is under feed in camera.
Since the film F is fed by one frame at Step 617, N is decreased by one in the same manner as at Step 614 (Step 619). It is then detected in the same manner as at Step 608 whether the frame with frame number N is exposed (Step 620). If it is unexposed, the flow returns through Step 624 to Step 616 to detect whether a next frame is exposed or unexposed. If the frame with frame number N is exposed then the flow goes to Step 621 to put N into the exposed frame number T on the trailer side on film F (Step 621). Since L and T are determined, the unexposed frames on film F are indicated (Step 622). (T+1)-th to (L-1)-th frames are unexposed. The indication is as shown in FIG. 4D as T=9 and L=21. In FIG. 4D numeral 38 represents an unexposed frame indication to indicate that 10th-20th frames are unexposed. Subsequently at Step 623, the film F is rewound into the cartridge C. Steps 624 and 625 are for a case that there is no exposed frame on the trailer side of film F. If the frame is not exposed and if N=1 at Step 624, there is no exposed frame on the trailer side. In this case, the flow goes to Step 625 to indicate the unexposed frames in the same manner as at Step 622. Since T=0, the indication is 1 to L=1.
After the feed of film is carried out at above Step 623, it is detected whether the film F is rewound by one frame in the same manner as at Step 606, 612, or 617 (Step 626). The unexposed frame indication presently indicated is then flashed to indicate that the film F is under feed (Step 627). Since it is detected at Step 626 that the film F is fed by one frame, N is increased by one (Step 628). Then, N-T and L-T-1 are calculated to indicate usable frames on film F (Step 629). N-T represents exposed frames after the film F is loaded this time. L-T-1 represents the number of unexposed frames at the time of latest loading of film F. If N=10, T=9, and L=21, the indication is as shown in FIG. 4E. In FIG. 4E numeral 39 represents an indication of usable frames showing "MRI" which is an abbreviation of Mid Roll Interrupt and "1 OF 11" which is the number of usable frames.
After the indication of usable frames, the feed of film F is stopped by stopping the feed motor 8 trough the motor driver 28 (Step 630). It is then detected whether the rewind switch 20 for mid-roll rewind is on (Step 631). If it is on then the flow goes to Step 640 to rewind the film F into cartridge. If it is off then the flow goes to Step 632. At Step 632 it is judged whether the switch SW 1 is on. If it is on, the operations of photometry and distance measurement are carried out. Subsequently, the data of shutter speed, aperture value, and so on obtained in the photometry and distance measurement operations is converted into camera information, and the converted information is transferred to the encoder 25.
The encoder 25 encodes the camera information transferred thereto, and the buffer 26 stores the encoded information. Further, it is judged whether the switch SW 2 is on. If it is on, the conventional exposure operation is carried out. In detail, the control circuit 27 receives a lens position signal from the lens encoder 2b through the lens actuator 2a, and when the photographic lens 1 reaches a position corresponding to the distance information the control circuit gives a stop command to the lens actuator 2a to stop the drive of photographic lens 1, that is, the focus operation. Almost at the same time, the open and close operation of shutter 3 is carried out with an output of photometric sensor 4 for a certain time.
After completion of exposure, the film F is fed by the film feed motor 8 into the cartridge C (Step 633). The magnetic head H is then driven to write on the magnetic track T of film F the camera information stored in the buffer 26 through the head amp 22 in the form of a line of data characters starting with ID sentinels (for example "00000000") of film information during the film feed (Step 634). When the perforations are detected, the data writing started at Step 634 is stopped (Step 635). The usable frame indication is then flashed to inform the user of camera that the perforations are detected at Step 635 (Step 636). Since the film F is rewound by one frame as the perforations are detected at Step 635, N is increased by one (Step 637). It is next detected whether N becomes equal to L, which is the leader side exposed frame (Step 638). If N=L, all the frames are exposed, and then the flow goes to Step 639. Unless N=L, there remains an unexposed frame, and then the flow returns to Step 629 to carry out a further exposure operation.
Since all the frames are exposed when N=L, an all-frames-exposed indication is indicated as shown in FIG. 4B (Step 639). In FIG. 4B numeral 36 represents an indication of "ALL EXPOSED", that is the all-frames-exposed indication. After that, the film F is fed by the motor 8 into the cartridge C (Step 640). The perforation detecting photoreflector 7 detects the state immediately before the film F is fully rewound into the cartridge C, and after a certain time elapsed it is determined that the film F is stored in the cartridge C (Step 641). Then, the film feed motor 8 is stopped (Step 642) and the indication on the indication plate 30 in the display 29 is turned off (Step 643).
Though not explained above, the pad 11 is urged by the pad position control mechanism 12 against the magnetic head H only during movement of film F to ensure the reading and writing of magnetic information.
FIGS. 12A to 12D are flowcharts to show the eighth embodiment of the present invention, in which the camera structure is the same as that shown in FIG. 5.
The embodiment as shown in FIGS. 11A to 11D showed the prewind camera, whereas the present embodiment shows a normal wind camera in which the exposure of film F is started from the leader side of film F. The normal wind camera of FIG. 5 is different from the prewind camera of FIG. 1 in that the magnetic head H, the pad 11, and the pad position control mechanism 12 are located on the opposite side to the locations thereof in the prewind camera, because the film F is fed in the direction to pull it out of the cartridge C after exposure of each frame.
FIGS. 12A to 12D correspond to the flowcharts of FIGS. 11A to 11D, in which different steps from those in FIGS. 11A to 11D are marked with star ahead. The same steps are denoted by the same step numbers as in Figs. 11A to 11D, but different steps by numerals of 700's.
The different steps from those in FIGS. 11A to 11D are described below.
At Step 705 the control circuit 27 puts values of L=EXP+1, T=0, and N=EXP=1 into the internal registers. This is different from the above embodiment because of the difference of position of magnetic head H.
At Step 706 the perforations are detected twice. This is because the position of magnetic head H is different from that in the prewind camera. At Step 710 N+1 is put into L. This is also because of the positional difference of magnetic head H. At Step 721 N+1 is put into T. This is due to the positional difference of magnetic head H as well. At Step 724 whether N=0 is detected. This is because it cannot be detected whether all frames on the trailer side of film F are exposed or not unless N becomes 0 because of the position of magnetic head H. At Step 725, since the film F must be again rewound to the leader side after the detection of exposed frames on the leader side and on the trailer side in the normal wind camera, the rewind of film F is continued until N becomes L-1. Unless N=L-1 then the flow returns to Step 626. If N=L-1 then the flow goes to Step 629.
At Step 733 the film F is pulled out of the cartridge C after exposure in the normal wind camera. At Step 737 N is decreased by one, since the one frame feed of film F is detected by detecting the perforations at Step 635. Further, whether N=T is detected at Step 738. If N=T, all frames are exposed, and then the flow goes to Step 639. Unless N=T, there remains an unexposed frame, and then the flow returns to Step 629.
FIGS. 13A to 14D are drawings to show the ninth embodiment of the present invention. The ninth embodiment is different from the embodiment of FIGS. 11A to 11D in that the exposed frame indication 37 on the indication plate 30 is changed every detection of exposed frame on the leader side of film F and in that the unexposed frame indication 38 on the indication plate is changed every detection of unexposed frame of film F, in the prewind camera. In the present embodiment, the user of camera can identify the film feed condition of camera by the change on the indication plate 30.
FIGS. 13A to 13D correspond to the flowcharts of FIGS. 11A to 11D, in which different steps from those in FIGS. 11A to 11D are marked with star ahead. The same steps are denoted by the same step numbers as in FIGS. 11A to 11D, but different steps by numerals of 800's.
The different steps from those in FIGS. 11A to 11D are described below.
At Step 810 exposed frames on the leader side on film F are indicated in the same manner as at Step 615. The exposed frames are from L to EXP. The indication is shown in FIG. 14A when L=EXP. In FIG. 14A numeral 40 represents an indication of exposed frames. Since EXP=36 in this example, the indication shows that the 36th frame is exposed. After that, in case that the flow proceeds through Steps 611, 612, 813, 614, 608, and 609, the indication plate 30 shows the indication as shown in FIG. 14B since L=EXP-1. In FIG. 14B numeral 41 represents the exposed frame indication. The indication shows that the 35th and 36th frames are exposed. The camera changes the indication of exposed frame every one frame feed of film F in such a manner, thereby the user of camera can identify the operation condition of camera.
At Step 813 the exposed frame indication is flashed to indicate that the film F is under feed in the same manner as at Step 618. This indication change permits the user of camera to identify that the film F is under feed. Step 813 can be omitted, since the user of camera can identify the operation condition of camera by the indication change at Step 810 every one frame feed of film F in camera.
At next Step 815, since T is not determined different from Step 622, the N-th to (L-1)-th frames are indicated as unexposed. FIG. 14C shows an indication state when L=21. In FIG. 14C numeral 42 represents the unexposed frame indication. This example shows that the 20th frame is unexposed. After that, in case that the flow proceeds further through Steps 616, 617, 818, 619, 621, 620, and 624, the indication is changed as shown in FIG. 14D. In FIG. 14D numeral 42 represents the unexposed frame indication. This example shows that the 19th-20th frames are unexposed. Since the camera changes the unexposed frame indication every one frame feed of film F in such a manner, the user of camera can identify the operation condition of camera.
At Step 818 the unexposed frame indication presently indicated is flashed to indicate that the film F is under feed in the same manner as at Step 627. Step 818 can be omitted, since the user of camera can identify the operation condition of camera by the indication change at Step 810 every one frame feed of film F in camera.
Further, at Step 825, if N-1 then T=0 is set since T must be zero at the steps after Step 825.
FIGS. 15A to 15D are drawings to show the tenth embodiment of the present invention. The embodiment of FIGS. 13A to 13D showed the prewind camera in which the indication plate 30 was changed every one frame feed of film F, whereas the present invention shows a normal wind camera in which the indication on the indication plate 30 is changed every one frame feed of film F.
FIGS. 15A to 15D correspond to the flowcharts of FIGS. 12A to 12D. The operations at the respective steps were already explained with FIGS. 12A to 13D, and therefore are omitted to explain here.
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A camera uses a film having a magnetic record member for each frame on film. When the film is loaded in the camera, the information recorded in the record member of each frame is detected. It is judged whether each frame is exposed or unexposed. Even if some frames on the leader side and on the trailer side of film were already exposed, the camera can perform accurate positioning of first unexposed frame and exposure on each unexposed frame.
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BACKGROUND OF THE INVENTION
The present invention relates to a new and improved construction of a Jacquard machine equipped with to-and-fro moving lifting wires equipped with arresting hooks for coupling the lifting wires with stationary arresting blades. The invention of the present disclosure has particular applicability with double lift-open shed-Jacquard machines using single lifting wires (single-leg lifting wires).
According to a prior art loom of this general type, as disclosed in Swiss Pat. No. 552,691, corresponding to U.S. Pat. No. 3,871,415 the lifting wires are guided at their lower region through a stationary lifting wire board or floor portion. In the event that the coupling action between the lifting wires and the lifting blades does not proceed according to the programme contemplated, for some reason or other, for instance due to oscillations or deformation of the lifting wires, then, the lifting wires undesirably can drop until reaching the lifting wire board, under the action of a spring which pulls such lifting wires downwards. The lifting wire-entrainment hooks coacting with the lifting blades can be guided out of the region where they can be coupled with the lifting blade-entrainment hooks, so that the lifting wires no longer can be entrained by the lifting blades. When this happens there is required relatively complicated repair work.
SUMMARY OF THE INVENTION
Hence, it is a primary object of the present invention to provide a Jacquard machine which is specifically improved in this regard.
Another and more specific object of the present invention aims at the provision of a new and improved construction of a Jacquard machine structured to increase the probability of proper operation of the lifting wires with the associated structure, thereby avoiding, or at least minimizing, expensive downtime of the loom and costly repairs.
Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the Jacquard machine of the present invention is manifested by the features that there is provided at least one stationary guide edge at the region of the stationary arresting blade fixing the lower shed position, this guide edge cooperating with a projection located at the neighboring lifting wire moving into the lower shed position, so that the lifting wire is deflected and when assuming the lower shed position is coupled with the associated stationary arresting blade.
With the inventive Jacquard machine or loom there can be obtained an extremely positive coupling or engagement between the lifting blades and the lifting wires such that the lifting wire-entrainment hooks positively remain at the region of the lifting blade-entrainment hooks, so that possible errors which may arise with respect to the coupling operation at the lifting wire-entrainment hooks and the lifting blade-entrainment hooks or during the so-called shifting or depressing operation of the shifting or depressing needles is immediately itself compensated. Even if, for instance, a lifting wire-entrainment hook nests with its tip upon the tip of an associated lifting blade-entrainment hook, as shown for instance in FIG. 4, and should jump out of this unstable position, nonetheless the lifting wire only can drop to such an extent, as shown for instance in FIG. 2, that it is coupled with its arresting hook in the arresting blade hooks provided for the lower shed. Further dropping of the lifting wire is impossible.
The lifting wire can be again guided upwardly at any time, out of the lower shed position, by an upwardly moved lifting blade, so that the operation can proceed immediately automatically. The mode of operation of the Jacquard machine therefore becomes particularly free of disturbances and loom downtime.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 illustrates a first position of lifting wire arrangement of a Jacquard machine constructed according to the present invention;
FIG. 2 illustrates the lifting wire arrangement of FIG. 1, in fragmentary view, in a different position;
FIG. 3 illustrates, for comparative purposes, a position assumed with a lifting wire arrangement not constructed according to the present invention;
FIG. 4 illustrates a further position of the lifting wire arrangement of the invention; and
FIG. 5 shows a modified construction of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, it is to be understood that only enough of the structure of the Jacquard machine or loom has been shown to enable those skilled in the art to readily understand the underlying concepts and principles of the present invention. Both of the lifting blades 1 and 2 will be seen to each have an upper beam 4, by means of which they can be driven and placed into a reciprocal up and down movement. At its lower end each such lifting blade 1 and 2 is provided with the entrainment hooks 6, 7 coacting with the hooks 14, 15 of the lifting wires 8, of which only one has been specifically shown to preserve clarity in illustration. These lifting wires or hooks 8 can be shifted or pushed in the direction of the arrow 13 of FIG. 1, in other words towards the right, by means of the so-called shifting or depressing needles 12, also known in the art as Jacquard needles. FIG. 1 illustrates the so-called shifted or depressed position for the therein illustrated lifting wire 8.
Below the shifting or depressing needles 12 there are stationarily arranged the arresting blades 17 fixing the upper shed position of the lifting wires 8 and furthermore the likewise stationary arresting blades 18 fixing the lower shed position. To provide the necessary coaction between the lifting wires 8 and the arresting blades 17, 18 these lifting wires 8 are provided with the arresting hooks or tongues 16 or equivalent structure. Considerably below the arresting blade 18 there is located a lifting wire board or floor 19.
The mode of operation of the above-discussed Jacquard machine is as follows:
Initially there is assumed a starting position where the lifting blade 1 is in its lower reversing position, the lifting blade 2 is in its upper reversing position and the lifting wire 8 with its arresting hook 16 is suspended in the stationary arresting blade 17 (upper shed position of the lifting wire). The shifting or depressing needle 12 is located in its left, ineffectual position, where the lifting wire 8 is not depressed or shifted towards the right.
Now the lifting blade 1 is moved upwards and at the same time the lifting blade 2 downwards. The hook 7 engages in the hook 14 and entrainably shifts the lifting wire 8 upwards. Thereafter, the shifting or depressing needle 12 is moved towards the right, as indicated by the arrow 13, so that the lifting wire 8 is primarily shifted or depressed at its intermediate shifting region 10 reinforced by a widened or enlarged portion 9. As soon as the arresting hook 16 is sufficiently elevated it is uncoupled from the upper arresting blade 17 and snaps towards the right. The components then reach the illustrated position (upper reversing position of the lifting blade 1 and at the same time the lower reversing position of the lifting blade 2).
Then, the lifting blade 1, as indicated by the arrow 31, is moved downwards and the lifting blade 2, as indicated by the arrow 32, is moved upwards. The lifting wire 8, under the action of a not particularly illustrated but conventional spring, together with the lifting blade 1 moves downwards and remains depressed, so that the hook 16 can move past and to the right of the arresting blade 17.
Finally, the hook 16 arrives at the position, indicated by the hook 16a shown in phantom lines in FIG. 1, where a rearward projection 21 assumes the position shown by phantom lines 21a in FIG. 1, where it impacts against an inclined guide edge 22 of the lower arresting blade 18a. Due to the resulting guiding action, and during further downward movement of the components 1 and 8, the hook 16 finally is shifted into the position, shown by the hook 16b illustrated in phantom lines in FIG. 2, where it is coupled with the lower arresting blade 18.
As a general rule the shifting or depressing needle 12 is again guided towards the left out of the illustrated shifted or depressed position, shortly prior to the coupling of the hooks 16, 18, so that also the arresting hook 16 and the projection 21 can snap or otherwise return towards the left. Even if these operations for some reason or other are not carried out exactly as explained, nonetheless there is ensured that in any event the hook 16 will be suspended in the hook 18 and specifically due to the guide edge 22. The lifting wire 8 cannot drop, for instance, into such a low position that the hook 16 can assume the position indicated by the hook 16c shown in phantom lines in FIG. 3 for comparative purposes which relates to a construction of Jacquard machine which is not equipped with the guide edge 22, and where, as it will be noted, such lifting wire can seat upon the lifting wire board 19 arranged a considerable distance beneath the hook 18 and further where the hooks 14, 15 no longer can be coupled with the hooks 7, 6.
During the upward movement of the lifting blade 1 it can happen at times that the hooks 7, 14 seat or nest upon one another, as shown in FIG. 4, as opposed to fixedly engaging or interlocking with one another. Out of this unstable position it is possible for the hook 14 to easily snap towards the right of FIG. 4, so that also in such case, during lowering of the lifting wire 8, the hooks 16, 18 will come into engagement with one another.
Also, it is not possible for there to arise the situation where the lifting wire 8 can seat by means of its rearward projection 21 for instance at the surface 30 (FIG. 3) of the known constructions of hooks 18, and thus again there would be present an unstable position of the components which could endanger further proper operation of the loom.
Finally, a modified construction of the invention, shown in FIG. 5, contemplates that the guide edges 22a are separate components in relation to the lower, stationary arresting blades 18. For instance, all of the guide edges 22a could collectively form a special grid.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims.
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A Jacquard machine of the type possessing to-and-fro moving lifting wires having arresting hooks for coupling with stationary arresting blades. At least one stationary guide edge is provided at the region of a stationary arresting blade fixing the lower shed position. This guide edge cooperates with a projection located at the neighboring lifting wire moving into the lower shed position, so that the lifting wire is deflected and in the lower shed position is coupled with the associated stationary arresting blade.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 14/254,440 filed Apr. 16, 2014, which is a continuation of U.S. patent application Ser. No. 14/037,462 filed Sep. 26, 2013, (now U.S. Pat. No. 8,821,220 issued Sep. 2, 2014) which is a continuation of United States patent application Ser. No. 13/804,222 filed Mar. 14, 2013 (now U.S. Pat. No. 8,613,644 issued Dec. 24, 2013), which is a continuation of U.S. patent application Ser. No. 13/465,631 filed May 7, 2012 (now U.S. Pat. No. 8,398,457 issued Mar. 19, 2013), which is a continuation of U.S. patent application Ser. No. 12/540,189 filed on Aug. 12, 2009 (now U.S. Pat. No. 8,172,642 issued May 8, 2012), which claims the benefit of U.S. Provisional Application No. 61/090,417, filed on Aug. 20, 2008. The entire disclosures of the above applications are incorporated herein by reference.
INTRODUCTION
[0002] The present disclosure generally relates to a sander having multiple platens that can be selectively attached to a common sander base without the use of a hand tool.
[0003] Sanders typically have a platen to which an abrasive media, such as sandpaper, is attached. Sanders with removable, differently shaped platens (e.g., rectangular, square, round) are available to permit the user of the sander to change the platen to one with a shape that is best suited for a given sander task. Such removable platens typically are secured to the sander by way of one or more threaded fasteners (e.g., socket head cap screws). These threaded fasteners require the use of tools (e.g., Allen wrenches) to remove them from the sander to thereby decouple the platen from the sander.
[0004] Various tool-less coupling systems have been developed for coupling a platen to the rotating output member of a rotary grinder. Such coupling systems, however are relatively large and costly and do not support an abrasive media in an area where one element of the coupling system is received against the platen.
SUMMARY
[0005] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
[0006] A tool for moving an abrasive media can include a tool body and a drive system housed in the tool body. The drive system can include an output member. A retaining member can be disposed on the tool body. A first platen having a first attachment hub can be selectively coupled with the retaining member in an installed position. The first platen can have a first rotatable member that selectively attaches to the output member in a first mode of operation. A second platen having a second attachment hub can selectively couple with the retaining member in an installed position. The second platen can have a second rotatable member that selectively attaches to the output member in a second mode of operation.
[0007] A mode selector can be disposed on the tool body. The mode selector can have a movable member and a key. The movable member can be movable between at least a first position that corresponds to a first output member speed and a second position that corresponds to a second output member speed. The movable member can be substantially aligned with a first zone on the key that corresponds to the first platen in the first position and second zone on the key that corresponds to the second platen in the second position.
[0008] According to other features, the first rotatable member of the first platen can be mounted for an orbit having a first offset relative to the output member. The second rotatable member of the second platen can be mounted for an orbit having a second offset relative to the output member. The first and second offsets can be distinct. The first rotatable member can include a first fan having a first counterbalance disposed thereon. The second rotatable member can comprise a second fan having a second counterbalance disposed thereon. The first and second counterbalances can have distinct masses. In one example, the first platen can be an orbital platen configured for orbital sander in the installed position and the second platen can be a random orbit platen configured for random orbit sander in the installed position. The first platen can comprise a plurality of flexible columns having first ends coupled to the first platen and second ends that are selectively retained by the tool body in the installed position.
[0009] According to additional features, the retaining member can comprise a wireframe that selectively nests in respective grooves defined around each of the first and second attachment hubs respectively in the installed position. A button can be disposed on the tool body. The button can cooperate with the wireframe and be movable to a release position to spread the wireframe and release the wireframe from the respective grooves to exchange between the first and second platens. According to one example, a chamfered annular leading edge is defined on each of the first and second attachment hubs respectively. Movement of a respective first or second platen to the installed position can cause the annular leading edge to spread the wireframe until continued movement toward the installed position causes the wireframe to nest in the respective grooves.
[0010] According to still other features, the tool can include a third platen having a third attachment hub that selectively couples with the retaining member in an installed position. The third platen can have a third rotatable member that selectively attaches to the output member in a third mode of operation. The first platen can define an iron-shaped profile having a substantially flat first end and a substantially pointed second end. The first platen can comprise a dust chute arranged proximate to the substantially pointed second end. The third platen can define an iron-shaped profile having a substantially pointed first end and a substantially flat second end. The third platen can comprise a dust chute arranged proximate to the substantially flat second end. The substantially flat first end of the first platen is aligned with a forward end of the tool in the installed position and the substantially pointed first end of a third platen is aligned with a forward end of the tool in the installed position.
[0011] According to still other features, the tool can comprise a speed control switch that communicates with the mode selector. The mode selector can define a rib that cams across an input of the speed control switch upon movement of the mode selector to toggle between the first output member speed and the second output member speed.
[0012] A method according to the present teachings can include providing a tool with a tool body, a drive system and a first and second platen. The tool body can have a mode selector including a movable member and a key. The drive system can have an output member. The method further includes, moving the movable member to one of a first position or a second position. The first position can correspond to the first platen and associated with a first output member speed and the second position corresponding to the second platen and associated with a second output member speed. The method can further include, mounting one of the first or second platen to the tool body according to the selected first or second position.
[0013] According to additional features, the method can include rotating a dial causing a rib defined on the dial to cam across an input of a speed control switch and change the speed of the output member between a first and second output member speed. According to one example of the method, mounting one of the first or second platens to the tool body can include urging an attachment hub associated with a respective first or second platen into engagement with a wireframe retaining member disposed on the tool body. The method further includes, urging the attachment hub into engagement with the wireframe retaining member, such that the wireframe retaining member rides over a chamfered annular leading edge defined on the attachment hub and spreads outwardly until the wireframe retaining member nests at least partially around the selected attachment hub in a groove defined on the selected attachment hub.
[0014] In another form, the present teachings provide a power tool that includes a tool body housing, a drive system, a tool head and a connection system. The tool body housing is at least partly formed by a pair of clam shell housing members and defines a cavity. The drive system is housed in the cavity and has an output member. The tool head, which is configured to perform work on a work piece, includes a tool head housing and an input member. The input member is matingly engagable to the output member to drivingly couple the output member of the drive system to the input member of the tool head when the tool head is coupled to the tool body. The connection system has at least one recess and a retainer. The at least one recess is formed in one of the tool head housing and the tool body housing. The retainer is movably coupled to the other one of the tool head housing and the tool body housing. The retainer is received into the at least one recess to fixedly but removably couple the tool head to the tool body. The tool head can be engaged to the tool body housing in at least two pre-defined and distinct orientations and the connection system secures the tool head to the tool body housing in each of the at least two pre-defined and distinct orientations.
[0015] In yet another form, the present teachings provide a power tool that includes a tool body, a tool head and a connection system. The tool body has a tool body housing and a drive system that includes a motor and an output member driven by the motor. The tool head, which is configured to perform work on a work piece, includes a tool head housing and an input member that is engagable to the output member such that the input and output members co-rotate about a rotational axis. One of the tool body housing and the tool head housing defines a hub cavity and a plurality of rail cavities, and the other one of the tool body housing and the tool head housing defines a cylindrical hub and a plurality of rails. The cylindrical hub extends longitudinally along the rotational axis and is configured to be received into the hub cavity. The rails are disposed about the cylindrical hub and extend parallel to the rotational axis. The rails are configured to be received into the rail cavities. The input member is matingly engaged to the output member to drivingly couple the drive system to the tool head when the cylindrical hub is received into the hub cavity and the rails are received into the rail cavities. The connection system has at least one recess and a retainer. The at least one recess is formed in one of the tool head housing and the tool body housing. The retainer is movably coupled to the other one of the tool head housing and the tool body housing. The retainer is received into the at least one recess to fixedly but removably couple the tool head to the tool body.
[0016] In a further form, the present teachings provide a power tool that includes a tool body, a tool head and a connection system. The tool body has a tool body housing and a drive system. The tool body housing defines a cavity and has a first handle with a portion that is configured to be gripped by a hand of a user of the power tool. The drive system includes a motor and an output member that is driven by the motor and rotatable about a rotational axis. The first handle has a first longitudinal axis that is aligned to a predetermined angle relative to the rotational axis. The predetermined angle is sized so that the longitudinal axis is closer to being parallel to the rotational axis than being perpendicular to the rotational axis. The tool head, which is configured to perform work on a work piece, includes a tool head housing and an input member. One of the tool body and the tool housing defines a mount, and the other one of the tool body and the tool housing defines a mating mount with a mount aperture that receives the mount. The input member is matingly engagable to the output member to drivingly couple the drive system to the tool head when the mount is inserted into the mount aperture. The connection system has at least one recess and a retainer. The at least one recess is formed in one of the mount and the mating mount. The retainer is movably coupled to the other one of the mount and the mating mount. The retainer is received into the at least one recess to fixedly but removably couple the tool head to the tool body.
[0017] In still another form, the present teachings provide a power tool system that includes a tool body and a tool head. The tool body has a body housing, a motor, an intermediate output member and a coupler. The body housing defines a tool head aperture and a pocket that is spaced apart from the tool head aperture. The motor is received in the body housing and drives the intermediate output member for rotation about an axis. The coupler includes a wire member and a push button. The wire member is housed in the body housing and has a pair of opposite engagement arms that extend into the tool head aperture. The push button is coupled to the wire member and is slidable between a first position and a second position. The tool head has a head housing, an intermediate input member, an output member. The head housing includes an attachment hub and a tongue that is spaced apart from and fixedly coupled to the attachment hub. The attachment hub has a generally cylindrical projection with at least one recess formed thereon. The attachment hub is received into the tool head aperture and the tongue being received in the pocket. Both the attachment hub and the tongue are non-rotatably engaged directly to the body housing. The engagement arms are received into the at least one recess to inhibit movement of the head housing along the axis in a direction away from the body housing. The intermediate input member is coupled to the intermediate output member for rotation therewith. The output member is drivingly coupled to the intermediate input member. The wire member biases the push button into the first position. Movement of the push button into the second position spreads the engagement arms apart from one another to permit the head housing to be withdrawn from the body housing along the axis.
[0018] In yet another form, the present teachings provide a power tool that includes a tool body housing, a drive system, and a tool head. The tool body housing is at least partly formed by a pair of clam shell housing members and defines a cavity. The drive system is housed in the cavity and includes a pneumatic motor and an output member that is driven by the pneumatic motor. The tool head, which is configured to perform work on a workpiece, has a tool head housing and an input member. One of the tool body and the tool housing defines a mount, and the other one of the tool body and the tool housing defines a mount aperture that receives the mount. The tool head is selectively interlocked to the tool body when the mount is inserted into the mount aperture. The input member is matingly engaged with the output member when the tool head is interlocked to the tool body.
[0019] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0020] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
[0021] FIG. 1 is a front perspective view of an exemplary sander constructed in accordance to the present teachings and shown operatively associated with a series of sander platens that can be interchangeably secured to the sander, FIG. 1 also including an enlarged plan view of an exemplary mode selector provided on the sander;
[0022] FIG. 2 is a side perspective view of an exemplary finishing sander platen;
[0023] FIG. 3 is a side perspective view of an exemplary random orbit sander platen;
[0024] FIG. 4 is a partial cut-away view of the sander and shown with the detail sander platen aligned prior to engagement with the tool body of the sander;
[0025] FIG. 5 is a partial cut-away view of the sander of FIG. 4 and shown with the detail sander platen selectively coupled to the tool body of the sander;
[0026] FIG. 6 is an exemplary plan view of a rotatable member having a fan and a counterweight and constructed in accordance to one example of the present teachings;
[0027] FIG. 7 is a plan view of another rotatable member including a fan and a counterweight constructed in accordance to additional features of the present disclosure;
[0028] FIG. 8 is a side perspective view of an exemplary random orbit sander platen and shown with a dual-outlet shroud according to one example of the present disclosure;
[0029] FIG. 9 is a partial cut-away view of the tool body of the sander and shown prior to engagement with a platen having the dual shroud;
[0030] FIG. 10 is an assembled view of an exemplary sander platen having the dual-outlet shroud and connected to the tool body of the sander, wherein one of the outlets is aligned for coupling with a plug and the other outlet is aligned for communicating air through a dust extraction port formed in the tool body;
[0031] FIGS. 11-14 illustrate an exemplary assembly sequence wherein an attachment assembly selectively couples with an attachment hub provided on an exemplary sander platen;
[0032] FIGS. 15 and 16 illustrate an exemplary sequence of releasing a sander platen from the tool body wherein a button of the attachment assembly is actuated causing a wireframe to spread and therefore release from engagement with a groove defined on the attachment hub;
[0033] FIGS. 17-19 illustrate an exemplary sequence of releasing a sander platen from the tool body wherein the button is actuated causing release of the wireframe from the groove defined in the attachment hub;
[0034] FIG. 20 is an exploded perspective view of the mode selector of FIG. 1 ;
[0035] FIG. 21 is a rear perspective view of a control panel of the mode selector of FIG. 20 and shown cooperating with a speed control switch;
[0036] FIG. 22 is a rear perspective view of the control panel of FIG. 21 and shown with the speed control switch and electrical communication with an on/off switch;
[0037] FIG. 23 is a side perspective view of a sander constructed in accordance to additional features of the present teachings;
[0038] FIG. 24 is a front perspective view of a pair of exemplary sander platens that include nubs that selectively communicate with a first and second plurality of notches provided on the sander for coupling a desired platen to the tool body of the sander;
[0039] FIG. 25 is a front perspective view of a sander constructed in accordance to additional features of the present teachings and shown operatively associated with a series of exemplary sander platens;
[0040] FIG. 26 is a bottom perspective view of the sander of FIG. 25 and shown with an exemplary key for selectively attaching a desired platen to the tool body;
[0041] FIG. 27 is a front perspective view of a sander constructed in accordance to additional features of the present teachings and including a dust collection canister;
[0042] FIGS. 28-30 are front perspective views of sanders constructed in accordance to additional features of the present disclosure and including elastomeric bellows;
[0043] FIG. 31 is a side perspective view of the exemplary sander platen of FIG. 28 and shown cooperating with elastomeric bellows for coupling the sander platen to the tool body;
[0044] FIG. 32 is a side perspective exploded view of the bellows associated with the sander platen of FIG. 31 ;
[0045] FIG. 33 is a front perspective view of a tool body and mode selector constructed in accordance to additional features of the present teachings;
[0046] FIG. 34 is a front exploded view of the mode selector of FIG. 33 including a central hub, a knob, a control panel and a wheel;
[0047] FIG. 35 is a rear perspective view of the mode selector of FIG. 34 ;
[0048] FIG. 36 is a front view of the mode selector shown with the knob located in a fourth position revealing a fourth image of the wheel through a window formed in the control panel; and
[0049] FIG. 37 is a front view of the mode selector illustrating the knob in a second position corresponding to the second image of the wheel being viewable through the window in the control panel.
DETAILED DESCRIPTION
[0050] Example embodiments will now be described more fully with reference to the accompanying drawings. Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
[0051] With initial reference to FIGS. 1-5 , an exemplary abrasive material removal tool is generally indicated by reference numeral 10 . The abrasive material removal tool, hereinafter sander 10 , can include a tool body or housing 12 having a pair of clam shell portions 14 and 16 . The sander 10 can further include a drive system 18 that is housed in a cavity defined by the clam shell portions 14 and 16 . The tool body 12 and the drive system 18 can be conventional in their construction and operation, and as such, need not be discussed in significant detail herein. The tool body 12 can further define a dust extraction port 20 ( FIG. 4 ) to which dust can be extracted to a dust chamber 21 . The drive system 18 can selectively couple with a plurality of platens, collectively referred at reference numeral 22 as will be described in greater detail herein.
[0052] A mode selector 24 can be arranged on a forward portion of the tool body 12 . The mode selector 24 can include a movable member or dial 26 and a pictorial key 28 . A base release button 30 can be provided proximate to the mode selector 24 . A power cord 32 can extend from the tool body 12 to supply electrical current to the sander 10 . It is appreciated that while the sander 10 is shown operatively associated with a power cord 32 for alternating current (AC) operation, the sander 10 can also be configured for operation with other power sources, such as direct current (DC) or a pneumatic input.
[0053] The sander 10 will be further described. The drive system 18 can include an electric motor 36 ( FIG. 4 ) mounted within the tool body 12 and having an output member 38 . In the exemplary configuration, the output member 38 can define a male spline 40 . A fan (not shown) can be mounted on the output member 38 for rotation therewith. The fan can include a plurality of upwardly projecting blades generally arranged to direct air toward the motor 36 . In this manner, the upwardly projecting fan blades can operate to generate a cooling air flow when the motor 36 is turned on to help cool the motor 36 during operation of the sander 10 . A bearing 44 can radially support the output member 38 .
[0054] With specific reference now to FIGS. 1-7 , the exemplary platens 22 will be described in greater detail. According to the present teachings, each of the plurality of platens 22 can be releasably connected to the tool body 12 without the use of a hand tool (such as a screwdriver, Allen wrench, etc.). The exemplary platens 22 can include a finishing sander platen 50 , a detail sander platen 52 , and a random orbit sander platen 54 . The detail sander platen 52 can include a releasable finger attachment 56 for detail sander. As will be described, the finishing sander platen 50 and detail sander platen 52 are configured for orbital motion while the random orbit sander platen 54 is configured for random orbit motion. U.S. Pat. Nos. 6,132,300 and 5,885,146 provide examples of abrading tools that provide orbital and random orbit motion. These patents are hereby incorporated by reference as is fully set forth in detail herein.
[0055] The finishing sander platen 50 can define a substantially flat bottom surface 62 , a curved upper surface 64 , and a peripheral edge with a point 66 that provides the finishing sander platen 50 with an iron-shape. The point 66 can be used for sander corners or other areas. In one example, an abrasive sheet (not shown) can be applied to the flat bottom surface 62 by way of a hook and loop fabric fastener. An underside of the abrasive sheet can have a first hook and/or loop surface, which can be attachable to a second hook and/or loop surface (not shown) provided on the flat bottom surface 62 of the finishing sander platen 50 .
[0056] According to one example, a portion 68 of the finishing sander platen 50 , adjacent to the point 66 of the peripheral edge, can be detachable from the remainder of the finishing sander platen 50 . The detachable portion 68 can be loosened or completely detached from the finishing sander platen 50 and rotated through 180°, or even replaced, as the edges on either side of the point become worn. Further details of the detachable portion 68 can be found in commonly owned U.S. Pat. No. 5,839,949, which is hereby incorporated by reference as if fully set forth in detail herein. As can be appreciated, the finger attachment portion 56 of the detail sander platen 52 can occupy the space of an otherwise located point 66 (i.e., see finishing sander platen 50 ). Those skilled in the art will readily appreciate that the shape and configuration of the finishing sander platen 50 and detail sander platen 52 are substantially equivalent, the finishing sander platen 50 being configured for mounting to the tool body 12 with a flat forward end 70 facing toward the front of the sander 10 , whereas the detail sander platen 52 , having the finger attachment 56 , can be secured to the tool body 12 having the finger attachment 56 being oriented toward the forward end of the sander 10 . Those skilled in the art will also appreciate that the detail sander platen 52 can also be mounted to the sander 10 without the finger attachment 56 .
[0057] With specific reference to FIGS. 2 and 4 , the finishing sander platen 50 can further define a plurality of elastomeric legs 72 . In the example shown, four elastomeric legs 72 are used, one pair toward the front of the sander 10 and another pair disposed toward the rear of the sander 10 . First ends 76 of the elastomeric legs 72 can be selectively received by mounting hubs 78 defined in the front and rear clam shell portions 14 , 16 . Second ends 80 of the elastomeric legs 72 can be fixedly secured to the finishing sander platen 50 by mounting bosses 79 . Other configurations may be employed for securing the elastomeric legs 72 between the tool body 12 and the finishing sander platen 50 .
[0058] The finishing sander platen 50 can further define a centrally located attachment hub 82 and a chute 84 . The attachment hub 82 can generally house a rotatable member 88 ( FIG. 6 ). The rotatable member 88 can generally be in the form of a fan 90 having a counterweight 92 . The fan 90 can be configured to direct air through the chute 84 and into the dust extraction port 20 . The rotatable member 88 can define a mounting hub 93 that aligns for rotation with a female spline 94 that cooperatively receives the male spline 40 of the output member 38 in an installed position. The mounting hub 93 can be offset from a central axis 98 of the rotatable member 88 . As can be appreciated, the offset can be any suitable distance to provide an orbital motion of the finishing sander platen 50 during operation. In one example, the offset can be 2 mm. Other configurations are contemplated. For example, other finishing sander platens may be provided having other offsets.
[0059] With reference again to FIGS. 2 and 4 , the attachment hub 82 can define a chamfered annular leading edge 100 . The attachment hub 82 can further define a groove 102 defined around a cylindrical outboard surface 104 . A shroud 106 can be defined on the finishing sander platen 50 . The shroud 106 can generally surround the rotatable member 88 . In one example, the attachment hub 82 , the chute 84 and the shroud 106 can be monolithic or integrally formed.
[0060] As can be appreciated, the detail sander platen 52 can be constructed similarly to the finishing sander platen 50 . Therefore, a detailed description of the detail sander platen 52 will not be repeated. As illustrated, however, a chute 84 ′ ( FIG. 1 ) can be arranged proximate to its rearward end (i.e., its flat end 70 ′) for cooperatively aligning with the dust extraction port 20 provided in the tool body 12 . An attachment hub 82 ′ can house a rotatable member 88 ′ ( FIG. 1 ).
[0061] With specific attention now to FIGS. 3 and 7 , the random orbit sander platen 54 can generally define a circular platen body 114 having an attachment hub 116 . Those skilled in the art will recognize that the random orbit sander platen 54 is not constrained outboard of the attachment hub 116 (i.e., such as with elastomeric legs) allowing a random orbit sander 54 to move in a motion during use. The attachment hub 116 can be formed generally equivalent to the attachment hub 82 described above with respect to the finishing sander platen 50 . Housed within the attachment hub 116 is a rotatable member 120 ( FIG. 7 ). The rotatable member 120 can define a similar mounting hub 93 ′, fan 90 ′ and counterweight 92 ′ arrangement as described above with respect to the fan 90 , counterweight 92 and mounting hub 93 . The rotatable member 120 , however, can define a distinct offset (e.g. the mounting hub can be offset from its central axis) as compared to the orbit sander platens 50 and 52 , described above. In one example, the offset can be about 4 mm. In another example, the offset can be 2 mm and the orbit can be 4 mm. It is appreciated, however, that each of the platens 22 can define mounting hubs (i.e., 93 ) that have an offset relative to a central axis of the rotatable member (i.e., 88 ) for providing a desired offset according to a given application. It is also appreciated that each of the counterweights (i.e., 92 ) can be provided with a mass that is specific to a given platen (i.e., 50 , 52 or 54 ).
[0062] Turning now to FIGS. 8-10 , a shroud 130 constructed in accordance to another example is shown. The shroud 130 includes a first chute 132 and a second chute 134 formed thereon. The shroud 130 can be integrally formed with an attachment hub 136 . The attachment hub 136 can be formed equivalently to the attachment hubs 82 and 116 described above. Those skilled in the art will recognize that the shroud 130 , having first and second chutes 132 and 134 , can operatively align with the dust extraction port 20 in either a forward mounted position (i.e., the pointed end aligned with the front of the sander 10 for an iron-shaped platen) or a rearward mounted position (i.e., the flat end arranged toward the front of the sander 10 ). In one example, a plug 140 can be provided in the tool body 12 for aligning with an unused chute 132 , 134 . In one example, the plug 140 can be formed of a compliant material and be generally captured by one of, or both of the clam shell housings 14 , 16 . According to one example, a dust chute connector 144 can be interposed between the functioning chute 132 or 134 and the dust extraction port 20 . It is appreciated that the shroud 130 can be adapted for use with any of the platens 22 disclosed herein. For example, the shroud 130 is shown in FIG. 8 operatively associated with a circular random orbit sander platen, whereas the shroud 130 is shown in FIGS. 9 and 10 cooperatively with an iron-shaped finishing sander platen.
[0063] With renewed reference now to FIGS. 4 and 5 , the sander 10 can include an attachment assembly 150 for releasably coupling the respective sander platens 22 to the tool body 12 . The attachment assembly 150 can generally include the button 30 , a retaining member or wireframe 152 and a spreader block 154 . In the exemplary embodiment, the retaining member 152 is in the form of a wireframe. However, other configurations are contemplated. In general, the wireframe 152 can selectively nest with the groove (i.e., groove 102 ) of a respective attachment hub (i.e., attachment hub 82 ).
[0064] As mentioned above, the attachment assembly 150 can selectively couple with an identified sander platen 22 without the use of a hand tool (such as a screwdriver or Allen key, etc.). An exemplary method of attaching the finishing sander platen 50 according to one example of the present teachings will now be described with reference to FIGS. 4, 5 and 11-19 . It is appreciated that attaching (and removing) other platens (i.e., 52 or 54 ) will be carried out similarly. At the outset, a user can generally align the female spline 94 of the rotatable member 88 with the male spline 40 of the output member 38 ( FIG. 4 ). Concurrently, a user can align the first ends 76 of the legs 72 with the respective hubs 78 defined in the tool body 12 . The user can then urge the tool body 12 downwardly (and/or the finishing sander platen 50 in a direction upward) as viewed in FIG. 11 . During such motion, the wireframe 152 can slidably urge over the chamfered annular leading edge 100 of the attachment hub 82 causing the wireframe 152 to generally spread outwardly until the wireframe 152 “snaps” into the groove 102 (see sequence of FIGS. 11-14 ). Those skilled in the art will appreciate that the wireframe 152 can have spring-like characteristics, such that in its relaxed state, the wireframe 152 can occupy a nested position within the groove 102 and therefore retain a respective sander platen 22 . In one example, the wireframe 152 can be formed of a metallic material. Those skilled in the art will appreciate that the attachment assembly 150 and/or the wireframe 152 can be configured differently. During the advancement of the attachment hub 82 toward the tool body 12 , the first ends 76 of the legs 72 can nest into the respective hubs 78 defined in the tool body 12 .
[0065] An exemplary method of releasing the finishing sander platen 50 according to the present teachings will now be described. Again, it is appreciated that releasing other platens (i.e., 52 or 54 ) will be carried out similarly. A user can push the base release button 30 inwardly (i.e., in a direction leftward as viewed in FIG. 16 ). Movement of the base release button 30 in a direction leftward (i.e., into the tool body 12 ) can cause the button to slide along the wireframe 152 and therefore urge an intermediate portion of the wireframe 152 to spread radially out of engagement with the groove 102 . With the wireframe 152 in a position clear from the groove 102 ( FIGS. 16 and 19 ), a user can then pull the finishing sander platen 50 in a direction downward (i.e., in a direction along an axis defined by the female spline 94 ) and away from the tool body 12 .
[0066] With reference now to FIGS. 1 and 20-22 , the mode selector 24 will be described in greater detail. The mode selector 24 can generally define a control panel 160 that rotatably supports the movable member 26 to a backing plate 162 by way of a threaded fastener 164 and washer 166 . A rear face 170 of the control panel 160 can define a pair of supports 172 that mount a pair of detent springs 176 , respectively. The backing plate 162 can define a plurality of depressions 180 formed around its annular surface. As will be described, the detent springs 176 can selectively nest within an aligned pair of depressions 180 to positively locate the movable member 26 at a desired operating location. The backing plate 162 can further define a rib 182 . The rib 182 can be aligned with a toggle bar 184 associated with a speed control switch 188 . According to one example, the toggle bar 184 can toggle between a first and second position upon movement of the rib 182 across the toggle bar 184 . As will be described, the first and second position can correspond to a first and second speed of the motor 36 (and therefore the output member 38 ).
[0067] An exemplary circuit associated with the mode selector 24 will be described briefly. The speed control switch 188 can include a diode 192 . The speed control switch 188 can be electrically connected to an on/off switch 194 of the sander 10 . In one example, when the speed control switch 188 is moved to the first or “on” position, current bypasses the diode 192 and the sander 10 runs at full speed. When the speed control switch 188 is turned to the second or “off” position, the current is forced through the diode 192 and the voltage is dropped causing the motor 36 (and, as a result, the output member 38 to rotate at a reduced speed).
[0068] With reference again to FIG. 1 , the pictorial key 28 of the mode selector 24 will be described in greater detail. As shown, the pictorial key 28 can have a first outer zone 200 , a second outer zone 202 , and a third outer zone 204 . In one example, each of the first, second and third outer zones 200 , 202 , and 204 can include graphical information, such as photos and/or sketches that correspond to a given sander task. As illustrated, the first outer zone 200 can include a graphic with a pictorial representation of the detail sander platen 52 . The second outer zone 202 can have a graphical representation of the finishing sander platen 50 . The third outer zone 204 can have a graphical representation of the random orbit sander platen 54 . In one example, each of the outer zones can be color-coded with a distinct color. In addition, a picture of a turtle can be provided on the first outer zone 200 and a picture of a rabbit can be provided on the third outer zone 204 . As can be appreciated, a rotational orientation of the movable member 26 pointing toward the third outer zone 204 can correspond with the first speed and with the toggle bar 184 in the first position, such that the speed control switch 188 is in the “on” position. Likewise, when the movable member 26 rotated to be pointed toward the first outer zone 200 , the toggle bar 184 is toggled to the second position (via movement of the rib 182 across the toggle bar 184 ) corresponding to the speed control switch 188 in the “off” position. It is appreciated that additional speed settings may be provided according to the outer zones and/or the inner zones (described below). It is contemplated that a potentiometer could be implemented to control speed.
[0069] According to other examples, indicia can be arranged around the pictorial key 28 that correspond to a grit value of sand paper optimized for a given task. Additionally or alternatively, the pictorial key 28 can have a graphic (e.g. picture, sketch, photograph, etc.) that corresponds to an exemplary article for sander (i.e., a door, a table, a pedestal, etc.). The grit value and picture of the article to be sanded can be arranged as a first inner zone 205 , a second inner zone 206 , a third inner zone 207 , a fourth inner zone 208 and a fifth inner zone 209 . It can be appreciated that while the mode selector 24 has been shown and described above in connection to a movable member 26 that rotates around an axis in the form of a dial or pointer, the mode selector can take alternate forms. For example, the mode selector 24 can alternatively comprise a lever configured for linear movement or other configurations.
[0070] With reference now to FIGS. 23 and 24 , a sander 210 constructed in accordance to another example of the present teachings is shown. Except as otherwise described, the sander 210 can comprise the features as discussed herein with respect to other sanders. The sander 210 can generally include a tool body or housing 212 having a pair of clam shell portions 214 and 216 . The sander 210 can further include a drive system 218 that is housed in a cavity defined by the clam shell portions 214 and 216 . The tool body 212 and the drive system 218 can be conventional in their construction and operation, and as such, need not be discussed in significant detail herein. A mode selector 224 can be rotatably coupled to the tool body 212 . As with the tool 10 described above, the sander 210 can be configured for selectively mating with a plurality of platens 222 . An underside of the mode selector 224 can define a first plurality of notches 225 formed around an annular ring 226 . The first plurality of notches 225 can cooperatively align with a second plurality of notches 227 defined in the tool body 212 . The mode selector 224 can further define a pictorial key 228 arranged therearound. The pictorial key 228 can define similar graphical representations as described above with respect to the pictorial key 28 . In the mode selector 224 , according to this example, however, the pictorial key 228 of the mode selector 224 is rotated to align with an arrow 230 provided on the tool body 212 .
[0071] The plurality of platens 222 can define a finishing sander platen 250 and a random orbit sander platen 254 . Other platens may be provided. The detail sander platen 252 can define an attachment hub 260 that includes a series of nubs 262 extending outwardly around a shroud 264 thereof. A female spline 268 can be provided on the finishing sander platen 250 and be configured for meshingly engaging a male spline 270 provided on an electric motor 272 of the drive system 218 . The nubs 262 are configured for slidably aligning and inserting into corresponding first and second notches 225 and 227 defined on the ring 226 of the mode selector 224 and the tool body 212 , respectively. As can be appreciated, the first plurality of notches 225 will be rotationally aligned with specific second plurality of notches 227 for accepting the correct platen 222 that corresponds with a given graphic provided on the pictorial key 228 aligning with the arrow 230 .
[0072] The random orbit sander platen 254 can include nubs 274 arranged around an attachment hub 276 . A tongue 280 can extend outwardly adjacent from the attachment hub 276 . The tongue 280 can be configured to cooperatively nest in a pocket 282 formed on the tool body 212 . As illustrated, the nubs 274 are located at a radially distinct location around the attachment of 276 as compared to the nubs 262 arranged around the attachment hub 260 . As can be appreciated, once a user rotates the mode selector 224 to a location in which a graphic of the pictorial key 228 that illustrates the random orbit sander platen 254 is aligned with the arrow 230 , the nubs 274 cooperatively align with predetermined notches 225 (of the ring 226 of the mode selector 224 ) and notches 227 (of the tool body 212 ). As can be appreciated, the rotational orientation of the notches 225 , 227 will permit attachment with only the sander platen 222 identified in the pictorial key 228 aligned with the arrow 230 . Therefore, attachment of other sander platens 222 is precluded.
[0073] It is appreciated that while the above embodiment has been described in association with “notches” and “nubs” other geometries may be provided for selectively keying specific platens to the tool body 212 .
[0074] While not specifically shown, a rotatable member can be provided in the respective attachment hubs 260 and 276 that can be configured to provide a desired offset and/or counterbalance mass according to a given task. Also, while not specifically shown, the platens 222 can be selectively coupled to the sander 210 , such as by way of an attachment assembly (see attachment assembly 150 described above), or other methods of attachment.
[0075] Turning now to FIGS. 25 and 26 , a sander 310 according to another example, of the present teachings is shown. Except as otherwise described, the sander 310 can comprise the features as described in herein with respect to other sanders. The sander 310 can include a tool body or housing 312 having a pair of clam shell portions 314 and 316 . The sander 310 can further include a drive system 318 that is housed in a cavity defined by the clam shell portions 314 and 316 . The tool body 312 and the drive system 318 can be conventional in their construction and operation, and as such, need not be discussed in significant detail herein. The drive system 318 can selectively couple with a plurality of platens, collectively referred to a reference 322 . The sander 310 can include a window 324 that provides viewing access to a wheel 326 . In one configuration, the wheel 326 can define a pictorial key 328 . The pictorial key 328 can include a first zone 330 , a second zone 332 , and a third zone 334 . The respective zones 330 , 332 and 334 can correspond to a graphic (i.e., picture, sketch) that illustrates the shape of a given platen 322 as well as a directional path that such given platen 322 will operate in.
[0076] The platens 322 can include a finishing sander platen 350 , a random orbit sander platen 354 , and a square footprint detail sander platen 356 . According to one example, a finger, or other structure 360 , such as shown on the detail sander platen 356 can be provided for rotating the wheels 326 into a rotational position that corresponds to the zone (i.e., 330 , 332 , or 334 ) associated with the attached platen 322 being viewed through the window 324 . In one example, a flip key 366 can extend from the output member 338 of the sander 310 . The flip key 366 can pass through the corresponding opening 370 , shown on the finishing sander platen 350 and rotated to a secured position to lock a given platen 322 relative to the tool body 312 . While not specifically shown, a similar opening is defined on the other platens 354 and 356 . The flip key 366 can also be provided on other sanders disclosed herein for securing other platens described herein.
[0077] Turning now to FIG. 27 , a sander 410 according to additional features of the present teachings is shown. Except as otherwise described, the sander 410 can comprise the features as described herein with respect to other sanders. The sander 410 can be constructed similar to the sanders 10 , 210 and 310 described above and also include a dust extraction fan 411 provided in a canister 413 of the tool body 412 . Because a dust extraction fan 411 is provided in a canister 413 , a plurality of platens (i.e., such as 350 , 354 and 356 , FIG. 25 ) can include rotatable members tuned for each platen. As such, each rotatable member can define a counterweight mass and offset, but without a fan (i.e., the fan 90 described above in relation with the sander 10 ).
[0078] Turning now to FIGS. 28-30 , a sander 510 constructed in accordance with additional features of the present teachings is shown. Except as otherwise described, the sander 510 can comprise the features as described herein with respect to other sanders. The sander 510 can include a tool body or housing 512 having a pair of clam shell portions 514 and 516 . The sander 510 can further include a drive system 518 that is housed in a cavity defined by the clam shell portions 514 and 516 . The tool body 512 and the drive system 518 can be conventional in their construction and operation, and as such, need not be discussed in significant detail. The drive system 518 can selectively couple with a plurality of platens. The platens are shown as a finishing sander platen 520 ( FIG. 28 ), a random orbit sander platen 522 ( FIG. 29 ) and a square finishing sander platen 524 ( FIG. 32 ). The sander 510 provides elastomeric bellows 528 for securing a respective platen 520 , 522 , 524 to the tool body 512 .
[0079] As shown in FIG. 29 , the elastomeric bellows 528 is shown coupled between a plate 530 having a fan shroud 532 and an exemplary finishing sander platen 520 . The fan shroud 532 can generally bound a fan 534 adapted for cooling the motor. The plate 530 can further define a dust chute 536 that is configured to exhaust air through a dust extraction chute (such as dust extraction chute 20 ). Referring to FIG. 30 , the elastomeric bellows 528 can couple between a pair of hose clips 560 . The hose clips 560 can couple on opposite ends to the plate 530 and a securing plate 562 . In one example, the securing plate 562 can define bosses 566 for selectively receiving pegs 568 formed on the finishing sander platen 520 . The elastomeric bellows 528 provides an enclosure for effective dust extraction.
[0080] Turning now to FIGS. 33-37 , a mode selector 624 constructed in accordance to additional features of the present teachings will be described. The mode selector 624 can be operably disposed on a tool body 612 and can include a movable member 630 , a control panel 632 , a wheel 634 ( FIG. 34 ) and a central hub 636 . The movable member 630 can be in the form of a dial or knob. The movable member 630 can have an indicator 640 formed thereon. The control panel 632 can include a pictorial key 642 that includes graphics in a first zone 644 a, a second zone 644 b, a third zone 644 c and a fourth zone 644 d. As will become appreciated, the movable member can be configured to rotate, such that the indicator 640 is aligned with a preferred graphic on the pictorial key 642 according to the desired sanding task. The control panel 632 can also define an opening 648 , a window 650 and a button passage 652 . The control panel 632 can also define recesses 654 adjacent to the opening 648 for selectively receiving a cap 658 that is biased by a spring 660 in a nested position. The biased cap 658 can give a user positive tactile feedback that the movable member 630 is located at the desired position aligned with a respective zone 644 a - 644 d of the pictorial key 642 . In an assembled position, a stem 661 of the central hub 636 locates through an opening 662 formed in the movable member 630 , through the opening 648 in the control panel 632 and couples with a hub 663 on the wheel 634 . The movable member 630 , the central hub 636 and the wheel 634 can then collectively rotate relative to the opening 648 of the control panel 632 .
[0081] The wheel 634 can include a first image 664 a, a second image 664 b , a third image 664 c, and a fourth image 664 d. The wheel 634 is fixed for rotation with the movable member 630 , such that one of the first through fourth images 664 a - 664 d can be viewable through the window 650 . The images 664 a - 664 d correspond with the appropriate graphic 644 a - 644 d on the pictorial key 642 according to the desired task identified by the user. Explained further, and as illustrated in FIGS. 36-37 , a user can rotate the movable member 630 from the location shown in FIG. 36 to the location shown in FIG. 37 when it is desired to change the sanding task. While not expressly described here, rotation of the movable member 630 can cooperate with a speed control switch, such as the speed control switch 188 to correspond with first and second speeds of the motor as described above in relation to FIGS. 20-22 .
[0082] As illustrated in FIG. 36 , the movable member 630 is shown rotated to a location, such that the indicator 640 is pointing at the fourth zone 644 d. Also shown in FIGS. 36 and 37 , a button 653 constructed similar to the button 30 described above is shown extending through the button passage 652 . Because the movable member 630 is rotatably fixed with the wheel 634 , this position corresponds to the fourth image 664 d of the wheel 634 to be viewable through the window 650 of the control panel 632 . In the example shown in FIG. 37 , the user can rotate the movable member, such as in a counterclockwise direction until the indicator 640 is pointing at the second zone 644 b of the pictorial key 642 . In this position, the second image 664 b is viewable through the window 650 of the control panel 632 .
[0083] While not specifically shown, those skilled in the art will appreciate that the first image 664 a of the wheel 634 will be viewable through the window 650 when the indicator 640 is pointing at the first zone 644 a of the pictorial key 642 . Similarly, the third image 644 c of the wheel 634 will be viewable through the window 650 of the control panel 632 when the indicator 640 is pointing at the third zone 644 c of the pictorial key 642 . According to additional examples, the respective images 664 a - 664 d can be provided with different colors indicating that some of the selected modes of sanding can include a change in motor speed. It is also appreciated that the mode selector 624 and related features can be configured for operation with any of the sanders described herein.
[0084] Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
[0085] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
[0086] When an element or layer is referred to as being “on”, “engaged to”, “connected to” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to”, “directly connected to” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
[0087] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
[0088] Spatially relative terms, such as “inner,” “outer,” “beneath”, “below”, “lower”, “above”, “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
[0089] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the invention, and all such modifications are intended to be included within the scope of the invention.
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A power tool that includes a tool body housing, a drive system, a tool head and a connection system. The drive system is housed in the tool body housing. The tool head, which is configured to perform work on a work piece, includes a tool head housing and an input member that is driven by the drive system when the tool head is coupled to the tool body housing. The tool head can be engaged to the tool body housing in at least two pre-defined and distinct orientations. The connection system secures the tool head to the tool body housing in each of the at least two pre-defined and distinct orientations.
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BACKGROUND OF THE INVENTION
The invention relates to a controller for controlling an actuator for a magnetic valve, and more specifically to a controller for an electromagnetic actuator for driving a valve of an engine mounted on such apparatus as an automobile and a boat.
Valve driving mechanism having an electromagnetic actuator has been known and called a magnetic valve. An electromagnetic actuator typically includes a moving iron or an armature which is placed between a pair of springs with given off-set load so that the armature positions at an intermediate part of a pair of electromagnets. A valve is connected to the armature. When electric power is supplied to the pair of electromagnets alternately, the armature is driven reciprocally in two opposite directions thereby driving the valve. Conventionally, the driving manner is as follows.
1) The magnetic attraction power that one of the electromagnets provides to the armature overcomes rebound power by the pair of springs and attracts the armature to make it seat on a seating position. The armature (valve) is released from the seating position by such a trigger as suspension of power supply to the electromagnet, and starts to displace in a cosine function manner by the force of the pair of springs.
2) At a timing according to the displacement of the armature, an appropriate current is supplied to the other electromagnet to produce magnetic flux which generates attraction force.
3) The magnetic flux rapidly grows as the armature approaches the other electromagnet that is producing the magnetic flux. The work by the attraction power generated by the other electromagnet overcomes the sum of (i) a small work by the residual magnetic flux produced by the one electromagnet which acts on the armature to pull it back and (ii) a mechanical loss which accounts for a large portion of the sum of work. Thus, the armature is attracted and seats on the other electromagnet.
4) At an appropriate timing as the armature seats, a constant current is supplied to the other electromagnet to hold the armature in the seated state.
In maintaining the armature in the seated state, it is desirable to supply the minimum driving current that can hold the armature in the seated state so as to minimize power consumption. However, when a minimum current is used every time the armature is to be held in the seated state, the armature moved to a seating position may from time to time leave the seating position due to secular changes of the electromagnetic actuator and/or variations of the movement. When the armature falls or lifts (collectively referred to as “leave”) from the seating position, such situation needs to be detected immediately and power supply needs to be boosted to pull the armature back to the seating position.
Conventionally, leaving of the armature was detected based on signals from a displacement sensor that detects displacement of the armature. Specifically, leaving (falling or lifting) of the armature is determined by detecting a situation that the sensor output does not indicate seated state of the armature in the period that the armature is in the seated state. In response to determination of leaving of the armature, a large current is supplied to the windings of the electromagnet to activate pullback operation immediately so that the armature may be pulled back to the seating position.
However, the conventional method includes the following problems. The air gap between the armature and the yoke of the electromagnet is very small when the armature is seated. The electromagnetic actuator has a very small magnetic reluctance when the armature is seated. When a constant current is supplied for holding the armature in the seated state, if the armature leaves the seating position by a small distance for some reasons, say less than 10 μm from the seating position, the attraction force decreases. It is very difficult to detect such a small movement with the displacement sensor. For example, when the armature moves in the range of 7 mm in order to open and close a valve of an automobile engine, the displacement sensor can only detect the movement of the armature which is larger than {fraction (1/100)} of the moving range. That is, the sensor can only detect armature movement larger than 70 μm due to noise and performance of the sensor. Leaving (falling or lifting) detection at 70 μm point is too late to ensure pullback operation of the armature.
In addition, when pullback operation is activated at 70 μm point, a larger current needs to be supplied, thereby increasing power consumption. This requires to increase the capacity of a driver element such as a field effect transistor, raising the cost of the driving circuit. Furthermore, a large current and the air gap produced by the leaving armature cause a large magnetic energy to be accumulated in the air gap. This magnetic energy is converted into kinetic energy of the armature and valve when the armature is attracted again to the seating position. As a result, seating speed of the armature becomes large producing a large collision sound when the armature seats.
As a specific example, a case for repetitively activating an electromagnetic actuator at a high speed as in the case of a valve train of an engine is described referring to FIG. 15 . The left vertical axis shows the magnitude of displacement of the armature (mm) and current (A) supplied to the electromagnet. The right vertical axis shows attraction power (N) and voltage (V) applied to the electromagnet. As shown in the figures, the minimum attraction power (falling limit or leaving limit) that prevents the armature from leaving from the seating position is 485 N.
FIG. 15 ( a ) shows a case in which the armature seats normally and a stable seated state is maintained. At time 0, the armature is released from one electromagnet and starts to move toward the other electromagnet by the operation of a pair of springs. During the period from time Te to Th, a constant voltage 42V is applied to the other electromagnet (over-excitation operation) to make the armature seat on the other electromagnet. After that, since the attraction force is a little larger than the leaving limit, a stable seated state is maintained. After the armature is seated, switching control of voltages 0 and +12V is performed to supply a constant holding current to the electromagnet.
FIG. 15 ( b ) shows a case where a seated armature leaves the seating position. A displacement sensor detects the leaving movement of the armature when the armature reaches 70 μm point, which is 1% of the lift (movement) range of 7 mm. A pullback operation is immediately initiated. The armature reaches 70 μm point around time 6.33 ms. For 0.5 ms from time 6.33 ms, over-excitation voltage is applied. The voltage application period is determined according to the leaving extent (70 μm).
After voltage application finished, a holding current value is renewed to a value which is larger than the preset normal holding current value by a predetermined value (for example, the predetermined value is 10% of the normal holding current value). Switching control of voltages of ±12V is carried out until the current converges into the renewed target holding current value. In the example shown in the figure, the switching control is carried out for 0.7 ms. Thereafter, switching control of voltages of +12V and 0V is performed so that current supplied to the electromagnet maintains the target holding current value.
In the example shown in FIG. 15 ( b ), the armature leaves the seating position about 0.22 mm and is pulled back. The energy needed for the pullback is about 0.12 J. The seating speed (not shown) of the armature at pullback is approximately 0.6 m/s, which generates collision noise. Thus, activating pullback operation responsive to detection of the leaving armature by the displacement sensor causes delay in the pullback operation and requires a large energy for pullback. It produces a large seating speed leading to collision noise.
Thus, there is a need for a controller for an electromagnetic actuator which enables detection of a minute movement of the armature leaving the seating position and carries out pullback operation responsive to such detection.
SUMMARY OF THE INVENTION
According to one aspect of the invention, a controller is provided for controlling an electromagnetic actuator having a pair of springs acting on opposite directions, and an armature coupled to a mechanical element. The armature is connected to the springs and held in a neutral position given by the springs when the actuator is not activated. The actuator includes a pair of electromagnets for driving the armature between two end positions. The controller comprises current supplying means for supplying holding current to the electromagnet corresponding to one of the end positions when holding the armature in said one of the end positions. The controller includes means for determining that the armature is leaving the seated position when the holding current increases more than a predetermined value while the holding current is supplied to the electromagnet corresponding to said end position.
According to the invention, leaving armature is detected based on the variation of the holding current, which allows earlier detection of the leaving armature.
According to another aspect of the invention, the controller further comprises pullback means, responsive to determination of leaving of the armature, for applying voltage to the electromagnet corresponding to the end position, thereby pulling back the armature to the end position.
Because pullback operation is activated responsive to detection of leaving armature in terms of variation in the holding current, quick pullback is realized with relatively small energy.
According to further aspect of the invention, the current supplying means raises the holding current by a predetermined value. The holding current is supplied to the electromagnet corresponding to the end position after voltage is applied to the electromagnet by the pullback means.
Because the holding current is set to a relatively large value after the armature is pulled back from leaving, the armature will be prevented from leaving thereafter.
According to an aspect of the invention, the controller further includes setting means for setting the period for applying voltage to the electromagnet by said pullback means, in accordance with the difference between the time the armature leaves the seating position as determined by said determination means and a schedule release time of the armature. When the armature leaves, the period of the pullback operation can be controlled according to the timing of the release movement of the armature.
According to another aspect of the invention, the setting means shortens the period of voltage application to the electromagnet by said pullback means when the difference between the time the armature leaves the seating position as determined by said determination means and a scheduled release time of the armature is equal to or less than a predetermined value. Thus, delay of release operation of the armature is avoided.
According to yet another aspect of the invention, the controller includes a counter for counting the number of times the armature is held in the end position without leaving over a sequence of cycles. When the number of times shown by the counter is larger than a predetermined value, the supplying means decreases the holding current to supply to the electromagnet corresponding to said end position. Thus, optimization of the holding current for respective electromagnetic actuators can be realized.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general block diagram of a controller for an electromagnetic actuator according to one embodiment of the invention.
FIG. 2 shows a mechanical structure of an electromagnetic actuator according to one embodiment of the invention.
FIG. 3 shows the behavior of various parameters according to one embodiment of the invention when the armature leaves the seating position.
FIG. 4 is a functional block diagram of a controller of an electromagnetic actuator according to one embodiment of the invention.
FIGS. 5 a and 5 b shows the behavior of various parameters in pullback operation when the armature leaves the seating position.
FIG. 6 shows the behavior of various parameters in normal operation of the armature according to one embodiment of the invention.
FIG. 7 shows the behavior of various parameters when the armature leaves the seating position around the scheduled release time according to one embodiment of the invention.
FIG. 8 shows the behavior of various parameters when the armature leaves around the scheduled release time, and pullback operation has been carried out according to one embodiment of the invention.
FIG. 9 illustrates relationship between Tr−Tf and Tγ.
FIG. 10 shows the behavior of various parameters according to one embodiment of the invention.
FIG. 11 is a flowchart showing general flow of controlling an electromagnetic actuator according to one embodiment of the invention.
FIG. 12 is a flowchart showing over-excitation operation according to one embodiment of the invention.
FIG. 13 is a flowchart showing holding operation according to one embodiment of the invention.
FIG. 14 is a flowchart showing post-pullback current control according to one embodiment of the invention.
FIGS. 15 ( a ) and ( b ) show behavior of various parameters according to a conventional.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, specific embodiments of the invention will be described. FIG. 1 is a block diagram showing a general structure of a controller for an electromagnetic actuator. A controller 1 comprises a microcomputer which includes a central processing unit 2 (CPU 2 ), a read only memory (ROM) 3 for storing computer executable programs and data, a random access memory (RAM) 4 providing a working space for the CPU 2 and storing results of operations by the CPU 2 . The controller 1 also includes an input-output interface (I/O interface) 5 .
I/O interface 5 receives signals from various sensors 25 which include signals relating to engine speed (Ne), engine water temperature (Tw), intake air temperature (Ta), battery voltage (VB), and ignition switch (IGSW). I/O interface 5 also receives a signal indicating desired torque, an output from a detector 26 for detecting a required load. For example, the detector 26 can include an accelerator pedal sensor, which detects the magnitude of movement of an accelerator pedal.
A drive circuit 8 supplies electric power provided from a constant voltage source 6 based on a control signal from the controller 1 to a first electromagnet 11 and to a second electromagnet 13 of an electromagnetic actuator 100 . In one embodiment of the invention, electric power for attracting the armature is supplied as a constant voltage, and electric power for holding the armature in a seating position is supplied as a constant current. Constant current control can, for example, be carried out by pulse duration modulation of the voltage supplied from the constant voltage source 6 .
A voltage detector 9 is connected to the drive circuit 8 . The voltage detector 9 detects the magnitude of the voltage supplied to the first and the second electromagnets 11 and 13 , and feedbacks the data to the controller 1 . A current detector 10 is connected to the drive circuit 8 and detects the magnitude of the current supplied to the first and the second electromagnet 11 and 13 . The current detector 10 feedbacks the data to the controller 1 .
Controller 1 determines such parameters as timing of power supply, magnitude of voltage to be supplied, and period of voltage supply, based on inputs from various sensors 25 and required load detector 26 as well as feedback signals from the voltage detector 9 and the current detector 10 , and in accordance with the control program stored in the ROM 3 . The controller 1 outputs a control signal for controlling the electromagnetic actuator 100 to the drive circuit 8 through the I/O interface 5 . Thus, the drive circuit 8 provides optimized current to the first and the second electromagnets 11 and 13 for mileage enhancement, emission reduction and output characteristic enhancement of the internal combustion engine.
FIG. 2 is a sectional drawing which shows the structure of the electromagnetic actuator 100 . A valve 20 is provided at an intake port or an exhaust port (referred to as intake/exhaust port) so as to open and close the intake/exhaust port 30 . The valve 20 seats on a valve seat 31 and closes the intake/exhaust port 30 when it is driven upwardly by the electromagnetic actuator 100 . The valve 20 leaves the valve seat 31 and moves down a predetermined distance from the valve seat to open the intake/exhaust port 30 when it is driven downward by the electromagnetic actuator 100 .
The valve 20 extends to a valve shaft 21 . The valve shaft 21 is accommodated in a valve guide 23 so that it can move in the direction of the axis. A disc-shaped armature 22 made of a soft magnetic material is mounted at the upper end of the valve shaft 21 . The armature 22 is biased with a first spring 16 and a second spring 17 from top and bottom.
A housing 18 of electromagnetic actuator 100 is made of nonmagnetic material. Provided in the housing 18 are a first electromagnet 11 of solenoid type placed above the armature 22 , a second electromagnet 13 of solenoid type located underneath the armature 22 . The first electromagnet 11 is surrounded by a first electromagnet yoke 12 , and the second electromagnet 13 is surrounded by a second electromagnet yoke 14 . The first spring 16 and the second spring 17 are balanced to support the armature 22 in the middle between the first electromagnet 11 and the second electromagnet 13 when no exciting current is supplied to the first electromagnet 11 or the second electromagnet 13 .
When exciting current is supplied to the first electromagnet 11 by the drive circuit 8 , the first electromagnet yoke 12 and the armature 22 are magnetized to attract each other, thereby pulling up the armature 22 . As a result, the valve 20 is driven upwardly by the valve shaft 21 , and seats on the valve seat 31 to form a closed state.
Cutting off the current to the first electromagnet 11 and starting current supply to the second electromagnet 13 will make the second electromagnet yoke 14 and the armature 22 magnetized to produce a force which combined with the potential energy of the springs attracts the armature 22 downwardly. The armature 22 contacts the second electromagnet yoke 14 and stops there. As a result, the valve 20 is driven downwardly by the valve shaft 21 to form an open state.
FIG. 3 shows a case where a larger attraction force is required to hold the armature due to secular change and operational variation. A target holding current that has been preset has become not large enough to hold the armature. The armature leaves a seating position. The armature seats at time about 3.6 ms. The attraction power at this time is larger than the leaving limit 485 N by a predetermined value. However, due to certain causes, the electromagnet fails to maintain an attraction force which is larger than the leaving limit, and the attraction force gradually weakens. The attraction power becomes less than the leaving limit around time 5 ms. The armature begins to leave the seated position around time 5.4 ms.
When the armature leaves the seating position, the air gap between the armature and the electromagnet yoke increases, causing magnetic reluctance to begin to increase. So as to reduce variation of the total magnetic flux through the magnetic path, current flowing through the windings of the electromagnet rises as shown by the reference number 31 in FIG. 3 . When holding of the armature is performed by constant current control, the drive circuit assumes a flywheel operation and no power is supplied from the power source. Therefore, magnetic energy of the electromagnetic actuator is consumed by a rapid rise of the current. As a result, magnetic energy is consumed by copper loss of the windings and eddy current loss, accelerating reduction of the magnetic flux. As a result, leaving of the armature is promoted.
As can be seen in the drawing, a little while after the attraction power becomes lower than the leaving limit, variation of the armature displacement is gentle. Leaving distance becomes 0.2 mm in 1.7 ms. In contrast, the variation of the current through the windings after the armature begins to leave is steep. The current increases about 10% (0.06 A) in about 0.3 ms after the attraction power fell below the leaving limit. Therefore, leaving of the armature can be expected or detected in advance based on variation of the current through the windings. Responsive to the early detection or estimation of leaving of the armature, pullback operation may be initiated at an early stage, which will enable completion of the pullback operation with small energy.
FIG. 4 is a detailed functional block diagram of the electromagnetic actuator controller 1 . An electromagnet controlling unit 50 controls the drive circuit 8 so that a constant voltage is applied to windings of the electromagnet during over-excitation operation for attracting the armature. The control unit 50 controls the drive circuit 8 so that a constant current is supplied to the windings of the electromagnet during holding operation for holding the armature.
Ne, Pb detecting unit 51 detects engine speed Ne based on the output from an engine speed sensor, and detects inlet pipe pressure Pb based on the output from an inlet pipe pressure sensor. Pb is a parameter expressing a load condition of the engine, and Ne is a parameter indicating a rate of the valve of an engine, or a rate of the armature. An armature displacement sensor 53 detects displacement (lift) from a yoke surface (a seating surface) of the armature.
A voltage application period determination unit 52 determines over-excitation start time Te and over-excitation completion time Th based on Ne and Pb. Specifically, the determination unit 52 refers to the relations among Ne, Pb, and Te that are prepared beforehand and are stored in the ROM 3 . It also refers to an over-excitation timing map which indicates the relations among Ne, Pb, and Th. The determination unit 52 determines the starting time Te and the finishing time Th based on present Ne and Pb. The starting time Te and finishing time Th are indicated in terms of the time from the point that the armature is released from the seated surface and moved 1 mm. The over-excitation timing map is made so that application period of voltage gets longer as the load becomes larger.
In another embodiment, the over-excitation timing map indicates relations among Ne, Pb, and application voltage. In this case, the map is prepared such that as the load increases the application voltage becomes bigger. In further another embodiment, the over-excitation timing map includes both of application voltage and application period in addition to Ne and Pb. In addition, the over-excitation timing map may be made based on other parameters such as throttle opening and the temperature of the windings, instead of or in addition to the inlet pipe pressure Pb and the engine speed Ne.
The electromagnet controlling unit 50 , responsive to the signal indicating detection of 1 mm displacement of the armature by the displacement sensor 53 , starts the over-excitation operation. Specifically, voltage application to windings is started at voltage application start time Te given by the application period determination unit 52 . This voltage application continues till application completion time Th.
When voltage application completion time Th has passed, a holding current setting unit 55 refers to the holding current map stored in the ROM 3 to determine a target holding current I obj , which is passed to the electromagnet controlling unit 50 . The electromagnet controlling unit 50 controls power supply to the windings so that the current becomes equal to the target holding current. The holding current map is a map indicating correspondency of Ne, Pb and the target holding current. The larger the load becomes, the larger the target holding current value is according to the map.
An armature state judging unit 54 monitors the current flowing through the windings after the over-excitation completion time Th has passed. If the current reaches the target holding current, a successful seating counter is incremented as it indicates that the armature has successfully seated. The successful seating counter is a counter indicating how many times the armature has consecutively succeeded in seating. One successful seating counter is provided at each of a closed valve side and an open valve side of a single valve.
In the electromagnetic actuator 100 shown in FIG. 2, for example, one successful seating counter is provided to the first electromagnet 11 and another counter is provided to the second electromagnet 13 . The successful seating counter provided to the first electromagnet 11 is incremented when the armature successfully seated on the yoke 12 of the first electromagnet in a close valve operation of valve 20 . The successful seating counter provided to the second electromagnet 13 is incremented when the armature successfully seated on the yoke 14 of the second electromagnet in an open valve operation of valve 20 .
In a holding operation after the armature seated, when the current through the windings increases more than a predetermined value over the target holding current, armature state judging unit 54 determines that the armature is leaving. In this case, the armature state judging unit 54 resets the successful seating counter.
Pullback voltage application period determination unit 58 , responsive to a determination of leaving of the armature by armature state judging unit 54 , determines period Tγ for applying pullback voltage to the the windings so as to pullback the armature to the seating position. In one embodiment of the invention, period Tγ is of a predetermined length (for example, 0.1 ms). In another example period Tγ is determined with reference to a pullback over-excitation map. This map indicates correspondence of period Tγ and the difference between the time armature leaving is determined and the predetermined time planned for releasing the armature. The electromagnet controlling unit 50 controls drive circuit 8 to apply pullback voltage of a predetermined magnitude to the windings during period Tγ given by the application period determination unit 58 .
A holding current setting unit 55 , responsive to a determination of leaving of the armature by armature state judging unit 54 , sets the target holding current to a higher value by a predetermined value. In response, the electromagnet controlling unit 50 controls the drive circuit 8 such that the current through the windings equals the newly set target holding current after the pullback voltage application period.
When the count of the successful seating counter is equal to or more than a predetermined count, that is, when the armature successfully seated a consecutive predetermined number of times without leaving the seating position, the holding current setting unit 55 resets the target holding current to a lower value by a predetermined magnitude, and passes it to the electromagnet controlling unit 50 . In response to this, the electromagnet controlling unit 50 controls the drive circuit 8 so that the current through the windings approaches the new target holding current.
When leaving does not occur after the holding current is made smaller, the target holding current value is lowered little by little until leaving of the armature takes place. In this manner, the holding current is optimized to a lowest possible value in accordance with variation and secular changes of the armature and power consumption is reduced.
Referring to FIG. 5 ( a ), pullback operation of the armature in accordance with one embodiment of the invention will be described. At time 0 ms, the armature is released from the yoke of the electromagnet and starts to displace. When the armature displacement reaches about 2 mm, namely at time Te, over-excitation operation is started by applying voltage 42 V to the windings. Application of voltage continues till time Th where the over-excitation operation terminates and the armature seats. If for some reasons the attraction power falls below the leaving limit 485 N, the armature begins to leave around time 5.4 ms. When the armature leaves, the current through the windings of the electromagnet increases as shown by reference number 71 . In response to detection of this current increase, pullback operation starts.
FIG. 5 ( b ) is a magnified drawing showing that portion of FIG. ( a ) where the armature starts to leave and is pulled back. The armature starts to leave around time 5.4 ms, and starts to displace. In response, the current through the windings of electromagnet starts to increase. When the current increases by a predetermined ratio over the target holding current, it is judged that the armature is leaving. In the drawing, this judgment is made at time 5.728 ms. The predetermined ratio may be set, for example, at 10% of the target holding current.
In response to the judgment of leaving, over-excitation operation for pulling back the armature is started. Over-excitation voltage of 42 V is applied for a predetermined period (in this embodiment, 0.1 ms). As the over-excitation power is supplied, the attraction power becomes larger (530.0 N in the drawing) than the leaving limit. As can be seen from FIG. 5 ( b ), the current rises too.
Over-excitation operation finishes at time 5.828 ms. Then, the target holding current value is set to a value 10% larger than before so as to prevent the armature from leaving. The ratio of increase can be any appropriate value. In order to make the current converge to the new target holding current quickly, −12V is applied (the period of this voltage application is referred to as rapid current regulation period). When the current reaches the new target holding current value at time 5.995 ms, switching control of ±12V is carried out for a very short period (5.995-6.03 ms). This is done in order to make the current through the windings converge to the target holding current value quickly. Then, switching control shifts to switching between +12V and 0V so as to maintain the current at the target holding current value. This shift to switching between +12V and 0V is made to reduce power consumption. As an alternative, switching between +12V and −12V may be continued.
As is apparent from FIG. 5 ( b ), leaving of the armature is limited to a very small distance (about 3.9 μm), and leaving ends in a very short period (about 0.55 ms). Seating speed of the armature in the pullback operation is as small as 0.06 m/s, and no substantial sound is generated. Because the over-excitation period for pullback is 0.1 ms, increase of the used energy is at most 0.004 J.
Thus, in contrast to the conventional scheme that was described heretofore referring to FIG. 15, according to the invention, leaving of the armature is detected at an early stage, and the pullback operation is started at an early stage. Therefore, leaving of the armature is limited to a small distance and the energy required to pull it back is very small.
According to one embodiment of the present invention, the period of the pullback operation is regulated as described hereafter in accordance with the time the armature stars to leave.
FIG. 6 shows a normal seating and releasing operation of the armature where the armature does not leave. At time 0 ms, the armature is released and stars to displace. Voltage 42V is applied to the windings from time Te through Th and the armature seats normally. The attraction force is larger than the leaving limit 485 N till time Tr, which is a scheduled time releasing the armature. Time Tr is predetermined based on valve timing and engine speed Ne. At time Tr, the armature is released. In FIG. 6, the armature displaces or lifts 1 mm at time T 1 , which is 7.2033 ms.
FIG. 7 shows the case where the armature leaves before it is released. For some reasons, attraction power falls to a smaller value (447.24 N) which is below the leaving limit. The armature starts to leave or lift at time 5.4 ms. At the scheduled release time Tr, the armature has already started to fall or lift to cause a displacement. Thus, time T 1 of 1 mm displacement is 7.0355 ms in contrast to 7.2033 ms in the case of FIG. 6 .
Referring to FIG. 8, pullback operation is activated to the leaving state as shown in FIG. 7 . Responsive to judgment of leaving of the armature at time Tf (5.7283 ms), over-excitation operation for pullback is activated and voltage is applied to the windings. With this voltage application, attraction power rises above the leaving limit as shown by reference number 81 . The attraction power remains high at the scheduled release time Tr (6.0 ms). Thus, time T 1 of 1 mm displacement lags to 7.2788 ms in contrast to 7.2033 ms in the case of FIG. 6 .
The armature pullback operation activated immediately before the scheduled release time causes delay in the armature release operation because of a relatively large attraction force. This will cause a delay in the valve timing possibly generating significant adverse effects to the engine. According to one embodiment of the invention, time lag of the valve timing in the pullback operation is avoided by the following steps.
1) calculating the difference between the scheduled armature release time Tr and the judged leaving of the armature time Tf;
2) if the difference Tr−Tf is equal to or larger than a predetermined value, performing a full pullback operation as indicated in FIGS. 5 ( a ) and ( b );
3) if the difference Tr−Tf is smaller than the predetermined value, applying voltage for pullback for shortened period Tγ. As the voltage application period is shortened, the rapid current regulation period thereafter is also shortened correspondingly because increase of the current due to voltage application is lower.
The predetermined value may be determined based on the estimate of the voltage application period required for pullback and the rapid current regulation period. For example, referring to FIG. 5, the voltage application period for pullback is set to 0.1 ms. The period for rapid current regulation is estimated to be 0.167 ms (such estimate can be made based on actual data, for example). The predetermined value can be set to 0.28 ms, that is the sum of the voltage application period of 1 mm and the rapid current regulation period 0.167 ms plus a tolerance.
FIG. 9 illustrates an example of pullback over-excitation map, which indicates the relation between the difference Tr−Tf and the pullback voltage application period Tγ. When Tr−Tf is less than the predetermined value, the period Tγ reduces as the difference Tr−Tf reduces. When Tr−Tf is equal to or more than the predetermined value, the period Tγ is constant, enabling a full pullback operation.
Referring to FIG. 10, a scheme for avoiding delay in the valve timing will be described. At time Tf (5.7283 ms), judgment is made that the armature leaves. Time Tr is the scheduled armature release time. Here, Tr−Tf=6.000−5.7283=0.2717 ms. Assume that the above mentioned predetermined value is set at 0.28 ms for example, the value of Tr−Tf is less than the predetermined value. With reference to the map as shown in FIG. 9, period Tγ corresponding to the value of Tr−Tf is extracted. As a result, pullback operation is performed over a shorter period. Attraction power at time Tr is substantially the same as the attraction power at time Tr in FIG. 6 . Time T 1 of 1 mm displacement is 7.2033 ms, which is the same timing as the normal releasing of the armature in FIG. 6 .
Thus, time lag of the armature release operation can be avoided by adjusting the period of the pullback operation in accordance with the timing that the armature leaves.
FIG. 11 is a flow chart showing the process of controlling the electromagnetic actuator in accordance with one embodiment of the invention. This process is repetitively carried out with a constant interval. In step 101 , initial setting flag is checked to see if it is “1”. This flag is set when initial setting is done. When this process is entered for the first time, the initial setting has not been done. Thus, the process proceeds to step 102 to make the initial settings. That is, the successful seating counter K is set to “0”. Then, the value 1 is set in the initial setting completion flag and value 1 is set to the over-excitation operation permission flag indicating that the next over-excitation operation is permitted.
Next time this routine is entered, the process proceeds to step 103 as the value of the initial setting completion flag is “1”, and over-excitation operation routine is executed to make the armature seated. After completion of the over-excitation operation routine, the process proceeds to step 104 to perform holding operation routine maintaining seated state of the armature. In step 105 , at the scheduled release time of the armature, armature release operation routine starts.
FIG. 12 is a flowchart of the process of the over-excitation operation routine executed in step 103 of FIG. 11 . In step 151 , determination is made whether or not value 1 is set in the over-excitation operation permission flag indicating that the initial setting has been completed. If it is “1”, the process proceeds to step 152 to determine if 1 mm displacement has been detected. If it has not been detected, the process leaves this routine. If it has been detected, pre-stored over-excitation timing map is looked up so as to extract over-excitation starting time Te and over-excitation completion time Th which are set based on the time of 1 mm displacement ( 153 ). In step 154 , an over-excitation timer set to zero is started. This timer counts up.
In step 155 , if the over-excitation timer has not reached over-excitation start time Te, the process exits the routine. If has reached Te, the process proceeds to step 156 . When the time has reached over-excitation start time Te first time from 1 mm displacement detection point, the process proceeds to step 157 to apply over-excitation voltage as decision of step 156 is No. In step 156 , application of over-excitation voltage is carried out till the over-excitation timer reaches over-excitation completion time Th.
When the over-excitation timer reaches over-excitation completion time Th in step 156 , application of voltage finishes. Steps 161 through 167 are performed to make the armature seated. In step 161 , pre-stored holding current map is referred to so as to extract target holding current I obj based on current Ne and Pb. In step 162 , 0V is applied for a predetermined period. This is because the current through the windings is large relative to the target holding current when over-excitation finished.
In step 163 , judgment is made whether the current through the windings is plainly decreasing for the predetermined period. This plain decrease of the current indicates successful seating. When the armature is moving to a seating position with the distance to the seating position decreasing, magnetic energy stored in the gap between the armature and the yoke of electromagnet is being converted into mechanical work and a magnetic path is closing. Accordingly, the current plainly decreases. When the armature has already been seated, magnetic energy is converted into copper loss and eddy current loss, and the current decreases plainly. Plain decrease of the current can be determined by checking the change of the current per unit time. If the change shows a larger decrease than a predetermined value, plain decrease of the current can be determined.
In step 163 , if the current is not decreasing plainly, it indicates that the armature has not seated normally by the voltage application performed in step 157 . Over-excitation operation is performed again ( 167 ) for a predetermined period such as 1 ms.
When this routine is entered after the re-over-excitation and it is determined in step 163 that the current has decreased plainly, the current through the windings is examined to determine if it has reached the target holding current extracted in step 161 (step 164 ). If it has not reached the target holding current, the process exits this routine. If it has reached the target holding current indicating that the armature seated successfully, a successful seating counter is incremented ( 165 ). As the over-excitation operation finished normally, the over-excitation permission flag is set to zero and the holding operation permission flag is set to “1” in order to perform the holding operation ( 166 ).
FIG. 13 is a flowchart showing the holding routine performed in step 104 of FIG. 11 . In step 171 , the holding operation permission flag is examined to determine if it is “1” indicating that the over-excitation operation routine has completed. If it is not “1”, the process exits this routine. If it is “1”, the process proceeds to step 172 to determine if holding operation period has finished. This period is a period that is preset in accordance with the scheduled release time of the armature. When this routine is entered for the first time, the process proceeds to step 173 since the holding operation period has not finished. In step 173 , a post-pullback current control flag is examined to determine if it is “1”, indicating that post-pullback current control is being carried out (step 182 , to be described referring to FIG. 14 ). When this routine is entered for the first time, the post pullback current control has not been performed and the flag just described is “0”. The process proceeds to step 174 .
In step 174 , power supply to the windings is controlled so as to keep the current through the windings at the target holding current I obj that is extracted in step 161 of FIG. 12 . This is done, for example, by performing a switching control with the voltage switched between 0V and +12V. Thus, the armature is held at the seating position.
When the armature leaves the seating position while control is being performed so as to maintain the current at the target holding current, the current through the windings increases automatically. In step 175 , if the current increases more than 10% over the target holding current, it is judged that the armature is leaving the seating position, and the successful seating counter is reset ( 176 ). The target holding current is renewed to a value 10% larger than before ( 177 ).
As described heretofore referring to FIG. 10, voltage application period Tγ is extracted from the pre-stored pullback over-excitation map ( 178 ). The period Tγ is predetermined in accordance with the difference between the time Tf and the time Tr. The period Tγ is set in a pullback over-excitation timer (a down-timer) and the timer is started. In steps 179 and 180 , voltage is applied the windings till the period Tγ ends.
When this routine is entered again, the process proceeds to step 182 if the pullback over-excitation timer has reached zero. Post pullback current control routine (FIG. 14) is performed to make the armature seat.
In step 175 , the process proceeds to step 186 if the current through the windings has not reached a value 10% larger than the target holding current. In 186 , it is determined whether the successful seating counter has a value larger than a predetermined value (for example, 10000) and the engine speed Ne is lower than a predetermined value (for example, 1000 rpm). If the determination is positive, the present target holding current value is set to a value that is 5% smaller than before ( 187 ). This is done in order to revise the holding current value to a lowest possible value necessary for maintaining a seated state. Thus, the target holding current is gradually lowered when leaving of the armature does not take place until resulting in a leaving of the armature takes place. This way, the target holding current value is revised to an optimum value for the electromagnetic actuator.
Revolution speed Ne is included in the conditions for correcting the target holding current value because it is not appropriate to change the holding current when the armature is moving at a high speed. Depending on the applications, revolution speed may not be included in the conditions. The predetermined value of the successful seating counter and the predetermined value of the revolution speed may be set to any desirable values.
When time passes and the preset holding operation period finishes, decision step 172 turns to Yes. The process proceeds to step 185 and the holding operation permission flag is set to zero. The process exits this routine.
FIG. 14 is a flowchart of the post-pullback current control routine to be performed in step 182 of FIG. 13 . In step 191 , the post-pullback current control flag is set to “1” indicating that the post-pullback current control routine is being performed. When this flag is set to “1”, such activities as current control and pullback over-excitation are not performed as described with respect to step 173 of FIG. 13 .
In step 192 , 0V is applied for a predetermined period. This is because the current through the windings is larger than the target holding current when over-excitation operation for pullback finishes. The process proceeds to step 193 to judge whether the current decreases plainly for the predetermined period. Plain decrease of the current indicates a successful seated state as described above.
When the current is not decreasing plainly, the armature has not been pulled back to the seating position yet. The same over-excitation operation as the one carried out in step 180 is carried out again ( 196 ). That is, voltage is applied to the windings of the electromagnet for period Tγ.
After re-over-excitation operation for period Tγ, when the process enters this routine again and plain decrease of the current is detected, the current is examined to see if it reached the target holding current I obj (step 194 ). If the current has not reached the target holding current, the process exits this routine. If it has reached the target current, the post-pullback current control flag is set to zero indicating that pullback to a seating position of the armature was successful.
An embodiment of the invention has been described. The value of applied voltage (42V), the value of voltage in switching control (±12V) are merely examples and are not intended to limit the invention. Different voltages can also be used. For example, holding operation can be carried out with a 42V power source.
While the invention has been described with respect to specific embodiments, such embodiments are not intended to limit the scope of the invention.
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A controller for an electromagnetic actuator is provided that enables detection of a minute movement of the armature leaving the seating position and carries out pullback operation responsive to such detection. The electromagnetic actuator has a pair of springs acting on opposite directions, and an armature coupled to a mechanical element such as a exhaust/intake valve of an automobile engine. The armature is held in a neutral position given by the springs when the actuator is not activated. The actuator includes a pair of electromagnets for driving the armature between two end positions. The controller having current supplying means for supplying holding current to the electromagnet corresponding to one of the end positions when holding the armature in said one of the end positions. The controller includes determining that the armature is leaving (falling or lifting) the seated position when the holding current increases more than a predetermined value while the holding current is supplied to the electromagnet corresponding to said end position. Leaving armature is detected based on the variation of the holding current, which allows earlier detection of the leaving armature.
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FIELD OF THE INVENTION
The present invention relates to anti-jackknifing devices for tractor-trailer vehicles utilizing braking means to oppose increasing relative angulation of the tractor and trailer when the service brakes of the vehicle are applied. In its particular aspects, the present invention relates to such an anti-jackknifing system utilizing plural braking means.
BACKGROUND OF THE INVENTION
The prior art has provided much attention to the problem of arresting lateral swinging of the trailer portion of a tractor-trailer before a jackknifing occurs. Since the tractor and trailer must be free to angulate relative to each other for maneuvering purposes, it is neither possible to rigidly couple the tractor and trailer nor to provide constantly active angular movement limitation stops. One method of solution to this problem is to provide for arresting of relative angular movement of the tractor and trailer only in response to application of the service brakes of the vehicle. However, a rigid locking together of the tractor and trailer on application of the service brakes creates serious control instability for the driver.
In my prior patent, U.S. Pat. No. 4,452,466 issued June 5, 1984, I provided apparatus that, in response to application of the service brakes of the vehicle, would limit further relative angulation of the tractor and trailer within angular stops established by the limits of travel on an angularly shifting caliper brake device cooperating with a control ring carried by the tractor and coupled by a hitch to the trailer to be responsive to angulation of the trailer. Therein the caliper brake device would, in response to application of the service brakes, and increasing relative angulation of the tractor and trailer, tend to dissipate offensive rotational energy. However, the environment of the control ring has been such that it has been difficult to keep clean so that full braking power can be applied thereto by the caliper brake device.
My prior invention would benefit from a redesign of the braking device to provide for a higher degree of braking reliability. Furthermore, a more easily accomplished coupling not requiring the physical attachment of a hitch between the control ring and the trailer would also be beneficial. This invention is based, in part, on my Disclosure Document No. 167703, filed Apr. 6, 1987 and the amendment thereto by Disclosure Document No. 175957, filed Aug. 21, 1987.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide anti-jackknifing apparatus for a tractor-trailer which will overcome the shortcomings of prior art devices.
It is a further, and more specific, object of the present invention to provide anti-jackknifing apparatus that is easily maintained and does not require additional steps in coupling or uncoupling the tractor and trailer.
It is still another object of the present invention to provide anti-jackknifing apparatus which is automatically operable in a highly reliable fashion.
SUMMARY OF THE INVENTION
The aforementioned and other objects of the invention are satisfied by providing a control apparatus for a tractor-trailer including a substantially horizontal control ring carried by the tractor below the fifth wheel for angulation about a central axis substantially co-axial with the kingpin of the tractor. A coupling comprising a pair of downwardly directed projections from the underside of the trailer and a cooperating pair of vertically upwardly directed projections from the control ring causes the control ring and the trailer to angulate relative to the tractor as a unit. This coupling is configured so as not to require any additional engagement steps beyond the usual coupling of the kingpin in the fifth wheel.
A sector-shaped brake support means is mounted for angulation, between angular stops, around an axis co-axial with the control ring and includes three angularly spaced-apart caliper brake devices, each positioned to selectively grip the control ring. A central one of the brake devices is hydraulically coupled to the vehicle service brake system so as to actuate in direct response to application of the vehicle service brakes. This actuation causes the brake support means to angulate with the control ring between the angular stops. A control valve and follower, also coupled hydraulically to the vehicle service brakes, senses the angular movement of the brake support means toward either of the angular stops and in response to a predetermined angular movement from a central normal position, causes the other two caliper brake devices to actuate for gripping the control ring and thereby provide a force opposing further relative angulation of the tractor and trailer when the brake support means reaches an angular stop.
The use of angularly spaced-apart separate and distinct brake devices provides redundancy in case either of the outer brake devices should fail and further allows the central one of the brake devices to wipe the control ring, thereby presenting a clean control ring surface to the outer brake devices.
BRIEF DESCRIPTION OF THE DRAWING
Other objectives, features and advantages of the invention will become apparent upon perusal of the following detailed description of the preferred embodiments of the invention when taken in conjunction with the appended drawing wherein:
FIG. 1 is a cross-sectional plan view of the tractor-trailer control apparatus of the present invention taken along the lines 1--1 in FIG. 2;
FIG. 2 is a cross-sectional elevational side view of the tractor-trailer control apparatus taken along the lines 2--2 in FIG. 1; and
FIG. 3 is a partial elevational cross-sectional front view of the control apparatus taken along the lines 3--3 in in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawing and, in particular, to FIGS. 1 and 2, there is shown the control device 10 of the present invention in conjunction with the lower front frame 12 of a trailer 14 and the rear frame 16 of a tractor 18. The frame 12, which comprises the underside of the front portion of trailer 14 has the usual downwardly projecting kingpin 20. The usual fifth wheel pad 22 carried by tractor 18 has the usual longitudinal rearwardly directed slot (now shown) for receiving kingpin 20 as the tractor 18 is backed into the front of trailer 14. The result of the engagement of fifth wheel pad 22 and kingpin 20 is to permit relative angulation of the tractor 18 and trailer 14 about the vertical axis of kingpin 20. To facilitate mating of the kingpin 20 and fifth wheel pad 22, in a conventional manner, fifth wheel pad 22 is mounted rockably about transverse axle 24 carried by vertical saddle arms 26a, 26b upstanding from horizontal base plate 28 which is in turn rigidly secured to tractor frame 16.
Base plate 28 carries an annular generally planar horizontal metal control ring 30 for angular movement around an axis co-axial with the axis of kingpin 20. This is accomplished by means of three radially directed holddown dogs 32, equi-angularly spaced around the circumference of control ring 30. Each dog 32 has a radially inwardly directed pad 34 secured to base plate 28 and a radially outwardly directed pad 36 bearing slideably on the upper face of control ring 30.
With reference now also to FIG. 3, the control ring 30 also has a pair of diametrically opposed wiings 38a, 38b which are bent out of the plane of control ring 30 to have upwardly projecting portions 40a, 40b terminated by elevated radially outwardly directed horizontal portions 42a, 42b. Corresponding thereto are a pair of transversely spaced apart downwardly projecting rigid webs 44a, 44b depending from lower front trailer frame 12. Webs 44a, 44b are located with their front vertical planar surfaces 46a, 46b substantially in line with the axis of kingpin 20 to engage the elevated horizontal portions 42a, 42b of control ring 30. The result is that as the tractor 18 and trailer 14 angulate relative to each other, the control ring wings 38a, 38b and the webs 44a, 44b form a coupling such that the trailer 18 and control ring 30 substantially angulate as a unit relative to the tractor 18. It should further be apparent that the holddown dogs 32 are secured to base plate 28 within the inner diameter of control ring 30 and do not project outside the outer diameter of control ring 30 in order not to interfere with the angular movement of control ring 30 and in particular the movement of wings 38a, 38b thereof.
The means for arresting undesireable relative angulation of the tractor 18 and trailer 14 comprises a sector-shaped generally horizontal planar brake support 48 which is mounted for angulation about vertical axle 50 passing through base plate 28 and the apex of brake support 48 co-axially with control ring 30 and kingpin 20. The sector-shaped brake support 48 is co-planar with control ring 30 and is sized to fit slideably within the inside diameter of the control ring 30. Stops 52a, 52b project upward from base plate 28 at positions angularly spaced from the radially directed sides 54a, 54b of brake support 48 so as to define an angular range of movement for the brake support 48. This range is preferably 41/2 degrees in either direction from a normal position at the center of said 9 degree total range. The stops 52a, 52b preferably have a resilient lining 56, as of rubber, to be engaged by a brake support side 54a or 54b as the same may come in contact therewith. Mounted on the base plate 28 proximate to stops 52a, 52b are hydraulic dampers 58a, 58b including tangentially directed elongated hydraulic cylinders 60a, 60b and pistons or plungers 62a, 62b which engage a brake support side 54a, 54b when the brake support 48 angulates from its normal or central position toward either stop and damper combination 52a, 58a or 52b, 58b by a predetermined angular amount less than the plus or minus 4 1/2 degrees angular position of the stops 52a, 52b. As either piston 62a or 62b is caused by angulation of brake support 28 to engage a side thereof, continued angular movement in the same direction causes retraction of the engaged piston 62a or 62b into its associated cylinder 60a or 60b so as to provide a viscous damping force exerted by the engaged piston on the brake support 48 in proportion to the angular velocity of the brake support.
Mounted on brake support 48 are three substantially identical separate and distinct angularly spaced apart radially directed hydraulic caliper brake devices 64a, 64b and 64c. Each brake device is fixedly secured to the brake support 48 and includes opposed radially outwardly projecting upper and lower jaws 66a and 66b carrying horizontal brake pads 68 normally slightly spaced above and below the control ring 30. A cutout 69 is provided in the base plate 28 for clearance for lower jaws 66b. In response to application of hydraulic pressure to a braking device 64a, 64b or 64c, the jaws 66a and 66b of said device are caused to squeeze toward each other resulting in the associated brake pads 68 carried by said jaws exerting a frictional force on control 30. The central one of said brake devices, 64b, is coupled by conduit 70 to the service brakes of the tractor-trailer so that application of the service brakes will cause brake device 64b to frictionally engage control ring 30 causing brake support 48 to angulate with the control ring as a unit, within the angular limits established by stops 52a, 52b.
The operation of the other two brake devices 64a and 64c is controlled by valve 72 mounted on base plate 28 and located within a cutout 74 in brake support 48. Cutout 74 includes a generally radial curve 76 having a central Vee shaped detent notch 78. Valve 72 includes a telescoping spring-loaded follower 80 cooperating with curve 76 and in particular the detent notch 78 thereof. The cooperation of follower 80 and notch 78 causes the brake support 48 to normally be positioned at its normal central angular position with the follower 80 at the center of the notch 78 when the brake support 48 angulates from this central position, which it does in response to actuation of brake device 64b as heretofore described. The notch 78 is shaped to trigger the valve 72 at a predetermined angular movement from said normal position which is preferably somewhat less than the angular limits established by stops 52a, 52b. In response thereto, the valve 72, which is hydraulically coupled to service brake hydraulic conduit 70 via tee 82 and conduit 84, and coupled hydraulically to brake devices 64a and 64c by conduits 86a and 86b, causes both said brake devices to actuate and frictionally engage the control ring 30. The result is that as the brake support engages a stop 52a or 52b, causing a retarding force to halt the movement thereof in the same direction, this retarding force is transferred to the control ring 30 by all three braking devices 64a, 64b and 64c and to the trailer 14 by means of the coupling comprising webs 44a, 44b and control ring wings 38a, 38b. Further, in the event the resilience of the stop lining 56 provides sufficient force to cause relative angulation reversal of direction, the brake support 48 will move toward its central position causing the follower and detent 80 78 to detect this return and cause valve 72 to release brake devices 64a and 64c. If the service brakes of the tractor-trailer vehicle remain engaged, the brake support 48 might continue moving in the opposite direction setting up an angular oscillation of the trailer relative to the tractor in which the brake devices 64a and 64c chatter on and off in a manner to dissipate the energy in said oscillation.
The design herein offers several advantages in that the control device 10 operates automatically without driver intervention. The coupling comprising the webs 44a, 44b and wings 38a, 38b are automatically engaged when the kingpin 20 and fifth wheel pad 22 are engaged. Further, the use of separate and distinct brake devices 64a, 64b and 64c not only provide redundancy if either of the other brake devices 64a, 64c fail, but also deal with the problem of keeping the upper and lower surfaces of the control ring sufficiently clean to maximize the amount of frictional force producable by the brake devices 64a, 64b and 64c co-acting therewith. In practice the central brake device 64b will be actuated each time the service brakes are actuated causing the central braking device 64b to wipe the upper and lower surfaces of the control ring 30. As the outer braking devices 64a or 64c are needed, due to excessive relative angulation of the trailer 14 and tractor 18, this wiped area of the control ring 30 will move toward one of the outer braking devices 64a or 64c to be engaged thereby in a manner to apply a full frictional force thereon.
While the preferred embodiment of the anti-jackknifing device of the present invention has been described in particular detail it should be appreciated that numerous modifications, or additions to or omissions in said details are possible within the intended spirit and scope of the invention.
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Anti-jackknifing apparatus beneath the fifth wheel of a tractor-trailer vehicle includes a control ring carried rotably by the tractor and coupled to the trailer by interfering vertical projections directed from each of the tractor and the control ring. A sector plate, shiftable between angular stops, is mounted on the tractor co-axial with the control ring and carries three angularly spaced apart braking devices for selectively gripping the control ring. The central one of the braking devices grips the control ring in response to application of the vehicle service brakes while a control valve causes the other braking devices to grip the control ring in response to angular shifting of the sector plate.
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BACKGROUND OF THE INVENTION
The invention relates to an open end spinning machine which includes an apparatus for re-attaching a thread which had previously been held in a clamping fixture and which had been severed at equal, predetermined distances from the fiber collection groove of the spinning rotor. The spinning machine further includes thread drawoff tubes through which air may enter the spinning rotors.
In a known machine of this type, the fixtures which clamp and sever the threads are so disposed that the clamping and severing operation takes place within the thread drawoff tubes, i.e. it takes place in relatively close proximity to the fiber collection groove of the spinning rotor. The thread drawoff mechanism must be stopped very rapidly and abruptly in order that a thread, whose breakage is sensed by a sensor also located in close proximity to the clamping and severing fixture, is stopped while it is still in the effective operating region of the clamping and severing fixture. Since the thread drawoff tube is usually fastened in or on a movable cover of the spinning rotor housing, the clamping and severing fixture and the sensor must also be mounted on this movable cover and this requires expensive clutches and connections for providing drive power from the spinning machine.
DT-PS No. 1,289,472 has disclosed a clamping device disposed outside of the thread drawoff tube and this device is capable of clamping a thread whose broken end still lies within the tube and the thread may be guided back into the fiber collection groove for re-attachment after being unclamped. However, this re-attachment attempt may fail because the uncut ends of the threads are unequal in length, shape and the same. At the restarting of such open end spinning machine therefore there is a risk that many threads are not re-attaching to the unspun fibers in the spinning rotors.
OBJECT AND SUMMARY OF THE INVENTION
It is a principal object of the invention to provide an apparatus for clamping and severing threads in an open-end spinning machine and re-attaching them to unspun fibers.
It is a further object of the invention to provide an apparatus for clamping, severing and reattaching threads which does not require the installation of actuating means in the cover of the spinning rotor housing.
Yet another object of the invention is to provide an apparatus for clamping and severing the threads which had broken due to the stopping of the open end spinning machine for a reliable re-attachment during the restarting of the open end spinning machine.
These objects are attained, according to a first exemplary embodiment of the invention, by providing a clamping and severing fixture which engages the thread outside of the thread drawoff tubes, in relation to the clamping and severing fixture, so that a relative position may be established in which the cut threads held in the clamping fixture lie definitely in the effective suction region of the orifices of the drawoff tubes.
In a second exemplary embodiment of the invention, the thread drawoff tube may be customarily rigid and may be rigidly attached to the housing of the spinning rotor. A setting mechanism may be provided for moving all of the spinning rotor housings of the spinning machine in unison or, alternatively, each housing may have its own setting mechanism. The former construction has the advantage of being less expensive, whereas the latter construction has the advantage that it may be used for repairing single thread breakages.
In a third exemplary embodiment, the change of position of the rotor housing performs two distinct functions.
In yet other cases, two further exemplary embodiments may be more advantageous. In these embodiments, the housing containing the spinning rotors may be locally fixed. Even in this case, it may be advantageous if a single setting mechanism moves all of the mutually interconnected orifices in the spinning machine or else that each individual orifice or each telescoping tube with an orifice has its own setting mechanism.
The invention will be better understood as well as further objects and advantages will become more apparent from the ensuing detailed description of the three exemplary embodiments taken in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic representation of those elements of an open-end spinning machine which are required for the explanation; only one of the plurality of spinning mechanisms of this machine being shown;
FIG. 2 is an enlarged partial representation of a thread drawoff tube of different construction from that shown in FIG. 1; and
FIG. 3 is a simplified representation of a third exemplary embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Open-end spinning machines are well known to the person skilled in the art, and, therefore, only those machine elements which serve to explain the invention are shown and only schematically. Therefore, an open-end spinning machine which is constructed according to the invention may be identical or similar to a known open-end spinning machine in all respects except those which are subject to the conditions of the invention.
Turning now to FIG. 1, it may be seen that, in known manner, the fibrous material 2 which is to be spun into threads within the driven spinning rotor 5 is pulled from a can or receptacle 1 by the input feed roller pair 3. The material is delivered to a spreader 4 which separates the material into individual fibers which are pneumatically aspirated through a thread supply channel into a spinning rotor 5. Here, the material is spun into a thread 6 which is continuously pulled out through a thread drawoff tube 31 by a thread drawoff roller pair 7 and is subsequently wound up on a wind-up spool 8. The described machine members are driven by a motor 9 which drives a plurality of identical spinning mechanisms which are all part of a single spinning machine but of which FIG. 1 shows only a single one. The belt takeoff 10 of the motor 9 drives a tangential drive belt 11 which is guided along the machine and to which the whorl 12 of the spinning rotor 5 is pressed for rotation. The belt 11 also drives other spinning rotors which are not shown and, preferably, it drives all of the spinning rotors of this machine. Broken lines 13 and 14, extending from the motor shaft, represent transmission drive means located between the motor 9 and the spreader 4 or the feed roller pair 3. The connection 14 also contains a switching clutch 15 which is shown by a line 16 to be connected to a controller 17. A broken line 18 extending from the shaft of motor 9 is intended to suggest a further driving transmission between the motor 9 and a transmission 19 whose output gear 20 and 21 rotate in mutually opposite directions and may be alternately coupled to a drive gear 22. The drive gear 22 is in driving engagement with a drive roller 23 of the wind-up spool 8, as suggested by the broken line. The connection 18 contains a switching clutch 24 which is connected by a line 25 to the controller 17 which also communicates with the transmission 19 through a line 26 and with the motor 9 through a line 27.
The spinning machine includes a second motor 28 which drives a low-pressure generator 29 (suction blower) which communicates through a pipeline 30 with the space surrounding the spinning rotor 5, i.e. with a chamber of the housing, not shown in greater detail, which contains the spinning rotor. The low-pressure generator 29 generates the reduced air pressure in this chamber by which the fibrous material 2 is pulled into the interior of the spinning rotor 5. In the same manner, outside air is drawn through the thread drawoff tube 31 which extends from a central opening in the spinning rotor 5 toward the thread drawoff roller pair 7. The thread drawoff tube 31 extends from a reciprocable housing member 32 which is its support means and which is also the support means and the housing for the rotor 5, for the spreader 4 and for the feed roller pair 3.
The housing member 32 is reciprocably mounted on the spinning machine for motion in the directions indicated by the double arrow 33, for example on rails or by a column-type guide mechanism. The position shown in the drawing is the operational position of the housing member 32. The broken line 34' shows the position of the lower edge of the housing member 32 when it assumes its rest position during a stoppage of the spinning machine. The movement of the housing member 32 is aided or opposed, as the case may be, by a spring or by pneumatic forces, and is effected by a setting mechanism 35 which is connected through a line 36 to the controller 17 which also controls the motor 28 of the low-pressure generator 29 via a line 37.
A thread clamping and severing fixture is located in spaced axial relation to the thread drawoff tube 31 in the path of the thread 6. This fixture includes a locally fixed clamping and severing anvil 38 and a locally fixed setting device 39 in which a clamping block 40 and a severing tool 41 are mounted for independent sliding movement. A line 42 connects the setting device 39 to the controller 17.
FIG. 1 shows the position of all the machine members while the machine is running, i.e., during the spinning process. In that case, the two clutches 15 and 24 are engaged and the drive gear 22 is so driven by the output gear 20 that the wind-up spool 8 rotates in the direction of the arrow.
The spinning machine is stopped by electrical signals received from the controller 17 which are fed through line 27 to the motor 9 and which cause a constantly decreasing speed of rotation and hence also decelerate the other moving machine members. When the driven machine members have reached the so-called reattachment rpm, i.e., when they rotate near that rpm which forms the lower limit for the spinning process, a signal may be delivered through line 37 to reduce the rpm of motor 28 which also reduces the suction power of the low-pressure generator 29. At the same time, signals are sent through lines 16 and 25 to disengage the clutches 15 and 24, respectively, whereby the feed roller pair 3, the thread drawoff roller pair 7 and the wind-up spool 8 are released and may run down to standstill. If necessary, rapidly acting brakes may be used to act on these members. When the feed roller pair 3 is stopped, the spun thread 6 breaks; suitable timing of the arresting process of the roller pairs 3 and 7 makes it possible that, when the thread drawoff roller pair 7 and the wind-up spool 8 are stopped, the end of the broken thread is still located within the thread drawoff tube 31. At this time, the controller 17 delivers a signal through line 36 to the setting mechanism 35 which, therefore, shifts the housing member 32 into the position suggested by the broken line 34'. In this position, the whorl 12 of the spinning rotor 5 is lifted from the tangential drive belt 11 and that end of the thread drawoff tube 31 nearest the clamping and severing fixture 38-41 moves into the position suggested by the broken line 31', i.e., it is spatially separated from the fixture 38-41. At the same time, the controller 17 delivers a first signal through the line 42 to the setting device 39 which causes a sliding displacement of the clamping block 40 which clamps the thread 6 on the clamping and severing anvil 38. Shortly thereafter, the controller 17 delivers a second signal which slidingly displaces the severing tool 41 which severs the thread and thereafter returns to its starting position.
The severed piece of thread, whose broken end still lies in the thread drawoff tube 31, is then sucked into the interior of the spinning rotor 5 due to the low air pressure still prevailing in the thread drawoff tube 31 and is removed from the spinning rotor together with the remainder of the fibers located therein. Finally, the controller 17 delivers a signal for shutting off the motors 9 and 28.
In order to re-start the machine and to begin the thread re-attachment process, the controller 17 first delivers signals for starting the motors 9 and 28 until these motors have reached a speed which is suitable for thread attachment. Soon after the switch-on, the setting mechanism 35 slides the housing member 32 back into its operative position, thereby moving the whorl 12 back in contact with the drive belt 11. At the same time, the thread drawoff tube 31, whose suction orifice lies outside of the housing member 32, moves far enough toward the severed end of the thread which is still being held by the clamping member 40 that the end of the thread is located within the effective suction space due to the reduced air pressure prevailing in the tube 31. The controller 17 then delivers signals for returning the clamping block 40 into the position where it releases the thread and then delivers further signals for engaging the clutch 24 and for so switching the transmission gears 19 that the output gear 21 is associated with the drive gear 22. Hence, the thread drawoff roller pair 7 and the wind-up spool 8 rotate in the direction opposite to the arrow, causing a return motion of the thread whose free end is then sucked into the thread drawoff tube 31. By choosing a suitable reduction ratio of the transmission 9, this reversal motion can be made slower than the drawoff motion which proceeds in the opposite direction. At the proper time, a signal is delivered which engages the clutch 15 and starts the rotation of the feed roller pair 3. The timing is so chosen that the reversing thread end reaches the fiber collection groove of the spinning rotor 5 at the same time as the fibrous material 2 to be spun into thread. At this point, the controller 17 delivers a signal to the transmission gear 19 for disengaging the output gear 21 and for reengaging the output gear 20 to the drive gear 22, thus causing the re-attached thread to be drawn off. Finally, the controller 17 delivers signals which cause the motors 9 and 28 to be switched to their operational rpm.
In the exemplary embodiment according to FIG. 2, the housing member which corresponds to housing member 32 in FIG. 1 carries the reference numeral 132. It is also equipped with a thread drawoff tube 131, which, in contrast to tube 31 of FIG. 1, consists of two telescoping tube sections, whereby the inner tube section 43 is fastened to the machine member 132 and the outer tube section 44 slides on it externally. In FIG. 2, the externally sliding tube section 44 is shown, to the left of the thread 6, in its fully retracted position and it is shown to the right of the thread in its fully extended position with respect to the interior telescoping member 43. One end of a compression spring 47 rests on a shoulder 45 of the tube section 43 and the other end rests on a bottom edge 46 of the tube section 44. The spring 47 urges the telescoping tube into its retracted position in which the orifice 48 is so far removed from the clamping and severing fixture 38, 40, 41 that the severed end of a clamped thread lies outside of the effective suction region of the low pressure prevailing in the thread drawoff tube 131. In its extended position, the suction orifice 48 of the thread drawoff tube 131 is near the end of the thread which then lies within the effective suction region of the tube. The displacement of the outer tube section 44 in opposition to the force of the compression spring 47 is effected by a pressure medium, for example by air, which is admitted through a hose 51 or the like from a container 52 and which is admitted through a nipple 50 on the tube section 44 and becomes effective in the hollow space formed between, on the one hand, the shoulder 45 of the tube section 43 which sealingly attaches to the tube section 44 and, on the other hand, a shoulder 49 of the tube section 44 which sealingly attaches to the tube section 43. The controller 17 actuates the fluid flow via a line 53 in such a manner that, at the latest at the beginning of the reversal motion of the severed thread released from the clamping fixture for the purpose of re-attachment, the tube orifice 48 is so close to the end of the thread that the latter is engaged by the suction at the orifice and pulled into the tube.
If suitable, the device according to FIG. 2 can be disposed, similar to the manner shown in FIG. 1, on a movably mounted housing member 32, e.g. if the inherent motions of this device do not suffice to bring the tube orifice close enough to the end of the thread which is to be aspirated. However, the apparatus may also be disposed on a housing member which is stationary relative to the clamping and severing fixture or, again, it may be disposed in a manner and in a way which, by itself, cannot produce a movement of the tube orifice to the end of the thread.
Instead of causing the reverse motion of the rollers 7 and of the spool 8 for backspacing the thread, it is possible to release an appropriately large thread reserve which may be formed, for example, in the space between the fixture 38-41 and the roller pairs 7. For example, this thread reserve may be formed by reversing rollers of which at least one can be adjusted in position to change the length of the effective reserve thread path.
FIG. 3 shows an apparatus which substantially corresponds to that of FIG. 1, except that a rigid thread drawoff tube 231 is mounted on a housing member 232 and is slidably movable in the direction indicated by the arrow 33, with its operational position being the lower position which is shown in solid lines. Signals delivered by the controller 17 through the line 36 to the setting mechanism 135 may move the housing member 232 to a first position, in which its lower edge 234 is actually located as shown by the broken line 234', which corresponds to the rest position of this member when the spinning machine is standing still. In that position, the whorl 12 of the spinning rotor is lifted off from the tangential drive belt 12 and the orifice of the thread drawoff tube 231 lies in the plane indicated by the broken line 231'.
When the spinning machine is first turned on, the controller 17 delivers a signal to the setting mechanism 134, which causes the housing member 232 to be lifted into that position in which its lower edge 234 lies along the dash-dot line 234". At the same time, the suction orifice of the thread drawoff tube 231 is moved into the plane suggested by the dash-dot line 231". Only then is the suction orifice close enough to the thread located in the clamping and severing fixture 38-41 so that it lies within the effective suction region of the low pressure prevailing in the thread drawoff tube 231 and may be aspirated into the thread drawoff tube 231 since it is released from the clamp, while being back-spaced. Thereafter, the controller 17 delivers a signal to the setting mechanism 134 which causes the housing member 232 to move into its operational position, as shown in solid lines, in which the end of the thread introduced into the rotor 5 is re-attached to the fiber.
The apparatus according to FIG. 3 has the particular advantage that, during the operation of the spinning machine, the suction orifice of the thread drawoff tube 231 is quite far removed spatially from the clamping and severing fixture 38-41 and is thus easily accessible if a thread breakage is to be repaired by manual insertion of the end of the thread into the drawoff tube. This insertion is not as simple when the suction orifice is located too near the fixture 38-41 while in the operational position.
The invention may preferably be used to ensure that all threads of an open end spinning machine or at least the threads at one side of an open end spinning machine are at the same time reliably re-attached during the re-starting of the spinning machine to the unspun fibers in the spinning rotors. In this case it may preferably be provided that all clamping members resp. all movable separating members resp. all movable drawoff tube orifices are operated commonly, and can be arranged in some applications in groups at corresponding machine members to that each group of such elements is movable together by movement of the corresponding machine member. But the invention could also be provided for that case that threads which are broken at different times during the spinning operation of the spinning machine can be reliably re-attached to the unspun fibers in the corresponding spinning rotors. In this latter case it is preferably provided that each drawoff tube orifice is setting in different relative positions independently of other drawoff tube orifices with respect to the corresponding clamping and severing fixture which is also independently operable of the other clamping and severing fixtures.
It will be understood that the invention is not limited to the described embodiments since there are many other possibilities to realize the invention in practice.
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A thread breakage repair apparatus for use in open-end spinning machines includes a fixture which holds the thread and trims its broken end and it also includes a movable assembly, on which a drawoff tube is mounted which is connected to a source of suction. This drawoff tube is brought close to the end of the thread held by the clamping and severing fixture, whereupon a controller releases the clamped thread which is then aspirated into the interior of the drawoff tube. The mechanical transport mechanism for the thread may be reversed in motion by the controller, permitting already spun thread to be backspaced so that the end of the thread may be reattached to the fibers located in the spinning rotor. The drawoff tube may also be of the telescoping type whose extension is determined by the controller.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a U.S. national stage of application No. PCT/EP2010/050665 filed 21 Jan. 2010. Priority is claimed on German Application No. 10 2009 006 533.4 filed 28 Jan. 2009, the content of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an actuator device having an open/close valve which is adjustable by a pneumatic actuating drive and by an actuating element that acts on the open/close valve, a position sensor which records the actual position of the actuating element, and an electropneumatic position controller that is supplied with compressed air through a feed air inlet and generates an actuating pressure at an actuating pressure outlet as a function of the actual position and a setpoint position, where the actuating pressure is supplied to the actuating drive by an activated solenoid valve which, in order to be activated, is supplied with a supply voltage and, in an emergency, can be deactivated by switching off the supply voltage in order to vent the actuating drive.
Actuator devices are known from WO 2008/138949 A1, US 2006/0219299 A1 and/or WO 2008/135417 A1.
An open/close valve, i.e., an emergency shut-down (ESD) valve, is moved either to an operating position, for example “open”, or a safety position, for example “closed”, by a pneumatic actuating drive. A solenoid valve, which is activated with a supply voltage which is provided, for example, by a control system, connects the pneumatic drive to a compressed air supply. In an emergency, the supply voltage is switched off to vent the pneumatic drive by the solenoid valve, so that the open/close valve is moved from the operating position to the safety position.
In order to be able to check the ability of the actuator device to function as part of a partial stroke test, the compressed air is supplied by an electropneumatic position controller. During the partial stroke test, the open/close valve is moved from the operating position over part of its actuating path and then moved back again by the position controller. Here, the change in position is so slight that ongoing operation of the system in which the open/close valve is incorporated is disturbed only to an insignificant extent and does not have to be interrupted. The actuating movement is recorded and stored, or passed on to the control system during the partial stroke test.
In the device disclosed in WO 2008/138949 A1, a solenoid valve test signal is generated to test the solenoid valve, where the solenoid test signal is used to actuate a controllable switch for interrupting the voltage supply to the solenoid valve so that the solenoid valve is deactivated. As a result, the actuating drive is vented. The actuating element then moves as far as a prespecified position, where a limit value switch opening and the path of the solenoid valve test signal to the controllable switch is interrupted when the prespecified position is reached. The controllable switch therefore re-connects the voltage supply for the solenoid valve, where the solenoid valve is activated as a result, and re-establishes the pneumatic connection between the position controller and the actuating drive, and therefore the movement of the actuating element is stopped and reversed. This leads to an oscillating movement of the actuating element, where the oscillating movement lasts for as long as the solenoid valve test signal is generated and the oscillating movement is detected by the position controller and being passed on to the control system.
In the device described in US 2006/0219299 A1, for the purpose of testing the solenoid valve, a solenoid valve is briefly deactivated by interrupting the voltage supply to the solenoid valve and, in the process, the pressure difference between the side of the solenoid valve connected to the position controller and the side of the solenoid valve connected to the actuating drive is monitored. The testing of the solenoid valve is judged as being successful when, in the event of a brief deactivation of the solenoid valve, the pressure on the side of the actuating drive drops significantly, while the pressure provided by the position controller remains largely unchanged.
In the device described in WO 2008/135417 A1, a partial stroke test and a test of the solenoid valve are performed in a single test sequence by deactivating the solenoid valve, where the actuating movement of an actuating element is detected by a position controller and is monitored to determine when it reaches a prespecified path change and is re-activated when the solenoid valve reaches the prespecified path change.
Patent application PCT/EP2008/059316 proposes, for the purpose of reducing the technical outlay, connecting the electropneumatic position controller directly, i.e., without the interposition of a solenoid valve which can be controlled by the supply voltage, to the pneumatic actuating drive. Instead, the position controller is connected to the supply voltage on the power supply side and is designed to vent the actuating drive in the event of failure of the power supply. Amongst other things, a routine for performing the partial stroke test is stored in the position controller.
Therefore, in actuator devices having an open/close valve, the electropneumatic position controller allows a partial stroke test to be performed and assists the testing of the solenoid valve. The safety of the actuator device is in no way compromised by the provision of the position controller because, in the event of an emergency, the actuating drive is always vented by the solenoid valve, and therefore the open/close valve is moved to the safety position. However, the availability of the actuator device can be reduced by the presence of the position controller if, as a result of a disturbance in the position controller or the supply of electricity to the position controller, the compressed air supply to the solenoid valve fails and the open/close valve is moved to the safety position without there being an emergency.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide an improved actuator device that solves the foregoing problem.
These and other objects and advantages are achieved in accordance with the invention, by providing an actuator device with a controllable valve arrangement between the feed air inlet of the position controller and the solenoid valve, where the valve arrangement is actuated by a position limit value sensor which is operable by the actuating element and/or a pressure limit value sensor which records the actuating pressure at the solenoid valve and connects the solenoid valve directly to the feed air when the position limit value sensor detects that a prespecified movement position of the actuating element has been reached or the pressure limit value sensor detects that a prespecified minimum pressure has been undershot.
Consequently, if a disturbance in the position controller causes said position controller to be vented, this disturbance is detected by a corresponding drop in the actuating pressure at the solenoid valve and/or by a corresponding movement of the actuating element out of an operating position. As a result, the controllable valve arrangement is actuated such that the solenoid valve is no longer supplied with feed air by the position controller but rather directly. The safety of the actuator device is in no way compromised as a result of this, because the actuating drive is still vented by the solenoid valve, and therefore the open/close valve is moved to the safety position in the event of an emergency.
The controllable valve arrangement preferably comprises a three-way valve situated between the feed air inlet, the actuating pressure outlet and the solenoid valve, where the three-way valve connects the solenoid valve either to the actuating pressure outlet of the position controller or directly to the feed air.
The pressure limit value sensor can directly mechanically actuate the valve arrangement. However, it is also possible for the pressure limit value sensor to electrically actuate the valve arrangement, similarly to the position limit value sensor. To this end, the valve arrangement can be electrically actuated and is connected to the supply voltage by the position or pressure limit value sensor which comprises a limit value switch. The limit value switch, which is open in the operating position of the actuating element or is open when there is a sufficiently high actuating pressure, closes when the actuating element reaches the prespecified movement position or the recorded actuating pressure falls below the prespecified minimum pressure. As a result, the supply voltage is connected-through to the valve arrangement which then connects the solenoid valve directly to the feed air. If the supply voltage fails, the valve arrangement remains deactivated, irrespective of the switching position of the limit value switch, and connects the solenoid valve to the actuating pressure outlet of the position controller.
As previously mentioned, a greater drop in the actuating pressure that is provided by the position controller for the solenoid valve leads to a changeover of the valve arrangement by the valve arrangement connecting the solenoid valve directly to the feed air. The pressure limit value sensor then records a higher pressure again and the actuating element again moves back to the operating position. Consequently, the valve arrangement is also switched back again and connects the solenoid valve to the actuating pressure outlet of the position controller. If the actuating pressure that is provided by the position controller for the solenoid valve is still too low, the valve arrangement is switched over again. This process is repeated for as long as the disturbance in the position controller lasts. This results in an oscillating movement of the actuating element, where the oscillating movement is preferably recorded by the position sensor of the position controller and is registered in the position controller and/or is signaled as a fault to the superordinate control system by the position controller. As an alternative or in addition, the periodic fluctuation of the actuating pressure can also be recorded by the pressure limit value sensor and registered in the position controller and/or signaled as a fault by the position controller.
If the position or pressure limit value sensor, as described above, comprises a limit value switch, the switching activity of the limit value switch in an auxiliary circuit (signaling circuit) can be recorded to detect the fault or the disturbance in the position controller.
In an actuator device, in which the electropneumatic position controller is directly connected to the pneumatic actuating drive without the intermediate connection of a solenoid value which can be controlled by the supply voltage, is connected at the power supply end to the supply voltage and is designed to vent the actuating drive if the power supply fails, the problem addressed by the present invention is achieved in an analogous manner in that a valve arrangement positioned between the feed air inlet of the position controller and the actuating drive, where it is possible for the valve arrangement to be electrically activated, the valve arrangement connects the actuating drive to the actuating pressure outlet in the passive state and directly to the feed air in the active state, and is actuated by a position limit value sensor which is operable by the actuating element and/or a pressure limit value sensor which records the actuating pressure at the solenoid valve. The limit value sensor comprises a limit value switch that connects the valve arrangement to the supply voltage and which closes when the actuating element reaches the prespecified movement position or the recorded actuating pressure falls below the prespecified minimum pressure.
Other objects and features of the present invention will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed solely for purposes of illustration and not as a definition of the limits of the invention. It should be further understood that the drawings are not necessarily drawn to scale and that, unless otherwise indicated, they are merely intended to conceptually illustrate the structures and procedures described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to further explain the invention, reference is made to the figures in the drawing in the text which follows in which:
FIG. 1 shows an exemplary embodiment of the actuator device having a solenoid valve in accordance with the invention;
FIG. 2 shows an alternative exemplary embodiment of the actuator device in accordance with the invention; and
FIG. 3 shows a further exemplary embodiment of the actuator device, without a solenoid valve, in accordance with the invention, with identical or corresponding parts being provided with corresponding reference symbols.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an actuator device having a pneumatic actuating drive 1 which, by use of an actuating element 2 , in this case comprising a lifting rod, operates an open/close valve 3 in a pipeline 4 through which a fluid flows. The open/close valve 3 has an operating position in which it is open or closed, and a safety position, which is provided if there is an emergency, in which it is closed or, respectively open. The actuating drive 1 is connected to the actuating pressure outlet 7 of a position controller 8 , which is supplied with compressed air (feed air) at a feed air inlet 9 , through a pneumatic line 5 with a solenoid valve 6 arranged therein. A position sensor 10 records the actual position of the actuating element 2 and supplies this actual position to the position controller 8 that sets a variable actuating pressure at its actuating pressure outlet 7 as a function of the actual position and a prespecifiable setpoint position, in order to move the actuating element 2 with the valve 3 to the setpoint position, for example 95% of the operating end position. In order to prespecify a setpoint position, the position controller 8 can be connected to a control system 12 by a communication line 11 , such as a 4-20 mA line.
The solenoid valve 6 comprises a three-way valve and receives a supply voltage Vs from the control system 12 over a line 13 .
In the normal case, the supply voltage Vs is switched on, and therefore the solenoid valve 6 is activated and pneumatically connects the actuating pressure outlet 7 of the position controller 8 to the actuating drive 1 . In the event of an emergency, the control system 12 switches off the supply voltage Vs, and therefore the solenoid valve 6 that is then deactivated disconnects the actuating drive 1 from the position controller 8 and instead vents through a solenoid valve outlet 14 . The actuating drive 1 is then at zero pressure and moves the actuating element 2 with the valve 3 , for example, under the action of a spring in the actuating drive 1 , to the safety position. The deactivation and subsequent re-activation of the solenoid valve 6 can additionally also be performed at the actuator device itself by a controllable switch 15 being opened and closed again over the course of the line 13 .
In a partial stroke test that is automatically initiated at regular intervals by the control system 12 , the open/close valve 4 is moved briefly out of the respective current position over part of its actuating path, and then moved back again, when the solenoid valve 6 is activated. Here, the change in position is so slight that ongoing operation of the system in which the valve 3 is incorporated is not disturbed or is disturbed only to an insignificant extent. In each test, the actual position reached by the actuating element 2 or the valve 3 is transmitted to the control system 12 , for example, by the communication line 11 , and stored and logged there. The partial stroke test is judged as being successful as a function of a prespecified change in position being reached within a minimum time or the change in position reaching a minimum value within a prespecified time. In this way, it is possible to determine when the valve 3 is blocked or reacts too slowly.
After each or each n-th partial stroke test, the ability of the solenoid valve 6 to function is tested, where the solenoid valve is deactivated for this purpose. To this end, the control system 12 generates a solenoid valve test signal MVT with which the controllable switch 15 is opened. The solenoid valve test signal MVT is supplied to the controllable switch 15 by a limit value switch 16 that is closed in the operating position of the actuating element 2 and is opened in a prespecified position of the actuating element 2 . The prespecified position is reached in the event of a small movement of the actuating element 2 of, for example, 10 to 20% of the actuating path from the operating position. In response to the solenoid valve test signal MVT that is generated by the control system 12 , the controllable switch 15 interrupts the voltage supply to the solenoid valve 6 , so that the solenoid valve is deactivated and, as a result, the actuating drive 1 is vented. The actuating element 2 then moves as far as the prespecified position in which the limit value switch 16 is open and the path of the solenoid valve test signal MVT to the controllable switch 15 is interrupted. The controllable switch 15 therefore re-connects the voltage supply for the solenoid valve 6 , where the solenoid valve is activated as a result and re-establishes the pneumatic connection between the position controller 8 and the actuating drive 1 , and therefore the movement of the actuating element 2 is stopped and reversed. This leads to the limit value switch 16 being re-closed and the solenoid valve test signal MVT that is produced being connected-through to the controllable switch 15 again, and therefore the limit value switch 16 is opened, where the solenoid valve 6 is deactivated and the actuating element 2 is again moved to the prespecified position. This process is repeated for as long as the control system 12 generates the solenoid valve test signal MVT, and therefore the actuating element 2 oscillates about the prespecified position. Here, the position that is recorded by the position sensor 10 in this case is transmitted to the control system 12 by the position controller 8 and stored there for logging purposes.
In the actuator device shown in FIG. 2 , the partial stroke test and the testing of the solenoid valve 6 are performed in a single test sequence, for which purpose the control system 12 automatically outputs a corresponding command to the position controller 8 over the communication line 11 . The position controller then generates a control signal for opening the controllable switch 15 , and therefore the solenoid valve 6 is deactivated and, as a result of this deactivation, the actuating drive 1 is vented. The movement of the actuating element 2 which begins as a result is recorded by the position sensor 10 and supplied to the position controller 8 . Said position controller monitors the actuating movement of the actuating element 2 for when it reaches a prespecified parameterizable path change and, when this prespecified path change is achieved, generates a control signal for closing the controllable switch 15 , so that the solenoid valve 6 is re-activated and the pneumatic connection between the position controller 8 and the actuating drive 1 is re-established. The position controller 8 now returns the actuating element 2 with the valve 3 back to the operating position before the test, with the actuating movement also being recorded. The position controller 8 transmits the test results to the control system 12 for further processing and analysis.
A disturbance in the position controller 8 , for example, in the event of a failure of the power supply to the position controller, may lead to said position controller being vented via an outlet 17 , so that the actuating pressure at the actuating pressure outlet 7 drops. As a result, the supply of compressed air to the actuating drive 1 fails and the open/close valve 3 is moved to the safety position without there being an emergency. In order to prevent this, a controllable valve arrangement 18 is situated between the feed air inlet 9 of the position controller 8 and the solenoid valve 6 , where the valve arrangement connects the solenoid valve 6 directly to the feed air and thus maintains the supply of compressed air to the actuating drive 1 in the event of the described fault in the position controller 8 . The controllable valve arrangement 18 comprises a three-way valve which is situated between the feed air inlet 9 , the actuating pressure outlet 7 and the solenoid valve 6 and which connects the solenoid valve 6 either to the actuating pressure outlet 7 of the position controller 8 or directly to the feed air.
In the actuator device shown in FIG. 1 , the valve arrangement 18 comprises a three-way solenoid valve that is connected to the supply voltage Vs by a position limit value sensor 19 that is operable by the actuating element 2 and comprises a limit value switch. The limit value switch 19 is open in the operating position of the valve 3 , and therefore the three-way solenoid valve 18 is deactivated and connects the solenoid valve 6 to the actuating pressure outlet 7 of the position controller 8 . If, on account of a disturbance in the position controller 8 , the position controller vents the actuating drive 1 through the outlet 17 and, as a result of this, the actuating element 2 reaches a prespecified movement position of, for example, 95% of the operating end position, the limit value switch 19 closes, with the three-way solenoid valve 18 which is then activated connecting the solenoid valve 6 to the feed air. As a result, the movement of the actuating element 2 is stopped and reversed in the direction of the operating end position, and therefore the limit value switch 19 re-closes and the three-way solenoid valve 18 that is activated as a result again connects the solenoid valve 6 to the actuating pressure outlet of the position controller 8 . Therefore, the actuating element 2 performs an oscillating movement for the period for which there is no compressed air supply to the actuating drive by the position controller 8 , it being possible for the oscillating movement to be detected by the position controller 8 and signaled to the control system 12 by the communication line 11 . This signal can also be output, for example, by an auxiliary contact (not shown) of the limit value switch 19 in an auxiliary circuit that leads to the control system 12 , or, for example, the current in the connecting path from the supply voltage Vs to the limit value switch 19 or, as indicated by a dashed line, the electrical voltage across the valve arrangement 18 is recorded.
If the supply voltage Vs fails or is switched off by the control system 12 in response to an emergency, the three-way solenoid valve 18 remains deactivated and the solenoid valve 6 vents the actuating drive 1 .
In the actuator device shown in FIG. 2 , the valve arrangement 18 is mechanically actuated by a pressure limit value sensor 20 that records the actuating pressure at the solenoid valve 6 , with the valve arrangement 18 connecting the solenoid valve to the feed air if the pressure limit value sensor 20 detects that a prespecified minimum pressure has been undershot. In this case, the actuating element 2 also performs an oscillating movement for the period for which there is no compressed air supply to the solenoid valve 6 by the position controller 8 , where it is possible for the oscillating movement to be detected by the position controller 8 and signaled to the control system 12 . As an alternative, the signal can be output by an auxiliary contact (not shown) of the pressure limit value sensor 20 in an auxiliary circuit that leads to the control system 12 .
Analogously to the limit value switch 19 in FIG. 1 , the pressure limit value sensor 20 can likewise comprise a limit value switch that opens when the recorded actuating pressure falls below the prespecified minimum pressure.
The valve arrangements 18 with the position limit value sensor 19 or pressure limit value sensor 20 shown in FIGS. 1 and 2 can be exchanged for one another or can be provided together, so as to supplement one another.
FIG. 3 shows an actuator device that is similar to that in FIG. 1 but with the essential difference that the position controller 8 itself assumes the function of the solenoid valve 6 and, to this end, is connected to the supply voltage Vs on the power supply side and is configured to vent the pneumatic actuating drive 1 in the event of failure of the power supply. If the supply voltage Vs fails or is switched off, the position controller 8 vents the actuating drive 1 through its outlet 17 , and therefore the valve 3 moves to the safety position. As long as the supply voltage Vs is applied to the position controller 8 , the position controller 8 controls the valve position in accordance with a stored setpoint value which is a small amount, for example 3%, lower than the operating end position of the valve 3 . As a result, control is continuously active, this reduces the risk of the output valves “sticking” in the pneumatic output stage of the position controller 8 . A partial stroke test can selectively be initiated manually by an operator control element on the position controller 8 , by a signal which is transmitted to the position controller 8 over the communication line 11 , or at regular intervals by a timer that is contained in the position controller 8 .
If the position controller 8 is vented because of a fault or a disturbance, even though the supply voltage Vs is applied and there is no emergency, the actuating element 2 moves out of its operating position until the position limit value switch 19 closes and connects the three-way solenoid valve 18 to the supply voltage Vs. The three-way solenoid valve 18 that is activated in this way switches the actuating drive 1 from the actuating pressure outlet 7 to the feed air 9 , and therefore the actuating element 2 is moved back again. Therefore, the actuating element 2 performs an oscillating movement for the period for which the position controller 8 fails, where it is possible for the oscillating movement to be detected by the position controller 8 , to the extent that the position controller 8 is still able to do this, and signaled to the control system 12 over the communication line 11 . In the disclosed exemplary embodiment, the signal can be output by the switching activity of the limit value switch 19 being recorded by the electrical voltage across the valve arrangement 18 and being signaled to the control system 12 by a signaling line 21 .
Thus, while there are shown, described and pointed out fundamental novel features of the invention as applied to preferred embodiments thereof, it will be understood that various omissions and substitutions and changes in the form and details of the illustrated method and apparatus, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. Moreover, it should be recognized that methods and structures shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice.
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An arrangement in which a valve assembly is provided between the supply air inlet and the magnetic valve that is activated by a position threshold sensor that can be activated by the actuator element and/or a pressure threshold sensor registering the actuating pressure on the magnetic valve and connects the magnetic valve directly to the supply air to increase the availability of the actuator device when the position threshold sensor detects the attaining of a specified operation position of the actuator element or the pressure threshold sensor detects the failure to attain a specified minimum pressure.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional patent application of prior U.S. patent application Ser. No. 11/153,305, entitled “INSURANCE PRODUCT, RATING SYSTEM AND METHOD,” filed on Jun. 15, 2005.
STATEMENTS REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] N/A
REFERENCE TO A MICROFICHE APPENDIX
[0003] N/A
BACKGROUND OF THE INVENTION
Field of the Invention
[0004] Pricing and rating methods for property and property-related asset performance insurance products can be classified into two categories: Value-based (VB) rating and Frequency-Severity (FS) rating. In both cases insurance costs are directly related to the financial loss potentials, but the computational methods reflect the characteristics of the property or assets being insured.
[0005] VB rating generally is applied to situations where risk or loss potential can be characterized by a series of variables. For example, the loss potential and pricing for a new car may be determined by the car type, the type of loss (e.g., collision, liability, glass windshield) the amount and type of miles driven, the driving record of the insured, the geographical location and perhaps other variables. Given these variables, loss potentials have been analyzed and tables produced enabling the underwriter to look up the rates, expressed in dollars of premium/dollar of coverage, in tables. The underwriter typically multiplies the client-specific variables by the corresponding rates then adds in company-specific administrative costs to compute the overall policy premium.
[0006] For property VB insurance, some common underwriting variables are business type, building activity (e.g., hospitals, office buildings, laboratories, etc.), square footage or other attributes of size, construction attributes, fire sprinkler coverage, number of stories, location, and age. Premium rates expressed are generally categorized by these variables and together produce a premium rate. This value multiplied by the building value produces the policy premium. Actual premium values may vary by historical precedent of pricing, market demands, policy terms and conditions, contents type and property replacement values.
[0007] FS pricing is a rating and pricing method for situations where there can be large differences between insureds in the same type of industry and geographical area. In this method the probability or failure frequency (events/year) of an insurance claim or failure may be modeled or directly obtained from available data.
[0008] Engineering and underwriting risk modifiers are factors applied to the loss cost computed premium that adjust for specific customer attributes present in the current situation. For example, an engineering risk modification factor to increase the loss cost 10% could be applied for clients who have poor procedures for record-keeping and plant cleanliness. Engineering inspectors have identified a high correlation with these behaviors and customers who will have insurance claims. An underwriting risk modification factor of 10% could decrease the policy premium if high deductibles and restricted coverages are negotiated with the client. These engineering and underwriting risk modification factors make detailed premium changes based on the specific attributes of the client and the policy terms and conditions.
[0009] An example of the FS pricing method for a client is applied to an equipment breakdown premium development for a power generation station 100 shown in FIG. 1 . The station has two (2) simple cycle GE 7FA turbine generators 102 , 104 with two (2) transformers 106 , 108 and various types of electrical switchgear and equipment (only switch 110 is shown). The first part of the premium calculation contains the frequency and severity calculation which determines the loss cost component of the premium. There are risk modification factors that customize the loss cost component for the specific client being analyzed. These factors can increase or decrease the credit and debit percentage that allows underwriting to modify the loss cost to reflect the subjective attributes (e.g., engineering factors) of the client, for example, housekeeping, recordkeeping, reliability planning, the number of equipment spares available and underwriting factors such as the deductible value selected.
[0010] The next part of the premium calculation determines the client-specific expenses, costs and profit. Another component of the premium calculation, the Excess Loss Potential refers to a loss cost premium component that accounts for the very low frequency, but very high severity loss events that are appropriate for the client. Examples of such loss events include five hundred (500) year recurrence period earthquakes, tsunamis and hurricanes. The loss event severities may be determined by specialized catastrophic modeling software. A portion of the insurance company's total loss potential may be allocated to each client as the Excess Loss Potential component of the premium.
[0011] The client may also be subjected to engineering inspections associated with jurisdictional requirements of the state or other governmental bodies. The underwriting process also includes certain client-specific costs associated with meetings, travel and the like.
[0012] Expenses considered in the underwriting process can also include costs for re-insurance and are usually added when the underwriter buys facultative re-insurance—re-insurance on a specific account. Although other expenses that involve a pro-ration of portfolio, line of business, department, or division expenses to the account level may also be added. Other premium costs are typically taxes, commissions to brokers, profit margin and other specified premium cost adders in the company's underwriting guidelines.
[0013] The FS pricing for the example above is shown below for constructing an equipment breakdown insurance price for a simple cycle gas turbine generation facility:
[0000]
Annual Failure
Premium
Equipment
Frequency
Severity
(Loss Costs)
2 GE 7FA turbines
0.025
$80,000,000
$2,000,000
2 Transformers
0.015
$4,000,000
$60,000
Switchgear + Electrical
0.030
$1,000,000
$30,000
Total Loss Costs:
$2,090,000
Engineering/Underwriting Modifier (+20% − 15%)
[−10%]
$1,881,000
Excess Loss Potential:
$100,000
Engineering Expenses
$25,000
Underwriting Expenses
$10,000
Allocated Expenses
$300,000
Taxes, Commissions
$30,000
Profit (5%)
$115,000
Total Policy Premium:
$2,461,000
[0014] Policy rating and pricing applied to property-related insurance pricing generally is a combination of applying the VB and FS methods. The insured's (client) property often contains a mix of highly specific equipment and other activities that are common to many similar types of locations. A client's power generation company may own a small number of highly specialized power generation locations that are rated and priced using FS but also has several branch offices where the premium may be computed by the VB method.
BRIEF SUMMARY OF THE INVENTION
[0015] The present invention referred to herein as the insurance product, rating system and method generally relates to a rating and pricing system for quantifying the risk that the annual savings will not fall below specified levels associated with implementing and maintaining economic improvements. The invention typically involves a unique combination of qualitative and quantitative functions and factors combined in a novel fashion to develop premium costs for risk transfer associated with insuring a minimum savings amount annually or in aggregate over a multi-year policy term.
[0016] Insurance pricing systems where there may be a large amount of exposure and loss data available use standard statistical and probabilistic methods. Policies are often standardized in format and simplified to the point where underwriters construct premiums from tables where the risk attributes such as insured's age, car type, location, or building values are the key elements used to lookup the appropriate rates. Other insurance policies, such as for property insurance, may include a premium component developed from catastrophe models which estimate losses from earthquakes, for example.
[0017] Insurance pricing systems are normally designed for products which are marketed to a large number of customers usually on an annual basis, each with a relatively small loss potential. The present invention comprises an insurance product rating and pricing system designed for a relatively small number of insureds annually or over a multi-year term with each insured having a relatively large exposure. This situation cannot rely on the Law of Large Numbers principle of statistics but applies as much knowledge and actual performance data as possible into the development of the risk analysis and subsequently the premium development.
[0018] The insurance policy rating and pricing system according to the present invention may generally be based on a risk analysis where actual performance data, technical uncertainties, and other factors are combined to form input information for the pricing system. The input files, called annual aggregate risk distributions, quantify the net performance risk of all initiatives for achieving the net annual savings for each year of the policy period. For example, an improvement program may consist of work force reassignments, process re-designs, installation of advanced process controls, and energy efficiency capital projects. However, this invention is not so limited. As a further example, it also applies to other methods capable of quantifying the total net annual savings risk of potentially several hundred initiatives. These risk distributions quantify the probability of exceeding a given net annual savings value and serve as the fundamental input files, data, or equations according to the present invention. The present invention enables underwriters to apply similar procedures they would perform in standard insurance situations even though the nature of the insured risk is unique.
[0019] According to the present invention, “Savings” can be tangible or intangible and include but are not limited to increased revenue; reduced operational expenses maintenance expenses and capital expenditures; increased production through-put; reduced energy consumption; reduced emissions; increased emission credits; etc. These savings will produce additional benefits to the client in the form of enhanced creditworthiness and resulting increased availability of financing and reduced cost of financing. One skilled in the art will recognize that the present invention can generate other savings and benefits not articulated in the lists above.
[0020] The aggregate risk distributions are defined for each location on a similar basis as that applied to develop property insurance. Underwriting may be first performed at a location level and then viewed at the client level. One novel part of this invention is to enable the underwriter to develop pricing at either level. At the location level, the aggregate risk distributions are formed for the subset of all initiatives designed to be implemented at the location. At the client level, the aggregation produces only one aggregate risk distribution per year or other time periods.
[0021] If location level pricing is desired, then according to the present invention, aggregate risk distributions are applied at each location and the client level premium may be equal to the summation of the location level premiums. Some premium components may appear only at the client level, such as profit, tax, and commissions, but the system and method according to the present invention contains the flexibility to include all pricing elements in either version of the application of this insurance pricing system.
[0022] While the invention is generally discussed from the perspective of either pricing a single location or pricing at a single client level, a multi-client pricing system is also within the scope of the present invention. Multi-client as used herein includes but is not limited to an investor(s) in one or more facilities, for example power, refining, chemical, manufacturing facilities, etc. in any permutation or combination of ownership and/or geography.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] A better understanding of the present invention can be obtained when the following detailed description of the preferred embodiment is considered in conjunction with the following drawings, in which:
[0024] FIG. 1 is a block diagram of a power generation station.
[0025] FIG. 2 is a flowchart of an embodiment of the claimed product, system and method.
[0026] FIG. 3 is a flowchart of an embodiment of the claimed product, system and method.
[0027] FIG. 4 is a flowchart of an embodiment of the claimed product, system and method.
[0028] FIG. 5A is a flowchart of an embodiment of the claimed product, system and method.
[0029] FIG. 5B is a flowchart of an embodiment of the claimed product, system and method.
[0030] FIG. 6A is a flowchart of an embodiment of the claimed product, system and method.
[0031] FIG. 6B is a flowchart of an embodiment of the claimed product, system and method.
[0032] FIG. 7A is a spreadsheet of an embodiment of the claimed product, system and method.
[0033] FIG. 7B is a spreadsheet of an embodiment of the claimed product, system and method.
[0034] FIG. 8 is a flowchart of an embodiment of the claimed product, system and method.
[0035] FIG. 8A is a table of an embodiment of the claimed product, system and method.
[0036] FIG. 8B is a chart of an embodiment of the claimed product, system and method.
[0037] FIG. 8C is a chart of an embodiment of the claimed product, system and method.
[0038] FIG. 9 is a chart of an embodiment of the claimed product, system and method.
[0039] FIG. 10 is a system block diagram of one embodiment of the claimed product, system and method.
[0040] FIG. 11 is a block diagram of an insurance policy according to the claimed product, system and method.
[0041] FIGS. 12A-12D are tables of an embodiment of the claimed product, system and method.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0042] The underwriter first determines the insured floor dollar values for each year as shown in step 200 in FIG. 2 . This may be performed by specifying a confidence level that is used to return the indicated or computed minimum insured savings values for all years or confidence levels and can be applied on a year by year basis. Selecting insured floors by first specifying an explicit confidence level is one unique characteristic of this invention. For this invention, “confidence level” is defined as the probability that the annual savings will exceed the insured floor value. Performing this function is called risk acceptance. For each policy year, the underwriters select the risk acceptance level they believe represent insurable positions under the terms and conditions of the policy at step 202 . The insured floors are also called risk acceptance thresholds in that if the insured's annual Savings results are below these values and the insured is in compliance with the terms and conditions of the policy, the insurer would pay the insured the difference between the actual achieved results and the insured floor value at steps 204 and 206 , respectively. Under the insurance policy, the insurer is accepting the risk of paying up to the risk acceptance threshold dollar amount each year.
[0043] These risk acceptance values are also related to claim frequency as depicted in FIG. 3 . The method starts at step 300 where a confidence level percentage is determined at step 302 . The difference between 100 percent and the confidence level percentage constitutes the probability that the Savings may be less than the risk acceptance value at step 304 . For example, a 90% confidence level indicates that 10% of the time, the Savings is expected to be less than the indicated acceptance value. While additional claim frequency mitigation elements are applied in this invention, the 100 minus confidence level may be an upper limit on the expected annual claim frequency.
[0044] Another unique characteristic of this invention is to use the confidence level approach to enable underwriters to apply different risk acceptance judgments for different policy years. This may be but one major advantage of setting deductibles by confidence level rather than directly in terms of absolute dollar values. However, underwriters can choose a risk acceptance value directly and apply the input annual aggregate risk distributions to determine the corresponding risk acceptance confidence level. Both methods are included in this invention. Also the application of input annual aggregate risk distributions to help specify multi-year deductibles is a unique part of this invention.
[0045] The flexibility of specifying yearly or overall confidence values enable underwriters to set risk acceptance values higher for years they believe there is higher risk and lower amounts when the risk is within normal tolerances. This can occur if the underwriters believe that the insured's implementation and scheduling plan will not either meet the expected Savings targets or that the project schedule is too aggressive implying that the insured's Savings will be achieved but not in the policy year indicated in the implementation and scheduling plan. This feature gives underwriters the flexibility to adapt their risk acceptance analysis to consider in addition to the insured's engineering performance, the available personnel, project management, and several other key factors.
[0046] As an example of how this process can be performed, suppose a potential insured's cumulative Savings engineering project plan forecasts $20M in year 1 , $30M in year 2 , and $35M in year 3 as depicted in step 400 of FIG. 4 . After a detailed review of the implementation and scheduling plan by underwriting, the completion schedule for the year 1 is judged to be too optimistic. Underwriters believe that the Savings as forecast by year 1 will be obtained but some of the initiatives will extend into year 2 . For the remaining initiatives, it is further concluded that the Savings targets will be achieved on the time schedule indicated in the implementation and scheduling plan for years 2 and 3 .
[0047] For this situation underwriters may apply a higher confidence level for year 1 than for years 2 and 3 at step 402 . A 95% confidence level could be applied to year 1 with a 90% confidence applied to years 2 and 3 . The resulting risk acceptance values may be $10M for year 1 , $22M for year 2 , and $25M for year 3 . It may be expected that the risk acceptance values will be less than the stated engineering forecasts as a matter of proper underwriting, for example, to reduce the potential for moral hazard.
[0048] With the risk acceptance values selected, the next underwriting decision is to choose the confidence level associated with the loss cost analysis at step 404 . For example if an underwriter chooses a 95% confidence level, the corresponding loss costs actually experienced should be less than this value 95% of the time. A unique characteristic of this invention is the capability of the underwriter to select a loss cost confidence level by year or, by default, use the same value for all years.
[0049] Another unique characteristic of this invention is the ability to apply different savings measurement criteria as claim triggers. One embodiment of the invention contains two types of savings measurement criteria although a combination or other methods could be applied.
[0050] The underwriter selects the measurement method and for this example of the invention, the methods are Escrow or No Escrow. The Escrow approach accumulates the excess above the risk acceptance values, if any, in the Savings over the policy years. If there is a shortfall in a policy year, the Escrow account may be debited first. A claim occurs when the Escrow account is zero and a yearly savings target is not achieved. The No Escrow method simple compares the actually achieved value, A, to insured Savings value, B, and a claim for the dollar difference $B−A occurs if A<B.
[0051] While the underwriter selects the measurement method in the system, it is not necessarily an input that is determined by the underwriting function. The claim measurement method may be identified as part of the policy and may be agreed to by the insured, insurer, and other interested parties such as investment firms, banks, or rating agencies (e.g., Standards & Poor).
[0052] At this point, FIGS. 5A and 5B illustrate the system for computing loss costs using a stochastic model that utilized the input annual aggregate risk distributions, risk acceptance values, the claims measurement method, and the required loss cost confidence level shown at steps 500 and 502 . This is a dynamic system where at any one of these inputs change, the stochastic model is re-run at step 504 . This combination of these policy-specific attributes and risk data to produce loss costs is a unique characteristic of this invention.
[0053] At the completion of the stochastic analysis which may require several thousands of different samples to accumulate the sufficient loss cost distributions, the loss costs at the underwriter specified levels is automatically placed into the pricing worksheet at step 506 . The values are summed over the years of the policy term (e.g., over a range of one to seven years) at step 508 and compared with a company-specific requirement of a minimum rate-on-line at step 510 . Rate-on-line is defined as the loss costs (or premium) divided by the total dollar exposure to the insurer. For example, a 5% rate-on-line requirement for a $1M total exposure produced a premium result of $50,000. The maximum of these two numbers: the sum of the loss cost values from the stochastic model and the rate-on-line estimated premium, is entered as the loss cost component of the multi-year policy premium at step 512 .
[0054] With the loss costs determined, the underwriter adds premium charges that are due to the engineering and underwriting fees that will be required to administrate the policy over the policy term at step 514 . These expenses include for example, on-site engineering review of work practices, initiative implementation progress, and the Savings measurement and verification procedures. These activities will generally vary according to the type of industry, facility location, policy term, policy conditions, and with several other factors. It is noted that the premium reflects the true costs of policy administration as well as the potential costs involved with actual losses. These costs are entered individually for each policy year, inflated using a supplied annual inflation rate, and summed to produce the overall engineering and underwriting (insurance) components at step 516 . These costs are mostly well defined expenses and are not typically risk-based nor do they possess a significant stochastic component. At this point in the premium development, these charges are placed into the year and category (Underwriting or Engineering). Additional analysis of factors that influence the loss cost premium component is generally required before the expense items can be used further.
[0055] Along with the quantitative aspects of underwriting and premium development, there are subjective factors that are designed to utilize the underwriter's intuition and experience to modify, if desired, the computed loss cost premium at step 518 . These factors can increase or decrease the loss cost component within prescribed percentage ranges. To facilitate the underwriter's use of these subjective factors, they are divided into engineering and underwriting categories. The actual list of risk modification factors and ranges will vary between industries and clients but they may include some of the items listed below.
[0056] A credit is interpreted as enhancing risk quality which then translates into a decrease the loss costs. A debit is configured as a decrease in risk quality which increases the loss cost component of the policy premium.
Engineering Quality Underwriting: [Debits, Credits]
[0057] 1) Organization/Culture: [+15%, −10%] Risk exposures, hazards, and human behaviors are inter-connected. A company's safety, environmental, reliability policies and basic cultural risk acceptance attitudes are important attributes for inferring how the corporation and its employees will routinely mitigate risk and also respond to accidents
[0058] 2) New Technology Applications: [+10%, −10%] Depending on the robustness of the new technology design, the operational and short term financial advantages can be offset by a decrease on reliability and availability in the long term. These factors need to be considered by the underwriter in this multiyear type of insurance policy which is intended to insure a minimum performance or Savings level.
[0059] 3) Management Motivation: [+15%, −10%]. The underwriter needs to understand how the company's management intends to leverage the financial applications of the overall implementation and scheduling plan. The multi-year program will require the long term commitment of management and the financial applications of the program will provide the underwriter valuable insights to judge the Savings sustainability.
[0060] 4) Supervisor Motivation: [+15%, −10%] The underwriting risk assessment for facility supervisors may be similar to what may be required for management. At the employee-level, supervisors need to be committed to the implementation and scheduling plan's success and to its sustainability over the multi-year policy term. One way for the underwriter to assess supervisor (and management) commitment may be to determine how the execution of the Savings implementation and scheduling plan is connected to the employee bonus program.
[0061] 5) Complexity: [+10%, −10%] Complexity refers to the difficulty of program execution. Some of the issues to be considered in this evaluation are initiative technical difficulty, volumetric inter-dependence, and schedule inter-dependence.
[0062] 6) Housekeeping and Recordkeeping: [+5, −5%] The cleanliness, arrangement, and organization of the insured's assets are valuable, observable indicators to infer employee reliability and safety awareness. Many studies have shown a strong productivity and reliability correlations to facility and asset cleanliness and organization. This characteristic may be easy to observe and inference to improved reliability may be a factor in the engineering aspects of policy underwriting. Also the level and accuracy of production and operational recordkeeping may be another visible indication of employees' and management's commitment to procedure compliance and attention to detail that also reflects the engineering risk quality of the insured's facilities.
[0063] Overall the summation of the debits and credits of one embodiment is generally limited to a total of a 20% credit (premium decrease) or a 25% debit (premium increase.)
[0064] Underwriting quality refers to the terms and conditions of the insurance policy that are negotiated given the operational and engineering conditions of the implementation and scheduling plan. These risk modification factors measure risk quality from a written contractual, rather than technical, perspective.
[0065] The credit and debit assignments follow the same convention as with the engineering risk modification factors. A credit is interpreted as enhancing risk quality which then translates into a loss cost reduction. A debit is configured as a decrease in risk quality which is expressed as an increase the loss cost component of the policy premium.
Underwriting Quality Underwriting: [Debits, Credits]
[0066] 1) Exclusions: [+10%, −10%] These policy terms refer to events for which the insurance policy would not respond to Savings achievement levels below the insured minimum. These events include, war, worker strikes, weather events, events covered under other insurances, failure of the insured to comply with policy conditions, and contractor performance errors.
[0067] 2) Self insured retention/Deductibles: (+10%, −10%] The self insured retention or deductibles determine the insured's total financial risk exposure. If the insured is willing to assume higher annual Savings levels, then the risk quality from an underwriting perspective can be increased since the insured accepts a larger annual Savings shortfall before the insurance policy would respond.
[0068] 3) Savings Measurement & Verification: [+15%, −10%] The type of Savings and the procedures for measurement verification are fundamental to insurance underwriting. These factors are essential to determine initiative implementation quality both in time and volumetric savings achievement. There are, however, different ways these functions can be accomplished. For example, the measurement and verification can be performed by the insured and audited by the insurer, or a third party can be charged with these tasks. Involving the insured in these actions can be problematic and provide a moral hazard if insufficient oversight is not maintained. Savings measurement and verification can also provide a proactive indication of initiatives which are behind implementation targets. The underwriter needs to assess the type of measurements being taken to measure the Savings, the frequency of measurement, the ability to access this data trending, and the propensity to obfuscate actual initiative performance.
[0069] Overall the summation of the debits and credits are limited to a total of a 20% credit (premium decrease) or a 25% debit (premium increase.)
[0070] The aforementioned factors are routinely applied in policy underwriting and premium development depending on the type of insurance, life, casualty, property, etc. and also on the nature of the insured's business. The actual number and type of Engineering and Underwriting risk modification factors will vary depending on the type and nature of asset performance under policy consideration.
[0071] The “Adjusted Premium” is now computed at step 520 . This term is defined as the aggregate policy term loss costs multiplied by the Engineering and Underwriting risk modification factors. If E=the aggregate engineering risk modification factor, U=the aggregate underwriting risk modification factor, and L the loss costs, then the adjusted premium, P adj is determined by
[0000] P adj =(1+ E+U )* L
[0072] The final stage of the premium development is to add premium components associated with insurance pricing elements at step 522 . These items typically include engineering & administrative expenses, profit, reinsurance costs, taxes and commissions.
[0073] There are several variations and combinations of these factors that can be applied to the insurance product, rating system and method. The most notable variation may be the decision on how to account for the engineering expenses. Some insurance policies of the present invention may include all engineering fees in the policy premium and some may exclude the charges from the policy premium and charge these fees as consulting expenses independent of the insurance policy.
[0074] As an example of how the insurance policy pricing according to the present invention is performed, the following example shows premium development according to the present invention for a three year policy where engineering fees are incorporated into the premium calculation and is used to develop the loss costs.
[0075] An embodiment of the overall claimed subject matter follows in FIGS. 6A and 6B .
[0076] 600 Input Basic Client data into system. At step 600 , the user enters: Insured Name, Lending Institution, Country & Region, Addresses of Covered Locations, Occupancy, Location Size in Production Output Metrics, and Application of Insured Savings. This basic data can be integrated with a client database so that other key variables required by the system can be automatically identified from this basic data.
[0077] 610 Develop the numerical or analytical distributions of Savings by year. At this step an overall annual probability distributions are compiled and placed in a format so they can be accessed dynamically. The distributions describe the probability of exceeding annual Savings vs. the savings values. The distributions can be taken by analytical methods designed to compute aggregate Savings exceedance probabilities. There is a separate distribution for each location, plant, unit, or other segment under analysis for each year. These distributions are composed of Savings values and the corresponding probability of exceeding these values.
[0078] 620 Enter Market and Company Pricing Criteria Data. At this step, the inflation rate that is representative for the policy period and the minimum and maximum rate-on-line company-specified criteria are entered into the system.
[0079] 630 Choose the probability of exceedance thresholds to be used to set the insured floors: the insured savings levels by year, by location, or by other groupings. At this step the amount of risk that the insurer is willing to accept is determined by setting the exceedance probability threshold for coverage. There are two ways this can be done, the user can choose a probability of exceedance for all years or a different value for each year depending on the underwriting information. The probabilities are matched in the probability distributions compiled on step 610 and the corresponding Savings values are identified. For example, suppose the insurer is willing to accept an exceedance probability (measured in percentage) of 90% for a given location for a given year. This value is matched to the appropriate probability distribution discussed in step 610 and the corresponding Savings value is found to be $15M. This means there is a 90% chance that the location's annual savings that year will be greater than $15M. An insurance claim may be triggered if the annual savings achieved is less than the $15M value.
[0080] 640 Record the Savings levels by year, location, or other grouping in the loss cost component of the pricing development system. At this step, the resulting Savings values that are calculated or accessed from the probability distributions compiled in step 610 , are entered into the loss cost component of the pricing system. These values are the resulting insured levels that correspond to the probability of exceedance values entered into the system in step 630 .
[0081] 650 Develop logic to test annual Savings results selected from the annual probability distributions compiled in step 610 to measure loss and excess event frequency and severity. At this step for each year or other grouping, the logic is developed to compare a sampled distribution Savings value from the probability distributions compiled in step 610 to the recorded values savings floor Savings values. If the sampled Savings value is greater than the inured floor, then an excess is produced for that year. If the value is less than the insured level as given in step 640 , then a loss event is produced for that year.
[0082] 660 Develop escrow account and claim trigger logic. At this step, the comparison logic developed to accumulate the total or a fraction of the Savings results that are in excess of the insured savings values. For example, in one year if the computed Savings is $50 and the insured floor is $40, $10 would be credited to the escrow account. On the other hand, if the computed Savings was $35, then first the Escrow account would be debited $5 to obtain the insured level. If the escrow account contained insufficient funds then an insurance claim would be triggered for the difference between the insured level and the sum of the actual Savings results and any funds able to be drawn from the escrow account.
[0083] 670 Develop claim count, claim amount and claim risk distribution logic. At this step, logic is developed to accumulate the number and financial amount of claims for both the escrow and no escrow accounting methods. The financial amount of the claims is called the loss costs. This information is used to compute numerical distributions for the cumulative probability of loss as a function of the loss amount. These distributions are called claim risk distributions.
[0084] 680 Run stochastic model to develop claim risk distributions. At the step, a numerical procedure is applied using commercial software or specialized programming that applies steps 640 , 650 , and 660 to accumulate sufficient loss data to develop a numerical distribution of the probability of loss as a function of the loss amount for both the escrow and no escrow accounting approaches.
[0085] 690 Determine Rate-on-Line premium. At this step, the prescribed rate-on-line criteria selected in step 620 is applied to each annual exceedance threshold selected in step 640 . The rate-on-line premium calculation may be performed by multiplying the exceedance threshold, the insured Savings minimum, or floor by the decimal value of the rate-on-line. For example, if the insured floor is $10,000 and the rate-on-line is 10%, then the premium requirement is $10,000*0.10 or $1,000. These calculations are applied to each insured annual savings floor as computed in step 640 . The results are summed and placed in a Term of Loss Cost Summary Section of the system.
[0086] 700 Determine loss cost confidence level and loss cost values. At this step the underwriter enters the likelihood requirement, in percent, that the loss costs obtained from the system will be actually less than the identified values. These percentages are then applied to the claim risk cumulative distributions for each year to determine corresponding value for the yearly loss costs contribution to the total multi-year premium. The resultant values are placed in the yearly loss cost fields. This is performed for the claim risk distributions with and without escrow accounting.
[0087] 710 Compute Loss Cost Policy Premium Component. At this step, the rate-on-line premium values for each year are summed to compute the total policy premium via the rate-on-line method. Next, the annual loss costs determined in step 680 are summed over the policy years for the Escrow and No Escrow pricing methods. The system user then selects which Escrow pricing method may be required for the client. The system subsequently computes the policy loss cost premium component as the maximum of (1) prescribed rate-on-line, and (2) the summed loss costs via the Escrow method selected.
[0088] 720 Determine Underwriting Expenses. At this step, the company expenses, required to perform the underwriting analysis and risk surveillance are entered. These costs are incurred in reviewing monthly, quarterly, and yearly Savings reports and periodically meeting with client management at the client sites. The underwriters' responsibility is to ensure the client is meeting their contractual responsibilities and the Savings targets. If the client is in compliance then coverage continues as defined in the policy. If the client is not in compliance, then it is the underwriters' responsibility to notify company engineering and notify client management, in writing. If compliance with engineering recommendations and other policy conditions are not met in the time constraints as specified in the policy, then the underwriters have the responsibility and the authority to terminate insurance coverage. The expenses incurred performing these activities are entered into the system for each policy year.
[0089] 730 Determine Engineering Expenses. At this step the technical engineering, project management, and Savings oversight activities are reviewed for compiling their associated policy expense costs. Engineering activities provides technical data to support underwriting activities, provides periodic loss prevention and Savings reporting, provides technical directions for initiative implementation, and serves as the on-site liaison between the insurer and the insured. The expenses incurred performing these activities are entered into the system for each policy year.
[0090] 740 Determine Engineering Related Underwriting Credits and Debits. At this step, pricing modification factors are determined that increase or decrease the premium based on engineering related attributes of the Savings implementation insured values as selected in step 620 . These factors include, but are not limited to, the insured's organization and business culture, new technology applications, management motivation to achieve the Savings targets, supervisor motivation, and plant complexity. The range of the modifiers will vary with application but generally are 10% for each factor with an aggregate factor of no less than −20% and no greater than +25%. The engineering risk modification factors are entered into the system for each policy year and an aggregate modification factor is computed.
[0091] 750 Determine Underwriting related Credits and Debits. At this step, the pricing modification factors are determined that increase or decrease the premium based on the underwriting related attributes of the Savings insured values as selected in step 620 . These risk modification factors include, but are not limited to, policy exclusions that are in place, the insured self insured retention, deductibles, limits, and the Savings measurement and verification program quality. The range of the modifiers will vary with application but generally are 10% for each factor with an aggregate factor of no less than −20% and no greater than +25%. The underwriting premium modification factors are entered into the system for each policy year and an aggregate modification factor is computed.
[0092] 760 Compute Adjusted Policy Premium. At this step, the numerical results determined in previous steps are combined to produce the basic policy premium. There are several versions or combinations of the steps outlined in this procedure that are claims. An example of one such embodiment is:
[0093] Adjusted Policy Premium=Step 710 (Loss Cost Policy Premium)*[1+Step 740 Engineering Modification Factors)+Step 750 Underwriting Modification Factors)]. This result is stored in the Premium: Insurance Adjusted Premium Section of the system.
[0094] 770 Compute Policy Underwriting and Engineering Expenses. At this step the underwriting expenses determined in step 720 and the engineering expenses determined in step 730 are inflated using the inflation rate entered into the system in step 620 over the policy term and summed to compute the total policy level underwriting and engineering expenses. These results are stored in the Premium: Insurance and Engineering Expense Sections of the system.
[0095] 780 Compute Engineering and Underwriting Profit. At this step, company-specific guidelines are applied to compute insurance and engineering profit based on the expenses computed in steps 760 and 770 . These results are stored in the Premium: Profit-Insurance and Engineering Sections.
[0096] 790 Compute Allocated Reinsurance Costs. At this step, reinsurance costs, whether facultative or treaty related, are entered into the Reinsurance section of the system.
[0097] 800 Compute Taxes. At this step, taxes are computed on the pertinent sections of the Premium Section of the system and entered in the system in the Premium-Insurance and Premium and Engineering: Taxes Section.
[0098] 810 Compute Commissions. At this step insurance related commissions are computed on the pertinent sections of the Premium Section of the system and entered in the system in the Premium-Insurance: Commissions Section.
[0099] 820 Compute Total Policy Engineering Costs. At this step, all premium costs entered into the Premium-Engineering related sections are summed to compute the total policy engineering costs.
[0100] 830 Compute Total Policy Premium. At this step, all premium costs entered into the Premium-Insurance related sections are summed to compute the total policy premium. Also, based on the policy requirements and the pertinent accounting procedures, the total policy premium can also include the total engineering costs. In this scenario, all risk transfer and direct engineering costs required to support the policy are included in the total policy premium which is divided by the policy term to determine the annual premium. Depending on the insurance conditions, the insured may pay the whole premium at the beginning of the policy term or pay on an annualized basis.
[0101] FIGS. 7A and 7B depicts a spreadsheet encompassing the steps disclosed in FIG. 6 .
[0102] The methods disclosed above can be used to ascertain a securitization rating VB and FS ratings can be based on benchmark data for a particular asset, e.g. the power generation station of FIG. 1 .
[0103] For example, FIG. 8 illustrates such method. Engineering data such as improving yields 940 or other initiatives 950 , both depicted in FIG. 8A is collected for each required asset at step 900 . The engineering data is compared with benchmark data to create an action plan and financial goals at steps 910 and 920 . FIG. 8B illustrates an exemplary action plan while FIG. 8C illustrates the financial goals.
[0104] For example, FIG. 8B includes various actions to be initiated by employees 960 , such as detailed process evaluation 970 and train operators 980 . FIG. 8C shows how the risk curves can be used to select annual insurance levels and also provide information to select financial goals for the improvement program overall. For example, following general insurance company guidelines, a company chooses the 90% exceedance probability and moves horizontally over until we cross the Year # 1 risk curve at 990 where at 90% risk acceptance value for insurance purposes is $20M at 995 . This typically means there is a 90% chance that the actual result will be greater than $20M. The company can also use these risk curves to set their internal financial goals at more aggressive risk acceptance values. For example, company management may target the 60 or 70% levels for the business unit targets which for year # 1 would be a goal between approximately $22-$25M. The same procedure is applied for Year # 2 . The insurance risk acceptance percentile intersects the risk acceptance curve at 1000 which corresponds to $26.7M NCM annual savings at 1005 . This amount would be selected as the insured floor. For the company's internal financial goals, using the 60-70% guidelines as in Year # 1 , Year # 2 company financial goals would be between $28-29$M. A securitization rating can be ascertained based on the action plan and financial goals at step 930 ( FIG. 8 ).
[0105] Implementation of the present invention may also improve an insured's bond rating. FIG. 9 illustrates cost savings as a result of a reduction of credit risk. For example, suppose improving the operations utilizing the present method can increase the Savings by $700 million of an insured over a ten (10) year period. In the course of developing this company's credit risk for the purpose of developing a bond issue, the lending institution and or credit agency involved may give the company credit for the enhanced operational and financial status by applying the margin benefit to the reduction of the principal at risk. This may be a subjective decision. However, the method applied to this situation offers a risk transfer of principal from the client to the insurer thereby securitizing at least a portion of the principal. Suppose the client has a credit rating of BB- by S & P. A policy utilizing the present invention for this client can have effect to reduce the principal at risk thereby also reducing the transaction's credit risk. Through the risk transfer of this principal to the insurance company, the initial transaction (now at effectively a lower principal) can have an equivalent credit risk of the full bond amount at a higher quality credit rating.
[0106] For example, if a client has an $600M policy according to the present invention for over the ten (10) years of a $800M bond, the reduced effective principal at risk ($200) make the transaction appears, from a credit risk perspective as slightly above investment grade, BBB-. This means mathematically the credit risk of a $200 BB- bond may be roughly equivalent to the credit risk of an $800M bond rated at BBB-. This situation illustrated at 1010 in FIG. 9 . This example assumes the insurance company's credit rating is at least BBB-.
[0107] Referring to FIG. 10 , a computer system used to implement some or all of the method and system is illustrated. The computer system consists of a microprocessor-based system 1100 that contains system memory 1110 to perform the numerical computations. Video and storage controllers 1120 enable the operation of the display 1130 , floppy disk units 1140 , internal/external disk drives 1150 , internal CD/DVDs 1160 , tape units 1170 , and other types of electronic storage media 1180 . These storage media 1180 are used to enter the risk distributions to the system, store the numerical risk results, store the calculation reports, and store the system-produced pricing worksheets. The risk distributions can be entered in spreadsheet formats using, e.g., Microsoft Excel. The risk calculations are generally performed using Monte Carlo simulations either by custom-made programs designed for company-specific system implementations or using commercially available software that is compatible with Excel. The system can also interface with proprietary external storage media 1210 to link with other insurance databases to automatically enter specified fields to the pricing worksheet, such as client name, location address, location size, location occupancy, and risk quality attributes applied in the “Credits and Debits” section. The output devices include telecommunication devices 1190 (e.g., a modem) to transmit pricing worksheets and other system produced reports via an intranet or the Internet to management or other underwriting personnel, printers 1200 , and electronic storage media similar to those mentioned as input device 1180 which can be used to store pricing results on proprietary insurance databases or other files and formats.
[0108] FIG. 11 is a block diagram that depicts the terms and conditions of an insurance policy 1300 according to the present invention. The insurance policy 1300 includes insured information 1310 such as a name of the insured, geographic or physical location(s) of the insured to be covered by the policy. Also included in the policy 1300 is a policy period 1320 . The policy period 1320 can be over a single year, multi-year or some other defined period of time. Policy terms 1330 , such as savings criteria is included. The savings criteria are generally crafted by a third party company (e.g., HSB Solomon Associates) that uses benchmark information in creating the savings criteria based on the particulars of the insured's business. The savings criteria include processes that if implemented by the insured establishes a sum certain savings to the insured. The third party company can serve as a facilitator in process execution enabling the insured to improve operating performance (resulting in a savings). If the process is implemented and the sum certain savings is not realized by the insured over the policy term (with certain exceptions outlined in the policy), the insurer will pay the insured the difference (referred to as a shortfall). The certain exceptions include, but are not limited to, hostile or warlike action, insurrection, rebellion, civil war, nuclear reaction or radiation, default or insolvency of the insured, vandalism, riot, failure of contractors to implement the processes, modification or alteration to the processes that were not approved by the insurer or other terms outlined in the policy. Other policy terms 1330 include duties of the insurer and duties of the insured such as execution of the processes in a timely manner, cooperation with the third party company, preparation of status reports, permission by others to audit the insured's accounts, performance records and data logs and other matters. Furthermore, if the savings are determined on a yearly basis and the policy is a multi-year policy, and as a result of the insured implantation of the processes, a shortfall occurs, such shortfall could be kept in an escrow account (herein referred to as a surplus account). The escrow could increase or decrease over the multi-year policy. Any surplus at the end of the policy term can be paid to the insured. Other terms can include cancellation terms, representations and warranty, assignment obligations and effects due to the sale or transfer of a covered location.
[0109] The policy 1300 also includes monetary policy limits (i.e. limit of liability) 1340 over the time period 1320 and premiums 1350 to be paid by the insured and endorsements 1360 . Such endorsements can include market price indexing and operational baselines unique to the insured's industry, the implementation plan and schedule, agreed metric plan, savings calculation procedures and baseline values, debt obligations and additional exclusions, definitions and conditions.
[0110] FIGS. 12A-12D illustrate an agreed metric plan. The agreed metric plan provides top level task lists of an implementation plan and schedule. For illustrative purposes, the plan is divided into four sections, namely, initiative 1400 , benefits and measurements 1402 , implementation 1404 , and savings 1406 .
[0111] For example, in FIGS. 12A , 12 B, 12 C and 12 D, the agreed metric plan pertains to a chemical industry policy. From the implementation plan and schedule, various top level initiatives 1400 are listed in FIG. 12A . For example, some of the initiatives from a chemical industry policy may include movement of an analyzer to trays and modification of regulatory controls on final product columns 1408 for a particular plant 1410 (Initiative # 1 ). The column titled “area” refers to geographical or functional location the initiative, e.g., Plant 1 . Another initiative for an insured's site may include the reduction of pressure in a stripper to save energy 1412 (Initiative # 2 ). Furthermore, another initiative for another plant may include the reduction of time to dry catalyst after regeneration 1414 (Initiative # 3 ). Documents or other deliverables 1418 are provided to document the results of the implantation of the initiatives. An example of such a document 1420 may include a report describing the savings achievement as a result of the implantation of initiative # 3 .
[0112] One embodiment of the benefits and measurement section of the agreed metric plan is provided in FIG. 12B . Implementation of the initiative may result in certain benefits that are described in this section. For example, for initiative # 1 , one benefit 1422 may be a production efficiency improvement. The plan includes various measurement values and methodologies that are directed to the results of the initiative. The values and methodologies may relate to engineering units (e.g., t/h) and time periods (e.g., measurements are done daily and then averaged over a period). Furthermore, the plan includes dates (target and actual) for the commencement of the initiatives and completion dates of the initiatives. The agreed metric plan typically requires the agreement and sign off (e.g., initials of the insured and insurer) 1424 of each initiative and initiative results (i.e., the agreement section).
[0113] The plan also includes target and actual dates as shown in FIG. 12C . Each initiative may have a target date of completion 1426 , actual date of completion 1428 and the number of days for completion 1430 .
[0114] The plan also include information regarding the economic Savings 1432 as a result of the implantation of the initiatives. Such information may include target Savings 1434 and actual Savings 1436 achieved as a result of the initiative.
[0115] The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the details of the illustrated method may be made without departing from the spirit of the invention.
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In the present invention, an insurance product, rating system and method generally relates to a rating and pricing system for quantifying the risk that the annual savings will not fall below specified levels associated with implementing and maintaining economic improvements. The product, system and method can be applied to various industries, including, power generation, petro-chemical, manufacturing and refining facilities. Various embodiments disclosed herein relate to a method for pricing an insurance policy for insuring a minimum level of return on investment.
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FIELD OF THE INVENTION
[0001] The present invention relates to the processing of waste glass and more particularly to the beneficiation of waste glass.
BACKGROUND
[0002] Glass containers have traditionally been made from sand (to provide silica), soda ash (to reduce the melting point) and limestone (to increase hardness) as raw materials. More recently, however, cullet or broken glass has become a raw material for manufacturing of glass containers. Other ingredients are also used in small amounts, depending on the type of glass to be manufactured.
[0003] Bottles and jars collected in recycling schemes are manually sorted into clear, amber and green glass. This typically occurs at a beneficiation plant, where the quality of the waste glass is improved before processing. Contaminants such as metals, plastics, china, ceramics and stones are removed, and the glass is broken into cullet. The cullet is transported to glassmaking factories where it is combined with other batch materials in a furnace to manufacture new glass containers. The use of cullet, as opposed to virgin materials, has real environmental and economic benefits in terms of saving both natural resources and energy.
[0004] Small amounts of contamination can result in the rejection of tons of recycled glass. For example, ceramic material such as a piece of crockery may be sufficient to cause a ton of cullet to be returned to the recycling process or to be consigned to landfill.
[0005] The volume occupied by waste glass awaiting disposal is also a significant problem, particularly in the hospitality industry. Hotels, restaurants, pubs, public events and hospitals, to name but a few examples, accumulate a substantial volume of waste glass that requires storage space and handling. Waste glass needs to be collected frequently and sometimes at not insignificant expense.
[0006] The economic feasibility of waste glass collection and beneficiation in the hospitality industry is particularly poor due to factors such as contamination and the cost of labour and transport. This results in a low percentage of waste glass being recycled.
[0007] FIG. 1 is a flow diagram of a method for the manufacture and subsequent processing of glass containers after use. Virgin material for producing glass containers is sourced at step 110 and transported to a glass container manufacturing plant at step 115 . The material is processed at step 120 and glass containers are manufactured at step 125 . The glass containers are filled (e.g, at a brewery or winery) and transported to customers at step 130 and are used at step 135 . An example of such use comprises the consumption of beverages in, say, a hotel pub.
[0008] The empty or waste glass containers are collected at step 140 , usually from the point of use, and transported to a central location for local processing at step 145 . Local processing or beneficiation typically comprises manual sorting of the glass containers into the 3 main colour groups (i.e., clear, amber and green) and removal of foreign contaminating material such as ceramics and metals. The manual processing results in a significant portion of the waste glass and foreign material (typically 40% of all waste glass) being used as landfill at step 165 . The remaining portion of waste glass is transported to a plant for final beneficiation at step 150 . Final beneficiation is performed at step 155 , which may involve further colour sorting, removal of foreign material, prior to breaking of the sorted glass containers. Final beneficiation is typically performed automatically (e.g., by a Binder colour sorting machine and a metal detector), as opposed to manually by human beings, and results in a further portion of the waste glass (typically 10%) being used as landfill at step 165 . Yet a further portion of the waste glass (typically 10%) is used in alternative applications at step 160 . The remaining portion of the waste glass (typically 30%) is used as raw material for new glass container manufacture at step 125 .
[0009] Current practices for processing and recycling glass containers thus involve a significant amount of handling and transportation of glass bottles to central processing depots or plants, during which some of the bottles are broken. Disadvantageously, detection of contamination and colour sorting of the glass is significantly more complex for glass cutlet than for whole bottles. Accordingly, only a relatively small portion of the waste glass can be used in the manufacture of new glass containers. A need thus exists for a method and apparatus for processing glass in a more efficient and/or cost effective manner.
SUMMARY
[0010] According to an aspect of the present invention, there is provided an apparatus for processing glass objects, The apparatus comprises a chute assembly with a first opening at one end thereof for receiving glass objects and a second opening at a distal end thereof for dispensing glass cullet, a rotatable chisel assembly located substantially transversely within the chute assembly for breaking glass objects travelling through the chute assembly, drive means for causing the chisel assembly to rotate, and a controller for controlling the drive means.
[0011] The chisel assembly may further comprise at least one protruding portion that extends substantially longitudinally within the chute assembly from the chisel assembly towards the fist opening. The chisel assembly may further comprise a central portion mounted on a shaft disposed substantially longitudinally within the chute assembly to which the blade portions and at least one protruding portion are mounted. The protruding portion may be mounted substantially midway between the blade portions.
[0012] The apparatus may further comprise an optical detector for detecting objects inserted into the first opening. The controller in conjunction with the optical detector may be adapted to count the number of objects inserted into the first opening. The controller in conjunction with the optical detector may also be adapted to detect and count the number of glass objects of a particular glass colour inserted into the first opening.
[0013] According to another aspect of the present invention, there is provided an automated method for processing glass objects. The method comprises the steps of performing beneficiation to identify foreign matter amongst the glass objects, breaking the glass objects to produce cullet, and identifying a portion of the cullet that is free of the foreign matter.
[0014] According to still another aspect of the present invention, there is provided an apparatus for processing glass objects that comprises means for performing beneficiation to identify foreign matter amongst the glass objects and means for crushing the glass objects to produce cullet. The means for performing beneficiation may comprise an optical detector. The apparatus may further comprise means for identifying glass objects of a particular glass colour.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Embodiments are described hereinafter, by way of example only, with reference to the accompanying drawings in which:
[0016] FIG. 1 is a flow diagram of a method for the manufacture and subsequent processing of glass containers after use;
[0017] FIG. 2 is a flow diagram of a method for processing of glass containers after use;
[0018] FIG. 3 is a perspective view of an apparatus for on-site processing of glass containers;
[0019] FIG. 4 is a perspective view of a motor assembly for the apparatus of FIG. 3 ;
[0020] FIG. 5 is a perspective view of a chisel assembly for the apparatus of FIG. 3 ;
[0021] FIG. 6 is a block diagram of electrical circuits for controlling the apparatus 300 of FIG. 3 ; and
[0022] FIGS. 7 and 8 are flow charts of operation of the apparatus of FIG. 3 .
DETAILED DESCRIPTION
[0023] Embodiments of a method and an apparatus for processing glass are described hereinafter. Although the embodiments described are specifically described with reference to processing of glass bottles, it is not intended that the present invention be so limited as the principles described herein may be applicable to other kinds of glass objects and containers such as glasses, jars, vases, and fluorescent tubes.
[0024] FIG. 2 is a flow diagram of a method for processing glass containers after use.
[0025] At step 210 , glass containers are processed at the location or on-site where the containers were used (e.g., at a hotel, pub, hospital, etc.). An apparatus positioned either temporarily or permanently on-site may perform the processing. Alternatively, the processing may be performed on-site by a transportable apparatus mounted on a vehicle such as a truck for operation at various sites. Processing comprises pre-beneficiation to identify items that are made from or include foreign materials (i.e., ceramics and metals) and breaking of the glass containers into cullet. Items and/or portions of the cullet containing foreign materials may thus be discarded (e.g., for use as landfill, etc.). The cullet is transported to a central processing plant at step 215 to undergo final beneficiation at step 220 . Final beneficiation involves colour sorting of the cullet (e.g., into the 3 main colour groups of clear, amber and green) and removal of portions of the cullet that are contaminated by foreign materials, which results in a portion of the cullet (typically 10%) used as landfill at step 230 , a further portion of the cutlet being used in alternative applications (typically 10%) at step 240 , and the remaining amount of cutlet (typically 80%) being used as raw material for the manufacture of new glass containers at step 235 . The steps of the method shown in FIG. 2 can replace steps 140 to 165 of FIG. 1 (indicated by the box 170 formed by broken lines in FIG. 1 ). In this case, step 235 of FIG. 2 corresponds to step 135 of FIG. 1 . The method of FIG. 2 advantageously enables a greater portion of the waste glass to be used as raw material for further glass container manufacture and reduces the amount of waste glass transportation required. More specifically, it is not required to transport whole waste glass containers.
[0026] FIG. 3 shows a perspective view of an apparatus 300 for on-site processing of glass containers. On-site processing means that the apparatus 300 is deployed for pre-beneficiation and breaking of glass containers at a location where the glass containers are used and disposed of.
[0027] Glass containers may be inserted into the apparatus 300 via an opening 306 in a lid 304 of an upper chute portion defined by sides 314 , 316 , 318 and other sides not shown. The shape and size of the opening 306 and the lid 304 may be designed to accept typical sized glass bottles such as wine bottles but to make insertion of other objects such as ceramic cups and saucers more difficult or impossible. The lid 304 is hingedly attached to a side of the upper chute portion by means of a hinge 302 . Hinged flaps are mounted on the underside of the lid 304 for obstruction of the opening 306 . The flaps may be locked in a closed position by a solenoid to prevent insertion of objects into the upper chute portion when the apparatus 300 is not ready to be operated. If not locked by the solenoid, the flaps open downwards from a centre line of the opening 306 in response to insertion of an object into the opening 306 . Thereafter, the flaps return to the closed position by means of a counter-weight biasing mechanism. As would be known by persons skilled in the art, other mechanisms, such as a spring-loaded mechanism, can also be practiced for the same purpose. The upper chute portion is mounted on a base plate 312 , which has an aperture (not shown) through which the glass containers can pass. The base plate 312 is of substantially the same cross-section as, and acts as a top plate for, a lower chute portion defined by sides 320 , 322 , 324 and other sides not shown. A control panel 326 for operating the apparatus 300 is mounted on the side panel 322 of the lower chute to portion. A dome vent 308 is mounted in an aperture in the base plate 312 by means of a vent flange, typically made of foam rubber 310 . The dome vent is typically made from plastic or stainless steel (other materials are also possible) and provides airflow and consequent cooling for a motor assembly located in the lower chute portion. The lower chute portion is of larger cross-section than the upper chute portion. The lower chute portion is mounted on a base plate 332 that also acts as a lid 332 of a base cabinet comprising a base plate 336 , a right-side panel 334 , a left-side panel (not shown), a rear panel (not shown), and left and right door panels 342 that are attached to the left-side panel (not shown) and the right-side panel 334 , respectively, by means of hinges 344 . The base plate 332 has an aperture (not shown) through which glass cullet can pass into the base cabinet of the apparatus 300 . A bin (not shown) can be located within the base cabinet of the apparatus 300 for collection of glass cullet falling through the aperture in the base plate 332 . The dimensions of the base cabinet allows insertion of a modified version of an 80-litre plastic refuse “wheelie bin” for collection of the glass cullet. The modification involves cutting the bin transversely into top and bottom portions, removing a portion of the sidewalls from at least one of the top and bottom portions, and rejoining the top and bottom portions to produce a bin of reduced height and volume. The modification reduces the volume of the bin to 60 litres with a consequent reduction in the mass of cullet the bin can hold, thus making manipulation of a full bin easier. An attachable/detachable handle extension provides a handle at approximately the usual handle height of a standard unmodified bin, which also contributes to easier manipulation of a full bin. A higher than usual handle height may be used, which advantageously assists taller users in manipulating the bin. The handle extension is required to be detached when inserting the bin into the base cabinet of the apparatus 300 .
[0028] Although the lid 304 and upper and lower chute portions are of hexagonal shape and cross-section, respectively, persons skilled in the art would understand that other shapes and cross-sections may be practiced.
[0029] The apparatus 300 is generally internally insulated, and particularly the lower chute portion containing the motor assembly, which reduces the noise level generated to less than 60 dB.
[0030] FIG. 4 shows a perspective view of a motor assembly 400 that can be mounted within the lower chute portion of the apparatus shown in FIG. 3 . A motor 408 is mounted on a motor base plate 402 . The motor base plate 402 is mounted on the base plate 332 by means of rubber mounts 410 . The motor 408 drives a rotatable chisel assembly 500 (shown in FIG. 5 but not in FIG. 4 ) by means of pulley wheels, a pulley and a shaft (not shown), which are located under the motor base plate 402 . The shaft connection on the driven side comprises a dog clutch, bore and key and grab screws (not shown). However, other drive train means and/or means of connection may be practiced, as would be understood by persons skilled in the art. The chisel assembly 500 is mounted within a lower portion 404 and an upper portion 406 of a chisel chamber, The lower and upper portions 404 and 406 of the chisel chamber are of circular cross section, though not necessarily, and abut the motor base plate 402 from either side. An aperture (not shown) in the motor base plate 402 is provided for mounting of the chisel assembly 500 . Glass containers enter the chisel chamber via a feed pipe 414 , which is located within the upper chute portion and is connected at a top end thereof to a feed pipe spacer 416 and at the bottom end thereof to the upper portion 406 of the chisel chamber. The glass containers are broken by the rotating chisel assembly 500 and the resulting cullet falls through the lower portion 404 of the chisel chamber and an aperture in the rectangular base plate 332 into the base cabinet of the apparatus 300 . A rubber shield with a narrow aperture therein may be transversely mounted proximate to the top of the feed pipe 414 to prevent or at least ameliorate cullet and other material flying back up the feed pipe 414 during processing. The rubber shield also contributes to reduction of the operating noise level of the apparatus 300 . In certain embodiments, an iris is used in place of the rubber shield. An iris comprises a flat member of resilient flexible material with a number of slits extending radially from the centre towards the outer perimeter of the iris, to provide resilient flaps that have to be forced open upon insertion of an object. The iris is transversely mounted within and proximate to the top of the feed pipe 414 . In an optional further arrangement, a second iris is transversely mounted substantially parallel to and approximately 1 cm above the first iris. A stainless steel drip tray may be provided that surrounds the opening of the feed pipe 414 . The second iris may be disposed over the top of the feed pipe 414 in the stainless steel drip tray. The irises, individually and in combination, advantageously reduce noise, prevent or reduce liquid spills in the stainless steel drip tray from entering the apparatus 300 , and substantially prevent unintentional insertion of objects into the apparatus 300 by an operator. Even insertion of broken glass bottles is made more difficult. The irises are produced from Promeg (a resilient plastic material) of 0.6 mm thickness. In one particular embodiment, a circular iris has 10 flaps resulting from diametrically slitting the iris at 36° intervals.
[0031] FIG. 5 shows a perspective view of a chisel assembly 500 that can be used with the apparatus of FIG. 3 . The chisel assembly 500 comprises chisel blades 504 mounted circumferentially on an annular collar 502 . A circular plate 512 is mounted within the annular collar 502 . A bolt 508 , which serves as a shaft disposed substantially parallel to the longitudinal axis of the feed pipe 414 and/or the upper and lower chute portions (shown in FIG. 4 ), passes through an aperture in the centre of the circular plate 512 for purposes of driving the chisel assembly 500 via a pulley system (not shown) by the motor 408 (shown in FIG. 4 ). The shaft or bolt 508 is supported substantially parallel to the longitudinal axis of the feed pipe 414 and/or the upper and lower chute portions (shown in FIG. 4 ) by means of bearings (not shown) mounted to the upper and lower chute portions. Other forms of shaft, drive system, and shaft support means may be practiced, as would be known to persons skilled in the art.
[0032] Steel rods 505 of circular cross-sectional area are located along the glass-breaking leading edges of the chisel blades 504 to provide additional strength and reduce wear of the chisel blades 504 . Sweeper portions 506 , for clearing an accumulation of glass cullet directly under the chisel assembly 500 , are mounted on the underside and proximate to the trailing edges of each of the chisel blades 504 , The sweeper portions 506 extend substantially perpendicularly to the major surfaces of the chisel blades 504 .
[0033] A protruding portion 510 is mounted on the rim of the annular collar 502 , substantially perpendicularly to the major surfaces of the circular plate 512 and extending in a direction from which glass containers will arrive for breaking. The protruding portion 510 is preferably mounted proximate to the outer circumferential edge of the rim of the annular collar 502 and substantially midway between the chisel blades 504 . The protruding portion 510 assists breakage of glass containers, prevents or at least ameliorates blockages in the apparatus 300 , and achieves a more consistent cullet size and shape than operation without the protruding portion 510 . The protruding portion 510 is shown in FIG. 5 as a quadrangular section, however, other shapes may be practiced such as a triangular section. The embodiment of the chisel assembly 500 described hereinbefore comprises a single protruding section 510 , however, more than one protruding sections can be practiced.
[0034] FIG. 6 is a block diagram of an electrical circuit for controlling the apparatus 300 of FIG. 3 . A controller 605 , including a control panel 326 mounted externally to the apparatus 300 , as shown in FIG. 3 , provides “START”, “STOP”, and “FORCE ON” functionality for controlling the apparatus 300 , Specifically, the control panel 326 includes switches for user actuation of the foregoing functions, a green “STATUS” LED, and a visual display for user feedback, The controller 605 comprises an electronic circuit including discrete logic and/or a microprocessor that receives inputs from the switches on the control panel 326 , magnetic switches 630 , an ultrasonic detector unit 630 , and an optical sensor unit 680 .
[0035] The magnetic switches are positioned to detect the open/close status of the doors of the base cabinet, the presence or absence of the lid 304 , and the open/close status of the flaps located on the underside of the lid 304 of the apparatus 300 . If a door of the base cabinet is open or the lid 304 is not present, the motor 655 that drives the chisel blade assembly of the apparatus 300 is prevented from operating. On the other hand, an open flap is indicative of insertion of an object into the apparatus 300 and causes the motor 655 to operate.
[0036] The ultrasonic detector unit 610 is connected to a bin present sensor 625 and a bin full sensor 620 , which detect whether a bin is present in the base cabinet of the apparatus 300 and whether a bin that is present is full, respectively, by way of distance measurement. For example, a full bin may be identified by detecting the level of cullet in the bin.
[0037] Other embodiments of the present invention may use heat and moisture resistant adjustable photo electronic detection sensors in place of or in addition to the ultrasonic bin present and bin full sensors 625 and 620 , respectively. Use of a photo electronic detection sensor simplifies measurement of the level of cutlet in the bin, particularly when a non-standard bin is used.
[0038] The controller 605 also provides an output to a solenoid 675 for locking the flaps located on the underside of the lid 304 of the apparatus 300 in a closed position to prevent objects being inserted into the apparatus 300 .
[0039] Operation of the motor 655 is controlled by means of the motor control unit 615 , which operates a contactor relay 650 to connect or disconnect power to the motor 655 . Power is provided from single-phase 230 V mains via a plug socket 635 , a circuit breaker 640 and a fused mains on/off switch 645 . An automatic thermal overload switch may be used to prevent overheating of the motor 655 and the motor control unit 615 . Accordingly, operation of the motor 655 can be prevented until a blockage or foreign material inserted into the apparatus 300 is cleared. Mains power is provided to the motor control unit 615 via a mains filter 660 , a fuse 665 , and a transformer 616 . The ultrasonic detector unit 610 , the motor control unit 615 and the main switching relay 650 are provided in a sealed unit 670 . Various connectors and/or cable glands facilitate inputs and outputs to/from the sealed unit 670 , A smaller cullet size is generally preferable on account of occupying a relatively smaller volume. Final beneficiation generally requires cullet size to be in the range of 10 mm to 65 mm. Additionally, certain glass manufacturers require cutlet to be less than 50 mm in size. The average size of the cullet produced is affected by the rotational speed of the chisel assembly in that a lower rotational speed results in a larger average cullet size. A typical range of rotational speed that provides a suitable average cullet size is 400 rpm to 1200 rpm. In one embodiment, the rotational speed is approximately 930 rpm.
[0040] The rotational speed of the chisel assembly may be fixed by the configuration of the motor (e.g., the number of poles) and the design of the drive train. In other embodiments, a user via the control panel 326 can control the rotational speed of the chisel assembly. For example, a 3-phase motor together with an inverter and a digital controller enable speed control of the chisel assembly.
[0041] FIGS. 7 and 8 are operational flow charts for the apparatus of FIG. 3 . Referring to FIG. 7 , when it is detected at step 710 that the “START” button is pressed by a user of the apparatus, operation of the motor is enabled (standby mode) subject to the magnetic switches 630 that provide a safety interlock and that detect operation of the flaps, the solenoid is activated (in-position) to enable operation of the flaps, the green LED is turned on, and the number of times the flaps are activated by insertion of an item into the chute opening is accumulated and shown on the display, at step 715 . At step 720 , various inputs produced by sensors 620 , 625 and switches 630 are sampled. A determination is made at step 725 whether the bin door is open. If yes (Y), power to the motor is removed, the green LED is turned off and the display is blanked at step 790 . Thereafter, processing continues at step 720 . If the bin door is not open (N), a determination is made at step 730 whether the top lid is open. If yes (Y), power to the motor is removed, the green LED is turned off and the display is blanked at step 790 . Thereafter, processing continues at step 720 . If the top lid is not open (N), a determination is made at step 735 whether the bin is present in the apparatus 300 . If the bin is out (Y), the display is made to flash the word “BIN”, the green LED is turned off, and the solenoid is deactivated (out-position), at step 780 . Thereafter, processing continues at step 720 . However, if the bin is not out (N), a determination is made at step 740 whether the bin is full. If the bin is full (Y), it is determined whether a 2-minute timer flag is set at step 780 . The 2-minute timer is activated when the “FORCE ON” button is pressed (see FIG. 8 ) and expires after a 2-minute interval. This permits 2 minutes of further operation of the apparatus 300 after a fill bin is detected. The status of the 2-minute timer flag indicates whether the 2-minute timer has expired (flag reset) or not (set). Resetting of the 2-minute timer flag occurs when insertion of a bin is detected by the bin present sensor (i.e., detection of a bin replacement). If the 2-minute timer flag has been reset (N), the display is made to flash the word “BIN”, the green LED is turned off, and the solenoid is deactivated (out) to prevent insertion of further items, at step 785 . Thereafter, processing continues at step 720 . If the 2-minute timer flag is set (Y), at step 780 , or the bin is not full (N), at step 740 , a determination is made at step 750 whether the top flap(s) is/are open. If open (Y), the motor is turned on, the green LED is made to flash, the counter is incremented, a 15-second timer is activated, and a 15-second timer flag is set, at step 765 , The 15-second timer provides a fixed interval of operation of the apparatus 300 after insertion of an object into the apparatus 300 . The 15-second timer flag indicates whether the 15-second timer has expired (flag reset) or not (set). The 15-second timer flag is reset after a 15-second interval at step 770 and processing continues at step 720 . If the top flap is not open (N), a determination is made at step 755 whether the 15-second timer flag has been reset. If not (N), processing continues at step 720 . However, if the 15-second timer flag has been reset (Y), the motor and the green LED are turned off at step 760 , Thereafter, processing continues at step 720 .
[0042] Turning now to FIG. 8 , if at any stage the “STOP” button is pressed at step 810 , the motor is turned off, the solenoid is deactivated (out), the green LED is turned off, and the number of times the flaps have been activated by insertion of an item into the chute opening is shown on the display, at step 815 , If the “START” button is pressed at step 850 , the 2-minute timer flag is set at step 855 and the 2-minute timer is activated at step 860 . Thereafter, processing continues at step 720 of FIG. 7 . Resetting of the 2-minute timer flag occurs when the bin present sensor detects insertion of a bin (i.e., a replacement bin is detected).
[0000] Additional Embodiments and/or Features
[0043] Another embodiment of the apparatus 300 includes a magnetic spring-triggered device for detecting bin presence and measuring the bin weight. Based on the bin weight, an indication of the fullness of the bin or the remaining bin capacity can be provided by means of a bar of LED's on the control panel 326 .
[0044] Yet another embodiment of the apparatus 300 includes an optical sensor subsystem 680 connected to the controller 605 (as shown in FIG. 6 ) for detecting foreign material, particularly ceramics. Detection is thus automatically performed on glass containers prior to breaking by one or more optical sensors mounted in the upper chute portion of the apparatus 300 . A contaminated bin or load of cullet can thus be identified and discarded prior to final beneficiation.
[0045] The optical sensor sub-system 680 also enables monitoring of the colour of glass containers inserted through the flaps of the apparatus 300 and the approximate quantity of glass containers per colour category. This information is stored in a data-logger, for providing information relating to:
The total quantity of glass containers processed by the apparatus 300 and the quantity of glass containers of each colour category that are processed. Contamination of batches/bins of cullet. Usage of the machine for billing purposes and logistical planning of collection services. Fault reporting.
[0050] Information from the datalogger can be transferred via GSM as an SMS message to a remote computer system for performing quantity and quality control of a waste glass stream.
[0051] A her optional feature allows the chisel assembly to be run in a reverse rotational direction for a predetermined period of time. This enables clearing of blockages of the chisels, for example, an object inserted while the chisels are stationary that prevents the chisels from rotating.
[0000] Conclusion
[0052] Embodiments of a method and an apparatus for processing glass have been described hereinbefore. The embodiments described advantageously reduce the amount of handling and transportation necessary for disposal of glass containers after use and/or improve the quality and consistency of the glass cullet produced. Improved quality and consistency of cullet enables an improved processing rate for the cullet at a beneficiation plant.
[0053] The foregoing detailed description provides exemplary embodiments only, and is not intended to limit the scope, applicability or configurations of the invention. Rather, the description of the exemplary embodiments provides those skilled in the art with enabling descriptions for implementing an embodiment of the invention. Various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the invention as set forth in the claims hereinafter.
[0000] For Australia Only
[0054] In the context of this specification, the word “comprising” means “including principally but not necessarily solely” or “having” or “including” and not “consisting only of”. Variations of the word comprising, such as “comprise” and “comprises” have corresponding meanings.
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An apparatus for processing glass objects is disclosed that comprises a chute assembly with a first opening at one end thereof for receiving glass objects and a second opening at a distal end thereof for dispensing glass cullet, a rotatable chisel assembly located substantially transversely within the chute assembly for breaking glass objects travelling through the chute assembly, drive means for causing the chisel assembly to rotate, and a controller for controlling the drive means. A method is disclosed for processing glass objects that comprises the steps of performing beneficiation to identify foreign matter amongst glass objects, breaking the glass objects to produce cullet, and identifying a portion of the cutlet that is free of the foreign matter.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to improved apparatus or equipment for garment finishing or conditioning operations which involves the use of a permeable fabric bag on which a garment to be conditioned is positioned and through which hot air and dry steam are to be applied to the garment. An important phase of the invention deals with the provision and employment of a tubular assembly or unit for utilizing a continuous flow of steam to provide a constant heat within the permeable bag, and for directly applying steam bursts within the bag during a garment finishing or conditioning operation.
2. Description of the Prior Art
Garments in the nature of shirts, blouses, etc., initially after manufacture, and later in a used condition, after laundering or dry cleaning, require finishing or conditioning and, in this connection, an expansible permeable bag-like fabric form, such as of nylon, has been employed to carry the garment while it is being subjected internally to heated air and substantially directly to hot, high pressure applied steam. This practice has required the use of relatively so-called dry steam to avoid excessive moisture as applied to the garment. Also, it has been customary, for example, as illustrated in Paris U.S. Pat. No. 3,568,900, to effect the application of steam from a relatively remote location, namely, from a steamer located at the juncture of a lower support base part and the upper bag form carrying part. At the same time, hot air supplied by the base part is moved upwardly into the bag along with the steam. Paris U.S. Pat. Nos. 2,417,838 and 2,915,229 are also representative of such a type of operation.
Although the above-mentioned practice makes use of a somewhat remote, direct introduction of steam within the chamber of the permeable bag and thus, to the garment positioned thereon, it has been determined that it is necessary to use a relatively dry, high pressure steam to avoid excessive moisture as applied to the garment. Considerable moisture collects within the base part that has to be removed. Also, such moisture is subject to pick-up from the hot air that is issuing upwardly from the base part. It is important to avoid spotting of the garment, such as will occur from moisture applied under steam pressure to the garment and thus, it is important to supply the steam with maximum dryness.
There has thus been a need for an apparatus which will, in itself, avoid the need for use of a remote steam introducing unit and which will enable the direct introduction of steam within the permeable bag form with a maximized reduction of moisture or condensate. In this connection, it has been found to be desirable to supply the steam for best efficiency and uniformity of garment conditioning along substantially the full length of the bag on which the garment is positioned.
There has thus been a need for an apparatus for more efficiently introducing steam and heated air and applying them as well as heat of the steam to a garment being conditioned or finished. This should be accomplished in such a manner as to substantially eliminate condensation within the conditioning chamber and importantly, to effectively eliminate steam spotting of the garment being finished.
Summarized briefly, there has been a need for an improvement in the manner of and in the apparatus for supplying heated air, steam heat and steam bursts to the inside of the bag form on which the garment is being finished.
SUMMARY OF THE INVENTION
It has thus been an object of the invention to meet the problem above-outlined and provide a garment finishing apparatus embodying an improved and better controlled useage of steam.
Another object has been to devise an improved garment finishing machine in which the heat and garment-conditioning fluid in the nature of steam and air may be more accurately supplied and controlled to accomplish an improved operation.
Another object has been to meet the heretofore limiting factors involved in the utilization of steam and enable its better and more effective utilization in accomplishing a garment finishing operation.
A further object has been to devise a garment finishing apparatus in which the operation may be expedited and accomplished more efficiently, particularly from the standpoint of utilization of high pressure steam.
A still further object of the invention has been to devise a garment finishing apparatus having a longitudinal, dual-functioning assembly through which heated steam is indirectly supplied during a garment finishing operation and from which high pressure steam is directly supplied only as needed in an accurate and controlled manner by the utilization of steam bursts substantially along the extent of the chamber defined by a permeable bag form.
These and other objects will appear to those skilled in the art from the illustrated embodiment and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical sectional view of apparatus embodying the invention and representatively showing a permeable fabric bag which is supported and used in a conventional manner for receiving a garment to be finished;
FIG. 1A is a side elevation showing detail of the construction of a support table of FIG. 1 that is mounted to carry a steam utilizing tubular assembly further illustrated in FIGS. 7, 8 and 9;
FIG. 2 is a fragmental section in elevation of a base part of the apparatus of FIG. 1, particularly illustrating means for heating and supplying hot air into an open bottom end portion of the permeable bag of FIG. 1;
FIG. 3 is a reduced top plan view of a quadrant-shaped or spoke-like, upper frame or bracket that is shown in its mounted position in FIG. 2;
FIG. 4 is a top plan view on the same reduced scale as FIG. 3, particularly illustrating a bottom-positioned, cruciform or quadrant-shaped support frame or bracket that is shown in its mounted position in FIG. 2;
FIG. 5 is a reduced plan view on the scale of FIGS. 3 and 4 of a top ring or rim piece that is employed, as shown in FIGS. 1 and 2, to provide a mounting fit for a selvedge edge that defines the bottom open mouth portion of a permeable bag;
FIG. 6 is a fragmental elevation on the scale of FIG. 5 further illustrating the ring or rim of such figure;
FIG. 7 is a system schematic and tubular assembly perspective view illustrating utilization of hot, high pressure steam in both directly and indirectly applying conditioning fluid within the chamber of an upper garment supporting part of the apparatus;
FIG. 8 is an enlarged vertical fragment taken through a representative dual tubular element pair of the assembly of FIG. 7, particularly showing the staggered orifices or out-flow openings in the wall of an outer tube element for enabling the direct supply of steam in bursts with and along the chamber of a permeable bag;
And, FIG. 9 is a reduced top plan, somewhat schematic view of the tubular assembly shown in FIG. 7, illustrating steam flow connections to inner and outer tube elements of element pairs of such assembly. It will be noted that these two FIGURES show the apparatus turned 180° with respect to FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring particularly to FIGS. 1 and 2, I have shown a lower, hot air-supplying base part or casing unit A, and an upper, garment-carrying, finishing or conditioning permeable bag part F that defines an inner, garment-conditioning chamber B. A suitable motor, such as an electric motor C is carried or mounted on the unit A and is adapted to actuate a vertical drive shaft 30 that extends through an open central portion of a heat exchanger G. A fan blade assembly D is secured on the shaft 30 above the heat exchanger G for the purpose of drawing-in ambient air through interstices or openings in a circular, screen or grate-like, louvered, lower shell wall 12, and through air flow passageways or interstices of a typical heat exchanger unit G, upwardly into conditioning chamber B. High pressure steam is supplied from a suitable pipe line source a to a centrally positioned, upwardly positioned, tubular steamer assembly E that extends along the conditioning chamber B defined by the bag F.
The base unit or part A is illustrated as a circular, upwardly extending part that is carried on a base plate member 10. The member 10 has a flange 10a that is secured, as by weld metal, between lower end portions of a group of quadrant-positioned, upwardly extending, rib-like support or leg members 11. A bottom-positioned, cruciform-shaped, support frame or bracket 15 (see also FIG. 4), a quadrant-shaped, spoke-like upper frame or bracket 17 (see also FIG. 3), a banding ring 14, and a top, bag-mounting top ring or rim flange 25 may be secured, as by weld metal w, to the upright legs 11. The screen-like, lower shell wall 12 is secured about a lower portion of the part A and has an edge-to-edge aligned relation with a cylindrical, upper, plate-like, enclosing, shell wall 13. The cylindrical, plate-like, main shell wall 13 extends from the ring 14 upwardly along the leg members 11, and is secured (see FIG. 2) along the legs 11 and within the bag-mounting, top ring or rim flange 25.
The bottom bracket member 15, see particularly FIGS. 2 and 4, has upwardly extending mounting ears 15a that enable it to be secured in position between the upright legs 11 by threaded bolts 16. As shown in FIG. 2, the bracket 15, in addition to spacing and supporting the lower end portions of the four leg members 11, provides a central mounting for the lower end of the fan drive shaft 30 through the agency of a lower bearing assembly 31. As shown in FIG. 2, the bearing assembly 31 is removably secured centrally of the bracket 15 by bolt and nut assemblies 32.
It wil be noted, as shown particularly in FIG. 2, that heat exchanger G is secured by clamping bolt assemblies 14a in a transverse positioning to an upper flange of the ring member 14.
As shown particularly in FIGS. 2 and 3, the quadrant-shaped, spoke-like, upper frame or bracket 17 has bent-over, side-extending, foot or tab portions 17a that are secured by threaded bolts 18 to the four, upwardly extending, leg members 11. The bracket 17, at its central axis, carries a mounting plate 17b on which an upper bearing assembly 33 is secured by bolt and nut assemblies 34. As shown, the bearing assembly 33 journals the upper end portion of the fan drive shaft 30.
With particular reference to FIGS. 1A, 5 and 6, it will be noted that a centrally positioned, upwardly extending, support post 20 is also carried in a secured relation on the bracket 17. The support post 20, at its lower end, is integrally secured on the mounting plate 17b. Four diagonal brace or arm members 21, at their upper ends, are secured as by weld metal w, within side-slotted portions of the post 20. The brace members 21, at their lower ends, are secured, as by weld metal w, on an associated spoke or arm of the bracket 17, see also FIG. 3.
A support table 22 for tube assembly E is carried and secured centrally, as by weld metal, on the upper end of the post 20. To complete the construction of the base part A and to enable internally connecting its hot air supply chamber with garment-finishing or conditioning chamber B that is defined by the permeable bag F of the upper part, the top ring or rim flange 25 is secured along the outer side of the shell wall 13. The ring 25 has an uppermost, annulus-like, rim edge portion 25a and a lower rim edge portion 25b of slightly smaller diameter which, as shown in FIG. 1, serve to provide a secure, sealed-off mounting for a lower selvage edge of the bag F that defines its open bottom portion. A tight, elastic-like fit of the selvage edge over the edge 25a is provided to prevent loss of conditioning fluid (heated air) being supplied from the chamber of the base part A.
The heat exchanger G is supplied with residual steam from return pipe line c, as shown in the schematic of FIG. 7, and ambient air entering through the lower shell wall 12 moves upwardly through passageways of the exchanger G with rotation of the fan blade assembly D. Actuation of the assembly D (see FIG. 1) is effected by upright driven shaft 30, a driven pulley 35 keyed on the lower end of the shaft, a drive belt 36, and a drive pulley 37 on a drive shaft 38 of side-mounted, electric motor unit C. The motor unit C, as particularly shown in FIGS. 1 and 2, is secured to extend from a side of the base part A. A dust cover 39 may be secured by weld metal w on the screen shell wall 12 to enclose the pulley 37 and the portion of the belt 36 that extends from base part A to the drive motor unit C.
An important phase of the invention is represented by the tubular assembly E which is particularly illustrated in FIGS. 7, 8 and 9. This assembly comprises four, equally spaced-apart, upwardly to vertically extending, tube element pairs 41, 42, etc. Each pair is shown as of the same construction, and as distinguished from each other, for reference purposes by prime affixes. Thus, description of elements 40, 41, 42 and 43 will also provide a description of corresponding prime elements. Each pair of elements of the upright tubular assembly E involves an inner, longitudinally upwardly extending, closed-wall tube or pipe element 41 through which entering steam is adapted to circulate in a continuous manner therethrough, and in series into and through similar inner tube elements 41', 41" and 41'" of the other three pairs. In addition, each pair has an outer perforated tube or pipe element 42 that is in a transversely, outwardly spaced relation with respect to and along the associated inner tube element 41 to define an outer flow chamber to which periodic bursts of steam may be applied, as will be hereinafter more fully explained.
Holes or orifices 43 in a spirally staggered or spaced relation along the outer tube element 42 provide for directly, transversely supplying the hot steam under high pressure within the bag F, substantially along the full vertical extent of its chamber B. The associated inner tube element 41 is, in accordance with contemplated operation, continuously supplied with hot steam for applying heat through its walls indirectly (by conduction) to and along the passageway of the outer tube 42, and to the fluid or air within the chamber B of the bag F.
With reference particularly to the circulating system illustrated in FIGS. 7 and 9, high pressure steam entering from a suitable source, such as a boiler (not shown), flows along input or source pipe line a into a separator H. Less dry or wet steam from the lower condensate collecting portion of the separator H is then flowed in a continuous manner during the conditioning of a garment, through a check valve assembly 55, along a preheating line b into the lower end of a first inner tube element 41 of the first pair. The steam which has completed its upward movement from the line b along the inside of the first pipe or tube element 41 is then introduced along cross connector 44 into the upper end of an adjacent inner tube element 41' to flow downwardly therealong and out from its lower end, through a bottom-positioned, cross-connector 45 into the lower end of a third inner tube 41" to flow upwardly therealong. The flow from the upper end of the inner element 41" is then out through a cross-connector 46, and down through the inner tubular element 41'" of the fourth pair of tube elements.
Steam exhausting from the series-connected group of inner pipe elements 41, 41', 41" and 41'", leaves the assembly through pipe line c to move through heat exchanger G, and thus heat air being supplied upwardly from the chamber of the base part A into the chamber B of the upper part F. Substantially fully heat-spent steam leaves the heat exchanger G piping and flows along condensate pipe line c' into and through steam trap I and check valve 58 to return along to the boiler for reheating and resupply to source pipe line a of the system.
As previously indicated, although it is desirable to supply a constant heat by a closed-off flow of steam through the assembly E, it is also desirable to provide a quick, momentary burst of steam directly to the garment through the agency of the permeable bag of the upper part F. This is accomplished by flowing high pressure, dry steam from the upper portion of the separator H, as controlled automatically by a timer or foot pedal through the agency of an electric solenoid valve 56, to give one or two bursts to the garment in accomplishing the finishing operation. The flow is along steam burst pipe line d, through a manual valve 57 which may be employed to throttle the flow or alternately to manually control the bursts independently of the solenoid-operated valve 56. Steam from the burst piping d simultaneously enters the bottom ends of the outer tube elements 42, 42', 42" and 42'" through a common manifold pipe connector assembly 50, 51 and 52. See particularly FIG. 9. Thus, steam is introduced from the line d simultaneously upwardly along each of the four, outer, tube elements and through their vertically spaced-apart jet openings 43, 43', 43" and 43'", directly into the inside of the chamber B.
As particularly illustrated in FIG. 1A, the inner and outer element pairs of the tube assembly E are secured in an upright, substantially equally spaced-apart, square defining arrangement on the table 22 through the agency of coupling mounts 40, 40', 40" and 40'" that extend from lower ends of the element pairs and are secured to the table.
The bag F may be of a conventional permeable construction, such as of nylon, and is of a type such as mentioned in patents previously listed herein. As will appear from the description of the system shown in FIG. 7, it will be apparent that a maximized use of the heat of steam being supplied along the source line a is accomplished, with remaining residual heat of steam exhausting from the inner elements of the tubular assembly E being applied to the heat exchanger G and thus, to the air that is supplied from ambient air entering through the screen-like side shell wall 12, upwardly from the chamber of the lower part A, through the open bottom end of the bag F into the conditioning chamber B.
The tube elements employed in the assembly, may from the standpoint of heat efficiency, be of copper material, and the holes or feed orifices 43, 43', 43" and 43'" may be provided by drilling the perforations or holes around the outer or steam burst tubes 42, etc., in an upwardly advancing spiral relationship. In a typical operating cycle employing the apparatus disclosed, steam may be constantly supplied to the pipe line b while a garment is positioned on the bag F. This supply will be continued to avoid cooling the tube assembly E and particularly the outer elements 42, etc., where in a typical operation, a series of garments are to be conditioned or treated. Cooling of the tubes forms condensate which, as previously intimated, is undesirable from the standpoint of a garment being processed. Initially, when the apparatus is heated-up any condensate will be drained-off from the bottom of the unit A.
The inner tubes 41, etc. maintain enough heat to avoid the formation of moisture on the outer or burst tube elements 42, etc., and serve to further the heating of the air which is being introduced from the base part A. The holes or orifices 43, etc. will have a size such, for example, as No. 55, to further insure against moisture burst and thus, spotting the garment. About 80 pounds of steam pressure at a temperature of about 300° F. may be introduced from the source line a. On entering the separator H, the steam strikes a centrally positioned condensing plate, with the hot condensate then dropping to the bottom which is slanted to keep a constant pressure on the line b which may be termed a preheat line. Dry steam then issues from the top opening in the separator H into the burst line d with the desired setting of flow adjusted by the manual valve 57.
The steam solenoid valve 56 may be operated by a foot switch or by a clock type of timer, if desired. The trap I, in what may be termed condensate line c', slows down the return flow and removes excess moisture from the steam to further the maintenance of about 80 pounds of steam pressure as applied to the assembly E. In the drawings, the solid arrows show the flow of so-called burst steam and the dotted arrows show the flow of so-called heating steam.
Primarily, the inner tubular elements 41, etc. which define a closed, series-flow system may be employed to maintain a substantially constant heat within the chamber B and prevent the forming of condensate. On the other hand, the steam burst elements 42, etc. of the tubular assembly E may be employed to provide conditioning steam directly to the bag F and thus, to the inside of a garment. A preliminary heating-up of the assembly E may be accomplished by passing steam through the line b for a minute or two, then a typical garment finishing operation may be effected by applying dry steam through line d, initially for about 3 to 5 seconds; next, the fan D may be actuated to inflate it, and steam bursts may be applied from line d to the bag F for 2 to 3 seconds. Finally, the steam burst supply from the line d may be turned-off, with the flow through heating line b continued, while the fan blade assembly D is rotated to continue the supply of hot air for about 3 to 8 seconds after which the garment may be removed. As will be appreciated, the full cycle of operation (after heat-up) may involve a period of approximately 8 to 12 seconds to enable a production-line type of garment finishing. Throughout the operations, heating steam will be supplied to the inner elements 41, etc. of each of the tube pairs 41, 42, etc.
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An upright apparatus for heating and conditioning shirts, blouses, jackets and leisure top clothing or garments has a hot-air-supplying, supporting and positioning base part on which an upright, tubular steamer assembly having inner and outer tube element pairs is operatively positioned. A steam supply and recycling system is connected to inner tubes of the pairs in such a manner to continuously indirectly apply heat along outer tubes of the pairs within a garment conditioning chamber defined by an upwardly extending, garment-supporting, permeable bag; dry, high pressure steam is supplied to the outer tubes to periodically directly apply bursts of hot steam within the chamber. To enable a maximum utilization of the heated steam as supplied from a source, such as a boiler, the output from the tube assembly is passed through an air heating heat exchanger positioned in the base part before it is returned to the boiler.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 07/343,506 filed Apr. 25, 1989, which application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to chip carriers for high-density integrated circuits (ICs). In particular, it is directed to metallized chip carriers fabricated from wafer-shaped substrates.
2. Description of Related Art
As integrated circuits become more dense, often containing hundreds of I/O connections, prior art techniques of packaging become less suitable. Packaging is considered by many in the industry to be the pacing technology for integrated circuit development. Many designers have recognized the need for developing new techniques for defining high-resolution traces on chip carriers. Up until the present invention, however, creating the required high-resolution traces presented significant manufacturing problems.
In the prior art, chip carriers are fabricated using substrates onto which metallized traces are placed to provide electrical connections from the periphery of the substrate to the integrated circuit packaged within. These traces are typically manufactured using thick-film technology. The need to provide increasing numbers of connections has resulted in thin-film technology being used as a partial solution to bring the traces from the integrated circuit to pins on the carrier. Prior art thin-film technology brings traces from the IC to vias within the carrier, and the vias provide connections to the pins. A primary shortcoming in the prior art is that thin-film technology can not be reliably used to bring the traces from the IC within the carrier to the periphery of the carrier.
Thus, there is a need in the art for high-density interconnects on chip carriers, which can provide traces directly from the integrated circuit packaged within the carrier to the periphery of the carrier, fabricated entirely with thin-film techniques. This shortcoming of the prior art requires that vias be used to connect trace to pin connections, making the overall footprint of the carrier larger than desirable. There is also a need in the prior art to manufacture chip carriers in quantity using thin-film technology, such that a high yield rate is attained with traces as narrow as 5 mils or less.
SUMMARY OF THE INVENTION
To overcome limitations in the prior art described above and to overcome other limitations that will become apparent upon reading and understanding the present specification, the present invention uses wafer-shaped substrates and thin-film manufacturing techniques to create high-density traces on chip carriers for direct connections from the IC to the periphery without the need of vias. One object of the present invention is to provide a method for manufacturing metallized chip carriers from substrates shaped similarly to semiconductor wafers. Wafer-shaped substrates permit the use of standard semiconductor fabrication apparatus and methods. As a result, very thin and finely dimensioned traces can be deposited simultaneously on a plurality of chip carriers.
DESCRIPTION OF THE DRAWINGS
In the drawings, where like numerals refer to like elements throughout the several views,
FIG. 1 is a top view of a wafer used in creating the chip carrier of the present invention.
FIG. 2 is a cross-sectional side view of a portion of the ceramic wafer taken along lines 2--2 of FIG. 1.
FIG. 3A is an individual chip carrier fabricated from the ceramic wafer and the trace pattern thereon.
FIG. 3B is a magnified view of the trace pattern along on edge of the chip carrier taken along the dotted lines of FIG. 3A.
FIG. 4 is a cross-sectional side view of a trace on the chip carrier of FIG. 3A and FIG. 3B.
FIG. 5 is a top view of the lid for the ceramic carrier.
FIG. 6 is a cross-sectional side view of the lid of FIG. 5.
FIG. 7 is a top view of a wafer as fabricated in a second preferred embodiment of the present invention.
FIG. 8 is a top view of a wafer as fabricated in a third preferred embodiment of the present invention.
FIG. 9 is a top view of a wafer as fabricated in a fourth preferred embodiment of the present invention.
FIG. 10 is a top view of a wafer as fabricated in a fifth preferred embodiment of the present invention.
FIG. 11 is a cross-sectional side view of a trace on the chip carrier of FIG. 3A and FIG. 3B including a first alternate barrier metallurgy.
FIG. 12 is a cross-sectional side view of a trace on the chip carrier of FIG. 3A and FIG. 3B including a second alternate barrier metallurgy.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration four specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.
The present invention describes metallized chip carriers for high-density ICs and the steps required to fabricate these carriers. The preferred embodiment of the present invention uses thin-film techniques to deposit a large number of finely dimensioned traces on the surface of a substrate. Central to this invention is the use of standard semiconductor processing apparatus and methods in the fabrication of the chip carriers.
First Preferred Embodiment
Referring initially to FIG. 1, a substrate in a first preferred embodiment is shaped into a wafer 10. The substrate may be ceramic, such as aluminum oxide, aluminum nitrate, beryllium oxide, etc., or silicon. This wafer 10 is circularly shaped and keyed substantially similar to semiconductor wafers, which permits the use of IC fabrication apparatus and methods. The flat portion or key 8 of the wafer 10 is a reference key, ensuring the proper orientation of the wafer 10 during fabrication. Each wafer 10 is comprised of an array of cavities 14.
In the first preferred embodiment, the wafer 10 contains 21 cavities 14. Thus, a plurality of chip carriers, generally identified by reference number 12, can be fabricated simultaneously. Each cavity 14 is substantially square and measures 0.426 inches in length (±0.003 inches) on each side. These cavities 14 will eventually contain an IC chip. The top surface of the IC is approximately planar with the top surface of the chip carrier 12.
FIG. 2 is a cross-sectional side view of wafer 10. The wafer 10 is 0.060 inches (±0.002/-0.001 inches) thick. Each cavity 14 is recessed within the wafer 10 to a depth of 0.030 inches (±0.002 inches).
If the substrate is ceramic, then the cavities may be fabricated by molding or other techniques known in the ceramic arts. For example, ceramic may be molded, milled, etc. Anvil and slurry milling will provide tighter tolerances than molding. When milled, the cavities are typically added after metallization, thereby avoiding problems with shrinkage of the cavities due to the sintering after punching or pressing the cavities.
If the substrate is comprised of silicon, then the cavities may be fabricated by etching or other techniques known in the silicon arts. The cavities can be etched in the silicon substrate as the first step in production or at any other step along the way, provided that the patterning material will sufficiently protect any metallization currently on the package. For example, if the cavities are etched in silicon after aluminum, titanium, platinum, and gold metallization layers have been deposited, the masking material must be able to sufficiently protect these metals with their large dimensions. An advantage of using silicon is the ability to use silicon's electrical properties for a substrate voltage bias, buried resistors, etc.
FIG. 3A shows a top view of a finished carrier 12 fabricated from the wafer 10. FIG. 3B shows a magnified view of the trace pattern along one edge o the carrier 12 taken along the dotted lines of FIG. 3A. The carrier 12 contains 90 traces per side (360 traces total), generally identified by reference number 16. The traces 16 are comprised of a plurality of metals. Using a plurality of metals in the trace 16 enhances bonding by allowing the trace 16 to metallically match both the bonding pads on the IC and the traces on the printed circuit board.
FIG. 4 is a magnified, cross-sectional side view of an individual trace 16 that better illustrates the barrier metallurgy 20. The aluminum portion 22 is created first, the barrier metallurgy 20 is added on top of the aluminum, and finally, the gold portion 18 is added atop the barrier metallurgy 20. FIGS. 11 and 12 illustrate individual traces fabricated with alternate barrier metallurgies.
Each metal is homogeneous for its portion of the trace 16. The inner length of each trace 16, generally identified by reference number 122 is preferably comprised of aluminum (Al). The outer length of each trace 16, generally identified by reference number 18, is preferably comprised of gold (Au). At the point where the inner length 22 meets the outer length 18, denoted by the dotted line 20 in FIG. 3, a barrier metallurgy is used. The barrier metallurgy 20 prevents the aluminum and gold from intermixing and forming "purple plague" and Kirkendall voiding. If Kirkendall voiding occurs, then the trace 16 could form an intermittent open due to localized heating from the electrical current, differences in expansion coefficients, and poor bond integrity. Those skilled in the art will readily recognize that other barrier metals could be used in the barrier metallurgy 20, depending upon a number of fabrication factors. For example, in a low temperature environment, titanium tungsten (TiW) or titanium under platinum could be used as shown in FIG. 11. At high temperatures, different combinations may be desired to improve adhesion and prevent diffusion of the metals. The rate of diffusion is at least partially determined by the temperature of the substrate. For example, nickel over chrome, platinum over titanium nitride over titanium (see FIG. 12), platinum over titanium tungsten over titanium or platinum over titanium tungsten nitride over titanium. Those skilled in the art will recognize that other metals such as palladium may be substituted for platinum to form the barrier metallurgy.
Aluminum is used for the inner portion 22 of the traces 16 because the electrical interconnections to the IC are aluminum. Thus, using aluminum for the inner portion 22 of the traces 16 prevents bonding problems between the IC and the chip carrier 12. Gold is used for the outer portion 18 of the traces 16 because the electrical interconnections to the printed circuit board are gold. Thus, using gold for the outer portions 18 of the traces 16 prevents bonding problems between the chip carrier 12 and a printed circuit board. Those skilled in the art will readily recognize that other metals could be used in the traces 16, such as an all gold trace if gold bonding was used on both the chip-to-carrier and carrier-to-board connections. The barrier metallurgy is used also to improve adhesion between the gold and ceramic. Thus, the barrier metallurgy is in direct contact with the ceramic or silicon substrate, with the gold on top of the barrier metallurgy.
The outer edges of the carrier 12 are 0.604 inches (+0.005/-0.005 inches) on each side. From the inner edge of the carrier 12, the traces 16 are brought out to the periphery of the carrier 12. The width of a trace 16, consistent from the inner edge of the carrier 12 and extending for a substantial portion of the length of the trace 16, is 0.002 inches (±0.0005 inches). The space between traces 16 at the inner edge of the carrier 12 is 0.002 inches (±0.0005 inches). At the outer edge of the carrier 12, the traces 16 are larger and less densely packed than at the inner edge. The width of a trace 16 at the outer edge of the carrier 12 is 0.0025 inches (±0.0005 inches). The space between traces 16 at the outer edge of the carrier 12 is 0.0025 inches (±0.0005 inches).
The traces 16 are larger at the outer edge of the carrier 12 because they connect to large, bulky traces on a printed circuit board. At the inner edge of the carrier 12, on the other hand, the traces 16 are sized to match bonding pads on the IC chip, which bonding pads are usually very small and densely packed. Thus, the traces 16 fan out from the inner edge to the outer periphery of the chip carrier 12 to facilitate electrical interconnection between an IC and a printed circuit board.
The creation of traces 16 surrounding each of the IC-receiving cavities 14 involves depositing metal layers in patterns on the wafer 10. Those skilled in the art will recognize that several techniques may be used for metal layer deposition, for example, sputtering, chemical-vapor deposition, plating, evaporation, etc., without departing from the scope of the present invention. The process steps are as follows in the order described in the preferred embodiment.
The wafer 10 is first cleaned and sputtered with aluminum. The wafer 10 is then patterned using spray-coating and photolithographic methods. The aluminum is etched and the photoresist removed. The wafer 10 is then sputtered with four layers of metal in the following order and thickness: titanium (2000 Å), titanium nitride (500 Å), platinum (2000 Å), and gold (1500 Å).
Next, the wafer 10 is patterned with photolithographic techniques so that the gold can be plated upwards. Gold is electroplated onto the sputtered gold, using the photoresist as a mask. The photoresist is removed and the exposed shorting metals are etched using ion beam milling, leaving the barrier metallurgy under all gold traces. Once the pattern of the traces 16 is complete, a passivation process may be used to prevent handling damage, for example, chemical-vapor deposition or sputtering the substrate with quartz or silicon nitride, etc. The final processing step is to separate the wafer 10 into its separate carriers 12. In the first preferred embodiment, a diamond saw separates wafer 10 into distinct carriers 12, but other techniques could also be used.
Once the individual carriers 12 are fabricated, with the traces 16 extending from the inner edge to the outer periphery of the carrier 12, an IC die is placed in the cavity 14 of the carrier 12 and bonded therein using known techniques. The connections between the bonding pads of the IC and the traces 16 on the carrier 12 can be made by a variety of techniques, for example, aluminum wire bonding, TAB tape bonding, or wire ribbon bonding. Once the electrical connections are made from the IC to the traces 16 on the carrier 12, the carrier 12 is ready for hermetic sealing.
FIG. 5 is a diagram of the lid 24 used to hermetically seal the carrier 12. Preferably, the lid 24 is comprised of the same material as the carrier 12. The lid 24 is 0.532 inches along each outer edge. Each inner edge of the recess 26 within the lid 24 is 0.472 inches in length. Note that the size of the lid 24 is such that only the gold portions 22 of the traces 16 are exposed. The lid 24 covers the aluminum portions 22 of the traces 16, forming a hermetic seal and thereby preventing corrosion. The gold portions 22 of the traces 16 extend underneath the lid 24 to the outer periphery of the carrier 12, thereby facilitating bonding. The lid 24 is sealed with glass, instead of metal, so that the prior art technique of burying electrically conductive vias in a non-conducting substrate is not required. If a prior art metal lid was used with the surface traces 16 of the present invention, the metal lid would electrically short the exposed traces 16. Thus, in the present invention, the glass-sealed lid 24 allows the traces 16 to reside on the surface of the carrier 12.
FIG. 6 is a cross-sectional side view of the lid 24 for the carrier 12. In the preferred embodiment, the lid 24 is 0.043 inches thick. The recess 26 within the lid 24 extends to a depth of 0.019 inches (±0.001 inches). The lid 24 is sealed to the carrier 12 by placing low-temperature sealing glass on the lid-to-ceramic interface and baking the package to melt the sealing glass at approximately 425° C.
Once it is hermetically sealed, the chip carrier 12 may be placed in a cavity or on the surface of a printed circuit board. The carrier-to-board connections may be made using bonding techniques well known in the art. Those skilled in the art will readily recognize that a wide variety of alternate techniques for hermetically sealing the carrier could be implemented. Depending upon the application, hermetically sealing the carrier may not be necessary.
Those skilled in the art will readily recognize that a wide variety of processing techniques may be used in conjunction with the teachings of the present invention. For example, thick film techniques may be used to produce much larger traces to supply, for example, power to the chips, distribute clock signals, etc. In addition, multi-layered ceramic substrates may be used in which inter-layers supply power to the integrated circuit chips. Such inter-layers may include buried resistors and capacitors.
Second Preferred Embodiment
FIG. 7 describes a second preferred embodiment, wherein the wafer 10 is fabricated in manner similar to the first preferred embodiment. In the second, preferred embodiment, the wafer 10 contains a plurality of cavities 14 as in the first preferred embodiment. However, the wafer 10 is not cut or otherwise separated into a plurality of carriers, each with an individual cavity 14. Thus, the wafer 10 itself is a single carrier for a plurality of ICs 30.
Each cavity 14 is preferably the same dimensions as described in the first preferred embodiment. Metallized interconnects 16 electrically connect to bonding pads at the periphery of the cavities 14. The interconnects 16 may consist of single or multi-layer metallization. Pads 28 provide for lead bonding 32 or TAB (Tape Automated Bonding) 32 between ICs and traces 28 or between traces 28 and interconnects or devices external to the wafer 10. Preferably, the IC 30 is electrically connected to the carrier using a Tape Automated Bonding technique such as that described in the co-pending and commonly assigned U.S. patent application Ser. No. 07/366,604 filed Jun. 15, 1989 by E. F. Neumann et al. entitled "CHIP CARRIER WITH TERMINATING RESISTIVE ELEMENTS", which application is hereby incorporated by reference. A lid similar to the lid described in the first preferred embodiment may be used to seal each cavity 14. Individually sealing each cavity 14 enhances reworkability.
Third Preferred Embodiment
FIG. 8 describes a third preferred embodiment, wherein the wafer 10 is fabricated in a manner similar to the first and preferred embodiments. In the third preferred embodiment, the wafer 10 contains four large cavities 14, each cavity 14 holding a plurality of ICs 30. In the third preferred embodiment, like the second preferred embodiment, the wafer 10 is not cut or otherwise separated into a plurality of carriers. Thus, the wafer 10 itself is a single carrier for a plurality of ICs 30. Metallized interconnects 16 electrically connect the cavities 14. The interconnects 16 may consist of single or multi-layer metallization. Pads 28 provide for bonding between ICs and traces 28 or traces 28 and interconnects or devices external to the wafer 10. Preferably, the IC 30 is electrically connected to the carrier using a Tape Automated Bonding technique such as that described in the co-pending and commonly assigned patent application entitled "CHIP CARRIER WITH TERMINATING RESISTIVE ELEMENTS". Each cavity 14 is preferably sealed individually to enhance reworkability.
Fourth Preferred Embodiment
FIG. 9 describes a fourth preferred embodiment, wherein the wafer 10 is fabricated in a manner similar to the first, second, and third preferred embodiments. In the fourth preferred embodiment, the wafer 10 contains two large cavities 14, each cavity 14 holding a plurality of ICs arrayed in a linear manner. Such a configuration is especially useful for memory ICs with bonding pads on only two sides. In the fourth preferred embodiment, like the second and third preferred embodiments, the wafer 10 is not cut or otherwise separated into a plurality of carriers. Thus, the wafer 10 itself is a single carrier for a plurality of ICs 30. Metallized interconnects 16 electrically connect the cavities 14. The interconnects 16 may consist of single or multi-layer metallization. Pads 28 provide for bonding between ICs and traces 28 or traces 28 and interconnects or devices external to the wafer 10. Preferably, the IC 30 is electrically connected to the carrier using a Tape Automated Bonding technique such as that described in the co-pending and commonly assigned patent application entitled "CHIP CARRIER WITH TERMINATING RESISTIVE ELEMENTS". Each cavity 30 is preferably individually sealed to enhance reworkability.
Fifth Preferred Embodiment
FIG. 10 describes the fifth preferred embodiment, wherein the wafer 10 is fabricated in a manner similar to the first, second, third and fourth preferred embodiments. In the fifth preferred embodiment, the wafer 10 contains a plurality of cavities, each cavity holding one or more integrated circuits. The wafer is metallized according to the teachings of the present invention to provide metal interconnects 16 between the peripheries of the cavities 14. The interconnects 16 may consist of single or multi-layer metallization. Pads 28 provide for lead bonding 32 or TAB (Tape Automated Bonding) 32 between ICs and traces 28 or between traces 28 and interconnects or devices external to the wafer 10. In a fashion similar to the first preferred embodiment, however, the wafer is cut along the dashed lines 50, dividing the wafer into quadrants. Thus in the fifth preferred embodiment, a wafer may be divided into sub-sections, or quadrants as shown in FIG. 10, to produce a plurality of multiple-cavity chip carriers.
Conclusion
Although a specific embodiment has been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement which is calculated to achieve the same purpose may be substituted for the specific embodiment shown. For example, different processing steps, different electrical connection patterns, different trace metals, or different barrier metals than those disclosed in the detailed description could be used. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.
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A method for simultaneously manufacturing metallized carriers from wafer-shaped substrates is described, wherein such wafer-shaped substrates permit the use of standard IC fabrication apparatus and methods. As a result, very thin and finely dimensioned traces can be deposited. Thin-film manufacturing techniques are used to create the high-density traces on the surface of the chip carriers, thereby permitting direct connections from the IC to the periphery of the carrier without the need for vias. A lid hermetically seals and protects the package. The traces are comprised of a plurality of metals to facilitate bonding, each of the metals homogeneous for a portion of the trace. One metal portion of the trace is of a type compatible with an IC chip placed in the carrier. Another metal portion of the trace is of a type compatible with a trace on a printed circuit board. A metal barrier is interposed between the metals to prevent metal diffusion from one metal to an adjoining portion of another metal.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to U.S. Application entitled “A METHOD OF EXECUTING CONFLICTING TRIGGERS IN AN ACTIVE DATABASE”, Ser. No. ______, filed on ______; and to U.S. Application entitled “A METHOD OF EXECUTING BEFORE-TRIGGERS IN AN ACTIVE DATABASE, Ser. No. ______,filed on ______
FIELD OF THE INVENTION
[0002] The present invention relates generally to executing triggers in active relational databases and more specifically to the concurrent execution of after-triggers in a relational data base management system.
DESCRIPTION OF THE RELATED ART
[0003] Database management systems (DBMS) 11 , such as the system shown in FIG. 1, have become the dominant means of keeping track of data, especially for servers connected to the Internet. These systems take an organized approach to the storage of data by imposing a data model, typically a relational data model, on the data 17 that is stored in the database 15 . Included in the typical DBMS are a Query Processing Engine 13 , a File Access and Storage Management subsystem 21 for accessing the database 15 , a Concurrency Control subsystem 19 for managing locks needed for concurrency on database items (tables and rows) and a Recovery Control Subsystem 23 for restoring the DBMS 23 to a consistent state after a fatal error. The latter two subsystems 19 , 23 , are interconnected with the File Access and Storage Management subsystem 21 .
[0004] In the relational data model, data is stored as a relation, which has two aspects, the relation schema and the relation instance. The relation schema specifies the relation's name, and the name and domain of each column in the relation. The relation instance is a set of records (also called rows or tuples) that conform to the relation schema. A relation instance is therefore a table of records, each of which has a column that meets the domain constraints imposed by the schema.
[0005] Not only does the DBMS impose a constraint on storage of data, a DBMS usually formalizes the means by which information may be requested from the database. In particular, a query language is specified by which questions may be put to the database. The language is usually based on a formal logic structure such as relational algebra or calculus. Queries are usually carried out in the DBMS 1 1 by a Query Processing Engine 13 , which has a number of components for parsing a query, creating a query plan, and evaluating the query plan. In particular, a component of the Query Processing Engine 13 , a Query Optimizer, creates one or more query plans, each in the form of a tree of relational operators, that are evaluated for execution of the query based on some efficiency metric.
[0006] Relational operators take one or more tables as inputs and generate a new table as the output. For example, a selection operator selects one or more rows of an input table meeting the selection criteria to produce an output table having only those rows. Operators can be composed since an operator may take as input a table generated as the output of another operator. A tree of operators is the representation of a composition of the relational operators appearing as the nodes of the tree.
[0007] A tree of such operators for a particular query plan is shown in FIG. 3. As can be observed from the tree of FIG. 3, relational operators are connected to each other and to base tables T 1 and T 2 by means of queues Q 1 -Q 4 . These queues supply input rows to a particular operator and store output rows from the operator. The queues allow an operator to start processing rows as soon as the operator that supplies the rows begins to produce them and before all rows are produced. Such pipelining improves the efficiency of the system because intermediate results need not be stored in a temporary table and then read again for input.
[0008] The standard language for implementing a DBMS is the Structured Query Language (SQL). This language includes Triggers, which are actions executed by the DMBS under certain conditions.
[0009] A database having a set of triggers is called an active database and each trigger in the database has three parts, an event, a condition and an action. The event part is a change to the database, such as an insertion, deletion, or modification of a table, that activates the trigger. The SQL statement which is the activating event, is termed the activating statement. A condition is a test by the activated trigger to determine whether the trigger action should occur and an action is an SQL statement that is executed if the trigger event and trigger condition are both satisfied. The set of rows affected (i.e., inserted, updated, or deleted) by the activating statement is termed the affected set of rows for the relevant trigger.
[0010] The action part of the trigger can occur either before or after the activating statement. If before, it is called a before-trigger and if after, it is called an after-trigger. In addition, triggers can operate at the row level or the statement level. A statement trigger executes its action once per activating statement and a row trigger executes its action for each row in the affected set. The combination of “before” and “after” with “row” and “statement” creates four different types of triggers. Chain reactions of trigger actions and recursive trigger actions are also possible.
[0011] The execution of triggers in a relational database is governed by the proposed ANSI standard for SQL (SQL:1999) which places certain restrictions on trigger execution. A chief restriction is that the triggers be executed serially in their creation time order or at least that the serial execution of triggers be equivalent in outcome and effect on the database to the execution of triggers in their creation time order. However, the serial execution of triggers, in accordance with the proposed ANSI:99 standard, would seriously affect the performance of the DMBS, especially if many trigger actions are involved. Thus, there is a need for the improved execution of multiple trigger actions which leads to improved performance of trigger actions over a purely sequential execution, but still conforms to the ANSI standard.
BRIEF SUMMARY OF THE INVENTION
[0012] The present invention is directed towards the above need. A method of forming an execution plan in accordance with the present invention includes the following steps. First, any triggers that may be activated by an activating statement and any rows in database tables that are affected by the activating statement are determined. An operator tree for the activating statement is then formed and a tree for the trigger that is activated by the activating statement is formed. The activated trigger is either a row-after trigger or a statement-after trigger. If the activated trigger is a row-after trigger, the tree for the row-after trigger is joined to the operator tree for pipelined execution with the operator tree and any rows affected by the activating statement are pipelined to the row-after trigger for input. If the activated trigger is a statement-after trigger, the tree for the statement-after trigger is joined to the operator tree for execution subsequent to the operator tree. The statement-after trigger obtains input during execution from a temporary table that accumulates affected rows from the execution of the activating statement.
[0013] If a plurality of row-after triggers is activated by the activating statement, each of the trees for the row-after triggers is joined to the operator tree for pipelined execution with the operator tree. In one embodiment, the plurality of trees for activated row-after triggers is connected to a parallel union operator to form a group and a flow operator is interconnected between the parallel union operator and the operator tree.
[0014] If a plurality of statement after triggers is activated by the activating statement, each of the statement-after trigger trees is joined to the operator tree for execution subsequent to the execution of the operator tree. In one embodiment, the activated statement-after actions are connected to a parallel union operator to form a group, a flow operator is interconnected between the operator tree and a temporary table that accumulates affected rows from the operator tree and an ordered union operator is interconnected between the parallel union operator and the flow operator.
[0015] Joining both a plurality of activated row-after triggers and a plurality of statement-after triggers to the operator tree is such that the activated row-after triggers execute in a pipelined fashion with the operator tree and the activated statement-after triggers execute subsequently to the execution of the operator tree. Each trigger tree within either the statement-after group or the row-after group executes in parallel with the other trigger trees in the group.
[0016] An advantage is that row after-triggers are executed substantially in parallel with each other and in a pipeline with the execution of the operator tree for the activating statement thereby substantially reducing the execution time of row-after triggers compared to purely sequential execution of the activating statement and the triggers.
[0017] Another advantage is that statement-after triggers are executed substantially in parallel with each other thereby substantially reducing the execution time of statement-after triggers compared to the purely sequential execution of the activating statement and the triggers.
[0018] Another advantage of the invention is that triggers execute in parallel with the activating statement and groups of triggers that are activated by the same activating statement execute in parallel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] These and other features, aspects and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
[0020] [0020]FIG. 1 illustrates a typical database management system;
[0021] [0021]FIG. 2A illustrates a Flow operator;
[0022] [0022]FIG. 2B illustrates an Ordered Union Operator;
[0023] [0023]FIG. 2C illustrates a Parallel Union Operator;
[0024] [0024]FIG. 3 shows an operator tree for a statement;
[0025] [0025]FIG. 4 shows a trigger tree and a representative statement for a trigger;
[0026] [0026]FIG. 5 shows an overview of an aspect of the present invention;
[0027] [0027]FIG. 6A illustrates a more detailed execution plan in accordance with the present invention;
[0028] [0028]FIG. 6B illustrates a timing chart for the plan of FIG. 6A; and
[0029] [0029]FIG. 7 shows a flow chart for creating an execution plan in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The present invention relies on a number of operators to control the execution of operations in both an activating statement and its associated trigger trees. The first of these operators is illustrated in FIG. 2A which shows a Flow Operator. The function of this operator is to move the output of operator op 1 12 to the input of operator op 2 14 , as the output of operator op 1 is produced. For example, if op 1 is a selection operator on a table which selects rows of the table meeting a certain condition, then as the rows meeting the condition are found, say by scanning the table, the rows are sent to the input of op 2 . This permits the op 2 operator to function in parallel to the op 1 operator, though, of course, not on the same row that op 1 is operating on. FIG. 2A illustrates this “pipelining” operation in a timing chart which shows the activity of op 1 overlapped with the activity of op 2 .
[0031] [0031]FIGS. 2B and 2C illustrate the Union Operators. The Ordered Union operator 16 of FIG. 2B forces op 2 to operate only after op 1 has completed its operations, in effect serializing the op 1 , op 2 operations as shown in the timing chart. The Parallel Union operator 18 allows op 2 to operate concurrently with op 1 , and assumes that op 2 has no data access conflict with op 1 . As is evident from FIGS. 2A and 2C, the flow operator 10 and the parallel union operator 18 reduce the time to carry out the functions of the op 1 and op 2 operators compared to the ordered union operator 16 .
[0032] Referring to FIG. 3, an operator tree 20 is shown for the given SQL statement 22 . The SQL statement 22 projects a desired column F 1 from the table created by joining tablesT 1 , T 2 and selecting the rows that meet the conjunction of conditions C 1 , C 2 and C 3 . The operator tree 20 shows one way of implementing the SQL statement 22 . According to the tree, first T 1 and T 2 are joined based on condition C 1 by the join operator 24 . Next, a selection operator 26 selects the rows of the joined table that meet the condition which is the conjunction of C 2 and C 3 . Finally, a projection operator 28 selects the column F 1 from any rows that result from the prior operations. As described above, the function of a Query Optimizer is to form alternative execution plans for a query so that the plans can be evaluated in terms of some performance metric. The tree in FIG. 3 is only one such tree that a Query Optimizer can produce for the given SQL statement.
[0033] [0033]FIG. 4 shows an SQL statement 30 for a row after-trigger, rt 1 . The event, condition and action for the trigger are shown in block 32 . The event for rt 1 is a row insertion into a table T 1 ; the condition is C 1 , which can be an arbitrary relational condition and the ACTION part of the trigger can be practically any sequence of SQL statements. The trigger tree 34 represents both the condition and the action parts of the trigger.
[0034] [0034]FIG. 5 shows an overview of the present invention. In FIG. 5, an operator tree 42 for an activating statement S is combined, i.e., “inlined,” with a trigger tree 44 of a trigger T activated by the statement to create an inlined tree 46 . The inlined tree 46 is then processed by an optimizer to create an optimized execution plan 50 for the operators and trigger trees caused by the activating statement S.
[0035] [0035]FIG. 6A illustrates a more detailed execution plan formulated in accordance with the present invention illustrated in FIG. 5. In FIGS. 6A and 6B it is assumed that there are no data access conflicts among the activated triggers and between the activated triggers and the activating statement and that all of the activated triggers are after-triggers.
[0036] Referring to FIG. 6A, statement S is represented by an operator tree 42 , row triggers rt 1 and rt 2 are represented by trees 52 , 54 , respectively, and statement triggers st 1 and st 2 are represented by trees 56 and 58 , respectively. It is assumed that statement S is the event that causes activation of the row and statement triggers. In accordance with the present invention, the operator tree 42 produces, as output, the set of affected rows. A flow operator 60 connects the operator tree 42 for statement S to a temporary table, TempTable 62 , so that rows that are output by the operator tree 42 are pipelined to the temporary table, TempTable 62 . Parallel union operators 64 and 66 connect the trees 52 , 54 for rt 1 and rt 2 and the trees 56 , 58 for st 1 and st 2 so that trees 52 and 54 execute in parallel and trees 56 and 58 execute in parallel.
[0037] Another flow operator 68 connects the parallel union operator 64 for rt 1 and rt 2 to the flow operator 60 connected to the operator tree 42 for statement S so that action trees 52 and 54 execute pipelined to the execution of the statement tree 42 . Finally, an ordered union operator 70 connects the flow operator 68 to the parallel union operator 66 for st 1 and st 2 so that the trees 56 and 58 execute subsequent to the execution of the statement tree 42 . The statement trees 56 and 58 receive their inputs by scanning the temporary table, TempTable 62 , as represented by the scan functions 72 and 74 .
[0038] The effect of structure of FIG. 6A is that the row triggers execute in parallel with each other and pipelined with the activating statement and statement triggers execute in parallel with each other but subsequent to the activating statement. Specifically, the structure operates as follows. The operator tree 42 of S operates to generate a stream of affected rows. As the operator tree for S produces the stream of rows, each row is pipelined by the flow operator 60 to the TempTable 62 to prepare for the operation of the statement trigger st 1 and st 2 , which must execute only after statement S is completed. TempTable 62 accumulates the set of affected rows that were produced by the operator tree 42 for S. These changes may need to be made available to the statement trigger trees st 1 and st 2 . Additionally, each row produced by statement S operator tree 42 is pipelined to the row trigger trees rt 1 and rt 2 , which execute in parallel on the pipelined rows. Upon completion of the execution of statement S, and the row triggers rt 1 and rt 2 , the statement triggers st 1 and st 2 are allowed to execute because of the ordered union operator 70 . The statement trigger trees execute in parallel with each other by scanning the TempTable 62 for input data as needed. After the temporary table is used, the contents of the temporary table are deleted by a special delete operator The timing of the execution plan 76 of Statement S, rt 1 , rt 2 , st 1 and st 2 , according to the structure of FIG. 6A, is illustrated in FIG. 6B, where S represents the time to execute the statement tree 42 , rt 1 , the time to execute the rt 1 action tree 52 , rt 2 the time to execute the rt 2 action tree 54 , st 1 the time to execute the st 1 action tree 56 , and st 2 the time to execute the st 2 action tree 58 . As can be noted from the figure, rt 1 and rt 2 execute in parallel and overlap with the execution of statement S because of pipelining. Statement triggers st 1 and st 2 execute in parallel but only after the execution of the row triggers. This gives a large decrease in the time to execute the statement S and its associated triggers compared to the case of sequential execution 74 shown in the figure.
[0039] [0039]FIG. 7 shows a flow chart of the process for creating an execution plan such as is shown in FIG. 6A. In the process depicted, first the triggers that may be activated by the activating statement are determined in step 90 and an operator tree of the activating statement is formed in step 92 . Next, a trigger tree for each of the activated triggers is formed in step 94 and, in step 95 , the process then verifies that there are no conflicts among activated triggers and between the activated triggers and the activating statement. An activated trigger is either a row or statement trigger as determined by step 96 . If a row trigger is activated, it is joined to the action tree for pipelined execution with the execution of the statement tree in step 98 . If a statement trigger is activated, it is joined, in step 100 , to the statement tree for execution after the execution of the statement tree using a temporary table as input for the action of the statement trigger. The temporary table accumulates the set of affected rows. The statement trigger scans the temporary table for its input.
[0040] The above covers the case of a single row trigger or statement trigger. If more than one row or statement trigger is activated by the activating statement, the row or statement triggers must be combined into the execution plan. In particular, if a number of row triggers is activated, the activated row triggers are combined together into a parallel row group (Group 1 in FIG. 6A) and this parallel row group is the object that is attached to the statement tree for pipelined execution. Internal to the parallel group, each trigger is interconnected by means of a parallel union operator to permit parallel execution of each row trigger within the group. Thus, the execution plan according to the present invention prescribes that each trigger in the parallel group executes in parallel with the other triggers in the group and the entire group execute in a pipeline with the activating statement tree.
[0041] If a number of statement triggers is activated, the activated statement triggers are combined together into a parallel statement group (Group 2 in FIG. 6A) and this parallel statement group is the object that is attached to the statement tree for execution subsequent to the statement tree. Again, internal to the parallel group, each trigger is interconnected by means of a parallel union operator to permit parallel execution of each statement trigger within the group. Additionally, each statement trigger during its execution typically scans the TempTable 62 for its input. The execution plan thus prescribes that the statement triggers execute in parallel and the entire group executes subsequent to the execution of the activating statement tree.
[0042] Of course, it is possible that both a plurality of row triggers and a plurality of statement triggers are activated by the activating statement. This means that the final execution plan combines the actions trees of both the activated statement triggers and row triggers according to FIG. 6A.
[0043] Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein.
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A method for executing after-triggers in an active database. A tree is constructed for each after-trigger and an operator tree is constructed for the statement that activates the trigger. The method joins each of the trees for the activated row-after triggers to the operator tree for pipelined execution with the operator tree. The trees for the activated row-after triggers form a group and each of the trees within the group execute in parallel with each other. The method joins trees for activated statement-after triggers to the operator tree for execution subsequent to the execution of the operator tree, the statement after trigger trees receiving rows from a temporary table that accumulates affected rows from the operator tree. Trees for activated statement after triggers form a group and each of the trees within the group execute in parallel with each other.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an apparatus for melting and refining glass from vitrifiable materials, more commonly called a melting furnace, with a view to the continuous supply of molten glass to forming installations, either for flat glass such as in rolling or float installations, or for hollow glass such as a plurality of forming machines.
The invention is more particularly directed at melting furnaces for flat glass with high molten glass production capacity levels which can, e.g., represent melting rates or outputs of at least 10 tonnes/day and can even reach 1000 and more tonnes/day. However, it is also advantageous for smaller furnaces.
2. Background of the Related Art
In known manner, such a furnace is generally broken down into a succession of compartments issuing into one another and each having specific functions and dimensions. The furnace must be able to melt vitrifiable materials and guarantee the chemical and thermal homogeneity of the glass when malted.
EP-B-264 327 discloses a melting furnace structure having a first compartment in which melting and refining of the glass-making composition takes place, followed by a second compartment forming a neck. The neck issues into a compartment in which thermal homogenization of the molten glass takes place and which is known as a conditioner. The conditioner issues into a flow channel having a significantly reduced section size, which discharges the molten glass to a forming installation.
Furnaces can be placed in two major categories as a function of the heating means used for melting the vitrifiable materials in the melting compartment.
On the one hand there are electric melting furnaces of the so-called cold top type, such as is e.g. known from EP-B-304 371, where melting taken place by electrodes immersed in the depth of the molten glass.
There are also fired furnaces, also known as regenerative furnaces, such as are known from U.S. Pat. No. 4,599,100. In this case, the heating power is supplied by two rows of burners generally operating with a fuel-air mixture and arranged in alternating manner. The combustion gases then alternately heat one or other of two regenerators positioned in facing manner on either side of the melting compartment and communicating therewith. The combustion gases are thermally extracted through stacks of refractories, which constitute the regenerators and which then restore the heat to the melting compartment.
This heating method is effective and widely used. But it suffers from a certain number of disadvantages inherent therein. For example, the energy costs of the fuel-air burners are relatively high. Moreover, the operating system of the burners, which are activated in an alternating manner with cycles of approximately 20 to 30 minutes, is not easy to strictly control. Their use also leads to the introduction into the melting compartment of a significant quantity of air and therefore nitrogen, which leads to an increased risk of forming polluting gases of the NO x type, which must then be treated.
Finally, the large amount of special, costly refractories necessary for the manufacture of the regenerators significantly increases the furnace construction costs.
SUMMARY OF THE INVENTION
An object of the invention is to obviate the disadvantages associated with the use of fired furnaces by proposing a new flame heating type, which greatly reduces the energy costs and the furnace construction material costs, which simplifies its operating procedure and at the same time guarantees the obtaining of a molten glass of an at least equivalent quantity.
The invention is directed to a furnace for melting vitrifiable materials, which has a melting/refining compartment for the glass and which is provided in its upstream part with at least one opening to be supplied with vitrifiable materials via charging devices positioned in front of said openings. In the downstream part, said melting/refining compartment has at least one discharge opening for the molten glass issuing into one or more successive downstream compartments for leading the molten glass to the forming or shaping zone. According to the invention, melting of the vitrifiable materials in the melting/refining compartment is provided by a plurality of burners using an oxidizer essentially constituted by oxygen.
In addition, the furnace is designed in such a way that there is no air supply into the melting and refining compartment, especially from the downstream compartment or compartments and/or from upstream of the melting compartment, e.g., from the vitrifiable material charging zone if the melting compartment is preceded by a preheating compartment for the vitrifiable materials issuing into the latter. To prevent any arrival or supply of air, the furnace can advantageously be equipped with at least one means for making it gas tight, particularly between the melting/refining compartment and the downstream compartment or compartments.
Within the scope of the present invention, the terms "upstream" and "downstream" refer to the overall flow direction of the molten glass through the furnace.
The choice of a heating procedure using burners operating with oxygen leads to a number of advantages compared with more conventional burners, more particularly as compared to operating with an oxidizer of the air type.
This heating procedure firstly makes it possible to abandon the traditional "inversion" operation of fired furnaces. Thus, oxygen burners can operate continuously, which makes the use of the furnace simpler, said continuous operation being more regular and allowing finer settings than in the case of inversion operation. In particular, it is possible to completely eliminate the presence of regenerators formed from stacks of expensive refractories which are subject to wear. Therefore oxygen burners are able to heat the roof, top or arch of the melting/refining compartment and the so-called laboratory volume between said top and the level of the molten glass, in a continuous manner and without having recourse to regenerators.
The atmosphere prevailing above the glass level in the melting/refining compartment is much more stable and controlled, which can be important for the production of so-called special glasses.
Moreover, the thermal efficiency of such burners is much higher than that of conventional burners operating with an oxidizer of the air type, due to the absence of nitrogen, which considerably reduces the volume of fumes generated. Thus, there are considerable energy cost reductions, and this type of burner makes it possible to significantly increase the specific output of the furnace.
The fact that the burners chosen according to the invention require introducing a very small or zero air quantity into the melting/refining compartment significantly reduces the possibilities of the formation of polluting gases of the NO x type, which greatly reduces the treatment costs for the combustion gases discharged out of the compartment.
Moreover, compared with conventional burners, oxygen burners make it possible to introduce into the melting/refining compartment a much larger oxidant volume and the gas volume resulting from combustion is greatly reduced, as indicated hereinbefore. This means that it is possible to reduce the so-called laboratory volume, e.g., by lowering the top of the melting/refining compartment, which in turn tends to reduce both the energy costs and the furnace construction costs.
The use of oxygen burners operating without inversion also leads to the obtaining of a furnace which is more reliable, less costly in its design and which permits energy economies which can extend well beyond 15% compared with a conventionally fired furnace having similar dimensions.
However, this very favorable balance would be compromised if, contrary to the invention, air were to enter into the melting/refining compartment, notably from downstream compartments. There would also be a risk of again creating a certain quantity of polluting gases of the NO x type in the melting/refining compartment and there would be a significant decrease in the energy economies of said compartment. This intake of air can be prevented by providing means for bringing about a gas seal of the melting/refining compartment with respect to the remainder of the furnace. Said sealing means therefore insulates the atmosphere prevailing above the molten glass in the melting/refining compartment from the atmosphere of the successive, downstream compartment or compartments adjacent thereto. These downstream compartments serve to condition the glass, i.e., to progressively cool it so that it reaches its forming or shaping temperature, perfect its chemical and thermal homogeneity and eliminate therefrom foreign bodies such as batch stones or refractory material particles. This thermal conditioning can take place in one or other of said downstream compartments in a known manner by the alternate or combined use of reheating means, e.g., conventional fuel-air burners, and cooling means introducing large amounts of air at ambient temperature into said compartments. It is therefore necessary to prevent such gases from coming back towards the melting/refining compartment, so that they do not disturb its highly controlled atmosphere.
It is obvious that if the downstream compartment or compartments are designed in a known manner, e.g., using cooling means without air introduction and having an atmosphere not constituted by gas, said sealing means are no longer indispensable.
In the melting/refining compartment, the oxygen burners according to the invention (this expression meaning that the oxidizer used is oxygen) are positioned heightwise and optionally at an adequate height, compared with the glass level, so that the flames from the burners do not come into direct contact with the surface of the glass.
These burners are preferably distributed in rows substantially parallel to the longitudinal axis of the melting/refining compartment. The simplest distribution consists of providing two rows of burners issuing into the melting/refining compartment through its side walls. For this purpose, the openings to be made in the wall have a very reduced section and consequently do not disturb the overall thermal insulation of the compartment. The best possible procedure is to combine the burners into a plurality of groups, whose heating power is regulated autonomously between the individual groups. These groups are preferably arranged successively and transversely with respect to the longitudinal axis of the compartment. Therefore heating is modulated and regulated in an optimum manner all along the compartment, and it is possible to create there all desired temperature profiles, particularly in accordance with the type of molten glass to be produced.
In the melting/refining compartment, it is possible to provide auxiliary heating means, e.g., in the form of electrodes immersed in the depth of the glass, in order to adjust or correct the temperature profile in the compartment.
Since the melting/refining compartment has no regenerators, its thermal insulation with respect to the outside is both better and easier to implement. The walls, particularly the side walls and top, can therefore be insulated in a reinforced manner by planar, simply geometrically shaped panels made from a fibrous insulating material and/or sprayed insulating concrete, and whose thickness is sufficiently small to give good accessibility to the side walls. This ease of access facilitates the modifications of the furnace between two glass production campaigns.
In order to thermally extract in an optimum manner the combustion fumes, the walls of said melting/refining compartment are provided with discharge openings in the vicinity of the vitrifiable material supply openings in the most upstream zone of the melting/refining compartment. These discharge openings are preferably positioned in the vicinity of said supply openings. Therefore the fumes can follow a counterflow path from the downstream part to the upstream part of the compartment, so that they are carried above the zone in which the vitrifiable materials float on the surface, and therefore aid the melting thereof. In order to optimize this thermal extraction of the combustion fumes, it is preferable to protect the furthest upstream part of the melting/refining compartment where the vitrifiable materials are charged from the radiation of the burner flames, e.g., with a heat shield of the shadow wall or drop arch type, and ensure that said zone contains no burners. Otherwise there would be a risk in said zone of reheating the fumes, whose temperature it is wished to lower to the greatest possible extent prior to discharge in order to transfer in the optimum possible way their heat to the supernatant, vitrifiable materials. The heat shield also facilitates the convergence of the fumes towards said vitrifiable materials.
In this connection, the invention also relates to a process for preheating a vitrifiable material composition in a furnace for melting said composition and which consists of passing the combustion fumes emitted in the melting compartment of the furnace and in particular the above-described furnace, above the vitrifiable material composition floating on the surface of the already melting phase.
Two different positions can be adopted for the vitrifiable materials supply opening or openings located in the upstream part of the melting/refining compartment. They can be made in the front wall of the compartment or in at least one of its two side walls.
In the latter case, the most advantageous embodiment consists of providing two symmetrical openings facing one another in the side walls and two types of front or side openings permitting an effective charging of vitrifiable materials. However, it would appear that the charging of vitrifiable material through side openings makes the charging operation simpler and more flexible and in particular makes it possible to increase the heat exchange surfaces between the supernatant, vitrifiable materials and the combustion fumes. Various, known charging devices can be used, such as pusher, slide and shovel devices, which may or may not be of an oscillating nature.
It is also possible to provide auxiliary discharge openings for fumes in the side walls of the melting/refining compartment. On leaving the compartment said fumes can still be relatively hot. It is for this reason that they are to be transferred into heat recovery devices of the boiler type or preheating devices for the vitrifiable materials prior to the charging of the latter, or into any other heat recovery device.
Various means for rendering the melting/refining compartment tight or sealed with respect to gases can be provided, which are arranged either singly or in succession, so as to protect the atmosphere of the melting/refining compartment. It is obvious that the larger the number of such means and/or the higher their efficiency, the more it is possible to guarantee the complete insulation of the compartment. These means are, e.g., in the form of a suspended shield and/or a dam partly submerged in the depths of the molten glass. Each of these means has its own special structural nature, although all are generally placed in a substantially vertical plane. Thus, a suspended shield is generally designed in such a way as to be flush with the surface of the glass. If the submerged dam starts from the top and penetrates by a significant depth into the thickness of the glass, it offers a total barrier with respect to the gases. However, it is subject to manufacturing constraints which may limit its use to zones having a relatively reduced section.
With respect to the location of said sealing means, advantageously they are placed at the junction between the melting/refining compartment and the downstream compartment adjacent thereto and/or at the junction between two adjacent downstream compartments and/or in one of the said downstream compartments in the vicinity of one or other of said junctions.
Advantageously the dimensions and in particular the length of the melting/refining compartment are chosen in such a way as to maintain within the molten mass in said compartment the presence of two convective circulation loops.
Preferably, the overall structure of the furnace is broken down into the aforementioned melting/refining compartment, which issues into a first downstream compartment having a reduced section and known as the pre-channel, which itself issues into a second downstream compartment called the channel and having an even smaller section, but which is much longer. Therefore the pre-channel serves as a buffer or transition zone regulating the speed of the glass evacuated from the melting compartment, while the channel is equipped with means for conditioning, cooling and chemically and thermally homogenizing the thus discharged glass.
Preferably, the dimensions of said downstream compartment are chosen in such a way with respect to those of the melting/refining compartment that they determine a sufficiently small glass depth to prevent the creation of a convective recirculation of the molten glass towards the melting/refining compartment. The energy economies are thus increased because once the glass has been evacuated from the melting/refining compartment it does not return there to be heated again. Such a design is more particularly described in French patent application 93/13022 filed on Feb. 11, 1993 (corresponds to the copending, commonly assigned, U.S. patent application being filed on this same date and having attorney docket no. 1247-564-3), whose teaching is incorporated into the present application.
Obviously, the melting/refining compartment according to the invention can be advantageously followed by downstream compartments of a completely different design, Such as, e.g., those described in EP-B-264 327.
The aforementioned heat shield is preferably in the form of a drop arch, which defines a change in the height of the laboratory volume. In other words, the ratio between the total height and the glass depth upstream of said shield is smaller than that downstream of said shield, still in the melting/refining compartment. This accelerates the speed of the combustion fumes converging towards the supernatant, vitrifiable materials.
The most immediate application of the furnace according to the invention in supplying molten glass to flat glass forming installations and particular attention is paid to float glass installations.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the invention can be gathered from the following description of a non-limitative embodiment with reference to the attached drawings wherein:
FIG. 1 is a longitudinal sectional view of the melting/refining compartment;
FIG. 2 is a plan view of the melting/refining compartment;
FIG. 3 is a longitudinal sectional view of the overall furnace; and
FIG. 4 is a plan view of the complete furnace.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 schematically show the glass melting/refining compartment 1 of a furnace according to the present invention. Said compartment is defined by upstream 2 and downstream 3 front walls, side walls 4 and 5, a floor 6 and a top, roof or arch 7, all made from appropriate refractory materials. The floor 6 is flat along a substantially horizontal plane, the walls 2, 3, 4 and 5 are also flat, but along a substantially vertical plane. The top 7 has a curvature transverse to the longitudinal axis X of the compartment 1 (FIG. 2). The molten glass level is indicated in FIGS. 1 and 3 by the horizontal, broken line Y.
This compartment 1 has two main, successive zones 8 and 9 with respect to the longitudinal axis, the first zone 8 being the upstream zone where the vitrifiable materials 10 floating on the surface of the molten glass bath are charged, while the second or downstream zone 9 is where the glass bath is heated and then discharged to the adjacent downstream compartments, which will be described hereinafter relative to FIGS. 3 and 4.
The transition between zones 8 and 9 is delimited by a drop arch 11. The height of the top 7 with respect to the glass level Y is reduced upstream of said arch. The vitrifiable material, also called glassmaking composition, is discharged in the zone 8, either at a front or side thereof.
In FIG. 1, the vitrifiable material supply opening 12 is made in the upstream, front wall 2 facing a conventional, not shown, charging device. In FIG. 2, there are also two symmetrical openings 13 in the side walls 4 and 5 permitting a double composition supply.
No matter whether a lateral or frontal charging type is adopted, openings 14 for the discharge of combustion fumes are provided in the vicinity of the front wall 2. For overall dimensional reasons, it to preferable for the lateral supply openings 13 to be combined with frontal fume discharge openings or vice versa. In the case shown in FIG. 2, the fume discharge opening or openings are therefore made in the upstream, front wall 2.
As a result of the relative positioning of the supply openings and the discharge openings for the fumes, and also due to the presence of the drop arch, a reverse discharge path is imposed on the fumes passing from the zone 9, making them flow upstream towards the not yet melted, vitrifiable material mass 10, which improves the energy efficiency of the furnace.
Once the fumes have been extracted, they are able to supply any heat recovery device or preheating device for the vitrifiable materials, prior to their discharge.
Zone 9 is such longer than zone 8 and is provided with auxiliary fume discharge ducts 15 in the side walls 4 and 5. Walls 4 and 5 also have small openings for rows of oxygen burners 16 which issue into the compartment 1 above the glass level Y. One of the rows is positioned in each of the walls 4 and 5. The accessibility of the walls and the adjustment of the positioning of the burners in the compartment are made possible by the fact that there is a reinforced thermal insulation of the side walls, which makes it possible to reduce the overall thickness thereof. This insulation is formed of planar panels of fibrous materials and/or sprayed insulating concrete.
The burners 16 are preferably positioned equidistantly of one another in each of the two rows. The burners of the two rows are subdivided into subgroups of one or more of pairs of burners. These pairs are constituted by two burners, each belonging to one of the rows, and positioned in a mutually facing manner, so that the burners of each pair are at opposite sides of the furnace and at substantially the same level in the longitudinal direction of the furnace.
As regards the heating power, each subgroup is regulated independently of the others. Therefore it is possible to obtain different temperature profiles along the longitudinal axis of the furnace, at any point and at any time, and in a reliable manner.
It should be noted that the upstream zone 8 has no burners. The fumes penetrating there are able to heat the vitrifiable materials in an optimum manner, and the heat from any burners would be lost with the discharge of the fumes.
The drop arch 11 serving as a barrier between the two zones 8 and 9 serves as a heat shield in order to prevent radiation heating of the zone 8 due to the flames of the burners 16. The reason for this is that, as previously, there is little advantage in reheating the fumes once they have entered the upstream zone 8. The lower part of the arch is sufficiently far from the molten glass level Y not to constitute an obstacle to the circulation of the combustion fumes from zone 9 to zone 8, and instead facilitates their flow towards the supernatant, vitrifiable materials 10.
In the zone 9 of compartment 1 is provided a discharge opening 17 for the molten glass in the downstream, front wall 3. This opening forms a raised sill with respect to the plane of the floor 6, which sill is extended and issues into the adjacent, downstream compartment. The choice of the height of this sill governs the thickness of the molten glass which will pass into said downstream compartment.
An advantage of using continuously operating oxygen burners is that their thermal efficiency is much higher than that of conventional burners while using a reduced gas volume and producing a reduced volume of combustion fumes. Therefore the design of the compartment can be modified, particularly by reducing somewhat the laboratory volume, without prejudice to the operation of the furnace, which leads to economies with respect to the furnace construction materials. Moreover, oxygen burners do not introduce air, particularly nitrogen, into the compartment, which prevents the formation of gases of the NO x type.
These advantages are guaranteed provided that this particular atmosphere in maintained above the molten glass in the melting/refining compartment 1, and for this purpose there are provided means for bringing about a seal with respect to the gases, which will be described relative to FIGS. 3 and 4 showing the overall furnace.
FIGS. 3 and 4 show the previously described melting/refining compartment 1 followed by a pre-channel 18, in turn followed by a channel 19. The sectional area of the pre-channel 18 is intermediate between that of the melting/refining compartment 1 and that of the channel 19. The bottom wall 20 of said compartments is raised with respect to the floor 6 of the melting/refining compartment 1. The channel 19 ends with a flow spout lip 21, which distributes the molten glass towards a, not shown, forming zone.
The dimensions, particularly the depth, of these two downstream compartments 18 and 19 are chosen so that there in no convective glass recirculation belt from the latter towards the compartment 1, which considerably reduces the heating required in the compartment 1.
There are three sealing means of the aforementioned type, the first being located at the junction between the melting/refining compartment 1 and the pre-channel 18. It in constituted by a suspended shield 22 partly fixed above the molten glass discharge opening 17 and flush with the glass level Y. The second means 23 is located at the junction between the pre-channel 18 and the channel 19 and has the same shape as the first.
The final sealing means is located in the vicinity of the junction between the pre-channel 18 and the channel 19, and specifically in the latter. It consists of a submerged dam 24, which is suspended from the top of the compartment and is partly immersed in the glass. It can also fulfill a drainage function.
The combination of these three means is of an optimum nature for totally sealing the compartment 1 with respect to each of the compartments 18 and 19 succeeding it. It is within the scope of the present invention to combine them in a different way or in a different order, or to use one, two or more such means.
In conclusion, the furnace according to the invention improves the heating system in the melting compartment and reduces its operating and manufacturing costs. A final advantage is an improved control of the atmosphere of the melting compartment, as well as a reduction in the pollution risks.
As stated, the heating system according to the invention can be used for a furnace provided with downstream compartments differing from those shown in FIGS. 3 and 4, and in particular provided with a neck followed by a conditioner.
It is also obvious that the melting/refining compartment can be equipped with any known means for refining and homogenizing the glass or for controlling the convection movements, e.g., all types of stirrers, bubblers, etc. The so-called downstream compartments can, in known manner, also be equipped with any means for conditioning the glass, as well as for draining, cooling and thermally or chemically homogenizing the molten glass.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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A furnace for melting vitrifiable materials having a compartment (1) for the melting/refining of the glass and which is provided in its upstream part with at least one opening (12) to be supplied with vitrifiable materials (10) with the aid of a charging device positioned facing and in the downstream part a discharge opening (17) for the molten glass issuing into one or more successive, downstream compartments (18, 19) for leading the molten glass to the forming zone. The melting of the vitrifiable materials takes place in the melting/refining compartment (1) essentially via a plurality of burners (16) with an oxidizer constituted by oxygen. It is designed to operate without any air introduction into the melting/refining compartment (1) coming from the downstream compartment or compartments.
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BACKGROUND OF THE INVENTION
The processing of staple fibers include several steps all directed toward the orientation and maintenance of the fibers in eveness and in parallel relation to one another. Eveness is a term used to define the desired uniformity of fiber diameter without thick and thin places along its length.
More specifically, the processing of staple fibers includes carding clumps or tufts of cotton or synthetic staple. The carding action separates these clumps or tufts into their individual fiber elements, thereby exposing and removing bits of foreign matter enclosed by the unopened fiber aggregates and feeds the cleaned disentangled fibers through the tapered hole or trumpet to define a continuous untwisted strand of fibers known as sliver. The compression of the fibers at the trumpet and calendar rolls of the carding machine causes fibers to be loosely held together to form the sliver. The size of sliver is expressed as the average weight in grains per yard of length, there being seven thousand grains in one pound. The normal range of sliver weights is from 40 to 70 grains per yard.
The card sliver may be delivered to a draw frame which progressively passes or slides fibers by each other, causing a reduction in size of the strand, but not breaking its continuity. The action is obtained by using several pairs of rolls running at different speeds. The purpose of all roller drawing is to straighten the fibers being treated and to reduce the size of the strand which they compose. The straightening is important because it arranges the fibers more nearly parallel to each other and to the direction of the strand. When the fibers are well straightened, the arrangement helps in producing uniform, strong, and smooth yarn.
The placement of the rolls must be adjusted to suit the length of the fibers being handled. Although the fibers of any given cotton are not uniform in length, the drawing rolls must control as many of the fibers as possible. This means that there are fibers longer and shorter than those for which the rolls are set, and those longer and shorter fibers will not be well controlled. The imperfect control of fibers in the drawing leads to uneveness in the strand, producing irregularities or thick and thin places which contribute to uneveness in the finished product. Conversely, the more perfect control of fibers in the drawing leads to eveness of the strand which contributes to the desired uniformity of the finished product.
The sliver is reduced in diameter by successive drafting and is processed on a spinning frame to provide additional drafting and twisting to produce the desired yarn.
Prior attempts have been made to control the fibers on the draw frame, roving frame and spinning frame including the use on draw frames and roller drafters of a saw-tooth roll with teeth extending at a positive angle to pull the fibers and separate them into spaces between the teeth. The pulling of the fibers by the positively angled saw-teeth is objectionable because it disorients the previous parallelization of the fibers. Balloon rolls have been used and they provide effective tension and maintenance of the yarns. The same is true of the prior art aprons comprising endless rubber belts extending around a special cradle on a spinning frame, known as the Casablanca system, and so arranged that the fibers on the spinning frame are fed between the aprons at their nip. The aprons satisfactorily control the fibers but are objectionable because of the need for frequent replacement. Another objection of the Casablanca system is its expense. The Casablanca system includes special stands for holding the front and back rolls on the spinning frame and the middle bottom roll is of special design with narrow bosses, each of which carries a short endless apron. The middle top rolls, the bosses of which are smaller in diameter than regular top rolls, are also narrow and each boss carries a short, endless apron like those on the bottom roll. It has been estimated that the cost of these special rolls and aprons amounts to 70% of the cost of a conventional spinning frame.
SUMMARY OF THE INVENTION
The control roll of the present invention is a metal roll with a novel circumferential surface configuration comprising teeth, axial channels and circumferential grooves uniformly spaced from each other circumferentially, radially, and axially. The teeth extend at a negative angle from the body of the roll and are axially and circumferentially spaced from each other.
In use, the control roll of the present invention is placed between two sets of calender rolls in a slightly elevated position. The spacing of the control roll between the calender rolls is preferably slightly less than the average staple length of the fiber being processed. The sliver or roving is trained upwardly over the control roll from the first calender roll set and then trained downwardly through the nip of the second calendar roll set. There is a differential in the rotational speed of the calender rolls and the control roll and this speed differential moves the fibers into engagement with the teeth which feed the fibers into the axially spaced circumferentially extending grooves on the control roll which tend to straighten the tensioned fibers as they are drawn into the axially spaced grooves of the control roll, whereby the control roll exerts a positive control on the sliver and orients and maintains the fibers in both eveness and parallelization.
The control roll is preferably used at each drafting station after the carding operation, that is on drafter rollers, draw frames, roving frames and spinning frames. It is placed between two calender rolls in each instance and on the spinning frame the control roll of the present invention replaces the Casablanca system including the aprons and special shafts for the middle top roll and middle bottom roll. In fact, the entire middle top roll may be eliminated and the special knurling and other features necessary for the Casablanca system is eliminated by the present invention. The control roll of this invention is mounted on a standard keyed shaft, there being a separate control roll for each strand of sliver spaced along the standard shaft which may be supported about even ten feet.
It is, accordingly, an object of the present invention to provide a control roll with a circumferential surface configuration arranged to exert a positive control on sliver or roving and orient and maintain the fibers in both eveness and in parallelization.
It is another object of the invention to provide a control roll of the type described which is split and assembled on the shaft by bolts so individual rolls can be replaced without taking off the entire shaft.
It is another objection of this invention to provide a control roll of the type described which will more effectively orient and maintain the orientation of the fibers during drafting than has heretofore been possible.
It is a still further object of the invention to provide a control roll which will effectively control the fibers during drafting with greater efficiency and economy than has heretofore been possible.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a control roll assembly according to the present invention;
FIG. 2 is an exploded sectional view of one of the control rolls shown in FIG. 1;
FIG. 3 is a vertical sectional view taken substantially along the line 3--3 in FIG. 1;
FIG. 3A is a vertical sectional view substantially along the line 3A--3A in FIG. 3;
FIG. 3B is a vertical sectional view taken substantially along the line 3B--3B in FIG. 3A;
FIG. 4 is a fragmentary top plan view of the control roll assembly shown in FIG. 1 positioned between two calender rolls, the upper roll being omitted for clarity;
FIG. 5 is a perspective view of a roller drafter illustrating the control roll assembly of FIG. 1 between two sets of calender rolls;
FIG. 6 is an enlarged horizontal sectional view taken substantially along the line 6--6 in FIG. 5;
FIG. 7 is a fragmentary somewhat schematic side elevation of a spinning frame, with parts broken away, equipped with the prior art aprons of the Casablanca system;
FIG. 8 is an enlarged fragmentary schematic side elevation of a spinning frame, with parts broken away, equipped with the control roll of the present invention instead of the prior art aprons;
FIG. 9 is a perspective view of the sliver in advance of the control roll looking in the direction of the arrow 9 in FIG. 8;
FIG. 10 is a perspective view of the sliver engaging the control roll looking in the direction of the arrow 10 in FIG. 8, and omitting the pressure roll for clarity;
FIG. 11 is a perspective view of the sliver as it leaves the control roll and looking in the direction of the arrow 11 in FIG. 8;
FIG. 12 is a fragmentary side elevation of a second embodiment of the control roll, with parts broken away;
FIG. 13 is fragmentary perspective view of the control roll shown in FIG. 12, with parts broken away;
FIG. 14 is a perspective view of a third embodiment of the control roll;
FIG. 15 is a top plan view of the control roll shown in FIG. 14 and illustrating in phantom lines alternative annular flanges on the ends of the roll; and
FIG. 16 is a fragmentary view of a fourth embodiment of the control roll, illustrating an alternative arrangement of the grooves and channels.
DETAILED DESCRIPTION OF THE INVENTION
Referring more specifically to the drawings, the control roll of this invention is broadly indicated at 20. A separate control roll 20 is provided for each strand of sliver on a processing machine such as the roller drafter shown in FIG. 5 and 6 or the spinning frame illustrated in FIGS. 7 and 8. Two control rolls 20 are suitably keyed and removably mounted on a correspondingly shaped driven shaft 21 in FIG. 1 to define a control roll assembly.
Each roll 20 is preferably split along its axis to provide equally sized and shaped roll segments 20A and 20B in the form of invention illustrated in FIGS. 1 through 11. Each of the roll sections 20A and 20B are of identical construction and include arcuate flanges or shoulders formed integral therewith and projecting axially from their ends and respectively indicated at 22A and 22B. The segments 20A and 20B are assembled about a shaft 21 and retained thereabout by pins or bolts 23 which penetrate juxtaposed flanges 22A and 22B as clearly shown in FIG. 2. The segmental construction of the control roll enables it to be replaced when needed without disturbing the remaining control rolls on the same shaft and is deemed desirable for this reason. It is contemplated, however, that there are instances where a monolithic control roll such as broadly indicated at 20' in FIG. 14 may be desirable and it is within the scope of the invention to make the control roll either segmental as shown in FIG. 1 through 8 or monolithic or unitary as shown in FIG. 14. The shaft 21 is preferably keyed as at 21A and one of the segments 20A or 20 and the roll 20' are correspondingly shaped to prevent slippage.
Whether segmental or monolithic, the control roll 20 and 20' each includes a circumferentially textured work surface 24 comprising teeth 25 spaced axially and circumferentially from each other and defining axially extending channels 26 and circumferentially extending grooves 27 there between. The peaks 25, channels 26 and circumferential grooves 27 are formed about the circumference of an arcuate body portion 28 in FIGS. 3A and 3B or a tubular body portion 28' in FIGS. 14, 15 and 16.
Viewed circumferentially, as seen in FIG. 3A, the teeth 25 taper inwardly and upwardly from their junctures with the body portion 28 so that the base of each tooth has a greater axial dimension than the top of the tooth. The circumferential grooves 27 are shown in FIGS. 3, 3A and 3B as being deeper than the axial channels 26. Alternatively, as seen in FIG. 16, the axial channels 26 may be deeper than the circumferential grooves. In both instances the teeth 25 feed the staple fibers into the circumferential grooves 27 which physically arrange the fibers in parallel relation to each other as they are delivered from the control roll. The axial channels 26 assist in preventing lap-ups and have an arcuate configuration which provides a negative pitch to the teeth 25. The negative pitch is desirable because it prevents the teeth from plucking and disorienting the fibers as the fibers approach and leave the control roll. The work surface 24 is bounded by annular flanges 19 between the work surface 24 and the shoulders 22A, 22B. The flanges 19 direct all of the sliver to the control roll.
In FIGS. 5 and 6, the driven shaft 21 and its control rolls 20 are mounted on a roller drafter 30 between calender rolls 31 and 32. The sets of calender rolls 31 and 32 are conventional and apply heavy pressure to the sliver as the sets are rotated at different speeds to draw the sliver by passing or sliding fibers by each other, causing a reduction in the size of the strand but not breaking its continuity. The roller drafter straightens the fibers being treated and reduces the size of the strand which they compose. The straightening is important because it arranges the fibers more nearly parallel to each other and to the direction of the strand which they compose. The straightening is important because it arranges the fibers more nearly parallel to each other and to the direction of the strand, indicated by the arrow in FIG. 6. When the fibers are well straightened, the arrangement helps in producing uniform strong and smooth yarn. The imperfect control of fibers in the drawing leads to uneveness in the strand, producing irregularties resulting in poor quality yarn. As more fibers are controlled in drawing the quality of the finished yarn is improved.
The several sets of calender rolls on the drafter roller illustrated in FIGS. 5 and 6 are spaced from each other along the direction of travel of the sliver a distance less than the average length of the fibers composing the sliver. Thus, assuming a staple length of one and one-half inches the calender rolls may be spaced one inch from each other and the control roll 20 spaced one inch from adjoining calender rolls. The diameter of the control roll 20 should be as great as the length of the fiber or staple plus at least 10 percent. For processing one and one-half inch sliver, a control roll having a diameter of two inches is satisfactory.
The calender rolls 31 and 32 rotate at different speeds with the calender roll 31 rotating at a faster speed than the calender roll 32. Similarly, the control roll 20 rotates at a faster speed than the rear calendar roll 32. For exampley, the first calender roll 32 may rotate at 10 rpm, the control roll 20 at 12 rpm and the last calender roll 31 at 100 rpm. Generally, the differential in speed between the first calender roll 32 and the control roll 20 is between 15 and 50 percent, at 20 percent differential being common.
The circumference of the control rolls 20 extends above the common plane occupied by the nips of the proximal sets of calender rolls 31 and 32 (FIG. 6) so that the sliver is moved upwardly as it reaches the control roll 20 and downwardly as it leaves. An elevational differential of 1/16 of an inch has been found satisfactory. The purpose is to move the fibers into the circumferential grooves 27. The teeth 25 feed the fibers to the circumferential grooves 27 and the grooves 27 condense and straighten the fibers as they traverse the control roll 20.
The sliver is initially condensed by vertical pins 33 in advance of the control roll 20. FIG. 4 illustrates the initial condensing of the sliver by the pins 33 and the subsequent condensing of the sliver by the pins 33 and the subsequent condensing of the sliver into small individual strands 34 by the control roll 30. The negative pitch of the teeth enables the teeth to guide the fibers into the circumferential grooves 27 without picking at the fibers and unnecessarily clumping them and disturbing the parallelization that they have previously obtained. The negative pitch of the teeth 25 also enables the fibers to leave the control roll without being plucked out of alignment by the teeth 25.
Referring to FIGS. 7 and 8, a prior art spinning frame is illustrated in FIG. 7 with its upper and lower aprons 35 and 36 between which the sliver S passes toward the spinning ring 37. The endless belts of the aprons 35 and 36 are driven by upper and lower knurled rolls 38 and 39 about bars 40 supported by upper and lower knurled rolls 38 and 39 about bars 40 supported by a special metal cradle 41. The aprons 35 and 36 apply yieldable tension to the sliver and control the fibers during their passage through the drafting portion of the spinning frame prior to delivery to the ring twister 37 through the pigtail 42. The knurling of the rolls 38, 39 is an expensive procedure and the need for periodic replacement of the aprons 35 and 36 causes unproductive downtime and is expensive maintenance.
According to the present invention the need for knurling the rolls and the need for replacing the aprons is obviated by substituting the control roll 20 for the aprons 35 and 36 and substituting the driven shaft 21 for the knurled roll 39. The shaft 21 is a simple plain keyed shaft. The control roll 20 tensions the sliver and at the same time positively parallelizes the fibers, which the aprons of the prior art didn't do. The control roll 20 occupies the same position on the spinning frame as the prior art aprons, between sets of calender rolls 43 and 44 driven at different speeds. For example, the rear set of rolls 44 may rotate at 3 revolutions per minute; the control roll at 5 revolutions per minute; and the front rolls at 100 revolutions per minute. The circumference of the control roll 20 extends above the plane occupied by the nips of the calender rolls 43 and 44 to desirably locate the circumferential grooves 27 in the path of travel of the slivers. A guide roll 45 is mounted above the control roll 22 in FIG. 8 and is adjustable forwardly and rearwardly along a track schematically illustrated at 46 as desired depending on the fiber being processed.
FIGS. 9, 10 and 11 illustrate, repsectively, the condition of the sliver S in advance of the control roll 20; as it traverses the control roll; as it leaves the control roll 20. The sliver is condensed into individual strands 47 by the control roll 20, the individual strands 47 in FIG. 11 corresponding to the individual strands 34 in FIG. 4.
Referring to FIGS. 12 and 13, a modified form of control roll is illustrated wherein the teeth 25' are each in the form of a pyramid with the point of the pyramid defining the top of the teeth and the teeth arranged in staggered rows about the circumference of the roll. Such a construction is preferable for use with certain fibers.
There is thus provided a control roll for exerting positive control on sliver to both orient and maintain the fibers in eveness and in parallel relation to improve the quality of the sliver and the resulting yarn. Although specific terms have been employed in the description of the invention they are used in an explanatory sense and not for purposes of limitation.
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A control roll is provided for use in the processing of staple fibers and comprises a plurality of radially and circumferentially spaced projections on the surface of a roll. The control roll is placed in the path of a strand of fibers and the individual fibers in the strand are physically oriented into parallel relation with one another and maintained in that relation until the fibers are processed as by drawing and twisting.
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CROSS REFERENCE TO RELATED APPLICATION
NONE
BACKGROUND OF INVENTION
This invention relates to a method for repairing a crack, particularly in a recreational court or surface.
A variety of methods exist for repairing cracks in surfaces, such as roadways, pavements and other concrete or asphalt surfaces, and particularly for recreational courts or surfaces, such as tennis courts, outdoor basketball courts, volleyball courts, running tracks and multi-sport play courts. Such cracks are a significant problem, especially in those areas of the country where there are significant variations in temperature throughout the year.
The conventional process for repairing cracks in recreational courts or surfaces requires cleaning debris out of the cracks and filling the cracks with a crack filler material which solidifies to a hardened state. Prior to hardening, this crack filling material is leveled to the level of the recreational court or surface.
Unfortunately, crack repairs made using this conventional process are only a temporary fix. Continued maintenance of the recreational court is necessary because of the formation of new cracks or the further deterioration of the earlier crack caused by changes in temperature and moisture in the environment as well as ground movement or settling and problems with the construction of the court or surface. Cracks repaired using this conventional process often tear open again as the asphalt or concrete pavement expands or contracts caused by temperature changes, moisture level increases, ground movement or settling, or the freeze and thaw of the surrounding ground.
A more complex process for repairing cracks in recreational courts or surfaces, particularly tennis courts, requires covering the filled crack with a slip-sheet, i.e. a non-adhering material which isolates the crack from the surrounding environment. This process requires the crack to be cleaned and filled with a hardened crack filler to the level of the surrounding pavement or recreational court. A slip-sheet is then secured, usually by an adhesive, to the surface of the recreational court, completely covering the filled crack. The top surface of this slip-sheet, which is applied over the crack, is required not to adhere to other materials which cover the slip-sheet. Another layer or layers of material, such as one or more fiberglass sheets, are then placed over the non-adhering surface of the slip-sheet and are secured at least at their peripheral edges to the pavement or recreational court. By this method, the top surface of the slip-sheet is isolated from the remaining materials, enabling the slip-sheet to expand and contract with the court or surface without putting stress on the crack repair. Early slip-sheet methods are disclosed in U.S. Pat. Nos. 3,663,350 and 3,932,051.
Another method of crack repair using a slip-sheet utilizes a tape material with a shiny outer surface, prepared from polyethylene, Mylar, Teflon or other such materials, as disclosed in U.S. Pat. No. 6,450,729. An adhesive tape, such as duct tape, which has a non-adhering polyethylene top surface, is one example of a slip-sheet of this invention.
In an alternative method, which is disclosed in U.S. Pat. No. 5,464,304, a liquid waterproofing material is applied directly over the filled crack. This liquid waterproofing material dries with a non-adhering top surface that isolates the crack from additional materials placed over the non-adhering surface. Over this non-adhering surface are secured several fabric layers by use of acrylic binders. The key step in this process, however, is the crack isolation step produced by the application of the liquid waterproofing material to the recreational court.
The process of U.S. Pat. No. 5,464,304 is similar to that of U.S. Pat. No. 6,450,729 in that both rely on the application of a non-adhering material to the recreational court or surface over which other materials are placed. Many different types of materials and adhesives may be applied over the slip-sheet or other non-adhering surface to complete the crack repair.
While these processes for filling cracks in recreational courts or surfaces have shown utility, they can be difficult to apply, require an extensive amount of time to cure and still result in problems caused by the recurrence of the cracks.
Accordingly, it is an object of the invention to disclose a method for repairing a crack in a court or surface, particularly a recreational court or surface, which addresses the problems of the prior art. These and other objects can be obtained by the process for repairing a crack in a recreational court or surface that is disclosed in the present invention.
SUMMARY OF THE INVENTION
The present invention is a process for repairing a crack in a recreational court or surface comprising
cleaning the crack to remove loose material,
filling the crack with a crack filling material, which adheres to and seals the inside edges of the crack,
applying a laminate to the recreational surface and to the exposed sealant material to cover the crack completely, wherein the laminate comprises an adhesive secured to one side of a flexible fabric material, wherein the adhesive is secured to the recreational surface and the exposed sealant material, and
securing a fabric, preferably a flexible polyester fabric, to at least the edges of the flexible fabric material of the laminate using an adhesive material.
In a further preferred embodiment one or more layers of paint, preferably an acrylic paint, are then applied to the fabric material, exposed laminate and recreational court or surface to complete the repair of the crack in the recreational court or surface.
DETAILED DESCRIPTION
The invention is a method for repairing a crack in a recreational court or surface. The court or surface to be repaired can be formed of any conventional material, such as concrete or asphalt and can be formed into a roadway, driveway, or sidewalk, but preferably is formed as an outdoor recreational court or surface, such as a tennis court, basketball court, volleyball court, running track, multi-sport or play court. In composition conventional recreational courts or surfaces have a certain thickness and are generally placed over a stone base or the ground. Cracks form in these recreational courts as a result of changes in the environmental conditions, such as occur when there are significant changes in the outdoor moisture or temperature, as well as ground movement or settlement and problems with the construction of the court or surface. Cracks formed in the recreational court or surface may have different shapes, widths and lengths and can extend a significant distance or only a small distance into the recreational court.
The first step in the repair of the crack in the recreational court is to clean the crack to remove all loose material and debris. This can be effectively done by brushing, hand removal, high pressure steam and/or the use of air under pressure.
After the crack has been completely cleared of loose debris, a crack filling material is introduced into the crack. In prior art processes this crack filling material was a material which formed a hardened fill material, such as an epoxy binder. In an alternative process, silica, sand, and Portland Cement were mixed together with a liquid to form a wet mortar to fill the crack. This mixture was then allowed to dry to a hardened consistency. These processes, which utilize hardened crack filling agents, may not provide flexibility for the fill material and sometimes permit water to reenter the crack.
While these crack filling materials are still useful for many types of courts, it has been surprisingly discovered that an improved crack filling material is one that can expand and contract with changes in the weather conditions, yet still forms a waterproof bond around the inside edges of the crack to prevent water from entering the crack and causing further deterioration of the existing crack. Any material which can fill the crack completely and securely, yet remain flexible to accommodate expansion and contraction when exposed to changes in temperature and moisture and which also is waterproof, is within the scope of the invention. In one preferred embodiment a flexible polyurethane foam product, such as “Great Stuff” manufactured by Dow Chemical Company, is introduced into the cleaned crack as the flexible sealant material. Sufficient flexible sealant material should be utilized to fill the crack completely up to the level of the surrounding recreational court. After application, the surface of the recreational court should be leveled prior to the complete drying and curing of the sealant material.
After the crack is filled and the crack filling material has been allowed to dry and cure, a laminate is applied to cover completely the crack and the surrounding recreational court or surface. Regardless of whether a flexible sealant is used, it is important that the laminate be flexible to expand and contract with the expansion and contraction of the court. If the crack filling material is a sealant material which is flexible and thus can expand or contract depending on the temperature, it is especially important that this laminate also be flexible to permit expansion and contraction with changes in weather conditions, especially temperature.
The laminate is preferably formed from an adhesive material, preferably waterproof, applied to a flexible fabric material. The adhesive material is preferably a waterproof adhesive which will tightly secure the laminate to the recreational court and to the exposed crack filling material. In one preferred embodiment the adhesive material comprises a waterproof, rubberized asphaltic adhesive.
Secured to the adhesive material is the flexible fabric material. The flexible fabric material can be any material which expands and contracts in coordination with the expansion and contraction of the recreational court. In one preferred embodiment this material may also be waterproof. In addition, this flexible material is preferably elastic. The adhesive portion of the laminate is secured tightly, preferably permanently bonded during production, to one side of this flexible material. In one preferred embodiment the adhesive portion is applied in liquid form to the flexible fabric and when cured, is or becomes bonded, preferably permanently bonded, to the flexible material. Prior to application of the laminate to the surface, the adhesive material is preferably covered by a paper release backing to assist in the storing, utilization and application of the laminate. One preferred laminate material is supplied by Protecto Wrap Company and comprises a construction waterproofing, flexible, adhesive anti-fracture membrane.
Following the filling and curing of the sealant material in the crack, the paper release backing is removed from the adhesive portion of the laminate and the adhesive is applied to and secured firmly to the recreational court and to the exposed sealant material.
In the next step of the inventive process, a flexible fabric is secured to at least the edges of the flexible fabric material of the laminate by an adhesive. This portion of the process differs dramatically from those processes which use a “non-adhering” surface. In the prior art processes the fabrics which cover the “non-adhering” surface are not secured to the “non-adhering” surface. In contrast in the process of the invention, the laminate is secured by adhesive to those fabrics which cover the laminate. In a preferred embodiment the flexible fabric of the invention comprises a flexible polyester fabric, sufficiently sized to cover at least the edges of the laminate. It is secured to at least the edges of the laminate and the surrounding recreational court by use of an adhesive material, preferably a waterproof acrylic or latex adhesive, which is applied to the polyester fabric, prior to or during application. The adhesive is also preferably applied to the edges of the flexible fabric layer, where the edges contact the recreational court or surface. In a preferred embodiment this flexible fabric is secured to portions of recreational court or surface which extends beyond the outer edges of the laminate. In a preferred embodiment the polyester fabric is Bamilex XP403 produced by St. Gobain Technical Fabrics.
After the adhesive on the polyester fabric has dried and cured, the court or surface that has been repaired may be coated with paint, preferably an acrylic paint, with its color coordinated with the color of the non-repaired section of the recreational court or surface that surrounds the repaired crack. Other recreational court or surface materials, such as sand, may be added to the acrylic paint to enhance the coating process.
In operation, the crack in the recreational court or surface is first cleaned and swept clear of debris. The crack is then filled with a crack filling material, preferably a flexible sealant material, and more preferably a polyurethane foam sealant material. A sufficient amount and type of the crack filling material is utilized to adhere completely to the edges of the crack and prevent or limit exposure of the crack to water. After the crack filling material has dried, paper release backing is removed from the adhesive side of the laminate. The adhesive side of the laminate is then applied to the recreational court, completely covering the crack. This adhesive side of the laminate is then pressed firmly in place against the recreational court or surface and the exposed crack filling material. Applied to at least to the edges of the top of the laminate by means of an adhesive material, such as an acrylic adhesive, is the flexible polyester fabric. Finally, the repaired surface is painted to coordinate its color with that of the surrounding recreational surface.
It will be apparent from the foregoing that while particular forms of the invention have been illustrated, various modifications can be made without departing from the scope of the invention.
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A process for repairing a crack in a recreational court or surface comprising cleaning the crack to remove loose material, filling the crack with a crack filling material, such as a flexible sealant material which adheres to the edges of the crack and securely seals the crack, applying a laminate to the recreational surface and to the exposed sealant material to completely cover the crack, wherein the laminate comprises a waterproof adhesive applied to a flexible material, and securing a polyester flexible fabric to at least the edges of the laminate using an adhesive material.
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This application is a continuation-in-part application of copending U.S. patent application Ser. No. 046,743, filed May 7, 1987 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of Invention.
This invention relates to novel cyclic carbamate derivativese having ring carbon substitution by a 4-[α,α-diaryl-hydroxymethyl]-1-piperidinylalkyl radical. The cyclic carbamate derivatives encompassed by the invention are those of the 2-oxazolidinones, the 1,3-oxazin-2-ones, the 1,3-oxazepin-2-ones, and the 1,3-oxazocin-2-ones. The compounds are useful in methods countering the effects of histamine already released and in combating allergic responses in a living animal body in need thereof and pharmaceutical compositions therefor. More specifically the methods employ the compounds inhibiting Type I allergic response (Gell & Coombs Classification of Immune Responses) and in preventing release of histamine as well as antagonizing end organ effects of mediators involved in the immediate hypertensivity response and as such are useful in treating allergic phenomena which includes asthma, rhinitis, atopic dermatitis, chronic hives, allergic conjunctivitis, and the like, as well as the symptomatic effects of the allergic phenomena. These pharmacological activities, i.e., antihistaminic and antiallergenic being complementary in effect when needed.
2. Information Disclosure Statement
4-[Bis(aryl)hydroxymethyl]piperidines used in synthesis are disclosed in U.S. Pat. Nos. 3,956,296; 4,032,642; and in copending application Ser. No. 811,799, filed 12/20/85 now U.S. Pat. No. 4,810,713. N-Substituted-haloalkyloxazolidin-2-ones and 1,3-oxazin-2-ones used in synthesis have been disclosed in U.S. Pat. No. 3,423,418 and in the following publications: J. MED. CHEM. 16, 1124-1128 (1973); J. ORG. CHEM. 35, 4100-4103 (1970); and J. PHARM. SCI. 58, 362-364 (1969). A search of the literature has not revealed a combination of these foregoing moieties to give the subject compounds of this invention.
OBJECTS AND SUMMARY OF THE INVENTION
The novel cyclic carbamate derivatives of this invention useful in treating allergy in animals are substituted on one of the ring carbon atoms by a 4-[(bis-aryl)-hydroxymethyl]-1-piperidinylalkyl radical and are represented by the formula: ##STR2## wherein; R is selected from hydrogen, loweralkyl, cycloalkyl, phenyl, ##STR3## phenyl-loweralkyl or ##STR4## loweralkyl; Ar and Ar 1 are selected from phenyl, ##STR5## or 2, 3 or 4-pyridinyl radicals; alk is a straight or branched hydrocarbon chain containing 1-8 carbon atoms;
R 1 is loweralkyl substituted for hydrogen on a ring carbon;
m is 1 to 4;
X, Y, and Z are selected from halogen, loweralkyl, loweralkoxy, or trifluoromethyl, and when more than 1 may be the same or different; optical isomers thereof and the pharmaceutically acceptable acid addition salts thereof.
In the further definition of symbols in the formulas hereof and where they appear elsewhere throughout this specification and claims, the terms have the following significance.
The term "loweralkyl" includes straight and branched chain hydrocarbon radicals of up to eight carbon atoms inclusive and is exemplified by such groups as methyl, ethyl, propyl, isopropyl, butyl, isobutyl, tertiary butyl, amyl, isoamyl, hexyl, heptyl, octyl, and the like. "Loweralkoxy" has the formula -O-loweralkyl.
The term "cycloalkyl" as used herein includes primarily cyclic alkyl radicals containing 3-9 carbon atoms inclusive and includes such groups as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, methylcyclohexyl, cycloheptyl and the like.
The terms "halogen" or "halo" include chlorine, bromine, fluorine and iodine radicals, preferably chlorine, bromine and fluorine radicals.
The "alk" straight or branched connecting hydrocarbon chain containing 1-8 carbons is exemplified by methylene (--CH 2 --), ethylene (--CH 2 CH 2 --), propylene (--CH 2 CH 2 CH 2 --), ethylidene ##STR6## 1,2-propylene ##STR7## isopropylidene ##STR8## or 1,3-butylene ##STR9## and the like;
Pharmaceutically acceptable acid addition salts are those salts formed with the free base compounds of Formula I with any acid which is physiologically compatible in warm blooded animals, such salts being formed either by strong or weak acids. Representative of strong acids are hydrochloric, hydrobromic, sulfuric and phosphoric acids. Representative of weak acids are fumaric, maleic, succinic, oxalic, hexamic, and the like, and hydrates or solvates thereof.
The primary screening method used to detect antiallergy properties of the compounds of Formula I is a modification of the procedure of R. R. Martel and J. Klicius, INTERN. ARCH. ALLERGY APPL. IMMUNOLOGY, Vol. 54 pp 205-209 (1977) which measures the effect of oral administration of the compound on the volume of a rat paw which was previously injected with anti-egg albumin serum and is described under Pharmacology Methods hereinbelow.
A method of studying potency in preventing guinea pig anaphylaxis relative to known antiallergy drugs is also described hereinbelow.
The Gell and Coombs Classification of Immune Responses referred to hereinabove is well known in the art and is described in ESSENTIAL IMMUNOLOGY, 3rd Ed. (1977) (Blackwell Scientific Publications) printed by William Clowes and Sons, Limited, London, Beccles and Colchester.
It is therefore a primary object of the present invention to provide novel 4-[(α,α-diaryl)hydroxymethyl]-1-piperidinylalkyl-cyclic carbamate derivatives useful in combating histamine and allergic responses in living animals and pharmaceutical compositions therefor.
Additional objects and advantages of the present invention will be apparent to one skilled in the art and others will become apparent from the following description of the best mode of carrying out the present invention and in the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
Compounds of Formula I are prepared by the method illustrated in the following schematic equation in Chart I. ##STR10##
Generally, compounds of Formulas II and III, base, iodide catalyst, and solvent such as butanol are heated together for a period of time, usually several hours, at about 100° C. or until reaction is complete. The mixture is then concentrated under reduced pressure and the residue is partitioned between water and a suitable solvent for the free base, e.g., benzene. The benzene layer is separated, dried and concentrated and the product is isolated usually, but not always, as an acid addition salt.
Certain of the starting oxazolidinones and 2H-1,3-oxazin-2-ones were prepared by a rearrangement method described in U.S. Pat. No. 3,419,559 for the oxazolidinones according to the following reaction scheme: ##STR11## Other references pertinent to the preparation of the starting 2-oxazolidinones and 2H-1,3-oxazin-2-ones are as follows: Fielden, M. et al., J. MED. CHEM. 16, 1124-1128 (1973); J. ORG. CHEM. (Sci. & Biol.) 35, 4100-4103 (1970); Darling & Beauchamp, J. PHARM. SCI. 58, 362-364 (1969); and U.S. Pat. No. 3,423,418.
The starting 3-pyrrolidinols wherein R 1 radicals are present may be obtained by the procedure of Ryan et al., J. ORG. CHEM. 27, 2901-2905 (1962) or according to U.S. Pat. No. 2,830,997 and other sources cited therein.
A more general method of preparation for cyclic carbamate starting materials is represented by the following reaction scheme: ##STR12## y=0-4; z=0-4 and the sum of y and z does not exceed 4.
In the instance where mixtures result, the compounds may be separated by chromatography.
Compounds of Formula IIa and IIb are encompassed by Formula II.
Compounds of Formula I have a chiral center in the cyclic carbamate ring at the site of the carbon carrying the side chain and therefore there is potential for separation of the enantiomers (optical isomers) or for synthesis of the enantiomers using already resolved starting chemicals or chemical intermediates. R and S enantiomers of the 2-oxazolidinone derivatives were prepared (see Examples 4 and 5 hereinbelow) starting with R and S enantiomers of 1-methyl-3-pyrrolidinol (preparation of optically active pyrrolidinols described in U.S. Pat. No. 4,592,866) and both isomers were found to be pharmacologically active for the activities of anti-allergenic and anti-histaminic methods of the invention. All of the enantiomers of compounds of Formula I may be prepared starting with optically active amino alcohols in the more general method outlined above for preparing compounds of Formula IIb.
The free bases of acid addition salts of starting materials and end products are prepared by conventional means by partitioning the salt between dilute aqueous alkali metal base and a solvent such as methylene chloride followed by evaporation of the solvent layer.
The following preparations and examples are given by way of illustration only and are not to be construed as limiting.
PREPARATION 1
5-(2-Chloroethyl)-3-(1-methylethyl)-2-oxazolidinone
To a cold (ice bath) solution of 98.5 g (10 mole) of phosgene in 500 ml of methylene chloride was added dropwise a solution of 129.2 g (1.0 mole) of 1-isopropyl-3-pyrrolidinol in 250 ml of methylene chloride at such a rate that the temperature did not exceed 10° C. After addition was complete, the mixture was stirred in the cold for 1 hr and then treated dropwise with 140 ml (101 g, 1.0 mole) of triethylamine at such a rate that the temperature did not exceed 25° C. The mixture was stirred at ambient temperature for 3 hr and then treated with 500 ml of 1N hydrochloric acid solution. The layers were separated and the organic layer was washed successively with 500 ml of a 1N hydrochloric acid solution, 500 ml of a 4% sodium hydroxide solution and 500 ml of brine, dried over sodium sulfate and concentrated under reduced pressure to give a brown oil as residue. The oil was subjected to vacuum distillation to yield 134.9 g (70%) of yellow oil, b.p. 110° C. at 0.2 mm.
Analysis: Calculated for C 8 H 14 ClNO 2 : C,50.14; H,7.36; N,7.31. Found: C,49.64; H,7.43; N,7.30.
PREPARATION 2
5-(2-Chloroethyl)-3,4-dimethyl-2-oxazolidinone
To a chloroform solution containing 68.12 g (0.7 mole) of phosgene at 0°-10° C. was added 80 g (0.7 mole) of 1,2-dimethyl-3-pyrrolidinol at a rate to maintain the temperature below 10° C. The reaction mixture was allowed to stir at room temperature overnight. The mixture was cooled in an ice bath and 100 ml of triethylamine was added dropwise maintaining the temperature below 10° C. The mixture was extracted in order with water, 3N hydrochloric acid solution, 3N sodium hydroxide solution and again with water. The chloroform layer was dried over anhydrous sodium sulfate and evaporated to yield 110 g of dark amber oil which was distilled at 113°-118° C. at 0.05 mm to give 80 g (64.8%) of pale yellow oil, n 22 =1.4796.
Analysis: Calculated for C 7 H 12 ClNO 2 : C,47.33; H,6.81; N,7.89; Cl,19.96. Found: C,47.40; H,6.88; N,7.94; Cl,20.02.
PREPARATION 3 (a to l)
Utilizing the procedures of Preparations 1, 2 and of U.S. Pat. No. 3,419,559, the following were prepared:
(a) 5-(2-chloroethyl)-3-ethyl-2-oxazolidinone,
(b) 5-(2-chloroethyl)-3-methyl-2-oxazolidinone,
(c) 5-(2-chloroethyl)-3-benzyl-2-oxazolidinone,
(d) 5-(2-chloroethyl)-3-phenyl-2-oxazolidinone,
(e) 5-(2-chloroethyl)-3-(1-butyl)-2-oxazolidinone,
(f) 5-(1-methyl-2-chloroethyl)-3-methyl-2-oxazolidinone,
(g) 5-(3-chloropropyl)-3-methyl-2-oxazolidinone,
(h) 5-(4-chlorobutyl)-3-methyl-2-oxazolidinone,
(i) 5-(2-chloroethyl)-3(4methoxyphenyl)-2-oxazolidinone,
(j) 5-(2-chloroethyl)-3-phenyl-2-oxazolidinone,
(k) 5-(2-chloroethyl)-3-(4-methylphenyl)-2-oxazolidinone,
(l) 5-(2-chloroethyl)-3-(3-chlorophenyl)-2-oxazolidinone.
PREPARATION 4
3-Benzyl-5-chloromethyl-2-oxazolidinone
A solution of 20 g (0.1 mole) of 3-benzyl-5-hydroxymethyl-2-oxazolidinone and 24 g (0.2 mole) of sulfonyl chloride in chloroform was refluxed for 3 hr. The reaction mixture was dried over anhydrous sodium sulfate, concentrated and subjected to distillation to give 18.2 g (81%) liquid, b.p. 176°-178° C. at 0.1 mm.
Analysis: Calculated for C 11 H 12 ClNO 2 : C,58.55; H,5.36; N,6.21. Found: C,58.30; H,5.24; N,6.27.
PREPARATION 5
5-(Chloromethyl)-3-methyl-2-oxazolidinone
A solution of 64.5 g (0.5 mole) of 1,3-dichloro-2-propanol in 200 ml of methylene chloride was treated with 28.5 g (0.5 mole) of methyl isocyanate and a few drops of triethylamine and allowed to stir at ambient temperature overnight. The solution was concentrated and the residue was dissolved in 200 ml of 95% ethanol and treated with a solution of 33.6 g (0.6 mole) of potassium hydroxide in 300 ml of 95% ethanol. The mixture was stirred at ambient temperature for 3.5 hr and then concentrated. The residue was partitioned between 250 ml of benzene and 100 ml of water. The organic layer was washed successively with 50 ml of a 2N hydrochloric acid solution and 100 ml of brine, dried over anhydrous sodium sulfate and concentrated to give 50.5 g of oil as residue. The oil was subjected to vacuum distillation to yield 36.9 g (49%) of clear oil, b.p. 131°-133° C. at 0.3 mm.
Analysis: Calculated for C 5 H 8 ClNO 2 : C,40.15; H,5.39; N,9.36. Found: C,38.77; H,5.39; N,9.08.
PREPARATION 6
S-(-)-5-(2-Chloroethyl)-3-methyl-2-oxazolidinone
To a solution of 102.9 g (1.04 mole) of phosgene in 500 ml of methylene chloride was added dropwise a solution of 105.3 g (1.04 mole) of S(+)-1-methyl-3-pyrrolidinol, (˜8% R-isomer) in 250 ml of methylene chloride at such a rate that the internal temperature did not exceed 15° C. After the addition was complete, the solution was stirred at ice bath temperature for 0.75 hr and then treated dropwise with 145 ml (105 g, 1.04 mole) of triethylamine at such a rate that the temperature did not exceed 25° C. The mixture was stirred at ambient temperature for 3 hr and then treated with a solution of 50 ml of concentrated hydrochloric acid in 500 ml of water. The layers were separated and the organic layer was washed once with 500 ml of a 4% sodium hydroxide solution, dried over anhydrous sodium sulfate and concentrated under reduced pressure to give an oil as residue. The oil was subjected to vacuum distillation to yield 99.3 g (61%) of clear oil, b.p. 128° C. at 0.5 mm, ([α] D 25 = -58.3° [methanol]).
Analysis: Calculated for C 6 H 10 ClNO 2 : C,44.04; H,6.16; N,8.56. Found: C,43.51; H,6.24; N,8.44.
PREPARATION 7
R-(+)-5-Chloroethyl)-3-methyl-2-oxazolidinone
To a solution of 133.8 g (1.35 mole) of phosgene in 650 ml of methylene chloride was added dropwise a solution of 136.8 g (1.35 mole) of R(-)-1-methyl-3-pyrrolidinol, (˜7% S-isomer) in 300 ml of methylene chloride at such a rate that the internal temperature did not exceed 15° C. After the addition was complete, the solution was stirred at ice bath temperatures for 0.75 hr and then treated dropwise with 188 ml (136.5 g, 1.35 mole) of triethylamine at such a rate that the temperature did not exceed 25° C. The mixture was stirred at ambient temperature overnight and then treated with a solution of 50 ml of concentrated hydrochloric acid in 500 ml of water. The layers were separated and the organic layer was washed once with 500 ml of a 4% sodium hydroxide solution, dried over sodium sulfate and concentrated under reduced pressure to give an oil as residue. The oil was subjected to vacuum distillation to yield 136.6 g (83%) of clear oil, b.p. 123°-126° C. at 0.5 mm, ([α] D 25 +71.1° C. (methanol)).
Analysis: Calculated for C 6 H 10 ClNO 2 : C,44.04; H,6.16; N,8.56. Found: C,43.19; H,6.21; N,8.38.
PREPARATION 8
6-(2-Chloroethyl)tetrahydro-3-methyl-2H-1,3-oxazin-2-one
To a cold (ice bath) solution of 85.8 g (0.868 mole) of phosgene in 500 ml of methylene chloride was added dropwise a solution of 100 g (0.868 mole) of 4-hydroxy-1-methylpiperidine in 250 ml of methylene chloride at such a rate that the internal temperature did not exceed 12° C. A crystalline solid precipitated during addition. The mixture was stirred in the cold for 1 hr after addition was complete and then 120.8 ml (87.7 g, 0.868 mole) of triethylamine was added dropwise at such a rate that the internal temperature did not exceed 25° C. The mixture was stirred at ambient temperature overnight and then diluted with 500 ml of toluene. The methylene chloride was removed by distillation and the resultant mixture was heated at reflux for 2 hr. The mixture was cooled and treated with 500 ml of 1N hydrochloric acid. The layers were separated and the organic layer was washed successively with 500 ml of 1N hydrochloric acid, 500 ml of a 4% sodium hydroxide solution and once with brine, dried over anhydrous sodium sulfate and concentrated to give an oil as residue. The oil was subjected to vacuum distillation to give 34.4 g (22%) of clear oil (b.p. 147°-150° C. at 0.4 mm).
Analysis: Calculated for C 7 H 12 ClNO 2 : C,47.33; H,6.81; N,7.89. Found: C,46.97; H,6.81; N,7.82.
PREPARATION 9
1-(Phenylmethyl)-4-piperidinecarboxylic acid ethyl ester hydrochloride
A mixture of 100 g (0.637 mole) of ethyl isonipecotate, 80.64 g (0.64 mole) of benzyl chloride and 67.84 g (0.64 mole) of sodium carbonate in 1 liter of absolute ethanol was refluxed for 8 hours and then was stirred at room temperature for 10 hours. The solvent was removed in vacuo, and the residue was partitioned between methylene chloride and dilute sodium hydroxide. The methylene chloride phase was dried over magnesium sulfate, and the solvent was removed in vacuo to give the free base of the title compound as a liquid. The free base was converted to the hydrochloride salt, and the salt was recrystallized from ethanol-ether to give 89.33 g (49.7%) of white, crystalline solid, m.p. 154°-155° C.
Analysis: Calculated for C 15 H 22 NO 2 Cl: C,63.48; H,7.81; N,4.94. Found: C,63.07; H,7.82; N,4.91.
PREPARATION 10
α,α-bis-(4-Fluorophenyl)-1-(phenylmethyl)-4-piperidinemethanol
To magnesium turnings (6.08 g, 0.25 mole) and an iodine crystal in 600 ml of dry tetrahydrofuran (THF) (distilled from lithium aluminum hydride) and under an atmosphere of nitrogen was added dropwise a solution of p-bromofluorobenzene in 125 ml of THF. The temperature of the reaction mixture was kept below 10° C. by cooling in an ice-methanol bath. The mixture was stirred at room temperature for 1.5 hr. A solution of 1-(phenylmethyl)-4-piperidinecarboxylic acid ethyl ester (24.7 g, 0.10 mole) in THF was added, and the mixture was stirred at room temperature for 17 hr. The reaction mixture was poured into an icy, aqueous solution of ammonium chloride, and the resulting solution was extracted with methylene chloride. The solution was extracted with dilute sodium hydroxide and was dried (magnesium sulfate). The solvent was removed in vacuo to give an oil. This was crystallized from ether-hexane to give 19.87 g (51%) of title compound, m.p. 113°-115° C.
Analysis: Calculated for C 25 H 25 NOF 2 : C,76.31; H,6.40; N,3.56. Found: C,76.24; H,6.38; N,3.50.
PREPARATION 11
α,α-Bis(p-fluorophenyl)-4-piperidinemethanol
A solution of 31.2 g (0.079 mole) of α,α-bis-(4-fluorophenyl)-1-(phenylmethyl)-4-piperidinemethanol in 400 ml of absolute ethanol was hydrogenated at 50 psi and 70° C. over 5% palladium-on-carbon over the weekend. The mixture was filtered and the filtrate was concentrated under reduced pressure to give a gum as residue. Methylene chloride was added to the residue and the gum crystallized. The mixture was diluted with petroleum ether and the solid was collected by filtration, washed with petroleum ether and dried to yield 22 g (99%) of white solid which was recrystallized from isopropyl ether and 2-propanol, m.p. 159.5°-160.5° C.
Analysis: Calculated for C 18 H 19 F 2 NO: C,71.27; H,6.31; N,4.62. Found: C,70.93; H,6.71; N,4.38.
PREPARATION 12
α,α-Bis(4-methylphenyl)-1-(phenylmethyl)-4-piperidinemethanol
A Grignard solution was prepared by the addition of 102.6 g (0.6 mole) of 4-bromotoluene in 500 ml of dry tetrahydrofuran (THF) to a mixture of 12.5 g (0.5 mole) of magnesium chips in 250 ml of THF. After the addition was complete, the mixture was heated at reflux for 1 hr to complete formation. To this Grignard reagent at ambient temperature was added in a stream 42.9 g (0.173 mole) of 1-(phenylmethyl)-4-piperidinecarboxylic acid ethyl ester in 250 ml of dry THF. The solution was stirred at ambient temperature overnight and then poured into 2.5 liters of a saturated ammonium chloride solution. The layers were separated and the aqueous layer was extracted twice with 375 ml portions of methylene chloride. The combined organic layers were washed successively with 500 ml of water, 750 ml of a 3% sodium hydroxide solution, 250 ml of water, and 250 ml of brine. The organic layer was dried over sodium sulfate and concentrated under reduced pressure to give a gum as residue. The gum gradually crystallized. The solid was triturated with petroleum ether (30°-60° C.), collected by filtration and dried to yield 63.6 g (95%) of white solid. An analytical sample, m.p. 115°-117° C., was prepared from 2-propanol.
Analysis: Calculated for C 27 H 31 NO: C,84.11; H,8.10; N,3.63. Found: C,84.23; H,8.13; N,3.66.
PREPARATION 13
α,α-Bis(4-methylphenyl)-4-piperidinemethanol
A solution of 38.5 g (0.1 mole) of α,α-bis(4-methylphenyl)-1-(phenylmethyl)-4-piperidinemethanol in 500 ml of absolute ethanol was hydrogenated at 50 psi and 60° C. over 5% palladium on carbon in a Parr apparatus for 3 days. The cooled mixture was filtered through Celite® and the filtrate was concentrated under reduced pressure to give a glass as residue. The glass was crystallized from 2-propanol to yield 17.7 g (60%) of white solid, m.p. 150°-153° C.
Analysis: Calculated for C 20 H 25 NO: C,81.31; H,8.53; N,4.74. Found: C,81.18; H,8.62; N,4.72.
PREPARATION 14
α,α-Bis(4-methoxyphenyl)-1-(phenylmethyl)-4-piperidinemethanol oxalate hydrate methanolate [1:1:0.5:0.5]
A Grignard reagent was prepared by the addition of a solution of 112.2 g (0.6 mole) of 4-bromoanisole in 500 ml of dry tetrahydrofuran (THF) to a mixture of 12.5 g (0.5 mole) of magnesium chips in 250 ml of THF. After the addition was complete, the mixture was heated at reflux for 0.5 hr to complete formation. To this Grignard reagent at ambient temperature was added a solution of 42.8 g (0.173 mole) of 1-(phenylmethyl)-4-piperidinecarboxylic acid ethyl ester in 250 ml of THF in a stream. The mixture was stirred at ambient temperature overnight and then poured into 2.5 liters of a saturated ammonium chloride solution. The layers were separated and the aqueous layer was extracted twice with 375 ml portions of methylene chloride. The combined organic layers were washed successively with 500 ml of water, 750 ml of a 3% sodium hydroxide solution, 250 ml of water and 250 ml of brine. The organic layer was dried over sodium sulfate and concentrated under reduced pressure to give a gum as residue. The gum was dissolved in 2-propanol and converted to the oxalic acid salt. The solid was collected by filtration, washed with 2-propanol and ethyl ether, and dried to yield 84.8 g (97%) of white powder. An analytical sample, m.p. 128°-131° C. with decomposition (slow heating; rapid heating gives m.p. ˜110° C.), was prepared from absolute ethanol.
Analysis: Calculated for C 29 H 33 NO 7 .0.5H 2 O.0.5C 2 H 5 OH: C,66.74; H,6.91; N,2.60. Found: C,67.08; H,6.77; N,2.67.
PREPARATION 15
α,α-Bis(4-methoxyphenyl)-4-piperidinemethanol
A solution of 36.7 g (0.088 mole) of α,α-bis(4-methoxyphenyl)-1-(phenylmethyl)-4-piperidinemethanol in 500 ml of absolute ethanol was hydrogenated over palladium on carbon at 60° C. in a Parr apparatus over the weekend. The mixture was cooled, filtered through Celite®, fresh catalyst added to the filtrate and the mixture hydrogenated. This process was repeated so that no starting material was present by mass spectral analysis. The filtrate was concentrated and the residue was partitioned between methylene chloride and a 5% sodium hydroxide solution. The organic layer was dried over sodium sulfate and concentrated to give a solid residue. The solid was recrystallized from 2-propanol to yield 8.6 g (30%) of white solid, m.p. 153°-155° C.
Analysis: Calculated for C 20 H 25 NO 3 : C,73.37; H,7.70; N,4.28. Found: C,73.42; H,7.72; N,4.30.
PREPARATION 16
α,α-Diphenyl-1-(phenylmethyl)-4-piperidinemethanol
A Grignard solution was prepared by the addition of 94.2 g (0.6 mole) of bromobenzene in 250 ml of dry (freshly distilled from lithium aluminum hydride) tetrahydrofuran (THF) to a mixture of 12.5 g (0.5 mole) of magnesium chips in 500 ml of dry THF. After the addition was complete, the mixture was heated at reflux for 15 min to complete formation. To this Grignard reagent at ambient temperature was added a solution of 44.2 g (0.179 mole) of 1-(phenylmethyl)-4-piperidinecarboxilic acid ethyl ester in 250 ml of THF in a stream. The solution was stirred overnight at ambient temperature and then poured into 2.5 liters of a saturated ammonium chloride solution. The layers were separated and the aqueous layer was extracted once with 500 ml of methylene chloride and twice with 250 ml of methylene chloride. The combined organic layers were washed successively with 500 ml of water, 750 ml of a 3% sodium hydroxide solution, 250 ml of water and 250 ml of brine. The organic layer was dried over sodium sulfate and concentrated to give a gum as residue. The gum was dissolved in 500 ml of ethyl ether, treated with activated charcoal, filtered through Celite®, and then concentrated to give a gum as residue. The gum crystallized when triturated with petroleum ether (30°-60° C.). The solid was collected by filtration and dried to yield 49.0 g (77%) of white solid. An analytical sample, m.p. 89.5°-90.5° C. was prepared from 2-propanol.
Analysis: Calculated for C 25 H 27 NO: C,83.99; H,7.61; N,3.92. Found: C,84.09; H,7.63; N,3.97.
PREPARATION 17
α,α-Diphenyl-4-piperidinemethanol
A mixture of 35.8 g (0.1 mole) of α,α-diphenyl-1-(phenylmethyl)-4-piperidinemethanol and 5% palladium on carbon in 500 ml of absolute ethanol was hydrogenated at 60° C. in a Parr apparatus for 3 days. The mixture was filtered through Celite® and the filtrate was concentrated to give a solid residue. The solid was triturated with petroleum ether (30°-60° C.), collected by filtration and dried to give 26.7 g (quantitative) of white solid. An analytical sample, m.p. 160°-161° C. was prepared from 2-propanol-isopropyl ether.
Analysis: Calculated for C 18 H 21 NO: C,80.86; H,7.92; N,5.24. Found: C,80.98; H,7.96; N,5.30.
PREPARATION 18
4-[bis(4-Chlorophenyl)hydroxymethyl]-N,N-diethyl-1-piperidinecarboxamide
A Grignard solution was prepared by the treatment of a slurry of 8.5 g (0.35 mole) of mangesium chips in 200 ml of dry tetrahydrofuran (THF) with a solution of 72.8 g (0.38 mole) of 1-bromo-3-chlorobenzene in 400 ml of THF. After the addition was complete, the mixture was heated at reflux for 15 min to complete formation. To the Grignard solution at ambient temperature was added a solution of 38.4 g (0.15 mole) of 1-[(diethylamino)carbonyl]-4-piperidine carboxylic acid ethyl ester in 200 ml of THF in a stream. The solution was stirred at ambient temperature overnight and poured into 2.5 liters of a saturated ammonium chloride solution. The layers were separated and the aqueous layer was extracted once with 500 ml of methylene chloride and once with 250 ml of methylene chloride. The combined organic layers were filtered through Celite® and the filtrate was washed successively with 500 ml of water, 750 ml of a 4% sodium hydroxide solution, 250 ml of water and 250 ml of brine. The solution was dried over anhydrous sodium sulfate and concentrated under reduced pressure to give a gum which crystallized. The solid was triturated with petroleum ether (30°-60° C.), collected by filtration, and dried to yield 56.7 g (87,) of a white solid. An analytical sample, m.p. 172°-175° C. was prepared from 2-propanol.
Analysis: Calculated for C 23 H 28 Cl 2 N 2 O 2 : C,63.54; H,6.48; N,6.43. Found: C,63.60; H,6.64; N,6.25.
PREPARATION 19
α,α-Bis(4-chlorophenyl)-4-piperidinemethanol
To a slurry of 8.5 g (0.225 mole) of lithium aluminum hydride in 400 ml of anhydrous tetrahydrofuran (THF) was added a solution of 39.2 g (0.09 mole) of 4-[bis(4-chlorophenyl)hydroxymethyl]-N,N-diethyl-1-piperidinecarboxamide in 400 ml of THF in a stream over a 15 min period. The mixture was heated at reflux for 24 hr, cooled, and treated successively with 8.5 ml of water, 25 ml of a 3N sodium hydroxide solution and 8.5 ml of water. The mixture was stirred for 0.5 hr and then filtered. The filtrate was concentrated under reduced pressure to give a gum which crystallized. The solid was triturated with petroleum ether (30°-60° C.), collected by filtration and recrystallized from benzene to yield 10.5 g (35%) of white solid. An analytical sample, m.p. 184°-188° C. was prepared from 2-propanol.
Analysis: Calculated for C 16 H 19 Cl 2 NO: C,64.30; H,5.70; N,4.17. Found: C,64.59; H,5.79; N,4.16.
PREPARATION 20
1Acetyl-4-(p-fluorobenzoyl)piperidine
The title compound was prepared as disclosed in U.S. Pat. No. 3,576,810 as follows: A mixture of 93 g (0.7 mole) of aluminum chloride in 150 ml of fluorobenzene was stirred while 70 g (0.37 mole) of 1-acetylisonipecotic acid chloride was added in small portions. After the addition was complete, the mixture was refluxed for one hour. The mixture was poured onto ice and the two resulting layers were separated. The aqueous layer was extracted twice with chloroform and the chloroform extracts were added to the fluorobenzene which was separated previously. The organic solution was dried over anhydrous sodium sulfate and filtered. The filtrate was concentrated and 73.7 g (80%) of 1-acetyl-4-(p-fluorobenzoyl)-piperidine was obtained as a crystalline residue. Recrystallization from ligroin-isopropyl ether gave a white crystalline product melting at 75°-78° C.
Analysis: Calculated for C 14 H 16 FNO 2 : C,67.45; H,6.47; N,5.62. Found: C,67.26; H,6.50; N,5.54.
PREPARATION 21
1-Acetyl-α-(4-fluorophenyl)-α-phenyl-4-piperidinemethanol
A solution (667 ml, 2 mole) of phenylmagnesium bromide (3M in ethyl ether) was diluted with 2 liters of anhydrous ethyl ether, cooled to 0°-10° C. and treated with a solution of 148 g (0.6 mole) of 1-acetyl-4-(p-fluorobenzoyl)-piperidine in 1.5 liter of anhydrous tetrahydrofuran dropwise over a 1.5 hr period. The mixture was stirred at ambient temperature overnight and then poured into a solution of 107 g (2 mole) of ammonium chloride in 2 liters of cold water. The mixture was extracted thrice with 1 liter portions of benzene. The combined extracts were washed with water, dried over magnesium sulfate, and concentrated to give a semi-solid as residue. The semi-solid was triturated with isopropyl ether and the mass cyrstallized. The solid was collected by filtration and dried to yield 87.8 g (45%) of white solid. An analytical sample, m.p. 173°-175° C., was prepared from 2-propanol.
Analysis: Calculated for C 20 H 22 FNO C,73.37; H,6.77; N,4.28. Found: C,73.20; H,6.93; N,4.22.
PREPARATION 22
α-(4-Fluorophenyl)-α-phenyl-4-piperidinemethanol
A mixture of 16.3 g (0.05 mole) of 1-acetyl-α-(4-fluorophenyl)-α-phenyl-4-piperidinemethanol and 5.6 g (0.1 mole) of potassium hydroxide in 150 ml of 95% ethanol and 20 ml of water was heated at reflux for 18 hr. The mixture was poured into 1.5 liter of ice water and a solid precipitated. The solid was collected by filtration and dried. The gummy solid was dissolved in ethyl ethyl ether, the solution was filtered, and the filtrate slowly evaporated to 50 ml volume. The resulting solid was collected by filtration and recrystallized from 2-propanol-isopropyl ether to yield 3.5 g (25%) of white solid, m.p. 144.5°-146° C.
Analysis: Calculated for C 18 H 20 FNO: C,75.76; H,7.06; N,4.91. Found: C,75.91; H,7.20; N,4.93.
PREPARATION 23
4-[(3-Chloro)propyl]-3-methyl-2-oxazolidinone
A cold (ice bath) solution of 4.0 g (0.041 mole) of phosgene dissolved in 50 ml of methylene chloride was treated dropwise with a solution of 4.7 g (0.041 mole) of 2-hydroxymethyl-1-methylpyrrolidine in 15 ml of methylene chloride at such a rate that the temperature did not exceed 10° C. After addition was complete, the solution was stirred in the cold for 1 hr and then treated dropwise with 4.0 g (0.041 mole) of triethylamine at such a rate that the temperature did not exceed 25° C. The mixture was stirred at ambient temperature for 3 hr and then treated with 50 ml of 1N hydrochloric acid. The layers were separated and the organic layer was washed successively with 50 ml of 1N hydrochloric acid, 50 ml of 4% sodium hydroxide, and 50 ml of brine. The organic layer was dried over sodium sulfate and concentrated to give 2.5 g of oil as residue. This oil was purified by column chromatography on 50 g of silica gel eluted with benzene. Fractions containing the desired product were combined and concentrated to give 1.8 g (25%) of product as an oil.
PREPARATION 24
α-(4-Fluorophenyl)-α-(4-piperidinyl)-2-pyridinemethanol
To a stirred solution of 36.3 g (0.23 mol) of 2-bromopyridine in 500 mL of anhydrous tetrahydrofuran (THF) at -65° C. was added 88 mL (0.22 mol) of a commercial solution of 2.5M n-butyllithium in hexane at such a rate that the temperature did not exceed -60° C. The dark solution was stirred at -65° C. for 1 hr and then treated dropwise with a solution of 24.9 g (0.1 mol) of 1-acetyl-4-(p-fluorobenzoyl)piperidine (See Preparation 1 of U.S. Pat. No. 4,151,285, col. 4, lines 10-30, herein incorporated by reference) in 250 mL of THF at such a rate that the temperature did not exceed -60° C. The mixture was stirred for 1 hr at -65° C. and overnight at ambient temperature. The dark mixture was poured into 2 liters of a saturated ammonium chloride solution. The layers were separated and the aqueous layer was extracted once with a 500-mL portion of methylene chloride. The combined organic layers were washed successively with 500 mL of water, 500 mL of a 4% sodium hydroxide solution, 250 mL of water, and 250 mL brine.
All of the combined aqueous layers were combined and allowed to stand in a filter flask for several weeks. As the soluble organic solvents in the aqueous solution evaporated, a solid precipitated. The aqueous solution was decanted and the solid was slurried with water, collected by filtration, and dried. The solid was recrystallized from absolute ethanol-pyridine to yield 4.5 g (14%) of the title compound as an off-white solid, mp 228°-230° C. (dec).
Analysis: Calculated or C 17 H 19 FN 2 O: C, 71.31; H, 6.69; N, 9.78. Found: C, 71.43; H, 6.54; N, 9.52.
PREPARATION 25
α-(4-piperidinyl)-α-(2-pyridinyl)-2-pyridinemethanol
To a stirred solution of 71.1 g (0.45 mol of 2-bromopyridine in 750 mL of anhydrous tetrahydrofuran (THF) at -65° C. is added 176 mL (0.44 mol) of a commercial solution of 2.5-M n-butyllithium in hexane at such a rate that the temperature does not exceed -60° C. The dark solution is stirred at -65° C. for 1 hr and is then treated dropwise with a solution of 39.8 g (0.2 mol) of ethyl-1-acetylpiperidine-4-carboxylate [G. R. Clemo and E. Hoggarth, J. Chem. Soc.: London 41-47 (1941)] in 500 mL of THF at such a rate that the temperature does not exceed -60° C. The mixture is stirred for 1 hr at -65° C. and allowed to stand at ambient temperature overnight. The dark mixture is poured into 3 liters of a saturated ammonium chloride solution and the layers are evaporated. The aqueous layer is extracted once with 1 liter of methylene chloride. The combined organic layers are washed successively with 1 liter of water, 1 liter of 4% sodium hydroxide solution, 500 mL of water, and 500 mL of brine.
The organic layer is concentrated and the residue is dissolved in 1 liter of ethanol. The solution is treated with 28 g (0.5 mol) of potassium hydroxide dissolved in 100 mL of water and the mixture is heated at reflux for 6 hr. The mixture is concentrated and the residue is partitioned between methylene chloride and water. The organic layer is washed with water and brine, dried (sodium sulfate), and concentrated to yield the title compound.
EXAMPLE 1
5-[2-[4[Bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]ethyl]-3-methyl-2-oxazolidinone oxalate [1:1]
A mixture of 3.0 g (0.01 mole) of α,α-bis(p-fluorophenyl)-4-piperidinemethanol, 1.6 g (0.01 mole) of 5-(2-chloroethyl)-3-methyl-2-oxazolidinone, 5.3 g (0.085 mole) of anhydrous sodium carbonate and 0.3 g of potassium iodide in 100 ml of 1-butanol was heated at reflux for 20 hr. The mixture was concentrated under reduced pressure and the residue was partitioned between water and benzene. The benzene layer was washed with water and brine, dried over anhydrous sodium sulfate and concentrated under reduced pressure to give a gum as residue. The gum was converted to the oxalic acid salt, recrystallizing from absolute ethanol to give 3.7 g (71%) of white powder, m.p. 124°-134° C. with decomposition.
Analysis: Calculated for C 26 H 30 F 2 N 2 O 7 : C,59.99; H,5.81; N,5.38. Found: C,59.59; H,5.83; N,5.36.
EXAMPLE 2
5-[2-[Bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]ethyl]-3-methyl-2-oxazolidinone fumarate [1:1]
Utilizing the procedure of Example 1, a mixture of 9.1 g (0.03 mole) of α,α-bis(p-fluorophenyl)-4-piperidinemethanol, 4.9 g (0.03 mole of 5-(2-chloroethyl)-3-methyl-2-oxazolidinone, 10.6 g (0.1 mole) of anhydrous sodium carbonate and 0.6 g of potassium iodide in 200 ml of butanol were reacted and the mixture concentrated to give a gum. The fumaric acid salt was prepared, recrystallizing from absolute ethanol, to give 10.0 g (61%) of white solid, m.p. 160.5°-162.5° C. with decomposition.
Analysis: Calculated for C 28 H 32 F 2 N 2 O 7 : C,61.53; H,5.90; N,5.13. Found: C,61.31; H,6.04; N,5.12.
EXAMPLE 3
5-[2-[4-Bis(4-methylphenyl)hydroxymethyl]-1-piperidinyl]ethyl-3-methyl-2-oxazolidinone oxalate hydrate [1:1:0.5]
This compound was prepared according to the procedure of Example 1. A mixture of 4.4 g (0.015 mole) of α,α-bis-(4-methylphenyl)-4-piperidinemethanol, 2.5 g (0.015 mole) of 5-(2-chloroethyl-3-methyl-2-oxazolidinone, 5.3 g (0.05 mole) of anhydrous sodium carbonate and 0.4 g of potassium iodide in 100 ml of 1-butanol gave a gum as residue. The gum was dissolved in ethyl ether, treated with activated charcoal, filtered through Celite®, and the filtrate concentrated under reduced pressure to give a glass as residue. The glass was converted to the oxalic acid salt and the solid was recrystallized from 95% ethanol to yield 4.8 g (62%) of white solid, m.p. 146°-159° C., with decomposition.
Analysis: Calculated for C 28 H 36 N 2 O 7 .0.5H 2 O: C,64.48; H,7.15; N,5.37. Found: C,64.92; H,7.11; N,5.39.
EXAMPLE 4
S-(-)-5-[2-[4-[Bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl)ethyl]-3-methyl-2-oxazolidinone fumarate [1:1]
This compound was prepared according to the procedure of Example 1. A mixture of 9.1 g (0.03 mole) of α,α-bis-(p-fluorophenyl)-4-piperidinemethanol, 4.9 g (0.03 mole) of S-(-)-5-(2-chloroethyl)-3-methyl-2-oxazolidinone, 10.6 g (0.10 mole) of anhydrous sodium carbonate and 0.9 g of potassium iodide in 200 ml of 1-butanol gave a gum as residue. The gum was converted to the fumaric acid salt and this solid was recrystallized from absolute ethanol to yield 11.0 g (67%) of white solid, m.p. 154°-157° C., with decomposition; [α] D 25 -16.1° C. (methanol).
Analysis: Calculated for C 28 H 32 F 2 N 2 O 7 :C,61.53; H,5.90; N,5.13. Found: C,61.30; H,5.93; N,5.14.
EXAMPLE 5
R-(+)-5-[2-[4-[Bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]ethyl-3-methyl-2-oxazolidinone fumarate [1:1]
This compound was prepared according to the procedure of Example 1. A mixture of 9.1 g (0.03 mole) of α,α-bis-(p-fluorophenyl)-4-piperidinemethanol, 4.9 g (0.03 mole) of R-(+)-5-(2-chloroethyl)-3-methyl-2-oxazolidinone, 10.6 g (0.10 mole) of anhydrous sodium carbonate and 0.5 g of potassium iodide in 200 ml of 1-butanol gave a gum as residue. The gum was converted to the fumaric acid salt and this solid was recrystallized from absolute ethanol to yield 9.0 g (55%) of white solid, m.p. 153°-156° C., with decomposition; [α] D 25 +19.5° C. (methanol).
Analysis: Calculated for C 29 H 31 F 2 NO 5 : C,61.53; H,5.90; N,5.13. Found: C,61.32; H,5.85; N,5.12.
EXAMPLE 6
5-[2-[4-[Bis(4-methoxyphenyl)hydroxymethyl]-1-piperidinyl]ethyl]-3-methyl-2-oxazolidinone
This compound was prepared according to the procedure of Example 1. A mixture of 3.2 g (0.01 mole) of α,α-bis-(4-methoxyphenyl)-4-piperidinemethanol, 1.6 g (0.01 mole) of 5-(2-chloroethyl)-3-methyl-2-oxazolidinone, 3.7 g (0.035 mole) of anhydrous sodium carbonate and 0.4 g of potassium iodide in 100 ml of 1-butanol gave 3.9 g (87%) of off-white solid, m.p. 145°-147° C. (2-propanol).
Analysis: Calculated for C 26 H 34 N 2 O 5 : C,68.70; H,7.54; N,6.16. Found: C,68.45; H,7.60; N,6.11.
EXAMPLE 7
5-[2-[4-[Bis(4-fluorophenyl)hydroxymethyl)-1-piperidinyl]ethyl]-3-phenyl-2-oxazolidinone hydrochloride [1:1]
This compound was prepared according to the procedure of Example 1. A mixture of 4.6 g (0.015 mole) of α,α-bis-(p-fluorophenyl)-4-piperidinemethanol, 3.4 g (0.015 mole) of 5-(2-chloroethyl)-3-phenyl-2oxazolidinone, 5.3 g (0.05 mole) of anhydrous sodium carbonate and 0.4 g of potassium iodide in 100 ml of 1-butanol gave a gum as residue. The gum was converted to the hydrochloride and the solid was recrystallized from absolute ethanol to yield 6.3 g (30%) of white solid, m.p. 148°-156° C., with decomposition.
Analysis: Calculated for C 29 H 31 ClF 2 N 2 O 3 : C,65.84; H,5.91; N,5.30. Found: C,65.40; H,5.98; N,5.27.
EXAMPLE 8
5-[3-[4-[Bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]propyl]-3-methyl-2-oxazolidinone oxalate [1:1]
This compound was prepared according to the procedure of Example 1. A mixture of 4.6 g (0.015 mole) of α,α-bis-(p-fluorophenyl)-4-piperidinemethanol, 2.7 g (0.015 mole) of 5-(3-chloropropyl)-3-methyl-2-oxazolidinone, 5.3 g (0.05 mole) of anhydrous sodium carbonate and 0.4 g of potassium iodide in 100 ml of 1-butanol gave a gum as residue. The gum was converted to the oxalic acid salt and the solid was recrystallized from absolute ethanol to yield 4.5 g (54%) of white solid, m.p. 150°-153° C., with decomposition.
Analysis: Calculated for C 27 H 32 F 2 N 2 O 7 .H 2 O: C,58.67; H,6.20; N,5.07. Found: C,58.77; H,5.89; N,4.98.
EXAMPLE 9
6-[2-[4-[Bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]ethyl]-3-methyl-tetrahydro-2H-1,3-oxazin-2-one oxalate [1:1]
This compound was prepared according to the procedure of Example 1. A mixture of 4.6 g (0.015 mole) of α,α-bis-(p-fluorophenyl)-4-piperidinemethanol, 2.7 g (0.015 mole) of 6-(2-chloroethyl)tetrahydro-3-methyl-2H-1,3-oxazin-2-one, 5.3 g (0.05 mole) of anhydrous sodium carbonate and 0.4 g of potassium iodide in 100 ml of 1-butanol gave a glass as residue. The glass was converted to the oxalate and the solid was recrystallized from absolute ethanol to yield 4.9 g (61%) of white solid, m.p. 193°-194° C., with decomposition.
Analysis: Calculated for C 27 H 32 F 2 N 2 O 7 : C,60.67; H,6.03; N,5.24. Found: C,60.45; H,6.06; N,5.21.
EXAMPLE 10
5[[4-[Bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]methyl]-3-methyl-2-oxazolidinone
This compound was prepared according to the procedure of Example 1. A mixture of 4.6 g (0.015 mole) of α,α-bis-(p-fluorophenyl)-4-piperidinemethanol, 2.2 g (0.015 mole) of 5-(chloromethyl)-3-methyl-2-oxazolidinone, 5.3 g (0.05 mole) of anhydrous sodium carbonate and 0.4 g of potassium iodide in 100 ml of 1-butanol gave a gum as residue. The gum was purified by column chromatography on 50 g of Florisil®. Fractions eluted with 5-20% acetone in benzene were combined and concentrated to give a solid residue. The solid was recrystallized from isopropyl ether-2-propanol to yield 1.5 g (24%) of white solid, m.p. 147°-148° C.
Analysis: Calculated for C 23 H 26 F 2 N 2 O 3 : C,66.33; H,6.29; N,6.73. Found: C,66.32; H,6.35; N,6.68.
EXAMPLE 11
5-[2-[4-[Bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]ethyl]-3-phenylmethyl-2-oxazolidinone oxalate [1:1]
This compound was prepared according to the procedure of Example 1. A mixture of 9.1 g (0.03 mole) of α,α-bis-(p-fluorophenyl)-4-piperidinemethanol, 7.2 g (0.03 mole) of 5-(2-chloroethyl)-3-benzyl-2-oxazolidinone, 10.6 g (0.1 mole) of anhydrous sodium carbonate and 0.4 g of potassium iodide in 175 ml of 1-butanol gave a gum as residue. The gum was converted to the oxalate salt and the solid was recrystallized from 2-methoxyethanol-water to yield 13.5 g (75%) of white solid, m.p. 234°-235° C., with decomposition.
Analysis: Calculated for C 32 H 34 F 2 N 2 O 7 : C,64.42; H,5.74; N,4.70. Found: C,64.33; H,5.75; N,4.69.
EXAMPLE 12
5-[2-[4-[Bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]ethyl]-3-phenyl-2-oxazolidinone hydrochloride hydrate [1:1:0.5]
This compound was prepared according to the procedure of Example 1. A mixture of 4.5 g (0.015 mole) of α,α-bis-(p-fluorophenyl)-4-piperidinemethanol, 3.5 g (0.015 mole) of 5-(2-chloroethyl)-3-phenyl-2-oxazolidinone, 5.3 g (0.05 mole) of anhydrous sodium carbonate and 0.4 g of potassium iodide in 100 ml of 1-butanol gave a brown gloss as residue. The glass was converted to the hydrochloride and the solid was recrystallized from 95% ethanol to yield 6.3 g (79%) of white solid, m.p. 180°-183° C. with decomposition.
Analysis: Calculated for C 29 H 37 ClF 2 N 2 O 3 .0.5H 2 O: C,64.02; H,7.04; N,5.15. Found: C,63.90; H,7.39; N,4.92.
EXAMPLE 13
5-[2-[4-[Bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]ethyl]-3-ethyl-2-oxazolidinone oxalate hydrate [1:1:0.5]
This compound was prepared according to the procedure of Example 1. A mixture of 4.5 g (0.015 mole) of α,α-bis-(p-fluorophenyl)-4-piperidinemethanol, 2.7 g (0.015 mole) of 5-(2-chloroethyl-3-ethyl-2-oxazolidinone, 5.3 g (0.05 mole) of anhydrous sodium carbonate and 0.4 g of potassium iodide in 100 ml of 1-butanol gave a glass as residue. The glass was converted to the oxalic acid salt and the solid was recrystallized from absolute ethanol to yield 5.1 g (64%) of white solid, m.p. 130°-132° C.
Analysis: Calculated for C 27 H 32 F 2 N 2 O 7 .0.5H 2 O: C,59.66; H,6.12; N,5.15. Found C,59.92; H,5.97; N,5.21.
EXAMPLE 14
5-[2-[4-[Bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]ethyl]-3-(1-methylethyl)-2-oxazolidinone fumarate [1:1]
This compound was prepared according to the procedure of Example 1. A mixture of 4.6 g (0.015 mole) of α,α(p-fluorophenyl)-4-piperidinemethanol, 2.9 g (0.015 mole) of 5-(2-chloroethyl)-3-(1-methylethyl)-2-oxazolidinone, 5.3 g (0.05 mole) of anhydrous sodium carbonate and 0.4 g of potassium iodide in 100 ml of 1-butanol gave a gum as residue. The gum was converted to the fumaric acid salt and the solid was recrystallized from absolute ethanol to yield 3.2 g (37%) of white solid, m.p. 219°-221° C., with decomposition.
Analysis: Calculated for C 30 H 36 F 2 N 2 O 7 : C,62.71; H,6.31; N,4.87. Found: C,62.75; H,6.33; N,4.90.
EXAMPLE 15
5-[2-[4-[Bis(phenyl)hydroxymethyl]-1-piperidinyl]ethyl]-3-methyl-2-oxazolidinone oxalate
Following the procedure of Example 1, α,α-diphenyl-4-piperidinemethanol and 5-(2-chloroethyl)-3-methyl-2-oxazolidinone are reacted and the product thereof is reacted with oxalic acid to give the title compound.
EXAMPLE 16
5-[2-[4-[Bis(4-chlorophenyl)hydroxymethyl]-1-piperidinyl]ethyl]-3-methyl-2-oxazolidinone oxalate
Following the procedure of Example 1, α,α-bis(4-chlorophenyl)-4-piperidinemethanol and 5-(2-chloroethyl)-3-methyl-2-oxazolidinone are reacted and the product thereof is reacted with oxalic acid to give the title compound.
EXAMPLE 17
5-[2-[4-[α-(4-Phenyl)-α-phenyl-hydroxymethyl]-1-piperidinyl]ethyl]-3-methyl-2-oxazolidinone oxalate
Following the procedure of Example 1, α-(4-fluorophenyl)-α-phenyl-4-piperidinemethanol and 5-(2-chloroethyl)-3-methyl-2-oxazolidinone are reacted and the product thereof is reacted with oxalic acid to give the title product.
EXAMPLE 18
Following the procedure of Example 1 and substituting the following for 5-(2-chloroethyl)-3-methyl-2-oxazolidinone:
5-(2-chloroethyl)-3,4-dimethyl-2-oxazolidinone,
5-(2-chloroethyl)-3-(1-butyl)-2-oxazolidinone,
5-(1-methyl-2-chloroethyl)-3-methyl-2-oxazolidinone,
5-(4-chlorobutyl)-3-methyl-2-oxazolidinone,
5-(2-chloroethyl)-3-(4-methoxyphenyl)-2-oxazolidinone,
5-(2-chloroethyl)-3-(4-methylphenyl)-2-oxazolidinone,
5-(2-chloroethyl)-3-(3-chlorophenyl)-2-oxazolidinone, and,
3-benzyl-5-chloromethyl-2-oxazolidinone,
there are obtained:
(a) 5-[2-[4-[bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]ethyl]-3,4-dimethyl-2-oxazolidinone oxalate,
(b) 5-[2-[4-[bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]ethyl]-3-(1-butyl)-2-oxazolidinone oxalate,
(c) 5-[2-[4-[bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]-(1-methylethyl)-3-methyl-2-oxazolidinone oxalate,
(d) 5-[4-[4-[bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]butyl]-3-methyl-2-oxazolidinone oxalate,
(e) 5-[2-[4-[bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]ethyl]-3-(4-methoxyphenyl)-2-oxazolidinone oxalate,
(f) 5-[2-[4-[bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]ethyl]-3-(4-methylphenyl)-2-oxazolidinone oxalate,
(g) 5-[2-[4-[bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]ethyl]-3-(3-chlorophenyl)-2-oxazolidinone oxalate, and
(h) 5-[2-[4-[bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]methyl]-3-(phenylmethyl)-2-oxazolidinone.
EXAMPLE 19
4-[3-[4-[Bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]propyl]-3-methyl-2-oxazolidinone oxalate
Following the procedure of Example 1, α,α-bis(p-fluorophenyl)-4-piperidinemethanol and 4-[(3-chloro)propyl]-3-methyl-2-oxazolidinone are reacted and the product thereof is reacted with oxalic acid to give the title compound.
EXAMPLE 20
7-[2-[4-[Bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]ethyl]-3-methyl-hexahydro-2H-1,3-oxazepin-2-one oxalate
Following the procedure of Example 1, α,α-bis(p-fluorophenyl)-4-piperidinemethanol and 7-(2-chloroethyl)hexahydro-3-methyl-2H-1,3-oxazepin-2-one are reacted and the product thereof is reacted with oxalic acid to give the title compound.
EXAMPLE 21
8-[2-[4-[Bis(4-fluorophenyl)hydroxymethyl]-1-piperidinyl]ethyl]-3-methyl-octahydro-2H-1,3-oxazocin-2-one oxalate
Following the procedure of Example 1, α,α-bis-(p-fluorophenyl)-4-piperidinemethanol and 8-(2-chloroethyl)octahydro-3-methyl-2H-1,3-oxazocin-2-one are reacted and the product thereof is reacted with oxalic acid to give the title compound.
EXAMPLE 22
5-[2-[4-(4-fluorophenyl)(2-pyridinyl)hydroxymethyl]-1-piperidinyl]ethyl]-3-methyl-2-oxazolidinone
A mixture of 2.9 g (0.01 mol) of α-(4-fluorophenyl)-α-(4-piperidinyl)-2-pyridinemethanol, 1.6 g (0.01 mol) of 5-(2-chloroethyl)-3-methyl-2-oxazolidinone, 3.7 g (0.035 mol) of anhydrous sodium carbonate and 0.1 g of potassium iodide in 100 mL of 1-butanol is heated at reflux for 16 hr. The mixture is concentrated and the residue is partitioned between benzene and water. The organic layer is washed with water and brine, dried over sodium sulfate, filtered, and concentrated to give the title compound.
EXAMPLE 23
5-[2-[4-[bis(2-pyridinyl)hydroxymethyl]-1-piperidinyl]ethyl]-3-methyl-2-oxazolidinone
A mixture of 2.69 g (0.01 mol) of α-(4-piperidinyl)-α-(2-pyridinyl)-2-pyridinemethanol, 1.6 g (0.01 mol) of 5-(2-chloroethyl)-3-methyl-2-oxazolidinone, 3.7 g (0.035 mol) of anhydrous sodium carbonate and 0.1 g of potassium iodide in 100 mL of 1-butanol is heated at reflux for 16 hr. The mixture is concentrated and the residue is partitioned between benzene and water. The organic layer is washed with water and brine, dried over sodium sulfate, filtered and concentrated to give the title compound.
Pharmacology Methods Antiallergy Screening Method-Rats
As stated above, the primary screening method used to demonstrate antiallergy properties of the compounds of Formula I is a modification of the procedure of R. R. Martel and J. Klicius, International Archives Allergy Appl. Immunology, Vol. 54, pp 205-209 (1977) which measures the effect of oral administration of the compound on the volume of a rat paw which was previously injected with anti-egg albumin serum following egg albumin challenge. The procedure is as follows: Fed rats are injected in the right hind paw with 0.2 ml of rat anti-egg albumin serum at a dilution previously shown to produce significant edema upon antigen challenge. The animals are then fasted, but allowed water ad libitum. The next day the rats are randomized into groups of 6 by means of tables generated by the IBM scrambler. Random number tables are used to determine the groups receiving the control, reference and test articles. On the test day, the right foot volume of each rat is determined plethysmographically using the hairline as the reference point. Volume of this foot is measured with a mercury filled tube that is connected to a P 23A Statham® pressure transducer that in turn is connected to a linear Cole Parmer® recorder (Model No. 255). The instrument is adjusted so that a pen deflection of 50 mm is equivalent to 1 ml volume. Separately, the reference and test compounds and control articles are dissolved or suspended in 0.5% Tween 80 in distilled water. Sonification is used to facilitate dissolution or reduce particle size. The animals are dosed orally (10 ml/kg) at 1 hr prior to the intravenous injection of the antigen, 2 mg of egg albumin in 0.2 ml of sterile saline. Thirty minutes later the right foot volume is measured again and edema is determined by difference. Results are expressed as the average foot edema (ml) ±S.D. A significant decrease (p<0.05) in the edema of the treated group from that of the control group is considered as indicative of antiallergic activity. The results are acceptable only if the group receiving the reference article shows a significant decrease in foot edema. The foot volume for each animal is measured twice, once prior to dosing and again 30 min following the intravenous administration of antigen. Data is analyzed with the Dunnett's t-test that compares several treated groups with a control group. Differences between groups are determined by the studentized Range Test. Regression analysis may be used to determine relative potency.
Guinea Pig Anaphylaxis Method
The method used to test antiallergy effectiveness of the compounds in guinea pigs as compared to other drugs is as follows:
Guinea pigs are first sensitized to egg albumin (EA, Sigma Chemical Co., St. Louis, Missouri), at least 20 days prior to aerosol challenge by receiving 0.5 ml of EA-Al(OH) 3 conjugate (33 μg EA/ml) intramuscularly in each hind leg.
On the test day, fasted, sensitized guinea pigs are divided into a control group (8 animals per group) and test groups of four animals per group by using random number tables generated by an IBM scrambler. The reference; e.g., theophylline or test drug (Formula I cpd.) dissolved or suspended in 0.5% Tween 80 in distilled water or the control article (0.5% Tween 80 in distilled water) are administered orally in a volume of liquid at 10 ml/kg. Either 1, 5, or 24 hours following the oral administration of the test drug, reference drug, or control article, each animal is placed in an aerosolization chamber. EA (10 mg/ml) aerosolized at a rate of 10 liters of air/min is delivered into the chamber for a maximum of 5 minutes. The anaphylactic response consists of coughing, dyspnea, reeling, collapse and death. Upon collapsing, the animals are removed from the chamber. Animals are considered protected if they do not collapse within 5 min of exposure to the aerosolized antigen. The number of animals that collapse in each group is recorded. ED 50 for collapse is calculated by the method of Litchfield and Wilcoxon (1949), J. PHARMACOL. EXP. THERAP. 95, 99-113 for evaluation of dose-effect experiments.
Comparisons of ED 50 s from different experimental trials and determinations of relative potency are determined by the Litchfield and Wilcoson method, ibid. The following conditions must be met before an experiment is acceptable:
(1) Control group shows collapse in 7/8 or 8/8 animals, and
(2) Theophylline reference group shows protection in 3/4 or 4/4 animals treated 1 hr or 5 hr prior to antigen exposure.
Screening Procedure for Antihistamine Activity
The compounds of the present invention exhibit antihistamine activity in guinea pigs. The method of testing is a modification of the procedure of Tozzi et al (Agents and Actions, Vol. 4/4, 264-270, 1974) as follows: Guinea pigs are fasted 18-24 hrs in individual cages. Water is available ad libitum. On the test day, animals in groups of 3 are injected intraperitoneally with 30 mg/kg of the test compound prepared in an appropriate vehicle. Thirty minutes later histamine at a dosage level of 1.2 mg/kg (=2×the LD 99 ) is injected into a marginal ear vein. Survival of the guinea pigs for 24 hrs is positive evidence of antihistaminic activity. If the vehicle used for the test compound is other than water, its effect is established by testing an equal amount as a control. The dose protecting 50% of the animals (PD 50 ) from death may be established from dose-response curves.
Pharmaceutical Compositions and Administration
Compositions for administration to living animals are comprised of at least one of the compounds of Formula I according to the antiallergy method of the invention in association with a pharmaceutical carrier or excipient. Effective quantities of the compounds may be administered in any one of various ways; for example, orally as in elixirs, capsules, tablets or coated tablets, parenterally in the form of sterile solutions, suspensions, and in some cases intravenously in the form of sterile solutions, intranasally and to the throat or bronchial region in the form of drops, gargles, sprays, aerosols and powders, etc. or cutaneously as topical ointments, solutions, powders, etc. Suitable tableting excipients include lactose, potato and maize starches, talc, gelatin, stearic and silica acids, magnesium stearate and polyvinyl pyrrolidone.
For parenteral administration, the carrier or excipient can be comprised of a sterile parenterally acceptable liquid; e.g., water or arachis oil contained in ampoules.
Advantageously, the compositions are formulated as dosage units, each unit being adapted to supply a fixed dose of active ingredients. Tablets, coated tablets, capsules ampoules, sprays and suppositories are examples of preferred dosage forms. It is only necessary that the active ingredient constitute an effective amount such that a suitable effective dosage will be consistent with the dosage form employed, in multiples if necessary. The exact individual dosages, as well as daily dosages, will of course be determined according to standard medical principles under the direction of a physician or veterinarian. Generally, the pharmacology tests on guinea pigs in comparison to certain other antiallergy drugs suggest an effective dose for an adult will be in the range of 1.0 to 20 mg for the more active compounds with a daily dosage amounting to about 4 to 160 mg/day.
Based on the animal data, unit dosages containing an amount of compound equivalent to about 0.02 to 0.2 mg of active drug per kilogram of body weight are contemplated. Daily dosages of about 0.10 to 2.0 mg/kg of body weight are contemplated for humans and obviously several small dosage forms may be administered at one time. However, the amount of the active compounds administered need not be limited by these contemplations due to uncertainty in transposing animal data to human treatment.
Oral dosages projected for use as antihistamines for an adult human are of the order 10-120 mg/day divided into 2 or 3 doses. Thus, for example, one or two capsules each containing 10-40 mg active agent of Formula I could be administered 2-3 times daily for temporary relief of cough due to minor throat and bronchial irritation which may occur with the common cold or with inhaled irritants.
Examples of compositions within the preferred ranges given are as follows:
______________________________________Capsules Ingredients Per Cap.______________________________________1. Active ingredient 10.0 mg2. Lactose 146.0 mg3. Magnesium Stearate 4.0 mg______________________________________
Procedure
1. Blend 1, 2 and 3.
2. Mill this blend and blend again.
3. This milled blend is then filled into #1 hard gelatin capsules.
______________________________________Tablets Ingredients Mg./Tab.______________________________________1. Active ingredient 10.0 mg2. Corn Starch 20.0 mg3. Alginic acid 20.0 mg4. Sodium alginate 20.0 mg5. Magnesium Stearate 1.3 mg______________________________________
Procedure
1. Blend 1, 2, 3 and 4.
2. Add sufficient water portionwise to the blend from Step #1 with careful stirring after each addition. Such additions of water and stirring continue until the mass is of consistency to permit its conversion to wet granules.
3. The wet mass is converted to granules by passing it through the oscillating granulator, using 8 mesh screen.
4. The wet granules are then dried in an oven at 140° F.
5. The dried granules are then passed through an oscillating granulator, using a 10-mesh screen.
6. Lubricate the dry granules with 0.5% magnesium stearate.
7. The lubricated granules are compressed on a suitable tablet press.
______________________________________Intravenous InjectionIngredient Per ml.______________________________________1. Active ingredient 1.0 mg2. pH 4.0 Buffer solution q.s. to 1.0 ml______________________________________
Procedure
1. Dissolve the active ingredient in the buffer solution.
2. Aseptically filter the solution from step #1.
3. The sterile solution is now aseptically filled into sterile ampuls.
4. The ampuls are sealed under aseptic conditions.
______________________________________Intramuscular InjectionIngredient Per ml.______________________________________1. Active ingredient 5.0 mg2. Isotonic Buffer solution 4.0 q.s. to 1.0 ml______________________________________
Procedure
1. Dissolve the active ingredient in the buffer solution.
2. Aseptically filter the solution from step #1.
3. The sterile solution is now aseptically filled into sterile ampuls.
4. The ampuls are sealed under aseptic conditions.
______________________________________Suppositories Ingredient Per Supp.______________________________________1. Active ingredient 10.0 mg2. Polyethylene Glycol 1000 1350.0 mg3. Polyethylene Glycol 4000 450.0 mg______________________________________
Procedure
1. Melt 2 and 3 together and stir until uniform.
2. Dissolve #1 in the molten mass from step #1 and stir until uniform.
3. Pour the molten mass from step #2 into suppository molds and chill.
4. Remove the suppositories from molds and wrap.
Various modifications and equivalents will be apparent to one skilled in the art and may be made in the compounds, methods of treatment and compositions of the present invention without departing from the spirit or scope thereof, and it is therefore to be understood that the invention is to be limited only by the scope of the appended claims.
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4-[(α,α-Diaryl)-hydroxymethyl]-1-piperidinylalkylcyclic carbamate derivatives having the formula: ##STR1## wherein; R is hydrogen, loweralkyl, cycloalkyl, phenyl and substituted phenyl;
Ar and Ar 1 are phenyl, substituted phenyl or pyridinyl;
alk is a straight or branched hydrocarbon chain;
R 1 is loweralkyl substituted for hydrogen on a ring carbon.
The compounds are useful antihistamines and in controlling allergic response.
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INTRODUCTION
[0001] The present invention relates to the field of radio frequency communication. More specifically, it relates to identification of a tag for accessing supplementary information regarding an object marked with the tag. The invention describes a method and system combining several technologies for accessing said information. By combining telecommunication, WLAN, and radio frequency identification, a novel and flexible method and system is accomplished.
[0002] The invention is suitable for different purposes, e.g. museum guiding, tourist guiding, non-contact payment systems, wireless security and authentication, and smart objects.
BACKGROUND OF THE INVENTION/PRIOR ART
[0003] Radio frequency identification (RFID) is a technology for storing and retrieving data from identification tags. RFID tags can be interrogated and read on a short distance from a RFID reader.
[0004] RFID technology in connection with mobile phones has been launched through Sony Felica technology, and Philips and Sony have recently teamed up with Nokia to establish the NFC (Near Field Communication) Forum, which will promote the implementation and standardization of NFC technology.
[0005] In most previous scenarios the mobile handsets have been the bearers of a tag while the RFID reader has been stationary. NFC technology have the possibility of both being an active reader and passive tag. This opens the possibility of having RFID readers in mobile handsets, giving the possibility of making the tag stationary and the handsets movable.
[0006] Known systems deploying RFID technology for Mobile phones in the area of non-contact Payment and Wireless Security and Authentication etc., locate the active RFID reader at a stationary fixed location where communication is to occur (contact point). This requires an infrastructure of active RFID readers at all contact points. The cost of an active RFID reader is significantly larger than a passive tag. In some scenarios, it is therefore advantageous to use passive RFID tags.
[0007] The present invention addresses scenarios where applications require a large number of contact points and where it is advantageous to use an active RFID reader located in the mobile unit and passive tags as contact points.
[0008] As an example, in Louvers there are exhibited around 29000 works of art. It would be cost effective to tag each piece of art with a passive RFID tag rather than an active RFID reader.
[0009] The present invention merges telecommunication, RFID, WLAN and SIM card technology. By introducing use of WLAN as means for accessing supplementary information regarding an object marked with a tag, the user of the system will experience a more cost effective and faster service.
[0010] By transmitting tag information to a local WLAN infrastructure instead of through the mobile network, the user of the system will get quicker response and may control services locally.
[0011] The present invention comprises a SIM card with its SIM card specific circuitry integrated with WLAN and active RFID reader circuitry on the handset. A tag is read by means of the RFID reader, and its information is sent to a WLAN network by means of the integrated WLAN transmitter on the SIM card.
[0012] Since the communication processing is performed on the SIM card, billing of local WLAN services can be performed.
[0013] The present invention can be utilized by telecom operators, thereby giving the possibility of launching new services.
SUMMARY OF THE INVENTION
[0014] The present invention covers different aspects of accessing information by using a mobile phone with RFID reader technology, and a SIM card with integrated WLAN means.
[0015] According to a first aspect, the invention establishes a novel method for using a mobile phone for acquiring supplementary information regarding an object provided with an identification tag. The method is characterised by performing the following steps:
[0016] broadcasting the presence and identification of the mobile phone by transmitting signals from active WLAN means, integrated on the SIM card in the mobile phone, to an information processing server available through a local WLAN network, said information processing server comprises means for communicating with the telecom operator of the mobile phone;
[0017] receiving a request presented on the mobile phone from the telecom operator asking the user of the mobile phone if the information acquiring service available is accepted, and if accepted:
[0018] reconfiguring the mobile phone making it ready for acquiring supplementary information regarding an object, said reconfiguring includes activating a radio frequency identification tag reader in the mobile phone;
[0019] reading identifier information from an identification tag close to the mobile phone by means of the radio frequency identification tag reader;
[0020] processing the read information on the SIM card.
[0021] sending the identifier information to the information processing server through the embedded WLAN on the SIM card to the local WLAN network;
[0022] receiving supplementary information on the mobile phone through the local WLAN network regarding the object provided with the information tag.
[0023] According to a second aspect, the invention describes a system for using a mobile phone for acquiring supplementary information regarding an object provided with an identification tag, and where the system comprises means for performing the method described above.
[0024] The objects stated above are achieved by means of a method, system and a device as set forth in the appended set of claims.
DETAILED DESCRIPTION
[0025] The invention will now be explained in more detail with reference to the figures where:
[0026] FIG. 1 shows an overview of the system according to the invention, and
[0027] FIG. 2 shows a flow chart describing an example of use of the invention.
[0028] As mentioned, the invention merges SIM cards, RFID systems and WLAN systems with mobile phone systems, thus opening the market for new applications and services for mobile phones.
[0029] Merging the SIM card with an active RFID reader/interrogator and a WLAN transmitter introduces a number of new possibilities.
[0030] From a system perspective the Subscriber Identity Module (SIM) card, is the device holding the A3 and A8 algorithms and the IMSI (International Mobile Subscriber Identity) and the Subscriber Authentication Key (Ki) in a GSM network. These keys and algorithms are used for authentication and identification in the GSM network. Introducing a RFID reader/interrogator in conjunction with the SIM card pursues the tasks of the SIM card for authentication and identification on a separate new wireless interface. This enables operators, third party developers and content/service delivery companies to perform billing toward such services.
[0031] One of the advantages of the GSM architecture and the SIM-card is that the SIM-card can be moved from one Mobile Phone to another. Arranging a WLAN transmitter on a SIM card makes upgrades very simple for the users and makes the SIM card a “personal” device. When linked to the concept of physical browsing a user may be authenticated and authorized towards an infrastructure of RFID tags and the WLAN infrastructure for service delivery.
[0032] The invention discloses a SIM card that controls a RFID reader/interrogator in the mobile phone. RFID based applications and services may thereby be user or telecom operator initiated, i.e. a service may use the location of a mobile phone within the GSM network to initiate a RFID service.
[0033] FIG. 1 shows the inventive system set up for accessing supplementary information with regard to an object linked to an identification tag.
[0034] The system comprises at least one object 30 , within a restricted area 10 , provided with an identification tag 40 making it possible to identify the object 30 .
[0035] The system further comprises a local WLAN server 20 for storing and handling relevant supplementary information regarding the object 30 .
[0036] For using the system, a mobile phone 60 with a display 70 for presenting information to the user is further provided with a SIM card 90 with integrated means for WLAN 100 .
[0037] The key feature of the system is a RFID reader 80 integrated in the mobile phone 60 . This makes it possible to read information from an identification tag 40 .
[0038] When the RFID reader 80 has read the identification from the identification tag 40 , the identification is transmitted through the integrated WLAN means 100 on the SIM card 90 thereby enabling requests for supplementary information from the local WLAN server 20 .
[0039] The system also comprises a mobile phone central 110 communicating with the mobile phone 60 through the antenna 50 of the mobile phone 60 , enabling the network operator of the mobile phone 60 to charge for services used. This is further described below.
[0040] In the following an example on how this system can be used is described.
[0041] FIG. 2 shows a flow chart describing an example of use of the system according to the invention. This is only one scenario meant to illustrate some of the concepts of the system. A skilled person in the art will realize that the invention can be used in a plurality of other implementations.
[0042] A subscriber to a “museum guide” service within a restricted area 10 is walking towards the restricted area 10 . The museums local WLAN network 20 detects the active WLAN 100 on the SIM card 90 and has this user on list of subscribers, indicated in 1). The “museum service” starts an initiation process of the service by asking the telecom operator through a cellphone central 110 to reconfigure the mobile phone 60 for the service, denoted in 2 ).
[0043] If the user accepts he/she will receive a new configuration for the mobile phone from the operator with a welcome message asking for approval before the new settings are operational, denoted by 3 ) and 4 ). The new configuration may include activating the RFID reader 80 , adding new themes, adjusting WLAN settings for content delivery, charging the customer etc.
[0044] When the subscriber of the service walks to a picture and holds the mobile phone toward a passive RFID tag close by the picture, denoted by 5 ), the tag containing an identifier and possibly content data is read 6 ). This information is processed in 7 ) enabling the SIM card to transmit the identifier by means of its local WLAN 100 to the WLAN server 20 , denoted in 8 ). The WLAN server 20 responds with delivery of supplementary content to the subscriber through the operator-controlled WLAN network, indicated in 9 ).
[0045] In a preferred embodiment, the RFID reader 80 is located in the mobile phone 60 , e.g. a mobile phone with a SIM card 90 containing integrated WLAN circuitry 100 and means for communicating with the RFID reader 80 .
[0046] In another embodiment, the RFID reader 80 is fitted on the SIM card 90 together with the WLAN circuitry 100 .
[0047] Fitting WLAN circuitry and SIM specific circuitry on one single SIM-card poses challenges in terms of physical size and antenna construction, but it is feasible by careful construction.
[0048] A SIM-card used in current GSM handsets has an outer dimensions 15×25×1 mm defined in ETSI TS 102 221 Smart cards; UICC-terminal interface; Physical and logical characteristics (Release 6).
[0049] Telenor has already implemented WLAN circuitry on a SIM card. The addition of circuitry for communicating with a RFID reader performing the communication with the tags and facilitating data transfers will make the SIM card far more flexible. The RFID reader/interrogator should perform functions like; signal conditioning, parity error checking and correction, algorithms for decoding and retransmission control.
[0050] The communication between the SIM card 90 and the mobile phone 60 is not changed with regard to standard SIM cards (3GPP standard). It is be possible to interact with the RFID reader 80 from the mobile phone 60 by making use of SIM-card programming. This enables turning the reader on/off, and thereby enabling/disabling mobile services from the mobile phone network.
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A method and system for acquiring information related to a transponder (RFID) tag 40 ) read by a mobile telephone 60 comprising a RFID reader 80 , and an identification and authentication module (SIM card 90 ). When the RFID reader has read the data from the RFID tag 40 , the identifier and the content data is processed and transmitted to a local network for further processing and delivery of supplementary information linked to the RFID tag 40 . The SIM card comprises a Wlan transmitter, and transmitting of the identifier is via the WLAN.
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REFERENCE TO APPLICATIONS
This application is a continuation of application Ser. No. 950,596, filed on Oct. 11, 1978, now abandoned, which was, in turn, a continuation of application Ser. No. 828,830, filed on Aug. 29, 1977, now abandoned, which was, in turn, a divisional application of application Ser. No. 462,314, filed Apr. 19, 1974, and issued as U.S. Pat. No. 4,045,003 on Aug. 30, 1977, which was, in turn, a continuation-in-part of application Ser. No. 341,131, filed on Mar. 14, 1973, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to support devices and in particular a support for protective devices used as guard rails, scaffolding, or the like.
Guard rails, hand rails, scaffolding, and the like are protective and supportive devices used around work areas, in connection with construction, and in protecting workers from dangerous machinery and other dangerous situations. In many instances such guard rail devices are temporary in nature, intended to be used only during periods of construction or installation of machinery. On other occasions, such guard rails are more permanent, meant to remain in place for long periods of time. In terms of the overall discussion of scaffolding, guard rails, and the like, it is to be understood herein that the term "stanchion" may refer generically to either vertically upright or horizontal members used in guard rails, scaffolding, and the like.
At the heart of any efficient stanchion, it is desirable to provide ones which are easily installable, may be used for long periods of time (even permanently), and, where desired, may be easily removed.
The disposition of guard rails around the perimeter of work areas has long been used and many arrangements have been suggested. The most common type of guard rail is often improvised and jerry-built. Recently, however, governmental agencies at various levels have begun to specify safety precautions along most work and building sites. Amongst these provisions is the Federal Goverment's Occupational Health and Safety Act (OHSA), which specifies not only the height of guard rails, but their rigidity and general configuration. Much of the present guard rails are not in conformance with these regulations or are too expensive for economical use.
One suggested guard rail was disclosed by Lionetto in U.S. Pat. No. 3,662,993. That device calls for stanchions which are wedged between upper and lower floors. The difficulty with a design such as this is that, in the first place, it requires an opposed upper floor. Secondly, the use of two bearing surfaces requires an uneconomical combination of parts in order to secure the railings to the site. Thirdly, the protective device cannot be left permanently on the site. Furthermore, it is doubtful that such a device would be absolutely secure, particularly if the opposed floors are uneven or if the screw jack combination is not sufficient to provide uniform and continuous pressures.
Still another suggested type of guard rail was provided by Melfi in U.S. Pat. No. 3,351,311. In this arrangement, there is provided a C-clamp for surrounding and engaging a cement floor. However, such a device tends to pivot about the point of engagement (that is, at the contact of the C-clamp with the floor). In addition, variation in floor sizes may require different size C-shaped clamped for practical engagement, thereby rendering such an arrangement complicated and expensive in use.
One other suggested means of engaging a post in a rail, or a rail in a floor, was disclosed by Macrea in U.S. Pat. No. 406,657. Macrea provides an end of a rail having two sleeves pivotally mounted for expansion within a frusto-conically-shaped cavity in a post. For this device to work, however, the cavity had to be especially designed with its special shape, and the grip of the rail would not be believed to be too secure, in any event. So that if such a post and rail combination were used with the railing taking the form of a stanchion, and having to support a guard rail, it would be weak and insecure.
All of the suggested devices herein, and other similar devices, are believed to be either permanent or of temporary design. None have the flexibility to be used as both permanent or temporary installations. This lack of flexibility adds to their cost and inconvenience of use.
In the past, brackets for supporting railings have been rigidly secured to stanchions. Thus, McCarthy in U.S. Pat. No. 791,713 shows a typically rigid, rail-holding brackets which are integral with the stanchion. This means that if the stanchion must be partially removed (so as to admit equipment to a work area, for example) the railings will have to be removed from the stanchion before removing the stanchion itself. This problem is further compounded where the stanchion is removed by rotation. A rigid bracket will obviously rotate with the stanchion thereby necessitating the removal of the railings.
Bettis, in U.S. Pat. No. 57,073 suggests brackets which are held in place by a wedge. Removal of the wedge, however, would necessarily result in the bracket dropping down the stanchion making more difficult removal of the stanchion. Williams, in U.S. Pat. No. 1,864,159 suggests a guard rail in which the brackets are rings held to the post by set screws. A loosening of the set screws would necessarily result in the dropping of the bracket thereby making removal of the rail more difficult.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a support device for supporting a stanchion, or the like, which is easily insertable and removable from a work area.
It is an object of this device to provide a reusable support device for supporting a stanchion or the like.
It is a further object of this invention to provide a support device for stanchions or the like which may form part of either a temporary or permanent installation.
In fulfillment of these objectives, there is provided a support means for stanchions or the like of the type having at least a portion thereof insertable within a cavity of a predetermined configuration. Support means comprises a base means which can be inserted into the cavity. An expansible means is provided upon the base means and is also insertable within the cavity. Finally, there is provided an engaging means which is coupled to the support means. When the engaging means is caused to move towards the base means upon the support means, both the engaging means and the base means exert compression forces upon the expansible means, thereby causing the expansible means to engage the cavity walls and secure therewithin the support means.
In one aspect of this invention, the base means comprises a waser and a vertically threaded rod, the expansible means is a rubber toroidal collar upon the support means and the engaging means may be a metal sleeve and nut. The nut screws down upon the sleeve forcing it against the rubber collar and pulling up on the washer, thereby causing the rubber collar to expand and engage the walls of the cavity.
A BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a plan view of a support device and stanchion, all constructed in accordance with the teachings of this invention;
FIG. 2 is a sectional view of the stanchion of FIG. 1 taken along line 2--2;
FIG. 3 is a partial sectional view of the stanchion of FIG. 1 taken along the line 3--3 in FIG. 2;
FIG. 4 is a sectional view of the stancion support device of FIG. 1 taken along line 4--4;
FIG. 5 is a partial sectional view of the stanchion support device of FIG. 1 taken along line 5--5;
FIG. 6 is a perspective view of a stanchion constructed in accordance with the teachings of this invention;
FIG. 7 is a perspective view of a support device and guard rail support means constructed in accordance with the teachings of this invention;
FIG. 8 is a sectional side view of the device of FIG. 7 taken along line 8--8;
FIG. 9 is a perspective view of a device for holding a column and secured to a work area by a support device of the type shown in FIG. 1; and
FIG. 10 is a partial sectional view of the device of FIG. 9 taken along line 10--10;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As has been previously indicated, "stanchion" as used herein means any post, scaffolding, or similar device for supporting any guard rail, scaffolding member, whether horizontal or vertical in orientation. Turning to the drawing, there will be seen (FIGS. 1, 4, and 5) one type of support device 20 for securing a stanchion. There are provided male 22 and female 24 members. The female member 24 may comprise a cup-like member 26 and a mounting bracket 28. The cup 26 may have any desired shape. Thus, as shown it may be cylindrical. On the other hand, the cup 26 may be replaced with a cavity or other opening in a work area having any other desired shape as well. The function of the cup or the cavity will be more fully discussed below.
The cup 26 may be made of any structural material such as, for example, polyvinyl chloride. The cup 26 may have annular grooves 30 (FIG. 5) formed therein. The bracket 28 may have any desired shape, such as a question mark shape with the straight portion 32 terminating in a perpendicular and planar nail plate 34. As disclosed in FIG. 5, the bracket 28 may comprise three resilient members which may be made of, for example, wire joined to the nail plate 34 by welding or the like. Any other convenient shape may be used for a bracket.
The male portion 22 of the support device 20 comprises a plate 36. The plate 36 may take the form of a washer of heavy guage steel, for example. The plate member 36 conforms generally to the interior configuration of the cup 26. Secured to the plate member 36 by welding, casting, or the like may be a centrally disposed rod-like member 38. This rod-like member 38 may take the form, for example, of a threaded steel rod. Placed over this rod 38 and resting upon the washer 36 may be a toroidal collar 40 of expansible material. Thus, resilient material may be used, such as, for example, vinyl, neoprene, or rubber.
Disposed on top of the collar 40 and about the rod 38 and movable with respect thereto, is a sleeve 42. The sleeve 42 may be hollow and substantially annular. The sleeve 42 may have a neck portion 44 which terminates in a small, marginal edge flange 46. The neck portion 44 extends from the marginal flange 46 outwardly to a body portion 48 of the sleeve 42. Both the neck portion 44 and flange 46, and the collar 40 that it abuts, are so dimensioned as to fit easily within the cup 26. The juncture of the neck 44 with the body portion 48 of the sleeve 42 may be so dimensioned as to contact the inner wall 50 of the cup 26.
The body portion 48 of the sleeve 42 may have any shape suitable to fit within an opening. Thus, as shown, it may be substantially cylindrical in shape and extend upwardly along a portion of the rod 38. A radially extending flange 52 is provided on the body portion 48 and rests upon the mouth of the cup 26. A tang 54 extends radially outwardly and terminates in the same radial plane as the radial flange 52. The purpose of the radial flange 52 and tange 54 will be more fully discussed below.
Opposed to the tang 54 and extending outwardly, as a tangent from a circle, is a toe board nail plate 56. The toe board nail plate 56 extends to either side of the body portion 48 of the sleeve 42 and may have apertures 58 (FIG. 4) for admitting nails therethrough.
In assembly, the cup 26 is placed in an area which may be cemented in. The bracket 28 is placed about the cup 26 in the annulr grooves 30. The nail plate 34 may then be nailed to the form board 60 by means of nails 62. The distance of the cup 26 from the form board 60 is arbitrary and is made to conform with any desired distance or existing statutory requirements of spacing a guard rail from the edge of a work area. Generally, if the support device is employed where, for example, cement floors are being laid, the cups 26, as indicated, are pre-set in place. Cement 64 is then floated into place. After the cement 64 has set, the male member 22 of the support device 20 is placed within the female member cup 26. At this time, the collar 40 is spaced from the inner wall 50 of the cup 26. A stanchion 66 (FIGS. 1 and 5) may have an integral nut or other engaging mens 68 secured at one end. The nut 68 may be threaded on the threaded rod 38. It will be noted that the support rod 38 extends only a short distance within the stanchion 66. As the stanchion 66 is tightened downwardly, the sleeve 42 presses upon the collar 40. Threading down upon the rod 38 causes the plate 36 to pull upwardly thereby applying forces to both sides of the collar 40. In response to the forces the collar 40 expands to engage the wall 50 of the cup 26. Thus engaged, a stanchion 66, or other device, may be locked in place either permanently or temporarily and easily removed by unthreading the stanchion 66.
Disposed at various points along the stanchion 66 may be collars 70 and 72 (FIGS. 1, 2, and 3). The collars 70 and 72 may be secured to the stanchion 66 by welding or the like. Disposed about the stanchion 66 and residing upon the collars 70 and 72 are planar L-shaped rail support members 74 and 76, respectively. The L-shaped rail support members 74 and 76 are rotatably secured upon the stanchion 66 and held in place by the collars 70 and 72, respectively. The stanchion 66 has at the end opposed to the end having an integral nut 68, a hex nut 78. The hex nut 78 may be made of any common material, such as steel, and may be welded or formed as an integral part of the stanchion 66.
In use, the cup 26 is placed in an area which is to be flooded with concrete 64 or the like. The bracket 28 is placed about the cup 26 and its nail plate 34 is secured against a form board 60 by nails 62. The distance from the cup 26 to the nail plate 34 may be the prescribed distance from the edge of a work area as set forth by statutory requirements (e.g., OHSA) or, in the alternative, any distance that is required or desired. The concrete 64 is next floated into place and permitted to harden. As a next step, the assembly which includes the support plate 36, rod 35, collar 40, sleeve 42, are lowered into the cup with the flange 52 resting on the lip or marginal edge of the cup 26. A plurality of these cups 26 with their male insert portions 22 may be disposed along a particular path adjacent the edge of a work area (not shown). Nails 57 (FIG. 4) may then be driven through the apertures 58 in the nail plate 56 into the toe board 80. Nailing the toe board 80 to the nail plate 56 of the sleeve 42 helps to orient and fix the sleeve 42 in place. Next, the stanchion 66 is lowered into place and the integral nut 68 engages the threaded rod 38 and is tightened downwardly thereon. In turning the stanchion 66, the hex nut 78 may be engaged by a wrench or the like (not shown) and the entire member tightened in that manner.
As shown in FIG. 1, the arms 74 and 76 may be perpendicular the toe board 80. However, any other arrangement may be employed. Generally, these arms 74 and 76 are used to hold boards (or guard rails) 82 which are secured in place by, for example nails 84 driven through nail holes 86 in the upright arms 88. It will be noted that the boards 82 terminate on each arm 74 and 76 so that a continuous smooth guard rail is formed between standing stanchions 66 (only one is shown).
The brackets or arms 74 and 76 are freely rotatable upon the stanchion 66. Thus, the stanchion 66 may be rotated for removal or installation independent of the position of the brackets 74 and 76. This is particularly useful when the stanchion 66 is to be removed to admist machinery to a work area. The stanchion 66 can be removed while the brackets 74 and 76 remain substantially stationary. The stanchion 66 is then lifted with the railings or boards 82 in place, thereby saving time. The collars 70 and 72 prevent the brackets 74 and 76, respectively, from slipping downwardly under the weight of the boards 82 as the stanchion 66 is lifted.
If guard rails were to be installed at corners, as for example about a shaft on a site of construction, a stanchion 66' (FIG. 6) may have a plurality of such arms 74' and 76' thereon. Thus, (as shown in FIG. 6) the arms 74' and 76' may be located at the two desired levels. In this way, a stanchion may form the corner of guard rails which are at right angles to one another (not shown).
The tang 54 is used to steady the stanchion 66 and prevent it from swaying. The radial flange 52 and the toe board 80 serve the same function. Thus, a rigid and secure but temporary guard rail installation may be made. On the other hand, it should be understood that this installation may be left permanently in place. In this regard, the support device 20 may be altered to include more permanent types of guard rails as is commonly known in the art. It is to be understood as well, that while the cup 26 is regarded as an important aspect of this invention, it is also contemplated that if the cavity into which the male portion 22 of this invention is inserted were properly dimensioned, a separate or pre-formed cup would not be essential. Rather, the male portion 22 could be inserted into the female cavity (not shown).
The support device 20 of this invention may be modified for other types of guard rail support means.
In another approach, the support device 20 is shown used in combination with a column 90 (FIGS. 7 and 8). The female portion 26' comprises a cup 26'. The male portion 24' of the support device 20 may then be inserted into the cup 26' in the column 90 substantially perpendicular thereto. The stanchion 92 in this instance takes the form of a rectangular member 94. L-shaped arms 96 and 98 may be secured at appropriate positions on the rectangular member 94. The rectangular member 94 may be made of structural material such as steel and may have on the side 100 opposed to the side to which are secured the arms 96 and 98, a pair of opposed legs 104. The legs 104 may be joined thereto by welding or the like, and are intended to support the member 94 and space it from the column 90. One leg 106 of each of the L-shaped arms 96 and 98 is disposed spaced from the member 94 and parallel thereto, in order to engage and hold guard rails which may be, for example, in the form of wooden boards 108. The legs 104 space the member 94 from the column 90. The member 94 may be secured to the male member 22 by a nut 110 (which may be made of steel or the like), which is secured by welding or the like, to a centrally disposed aperture 112 in the member 94. To avoid having to rotate the member 94 while tightening the sleeve 44 and plate 36 against the collar 40, the nut 110 may be rotatably mounted in the member 94 in a manner well known in the art. It is not required that the member 94 be rectangular or that the arms 96 and 98 be L-shaped. The purpose of this device is to permit guard rails to be interconnected between columns or from a stanchion to a column.
In another aspect of this invention (shown in FIGS. 9 and 10), a box-like member 114 may be secured to the threaded rod 38 of the male member 22 by means of a nut 116 centrally disposed in the bottom wall 118 thereof. Legs 120 may be secured to the bottom wall 118 to keep the box 114 upright. The box 114 is used to retain therein a column (not shown). Thus, for example, the box 114 may be made of any sturdy structural material such as steel. An ordinary wooden column, for example, one 4 inches by 4 inches, or any other desired dimensions, may be placed in the box 114 and rails nailed directly thereto (not shown).
While the preferred form of male and female members 22 and 24, respectively, have been disclosed herein (FIGS. 1-10), there may be other related male and female members in accordance with this invention. Several are discussed hereinbelow. It will be appreciated that any of the previous discussed stanchion members (see FIGS. 1-10) may be used in conjunction with any of the followed suggested devices.
It will be understood throughout that the shape of the male and female members may be altered to any desired or convenient shape--from cylindrical (as disclosed) to elliptical, rectangular, or the like. Further, it is also understood that the use of a threaded rod is not necessary and any other engaging means may be used in its place.
Not only may the type of support device and the type of stanchion supported thereby (compare FIGS. 1, 6, 7, and 9) be varied, but so may the manner of securing a female member to a work area. As disclosed thus far, a female member may be inserted into a hardenable material or be formed as an integral part thereof (as in precast cement planks).
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Disclosed is a stanchion support device which comprises a washer having secured thereto a threaded column. About the threaded column is a toroidal collar of hard rubber. Placed over the threaded column is a metal sleeve. Threaded onto the threaded column is a nut which forces the metal sleeve downward against the rubber collar and pulls upwardly on the washer. The combined force of the sleeve and washer causes the rubber to expand. When this combination is placed within a cavity, such as may be defined by a cup placed in a cement floor, the rubber is so dimensioned as to engage the cup wall, thereby securing the stanchion support device within the cup. A stanchion may be secured to the nut. The stanchion itself may be provided with one or more L-shaped brackets which are freely rotatable thereupon and retained from sliding down the stanchion by a support, such as a ring, welded to the stanchion. An enlarged head of the stanchion prevents the removal of the bracket off the top of the stanchion.
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The rain and storm water filtration systems discussed herein relate to filtration systems that employ screens to filter debris and other unwanted material from water streams and, more specifically, to filtration systems having a Coanda screen for filtering water streams.
BACKGROUND OF THE INVENTION
Rainwater downspouts, curbside storm water runoff collectors, and similar water conduits share a common purpose: removal of water from where it is undesired, be it the roof of a building, a city street, a storm basin, or the like. All such conduits allow a volume of water to pass therethrough. Leaf litter, sand, dirt, grit, and other debris can accumulate within such conduits and clog them, rendering them ineffective. Equally bad, the poor design of many water conduits allows debris to pass through to downstream channels and, ultimately, the ocean, with a consequent negative environmental impact.
Not surprisingly, much effort and money has been spent devising ways to avoid clogged water conduits and contaminated water streams. Patents have been granted for inventions designed to filter water at curbside storm drains (U.S. Pat. No. 6,231,758 to Morris et al.), to treat water in a horizontal passageway (U.S. Pat. No. 6,190,545 to Williamson), to create temporary stream filtration systems (U.S. Pat. No. 4,297,219 to Kirk et al.), to remove downspout debris (U.S. Pat. No. 5,985,158 to Tiderington), and to shield rain gutters on the eaves of a building (U.S. Pat. No. 4,435,925 to Jefferys).
However, with respect to downspouts and storm water systems, the prior art has several shortcomings. Among other things, it is difficult to devise a system that both operates under high flow and effectively filters out small particulate matter and other debris. This is because a filter element that accommodates large flow must also be designed with large spacing to suit the large flow. However, large spacing allows medium to small particulates and waste to pass through unfiltered. Conversely, a filter element designed to trap small particulate matter typically obstructs flow. An ideal water runoff filter would be both capable of passing high flow therethrough and removing small waste and debris.
Accordingly, there remains a need for a filter system for removing debris from a water stream using a filter element that is amenable to high volume flow, capable of removing or trapping waste the size of or even smaller than the size of the gap used for the filter and, preferably, self-cleaning.
SUMMARY OF THE INVENTION
The present invention integrates a Coanda screen (sometimes called “Coanda-effect” screen) into water collection systems such as downspouts, storm runoff collectors, sewer drains, and similar conduits and receptacles. An exemplary embodiment includes retrofitting an existing downspout section (or customizing a new downspout section) with a Coanda screen to provide a downspout with a highly efficient filter for removing debris from a stream of water. Depending on the water flow rate and the size of the debris encountered, different screen sizes and different screen mounting angles maybe selected to accommodate the same. Filtered water can pass through the screen, while debris is retained by the Coanda screen and then collected in an optional retaining basket.
In another embodiment, a curbside inlet to a storm drain is fitted with a Coanda screen. The screen is mounted between a raw inlet basin and an outlet basin. Filtered water is allowed to pass over the screen and then fall through the screen into the outlet basin, which then flows onward via an outlet pipe. Captured debris and waste are allowed to fall into a retention basin. To remove waste and debris more effectively, a retaining basket is used. When full, the basket can be lifted out of the curbside inlet and emptied.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the invention will be better understood when considered in conjunction with the accompanying drawings, wherein like part numbers denote like or similar elements and features, and wherein:
FIG. 1 is a side elevation view of a downspout with a Coanda screen in accordance with practice of the present invention;
FIG. 2 is a front elevation view of the downspout of FIG. 1;
FIG. 2A is a partial cross-sectional view of a deflector plate;
FIG. 3 is a cross-sectional view of the downspout of FIG. 2, taken at line 3 — 3 ;
FIG. 4 is an enlarged view of the Coanda screen attached at its downstream end to the downspout;
FIG. 5 is another enlarged view of the same Coanda screen attached at its upstream end to the downspout;
FIG. 6 is an enlarged view of a section of the Coanda screen of FIGS. 4 and 5;
FIG. 6A is a depiction of a concave screen surface;
FIG. 7 is a side elevation view of a storm drain system in accordance with practice of the present invention;
FIG. 8 is a top plan view of the storm drain system of FIG. 7;
FIG. 9 is a partial cross-sectional view of the storm drain system of FIG. 7 taken at line A—A;
FIG. 10 is a front elevation view of an alternative downspout with a Coanda screen;
FIG. 11 is a side elevation view of the embodiment of FIG. 10;
FIG. 12 is a front elevation view of another alternative downspout embodiment with a Coanda screen; and
FIG. 13 is a side elevation view of the embodiment of FIG. 12 .
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the present invention, a highly effective filter system for a rain water downspout, sewer inlet, curbside storm water drain, or similar water runoff conduit or receptacle is provided. A preferred embodiment of an improved downspout 10 is shown in FIG. 1 . The downspout is mounted to an exterior wall 12 of a building by conventional mounting means (not shown), such as welds, adhesives (e.g., glue, cement, mortar, etc.), mechanical fasteners (e.g., rivets, bolts, screws, clamps, bands, straps, etc.), and other means known in the art. The downspout 10 includes a Coanda screen 20 mounted within a portion 40 of the downspout, referred to herein as the “upgraded downspout portion” or “upgraded downspout section”. The screen is accessible via a downspout opening 60 in the upgraded downspout portion. Water that flows into the downspout from a gutter (not shown) is filtered as it passes through the Coanda screen. Debris caught by the screen can slide out of the downspout opening into an optional retaining basket 80 mounted outside of and below the downspout opening. Effluent from the downspout empties into a splash guard or basin 100 which, preferably, is seated on a concrete slab 102 . Alternatively, the downstream end of the downspout is coupled to an underground header or a drain line (not shown) running to a main sewer or storm drain. The Coanda screen, upgraded downspout portion, retaining basket, and other features are described below in more detail.
An existing downspout can be upgraded or retrofitted by cutting out or otherwise removing a portion thereof, and installing an upgraded downspout portion or section 40 therein, using a slip joint, welds, adhesives, mechanical fasteners, or other conventional attachment means. Alternatively, an entire downspout can be fabricated as such and installed as part of a rain water removal system that includes one or more gutters and mounting hardware. In either case, the improved downspout provides a path for funneling water from a roof (or a deck, mezzanine, or other surface) to grade (e.g., street level) or to a storm water runoff drain or a main sewer line. Effluent from the downspout eventually flows to a storm drain or sewer system and then to the ocean, in some cases via a water treatment facility.
The downspout 10 is preferably constructed of stainless steel, galvanized steel, aluminum, plastic, or some other durable and water-resistant material, and has an interior and an exterior, and a cross-sectional shape that is generally rectangular. Alternatively, the downspout can have a generally circular cross-section or other desired geometry. In an exemplary embodiment, the downspout 10 is physically attached to an exterior wall 12 of a house or a building by any conventional means, such as downspout bands (not shown) anchored to the exterior wall. Water falling into the downspout passes into the upgraded downspout section 40 to the Coanda screen 20 . The Coanda screen 20 allows water to pass through, but traps waste and debris behind.
A Coanda screen acts by a shearing action referred to as the “Coanda effect,” which is discussed below in greater detail. In FIG. 1, the Coanda screen 20 has an upper surface 22 , a lower or underside surface 24 , a first (upstream) end 26 , a second (downstream) end 28 , and left and right sides, and is made of a plurality of wedge-shaped wires 30 . Additional details of the wires' shape and relative orientation is provided below.
The Coanda screen 20 is mounted at an angle within the upgraded downspout portion 40 , with the upstream end 26 of the screen elevated relative to the downstream end 28 of the screen. As shown in FIG. 1, the upgraded downspout portion 40 has four walls—front 46 , back 47 , left 48 , and right 49 —and has substantially the same shape and dimensions as the remainder of the downspout. The Coanda screen is affixed within the upgraded downspout portion by, e.g., securing the upstream end 26 of the screen to the back wall 47 of the upgraded downspout portion, and the downstream end 28 of the screen to the front wall 46 of the upgraded downspout portion. So installed, the screen is seen to form an angle θ (theta) with the back wall. In practice, it has been found that best results are achieved when θ has a value of about 15 to 50 degrees, more preferably, about 20 to 45 degrees.
To ensure that a substantial portion of the water entering the downspout is filtered, it is preferred that the screen have a large enough area to make contact with all four walls 46 - 49 of the interior of the downspout housing. Alternatively (or, in addition), one or more baffles are mounted within the downspout to divert the flow of water toward the screen. In FIG. 1, two baffles 52 and 54 are shown secured to the front wall 46 and side wall 48 , respectively, of the upgraded downspout portion at a position above the downspout opening 60 , and oriented such that the baffle projects toward the Coanda screen 20 . The side baffle 54 comprises a front plate 58 and a rear plate 59 . The rear plate 59 is attached to the side wall 48 by known methods, including welding, adhesive, mechanical fasteners and the like while the front plate 58 protrudes from the side wall 48 . The front plate 58 protrusion acts as a diverter to divert water that clings to the side wall towards the screen 20 . Similar attachment and configuration is discussed below for a deflector plate (FIG. 2 A).
In FIG. 3, two side baffles 54 and 56 are shown, secured to the left 48 and right 49 side walls of the downspout. Fewer or greater numbers of baffles can be mounted within the downspout to provide optimal diversion of water toward the Coanda screen. For example, the back wall 47 can also be configured to include a baffle. This may be desirable where the upstream end 26 of the screen is not recessed within the surface of the back wall 47 . The presence of such a baffle ensures that water cannot bypass the screen. The baffles can be attached to the inside walls of the downspout using any conventional means, including, without limitation, welding, adhesives, and mechanical fasteners.
The downspout opening 60 provides access to the Coanda screen for maintenance and cleaning. Although the screen is self-cleaning, occasionally debris may become trapped within the downspout or (rarely) wedged between the wires 30 that form the screen. Access to the screen is facilitated by providing the downspout opening 60 with appropriate dimensions relative to the screen 20 . A preferred downspout opening 60 has a width approximately 50-100% of the interior width of the downspout, and a height approximately 33-75% of the vertical profile of the screen 20 , the latter being measured at the wall opposite the downspout opening (the back wall 47 in FIG. 1 ). The downspout opening 60 is located intermediate the upstream and downstream ends of the downspout 10 , but not necessarily equidistant from both ends.
A retaining basket 80 to catch debris caught by the Coanda screen is mounted to the downspout just below a debris deflector plate (further discussed below), using conventional means, such as welding, adhesives, mechanical fasteners, and the like. In an exemplary embodiment, the retaining basket 80 comprises a tightly woven screen made of steel, aluminum, or other weather-resistant material. Debris that does not freely fall into the retaining basket 80 (i.e., debris that clings to the filter due to friction) is eventually pushed out the downspout opening 60 by additional water flowing from the gutter. Water clinging to debris caught in the retaining basket 80 can drip onto the splash guard 100 by passing through the holes of the retaining basket 80 . Alternatively, if an underground header is used to connect with the downspout, water that passes through the retaining basket can be caught by a collector (not shown) mounted beneath the retaining basket, and channeled to the header.
In an exemplary embodiment, the downspout is also equipped with an external debris deflector plate 110 . The debris deflector plate is mounted just below the downspout opening 60 along the external surface of the front wall 46 , just above the retaining basket 80 . The debris deflector plate covers any space between the downspout 10 and the retaining basket 80 , and ensures that debris exiting the downspout opening does not fall between the downspout and the retaining basket.
In an exemplary embodiment shown in FIG. 2A, the deflector plate 110 includes a front plate section 112 configured to deflect debris into the retaining basket, and a rear plate section 114 configured to be attached to the downspout. In an exemplary embodiment, the deflector plate 110 , like the downspout itself, is made of a durable, weather-resistant material, such as aluminum, plastic (e.g., polyvinyl chloride and unplasticized vinyl), galvanized steel, and the like. The deflector plate can be mounted to the downspout by known methods, including welding, adhesives, mechanical fasteners, and so forth.
Reference is now made to FIG. 4, which is an enlarged view of Detail A indicated in FIG. 1 . The downstream end 28 of the Coanda screen is shown secured to the downspout front wall 46 by an upper bracket 70 and a lower bracket 72 , without obstructing the flow of debris from the upper surface of the Coanda screen into the retaining basket. The two brackets are attached to the downspout by conventional means, such as welding, adhesives, mechanical fasteners, and so forth. Preferably, the upper bracket is substantially flush with the outer wall of the downspout housing at the bottom of the downspout opening.
Similarly, FIG. 5 provides an enlarged view of Detail B indicated in FIG. 1 . The upstream end 26 of the Coanda screen 20 is shown secured to the downspout back wall 47 by upper 74 and lower 76 brackets. However, in addition to securing the upstream end of the screen 20 , the upper bracket 74 also serves to divert water flow along the back wall 47 of the downspout to the screen. Although not shown, similar upper brackets may also be mounted around the entire perimeter of the screen so that any water flow along any of the four downspout walls is diverted toward the screen. The two brackets 74 , 76 are attached to the downspout by conventional means, such as welding, adhesives, mechanical fasteners, and so forth.
FIG. 6 shows an exemplary cross-sectional view of the Coanda-effect screen 20 . The screen comprises a plurality of individual wedge wires 30 , which are parallel to one another and separated from each other by a gap or a spacing 32 . The individual wedge wires 30 are held together in the indicated arrangement by welding two or more backer rods (not shown) to the base portions 34 of each individual wedge wire 30 . Coanda screens are commercially available in several standard sizes. Generally, the difference in screen selection relates the width, height, and tilt angle 36 of the wedge wires, and the gap spacing 32 between the wedge wires. In addition, the Coanda screen may be ordered with an overall concave shape. As shown in FIG. 6A, the term “concave” implies a curved contour when viewed with respect to the upper surface 22 of the screen 20 . When a concave screen is specified, the concave shape has the effect of increasing the tilt angle of the individual wedge wires. This in turn allows the leading (upstream) edge 38 of the wedge wire to shear a greater amount of the water, provided that all other parameters are unchanged. In an exemplary embodiment, the Coanda screen has a gap spacing of about 0.1 to 1.0 mm and a tilt angle of about 3 to 15 degrees, with a radius (“R”) of concavity of from about 6 inches to infinity (when R=infinity, the screen is flat). Alternatively, other screen parameters may be used, taking into account the size of the debris likely to be encountered, the anticipated water flow rate and volume, and so forth.
Coanda screens are available from a number of manufacturers and retailers, including on-line retailers such as www.hydroscreen.com, www.johnsonscreens.com, and www.eni.com/norris/default.html. The screen is described in an article entitled “Hydraulic Performance of Coanda-Effect Screens” by Tony Wahl for publication in the Journal of Hydraulic Engineering, Vol. 127, No. 6, June 2001, the entire contents of which are expressly incorporated herein by reference as if set forth in full.
As explained by Wahl, the Coanda effect is a tendency of a fluid jet to remain attached to a solid flow boundary. As shown in FIG. 6, when water 130 flows across the screen 20 from the upstream direction, it tends to remain attached to the upper surface of the screen as it travels in the direction of the downgrade 79 . At a given point along the screen, the water has a thickness “X”. As water 130 flows down the screen, its thickness X is sheared by the leading edge 38 of each individual wedge wire 30 . The sheared water is then redirected approximately tangentially 120 to the direction of the original flow due to the contour of the wedge wire 30 . Thus, different wedge wire contour will cause water to be redirected differently. This shearing action is repeated as water traverses down the screen along the direction of the downgrade 79 . Water is sheared as it travels over other wedge wires 30 . After each layer of water is sheared, it is caused to flow along one of several filtered water paths 120 a , 120 b , 120 c , 120 d , etc. The thickness of the water stream gets progressively smaller as the downstream end of the screen is approached, and the flow of water appears to slow to a mere trickle, or even drop off altogether.
This phenomenon is used to great effect in the present invention. Debris-laden water is effectively filtered at the Coanda screen. Any debris that does not fall into the retaining basket 80 during rainfall eventually dries on the screen, and either falls into the basket later, or can be manually removed via the downspout opening 60 .
In an alternate embodiment of the invention shown in FIGS. 7-9, an effective filter system for removing debris from a storm water runoff collector is provided. The runoff collector 200 comprises a Coanda screen 20 installed between a raw inlet basin 210 and an outlet basin 220 . As before, the screen 20 filters incoming water while trapping debris, but the source of water is a raw stream 212 , from an inlet 214 , and the effluent is a discharge stream 222 for an outlet line 224 .
In an exemplary embodiment, the Coanda screen 20 is mounted between a first weir 230 and a second weir 240 . The screen has a concave surface, with a radius of from about 6 inches to infinity, and is outfitted with an acceleration plate 250 . The acceleration plate 250 is a metal plate of hardened steel, such as stainless steel and the like, mounted to the upstream end 26 of the screen.
The acceleration plate has a width of approximately 2 inches or higher depending on the size of the storm drain system. When water flows from the raw inlet basin 210 over the weir 230 , it has a relatively low flow velocity. If water is allowed to flow over the screen 20 without first having the necessary flow velocity, the screen's ability to filter out debris will greatly decrease. The acceleration plate provides a vertical drop of about 2 inches or higher, allowing in-coming water to build up velocity before it contacts the first wedge wire on the screen.
Debris caught by the Coanda screen can slide into a retention basket 260 located within a retention basin 262 . In an exemplary embodiment, the retention basket 260 is equipped with a handle 264 , which allows the retaining basket to be lifted out of the basin, whereupon the debris can be discarded. The basket 260 may be a conventional basket and may be constructed out of medium to large steel wire mesh. Due to its size, it may be necessary to lift the basket with a crane or a flit truck having a lift.
In an alternate embodiment of the upgraded downspout 10 shown in FIGS. 10 and 11, a tapered front wall 46 and a modified back wall 47 having a tapered back wall section 270 is provided. The tapered front wall 46 and tapered back wall section 270 allow the screen 20 to be moved forward in the direction of the retaining basket 80 , and provide clearance for the installation of an acceleration plate 250 . In an exemplary embodiment, additional wall mounted baffles for diverting water toward the screen 20 are not necessary, as the screen is positioned directly below the incoming flow path and even extends past the incoming path. This screen configuration allows all or substantially all of the incoming flow to flow through the screen.
In another alternate embodiment of the upgraded downspout 10 , shown in FIGS. 12 and 13, an optional hinged cover 272 is provided over the downspout opening 60 of an enlarged upgraded downspout 10 . The enlarged upgraded downspout 10 is slightly larger than a conventional or existing downspout section, but has a much larger depth (the distance between the front wall 46 and the back wall 47 ), e.g., on the order of about 1.3 to 3 times deeper. This allows the enlarged upgraded downspout to accommodate a much larger screen 20 than a standard size upgraded downspout. This in turn, allows the much larger screen 20 to filter substantially all of the incoming flow without the need for wall mounted baffles. However, in the embodiment of FIGS. 10-13, wall mounted baffles, such as baffles 52 and 54 , can be used.
Although the invention has been described with reference to preferred and exemplary embodiments, various modifications can be made without departing from the scope of the invention, and all such changes and modifications are intended to be encompassed by the appended claims. For example, an upgraded downspout section can be manufactured as a separate unit and installed as a new downspout. Other materials than those described herein can be used to make the various components of the apparatus described. Changes to the way the baffles are installed, the way they are shaped, the way the deflector plates are installed, and the way the screens are installed within the housing can be made. Other alterations and modifications may be made by those having ordinary skill in the art, without deviating from the true scope of the invention.
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A debris-filtering downspout and other water runoff conduits and receptacles are disclosed, and include a Coanda screen mounted within a conduit, a culvert, a storm water conveyance or secured to a water collection basin. The Coanda screen provides high water throughput and is self-cleaning while effectively filtering debris contained in an incoming water stream.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a clothes washing machine, and more specifically to a wash plate therefor having fins and triangular protrusions positioned along its surface to distribute wash liquid and clothes evenly and enhance washability.
2. Description of the Related Art
The general construction of clothes washers is well known in the art. A common type of washing machine is the vertical axis washer having an agitator and incorporating a submersion process. An imperforate tub is mounted in a perforated wash basket for receiving clothing and the tub is filled with a wash liquid of detergent and water. An oscillating agitator imparts mechanical energy to the submerged clothing.
There have been advances in agitator washers improving the overall energy efficiency such as the vertical axis washer described in U.S. Pat. No. 4,987,627 (Cur et al.) that uses less energy and water through an improved wash process.
Additionally, since a relatively large amount of water is used to submerge the clothes in an agitator washer, alternate clothes washers have been developed that do not require a conventional agitator. One type of agitatorless washer that does not require complete submersion of clothes is described in U.S. Pat. No. 5,504,955 (Mueller). The washer in this patent has a wash basket disposed within a tub and rotatable about a vertical axis. A bottom plate is disposed within the lower portion of the wash basket and is mounted for a wobbling motion. This wobbly motion within the tub agitates and distributes the clothes during washing.
Furthermore, clothes washers range from those not having a wash plate to those having a wash plate that enhances washability. For example, the washer described in U.S. Pat. No. 2,802,356 (Kirby) does not have a wash plate or agitator. Instead, the wash basket is mounted for providing a wobbly motion within the tub. In U.S. Pat. No. 5,253,380 (Lim et al.), the pulsator, or wash plate, is designed with a plurality of radial ribs to cause a vortex flow within the rotatable tub. The ribs have axial holes to pass air bubbles to the tub. In U.S. Pat. No. 5,791,167 (Wyatt et al.), a wash plate having a clothes deflector is described. This wash plate is designed to seal the wash plate against the wash basket.
For clothes washers having a wash plate, it is desirable to have one that increases washability and reduces twisting and damaging of the clothes.
SUMMARY OF THE INVENTION
The present invention is directed to a wash plate for an automatic clothes washer. Typically the washer has an imperforate wash tub, a rotatable wash basket provided within the tub and a wobble/nutate wash plate within the wash basket. The clothes washer has a drive system for rotating the wash basket and wobbling/nutating the wash plate.
It is an object of the invention to provide a wash plate with a center area and a surrounding skirt area having a substantially circular outer perimeter. There is a hub extending upwardly from the center of the wash plate and fins and protrusions encircling the hub and extending upwardly from the wash plate. The hub is at a height greater than that of the fins and the fins are at a height greater than that of the protrusions.
It is an object of the invention to provide a wash plate having at least three fins extending upwardly from the skirt so as to divide the skirt area into at least three substantially equal sections. A plurality of protrusions extend upwardly from the skirt area and are provided within each of the sections.
It is a further object of the invention to provide at least three fins on the wash plate. Each fin has a left and a right planar side and a top and a bottom edge. Each fin is connected to the skirt area along its bottom edge and extends radially away from the hub toward the skirt perimeter. The top edge of each fin is positioned further from the skirt near the hub than near the skirt perimeter. The fins are integrally molded to the wash plate.
Another object of the invention is to provide protrusions that are polygonal in shape and are integrally molded to the wash plate. The protrusions have three planar faces, each face being substantially triangularly shaped. Each face has three angles and one angle of each face meets at a common point making each protrusion substantially a three-sided pyramid.
It is an object of the invention to provide three protrusions within each of the sections. Therefore, there are fins defining equal sections, and three protrusions are positioned within each of the three sections.
It is a further object of the invention to provide protrusions on the skirt at different radial lengths from the hub. Each section has a middle protrusion and two outer protrusions. The middle protrusion is positioned at a first length from the hub and the outer two protrusions are positioned at a second length from the hub.
An object of the invention is to provide a wash plate having a substantially circular center area with a hub extending upwardly therefrom. A skirt area surrounds the center area and has an outer perimeter. Three fins are spaced equidistantly on and extend upwardly from the skirt area. The fins extend substantially radially away from the center area and define three equal sections. Two outside and one inside multi-faced protrusions extend upwardly from the skirt within each section.
Further, it is an object of the invention to provide a wash plate having a skirt that defines an upwardly sloping surface from the outer perimeter toward the hub.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side sectional view of an automatic washer incorporating a wash plate with fins and protrusions according to the present invention.
FIG. 2 is a planar view of the wash plate.
FIG. 3 is a side view of the wash plate.
FIG. 4 is a cross-sectional view of the wash plate taken along line 4 — 4 of FIG. 2 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention may be used with an impeller action or wobble action washer. The wash plate works particularly well in a washer that imparts a wobbling or nutating action to the wash plate similar to that disclosed in U.S. Pat. No. 5,460,018 (Werner et is al.) issued Oct. 24, 1995, the disclosure of which is hereby incorporated by reference.
FIG. 1 illustrates a clothes washing machine 10 providing the environment of the invention. The washer comprises a frame 12 supporting a cabinet 14 . An imperforate wash tub 16 is supported within the cabinet 14 by multiple struts 18 extending from the frame 12 . A wash basket 20 is positioned within the wash tub 16 and a wash plate 22 is positioned within the wash basket near its bottom. The detailed internal structure of a washer that might contain the wash plate herein is disclosed in U.S. Pat. No. 5,460,018.
FIGS. 2-4 illustrate the wash plate 22 in greater detail. The wash plate is generally circular and comprises a substantially circular center area 24 having a midpoint 28 and a surrounding skirt area 26 . There is a raised hub 30 having a generally circular perimeter 29 positioned at the center area of the wash plate. The hub has a generally cylindrical body with a dome shaped top to facilitate separation of clothes without damaging them, as shown in FIG. 3 . However, there are many different possible ornamental appearances for the hub, for example, the hub 30 could have ribs extending across the top and down the cylindrical body or the hub could consist of multiple fins extending from the top downwards to form the body. The hub is at a height Hi to facilitate separation of clothes; not too low so that clothes just slide unaffected over it, but not too high that it impedes the movement of clothes. To increase the clothes capacity within the washer, a preferred height range for the hub could be anywhere from 4 to 10 inches from the skirt area nearest the hub, or the hub's circular perimeter 29 . The hub 30 may be integrally molded with the wash plate 22 or it may be a separate member that is attached to the wash plate 22 .
The skirt area 26 of the wash plate extends from the hub's perimeter 29 in a generally downward slope to the perimeter of the skirt or periphery lip 32 . It is found that the sloped skirt helps keep clothes from tangling during the wash process and the slope of the skirt 26 might be between 150° to 35°. The slope of the described embodiment is approximately 25°, as shown in FIG. 4 . The periphery lip 32 is substantially circular and might have a clothes deflector 34 to seal the wash plate 22 with respect to the wash basket 20 as shown in U.S. Pat. No. 5,791,167. The skirt area 26 may have multiple perforations 35 as shown in FIG. 3 to allow mixing of a detergent and draining of wash liquid from the clothes and the area above the wash plate 22 .
Fins 36 are positioned on the wash plate 22 and extend upwardly therefrom. As can be seen in FIGS. 2-4, the fins 36 have a left planar side 38 and a right planar side 40 . Each fin has a top edge 42 and a bottom edge 44 . The fin is positioned on the skirt 26 along its bottom edge 44 and may be integrally molded with the wash plate 22 . Each fin has a front end 46 and a back end 48 whereby the front end 46 is positioned near the hub 30 and the fin 36 extends radially therefrom with the back end 48 positioned toward the periphery lip 32 . The front end 46 of the fin 36 shown in FIG. 2 is positioned at the circular perimeter 29 of the hub and the back end 48 is positioned a distance from the periphery lip 32 of the wash plate 22 . The top edge 42 of the fin is generally smooth without any sharp angles to avoid damage to the clothes and the top edge 42 of the fin is at a greater distance from the skirt area toward the periphery lip than toward the hub.
At least two fins 36 extend radially from the hub 30 to facilitate the movement of clothing in a circular direction around the hub. As shown in FIG. 3, the fins 36 are at a height H 2 less than the height Hi of the hub 30 , but at a height H 2 great enough to help push the clothes. There may be any number of fins 36 , however too many fins result in the clothing moving across the top of the fins and negates their purpose. It is found that three fins 36 work well to control the motion of the clothes by pushing them in a circular direction while allowing them to contact the skirt area 26 of the wash plate 22 during rotation and/or wobbling.
The fins 36 divide the wash plate and thus the skirt into substantially equal sections 50 . Thus, three fins divide the skirt area 26 into three substantially equal sections 50 .
Polygonal protrusions 52 are positioned on the wash plate 22 and extend upwardly therefrom, as shown in FIG. 3 . They are at a height H 3 less than the height of the fins H 2 . The protrusions 52 may have any number of faces 54 , but are preferably not round. Each face 54 is planar and has edges 56 and angles 58 defining the shape of the face. For example, the preferred embodiment shown in FIG. 2 has three faces 54 and each face has three edges 56 a , 56 b , 56 c and three angles 58 a , 58 b , 58 c forming a triangular shaped face. Each face has a bottom edge 56 c integrally formed on the wash plate 22 and a right edge 56 a and a left edge 56 b that extend upwardly from the wash plate. Right edge 56 a and left edge 56 b meet at an angle 58 a and angle 58 a of all three faces 54 meet at a common point 60 . Right edge 56 a and bottom edge 56 c of each face meet at right angle 58 b and left edge 56 b and bottom edge 56 c of each face meet at left angle 58 c.
It can be seen in FIGS. 2 and 3 that left edge 56 b of a first face is positioned along right edge 56 a of a second face and right edge 56 a of a first face is positioned along left edge 56 b of a third face and right edge 56 a of a third face is positioned along left edge 56 b of a second face to form three edge junctures 62 . Left angle 58 c of a first face abuts right angle 58 b of a second face and right angle 58 b of a first face abuts left angle 58 b of a third face and right angle 58 b of a third face abuts left angle 58 b of a second face to form three points 64 that are positioned substantially on the wash plate 22 . It is preferable that the three edge junctures 62 do not form sharp edges and the common point 60 does not form a sharp point. The junctures and common point may be somewhat rounded or multi-faceted to prevent clothing from being damaged. As shown in FIG. 2, the protrusion 52 has three smooth, rounded junctures 62 and points 64 and one smooth, rounded common point 60 .
The protrusions 52 are positioned on the skirt within the sections and an equal number of protrusions may be provided within each section. The protrusions 52 act like “fingers” poking at the clothes to open them up. There should be enough protrusions to open the clothes and allow an even distribution of the wash liquid, but not too many protrusions so that the clothes slide across the top of the “fingers” resulting in twisting of the clothes. It is found that three protrusions 52 a , 52 b , 52 c work well within each of the three sections 50 formed by the three fins 36 .
The three protrusions 52 consist of one inner protrusion 52 b and two outer protrusions 52 a , 52 c . Each of the protrusions is positioned a radial length L from the midpoint 28 of the center area. It is found that positioning the protrusions 52 at more than one length from the midpoint increases their effectiveness. The preferred wash plate embodiment provides a first length L 1 for the inner protrusion 54 b and a second length L 2 for the outer protrusions 52 a , 52 c.
While the present invention has been described with reference to the above described embodiment, those of skill in the art will recognize that changes may be made thereto without departing from the scope of the invention as set forth in the appended claims.
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A wash plate for a clothes washer having upwardly extending fins and triangular shaped protrusions spaced between the fins. A hub extends upwardly from the center of the wash plate to keep clothes separated. The wash plate has holes provided on the surface to allow mixing of wash liquid and draining of water from clothing. The fins assist in pushing clothing in a circular motion around the hub and the triangular protrusions open the clothes. Opening the clothes keeps them from tangling and allows wash liquid and water to be more evenly dispersed on the clothing.
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TECHNICAL FIELD
The present invention relates to a pipe handling system, especially a new preferably electrically operated pipe handling system.
The invention also relates to a new type of fingerboard, especially for co-operating with an electrically driven preferably pipe-shaped pipe handling machine.
The invention also relates to a sidestep retraction system.
BACKGROUND OF THE INVENTION
The object of the invention is to provide an improvement in a pipe handling system. The object is achieved by the inventive features as defined in the appended claims and as described in the following.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view illustrating an embodiment of an arrangement in a pipe handling system according to the present invention.
FIG. 2A and 2B are side views of a pipe handling machine included therein.
FIG. 3 is a top view of a pipe handling fingerboard included therein.
FIG. 4a illustrates a prior art fingerboard.
FIG. 4b-4d illustrates alternative fingerboards according to the invention.
FIG. 5a-5d depict the principle function of the pipe handling according to the present invention, i.e.:
FIG. 5a illustrates pipe handling machine grips pipe at well center.
FIG. 5b illustrates pipe handling arm retracted for bringing pipe into finger locking ring groove.
FIG. 5c illustrates pipe handling arm rotating to select finger.
FIG. 5d illustrates pipe handling arms extended for bringing pipe into fingers.
FIG. 6a-6c are various views of the locking ring of the fingerboard according to the present invention.
FIG. 7a-7d illustrate the principles of the operation of the sidestep retraction system according to the present invention.
FIG. 8 is a side view of a derrick equipped with a drill block in accordance with the invention, shown centrally placed over the drill pipe.
FIG. 9 is a side view where the drill block is retracted from the central position to have connected thereto additional drill pipe sections
FIG. 10 shows the arrangement in same position as FIG. 9, but where the drill block and connected equipment are in upper position.
FIG. 11 shows the arrangement in plan view and horizontal section.
DESCRIPTION OF EMBODIMENTS
With reference to the enclosed drawings, various embodiments of the present invention and various concepts relating thereto, will be described.
The pipe handling system and the machine included therein will be built to fit into the derrick or rig floor design 1A. The main principles of the design are illustrated especially in FIGS. 1 and 2A and 2B.
The machine is based on a tower 1 built from for example 700 mm diameter pipe with two operating arms 2a, 2b built into the tower 1. This gives a very clean outside design. The tower 1 will be fixed in a position in the derrick and rig floor to handle all pipe operations between the well center --fingerboard--mouse hole.
The main load is taken on the rig floor. The pipe is handled by the two independently operated arms 2a, 2b, which may be compared with scissor arms.
The scissor arm principle used gives a horizontal in-out movement. This principle is easy to control with regard to position accuracy.
Using the scissor arm principle gives a very controlled extended reach. The forces imposed on the tower/arm/carriages are less than on other designs, by using this principle.
All drives are preferably based on A.C. motors with disc brakes driving through gear boxes, which operate on rack and pinion, driving the arms up and down--in and out. The A.C. motors are speed controlled by invertors. Proposed supplier of motor, brake, gear box, invertors is S.E.W. Eurodrive, using standard components. Using A.C. motor drives will give a controlled high speed and a very clean pipe handling machine (no hydraulic leaks).
The pipe handling machine is an independent unit not mechanically connected to the iron roughneck. This has caused problems in other designs including too much downtime due to units connected together. Prior designs also required the pipe handling and iron roughneck work to be carried out very close to the well center, creating the potential for clash problem in pipe handling wit top drive/block. An independent unit, only connected together with the other machines through the control system, iron roughneck, top drive is a better solution.
The upper and lower arms 2a, 2b are generally of the same design. They are, in the illustrated embodiment, not mechanically connected together, only electrically by the control system. The arms can be operated as independent arms if so required. They can operate at different angles of the pipe. (Other designs have problems with connected arms, as they can only be operated mechanically and are very limited).
A preferred embodiment may be based on a 5" pipe claw (3a) with 2 tons lift. The pipe handling machine is designed for high speed tripping of drillpipe. For handling drill collars the machine will only position the drill collars in the set-back using the drawworks to lift the load. This will give a faster pipe handling for more than 95% of the operating time.
Based on 2 tons lift at 2.5 m, it is estimated that the total weight of the machine with supports and fingerboard will be 14.403 Kg.
The claw design is based on a slip principle with an air operating cylinder. This is a fail-safe device. The load has to be removed before the slips can operate. Only the bottom claw 3a holds the load. The top claw 3b is only used to hold the pipe into position. A load cell is built into the pipe handling machine to give the operator and control system information on weight in the claw. The claws 3a, 3b will also have a sensor for sensing pipe inside claw.
The control system may be based on a Siemens robotic control system "SIROTEC RMC" and a "SIMATIC S 51354" for operator communication and interfacing with other systems (e.g., iron roughneck, fingerboard, top drive, block position, slips, etc.).
The pipe handling machine is designed to work in a robotic semiautomatic mode with one operator. The operator can also operate in a remote manual mode if so required. The control system is designed for high accuracy, high operating speed, high security--with very good control over interface between other systems.
Maintenance equipment has been considered by using standard motor/gear box/rack and pinion drives, so as to give the rig mechanics and electricians a rapid understanding of the equipment.
The design will reduce the number of personnel working close to the drill pipe 4P. The operator will have a very good communication with the driller. With all pipe positions programmable, the pipe handling controls are very easy to operate. This leads to less work and lower stress which, in turn, increases the safety and efficiency of the operation.
The overall design provides an improved automatic unit compared with existing pipe handling units which are in operation today. The present invention provides especially a favourable combination of electrical and mechanical equipment and control systems to make an effective automatic pipe tripping machine.
FIGS. 3-6 illustrate star fingerboard concept, in which the top element 4 includes fingers 4a, 4n which are all pointing towards the center of the pipe handling machine 1.
The reason for orientating the fingers 4a-4n in this manner, is to have the pipe handling machine 1 mounted in a fixed position with a minimum of movements, the machine 1 will turn around its "stationary" vertical axis of rotation 1c, and thus manoeuvre its arms 2a, 2b towards the well center or towards the actual finger, the arms 2a, 2b then being manoeuvered straight into and out of the pipe holding finger slots 4x.
The star fingerboard concept will fit into all types of derricks or masts and the benefits thereof can be listed as follows:
The star fingerboard concept allows a fixed position of the pipe handling machine 1.
A fixed position provides benefits as to:
a) Less movements, easy control
b) Slim design, due to less forces, less weight, less space
c) Faster and safer pipe handling
The star fingerboard 4 will give a good racking capacity.
Locking of fingers will be done very easy with a locking ring 4R around the top of the pipe handling tower 1.
d) The fingers 4a-4n will be strong with slim tips 4T and wide root 4.
e) The star fingerboard will also be easy to operate manually.
FIG. 4a illustrates a prior art fingerboard, in which a mobile unit or wagon 4M must be used for handling the pipes.
FIG. 4b-4c illustrate various embodiments of fingerboards adapted to various pipe types and dimensions.
FIG. 5a-5d depict the principle function of the pipe handling according to the present invention, i.e:
FIG. 5a illustrates pipe handling machine arm 2b grips pipe 4P at well center.
FIG. 5b illustrates pipe handling arm retracted for bringing pipe 4P into finger locking ring groove 4G.
FIG. 5c illustrates pipe handling arm rotating to selected fingers or finger slot 4x.
FIG. 5d illustrates pipe handling arm 2b extended for bringing pipe 4P into fingers.
FIG. 6a-6c illustrate details of a locking ring 4R.
In FIG. 7-11 there is illustrated a sidestep retraction system which is designed for use with a top drive drilling system.
A top drive drilling system is functioning with a wire block system in the top of the drilling tower. It serves the purpose of lifting and lowering various equipment. An example of such equipment is a drilling machine for the drill pipe to be rotated, which equipment is connected through a joint to the block taking the form of a wagon which is guided by vertical guide rails.
When drilling for water, gas or crude oil it is necessary to bring the drilling block with connected equipment up and down while the drill pipe maintains its drilling position.
Today this problem is solved by retracting the block with equipment between the guide rails and the drill pipe.
This is space consuming and results in unwanted wire bend. The moment of force will, while drilling, become larger and create larger stress factors. This results in increased dimensioning.
This invention can solve some of these problems and make it possible to design a smaller space demanding derrick. It will reduce the moment of force on the guide rails as well as avoid the bended wires when retracting from a symmetric position over the drill pipe.
This is achieved primarily by arranging the drill block decentralized and designed as characterized in the appended claims.
By decentralized design of the drill block, the retracting operation will demand less space. It is of greater importance in space critical area and will result that the construction can be significantly dimensionally reduced compared with previous methods. With this invention the wires will not have negative stress factors.
With reference to enclosed drawings and descriptions, the following will describe an embodiment of a sidestep retraction system.
In FIGS. 7 through 11 of the drawings reference number 11 is a drill block in the derrick. The drill block 11 is connected through a joint link 12 with the equipment unit 13, for example a drilling machine for drilling of the drill pipe 14.
The equipment 13 is guided by a wagon 15 on vertical guide rails 16.
In drilling position the drill block 11 and equipment 13 connected thereto are kept in a central position over the drill pipe 14.
Wires 17 are connected to and from the top block 18 in the top of the derrick.
A hydraulic cylinder operated skid mechanism 19 is connected to the drill block 11, which in turn is mounted on the wagon 15.
In order to change directions of the wire closest to the vertical centerline of the derrick, the top block 18 comprises a turnable roller 20, which by a joint arm 21 is connected to the top block 18. A skid system is arranged by guiding the roller 20 with a hydraulic cylinder 22 connected with a top block 18. The block 18 and the guide roller 20 can exert pressure on the adjacent wire, with the effect of decentering the direction of the wire to a position of choice. This is particularly so when the drill block 11 is in retracted position, see FIGS. 9 and 10, and shown in a broken line in FIG. 11.
When the drill block 11 with connected equipment 13 is retracted to give space for a new drill pipe section 14', the hydraulic cylinder 19 is activated and will bring the drill block 11 decentralized (sideways) position away from the central area over the drill pipe. This opens the possibility to connect new drill pipe sections 14' even before the drill block 11 is retracted to upper position.
In order to also move the wire 17 in the same direction as the drill block 11 and bring this also sideways away from the central area in the derrick, the hydraulic cylinder 22 at the top block 18 moves the skid roller 20 against the adjoining pair of wires 17.
When the drill block with connected equipment including the wire is brought to a retracted position, the parts shown in FIGS. 9 and 10 will take the position as shown by the broken line in FIG. 11.
FIG. 11 illustrates the platform deck 23, the derrick 24 and the fingerboard 25 where drill pipe sections are stored in a vertical position. The various drill pipes can be transported between the fingerboard 25 and the mousehole with the use of the pipe handling machine previously discussed, and with a fingerboard arrangement as illustrated in FIG. 5a-5d.
In accordance to the invention the retracted drill block 11 is laterally decentralized, which means that the center axis is parallelly moved.
This movement, as shown in FIG. 11, will take place by moving the drill block 11 parallel to the guide rails 16 as well as the fingerboard slots 25'.
This system creates less moment forces and demands less space than conventional known methods where the drill block is retracted between the guide rails 16 and the drill pipe 14 towards the outer limits of the derrick.
With the guided wires at the top block, no negative factors will occur, as with the normal techniques.
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The invention relates to an arrangement in a pipe handling system, especially for handling pipes (4P) in connection with a derrick 1A, wherein the arrangement comprises a tower (1) and two preferably individually controlled operating arms (2a, 2b). The pipe handling system operates favorably in connection with a finger board (4) in which all fingers (4a, 4n) are pointing towards the center of the pipe handling system and especially towards a disc-shaped locking unit (4R) mounted on the top of the tower (1), and in connection with a side-step retraction system designed for use with a top drive drilling system.
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BACKGROUND
Selectively openable ports are used in the downhole drilling and completions industry for enabling fluid communication between tubulars, annuli, etc., in a variety of applications. Some systems use one or more slidable sleeves for providing the selective control of the ports. One way of increasing the pressure rating of the system is to increase the wall thickness of the components of the system. However, this can become very expensive and result in the need for a larger borehole or an unnecessarily large usage of radial space. As a result, the industry always well receives new port control systems having improved pressure ratings.
BRIEF DESCRIPTION
A system for selectively enabling fluid communication between two volumes, including a tubular having a port housing with at least one port; a member disposed with the tubular and movable between a closed position in which the port is closed and an open position in which the port is open; a lock element positively engaged with both the member and the tubular for maintaining the member in the closed position; and an actuator in keyed engagement with the lock element for biasing the lock element, wherein actuation of the actuator releases the lock element to resiliently spring into engagement with solely one of the member or the tubular for enabling the member to move relative to the tubular to the open position for opening the port.
A method of selectively enabling fluid communication between two volumes, including running a system having a member radially disposed with a tubular, the tubular having at least one port, the port closed when the member is in a closed position and open when the member is in an open position; maintaining the member in the closed position with a lock element positively engaged with both the member and the tubular, the lock element in keyed engagement with an actuator for biasing the lock element; pressurizing the system for actuating the actuator for releasing the lock element to resiliently spring into engagement with solely one of the member or the tubular for enabling relative movement between the member and the tubular; and depressurizing the system for moving the member to the open position to open the port.
BRIEF DESCRIPTION OF THE DRAWINGS
The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
FIG. 1 is a cross-sectional view of a system for enabling selective fluid communication between opposite radial sides of a tubular in an initial run-in position;
FIG. 2 is an enlarged view of the area encircled in FIG. 1 ;
FIG. 3 is a cross-sectional view of a locking assembly of the system of FIG. 1 taken generally along line 3 - 3 ;
FIG. 4 is a cross-sectional view of the system of FIG. 1 under high tubing pressure for actuating a piston to release the locking assembly of FIG. 3 ;
FIG. 5 is a cross-sectional view of the system of FIG. 4 after tubing pressure has been dropped for enabling actuation of an outer sleeve and fluid communication between an inner passage and outer volume via a set of ports;
FIG. 6 is a cross-sectional view of the system of FIG. 5 in which an inner sleeve is shifted for selectively opening the ports after the outer sleeve has been actuated; and
FIG. 7 is a cross-sectional view of a balanced piston embodiment requiring an isolation device to be set before ports can be opened.
DETAILED DESCRIPTION
A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
Referring now to FIG. 1 , a system 10 is shown including a tubular 12 formed, e.g., from a first sub 12 a and a second sub 12 b . The system 10 as illustrated in FIG. 1 is arranged for being initially run in a borehole or the like. In one embodiment, the first sub 12 a is an upper sub and the second sub 12 b is a lower sub. The system 10 includes a port housing 14 that is secured between the subs 12 a and 12 b . The housing 14 includes at least one opening or port 16 therein. An inner sleeve 18 is radially disposed within the tubular 12 , having at least one opening or port 20 initially aligned with the port 16 in the coupling 14 .
Initially, as shown in FIG. 1 , the alignment of the ports 16 and 20 enable fluid communication between an interior passage 22 of the tubular 12 and a chamber 24 formed by an outer sleeve 26 . As described in more detail below, the sleeve 26 is actuatable to release the ports 16 and 20 from the chamber 24 in order to enable fluid communication between the interior passage 22 and an outer volume 28 (e.g., a casing annulus) located radially outwardly of the system 10 . Of course, other actuatable members such as valve mechanisms, rods, pistons, etc. could be used in lieu of the sleeves as disclosed herein for selectively opening ports. The ports 16 and 20 and the sleeve 26 are arranged, for example, to selectively enable fluid communication between a tubing and casing annulus in a downhole completion for providing fluid circulation therebetween, for providing high pressure fluid for fracturing a formation wall, etc. Also, for example, it is to be appreciated that the sleeve 26 could be any other actuatable member for opening a port or opening.
A retainer 30 is included affixed to the tubular 12 between the tubular 12 and the sleeve 26 for retaining a spring 32 . The spring 32 urges a ring 34 of the sleeve 26 in a direction opposite the retainer 30 . However, the sleeve 26 is initially locked by a locking assembly 36 . The locking assembly includes a snap ring 38 disposed in both a groove 40 formed in the sub 12 a and a groove 42 formed in the sleeve 26 , as shown in more detail in FIG. 2 . As shown in FIG. 3 , a rod piston 44 includes a key member 46 engaged with both ends of the snap ring 38 , which is formed as a substantially c-shaped ring. Locking both ends of the snap ring 38 with the key member 46 biases the snap ring 38 radially inwardly, as the snap ring 38 is arranged to expand radially outwardly or spring open in order to return to its neutral position. The snap ring 38 could take forms of other elements for providing a similar selective positive locking of the tubular 12 and sleeve 26 , e.g., a leaf spring or other resilient or spring-like member, disposed in the grooves 40 and 42 and springing or expanding out of the groove 40 upon release from the key member 46 . Further, the grooves 40 and 42 could be formed as notches or any other feature for enabling positive engagement of the snap ring 38 with the sleeve 26 and/or the tubular 12 . Relative movement of the sleeve 26 with respect to the tubular 12 is prevented while the snap ring 38 is disposed in both the grooves 40 and 42 , as the snap ring 38 causes positive interference between these components.
By increasing the tubing pressure (i.e., pressurizing the interior passage 22 ), the sleeve 26 is urged against a stop 48 of the sub 12 b due to pressure in the chamber 24 . Simultaneously, a piston chamber 50 for the piston 44 is pressurized via a channel 52 . Pressurizing the passage 22 , and therefore the piston chamber 50 , actuates the piston 44 toward the sub 12 b as shown in FIG. 4 . Actuation of the piston 44 moves the key member 46 axially out of engagement with the ends of the snap ring 38 , thereby releasing the snap ring 38 to expand radially outwardly fully into the groove 42 and out of the groove 40 . When released from the key member 46 , the snap ring 38 is thus no longer locked in the groove 40 and accordingly no longer prevents relative movement between the sleeve 26 and the tubular 12 . The groove 40 and snap ring 38 may include complementarily sloped surfaces for assisting in the tubular 12 expanding the snap ring 38 into the groove 42 when relative movement between the sleeve 26 and the tubular 12 begins. A release member 54 , e.g., a set screw, could be included to prevent premature actuation of the piston 44 , i.e., until a predetermined minimum pressure is reached in the chamber 50 . A check valve 55 may also be included to hold the piston 44 in the actuated position once sufficient pressure has been introduced to the chamber 50 .
When tubing pressure is dropped, as shown in FIG. 5 , the sleeve 26 , now released from the locking assembly 36 as discussed above, is urged by the spring 32 toward the sub 12 a . The spring 32 shifts the sleeve 26 until the ring 34 travels in the axial direction past a stop 56 of the sub 12 a . The stop 56 receives the spring 32 and prevents further movement of the sleeve 26 . By shifting the sleeve 26 , the ports 16 and 20 have become opened to the volume 28 for enabling fluid communication between the interior passage 22 and the volume 28 . Of course, it is to be appreciated that the above-described components could be radially reversed but following a similar method, i.e., for enabling fluid communication between radially inner and outer volumes, but instead being actuated by the pressure in the outer volume. Further, it is to be noted that the unique arrangement of the currently described embodiments enables a higher pressure rating with respect to prior systems without the need to increase radial size.
After actuation of the sleeve 26 , the ports 16 and 20 can be selectively opened and closed by shifting the inner sleeve 18 , as shown in FIG. 6 . For example, the inner sleeve 18 includes a locking profile 58 for enabling shifting of the sleeve 18 by a standard shifting tool and wireline methods and equipment (not shown), which are well known in the art and require no further description.
Another embodiment is shown partially in FIG. 7 . Specifically, a system 60 is shown including many of the same components as the system 10 , which components are similarly numbered and included for the reasons discussed above. However, unlike the system 10 , the system 60 is of a balanced piston design. That is, a balanced piston 62 , in lieu of the piston 44 , is associated with a first piston chamber 64 and a second piston chamber 66 , the chambers 64 and 66 disposed at opposite ends of the piston 62 . The piston chamber 64 is in communication with the passage 22 via a channel 68 . The piston chamber 66 is in communication with the passage 22 via the channel 70 . In another embodiment, the channel 70 could be formed axially between the chamber 66 and the chamber 24 (the retainer 30 positioned in the chamber 24 and not dynamically sealed to the sleeve 26 , or including passages therethrough), with the chamber 24 open to the passage 22 via the ports 16 and 20 , for achieving the same results.
Thus, by merely pressurizing the passage 22 , a differential pressure will not be formed across the piston 62 , as both chambers 64 and 66 are open to tubing pressure. If a differential pressure is not formed across the piston 62 , the piston 62 will not actuate, thereby preventing the sleeve 26 from opening the passage 22 to the volume 28 via the ports 16 and 20 . Accordingly, actuation of the piston 62 is only possible if isolation is first achieved between the chambers 64 and 66 . In FIG. 7 , an isolation device 72 is shown in the passage 22 for isolating the chambers 64 and 66 from each other. For example, the isolation device 72 could be a service packer sealing opposite ends from each other, a ball, plug, or dart landing in a seat for blocking the passage 22 , or any other suitable means for isolating or sealing the chambers 64 and 66 from each other.
While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
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A system and method for selectively enabling fluid communication between two volumes includes a tubular having a port housing with at least one port and a member disposed with the tubular and movable between a closed position in which the port is closed and an open position in which the port is open. The system further includes a lock element positively engaged with both the member and the tubular for maintaining the member in the closed position. Further, an actuator is in keyed engagement with the lock element for biasing the lock element for enabling the member to move relative to the tubular to the open position for opening the port.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is directed to an apparatus for producing textured products. More particulaly, the present invention relates to an apparatus for producing fibers or filaments of protein products which have a fibrous or crispy texture. Examples of protein products having a fibrous texture include foods which are intended to be used as substitutes for meats; and examples of protein products having a crispy texture include foods which serve as substitutes for breakfast cereals.
2. Description of the Prior Art
In copending application Ser. No. 481,853, filed June 21, 1974 and entitled "PROCESS FOR THE PRODUCTION OF TEXTURED PRODUCTS", there is described a process by means of which it is possible to obtain textured products, more particularly, textured protein products, which can very well be used as substitutes for meat or other foods. This process basically establishes that in order to obtain a good orientation of the molecules in the finished textured product while at the same time making the process trouble free and economical, the filaments produced from the raw products are treated in a fluid medium which travels at a speed which is lower, equal or higher than the speed of the continuous filaments as they exit from a spinneret, tube or the like.
According to Robert Boyer, in U.S. Pat. No. 2,682,466, dated June 29, 1954, the filaments are oriented by means of a series of rollers which exert a traction on the filaments due to the fact that the filaments are picked up by the rollers and that the rollers rotate at increasing speed relative to one another. This apparatus can be used only for obtaining a mechanical drawing of the filaments. However, the process which uses rollers for drawing the fibers is quite sophisticated. On the other hand, there is a definite possibility of breaking the filaments which may cause all sorts of problems. It is therefore an object of the present invention to provide an apparatus which will enable the drawing of the filaments or fibers to be carried out in a fluid medium, without running the risk of breaking the filaments, while at the same time making sure that the process is economical.
SUMMARY OF THE INVENTION
This invention relates to an apparatus for producing textured products which comprises:
(A) MEANS FOR PRODUCING A DISPERSION OF RAW PRODUCTS,
(B) MEANS FORMING FILAMENTS FROM SAID DISPERSION OF RAW PRODUCTS,
(C) MEANS ESTABLISHING A FLUID MEDIUM,
(D) MEANS FOR FEEDING SAID FILAMENTS INTO SAID FLUID MEDIUM, AND
(E) MEANS FOR COAGULATING SAID FILAMENTS.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings which illustrate the invention,
FIG. 1 is a diagram of a unit for producing textured proteins according to the invention;
FIG. 2 is a large scale view of the spinning unit;
FIG. 3 is a section taken along a line 3--3 of FIG. 2;
FIG. 4 is a longitudinal view of a spinning tube associated with a coagulating tube;
FIG. 5 is a longitudinal view of another spinning tube also associated with a coagulating tube;
FIG. 6 is a section taken along a line 6--6 of FIG. 4;
FIG. 7 is a section taken along a line 7--7 of FIG. 5;
FIG. 8 is a view of a modified unit for producing and drawing filaments;
FIG. 9 is a view from above of the unit illustrated in FIG. 8;
FIG. 10 is a view of a filament produced when the apparatus is operating a Δ v > O;
FIG. 11 is a view of a filament produced when the apparatus is operating at Δ v = O; and
FIG. 12 is a view of a filament produces when the apparatus is operating at Δ v > O.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, more particularly, FIGS. 1 to 7, the device illustrated comprises inter alia a tank 1 to which are connected feed ducts 3 and 5 for respectively introducing into the tank 1, water at 100° C and sodium alginate. As shown in FIG. 1, the feed duct 5 is in the form of a dispensing funnel. The tank 1 also comprises a stirrer 7 by means of which it will be possible to thoroughly mix the hot water and the alginate in order to obtain a good dispersion of sodium alginate a in water. It should be noted that the combination of dispensing funnel 5 and stirrer 7 is well known in the art.
The device also comprises another tank 9 which is similar to tank 1 and to which are connected feed ducts 11 and 13 which will enable to respectively introduce water at 40° C and proteins into the tank 9. As in the case of tank 1, the tank 9 is provided with a stirrer 15 by means of which it will be possible to mix the water at 40° C and proteins in order to obtain a good dispersion of proteins b in water. The tanks 1 and 9 are in turn connected to a main feed duct 17 by means of exit lines 19 and 21. The main feed duct 17 will serve to feed a mixture of sodium alginate dispersion a and proteins dispersion b into the mixing unit 23.
The mixing unit 23 will be seen to consist of a tank 25 which is somewhat associated with a pump (not shown) and a stirrer 27 all of which will contribute in the thorough mixing of the two solutions a and b originating both in tanks 1 and 9. The unit 23 also comprises an inlet line 29 which will be used for introducing coloring matter such as caramel, beet extract, etc. and various flavoring agents into the mixed solutions.
The apparatus also comprises a colloid mill or disintegrator 31 which is connected to the unit 23 by means of duct 33. The latter is used to first feed the mixture obtained in mixing unit 23 into a funnel 35 after which the mixture is introduced into the disintegrator or colloid mill 31 to be treated therein and to form a homogenized spinning dope c. This type of machine is well known in the art and for practical purposes, one can use the one which is known and sold under the trademark "COMITROL". At the lower end of the disintegrator 31, there is another duct 37 which will be used to carry the spinning dope c obtained in the disintegrator 31 into ballast tank 39. This tank 39 is what could be called a storage unit which is used to receive the spinning dope from the disintegrator 31 via duct 37, and to store large quantities of the same, ready to be used in the succeeding parts of the apparatus. In order to maintain a good homogeneity of spinning dope c in the ballast tank 39, there are provided a pair of stirrers 41 and 43 which of course operate in known manner.
The spinning dope c is now ready to be converted into filaments and this will be carried out in the spinning unit 45 which we will now describe. It will be realized that the spinning unit has only been illustrated schematically in FIG. 1 and for a better illustration of this portion of the apparatus, reference is made to FIGS. 2 through 7 of the drawings.
The spinning unit 45 is connected to the ballast tank 39 by means of duct 46 which also includes a pump 49. It will be realized that the presence of the pump 49 is required for the purpose of always keeping the spinning dope under pressure in the spinning unit. The spinning unit 45 generally comprises an inverted T-shaped tubular member 47 (FIG. 2) which has an upward portion 48 and two lateral portions 51 and 53. The upward portion 48 of the tubular member 47 is closed by a stopper 55 through which extend spinning tubes 57, 59, 61 and 63. It will be realized that spinning tubes 61 and 63 have only been illustrated in FIG. 3 of the drawings and that they have been cut off from FIG. 2 for the purpose of clarity. It is of course understood that any number of tubes can be used depending on circumstances and the dimensions of the tubes and of the stopper 55.
The spinning tubes 57, 59, 61, 63 will therefore connect the pump 49 to the spinning unit 45, more precisely, to tubular member 47.
Each spinning tube 57, 59, 61, 63 is bent inside the tubular member 47 to be directed toward the portion 53 of the tubular member 47.
The portion 53 is closed by a sealing stopper 65 through which extend as many coagulation tubes as there are spinning tubes. In the present case, we will have coagulation tubes 67, 69, 71, 73. The coagulation tubes 67, 69, 71, 73 must have a much larger inside diameter than the outside diameter of the corresponding spinning tubes 57, 59, 61, 63. For example, we may have spinning tubes having an outside diameter of 2.6 mm. while the inside diameter of the coagulation tubes is 1.5 cm. These measurements are of course subject to variation it being understood that their respective dimensions will be adjusted according to the types of proteins that are spun and the amount of drawing required.
As illustrated, each spinning tube enters a corresponding coagulation tube in such a way that after the filaments are forced out of the spinning tube, they will be taken over by the drawing and coagulating fluid d.
The drawing and coagulating fluid d is contained in reservoir 75 which is in communication with the tubular member 47 via duct 77 and pump 79. It should be remembered that the pump 79 will be adjusted to pick up the coagulating liquid d, from the coagulating reservoir 75 and to introduce it into the portion 51 of the tubular member 47. The coagulating liquid d will thereafter enter all the coagulating tubes 67, 69, 71 and 73 to form a picking stream 77 in each coagulating tube, which stream will pick up the filaments at the outlet of the spinneret which is provided at the end of each spinning tube.
It should be remembered that the pump 79 will operate to produce a stream 77 which can be moved at various relative speeds with respect to the speed at which the filaments are delivered into the stream 77. For example, if the speed of the moving stream is lower than the speed of the filaments being delivered into the stream 77, the product will look like absorbent cotton wherein the filament has a very small cross-section and is all intermingled and cut up, as shown in FIG. 12. If on the other hand, the velocity of the picking stream is the same as the speed of the filaments, this should produce a continuous filament with a good cross-section and an undulated outside surface as shown in FIG. 11 of the drawings. Finally, if the speed of the moving stream is higher than the speed of the filaments, the net result will be a well defined thread-like filament as shown in FIG. 10.
To summarize, given Δ v, the difference between the speed at which the picking stream travels and the speed at which the filament is injected into that stream, one can have the three following possibilities:
Δ v < 0
cotton-like bundle of cut-up filaments (FIG. 12);
Δ v = 0
filament with large cross-section and undulated outer surfce (FIG. 11);
Δ v > 0
thread-like continuous filament with small cross-section (FIG. 10).
Turning now to the spinneret and with particular reference to FIGS. 4 and 5, it will be realized that the spinneret can either consist of the outlet end 78 of the spinning tube itself or can also be made of a standard multi-holes spinneret 80. In practice, it may be more useful to use a spinneret of the type illustrated in FIG. 5, for it is less costly per single filament and takes less space in the spinning unit.
The coagulating and drawing tubes 67, 69, 71, 73 extend a certain distance outside the tubular member 47 after which they are connected to a fiber slowing table 81 which has a somewhat flared shape. Coming back to the coagulating tubes 67, 69, 71, 73, it should be pointed out that the diameter of the tubes and the flow from the pump 79 are such that the speed of the coagulating stream inside the coagulating tubes 67, 69, 71, 73 is lower or at least equal to and even higher than the speed at which the jets of spinning dope exit from the spinneret.
The length of the coagulating tubes is also important and sould be made dependent on the amount of coagulation necessary to give a self-supporting fiber and to give the desired amount of stretching to the fiber.
The length of the coagulating tubes should also depend on the time of coagulation. It must also be remembered that the diameter of the fiber and the physical characteristics of the spinning dope are directly related to the coagulating time (viscosity, aeration, etc.).
It will be seen that upon coagulation the jet of spinning dope is solidified and thereafter becomes a fiber. The time of residence of the fiber in the coagulating tube should be sufficiently long to enable it to keep its shape.
It should be noted that the friction of the liquid bath against the fiber increases with the length of the coagulating tube. The tube should be sufficiently long to give the desired amount of stretching to the fiber.
Following the slowing down system 81, there is a further coagulation unit 83 to finalize the coagulation of the fiber, the unit 83 incorporating a conveyor 85 which is used for further carrying the fibers. A portion of the liquid passing through the slowing down system 81 is recirculated to reservoir 75 via duct 82, along which there is provided a bath regeneration unit 82a and a pump 82b. Bath regeneration unit 82b will be used for monitoring and regenerating acids and salts in the coagulating bath.
At the exit 86 of the coagulation unit 83 there is a downward prewashing conveyor 87 which is followed by a final washing bath 89 which also includes a conveyor 91. A recirculating duct 92 along which a pump 92a is mounted connects both ends of the coagulation unit 83, all in the manner illustrated in FIG. 1 of the drawings.
In accordance with another embodiment of the invention, which is illustrated in FIGS. 8 and 9 of the drawings, the coagulating bath d will be contained in a cylindrical container 93 in which there is provided an axially mounted stirrer 95 for inducing a rotary motion to the coagulating bath d. The spinning tube 97 is inside the container and as shown in the drawings is constructed and arranged to produce a continuous filament which tangentially hits the coagulating bath in motion as illustrated in FIG. 9 of the drawings.
If the apparatus is to be operated using ingredients such as proteins, homogenizing agents, coloring matter, flavoring ingredients, such as onions, beef, chicken, fish, other seafoods, etc., the first step includes the dissolving of the alginates which can also be a mixture of various gums depending on the properties such as viscosity, etc., which one wishes to obtain in the spinning solution. These properties are mainly aimed at obtaining a solution which can easily coagulate and form fibers in which firmness is easy to control.
Dissolving of the alginates is carried out in tank 1 with the aid of the combination mixing funnel and stirrer 5, 7. At the same time, proteins of various sources, such as soya, colza, wheat gluten, corn, cotton, kidney beans, milk, etc., are hydrated in water which is heated between 40° and 100° C in order to produce a solution which is homogeneous and has no lumps in it. This is carried out in tank 9. It is also possible to add in tank 9 small amounts of sodium metabisulphite, such as 0.1%. After the two solutions have been prepared respectively in tanks 1 and 9, they are thereafter mixed together in the mixing unit 23. At this point, the coloring matter, such as caramel, beet extract, and the various flavoring agents, are added.
From then on, the combined solution is passed into the disintegrator 31 which will be used to complete the dispersion. The mixture obtained consists of an aerated spinning dope c, which has a viscosity varying between 5000 and 50,000 centipoises, and which is stored in ballast tank 39 while stirring in order to prevent the formation of lumps. Although this has not been shown in the drawings, it is possible to mount a unit for de-aerating the paste. This unit will be mounted on ballast tank 39.
The next step comprises the coagulation, drawing and washing of the fibers and it would seem to be quite important in order to obtain the desired final texture in the product.
Coagulation is carried out in bath d which contains an acid and a salt, said bath being in movement and having a pH between 1 and 4. In the case illustrated in FIG. 1, the coagulating bath is circulated from the container 75 into the spinning unit 45. In the embodiment illustrated in FIGS. 8 and 9, the bath is induced into rotation and the filaments are injected into the bath at a speed less than the rotation speed of the bath which itself will make sure that the filaments will be drawn. As we have indicated above, the spinning unit 45 consists of a tubular T-shaped member in which the spinning tubes are inserted and in which the coagulating bath d flows. The spinnerets are all of the same length and of the same inner diameter in order that the spinning dope exit at the same speed from each of the spinning tubes.
In the drawings, we have shown four spinning tubes. It is obvious that this number can be decreased or increased depending on the product desired. Many systems of injecting the spinning dope can be combined such that the same solution is fed into them. The pump 49 which pushes the mixture of protein and alginate into the spinning tubes is preferably of the positive action type such as a Waukesha pump. The pump must be able to deliver a pressure of the order of 75 to 500 pounds per square inch.
As shown in the drawings, the coagulating bath enters the member 47 in portion 51 thereof. Obviously, the jets which are produced by the spinnerets and the coagulating solution circulate inside the apparatus in the same direction in parallel relationship to one another.
After the filaments have been formed and coagulation has been initiated in the coagulation tubes, the fibers are slowed down in slowing down unit 81. This is for the purpose of preventing the fibers from being crushed in the final coagulation unit 83. In addition, the slowing down of the fibers enables to obtain a good distribution of the fibers before they enter the final coagulation unit 83. The latter will be seen to consist of a coagulation tank 84 and a conveyor 85 which is movable in the coagulation tank 84.
The final step includes prewashing at 87 and a final washing at 89. Unit 87 includes a sloping table with pressure water jets for washing fibers.
Final washing is carried out in unit 89 which has a tank 90 and a conveyor 91 to move the filaments in the bath f.
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This invention relates to an apparatus for producing textured products which comprises means for producing a dispersion of raw products, means forming filaments from the dispersion, means establishing a fluid medium, means for feeding the filaments into the fluid medium, and means for coagulating the filaments. Given Δv, the difference between the speed at which the fluid medium travels and the speed at which the filaments are introduced into the fluid medium, the apparatus can be adjusted in the following manner:
Δv < 0,
product: cotton-like bundle of cut-up filaments;
Δv = 0,
product: filament with large cross-section and undulated outer surface;
Δv > 0,
product: thread-like continuous filament with small cross-section.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is broadly concerned with an improved expansion joint assembly adapted for bridging adjacent, elongated, relatively shiftable structural sections in order to accommodate normal settling or other movement of the sections. More particularly, the invention is concerned with such an expansion joint assembly having as a part thereof a filler in the form of a compressible, resilient body including a plurality of walls defining a series of openings in the body permitting the latter to alternately compress and expand in response to movement of the assembly. This allows full and free movement of the expansion joint which is not possible using conventional thick-walled filler strips which allow only limited movement and are subject to bulging when compressed.
2. Description of the Prior Art
Expansion joints have long been used in floors and walls of buildings in order to accommodate normal relative shifting movement occurring by virtue of settling or thermal cycling. In the case of floor expansion joints, such have included a pair of extruded aluminum supports fixed to adjacent joint-defining structural sections, together with a bridging member in overlying relationship to the joint and operatively engaging the space supports. These assemblies are constructed so as to permit relative movement between the bridging member and adjacent supports, thereby insuring that the joint is covered at all times and does not present a hazard to traffic.
Many types of prior expansion joints makes use of filler strips between the rigid extruded aluminum supports and the bridging cover. These fillers are typically formed of thick-walled elastomeric material in order to support traffic loads. However, this construction inherently means that the range of movement of the expansion joint assembly is restricted. Moreover, these fillers tend to bulge when compressed, causing a traffic hazard.
There is accordingly a real need in the art for an improved expansion joint assembly making use of a thin-walled filler which not only permits essentially complete movement of the assembly but also avoids the problem of bulging when the filler is compressed.
SUMMARY OF THE INVENTION
The present invention overcomes the problems outlined above and provides an improved expansion joint preferably including a perforate, resilient compressible filler in lieu of conventional elastomeric fillers.
Broadly speaking, the expansion joint assembly of the invention includes a pair of elongated supports respectively coupled to a pair of adjacent structural sections cooperatively defining therebetween an expansion void of nominal width. An elongated bridging member presenting a pair of side margins and having a width greater than the nominal width of the expansion void is also provided, with each of the side margins operatively engaging a corresponding support for spanning the void. In addition, a space is provided between at least one of the margins of the bridging member and adjacent portions of the corresponding support for accommodating movement of the bridging member during shifting of the structural sections. A filler is disposed within this space and comprises a compressible, resilient body including a plurality of walls defining a series of openings in the body, so that the latter may alternately compress and expand in response to relative movement between the bridging member and supports.
In more detail, the filler is advantageously a honeycomb material comprising a plurality of serpentine walls each presenting a series of alternating, oppositely directed peaks along the lengths thereof, with the walls being connected peak-to-peak to define a series of cells between the walls. This type of honeycomb material is commercially available as commercial grade honeycomb, sold by Hexcel, Inc. of Pleasanton, Calif.
In actual practice, a cover may be disposed over the perforate filler, but given the strength of the latter the cover need only be a light metallic (e.g., aluminum) plate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary vertical sectional view of a corner expansion joint assembly in accordance with the invention operably coupled between a wall and floor;
FIG. 2 is a fragmentary plan view of the assembly illustrated in FIG. 1 with parts broken away for clarity and certain parts being shown in phantom;
FIG. 3 is a vertical sectional view of a floor expansion joint assembly pursuant to the invention and operably coupled between a pair of adjacent floor sections;
FIG. 4 is a fragmentary plan view of the assembly depicted in FIG. 3, with parts broken away for clarity and certain parts shown in phantom; and
FIG. 5 is an enlarged plan view of a portion of the preferred honeycomb filler used in the expansion joint assemblies of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to the drawings, and particularly FIGS. 1-2, a corner expansion joint assembly 10 is illustrated. The assembly 10 is adapted to cover an expansion void 12 defined between a pair of structural sections, namely floor section 14 and adjacent wall section 16.
Broadly speaking, the assembly 10 includes a pair of elongated, extruded aluminum supports 18, 20 respectively coupled to the sections 14, 16, an elongated, extruded aluminum bridging member 22, resilient filler 24 and lightweight aluminum filler cover 26.
In more detail, support 18 is adapted to be positioned within a rectangular cutout region 28 in floor section 14, and includes a lowermost, apertured, floor section-engaging web 30 as well as an upper web 32 spaced above the web 30 as shown. The righthand end of support 18 is in the form of an elongated, generally C-shaped section 34 integral with the webs 30, 32. The end of support 18 remote from void 12 is in the form of an upstanding, elongated apertured sidewall 36. The support 18 is secured to floor section 14 by means of plural threaded fasteners 38 extending through lower web 30. Conventional grout 39 is employed to fill the remainder of the cutout region 28 of the section 14 as depicted.
Support 20 is adapted for coupling to wall section 16 and includes an elongated channel member 40 presenting a planar outer section as well as a pair of inwardly extending legs 42, 44. A plurality of fasteners 46 extending through the outer section of the channel member 40 and into wall section 16 are employed for securing support 20 in place. It will be noted in this respect that leg 42 is in direct engagement with wall section 16, whereas a space is provided between the inner butt end of leg 44 and wall section 16. Moreover, a resilient, elongated bladder 48 is secured to leg 40 and extends downwardly therefrom.
Bridging member 22 is designed to cover the expansion void 12 as best seen in FIG. 1. To this end, the expansion member includes an elongated, rigid metallic (aluminum) plate 50 having a width greater than the nominal width of void 12 and presenting a pair of integral side margins 52, 54 respectively adapted for engaging the corresponding supports 18, 20. In particular, the side margin 26 is in the form of a block 56 whose underside is adapted to freely slide along the upper surface of web 32. A space 57 is therefore defined between the lefthand face of block 56 and the adjacent face of sidewall 36.
Side margin 54 on the other hand is in the form of an elongated web 58 oriented transverse to plate 50. The upper end of web 58 presents an outwardly extending locking rib 60, with the web 58 extending through the opening between leg 44 and section 14 and into the confines of channel member 40.
Filler 24 is best illustrated in FIG. 5, where it will be seen that the filler includes a plurality of side-by-side webs 62 each presenting along the length thereof a series of alternating, oppositely directed peaks 62a. The webs 62 are interconnected peak-to-peak in order to define a large number of voids 64. In plan configuration, the filler 24 is at least about 90% voids, thereby allowing the filler to undergo significant compression. By the same token, by virtue of the construction of the honeycomb-like filler, it resiliently expands when compressive forces are reduced. As will be readily apparent from a study of FIGS. 1, 2 and 5, the filler 24 is oriented with the respective webs 62 extending along the length of the space 57 between side margin 52 and sidewall 36.
The most preferred filler material is the commercially available HRH-78 Nomex commercial grade honeycomb sold by Hexcel, Inc. of Pleasanton, Calif. This material is described in Hexcel Data Sheet 4400, which is incorporated by reference herein. Various sizes of this HRH-78 material may be used in the context of the invention.
Cover 26 is in the form of an elongated, thin metallic (e.g., 1/8" thick) plate 66 having a width sufficient to cover space 57 and engage the upper surface of block 56 and side margin 36. The plate 66 is secured in place by means of a plurality of metal screws 68 extending into side margin 36 as shown.
In use, the assembly 10 is operable to accommodate relative shifting between the sections 14, 16. During such shifting, the respective side margins 52, 54 of the bridging member 22 will move relative to the fixed supports 18 and 20. This may cause movement of side margin 52 toward and away from sidewall 36, i.e., the width of space 57 may vary. In such a case, the filler 24 serves to compress or expand as necessary to maintain its position within the space 57. The filler 24 is very strong and resists crushing under traffic loads. At the same time, significant compression of the filler causes essentially no bulging or upward movement thereof, thereby eliminating one of the significant problems with prior elastomeric fillers.
FIGS. 3-4 illustrate a similar expansion joint assembly 70 adapted for covering a void 72 between a pair of adjacent floor sections 74, 76. Again, the assembly 70 includes a pair of rigid metallic supports 78, 80 respectively secured to the sections 74, 76, as well as bridging member 82 operatively coupled with the supports and bridging void 72. In this instance, a pair of fillers 84, 86 are used, along with corresponding filler plates 88, 90.
The integral metallic supports 78 and 80 are very similar, each including a lowermost web 92, 94, C-shaped sections 96, 98 and upper webs 100, 102. Upper web 102 terminates in an upstanding sidewall 104 as depicted, whereas a depending, generally, elongated U-shaped segment 106 is provided at the inner end of web 100; an inner sidewall 108 extending upwardly from segment 106 completes the support 78. Grout 109 is used to fill the cutout regions of the sections 74, 76 where the supports 78, 80 are attached.
Support member 82 is in the form of an elongated, apertured metallic plate 110 of width sufficient to span the width of void 72 and having a pair of depending side margins 112, 114 respectively and slidably engaging the upper webs 100, 102. A pair of elongated spaces 116, 118 are thereby defined between side margin 112 and sidewall 108, and between side margin 114 and sidewall 104.
A plurality of screws 120 extend through plate 110 and into void 72 as best seen in FIG. 3. Each of the screws 120 is in turn connected with a laterally extending connector 122, the latter being operatively secured with ball-like elements 124, 126 respectively disposed within the C-shaped sections 96, 98. The connector 122 and elements 124, 126 serve as a guide and assist the assembly in conforming with the relative movement of sections 74, 76.
Two separate fillers 128, 130 are used in conjunction with assembly 70, i.e., the filler 128 is located within space 116, and filler 130 is within space 118. The fillers 128, 130 are identical with filler 24 described with reference to assembly 10.
Filler plate 88 is a thin metallic member and presents a depending leg 132 extending downwardly along the length of sidewall 108 and into U-shaped segment 106. A laterally extending section 134, integral with leg 132, extends across the top of filler 128 and engages the upper surface of plate 110. Filler 86 on the other hand is in the form of a planar metallic plate member 136 which is secured to sidewall 104 by means of metal screws 138. The plate 136 likewise engages the upper surface of plate 110 as shown, thereby covering the filler 130.
The operation of assembly 70, insofar as the function of fillers 128, 130 is concerned, is identical with that described with reference to assembly 10. That is, the respective fillers 128, 130 are compressed or expand in order to accommodate movement of the bridging member 82, all without bulging and while providing adequate support for normal traffic.
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An improved expansion joint assembly (10, 70) is provided for bridging an expansion void (12, 72) between adjacent, relatively shiftable structural sections (14, 6, 74, 76). The assembly (10, 70) includes a pair of supports (18, 20, 78, 80) respectively secured to the sections (14, 16, 74, 76), as well as a bridging member (22, 82) operatively engaging the supports (18, 20, 78, 80). A resilient compressible filler (24, 128, 130) is located between a bridging member (22, 82) and adjacent portions of the supports (18, 20, 78, 80). The filler (24, 128, 130) is preferably in the form of a compressible, resilient body including walls (62) defining a series of openings (64), so that the filler can accommodate significant movement without bulging or failure.
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This invention relates to raster output scanners, and more particularly, to a technique for producing both start of scan timing signals and laser beam intensity differential signals using a single light sensing element.
BACKGROUND OF THE INVENTION
Electrophotographic marking is a well known method of copying or printing documents by exposing a substantially uniformly charged photoreceptor to an optical light image of an original document, discharging the photoreceptor to create an electrostatic latent image of the original document on the photoreceptor's surface, selectively adhering toner to the latent image, and transferring the resulting toner pattern from the photoreceptor, either directly to a marking substrate such as a sheet of paper, or indirectly to a marking substrate after an intermediate transfer step. The transferred toner powder image is subsequently fused to the marking substrate using heat and/or pressure to make the image permanent. Finally, the surface of the photoreceptor is cleaned of residual materials and recharged in preparation for the creation of another image.
While several exposure systems have been developed for use in electrophotographic marking, one commonly used system is the raster output scanner (ROS). A raster output scanner is comprised of a laser beam source, a means for modulating the laser beam (which, as in the case of a laser diode, may be the action of turning the source itself on and off) such that the laser beam contains image information, a rotating polygon mirror having one or more reflective surfaces, pre-polygon optics for collimating the laser beam, post-polygon optics for focusing the laser beam into a well-defined spot on the photoreceptor surface and for compensating for a mechanical error known as polygon wobble, and one or more folding mirrors to reduce the overall physical size of the scanner housing. The laser source, modulator, and pre-polygon optics produce a collimated laser beam which is directed to the reflective polygon facets. As the polygon rotates, the reflected beam passes through the post-polygon optics and is redirected by folding mirrors to produce a focused spot that sweeps along the surface of the charged photoreceptor. Since the photoreceptor moves in a direction that is substantially perpendicular to the scan line, the spot sweeps the photoreceptor surface in a raster pattern. By suitably modulating the laser beam in accordance with the position of the spot, a desired latent image can be produced on the photoreceptor.
Some raster output scanners employ more than one laser beam. Multiple laser beam systems are advantageous in that higher overall process speeds can result if the individual laser beams expose the raster scan lines in parallel at a given resolution, or higher resolution can be provided if the individual laser beams expose multiple raster scan lines at the same process speed. Multiple laser beams can be produced by optically splitting one beam into multiple paths and individually modulating each component, or by incorporating multiple independent laser sources. Typically, raster output scanners that employ multiple sources have a parallel path architecture with closely spaced beams. Parallel, closely spaced laser beams are beneficial in that they can be arranged to share common optical components including the same polygon facets, the same post-polygon lens, and the same mirror system. This tends to minimize relative misalignment errors caused by manufacturing differences in the optical components.
To assist the understanding of the present invention, several additional factors should be understood. First, a phenomenon known as scan line jitter exists in electrophotographic printing. Scan line jitter refers to the failure of pixels in successive scan lines of the raster to be precisely aligned with each other. To help reduce scan line jitter it is common to position a photodetector element in the scan line path just ahead of the latent image area in order to establish accurate data clock phasing on successive scans, a technique generally referred to as start-of-scan detection. When a laser beam crosses the photodetector, a fast start-of-scan transition or edge is produced which is used to initialize the pixel clock controlling the phase of the data stream that modulates the laser beam. Second, in high quality multiple laser beam imaging systems it is important that the individual laser beams deliver the same light flux at the photoreceptor so that the resulting latent image is uniformly exposed. Achieving uniform exposure with independent sources is difficult since each device has slightly different characteristics such as lasing threshold and efficiency at the same operating current. Additionally, the behavior at different operating temperatures and the effects of aging on different sources also can be quite different. Therefore the ability to dynamically regulate the effective exposure provided by the individual laser beams can be important.
Most prior art start-of-scan detectors employ differential sensing using split photodetectors located a short distance upstream from the plane of the photoreceptor. Even though the scan line is slightly out of focus at this position, the differential split photodetector configuration preserves timing accuracy by utilizing common mode rejection to compensate for fluctuations in overall beam intensity. However, because of the high response speed required, the differential split photodetector configuration usually incorporates local electronic circuitry components which are located well away from other electronic subsystems. As a consequence, special electrical hardware harnesses, connectors, and special mounting structures for the start-of-scan detector electronics are often required. One alternative that avoids many of these difficulties is the use of low cost plastic light-pipes or multimode fibers to route the light from the vicinity of the photoreceptor to a more desirable location for the associated light detection circuitry. In this arrangement, a detection method that is insensitive to variations in beam intensity is still required. Furthermore, since multimode light-pipes are significantly larger in cross section than a typical spot in the image plane (as much as 500-700 microns verses 43 microns or smaller), the light is substantially diffused by the time any flux reaches the light sensor.
While the production of a start-of-scan signal and the regulation of the intensities of multiple laser beams can be carried out independently, with separate photodetectors and separate preamplifiers for each, this substantially increases costs and manufacturing and assembly overhead while reducing overall system reliability. Therefore, a technique for achieving start-of-scan detection and dynamic beam intensity regulation of multiple laser beam systems using a single photodetector element would be beneficial. Furthermore, such a technique that can be used with an optical fiber would be even more beneficial.
SUMMARY OF THE INVENTION
The principles of the present invention provide for start-of-scan detection and dynamic beam intensity regulation of multiple laser beams using a single photodetector system. A raster output scanner according to the principles of the present invention includes a plurality of laser sources for generating a plurality of laser beams, a rotating polygon having one or more reflecting mirror facet for sweeping the laser beams along a scanning path, and a photodetector for receiving light flux from the multiple laser beams and for converting the flux into beam-dependent electrical currents. The raster output scanner further comprises a scan detection circuit for producing a start-of-scan signal from the beam dependent current, and a beam intensity circuit for producing an electrical output signal which is a measure of the difference in exposing power of at least two laser beams. Beneficially, a raster output scanner according to the present invention includes an optical fiber with a light receiving end positioned at a predetermined location in the scanning path to collect a portion of the light flux in the sweeping laser beams, and an exit end directing the laser beam flux onto the photodetector.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates an electrophotographic printing machine which incorporates the principles of the present invention;
FIG. 2 is a top view of the raster output scanner used in the electrophotographic printing machine illustrated in FIG. 1;
FIG. 3 schematically illustrates a sensor network which produces a start-of-scan signal and a beam intensity control signal for use in the electrophotographic printing machine of FIG. 1;
FIG. 4 assists in explaining the operation of the sensor network illustrated in FIG. 3;
FIG. 5 illustrates the beam intensity signal from the sensor network of FIG. 3;
FIG. 6 illustrates the response waveform of a tangentially offset raster scanner system;
FIG. 7 illustrates a method of providing well-defined rectilinear boundaries for the input end of an optical fiber; and
FIG. 8 illustrates an alternative method of providing well-defined rectilinear boundaries for the input end of an optical fiber.
In the drawings, like numbers designate like elements. Additionally, the text includes directional signals which are taken relative to the drawings (such as right, left, top, and bottom). Those directional signals are meant to aid the understanding of the present invention, not to limit it.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates an electrophotographic printing machine 8 designed to produce original documents. Although the principles of the present invention are well suited for use in such machines, they are also well suited for use in other devices. Therefore it should be understood that the present invention is not limited to the particular embodiment illustrated in FIG. 1 or to the particular application shown.
The printing machine 8 includes a charge retentive component in the form of an Active Matrix (AMAT) photoreceptor 10 which has a photoconductive surface and which advances in the direction indicated by arrow 12. Photoreceptor 10 is mounted on a drive roller 14 and tension rollers 16 and 18, with the drive roller 14 being turned by a drive motor 20.
As the photoreceptor advances, each part of it passes through the subsequently described processing stations. For convenience, a single section of the photoreceptor, referred to as an image area, is identified. The image area is a part of the photoreceptor that will be processed by the various stations to produce toner layers. While the photoreceptor 10 may have numerous image areas, each is processed in the same way. Therefore, a description of the processing of one image area will suffice to explain the operation of the printing machine 8.
As the photoreceptor 10 advances, the image area passes through a charging station A. At charging station A, a corona generating scorotron 22 charges the image area to a relatively high and substantially uniform potential, for example -500 volts. While the image area is described as being negatively charged, it could be positively charged if the voltage levels and polarities of the other relevant sections of the printing machine are appropriately reconfigured. It is to be understood that the scorotron 22, as well as the other components mentioned herein, is supplied with electrical power as required for proper operation.
After passing through the charging station A, the photoreceptor advances to an exposure station B. At exposure station B the charged image area is exposed by a dual laser diode raster output scanning assembly 24 that raster scans the image area with multiple (two) laser beams to form an electrostatic latent image of a first color, say black. Laser diodes 150 and 151 in FIGS. 1 and 2, are individually modulated to create beams 103 and 104 that expose separate and distinct scan lines in the raster. While various aspects of the raster output scanning assembly 24 are described in more detail subsequently, it should be understood that the raster output scanning assembly includes an optical fiber 102 strategically placed in the path of the laser beams 103 and 104 such that light flux collected by the optical fiber 102 from either source is guided to a sensor network 106. The sensor network 106 generates a start-of-scan signal 108 and a differential beam intensity signal 110 from the detected light flux in a manner that is described subsequently. The sensor network 106 also generates a diode select signal 112. Signals from the sensor network 106 and an image data source control laser driver circuit 152, which provides a timed data stream that represents the desired image in the form of electrical current that excites the laser diodes 150 and 151.
After passing the exposure station B, the exposed image area is transported through a first "discharged area development" station C, where a negatively charged development material 26 comprised of black toner particles is advanced onto the image area. The development material is attracted to the less negative discharged sections of the image area and repelled by the more negative unexposed sections. The result is a first toner layer on the image area corresponding to the first electrostatic latent image. It will be recognized by those skilled in the art that the present invention can be applied in the case of charged area development, and that the development structures illustrated in FIG. 1 and labeled C, F, G, and H, are of a design suitable for advancing toner particles suspended in a liquid solution to the surface of photoreceptor 10. However, it should be understood clearly that the present invention is not limited to the particular embodiment shown.
After passing the first development station C the image area advances to a transfusing module D that includes a positively charged transfusing member 28, which may be a belt as illustrated in FIG. 1, or a drum, forming a first transfer nip 29 with the photoreceptor surface. The first transfer nip is characterized by a first region of compression or pressure between the photoreceptor 10 and the surface of transfusing member 28. The negatively charged toner layer on the photoreceptor is attracted by the positive potential of the transfusing member.
After the first toner image is transferred to the transfusing member 28, the image area passes to a cleaning station E which removes residual development material and other residue from the surface of photoreceptor 10 using one or more cleaning brushes contained in housing 32.
The image area is again advanced through the charge-expose-develop-transfer-clean sequence for a second color of developer material (for example, yellow). Charging station A recharges the image area and exposure station B illuminates the recharged image area with an optical raster representation of a second color of the composite image (yellow) to create a second electrostatic latent image. The image area is then advanced to a second development station F, where negatively charged development material 34 comprised of yellow toner particles is deposited on the image area in a pattern corresponding to the second electrostatic latent image. The image area and adhered toner pattern advances to the transfusing module D where the second color toner is transferred to the transfusing member 28 in superimposed registration with the first toner layer.
The image area is again cleaned by the cleaning station E, and the charge-expose-develop-transfer-clean sequence is repeated for a third color of development material 36 (magenta for example) using development station G, and for a fourth color 38 (cyan) of development material using development station H.
The transfusing member 28 is entrained between a transfuse roller 40 and a transfer roller 44. The transfuse roller is driven at constant velocity by a motor, which is not shown, such that the transfusing member advances in the direction 46 at the same velocity as photoreceptor 10. The spacing between successive image areas is regulated to match the circumference of transfusing member 28 in order to maintain mechanical synchronism and allow the various toner images to be transferred to the transfusing member 28 in proper registration.
Still referring to FIG. 1, the transfusing module D includes a backup roller 56 which rotates in direction 58. The backup roller 56, which is opposite the transfuse roller 40, forms a second nip with the transfusing member 28, and thus forms a transfusing zone. When a substrate 60 such as a sheet of paper passes through the transfusing zone, the composite toner layer on the surface of transfusing member 28 is heated by thermal energy accumulated from a radiant preheater 61 or from a conductive preheater 62, as well as heat conducted directly from the transfuse roller 40. The combination of heat and pressure in the nip fuses the composite toner layer onto the surface of substrate 60 making a permanent color image.
The present invention is most closely associated with the raster output scanning assembly 24. Referring now to FIG. 2, the raster output scanning assembly 24 laser diodes 150 and 151 which produce laser beams 103 and 104, respectively, are modulated according to image data from the data source and laser driver 152 (which may be physically remote from the raster output scanning assembly 24). The image data from the data source and laser driver 152 might originate from an input scanner, a computer, a facsimile machine, a memory device, or any of a number of other image data sources. The purpose of the data source and laser driver is to excite lasers 150 and 151 with modulated drive currents such that the desired electrostatic latent image is interlaced on the photoreceptor in precise registration with uniform exposure. The output flux from laser diodes 150 and 151 are collimated by optical element 154, reflected by fold mirror 156, and focused on reflective facets 157 of rotating polygon 158 by cylindrical lens 160. The facets of rotating polygon 158 deflect the beams which are then focused into well defined spots focused on the surface of photoreceptor 10 (also see FIG. 1) by scan lens elements 162 and 164.
As polygon 158 rotates, the focused spots trace parallel raster scan lines on the surface of photoreceptor 10. An input end 166 of the optical fiber 102 is positioned in the scan path to collect light flux from beams 103 and 104 at the beginning of the scan. The optical fiber 102 transmits the intercepted flux to the sensor network 106. It should be noted that the scan lines defined by the laser beams 103 and 104 are sufficiently close together and the focused spots small enough in comparison with the geometrical size and shape of optical fiber 102, that both are captured at the input end 166.
FIG. 3 illustrates, in a block diagram form, the functional elements of sensor network 106. It is to be understood that the light flux emerging from the output end of optical fiber 102 is directed onto a fast photodetector 170. The photodetector converts the incident photon flux into photocurrent that is amplified and buffered by an amplifier 172. The amplifier output is applied to a sample-and-hold circuit 174 and to a start-of-scan detector circuit 176. The sensor network 106 is further comprised of a diode select network 178, a polygon position sequential circuit 180, and an AC amplifier 182.
It is noted at this time that, depending upon various design factors, the principles of the present invention can be implemented in many ways. It will be assumed in what immediately follows that the laser beams are sized and aligned and the geometry of the input end 166 of optical fiber 102 has be shaped so that there is no start-of-scan timing differential. That is, either laser beam could be used to generate the start-of-scan signal without measurable scan line displacement. It will further be assumed that the number of polygon facets are known, that a synchronizing signal in the form of a once-around pulse or transition synchronized with the rotation of the polygon is derived by the polygon position sequential circuit, and that the approximate delay times between successive scans intersecting with the input end 166 are known. With these assumptions, at an appropriate time in the scan sequence diode select network 178 enables one of the laser beams, for example laser beam 103, in order to provide the optical flux needed for generating a start-of-scan signal. The diode select network supplies a diode select level on line 112 that causes laser driver circuit 152 to excite laser diode 150 but not laser diode 151. When the resulting flux of laser beam 103 is captured by the input end 166 of optical fiber 102, the photodetector 170 produces a photocurrent response that is amplified and buffered by the amplifier 172. The sample and hold circuit 174 is configured to temporarily store the peak voltage amplitude of amplifier 172 with minimum droop until it is updated by the next cycle of the polygon position sequential circuit 180. Small cyclic shifts in the output voltage of sample and hold circuit 174 are amplified by AC amplifier 182.
During this same time period the start-of-scan detector circuit responds to the output waveform of amplifier 172. Because the input end 166 of optical fiber 102 is relatively large compared with the scanned spots, the output voltage waveform from amplifier 172 plotted with respect to time is rather broad. A representative plot of signals from the amplifier 172 is shown in FIG. 4. Turning now to FIG. 4, it will be assumed that the voltage profile of trace 190 shown as a solid line represents the signal output of amplifier 172 in response to laser beam 103, and the profile indicated by trace 194 shown as a broken line is the response to laser beam 104. The preferred condition for generating a start of scan signal is when the trailing edge of the voltage waveform crosses a threshold reference voltage or trip point 192.
In the preferred arrangement, in order to minimize the timing uncertainty the reference voltage is chosen to coincide with the steepest portion of the trailing edge of the voltage waveform shown in FIG. 4. Those experienced in the art will recognize that several factors affect the choice of the reference voltage. First, the slope of the leading and trailing portions of the voltage waveform are significantly affected by the relative position of the input end 166 of optical fiber 102 with respect to the raster imaging plane. In typical ROS imaging systems as mentioned earlier, most prior art start-of-scan detectors employ differential sensing using split photodetectors located a short distance upstream from the plane of the photoreceptor even though the scan line is slightly out of focus at this position. Thus if the input end 166 of optical fiber 102 is positioned in place of the split detector, the out-of-focus condition reduces the slope of both the leading and trailing edges of the voltage waveforms depicted schematically in FIG. 4, and therefore, like the prior art methods, the timing uncertainty is increased when the sensing aperture is outside the normal depth of focus limits of the scanner.
It will be appreciated that in the case of a high quality scanning system where the focused spot can be described as having a symmetric Gaussian profile, the leading and trailing edges of the voltage vs. time waveforms in FIG. 4 are ideally described as having Gaussian first derivatives where the steepest slope coincides with the 50% level of the waveform. This is not necessarily the case when the spot is distorted by intrinsic wavefront errors or contains complex internal structure due to optical interference. It will be further appreciated that the precision of the present invention is reduced when an irregular portion of an input beam is occluded or the beams are differentially occluded, or when the input end 166 of optical fiber 102 does not present a sharp, preferably rectilinear boundary to incident light flux due to excessive contamination or physical damage. FIGS. 7 and 8 illustrate methods of providing well-defined rectilinear boundaries for the input end 166 of an optical fiber 102. In FIG. 7, external opaque light stops 177 create well-defined rectilinear boundaries, while in FIG. 8 the optical fiber itself is provided with opaque regions 179 to create well-defined rectilinear boundaries. For examples of additional methods for shaping fiber ends to reduce alignment sensitivity and present rectilinear boundaries to the scanning beams, reference is made to U.S. Pat. No. 4,952,022 which is assigned to the assignee hereof and incorporated herein for reference.
Assuming negligible light flux is lost in the fiber and the photodetector element responds rapidly in proportion to the captured flux, the steepest portion of the leading and trailing edges will occur at the nominal 50% level of the waveform. Ideally, the input end 166 of optical fiber 102 is positioned within the nominal depth-of-focus of the scanning system and the light collection aperture is sufficiently wide that the rising and falling edges of the waveform illustrated in FIG. 4 represent the time period of approximately one pixel, and the top of the waveform is relatively flat for a period of from one to ten pixels.
Second, since many factors such as ambient temperature, differential aging rates, facet damage, and contamination of optical surfaces, contribute to changes in the mean optical power of the laser beams, there are also dynamic changes associated with duty cycle heating and other interactions which can be appreciable. Thus in order to minimize the start-of-scan timing uncertainty for similar voltage waveforms of uncertain amplitude, the reference voltage should dynamically adjust in proportion to the actual amplitude of each successive waveform. The split detector schemes of prior art can be interpreted as a version of this approach where the first channel is used to establish a dynamic reference level for the second channel, thereby minimizing timing uncertainty due to fluctuations in the incident beam power.
In the preferred embodiment, the reference voltage for each scan cycle is derived from the amplitude of the waveform by a passive network that establishes the desired reference as a proportion of the waveform peak amplitude that is sequentially captured, for example, by means of a resettable pulse-stretching circuit, or by a separate sample and hold circuit. Ideally the reference value would be proportioned to be 50% of the peak value, but it will be understood that provisions must normally be made to compensate for various circuit voltage offsets and biases. Turning back to FIG. 3, when the start of-scan condition is reached and the trailing edge of the voltage waveform equals the threshold reference value, the start of scan detector generates a fast start-of-scan logic transition on the line 108. That transition is also delivered to the polygon position sequential circuit 180. One function of the polygon position sequential circuit 180 is to identify the specific polygon facet in use during a given scan. For example, if the polygon has 8 facets as shown in FIG. 2, and if facet number one has been selected as the standard facet for intensity measurements, the polygon position sequential circuit 180 tracks the facet sequence and enables the logic that controls the diode select network and initiates the sample and hold sequence that captures the associated output waveform peaks delivered by amplifier 172.
In response to the output of polygon position sequential circuit 180, the diode select network toggles the select command on line 112, which causes laser driver circuit 152 to excite laser diode 151 but not laser diode 150. Thus, the next response from amplifier 172 will be caused by flux from laser beam 104 reflected from standard facet number one. The sample and hold circuit then samples and stores the peak response caused by laser beam 104. As a consequence, the output of the sample and hold circuit continuously toggles between the peak voltage responses to beam 103 and 104 reflected by the same polygon mirror facet.
Turning once more to FIG. 4, traces 190 and 194 represent the waveforms associated with laser beams 103 and 104. As illustrated in FIG. 5, since the peak of trace 194 is slightly less than the peak of trace 190, the input to the AC amplifier 182 is a low level square wave with a period twice the rotational period of the polygon and phase and amplitude relationships that depend upon the difference in exposure power between laser beams 103 and 104. That square wave is amplified by the AC amplifier 182 and the amplified version is output on line 110. Using well known circuitry the signal on line 110 can be employed to dynamically control one or both of the drive currents exciting laser diodes 150 and 151 such that the AC component of the signal on line 110 is minimized and such that the mean amplitude represented by the average peak voltages is maintained at a predetermined calibrated level line. Beneficially, a direct current signal that represents the intensity of the received light flux is output on line 113. That signal can be used to maintain the flux of the laser diodes at the predetermined calibrated level line. Significantly, since a common facet, photodetector, sample and hold, and AC amplifier are used to produce the square wave, the most important sources of common mode measurement errors are minimized. Those familiar with the electronic art will recognize that the relative responses to multiple beams might also be compared by toggling the sources at a high rate near the waveform peak and noting the phase and amplitude of the response. However, this assumes tight tangential alignment of the beams that may not be possible in some scanner designs. It will also be recognized that once the square wave appearing on line 110 has been minimized through action of the control circuitry, traces 190 and 194 can be used interchangeably to establish the start-of-scan threshold reference voltage.
The foregoing has described an apparatus and method for both sensing the start of scan and beam intensity differences of a plurality of laser beams, given the assumption that the laser beams 103 and 104 are sized and aligned so that there is no relative timing differential, that is, either laser beam could be used to generate the start-of-scan signal without measurable scan line displacement. However, the present invention is not limited by such constraints. For example, if the laser beams are offset such that a scan timing differential exists, one could compensate by shifting the data stream by an appropriate number of whole pixels and include an adjustable hardware timing delay in either data path to null any residual timing offset.
However, if the beams are reasonably well aligned, an alternative solution is to excite both laser diodes for sensing the start-of-scan condition since the threshold reference value with both beams simultaneously excited is roughly equal to the peak value of either beam alone once they have been equalized. Turn now to FIG. 6, which presents a graph of the output waveform of amplifier 172 and which will be helpful in explaining how the principles of the present invention can be used when the laser beams are tangentially offset. When the tangential offset of laser beams 103 and 104 is sufficiently large, the resulting responses of the two beams will be well separated in time so that each can be processed without interference from the other. In this embodiment of the present invention, the laser diode sources are excited and their associated waveform amplitudes are captured on sequential scans. For the laser source having the later response, the waveform amplitude is captured and the start-of-scan transition is generated shortly afterward on the trailing edge of the detected waveform. For the laser source having the earlier response, the waveform amplitude is captured, the laser source is quenched, and the diode associated with the later response is excited. As a consequence, the start-of-scan condition is always generated using a response to the later diode.
When the tangential offset produces partial waveform overlap as shown in FIG. 6 with trace 190 occurring before trace 194, a conventional start-of-scan system might produce a start-of-scan output at either the trailing edge of 194, or in the area of the intermediate minimum 196 between traces 190 and 194. It will be appreciated that the waveform slope at any point near the intermediate minimum is necessarily reduced making this region a poor choice for a timing reference point. In a conventional system, the worst case would be when the reference threshold coincides approximately with the minimum dip 196 between traces 190 and 194, so that the start-of-scan condition toggles arbitrarily between the trailing edge and the intermediate minimum 196.
One embodiment of the present invention avoids these uncertainties by using an optical fiber 102 that provides a waveform response with a broad maximum, and takes advantage of the fast response of the laser diode sources. Since the quenching of the laser source having the earlier response and the excitation of the source having the later response is controlled by the select command on line 112, it is straightforward to disable the output of the start-of-scan detector 176 during the transition from exciting one source to exciting the next, thereby avoiding false responses to temporary waveform instabilities caused by the exchange. For example, response to false start-of-scan conditions can be suppressed from just before initiation of the exchange to one data clock after the exchange. Those practiced in the electronic arts will immediately recognize that this is a well known technique used in state machine design for eliminating logic errors caused by voltage "glitches" and similar disturbances. An example of such a transient is shown on the right hand side of the waveforms illustrated in FIG. 4 where trace 190 transitions to the trailing edge 192 of trace 194. The broad waveform provides ample time to capture the peak value and switch from exciting one device to the next on alternate scans while suppressing false responses. The present invention assumes that the laser diodes respond rapidly to changes in excitation, but as those familiar with the art are aware, this is already a laser requirement for imaging in a raster output system. Thus, while simple timing circuitry to enable the start-of-scan circuitry only during a narrow time window might be employed, the preferred method of the present invention eliminates the need for precise timing circuits and provides a more robust solution that can be extended in a straightforward way to multiple beam raster output scanner systems.
It is to be understood that while the figures and the foregoing descriptions illustrate the principles of the present invention, they are exemplary only. Skilled workers in the applicable arts will recognize numerous modifications and adaptations which will remain within the principles of the present invention. Therefore, the present invention is to be limited only by the following claims.
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A technique for achieving both start-of-scan detection and dynamic beam intensity regulation in a multiple laser beam raster output scanner using a single photodetector. The raster output scanner includes a source or sources of a plurality of laser beams, a rotating polygon having at least one reflecting facet for sweeping the laser beams to form a scan line path, and a photodetector for receiving illumination from the multiple laser beams and for converting those beams into beam-dependent electrical currents. The raster output scanner further includes a scan detection circuit for producing a start-of-scan signal from the beam dependent current, and a beam intensity circuit for producing an electrical output signal which depends upon the difference in beam intensity of at least two of the laser beams. Beneficially, the raster output scanner also includes an optical fiber that collects a portion of the light flux in the sweeping laser beams which directs the light flux onto the photodetector.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a jointing structure in vehicle traveling path joints and the like having an expansion function and also to a method of mounting an elastic member therein, and is useful in applications mainly to vehicle traveling path joints in new transit systems, monorails and the like and besides, to road bed plate joints in road bridges, footbridges and the like.
[0003] 2. Description of the Related Arts
[0004] One well-known urban traffic means is a new transit system which makes use of rubber tires to provide traveling on an exclusive vehicle traveling path using a motor, with power fed via a feeder line laid parallel to the traveling path.
[0005] This type of traffic means is such that a vehicle traveling path is built continuously in a belt-like form with concrete on a bridge girder and has an expansion gap in the same position as a bridge girder joint in order to absorb bridge girder expansion or contraction caused by temperature changes or the like.
[0006] With this type of traffic means, a traveling path joint is especially fitted with a rubber or steel expansion joint to prevent the occurrence of tire fallen-in, stuck-in and/or like situations so that the increased riding quality as well as the maintainability of in-traveling safety are provided.
[0007] Regarding an expansion joint applied to an expansion gap and having an elastic function with respect to the bridge girder expansion or contraction, the patent document 1 , for instance, describes an expansion joint having a top-plate reinforcing material laid over the expansion gap, side-plate reinforcing materials respectively fixed to the traveling path ends, and chloroprene rubber or the like adapted to join the top-plate reinforcing material and both the side-plate reinforcing materials together.
PATENT DOCUMENTS ON THE RELATED ARTS
[0008] [Patent document 1] Japanese Laid-open Patent Publication No. Hei.9-59904
[0009] [Patent document 2] Japanese Laid-open Patent Publication No. Hei.10-82002
[0010] [Patent document 3] Japanese Laid-open Patent Publication No. 2000-104204
[0011] [Patent document 4] Japanese Laid-open Patent Publication No. 2003-184006
[0012] However, the rubber expansion joint has encountered with such problem that it is difficult to ensure slip resistance to rubber tires and/or to pass judgement on the time for replacement because of a lack of its durability required for a tire-supporting surface.
[0013] Meanwhile, the steel expansion joint has encountered with, in addition to the problem about the slip resistance to the rubber tires, such problem that it is difficult to be given difference-in-level management by reason that a difference in level is liable to occur between the expansion joint and the traveling path, and consequently, would be considered to have a great effect on the tires and the like unless it is managed in several millimeter units.
[0014] The steel expansion joint has further involved the problem of in-traveling safety by reason that it may well be that tire punctures will occur in course of traveling due to cracks resulting from metal fatigues of mounting bolts or like components.
[0015] With both the above types of expansion joints, there has been still some fear of the tire fall-in and/or stuck-in situations occurring in cases of bridge girder portions in which a greater extent of expansion or contraction caused by temperature changes is found and/or of small-sized vehicles whose tires are small in diameter, in which case, it has been likely to lead to a reduction in riding quality.
[0016] In conventional expansion joint applications, vertical differences in level (which are such that the bridge girders are displaced in their joints on different levels) and/or lateral displacements (which are such that the bridge girders are displaced in their joints perpendicularly to a bridge girder axis) and besides, kinked joints (which are such that the bridge girders are kinked in their joints laterally) and the like when occurred in the joints of the bridge girders due to an earthquake or the like could be left as they were even after the earthquake, or could lead to the complete collapse of the bridge girders under certain circumstances. Accordingly, for the passage of emergency vehicles and the like, it has been necessary to take such emergency measures as to cover the bridge girder joints with steel sheets or the like.
SUMMARY OF THE INVENTION
[0017] It is an object of the present invention to provide a jointing structure in vehicle traveling path joints and the like having an expansion function, more specifically, a jointing structure which is adaptable for applications of various tire configurations different in tire diameter and the like, ensures high slip resistance to tires, permits less occurrence of tire fallen-in and/or stuck-in situations and is easy to be given maintenance, and also to provide a method of mounting an elastic member therein.
[0018] A jointing structure in vehicle traveling path joints and the like having an expansion function according to the present invention comprises more than one step provided face to face at the coaxially built traveling path ends with an expansion gap between, more than one elastic member respectively mounted inside the above more than one step, and a joint block mounted on the above more than one elastic member across the above expansion gap.
[0019] The present invention is to be adapted to prevent, by blocking up the expansion gap in a bridge girder joint with the joint block while permitting an expansion gap function to be maintained, the occurrence of tire fall-in and/or stuck-in situations for the achievement of smooth and safe vehicle traveling (see FIG. 2 ), and is thus useful in applications mainly to vehicle traveling path joints in new transit systems, monorails and the like, i.e., joints of vehicle traveling paths respectively built on bridge girders as an integral part thereof, and besides, to road bed plate joints in road bridges, foot bridges and the like.
[0020] According to the present invention, it will be appreciated that even in the occurrence of any displacement such as the vertical differences in level and/or the lateral displacements and besides, the kinked joints in the joints of the bridge girders especially due to the earthquake or the like, the joint block may be conditioned to be always in the center of the expansion gap thanks to elastic member deformation for the elimination and/or relief of the differences in level and/or the lateral displacements and the like, resulting in the achievement of smooth vehicle traveling without the need for any emergency measures involving the use of the steel sheets or the like.
[0021] It will be appreciated also that the joint block is placed across the expansion gap, and thus, the adequate management of accuracy of each member if given may be adapted to prevent the differences in level from occurring in any joint portion between the joint block and the traveling path.
[0022] It is noted that the use of a joint block made of the same concrete as that of the traveling path may be adapted to provide more substantially increased slip resistance to the tires, as compared with the rubber or steel expansion joint. It is noted also especially that a high-strength fiber-reinforced concrete joint block is as highly durable as hardly worn away, and is thus considered to be suitably applicable to the joint block for use in the present invention.
[0023] The elastic members are desirably of a material that is hard to be deformed vertically and vice verse easy to be deformed horizontally in a soft manner. The present invention employs elastic members mainly consisting of laminated rubber. Further, the elastic members and the joint block are fitted to each other detachably by bolting or the like and consequently, may be easily given the maintenance thereof as well.
[0024] It would be possible also to mount supporting blocks inside the steps with the joint block between in order to protect the traveling path ends with the thus mounted supporting blocks so as to prevent the traveling path ends from being damaged due to tire impingement and/or impact responses and the like at the time of passage of the vehicles (see FIG. 2 ). The supporting blocks may be of concrete or high-strength fiber-reinforced concrete like the traveling path and the joint block.
[0025] In this case, the supporting blocks are fitted detachably to the intra-step traveling path side walls in close contact therewith with mounting bolts or the like to form a continuously extending traveling path surface and consequently, may be easily restored to normal by replacement even if damaged.
[0026] It would be possible also to mount, in a manner that one or more than one intermediate joint block is mounted inside the steps with the joint block between, more than one joint block in the traveling path joint in order to decentralize the expansion gap in the traveling path joint into more than one expansion gap to make the size of each individual expansion gap smaller, so that the occurrence of tire fall-in and/or stuck-in situations may be prevented more surely for the achievement of the increased driving quality (see FIG. 6 ). For instance, the size of the expansion gap in the traveling path joint may be reduced down to one fourth by mounting the intermediate joint blocks one by one to the opposite sides of the intra-step joint block.
[0027] Furthermore, the use of a joint block, supporting blocks and intermediate joint blocks that are of concrete of the same quality as that of the traveling path or of high-strength fiber-reinforced concrete may be adapted to lead to such advantage that the difference in level will be hard to occur in any joint portion between the blocks because of the substantially same-mannered developments of wear on each member, so that the difference-in-level management of the joints becomes more facilitated.
[0028] By reason of a structure which is such that members such as metal members and rubber members are not exposed to the traveling path joints, especially, to the traveling path surface, it is possible not only to eliminate the problems such as developments of rust on these members and degradations thereof but also to prevent scattering of these members for the achievement of the increased in-traveling safety for vehicles.
[0029] It would be possible also to provide, obliquely with respect to the axial direction of the traveling path, the expansion gap in a joint portion between each of the traveling path ends and the joint block in order to prevent the occurrence of tire fall-in and/or stuck-in situations particularly in cases of small-sized vehicles whose tires are small in diameter, while ensuring a required expansion gap (see FIG. 7 ).
[0030] It is noted that it is possible to prevent the occurrence of tire fall-in and/or stuck-in situations in cases of small-sized vehicles whose tires are small in diameter, while ensuring a required expansion gap, also by providing, obliquely with respect to the axial direction of the traveling path, the expansion gap in a joint portion between the joint block and each of the supporting blocks, that in a joint portion between the joint block and each of the intermediate joint blocks and that in a joint portion between each of the intermediate joint blocks and each of the supporting blocks.
[0031] In a method of mounting an elastic member in vehicle traveling path joints and the like having an expansion function and each composed of more than one step provided face to face at the coaxially built traveling path ends with an expansion gap between, more than one elastic member respectively mounted inside the above more than one step, and a joint block mounted on the above more than one elastic member across the above expansion gap, a method of mounting an elastic member in vehicle traveling path joints and the like having an expansion function comprises the steps of joining the above elastic members together across the above expansion gap and fixing the elastic member on one side to the step on one side, then subjecting the thus fixed elastic member to deformation toward the bridge girder axis, and thereafter fixing the elastic member on the other side to the step on the other side.
[0032] It is generally known in the bridge girders of RC construction, PC construction and/or steel-frame construction that the width of the expansion gap in the joint between the bridge girders varies with seasonal changes and temperature changes in a day as well. It is known also that the bridge girders of RC construction and/or PC construction easily produce fluctuations of the expansion gap width even with concrete drying shrinkage and/or creep effects
[0033] In designing the elastic member under such environments, it is the most economical as the elastic member that it is designed so as to permit no deformation to occur in the elastic member too at the time when the drying shrinkage and/or any shrinkage resulting from the creep has come to be convergent and besides, a bridge girder length varying with temperature has reached a median (i.e., a bridge girder length in time of ordinary temperatures) between a bridge girder length in time of high temperatures and that in time of low temperatures.
[0034] For that reason, the elastic member may be mounted without being affected by the seasons and/or the periods of time in a day and besides, by the bridge girder ages. Desirably, the elastic member should be so mounted that it will be conditioned to be free of any deformation therein at the time when the drying shrinkage and/or the creep of the bridge girders has come to be convergent and besides, the bridge girder length in time of ordinary temperatures has been reached.
[0035] In attempting to make setting of the expansion gap in conventional expansion joint applications in order to provide an expansion gap that meets a temperature at the time of mounting and/or the bridge girder ages, expansion gap adjustments have been made by taking steps of predicting a temperature at the time of mounting, then preliminarily adjusting the expansion gap width in a factory and the like, then temporarily fixing the expansion gap with an exclusive fixing jig or the like, and finally releasing the expansion gap from its temporarily fixed state after mounting in a construction site.
[0036] However, by reason that the temperature at the time of mounting is of a predicted value, it is necessary to make expansion gap readjustments in accordance with an actual temperature at the time of mounting in cases where the predicted value is much different from the actual temperature at the time of mounting, resulting in the need for troublesome mounting.
[0037] According to the present invention, it will be appreciated that it is possible to easily mount the elastic member without being affected in any way by the seasons and/or the periods of time and besides, by the bridge girder ages and the like so that it will be conditioned to be free of any deformation therein or in normal position whenever the bridge girder length in time of ordinary temperatures has been reached.
[0038] In this case, it would be possible also to set the expansion gap width in time of ordinary temperatures at a median between the greatest expansion gap width and the smallest expansion gap width in order to minimize the expansion gap of the greatest width and also to avoid bringing the bridge girder ends into contact with each other even if the expansion gap comes to be narrowed.
[0039] It is noted that the elastic members may be easily joined together by mounting, across the expansion gap over the elastic members, the joint block or a backing plate used to mount the joint block (see FIG. 9A ). It is noted also that the elastic members may be easily subjected to deformation by pressing them toward the bridge girder axis using an oil hydraulic jack or the like (see FIGS. 9B and 9C ).
[0040] According to the present invention, it will be appreciated that it is possible to prevent, by decentralizing the expansion gap in the joint between the bridge girders into more than one smaller-width expansion gap with the joint block while permitting the expansion gap function to be maintained, the occurrence of tire fall-in and/or stuck-in situations for the achievement of smooth vehicle traveling. It will be appreciated also that the components such as the joint block are fitted in detachable fashion by bolting or the like and consequently, may be easily given the maintenance thereof.
[0041] It will appreciated also that the present invention is adaptable for applications of various tire configurations different in tire diameter, ensures high slip resistance to the tires, permits less occurrence of tire fall-in and/or stuck-in situations, and is easy to be given the maintenance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] Other features and advantages of the invention will become apparent from the following description taken in connection with the accompanying drawings in which:
[0043] FIG. 1A is a fragmentary side view showing the track of an urban transit system;
[0044] FIG. 1B is an enlarged plan view showing a portion A in FIG. 1A ;
[0045] FIG. 2A is a sectional view, taken on line B-B in FIG. 1B , showing one embodiment of a jointing structure in vehicle traveling path joints and the like having an expansion function according to the present invention;
[0046] FIG. 2B is a sectional view, taken on line C-C in FIG. 1B , showing one embodiment of a jointing structure in vehicle traveling path joints and the like having an expansion function according to the present invention;
[0047] FIG. 3A is an exploded sectional view showing one embodiment of a jointing structure in vehicle traveling path joints and the like having an expansion function according to the present invention;
[0048] FIG. 3B is a perspective view showing another embodiment of the jointing structure in the vehicle traveling path joints and the like having the expansion function according to the present invention;
[0049] FIG. 4A is a plan view showing the traveling path ends in the traveling path joints and the like;
[0050] FIG. 4B is a sectional view, taken on line D-D in FIG. 4A , showing the traveling path ends in the traveling path joints and the like;
[0051] FIG. 5A is a sectional view showing the behavior of an expansion gap in the traveling path joints and the like in association with bridge girder expansion or contraction caused by temperature changes or the like;
[0052] FIG. 5B is a sectional view showing the behavior of an expansion gap in the traveling path joints and the like resulting from bridge girder expansion caused by temperature changes or the like;
[0053] FIG. 5C is a sectional view showing the behavior of an expansion gap in the traveling path joints and the like resulting from bridge girder contraction caused by temperature changes or the like;
[0054] FIG. 6 is a sectional view showing a further embodiment of the jointing structure in the vehicle traveling path joints and the like having the expansion function according to the present invention;
[0055] FIG. 7 is a plan view showing a still further embodiment of the jointing structure in the vehicle traveling path joints and the like having the expansion function according to the present invention;
[0056] FIG. 8A is a plan view showing a still further embodiment of the jointing structure in the vehicle traveling path joints and the like having the expansion function according to the present invention;
[0057] FIG. 8B is a plan view showing a still further embodiment of the jointing structure in the vehicle traveling path joints and the like having the expansion function according to the present invention;
[0058] FIG. 9A is a sectional view showing a method of mounting an elastic member;
[0059] FIG. 9B is a sectional view showing a method of mounting an elastic member; and
[0060] FIG. 9C is a sectional view showing a method of mounting an elastic member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0061] FIGS. 1A to 5C respectively show one embodiment of the present invention wherein a bridge girder 2 serves to support a traveling path 1 adapted for vehicle traveling. The traveling path 1 is of concrete and extends continuously in a belt-like form on the bridge girder 2 in the axial direction thereof. The traveling path 1 is formed as an integral part of the bridge girder 2 and has an upper end surface in a flat form.
[0062] The bridge girder 2 is formed with manufactured girders such as RC girders, PC girders and steel girders. A joint between the bridge girders 2 , 2 has an expansion gap ±ΔL extending perpendicularly to the axis of the bridge girder 2 in order to absorb the expansion or contraction of the bridge girders 2 caused by temperature changes or the like.
[0063] Further, there is provided between the traveling paths 1 , 1 the same joint as the joint between the bridge girders 2 , 2 in the direction perpendicular to the axis of the traveling path 1 in conformity with the bridge girder joint, and the joint between the traveling paths 1 , 1 also has the same expansion gap ±ΔL as the expansion gap ±ΔL in the joint between the bridge girders 2 , 2 in the direction perpendicular to the axis of the traveling path 1 .
[0064] The traveling paths 1 , 1 have, at the ends thereof in the traveling path joint, steps 3 , 3 facing each other with the expansion gap ±ΔL between, and laminated rubbers 4 , 4 are respectively mounted inside the steps 3 , 3 with the expansion gap ±ΔL between.
[0065] The laminated rubber 4 is formed by piling up a thin rubber layer and a steel sheet alternately in multiple layers to place the rubber layers under restraint so that it will be hard to be deformed vertically and vice verse easy to be deformed horizontally in a soft manner.
[0066] Further, the laminated rubber 4 is formed in the shape of a rectangular parallelepiped lengthwise in the direction perpendicular to the axis of the traveling path 1 and has at a lower end thereof a base plate 4 a . And, the laminated rubber 4 is fixedly placed in detachable fashion on a bottom 3 a of each of the step 3 , 3 by fastening the base plate 4 a to the bottom 3 a with more than one anchor bolt 5 .
[0067] Further, a backing plate 6 is mounted on the laminated rubbers 4 , 4 across the expansion gap ±ΔL, so that the laminated rubbers 4 , 4 are integrally joined together through the thus mounted backing plate 6 . Thus, the laminated rubbers 4 , 4 are supposed to get deformed as a unit, following the expansion or contraction or the like of the bridge girders 2 as shown in FIGS. 5A , 5 B and 5 C.
[0068] FIG. 5A shows that the laminated rubbers 4 are being free of any deformation therein (or in normal position) as the result of no development of the expansion or contraction caused by temperature changes or the like on any bridge girder 2 , wherein the backing plate 6 is fixedly placed on the laminated rubbers 4 , 4 . From the seasonal point of view, such deformation-free state is considered to be that found in the spring and/or autumn time with the smallest difference in temperature.
[0069] FIG. 5B shows that the laminated rubbers 4 are being deformed such as to absorb the expansion of the bridge girders 2 caused by the temperature changes as the result of the narrowed expansion gap ±ΔL due to the above bridge girder expansion, and such deformed state is considered to be that found in the summer time from the seasonal point of view. Meanwhile, FIG. 5C shows that the laminated rubbers 4 are being deformed such as to absorb the contraction of the bridge girders 2 caused by the temperature changes as the result of the widened expansion gap ±ΔL due to the above bridge girder contraction, and such deformed state is considered to be that found in the winter time from the seasonal point of view.
[0070] It is noted that the laminated rubber 4 may be also in a square or circular-in-plan form, in which case, such laminated rubber may be mounted to the bottom 3 a in each step 3 in such a manner as to be placed in more than one position. Referring to FIG. 3B , there is shown one laminated rubber arrangement which is such that three pieces of square-in-plan laminated rubbers 4 are spaced at fixed intervals in the direction perpendicular to the axis of the bridge girder 2 .
[0071] The backing plate 6 is formed in the shape of a rectangular plate lengthwise in the direction perpendicular to the axis of the traveling path 1 , and is attached with, respectively in the center and at the opposite ends in the direction of the lengthwise sides thereof, projecting anchor bolts 7 .
[0072] Further, a joint block 8 is mounted on the backing plate 6 , and supporting blocks 9 , 9 are respectively mounted to the opposite sides of the joint block 8 with this joint block between.
[0073] Both the joint block 8 and each supporting block 9 are of the same concrete as the traveling path 1 and in the shape of a rectangular parallelepiped lengthwise in the direction perpendicular to the axis of the traveling path 1 , an upper end surface of the joint block 8 and that of each supporting block 9 being made flush with the upper end surface of the traveling path 1 .
[0074] The joint block 8 has, respectively in the center and at the opposite ends in the direction of the lengthwise sides thereof, loose holes 8 a , 8 b , into which the anchor bolts 7 are respectively inserted.
[0075] Further, the loose holes 8 a , 8 b are respectively charged with a hardening material 10 such as mortar. Thus, the joint block 8 is fixedly placed on the backing plate 6 .
[0076] It is noted that the loose hole 8 a is formed in the shape of a circular cone having a downwardly gradually increasing inner diameter, and the loose hole 8 b at each of the opposite ends of the loose hole 8 a is formed in the shape of a circular cone having an upwardly gradually increasing inner diameter.
[0077] By reason that the loose holes 8 a , 8 b respectively take the shapes as described the above, the joint block 8 is firmly fixed in three positions to the upside of the backing plate 6 . Further, the removal of the joint block 8 from the upside of the backing plate 6 , if required, can be made in such a relatively easy manner as to only crush the hardening material 10 in the loose hole 8 b.
[0078] Each supporting block 9 is fixedly fitted in detachable fashion to the side wall 3 b of each step 3 in close contact therewith with more than one mounting bolt 11 .
[0079] It is noted that it would be possible also to mount the joint block 8 directly on the laminated rubbers 4 , 4 with bolts, adhesives or the like in order to eliminate the need for the backing plate 6 so that a simplified structure may be provided.
[0080] With the above arrangements, it will be appreciated that the expansion gap ±ΔL in the joint between the traveling paths 1 , 1 is blocked up with the joint block 8 so that an expansion gap ±ΔL/2 smaller in width than the expansion gap ±ΔL is provided between the joint block 8 and each of the supporting blocks 9 at the opposite sides thereof, and this allows the occurrence of tire fallen-in and/or stuck-in situations in vehicles to be substantially reduced, resulting in the achievement of smooth vehicle traveling on the traveling path 1 . It will be appreciated also that the absorption of the expansion or contraction of the bridge girders 2 caused by the temperature changes or the like may be achieved as well thanks to the deformation of the laminated rubbers 4 , 4 .
[0081] It is noted that each expansion gap ±ΔL/2 in a joint portion between the joint block 8 and each of the supporting blocks 9 at the opposite sides thereof will be made uniform by adjusting the shear modulus of the laminated rubber 4 .
[0082] It will be appreciated also that the laminated rubbers 4 , the joint block 8 and the supporting blocks 9 are all fitted in detachable fashion so that the maintenance of the joints may be facilitated.
[0083] FIG. 6 shows another embodiment of the present invention which is especially such that the bottom in each step 3 is in the form of a two-stepped bottom composed of a bottom 3 a and a bottom 3 b extending in the axial direction of a traveling path 1 . In this embodiment, first-stage laminated rubbers 4 A, 4 A are respectively mounted on the first-stage bottoms 3 a , 3 a.
[0084] Further, a first-stage backing plate 6 A is mounted on the laminated rubbers 4 A, 4 A across an expansion gap ±ΔL, and on the first-stage backing plate 6 A is mounted a joint block 8 .
[0085] Furthermore, second-stage laminated rubbers 4 B, 4 B are respectively mounted on both the second-stage bottom 3 b and the first-stage backing plate 6 A, and on the second-stage laminated rubbers 4 B, 4 B is mounted a second-stage backing plate 6 B across a space between the laminated rubbers 4 B, 4 B.
[0086] Moreover, an intermediate joint block 12 is mounted between the joint block 8 and each of the supporting blocks 9 , wherein it is fixedly placed on the second-stage backing plate 6 B. The upper end surface of each supporting block 9 , that of the joint block 8 and that of each intermediate joint block 12 are made flush with the upper end surface of the traveling path 1 .
[0087] With the above arrangements, it will be appreciated that the expansion gap ±ΔL in the joint between the traveling paths 1 , 1 is blocked up with the joint block 8 so that an expansion gap ±ΔL/4 smaller in width than the expansion gap ±ΔL is provided between the joint block 8 and each of the intermediate joint blocks 12 at the opposite sides thereof and between each of the intermediate joint blocks 12 and each of the supporting blocks 9 , and this allows the occurrence of tire fallen-in and/or stuck-in situations in vehicles to be substantially reduced, resulting in the achievement of smooth vehicle traveling on the traveling path 1 . It will be appreciated also that the absorption of the expansion or contraction of the bridge girders 2 caused by the temperature changes or the like may be easily achieved as well thanks to the deformation of the laminated rubbers 4 , 4 .
[0088] It will be appreciated also that the laminated rubbers 4 B, 4 B, the joint block 8 , the intermediate joint blocks 12 and the supporting blocks 9 are all fitted in detachable fashion so that the maintenance of the joints may be facilitated.
[0089] It will be appreciated also that each expansion gap ±ΔL/4 in a joint portion between the joint block 8 and each of the intermediate joint blocks 12 at the opposite sides thereof and each expansion gap ±ΔL/4 in a joint portion between each of the intermediate joint blocks 12 and each of the supporting blocks 9 in the case of the embodiment shown in FIG. 6 can be made uniform by adjusting the shear modulus of the laminated rubber 4 .
[0090] FIG. 7 shows a further embodiment of the present invention which is especially such that joint portions between a joint block 8 and each of traveling path steps 3 at the opposite sides thereof respectively have mutually parallel expansion gaps ±ΔL/2 extending obliquely with respect to the axial direction of a traveling path 1 , wherein the joint block 8 is in a parallelogrammic-in-plan form whose two sides respectively facing the expansion gaps ±ΔL/2 are assumed to be oblique sides.
[0091] Other arrangements are substantially the same as the embodiment having been previously described with reference to FIGS. 1A to 5C . According to the embodiment in FIG. 7 , it will be appreciated that the occurrence of tire fall-in and/or stuck-in situations particularly in cases of small-sized vehicles whose tires are small in diameter may be reduced.
[0092] FIGS. 8A and 8B respectively show a still further embodiment of the present invention which is especially such that joint portions between a joint block 8 and each of supporting blocks 9 at the opposite sides thereof respectively have symmetrical expansion gaps ±ΔL/2 extending obliquely with respect to the axial direction of a traveling path 1 , wherein the joint block 8 is in a trapezoidal-in-plan form whose two sides respectively facing the expansion gaps are assumed to be oblique sides.
[0093] With the embodiment shown, the laminated rubber is supposed to be placed with no deformation developed therein (or in normal position) at the time when the expansion gap ±ΔL between the bridge girders 2 , 2 reaches its maximum due to the contraction of the bridge girders 2 caused by the temperature changes. Other arrangements are substantially the same as the embodiment having been previously described with reference to FIGS. 1A to 5C .
[0094] In such arrangements, shifting of the joint block 8 in the direction perpendicular to the axis of the traveling path 1 is applied to meet the fluctuations of the expansion gap ±ΔL with the expansion or contraction of the bridge girders 2 .
[0095] As shown in FIG. 8A , in cases where the expansion gap ±ΔL comes to be widened due to the bridge girder contraction caused by the temperature changes so that the laminated rubber deformation occurs to absorb such bridge girder contraction, the joint block 8 shifts in the direction shown by an arrow in association with the above laminated rubber deformation.
[0096] As shown in FIG. 8B , in cases where the expansion gap ±ΔL comes to be narrowed due to the bridge girder expansion caused by the temperature changes so that the laminated rubber deformation occurs to absorb such bridge girder expansion, the joint block 8 shifts in the direction shown by an arrow in association with the above laminated rubber deformation.
[0097] FIGS. 9A , 9 B and 9 C respectively show a method of mounting a laminated rubber for use in the embodiment having been previously described with reference to FIGS. 1A to 5C , and the procedure thereof will be described in the following.
(1) Firstly, the laminated rubbers 4 are joined together by placing the backing plate 6 across the expansion gap ±Δ over the laminated rubbers 4 , 4 respectively mounted inside the steps 3 (see FIG. 9A ). The backing plate 6 is joined to the laminated rubbers 4 by bolting or with adhesives or the like.
[0099] It is noted that it would be possible also to place the joint block directly across the expansion gap ±Δ over the laminated rubbers 4 , 4 in order to eliminate the need for the backing plate 6 .
(2) Subsequently, the laminated rubber 4 on one side is fixed to the bottom 3 a in the step 3 with the anchor bolts 5 . It is noted that the laminated rubber 4 on the fore side ahead of the expansion gap ±Δ is supposed to be fixed in cases where mounting of the laminated rubbers takes place in the summer time and the like considered that the bridge girder expansion will be ready to occur with increasing temperature (see FIG. 9B ). Meanwhile, it is noted also that the laminated rubber 4 on this side of the expansion gap ±Δ is supposed to be fixed in cases where mounting of the laminated rubbers takes place in the winter time and the like considered that the bridge girder contraction will be ready to occur with decreasing temperature (see FIG. 9C ). The anchor bolt 5 is fitted into a preliminarily embedded insert in the bottom 3 a. (3) Then, an oil hydraulic jack 13 is set inside the step 3 on one side. Then, the backing plate 6 is pressed out toward the bridge girder axis by bringing the oil hydraulic jack 3 into contact with the end of the backing plate 6 . By so doing, the laminated rubber 4 fixed to the bottom 3 a in the step 3 comes to be deformed toward the bridge girder axis. (4) Then, after the deformation of the laminated rubber 4 reaches a predetermined amount, the laminated rubber 4 on the other side is fixed to the bottom 3 a in the step 3 with the anchor bolts 5 . Then, the jack 13 is removed, and it therefore follows that the laminated rubbers 4 , 4 in such form as shown in FIG. 5B or 5 C will be obtained. It is noted that the anchor bolt 5 is fitted into the preliminarily embedded insert in the bottom 3 a.
[0103] It will be thus appreciated that the present invention is adaptable for applications of various tire configurations different in tire diameter, ensures high slip resistance to tires, permits less occurrence of tire fall-in and/or stuck-in situations and is easy to be given the maintenance.
[0104] While the preferred embodiments of the invention have been described, it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims.
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A jointing structure comprising multiple steps provided face to face at the coaxially built traveling path ends with an expansion gap between, multiple elastic members respectively mounted inside the multiple steps, and a joint block mounted on the multiple elastic members across the expansion gap. Multiple supporting blocks and one or more than one intermediate joint block are mounted inside the multiple steps with the joint block between. The multiple supporting blocks, the joint block and the one or more than one intermediate joint block are of concrete. The elastic members are joined together across the expansion gap. The elastic member on one side is fixed to the inside of the step on one side and then subjected to deformation toward the bridge girder axis, and thereafter, the elastic member on the other side is fixed to the inside of the step on the other side.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to ice body delivery mechanisms and in particular to mechanisms for delivering any one of a preselected different quantity of ice bodies to correspondingly different sized receptacles.
2. Description of the Prior Art
In fast food establishments and the like, soft drinks are prepared in suitable cups into which ice bodies, or cubes, are first placed with the liquid portion of the drink being introduced subsequently thereinto. It is conventional to provide different size drinks utilizing different size cups.
It is desirable that preselected quantities of ice cubes be provided in the cups corresponding to the size of the cups so as to provide uniform icing of the drinks. Where manual introduction of ice into the cups is effected, a wide variation in the amount of ice provided in each cup may result, thus causing a wide variation in the icing of the different drinks. It is therefore desirable to effect such accurately metered ice delivery automatically and rapidly.
A number of devices have been developed for use in metering particulate material from a storage chamber to a delivery position. One such metering device is shown in U.S. Pat. No. 307,629, of G. S. Church. Church shows a canister having a delivery tube opening downwardly from a bottom portion of the canister which is adapted to contain grain or other similar material. The delivery tube is provided with a plurality of slots cut halfway therethrough adapted to receive a valve plate which is selectively positionable on a vertical shaft so as to be aligned selectively with any one of the slots. The lower end of the shaft carries a closure valve. Manipulation of the shaft by means of a suitable handle concurrently removes the closure valve from the lowermost portion of the delivery tube and simultaneously introduces an upper valve into the delivery tube so as to permit delivery of only that quantity of the grain in the delivery tube previously above the level of the bottom closure plate and below the level of the adjusted inserted valve plate. Church teaches that the delivery tube be made slightly tapering internally with the larger end lowermost to facilitate the discharge of the grain.
Arthur J. Sylvester, in U.S. Pat. No. 1,517,923, shows a dispensing and measuring apparatus having a measuring chamber which is divided into a plurality of compartments by a number of gates which are pivotally swung between a retracted position externally of the measuring chamber and a measuring position extending across the interior of the measuring chamber. The different gates are spaced vertically so as to provide selectively different quantities of granular material from the measuring chamber. The device is arranged so that the top of the pile of material adjacent the slot through which the gate is inserted slopes away from the slot so as to permit a free space to be provided through which the gate passes before striking the granular material.
Edgar Hayes Moore et al, in U.S. Pat. No. 1,669,624, shows a dispensing device for dispensing odd lots of articles through an outlet spout also using a number of slide valves. The slide valves are arranged to be either completely withdrawn or advanced controlling the delivery of the articles. The device is arranged for dispensing particulate material, such as sugar, and requires separate manipulation of the different valves to deliver the preselected quantity of sugar to a bag placed in receiving position at the bottom of the chute.
James E. Dye discloses, in U.S. Pat. No. 3,181,739, an ice dispenser which dispenses a predetermined amount of ice to each of a plurality of drinking cups. The quantity of ice to be delivered to each cup is provided in a corresponding pocket by means of a paddle which clears excess ice from the top of the pocket. The bottom of each pocket is then concurrently opened to drop the thusly collected ice into the subject receiving cup.
Carmen G. Morena, in U.S. Pat. No. 3,227,313, shows an apparatus for storing and automatically dispensing flowable material, such as solid or liquid detergent. Delivery of the detergent is effected by manipulation of a plurality of control gates which are moved by means of solenoids. The lowermost gate defines a closure member. When it is desired to dispense a preselected amount of detergent such as into the washing machine tub, the user firstly causes one of the measuring gates to be moved across the delivery duct to block off the upper portion of the duct. When the level of the water in the tub reaches a preselected level, a suitable control is actuated so as to then open the lowermost closure gate to thereby dump from the lower end of the delivery duct the detergent disposed therein below the upper selected control gate which is now holding back the material in the upper portion of the duct. Upon completion of the delivery operation, the closure gate is then repositioned across the lower end of the duct and all upper measuring gates restored to the open position, thereby refilling the duct for a subsequent delivery of a measured quantity of detergent therefrom in the same manner.
U.S. Pat. No. 3,516,579, of Carl O. Bromarker, shows a portion dispenser for dispensing food portions to cattle in cattle pens. Each container for delivering food to the cattle pen is provided with a flexible balloon which forms a closed bottom of the container when inflated. The balloons of the respective containers are connected to a compressed air supply and suitable controls are provided for selectively inflating and deflating the baloons. The container space above an inflated balloon is filled with food by a suitable conveyor and the collected food is then discharged by release of the pressure on that balloon to dump the food to the cattle pen.
SUMMARY OF THE INVENTION
The present invention comprehends an improved ice body dispenser including means defining a storage chamber for storing a plurality of ice bodies, means defining a delivery duct having an upper end opening into the storage chamber for receiving ice bodies therefrom, and a lower end for dispensing ice bodies therefrom, a tined element selectively insertable laterally into the duct at a preselected position intermediate the ends to prevent delivery of ice bodies downwardly therepast, closure means for selectively closing the lower end, and operating means for concurrently inserting the tined element into the duct and removing the closure means from the lower end to dispense from the duct those ice bodies previously delivered thereto from the storage chamber disposed above the closure element and below the preselected position.
The tined element may comprise a fork having one or more tines adapted to be freely inserted through the column of ice in the duct with minimum breakage and deformation of the ice as a result of the facilitated insertion provided by the tine arrangement.
The invention further comprehends the provision of additional tined elements spaced vertically from the first named tined element. The operating means is arranged to selectively insert any one of the tined elements into the duct to provide different amounts of ice bodies from the duct as desired.
The control of the delivery of the different amounts of ice bodies may be effected automatically as a function of the size of the receptacle, or cup, placed below the delivery, lower end of the duct.
In the illustrated embodiment, the operating means includes a plurality of switches responsive to the different sizes of the receptacles to effect insertion of corresponding different ones of the tined elements so as to provide a corresponding one of the different quantities of ice bodies provided automatically by the different tine insertions.
In the illustrated embodiment, a support is provided for the cups and the operating means includes control means for detecting the height of the receptacle to provide an indication of the size of the receptacle for controlling the tine insertion operation.
In the illustrated embodiment, a plurality of such delivery ducts is disclosed leading from the storage chamber so as to provide concurrently, or individually as desired, measured delivery of ice bodies from the storage chamber in the manner discussed above.
An agitator means is provided in the storage chamber to effect a suitable agitation of the ice bodies therein to maintain the ice bodies in individual, or separated, condition for facilitated delivery thereof through the duct delivery means. This operation of the agitator means is described more fully in the co-pending application of Keith E. Carr, "Commercial Ice Maker Ice Body Dispenser Hopper and Auger Construction" PA-5013-0-CI-USA, assigned to the same assignee as the present invention.
An opening is provided from the upper end of the duct to the storage chamber extending at an angle to the horizontal. The agitating means causes movement of the ice bodies through the duct opening into the generally vertically extending duct.
The cross-sectional area of the opening to the upper end of the duct is preferably smaller than the cross section of the duct so as to assure facilitated downward delivery of the ice bodies delivered into the duct from the storage chamber.
In the illustrated embodiment, the duct has a constant cross section, but may change to a larger cross section at the bottom to facilitate downward delivery.
The ice body dispenser of the present invention is extremely simple and economical of construction while yet providing the highly desirable features discussed above.
BRIEF DESCRIPTION OF THE DRAWING
Other features and advantages of the invention will be apparent from the following description taken in connection with the accompanying drawing wherein:
FIG. 1 is a side elevation of an ice body dispenser embodying the invention, with a portion of the sidewall broken away to facilitate illustration of the mechanism;
FIG. 2 is a front elevation thereof with a portion of the front wall broken away to facilitate illustration of the mechanism;
FIG. 3 is a fragmentary enlarged horizontal section taken substantially along the line 3--3 of FIG. 1;
FIG. 4 is a fragmentary perspective view illustrating in greater detail the arrangement of the tine and closure plate mechanism; and
FIG. 5 is a schematic electrical wiring diagram of the dispenser.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the examplary embodiment of the invention as disclosed in the drawing, an ice body dispenser generally designated 10 includes an outer cabinet 11 provided with a removable top portion 12 and a base portion 13. The base portion is provided with a grid 14 below which is mounted a drain pan 15. The grid is adapted to receive any one of a plurality of different size cups 16, such as large cups 16a, medium size cups 16b, and small cups 16c, as shown in FIG. 1.
Mounted within the upper portion of cabinet 11 below the removable top 12 is a hopper 17 internally defining a storage chamber 18 for storing a plurality of ice bodies, such as ice cubes 19, to be dispensed into the cups 16, as desired and as shown in FIG. 2.
The ice bodies 19 in storage chamber 18 are agitated therein by means of an auger type blade 20 with its outer edge fit closely to the frusto-conical wall 25, driven by a suitable electric motor 21 having a shaft 22 extending upwardly through a bottom wall 23 of the hopper 17 and secured to the agitator blade 20 by means of a support plate 24.
The lower portion of the hopper 17 upstanding from bottom wall portion 23 defines a frusto-conical wall 25 provided with a plurality of openings 26 which thusly extend angularly to the horizontal and in the illustrated embodiment, at approximately a 60° angle to the horizontal.
Communicating with the storage chamber 18 through the opening 26 is a corresponding plurality of ducts 27 for delivering ice bodies downwardly from the storage chamber 18 into the cups 16 positioned on the supporting grid 14 of base 13. Each delivery duct is similar and, thus, the description of the specific construction thereof will be limited to the description of the duct at the left-hand side of FIG. 2.
As shown, the duct 27 includes a connector portion 28 extending downwardly from the upper wall portion 25 and telescopically receiving the upper end 29 of a lower duct portion 30. The lower end 31 of the duct portion 30 opens through an opening 32 in a cover wall 33 overlying the dispensing space 34 in which the cups 16 are placed on the grid 14 for receiving ice bodies in the dispensing operation.
In the illustrated embodiment, the cross-sectional area of duct 27 is substantially constant and somewhat larger than the cross-sectional area of opening 26 so as to assure a free downward movement of the ice bodies during the dispensing operation. While the cross-sectional area of duct 27 is substantially constant, the lower portion of duct 27 may be made progressively larger in area to facilitate free downward movement of the ice bodies.
Movement of the ice bodies from the storage chamber 18 through opening 26 into duct 27 is effected by the auger type blade 20 concurrently with the effecting of the agitation of the ice bodies in the storage chamber as a result of the lifting action of the ice bodies as they are pushed up the hopper wall 25 by the rotation of agitator 20. This lifting causes a void space under blade 20. The ice bodies below the void space are free of any downward pressure from above therefore they will fall through opening 26 until duct 30 is filled. The blade 20 causes the ice bodies to be pushed up the hopper wall 25 and allows them to return down the center of hopper 17 all as described in the co-pending application of Keith E. Carr referred to above. When duct 30 is filled, continued rotation of blade 20 creates the lifting action, however, the ice bodies below the void space cannot fall through opening 26 so they continue to rotate. As the openings 26 are parallel to the surface of the hopper wall 25, the ice bodies fall therethrough into the upper end of duct 27, and as a result of the somewhat larger cross-sectional area of the duct 27, are freely passed downwardly therefrom into the duct.
A closure plate 35 is provided for selectively closing the lower end 31 of the duct. When the closure plate is disposed across the lower end 31, the duct may be filled with ice bodies from the storage chamber by the action of the agitator 20 for facilitated subsequent delivery of a measured quantity of the ice bodies from the duct to the cup 16 when desired.
As indicated briefly above, the dispenser 10 is adapted to deliver different quantities of ice bodies corresponding to the size of the different size cups placed in the delivery space 34 subjacent the duct end 31. To effect such selective quantity delivery, device 10 includes an operating means generally designated 36 (FIG. 2) having a pivot rod 37 (FIG. 4) having a first end 38 pivotally mounted to a support 39 (FIG. 1), and an opposite end 40 pivotally mounted to a support 41 carried on a frame member 42. The pivot rod 37 is urged to a centered position by a tension spring 43 connected between the frame 42 and an upstanding flange 44 on an extension 45 of the closure plate 35. Thus, as shown in FIG. 4, the closure plate 35 is normally biased to the position in which it closes the lower end 31 of the duct 27 by the spring 43. A stop 46 may be provided for limiting the pivotal movement of the pivot rod or bar 37 by engagement of a stop portion 47 of the pivot bar with the stop 46.
As illustrated in FIGS. 1 and 2, duct 27 is provided with a plurality of approximately 180°-semiannular slots 48, 49 and 50 at vertically spaced positions in the duct. A corresponding plurality of control elements 51, 52 and 53 are associated with the slots 48, 49 and 50, respectively, for controlling the amount of ice bodies delivered from the duct during the dispensing operation. Each of the control elements is similar. As shown in FIG. 4, control element 51 comprises a forked element having a pair of tines 54 and 55 at its distal end 56. The tined elements 51, 52 and 53 are respectively freely pivoted to a vertical pivot rod 57 carried on frame 42 (FIG. 3) for pivotal movement about a common vertical axis at the planes of the respective slots 48, 49 and 50.
The opposite end 58 of the tined element 51 is connected by a suitable tension spring 59 to the frame 42 to bias the forked element in a clockwise direction, as seen in FIG. 4, thereby to move the tines 54 and 55 of the tined element 51 outwardly from the slot in the normal arrangement of the control elements.
Controlled pivoting of the tined elements 51, 52 and 53 is effected by operation of a corresponding plurality of electrical solenoids 60, 61 and 62, respectively. As shown in FIG. 4, a plunger solenoid 63 is connected to a midportion 64 of the tined element by a suitable buffer spring 65. Thus, when the solenoid is energized, the plunger 63 is drawn to the right, as seen in FIG. 4, to pull the tined control element in a counterclockwise direction about the pivot rod 57 against the action of spring 59 and thereby urge the tines 54 and 55 to the right, as seen in FIG. 4 and in FIG. 2. Such movement of the tines 54 and 55 causes them to become inserted through the aligned slots into the duct 27. As the tines comprise elements which may readily penetrate the column of ice bodies in the duct 27 without breaking or chipping the ice bodies, a facilitated insertion of the tines is effected with minimum damage to the ice bodies in the column.
As further shown in FIG. 4, the solenoid plunger may be further provided with an actuating pin 66 which engages the pivot member 37 to pivot member 37 about its ends 41 and 38 concurrently with the movement of the selected tined element. Thus, the closure plate 35 is concurrently moved from its underlying relationship to the duct end 31 to an open position, as shown at the left-hand side of FIG. 2, permitting the ice bodies in the duct to fall downwardly through the lower end 31 of the duct and opening 32 in the cover plate 33 into the receiving cup 16. However, as the tine elements 54 and 55 are now inserted into the column of ice bodies in the duct, only those ice bodies which were disposed in the duct subjacent the level of the selected tined element, such as tined element 51 shown in FIG. 4, will be dispensed during the dispensing operation.
Control of the respective solenoids 60, 61 and 62 is effected by suitable control switches 67, 68 and 69 mounted on a suitable switch panel 70 at the rear of the cabinet, as shown in FIGS. 1 and 2.
Referring now to FIG. 5, the electrical control generally designated 71 includes a first control line 72 connected to power supply lead L1 and a second control line 73 connected to power supply lead L2. The coil 60a of solenoid 60 is connected in series with the switch 67 across lines 72 and 73, solenoid coil 61a of solenoid 61 is connected in series with switch 68 across lines 72 and 73, and coil 62a of solenoid 62 is connected in series with switch 69 across the lines 72 and 73. Thus, depending on the switch actuated by the given cup in the dispensing space 34, one of the solenoids 60, 61 or 62 will be energized to insert its associated tined element into the duct while concurrently removing the closure plate 35 from the bottom of the duct to deliver a preselected quantity of ice bodies from the duct which will automatically be the ice bodies which were in the duct below the level of the selected control element. As these quantities may be accurately preselected and correlated with the sizes of the different cups 16a, 16b and 16c, respectively, proper coordinated icing of the drinks in the different size cups is automatically effected by the simple expedient of placing any one of the different size cups in the dispensing space to engage the associated switch mechanism 67, 68 or 69.
As further shown in FIG. 5, the control may include a left closure plate switch 74 connected in series with a time delay relay 75 across lines 72 and 73. The time delay relay, in turn, may be connected in series with the agitator motor 21 so as to effect a preselected operation of the agitator each time the left closure plate is actuated to effect delivery of ice bodies into a cup in the left side of the dispenser space 34. The time delay causes the agitation to continue for a preselected time suitable to refill the duct 27 upon completion of the previous dispensing operation, as discussed above. More specifically, upon delivery of the ice bodies as discussed above, the de-energization of the selected solenoid permits spring 59 to retract the tines 54 and 55 from the duct and to bring closure plate 35 again to underlying relationship to the lower end 31 of the duct, thereby permitting further ice bodies to be delivered into the duct from the storage chamber by the subsequent energization of the agitator motor 21 during the extended timed interval controlled by time delay 75.
A similar operation is effected relative to the right-hand duct which is controlled by a closure plate switch 77 associated with the right-hand closure plate and solenoid coils 60b, 61b and 62b associated with the control switches 67', 68' and 69', as shown in FIGS. 2 and 5. In the illustrated embodiment, the use of the tined elements 51, 52 and 53 for controlling the quantities of ice bodies delivered provides additionally the function of separating the ice bodies, to some degree, in the duct 27 for further facilitating the dispensing operation. Thus, the tined elements tend to separate rather than crush or break the ice bodies as they are moved into the duct in effecting the desired selective dispensing. Further, by sizing the opening 26 to be smaller in cross section than the duct, a relatively free transfer of the ice bodies in the duct is provided, again providing for facilitated dispensing.
Spring 59 effectively fully withdraws the tines 54 and 55 from the duct in the retracted disposition thereof so as to permit free downward movement of the ice bodies in refilling the duct and during the dispensing operation relative to those forked elements disposed below the selected inserted forked element.
The foregoing disclosure of specific embodiments is illustrative of the broad inventive concepts comprehended by the invention.
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An ice body dispenser arranged to provide preselected different quantities of ice bodies from a storage chamber as a function of the size of a receptacle, or cup, placed in a receiving position below a delivery duct thereof. The dispenser includes one or more control elements selectively insertable into the delivery duct to correspondingly adjust the amount of ice bodies delivered by a concurrent opening of the lower closure member of the device. The device includes control switches which sense the size of the cup placed in the ice body receiving position so as to cause a selective use of the different control elements. The control elements may be fork elements having one or more tines for providing improved column interception with effectively minimal crushing and breaking of the ice bodies in the column.
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RELATED APPLICATIONS
There are no current co-pending applications.
FIELD OF THE INVENTION
The presently disclosed subject matter is directed toward shower accessories. More particularly, the present invention relates to a handheld shower scrubber for those hard-to-reach areas of the body.
BACKGROUND OF THE INVENTION
Bathing is an important function in today's society. People bathe or shower on a daily basis to become clean, eliminate body odor, and remove dirt. It can be very unpleasant to work with someone that has not bathed or showered for some time.
Today, most people tend to shower instead of taking a bath in a tub. The use of a shower instead of a tub saves time and water and can take up less space. Many people are rushed in the morning so getting ready for work, school, and social obligations means one often doesn't have adequate time to fill a tub, bath, and towel dry, and then get ready for their day. Therefore a shower is often more convenient. There is no need to fill a shower with water, which saves time, water, and thus money.
While some showers are very large, some are also small and very cramped. Therefore in many showers a handheld wand is not only useful it is a necessity. As useful or necessary as a shower wand is it still does not solve the age-old problems associated with washing the very hard-reach-areas of the body. While long-handled scrub brushes have been used they often do not enable adequate rinsing, they take storage space, and they can take significant time to use.
Accordingly, there exists a need a device by which a person can scrub and rinse those hard-to-reach body areas without the disadvantages described above. Beneficially such a device would be easy to use and low in cost. Preferably such a device would take the form of a shower wand, would incorporate a selectively used scrub brush, would provide for thorough rinsing, and would be useful for cleaning those hard to reach areas.
SUMMARY OF THE INVENTION
The principles of the present invention provide for a shower wand with scrub brush for scrubbing and rinsing hard-to-reach body areas. Beneficially the shower wand with scrub brush is easy to use, low in cost, takes the form of a shower wand, and incorporates a selectively used scrub brush.
A shower wand with scrub brush that is in accord with the present invention includes an elongated hollow handle having a shower head with a face on one (1) end and a water input on another end. The face includes water apertures for dispensing input water. The handle further includes an elongated slot and a locking feature at an upper end of said slot. The shower wand with scrub brush further includes a brush having a scrubbing feature and an integral arm with a protrusion. The integral arm is configured to slide along the slot and the protrusion is configured to fit into the lock feature. When the protrusion fits into the locking feature the scrubbing feature is in position over the face.
Beneficially the water input is threaded with external threads and a hose is threaded onto the water input. Also beneficially the locking feature locks the brush in an in-use position and prevents the brush from sliding along the slot until the locking feature is unlocked. In practice it is best if the scrubbing feature fits over the face such that the water apertures pass water through the scrubbing feature. Preferably the scrubbing feature includes a porous scrubbing surface.
The shower wand with scrub brush may further includes holder having an input spigot adaptor for receiving water from an existing spigot and a hose adaptor in fluid communication with the input spigot for passing received water into the hose. The holder may further include a handle opening for receiving and holding the handle and a valve for controlling water flow between the input spigot adaptor and the hose adaptor. Beneficially, the valve is a rotating ball valve having an angle that is controlled by an actuator.
An alternative shower wand with scrub brush that is in accord with the present invention includes an elongated hollow handle having a shower head with a face on one (1) end and a water input on another end. The face includes water apertures for dispensing input water. The handle further includes a pair of opposed elongated slots and that each ends in a locking feature. The alternative shower wand with scrub brush further includes a brush having a scrubbing feature and a pair of integral arms, each having a protrusion, that extend from the scrubbing feature. Each integral arm is retained in and slides along an associate elongated slot. Each protrusion fits into an associated locking feature when the scrubbing feature is over the face, and when a protrusion fits into a locking feature the brush is locked into position.
Beneficially, the alternative shower wand with scrub brush includes a hose that is threaded onto the water input. Also beneficially, when the scrubbing feature fits over the face water passing through the water apertures pass through the scrubbing feature. Preferably the scrubbing feature includes a porous scrubbing surface.
The alternative shower wand with scrub brush may further include a holder having an input spigot adaptor for receiving water from an existing spigot and a hose adaptor in fluid communication with the input spigot for passing received water into the hose. The holder may further include a handle opening for receiving and holding the handle. The holder beneficially includes a valve for controlling water flow between the input spigot adaptor and the hose adaptor. Preferably that valve is a rotating ball valve having an angle controlled by an actuator.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which:
FIG. 1 is a perspective view of a shower wand with scrub brush 10 that is in accord with a preferred embodiment of the present invention;
FIG. 2 is another perspective view of the shower wand with scrub brush 10 shown in FIG. 1 ;
FIG. 3 is a front view of the shower wand with scrub brush 10 shown in FIGS. 1 and 2 ;
FIG. 4 is a perspective view of a holder 30 used in the shower wand with scrub brush 10 shown in FIGS. 1 through 3 ; and,
FIG. 5 is a perspective view of a hose 40 used in the shower wand with scrub brush 10 shown in FIGS. 1 through 3 .
DESCRIPTIVE KEY
10 shower wand with scrub brush
20 handle
21 head
22 a face
22 b water aperture
23 input opening
24 exterior threads
25 a slot
25 b locking feature
26 brush
27 scrubbing surface
28 arm
29 protrusion holder
31 hose adapter
32 spigot adapter
33 handle opening
34 actuator
35 ball valve
40 hose
41 holder fitting
42 handle fitting
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within FIGS. 1 through 5 . However, the invention is not limited to the described embodiment, and a person skilled in the art will appreciate that many other embodiments of the invention are possible without deviating from the basic concept of the invention and that any such work around will also fall under scope of this invention. It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
FIGS. 1 , 2 , and 3 illustrate a shower wand with scrub brush 10 that provides a scrubbing feature that enables thorough washing of oneself and which is in accord with the preferred embodiment of the present invention. FIGS. 1 and 2 show opposing perspective views of the shower wand with scrub brush 10 while FIG. 3 shows a front view. As shown, the shower wand with scrub brush 10 has an ergonomic, elongated, generally cylindrical handle 20 which extends from a bottom end having an input 23 upward to form an integral head 21 . The handle 20 is hollow and can supply water to the head 21 when connected to a water source.
The head 21 has a generally oval-shape and includes a flat front face 22 a having a plurality of water apertures 22 b . The water apertures 22 b enable water to be dispensed onto desired areas of a person showering. The bottom end of the handle 20 has the input 23 for receiving water that is to be routed to the head 21 . The input 23 takes the form of a connector with exterior threads 24 that enable attachment of the handle 20 to a hose 40 (described in more detail below and reference FIG. 5 ).
The handle 20 includes a pair of elongated slots 25 a that extend along the sides of the handle 20 and which are used to selectively slide a brush 26 up the handle 20 . At the upper ends of the slots 25 a are locking features 25 b that lock the brush 26 in an in-use position (described in more detail subsequently) by preventing the brush 26 from descending until a user actively releases the brush 26 . The in-use position has the brush 26 directly over the face 22 a and water apertures 22 b.
The brush 26 adds a scrubbing element to the shower wand with scrub brush 10 . The brush 26 has a generally circular-shape that matches that of the face 22 a . This enables the brush 26 to completely cover the face 22 a when in the in-use position. The brush 26 has a scrubbing surface 27 fabricated from porous materials such as, but not limited to: loofah, wood fibers, or the like. The scrubbing surface 27 enables water from the face 22 a and water apertures 22 b to pass through the brush 26 . The sides of the brush 26 extend into integral opposed arms 28 that slide along the elongated slots 25 . At the end of each arm is a protrusion 29 that selectively fits into a locking feature 25 b . This locks the brush 26 in position over the face 22 a until a user removes the protrusions 29 from the locking features 25 b which enables the brush 26 to move away from the face 22 a.
FIG. 4 shows a perspective view of a holder 30 that is used to attach the shower wand with scrub brush 10 to existing plumbing. The holder 30 is fabricated from various rust-proof materials and may have a variety of finishes for use with various decors. The holder 30 includes a threaded hose adapter 31 , a threaded spigot adapter 32 , a handle opening 33 , and an actuator 34 . The spigot adapter 32 threads onto an existing spigot (not shown) to receiving incoming water while the hose adapter 31 enables attachment of the hose 40 which has threaded ends. That hose 40 is described in more detail subsequently. The handle opening 33 is used to suspend the handle 20 while the actuator 34 is used to control the flow of water between the spigot adaptor 32 and the hose adaptor 31 .
The actuator 34 operably controls the rotation of an inner ball valve 35 . The rotational position of the ball valve 35 controls the flow of water through the holder 30 and thus through the handle 20 . As do most ball valves the ball valve 35 regulates the flow of water through internal apertures (not shown) by changing the angle of a ball aperture relative to pipe apertures. When the actuator 34 is manipulated to align the ball aperture with the pipe apertures maximum flow occurs, but when the ball aperture no longer aligns water flow is restricted.
The handle opening 33 is comprised of a generally “U”-shaped feature for suspending the handle 20 in an upright position with the head 21 oriented toward a user. The handle 20 is held in position when the handle opening cups the handle 20 from the holder 30 . This configuration enables easy removal of the handle 20 from the handle opening 33 .
FIG. 5 presents a perspective view of the hose 40 . Connecting the hose 40 to the hose adapter 31 directs water into the handle 20 and then to the head 21 . The hose 40 is beneficially a hollow tube fabricated from materials such as, but not limited to: nylon, rubber, or the like. The hose 40 can be made available in various lengths to accommodate the needs of the user. One (1) end of the hose 40 has a holder fitting 41 which threads onto the hose adapter 31 while the other end has a handle fitting 42 which threads onto the exterior threads 24 of the handle 20 .
It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The preferred embodiment of the present invention can be used by a common user in a simple and effortless manner with little or no training. After initial purchase or acquisition of the shower wand with scrub brush 10 it would be installed by attaching the spigot adapter 32 onto an existing spigot; orientating the actuator 34 to close the ball valve 35 ; attaching the holder fitting 41 of the hose 40 to the hose adapter 31 of the holder 30 ; attaching the handle fitting 42 of the hose 40 to the handle 20 via the exterior threads 24 ; inserting the handle 20 into the handle opening 33 on the holder 30 as desired; using the shower wand with scrub brush 10 as desired via activating water flow into the shower wand with scrub brush 10 via manipulating the actuator 34 to open the ball valve 35 , thereby routing the water out of the water apertures 22 b ; extending the brush 26 as desired via moving the protrusions 29 of the arms 28 to mate with the locking feature 25 b to lock the brush 26 in position; removing the handle 20 from the holder 30 and scrubbing a desired area; utilizing the shower wand with scrub brush 10 as desired; and providing for bathing in a shower in a manner which is quick, easy, and effective for all.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, 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.
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A hand-held shower head with an integral deployable brush for cleaning one's back and other hard-to-reach body areas is mounted to the shower head handle upon a sliding mechanism. In a lowered position, the brush is out of the way of the water stream enabling operation similar to a conventional hand-held shower. When in a raised position, the water stream flows through openings in the brush body.
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BACKGROUND OF THE INVENTION
The present invention relates to a novel splashboard assembly for a countertop and a method of installing the same.
Conventionally, countertops having splashboards are installed using one of two general methods. In the first method, the countertop is placed onto the cabinet. The splashboard, then, is bonded to the wall. While caulking is usually applied along the countertop where the boards join, leakage often occurs at this point. In time, the wall and cabinet expand at different rates, thereby breaking this seal.
In the second method, the splashboard is formed integral with, or is otherwise attached to the countertop prior to installation. While leaking is prevented, installation limitations are introduced when the distance between opposing walls is greater at the back of the counter than at the front, since the degree to which the counter may be tilted from side to side is dependent on its height.
Accordingly, there is a need for a separate splashboard assembly which will provide the sealing benefits heretofore found only with integral splashboard and countertop units and which can be easily installed regardless of surrounding structural limitations.
SUMMARY OF THE INVENTION
In accordance with the illustrative embodiments demonstrating features and advantages of the present invention, there is provided a splashboard assembly for mounting upon a countertop and against a vertical wall. The assembly has a splashboard and a clip. The clip has upper and lower portions. The clip can couple the splashboard to the countertop adjacent the vertical wall. The lower portion of the clip has a fastening means for fastening the lower portion to the countertop. The upper portion of the clip has a support means for supporting the splashboard. The clip has a biasing means for biasing the splashboard against the vertical wall with respect to the countertop.
In a related method according to the principles of the same invention a splashboard can be mounted to an edge of a countertop, and against a vertical wall, with a clip arranged to be snapped onto the splashboard. The method includes the step of fastening the clip to the edge of a countertop to project partially above the countertop. Another step is installing the countertop at a desired location adjacent a vertical wall. The method also includes the step of snapping the splashboard onto the clip after the countertop is installed.
In a preferred embodiment, the splashboard has a pair of rear rails that snap into concavities on the clips. The clips are F-shaped with fingers projecting outwardly. The upper portion of the preferred clip connects to the splashboard and the lower portion connects to the countertop. The fingers have the concavities that engage the rails.
The clip is formed with a bias to urge the top of the clip against the wall when the lower portion of the clip is fastened to the rear edge of a countertop. An alignment stop, which is spaced apart from the fingers serves to position the clip relative to the countertop by engaging the top surface thereof.
The preferred method of installing the novel splashboard assembly involves first fastening the rear edge of the countertop. Then the unit is placed over a cabinet, or similar structure. The splashboard is pressed against the clip until the clip fingers engage the engaging means on the splashboard. The bias means in the clip urges the splashboard against the wall. The use of this splashboard assembly and method of installation will allow a countertop to be easily installed between opposing walls where their angles require the countertop to be tilted sideways, for, as an example, when the distance between them is greater toward the back of the counter than at the front.
In addition, this splashboard assembly may be used with the convenience of two-step arrangements without the long-term destructive effects of water seepage, since the splashboard is finally attached to the countertop, and not to a wall which expands at different times and rates. Furthermore, by forming the clips with a bias, it is assured that the splashboard will be pressed against the wall whether or not the countertop is perfectly normal to the plane of the wall, or, in the case of a long cabinet, the one end is slightly out of alignment with the other.
BRIEF DESCRIPTION OF THE DRAWINGS
The above summary of the invention, as well as other objects, features and advantages of the present invention will be more fully appreciated by reference to the following detailed description of presently preferred, but nonetheless, illustrative embodiments in accordance with the present invention when taken in conjunction with the accompanying drawings wherein:
FIG. 1 shows an end view illustrating the preferred embodiment of the invention, being fully assembled except for the end cap, which is detached to allow the arrangement of the elements to be viewed;
FIG. 2a shows an end view of a splashboard having an alternate engaging means comprised of rails with concavities;
FIG. 2b shows an end view of a splashboard having, yet, another engaging means comprised of grooves having convexities;
FIG. 3a shows a side view of the clip comprising the preferred embodiment of the invention;
FIG. 3b shows the upper portion of an alternative design for the clip having rails with convexities for engaging the splashboard and an arch to create a bias when installed against a wall;
FIG. 4 shows a rear view of a conventional splashboard equipped with latching elements enabling it to engage the upper portion of the clip of the subject invention as the lower portion of the clip is attached to the countertop;
FIG. 5 illustrates the first step of the method of installing the splashboard assembly as the countertop is placed against a wall;
FIG. 6 illustrates another step of the method of installing the splashboard assembly as the splashboard is engaged with the clip;
FIG. 7 illustrates the final step of the method of installing the splashboard assembly as the splashboard is fastened to the clips.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1, 2a, 2b, 3a, and 3b, a clip 2 is shown having upper U and lower L portion. The upper portion U is formed so that its longitudinal axis, as represented by the line labelled A, is slightly out of alignment with that of the lower portion L, whose longitudinal axis is represented by the arrow labelled B. The purpose for this misalignment is to create a bias in the clip 2 after the lower portion L of the said clip 2 has been attached to the edge of a countertop 9, and after the same has been placed against a wall. This bias ensures that the splashboard 1, which subsequently engages the clip 2, will be urged against the wall.
As a series of clips 2 are placed about the length of the countertop 9, the splashboard 1 will be urged against the wall at each of these points. If the wall is inclined slightly out of the plane normal to the countertop 9 at some point, the clip 2, or clips, used at this point will tend to bend the splashboard 1 to conform the same thereto. Dealing with this situation has been a particular frustration to builders involved in the renovation of homes built before the use of wallboard, or plasterboard. Quite often, a countertop 9 having an integral splashboard 1 will be installed in a room where the plane of the walls deviate from the plane normal to that of the countertop 9 at one end of the splashboard 1. This requires the additional step of installing a shimming element to bridge this gap. Usually, these shimming elements are formed on site from scrap materials or putty, neither of which are aesthetically appealing.
FIGS. 3a and 5 show the degree of longitudinal misalignment of upper U and lower L portions to be between two and three degrees. This insures that the splashboard 1 will rest flush against the wall W when the latter is as much as six degrees out of the normal plane to the countertop 9 from one end to the other. Means for providing the misalignment may take any of several forms. In the preferred embodiment, a straight upper portion U is integrally attached to a straight lower portion L at point 6, which appears as a bend. Alternatively, this misalignment may take the form of an arcuately bent upper portion U as seen in FIG. 3b. Since other possible designs exist for forming the misalignment means, it is understood that this invention does not limit itself to the preferred and alternative embodiments, but broadly encompasses any means of forming a clip 2 which will create a bias when attached to a countertop 9 and placed against a wall W for the purpose of urging a splashboard 1 there against. The clip 2, in the preferred embodiment has been stamped from a piece of plastic. The same may be injection molded, or the like. Alternatively, the clip 2 may be stamped from metal so that the bend 6 would be formed during the stamping operation. To the upper portion U of the clip 2 are formed extending fingers F having concavities 3 which are designed to engage convexities 4 formed on rails R attached to the rear of the splashboard 1. The plastic material, from which the clip 2 is made, affords the same with a degree of resilience so that the fingers F will spread as the convexities 4 on the rails R are forced there between. FIG. 3b illustrates an alternative clip 2 design having a broader width to accommodate rails R in place of fingers F. The rails may be formed with either concavities or convexities. In this figure, they are formed with convexities 3a which would correspond to engaging means on the rear of the splashboard having concavities. The clip 2 further comprises means 7 for aligning the same with respect to the countertop 9. In the preferred embodiment, the alignment means 7 is comprised of a small extension of plastic forming a tab which engages the top of the countertop. This ensures that each clip will be precisely in vertical alignment with respect to the countertop. Alternatively, the alignment means may comprise a vertical extension from the lowermost finger F. The present invention does not limit itself to a specific means for achieving alignment of the clips 2 with respect to the countertop 9, but broadly encompasses any clip structure which, when attach to a countertop 2, would produce the desired result.
The rails R in FIG. 4a with concavities 4a comprise engaging means for engaging the fingers F formed on the upper portion U of the clips 2. These means are to correspond, or mate with whatever configuration is selected for the engaging fingers F formed on the upper portion U of the clip 2. In this drawing, the rails mate with fingers having convexities. In place of rails, the splashboard may be provided with grooves having mating concavities or convexities as seen in FIG. 2b. This design might simplify manufacturing and eliminate the possibility of being damaged by the fingers F during installation. The grooves G would be formed with mating convexities or concavities. In this case, the rails R are formed with convexities 4a, which would correspond with fingers having concavities. It might be desired to utilize the splashboard assembly of the present invention with existing splashboards which were manufactured without rails or grooves. This would be possible with the use of latching elements 9 as shown in FIG. 4. These latching elements might take any of several forms. In the embodiment shown in FIG. 4, these latching elements 9 are fastened to the rear of the splashboard 1 in spaced relation to each other. Latching means 4c engage corresponding fingers F or rails R formed on the upper portion U of the clip 2. In this figure, the latching means comprises convexities, which would mate with concavities formed on the fingers F of a clip 2.
A particular advantage of the present invention resides in the method of assembling the splashboard 1 to a countertop C, which provides the sealing advantages of integrally attached splashboard and countertop units with the installation flexibility of separate units. This method is illustrated in FIGS. 5 through 7. FIG. 5 shows the first step, as the clip 2 lower portion is being attached to the countertop 9 by screws S. An alignment means 7 on each clip 2 engages the top surface of the countertop 9 to ensure relative alignments there between. In this preferred embodiment, the straight upper portion U is out of longitudinal alignment with the lower portion L. This can be seen by the lines A and B. The longitudinal axis of the upper portion U, indicated by line A, is two or three degrees out of alignment with that of the lower portion U, which is indicated by line B. FIG. 6 shows the second installation step, as the clip 2, and countertop 9 are placed onto a cabinet C and against a wall W. The wall W substantially straightens the clip 2 so that a bias is formed in the upper portion U to urge the same toward the wall. In this case, the wall is in a plane perfectly normal to that of the countertop. This is seen in the fact that the longitudinal axis of the upper portion U, indicated by line A, is in alignment with that of the lower portion L, indicated by line B. The third and final step is illustrated in FIG. 7, where the splashboard is pressed against the clips until the fingers F on the upper clip portion U engage the engaging means 4 on the rear of the same. At this point, the splashboard 2 will be securely fastened to the wall W along its entire length regardless of whether or not the wall W deviates from the plane normal to that of the countertop 9. The alignment means 7 ensures that the lower edge of the splashboard 1 rests evenly along the top of the countertop 9.
Several methods may be employed to seal the joint between the countertop 9 and splashboard 1. One method would be to install commercially available, adhesively attached strips along the outer length thereof. This method would provide a lasting seal since the problems experienced with the differing expansion rates of the splashboard 2 and countertop 9 with known two-part arrangements is eliminated by virtue of the fact that these parts are effectively attached to each other. Alternatively, and as represented in FIG. 7, the bottom of the splashboard may further comprise a groove 10 which would be of sufficient depth to receive an appropriate amount of caulking prior to attaching the same to the clips. This latter sealing method provides a more aesthetic overall appearance.
To further enhance the overall appearance of the assembly, closure means may be provided for sealing the exposed ends of the splashboards 1 and for obscuring the inner elements thereof. The closure means may take any of several forms. In the preferred embodiment, as seen in FIG. 1, the closure means is comprised of a plastic plate 8, which is shaped to correspond to the shape of the cross-section of the splashboard 1. After the splashboard 1 is fully assembled, the plastic plate 8 is pressed onto the exposed end thereof until the two are flush with each other. The present invention does not limit itself to any specific form of closure means, but broadly encompasses any means for aesthetically sealing the exposed end of the splashboard 1 for obscuring the inner elements thereof and might include plates or other decorative means which cover fully the end of the splashboard 1.
Backsplash 1 may be formed a plastic extrusion 1b that is prelaminated or has a laminate 1a installed at the site. The laminate may be Formica™. In some embodiments there need not be a laminate, but the backsplash will have a continuous color throughout (Colorcore™). In any event, it is advantageous to have the laminate secured in advance to reduce installation time and expense. While a plastic backsplash is described in some embodiments, a layered construction or non-plastic material may be used instead.
It is to be appreciated that various modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than specifically described.
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A splashboard assembly for mounting upon a countertop and against a vertical wall. The assembly includes a splashboard and a clip. The clip has an upper and lower portions, and can couple the splashboard to the countertop adjacent said vertical wall. The lower portion has a fastening arrangement for fastening the lower portion to the countertop. The upper portion has support devices for supporting the splashboard. The clip has a section for biasing the splashboard against said vertical wall with respect to said countertop. One, or more, clips are first attached to the countertop edge. When the countertop is in place, the splashboard is snapped onto the clips. A decorative end cap may also be provided to cover any exposed end of the splashboard.
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TECHNICAL FIELD
The present invention relates to an operating device, more specifically, an operating device in which an operating pressure is communicated through a pressure communicating medium.
BACKGROUND OF THE INVENTION
Conventionally, a device, which communicates a pressure by a fluid, such as oil, to communicate an operating amount at an action side from an operating side, has been used. In such a device, it is common to have a configuration, for example, such that oil in a cylinder is pushed out by pressing a piston on the operating side, and move the piston on the action side through an oil conducting tube, thereby the operating amount is communicated to a predetermined device. Such device is disclosed, for example, in Japanese Unexamined Patent Application No. H5-4570.
However, when the conventional operating device is applied to communicating an operating amount of fluid by using a foot brake operated by a foot, there has been an issue of difficulty in accurately communicating a subtle move of an operating side to an action side. Further, in a case when communicating an operating amount of fluid from the operating side to a plurality of pistons on the action side, the amount of movement for each piston on the action side may result in difference movements, thus there has been a problem of further difficulty in accurately communicating a subtle move to the action side.
SUMMARY OF THE INVENTION
The present invention has been made considering the above facts, and the objective is to provide a device capable of accurately communicating a slight movement of an operating side to an action side. Further, the present invention provides a device capable of equally communicating an operating amount of fluid from the operating side to a plurality of action sides.
One aspect of the present invention is an operating device that includes a pressurizing operation unit for pressurizing a pressure communicating medium in a fluid form by the displacement of an operating member by an external operation, a plurality of action units for operating the pressure applied from the pressurizing operation unit by converting a switching operation of a position fixed state and a released state of a positioning unit, a conducting channel for leading out the pressure communicating medium from the pressurizing operation unit, a bifurcating section for distributing the pressure communicating medium to the plurality of the action units from the conducting channel, a branch channel for guiding the pressure communicating medium to each action unit from the bifurcating section, wherein each of the branch channels further includes a flow rate regulating unit for regulating the flow rate of the pressure communicating medium and each of the flow rate regulating units equalizes the flow rate of the pressure communicating medium circulating each of the branch channels.
The positioning unit is a positioning unit of an extension device provided with a cylinder and a piston inserted into the cylinder. And the positioning unit may further be provided with an on-off valve to open and shut the flow of a fluid flowing in the cylinder chambers formed on both sides of the piston.
The flow rate regulating unit has a valve chamber provided with an inlet and an outlet for the pressure communicating medium, and an inside of the valve chamber may be provided with a throttle section for regulating the amount of the pressure communicating medium outflowing from the outlet and a valve for operating the throttle section.
Each of the throttle sections and the valve has a channel capable of circulating the pressure communicating medium, and the traverse area of the channel of the throttle may be smaller than the traverse area of the channel of the valve.
A bias member may be provided at a position which contacts the valve. The bias member may be a compressed spring.
The flow rate regulating unit includes a bias member for operating the position of the valve, and a valve and a valve seat for adjusting the traverse area of the circulating channel. And the flow rate of the pressure communicating medium may be regulated by adjusting the space formed between the valve and the valve seat. The present invention may be a nursing care bed characterized by having the operating device.
Another aspect of the present invention is an operating device that includes a pressurizing operation unit for applying a pressure to the pressure communicating medium in a fluid form by a displacement of the operating member from an external operation, an action unit for operating the pressure applied from the pressurizing unit by converting the pressure to a switching operation of a fixed state and a released state of a positioning unit, a flow rate regulating unit for regulating the flow rate of the pressure communicating medium leading out from the pressurizing operation unit, and a conducting channel for leading out the pressure communicating medium from the pressurizing operation unit, wherein the flow rate regulating unit further includes a valve chamber having an inlet for inflowing the pressure communicating medium fed from the pressurizing operation unit and an outlet for outflowing the same, a valve that is pressed to the inlet by a bias member for closing the outlet in a case when the flow rate of the pressure communicating medium exceeds a predetermined amount, and a throttle for regulating the flow rate passing through the outlet when the valve closes the outlet.
The conducting channel is provided with a plurality of branch channels leading out of the pressure communicating medium, and the flow rate regulating unit may be provided to each of the bifurcating channels.
The flow rate of the pressure communicating medium leading out to the action unit from each bifurcating channel may be equal.
The throttle section and the valve each has a channel capable of outflowing the pressure communicating medium, and the traverse area of the channel of the throttle section may be smaller than the traverse area of the channel of the valve.
The bias member may be a compressed spring.
The flow rate regulating unit further includes a bias member for operating the position of the valve, and a valve and a valve seat for adjusting the traverse area of the circulating channel. And the flow rate of the pressure communicating medium may be regulated by adjusting the width of the space formed between the valve and the valve seat.
Another aspect of the present invention is an operating device that includes a pressurizing unit for pressurizing the pressure communicating medium, an action unit for feeding the pressure applied by the pressurizing unit to a plurality of positioning units, a plurality of branch channels for distributing the pressurized pressure communicating medium to the plurality of positioning units, a flow rate regulating unit provided to each of the plurality of branch channels for regulating the flow rate of the pressure communicating medium, wherein the flow rate regulating unit equalizes the flow rate of the pressure communicating medium circulating in each of the branch channels.
The flow rate regulating unit further includes a valve chamber having an inlet for inflowing the pressure communicating medium and an outlet for outflowing the same, and in the valve chamber, provided are a valve and valve seat for adjusting the flow rate of the pressure communicating medium, and a bias member for operating the position of the valve. And the flow rate of the pressure communicating medium may be regulated by adjusting the width of the space formed between a valve and the valve seat.
The bias member may be a compressed spring. The width of the space formed between the valve and the valve seat may be adjusted in a case when the outflow rate of the pressure communicating medium exceeds a predetermined amount. The conducting channel and the branch channel may be formed with a flexible material. And the flexible material may be a synthetic resin.
According to the present invention, because each of the branch channels is provided with the flow rate regulating unit, an equal operating amount can be communicated to the plurality of action units. According to the present invention, the operation of the positioning unit of the plurality of the extension devices can be simultaneously performed by one pressurizing operation unit on the operating side, and the timing of the operation of the positioning unit can be the same.
According to the present invention, because the valve closes the outlet and the throttle operates when the operating amount of the pressurizing operation unit by an operator exceeds a predetermined value, a rapid change in the operating amount communicated to the action unit can be regulated. For this reason, for example, trouble during positioning by an extension device equipped with an air spring, such as sudden expansion of the extension device due to the sudden opening of the valve of the positioning device may be suppressed. Further, the pressure communicating medium is supplied in a very small amount through the throttle, thus the communication of the operating amount is continued and an interruption of the operation does not occur.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overall perspective view of a nursing care bed as a first embodiment using an operating device according to the present invention.
FIG. 2 is an overall perspective view of a nursing care bed using an operating device according to the present invention.
FIG. 3 is a cross-sectional view showing a configuration of an operating section of an operating device.
FIG. 4 is a cross-sectional view showing a configuration of an operating section of an operating device.
FIG. 5 is a cross-sectional view showing a configuration of an operating section of an operating device.
FIG. 6 is an overall perspective view showing a mounting state of an action section of an operating device.
FIG. 7 is a cross-sectional view of an acting section.
FIG. 8 is a cross-sectional view of a bifurcating section.
FIG. 9 is an overall cross-sectional view of an extension mechanism.
FIG. 10 is a partial enlarged cross-sectional view of an operating device showing another configuration.
FIG. 11 is an overall perspective view of a desk with an operating device of the present invention mounted as a second embodiment.
FIG. 12 is a plane view showing a height adjustment mechanism.
FIG. 13 is an overall perspective view of a desk with the operating device according to the present invention mounted as a second embodiment.
FIG. 14 is an overall perspective view of a table with an operating device of the present invention mounted as a third embodiment.
FIG. 15 is a cross-sectional perspective view of a configuration of leg section in the third embodiment.
DETAILED DESCRIPTION OF INVENTION
Embodiments of the present invention are hereinafter explained in detail with reference to drawings. FIGS. 1 and 2 illustrate an overall perspective view showing a configuration of the operating device 1 of the present invention used in a nursing care bed 2 as a first embodiment. In the nursing care bed 2 , a frame body 21 formed in a rectangular form is horizontally arranged, and four legs protruding downward at the four corners of the frame body 21 and top panels 24 and 25 covering the upper side of the frame body 21 are provided. The top panel 24 is fixed to the upper side of the frame body 21 , and the top panels 24 and 25 are arranged in a way that are reciprocally facing at a center of the bed 2 . And the top panel 25 is connected to the top panel 24 with hinges 26 A and 26 B, and the top panel 25 is configured to oscillate upward against the top panel 24 .
Onto legs 22 B and 22 C on the top panel 25 side, a supporting bar 23 is provided, and the rear ends of two extension devices 5 A and 5 B are connected oscillatably to the supporting bar 23 . On the lower side of the top panel 25 , a pair of supporting projections 251 A and 251 B, and a supporting bar 252 is installed between the supporting projections 251 A and 251 B. On the supporting bar 252 , the front ends of the extension devices 5 A and 5 B, which are connected to the supporting bar 23 at the rear end, are oscillatably connected. By such configuration, the inclination angle of the top panel 25 is configured to be adjusted by the extension and contraction of the extension devices 5 A and 5 B.
Onto the extension devices 5 A and 5 B, an operating device is connected for the operation of positioning these lengths. An operating device 4 is provided with an operation section 41 A as a pressurizing operation unit, an action section 41 C as an action unit, and branch channels 42 B and 43 B as conducting channels for guiding oil, which is a pressure conducting medium, between the operating section 41 A and the action section 41 C.
As shown in FIGS. 1 and 2 , the operating section 41 A is provided for a user to operate lock release of the extension mechanism. The operating section 41 A is fixed to the side face of the frame body 21 of the nursing care bed 2 , and is provided adjacent to the top panel 25 , thus the release operation can be performed simultaneously when performing an oscillating operation on the top panel 25 . FIGS. 3 to 5 are cross-sectional views of the operating section 41 A of the operating device 4 . On to the operating section 41 A, which is a pressurizing operating unit, provided are, an operating section main body 410 A, a mounting section 411 to fix the operating section main body 410 A to the frame body 21 , an operating member 412 A, and a piston 44 A, which has a piston rod 45 A.
The operating section main body 410 A and the mounting section 411 are formed as a unit. A cylinder 43 A is formed inside the operating section main body 410 A and a piston 44 A is stored in the cylinder 43 A. The cylinder 43 A communicates to a valve chamber 47 A through a communicating channel 431 A, and a lid body 48 A is inserted into the rear end portion of the valve chamber 47 A. The lid body 48 A is communicated with a lead-out channel 473 A. And one end of the lead-out channel 473 A has an opening 472 A inside the valve chamber 47 A, and the other end has an opening at a connecting portion of the connecting tube 411 B. The front end of the cylinder 43 A is blocked by the lid body 42 A. The piston rod 45 A connected to the piston 44 A is inserted through the lid body 42 A, and protrudes outside of the operating portion main body 41 A, and its front end contacts the operating member 412 A.
Onto the opening 471 A, where the valve chamber 47 A and communicating channel 431 A are connected, a taper is formed and the front end of the valve body 46 A is caught in this opening 471 A. The valve body 46 A is stored inside the valve chamber 47 A and is provided reciprocatably in the axis direction of the valve chamber 47 A. Onto the front end of the valve body 46 A, a seal member 463 A is installed and this contacts to the taper face of the opening 471 A. Also, onto the rear end of the valve body 46 A, a taper face 464 A is formed. This taper face 464 A contacts the opening 472 A when the valve body 46 A moves to the rear end side.
Also, the valve body 46 A has a circulation opening 461 A on the front end, and this circulation opening 461 A is communicating to the external side face of the valve body 46 though a channel 462 A. The cylinder 43 A and the valve chamber 47 A are maintained in a state that the oil can be circulated under a predetermined amount even when the valve body 46 A is blocking the opening 471 A by the circulation channel 461 A and the channel 462 A. Further, a throttle section 466 A, which communicates with the channel 462 A and the rear end, is formed. The throttle section 466 A functions as a throttle to regulate the flow rate when the valve body 46 A contacts the opening 472 A. The throttle section 466 A is a channel with a smaller traverse area compared to the circulation opening 461 A.
Between the valve body 46 A and the lid body 48 A of the rear end side, a compressed spring 465 A as a bias member are provided, thereby the valve body 46 A is constantly biased towards the opening 471 A. A spring 451 A is externally mounted to bias in a direction to which the piston rod 45 A is pulled out. This is also to restore the piston rod 45 after a release operation.
Next, the action section 41 C is explained. The action section 41 C is provided to each of the piston rods 52 A and 53 B on each of the extension mechanisms 5 A and 5 B. The action section 41 C provided to the piston rod 52 A of the extension mechanism 5 A is hereinafter explained. FIG. 6 is an overall perspective view of an attaching state of the action section 41 C. FIG. 7 is a cross-sectional view of the action section 41 C. The action section 41 C is provided with an action section main body 410 C, a connecting section 42 C to connect and fixed the front end of the piston rod 52 of the extension mechanism 5 , and a piston 44 C.
A cylinder 43 C is formed inside the action section main body 410 C, and a piston 44 C is stored in the cylinder 43 C. Also, inside the cylinder 43 C, an operating button 53 A of the piston rod 52 A connected though the connecting section 42 C is inserted and contacts a face on one side of the piston 44 C. On the face on the opposite side of the piston 44 C, an oil chamber filled with oil by the cylinder 43 C and the piston 44 C is formed ( FIG. 7 illustrates a condition where the oil is pressed out). Onto the cylinder 43 C, the communicating channel 45 C is connected, and the communicating channel 45 C is connected to the branch channel 43 B though the connecting section 432 B.
Onto the action section main body 410 C, a looped section 47 C is formed as a connecting section, and a supporting bar 252 is inserted into a insertion hole 471 C, which is formed in a center of the looped section 47 C. The action section main body 410 C is rotatably connected against the supporting bar 252 at the looped section 47 C. The operating section 41 A and the action section 41 C are connected through an oil feeding pipe, and the oil, that is a pressure communicating medium, is circulated between the cylinder 43 A of the operating section 41 A and the cylinder 43 C of the action section 41 C through the oil feeding pipe.
The oil feeding pipe is provided with a conducting channel 41 B, a bifurcating section 6 , and two branch channels 42 B and 43 B. The conducting channel 41 B and the branch channels 42 B and 43 B are loop bodies configured from a flexible material, and for example, it may be configured from a synthetic resin. By configuring the conducting channel 41 B and branch channels 42 B and 43 B from a soft material, the resistance against deformation is decreased, thereby the resistance applied to the up and down of the top panel 25 can be decreased.
The conducting channel 41 B and the two branch channels 42 B and 43 B are connected through the bifurcating section 6 . The configuration of the bifurcating section 6 is explained with reference to a cross-section diagram of FIG. 8 . The bifurcating section 6 is provided with a housing 61 , storing sections 63 A and 63 B to store flow rate regulating sections 60 A and 60 B, a flow dividing chamber 62 , and bifurcating channels 67 A and 67 B. The flow-dividing chamber 62 is provided with a connecting opening 621 to be connected to the conducting channel 41 B, and further, each one end of the storing sections 63 A and 63 B are opened. The flow rate regulating sections 60 A and 60 B are stored in each of storing sections 63 A and 63 B. Each of connecting ends 421 B and 431 B of the branch channels 42 B and 43 B are connected to each bifurcating channel 67 A and 67 B. Each of the flow-rate regulating sections 60 A and 60 B have the same configuration, thus one of the flow-rate regulating sections 60 A is explained here, and the explanation for the configuration of the other flow rate regulating section 60 B is omitted.
On an opening 632 A on the flow-dividing chamber 62 side of the storing section 63 A, a loop-form stopper 633 A is buried in the inner wall. A tube-form valve 64 A contacts the stopper 633 A. The valve 64 has a tube section 641 A and a plate-form valve section 642 A, which is provided to the stopper 633 A side of the tube section 641 A. The tube section 641 A is movably fitted to the inside of a projection section 631 A that protrudes into the storing section 63 A. The plate-form valve section 642 A has a circular-form valve opening 644 A at a center. The valve 64 A is biased towards the stopper 633 A by a compressed spring 65 A inserted between the circumferential end of the valve section 642 A and the projection section 631 A. A valve seat 66 A is arranged inside of the valve 64 A. The valve 66 A has a conical form, and its front end reaches inside the valve opening 644 A formed in the center of the valve 64 A. The oil circulates between the flow-dividing chamber 62 and an inner space 643 A of the valve 64 A though a gap formed between the valve opening 644 A and the front end portion of the valve seat 66 A. On the front end portion of the valve seat 66 A, a taper 661 A is formed. Thus, when the oil flows into the flow rate regulating sections 60 A from the flow dividing chamber 62 , the gap gradually decreases as the valve body 64 A moves towards the rear end of the valve seat 66 A by the hydraulic pressure, and ultimately blocks the valve opening 644 A of the valve 64 A. The rear end 662 A of the valve seat 66 A is screwed to fix to a supporting section 671 A provided inside the storing section 63 A. At a rear end opening of the storing section 63 A, a tube-form connecting member 68 A is threaded in and the connecting end 421 B of the branch channel 42 B is connected. The oil flowing into the rear end direction of the valve seat 66 A from the valve opening 644 flows into the branch channel 42 B though a space formed around the supporting section 671 A.
By the balance of the spring 65 A and the pressure from the oil flowing into the valve opening 644 A of the valve 64 A, the spacing formed between the valve opening 644 A and the valve seat 66 A is adequately adjusted and regulated to constantly flow in a certain flow rate. Because the flow rate regulating section 60 B, which has the same configuration as such flow rate regulating section 60 A, is proximately provided, the amount of the oil, that is a pressure communicating medium, supplied to each of branch channels 42 B and 43 B can be virtually equal, and the amount of the positioning operation of the extension mechanisms 5 A and 5 B (namely, the distance of the piston 44 C) can be virtually equal. In this way, the extension operation for the extension mechanisms 5 A and 5 B can be performed at the same time.
Next, the configuration of the extension mechanisms 5 A and 5 B is hereinafter explained. FIG. 9 is a cross sectional side view of the extension mechanism 5 A. The extension mechanism 5 B has the same configuration as the extension mechanism 5 A, therefore the explanation is omitted. The extension mechanism 5 A is provided with a cylinder main body 51 A, a piston 54 A, a piston rod 52 A, a gas 55 RA, a piston 551 RA for a gas spring, and a positioning mechanism 56 A.
One end of the cylinder main body 51 A is provided with a looped section 511 A as a connecting section, and the supporting bar 23 is rotatably inserted into a hole of the looped section 511 A. The cylinder main body 51 A is formed in a tube form, and a cylinder 55 A is formed inside the cylinder main body 51 A. Inside of the cylinder 55 A, a piston 54 A is stored and divides the cylinder 55 A into a first chamber 55 AA and a second chamber 55 BA. A fluid 55 WA, such as oil, is filled in each of the first chamber 55 AA and the second chamber 55 BA.
In the piston 54 A, a mounting section 542 A of the piston rod 52 A on the second chamber 55 BA side, and one end of the piston rod 52 A is connected to the mounting section 542 A. The other end of the piston rod 52 A protrudes outside of the cylinder 55 A, and an operating button 53 A protrudes from the front end of the piston rod. As the piston 54 A moves inside the cylinder 554 A, the piston rod 52 A advances and retracts against the cylinder 55 A, thereby the total length of the extension mechanism 5 A extends and retracts.
On the center of the piston rod 52 A, an operating rod 541 A is inserted in the axis direction, one end of the operating rod 541 A is connected to a valve 561 A, with the other end configuring the operating button 53 A described above. The valve 561 A is stored in the piston 54 A. A circulation channel 562 A is formed in the piston 54 A. One end of the circulation channel 562 A is open to the first chamber 55 AA, and the other end is open to the second chamber 55 BA. In this way, the fluid 55 WA filled in the cylinder 55 A can move between the first chamber 55 AA and the second chamber 55 BA through this circulation channel 562 A, thereby the piston 54 A is enabled to move while the fluid is in a movable state.
On the opening on the first chamber 55 AA side of the circulation channel 562 A, a valve 561 A is provided. When the operating button 53 A is pressed in, the valve 561 A protrudes to the first chamber 55 A side and opens the circulation channel 562 A, thereby the piston 54 A is in a movable state, that is, an expandable state. Also, when the valve 561 A blocks the opening on the first chamber 55 AA side of the circulation channel 562 A, the extension mechanism 5 A is in a non-expandable state, and in a state that is positioned at a predetermined length. In this way, the positioning mechanism 56 A is provided with an operating rod 541 A, a valve 561 A, and a circulation channel 562 A.
In the first chamber 55 AA, a gas 55 RA and a piston 551 RA for gas spring is provided. The piston 551 RA segregates the gas 55 RA and the oil 55 WA and acts as a buffering mechanism when a load is applied in the compressing direction of the extension mechanism 5 A and the gas 55 RA is compressed and increased in volume.
In the configuration described above, when operating the operating lever 471 A and a large operating amount is taken, a rapid increase in the operating amount of the pressure communicating medium can be suppressed by the effect of the valve 46 A of the operating section 41 A. Further, the operating amount communicated to the positioning mechanism of each of the extension mechanisms 5 A and 5 B is adjusted to be equal by the bifurcating section 6 . Namely, because the rapid increase in the operating amount of the pressure communicating medium is suppressed, a fine adjustment of the distance of the valve 561 A of the positioning mechanism 56 A can easily performed, thus the top panel 25 can easily be operated such that up and down speed of the top panel 25 is gradual. Further, by the bifurcating section 6 , the operating amount communicated to the positioning mechanism of each of the extension mechanisms 5 A and 5 B is adjusted to be equal, thereby the contraction amount of two of the extension mechanisms 5 A and 5 B can be equal.
Another example of a configuration is hereinafter explained. In FIG. 10 , a groove 474 A is formed in a diameter direction at the taper face of the opening 472 A, instead of the throttle section 466 A formed on the valve 46 A. Both ends of the groove 474 A reach to the outer circumference edge and the inner circumference edge of the opening 472 A. The oil circulates in the groove 474 A and acts as a throttle section while the valve 46 A blocks the opening 472 A. As another configuration of the throttle, other than forming a groove on the opening 472 A, a circulation channel 475 A, which communicates the valve chamber 47 A and the lead out channel 473 A, may be formed separately and the circulation channel 475 A functions as a throttle.
FIGS. 11 and 13 illustrate overall perspective views of a desk 3 with the operating device of the present invention mounted as a second embodiment. The desk 3 is configured to be able to adjust heights. FIG. 11 shows the desk set to the highest position, and FIG. 13 shows the desk 3 set to the lowest position. FIG. 12 is a plane view of a height adjustment mechanism.
The desk 3 has a top panel 31 , two elevation supporting devices 32 A and 32 B, height adjusting mechanisms 33 A and 33 B, which adjust the height of the top panel 31 through the elevation supporting devices 32 A and 32 B, and an operating device 4 . The top panel 31 is formed in a rectangular form and on the lower face side of the top panel 31 , the height adjusting mechanisms 33 A and 33 B are arranged along the edges facing each other. On each height adjusting mechanism 33 A and 33 B, the elevation supporting devices 32 A and 32 B are connected respectively. Each of the height adjusting mechanisms 33 A and 33 B and the elevation supporting devices 32 A and 32 B have the same configuration, thus the configuration of the height adjusting mechanism 33 B and the elevation supporting device 32 B is explained and the explanation of the height adjusting mechanism 33 A and the elevation supporting device 32 A is omitted.
The height adjusting mechanism 33 A is connected to the elevation supporting device 32 A and the height adjusting mechanism 33 B is connected to the elevation supporting device 32 B. The elevation supporting device 32 B is provided with two leg members 321 B and 322 B, and a fulcrum axis 323 B rotatably connects the leg members 321 B and 322 B at the center. The fulcrum axis 323 B is inserted into an elongate hole 312 B formed on a side panel 311 B fixed to the lower face of the top panel 31 . The elongate hole 312 B is formed in a vertical direction and the fulcrum axis 323 B moves up and down in the elongated hole 312 B corresponding to the change in the height of the top panel 31 .
On the lower end of each of the leg members 321 B and 322 B, a roller is provided, and slide pins 321 P and 322 P are inserted into the upper ends. The height adjusting mechanism 33 B is arranged parallel on the lower face of the top panel 31 , and provided with guiding members 331 and 332 , and an extension mechanism 5 CB. In a guiding space 333 between the guiding members 331 and 332 , upper end portions of the leg members 321 B and 322 B are stored. Slide pins 321 P and 322 P inserted into the upper end portion of the each leg members 321 B and 322 B are further inserted into slits 331 S and 332 S formed on the guiding members 331 and 332 .
Between the slide pins 321 P and 322 P protruding outside of the guiding space 333 , an extension mechanism 5 CB is installed. The configuration of the extension mechanism 5 CB is the same as the extension mechanisms 5 A and 5 B, thus the explanation is omitted. Further, in the configuration of the extension mechanisms 5 A and 5 B, the gas 55 RA and the piston 551 RA for gas spring in the first chamber 55 AA may be omitted. Alternatively, a gas 55 RA and a piston 551 RA for gas spring on the second chamber 55 BA side may be provided to the configuration.
The height adjusting mechanisms 33 A positioned on the facing side are also provided with an extension mechanism 5 CA, and the elevation supporting device 32 A is also provided with leg members 321 A and 322 A, and a furculum axis 323 A. In a case when the extension mechanism 5 CB changes to the direction of compressing, the crossing angle α of the leg members 321 B and 322 B decreases, thereby the height of the top panel 31 elevates as shown in FIG. 11 . Further, in a case when the extension mechanism 5 CB changes to the direction of extension, the crossing angle α of the leg members 321 B and 322 B increases, thereby the height of the top panel 31 descends as shown in FIG. 13 .
The extension mechanisms 5 CA and 5 CB are operated by the operating device 4 . The configuration and effects are the same as the configuration described above based on FIGS. 1 to 8 , and the same reference numbers are used, thus the explanation is omitted. Onto the slide pins located diagonally on the top panel 31 , connecting pins 345 A and 345 B are provided, and the connecting pins 345 A and 345 B are connected with a link mechanism 34 . The link mechanism 34 has an oscillating member 341 rotatably supported by a rotation axis 342 on the center of the lower face of the top panel 31 , and connecting members 343 A and 343 B are oscillatably connected on the both ends of the oscillating member 341 . One end of each of the connecting members 343 A and 343 B are connected to the oscillating member 341 through the furculums 344 A and 344 A, and the other ends are oscillatably connected to each of connecting pin 345 A and 345 B. Such a link mechanism 34 equalizes the distance of the leg members at the height adjusting mechanisms 33 A and 33 B on the both ends.
FIG. 14 is an overall perspective view of a table 7 , which is another example of use of the operating device 4 . The table 7 has a circular shaped top panel 71 , and three leg sections 72 A, 72 B and 72 C. Each of the leg section 72 A, 72 B and 72 C has the same configuration, thus the configuration of the leg section 72 A is explained and the explanations for the other leg sections are omitted. FIG. 15 is a cross-sectional perspective view of the leg section 72 A. The leg section 72 A has a cylindrical form inner storing section 74 A and an armor body 73 A. The armor body 73 A is fixed to the lower face of the top panel 71 , and the lower end has an opening. In this opening, the inner storing section 74 A is inserted. Inside the inner storing section 74 A, the extension mechanism 5 DA is stored, the cylinder main body 51 A is located on the lower side, and the piston rod 52 A protrudes upward. The action section 41 C connected to the front end of the piston rod 52 A is fixed to the top panel 71 side. Onto the action section 41 C, the branch channel 422 B is connected and extends outward from the armor body 73 A.
Similarly, the other leg sections 72 B and 72 C have the inner storing sections 74 B and 74 C, and the armor bodies 73 B and 74 C, and each of the armor body stores the extension mechanisms. In these three extension mechanisms, the operating device 4 locks and releases the extending position, and the extension of the extension mechanisms adjusts the height of the top panel 71 . That is, the height of the top panel 71 increases as the extension mechanism extends, and the height of the top panel 71 decreases as the extension mechanism contracts.
The bifurcating section 6 of the operating device 4 operates the extension mechanism and has three flow rate regulating sections, and three bifurcating channels communicating to each of the flow rate regulating sections. Each bifurcating channel is connected to one end of the branch channels 421 B, 422 B and 423 B, and the other ends are connected to the action section 41 C of the extension mechanism integrated into each leg section 72 A, 72 B, and 72 C. By configuring in this way, the flow rate of the pressure communicating medium supplied from the operating section 41 A is distributed equally to each of the leg sections 72 A, 72 B and 72 C. And the leg sections 72 A, 72 B, and 72 C start or stop extending and contracting at the same time.
The present invention is explained with reference to examples, however, the present invention is not limited to these. For example, the operating device of the present invention may be applied to anything that adjusts the operating amount by communicating the pressure, and not limited to the nursing care bed, desk, or table. For example, the operating device of the present invention may be applied to a foot pedal for an automobile (such as a foot brake or a gas pedal). Also, various members are explained above, however, all of the members explained above may not be necessary to function each unit. For example, in the flow rate regulating unit, the compressed spring is used as a bias member, however, the bias member other than the compressed spring may be used and the function to regulate the flow rate of the pressure communicating medium can be fulfilled.
The conducing channel and the branch channel may be configured with a thermoplastic resin. As an effect, the thermoplastic resin softens and is capable of expanding outward in a case when the pressure communicating medium expands due to an increase in an ambient temperature, thereby the increase in volume from the rise in the temperature of the pressure communicating medium can be absorbed in the expansion. Specially, in a system in which the pressure communicated though the pressure communicating medium is operated by converting the pressure by the pressure operating unit into the switching operation of the position fix state and the released state of the positioning unit, the thermal expansion of the pressure communicating medium can suppress the pressure from reaching the release state from the position fix state.
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The objective of the present invention is to provide a device that accurately communicates a subtle variation of an operation side to an action side. Specifically, in the present invention, an operating device is provided to perform a lock release operation of an extension device. The operating device feeds oil to a valve chamber by pressing a piston. When the flow rate of the fed oil is excessive, the valve is pressed to an opening resisting a biasing force of a compressed spring, thereby a rapid increase in the oil supplied to the action section is suppressed. Further, the supplied oil is suppressed to a very small amount by the throttle section, thereby an increase in the operation amount on the action section side is suppressed while maintaining the supply of the oil.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. §119(e) of the earlier filing date of U.S. provisional patent application No. 61/790,213 filed on Mar. 15, 2013.
BACKGROUND OF THE INVENTION
[0002] Various formulations for effervescent tablets have been disclosed in U.S. Pat. No. 5,178,878; U.S. Pat. No. 6,200,604; U.S. Pat. No. 8,119,158; U.S. Pat. No. 6,974,590; U.S. Pat. No. 5,223,264; U.S. Pat. No. 5,458,879; EP 1,814,831; US 2011/0281008; U.S. Pat. No. 5,171,571; U.S. Pat. No. 5,817,337; EP 2,515,857; U.S. Pat. No. 6,066,355; U.S. Pat. No. 5,707,654; and U.S. Pat. No. 5,888,544, which are hereby incorporated by reference in their entireties. However, these teach directly mixing the acid and base parts of the effervescent couple, along with other excipients, before tableting. EP 1,945,190 teaches the wet granulation of the acid and the active with silicon dioxide. We found that using a variety of these methods resulted in sticking of the mixture to the tablet punches, which results in a loss of active potency over the course of the run. Alternatively, U.S. Pat. No. 3,577,490 (which is hereby incorporated by reference in its entirety) states that in order to get a tablet which can be manufactured with commercially feasible tableting rates, that the use of Mg stearate and other non-water soluble lubricants must be avoided.
SUMMARY OF THE INVENTION
[0003] The present invention encompasses a method of manufacturing an effervescent tablet using a dry, direct compression process which does not result in the sticking of the mixture to be tableted to the punches.
DETAILED DESCRIPTION OF THE INVENTION
[0004] Initially, a blend compress process was evaluated and determined to be unacceptable due to poor compression characteristics of the final blend, in particular sticking. In an effort to improve the processing characteristics, experiments were conducted utilizing a series of blending and milling steps prior to compression. The process of individually blending the effervescent agents (sodium bicarbonate/sodium carbonate and citric acid) with the glidant (silicon dioxide) followed by the milling process, and incorporating the filler (mannitol) and disintegrant (sodium starch glycolate) through blending and milling steps, produced a blend with acceptable flow, density, and tableting characteristics. The processes and formulations of the present invention result in good tablets across all normal operating conditions, including in the higher humidity range of 20-60% relative humidity. As such, the present invention provides a robust method of formulating solid dosage forms that is resilient to traditionally disruptive variables, such as humidity.
[0005] The process of coating the acid and/or base components with the glidant protects these agents from ambient moisture as well as from reaction with each other. When either event occurs, the mixture that is in the process of being tableted becomes sticky and gummy. The formulations exemplified here use colloidal silicon dioxide as a coating agent. However, any neutral, non-hygroscopic material with a small enough particle size would function in the same way to evenly coat and protect the acid and/or base component from adventitious reaction with water and/or the complementary half of the effervescent couple. Obvious examples of this include silicon dioxide, talc, and starch. Other examples might include diluents such as cellulose derivatives such as hydroxypropylmethyl cellulose (HPMC), hydroxyethyl cellulose (HEC), hydroxypropyl cellulose (HPC), methyl cellulose, ethyl hydroxyethyl cellulose, starch derivatives such as moderately cross-linked starch; acrylic polymers such as carbomer and its derivatives (Polycarbophyl, Carbopol™, etc.), or microcrystalline cellulose such as Avicel.
[0006] Note also that in cases where the acid or base component is not very hygroscopic, then coating of that component is not necessary. See, for examples, some of the following examples where tartaric acid can be used without coating.
[0007] The tablet composition itself is fairly straightforward. Appropriate formulation methods are well known to the person skilled in the art: see, for instance, Pharmaceutical Dosage Form: Tablets. Volume 1, 2nd Edition, Lieberman H A et al.; Eds.; Marcel Dekker. New York and Basel 1989, p. 354-356, and literature cited therein, which are hereby incorporated by reference. Suitable additives cited therein comprise additional carrier agents, preservatives, lubricants, gliding agents, disintegrants, flavorings, and dyestuffs.
[0008] In addition to the active agent and the glidant, other excipients such as binders, lubricants, humectants, disintegrants, basic agents, acidic agents, sweeteners and the like can be used.
[0009] Binder can be selected from, but not limited to, a group comprising ethyl cellulose, gelatine, hydroxy ethyl cellulose, hydroxy methyl cellulose, hydroxypropyl cellulose, hypromellose, magnesium aluminum silicate, methyl cellulose, and povidone.
[0010] Lubricant can be selected from, but not limited to, a group comprising calcium stearate, magnesium stearate, polyethylene glycol, PEG6000, polyvinyl alcohol, potassium benzoate, sodium benzoate, sodium stearyl fumarate, and leucine.
[0011] Humectant can be selected from, but not limited to, a group comprising anhydrous sodium sulphate, silica gel, and potassium carbonate.
[0012] Disintegrant can be selected from, but not limited to, a group comprising carboxymethyl cellulose calcium, carboxymethyl cellulose sodium, microcrystalline cellulose, silicon dioxide, croscarmellose sodium, crospovidone, hydroxypropyl cellulose, methyl cellulose, povidone, magnesium aluminium silicate, starch, and combinations thereof.
[0013] Diluent can be selected from, but not limited to, a group comprising calcium carbonate, calcium sulfate, dibasic calcium phosphate, tribasic calcium sulfate, calcium sulfate, microcrystalline cellulose, lactose, magnesium carbonate, magnesium oxide, maltodextrine, maltose, mannitol, sodium chloride, sorbitol, starch, xylitol, and combinations thereof.
[0014] The alkaline component of the effervescent couple can be any suitable alkaline effervescent compound, and typically it is an inorganic base (e.g., an alkali metal carbonate) that is safe for human consumption and provides an effective and rapid effervescent disintegration upon contact with water and the acid compound. The alkaline effervescing compound may be selected from the group consisting of carbonate salts, bicarbonate salts, and mixtures thereof. In some embodiments, the alkaline compound is sodium bicarbonate, sodium carbonate anhydrous, potassium carbonate, and potassium bicarbonate, sodium glycine carbonate, calcium carbonate, L-lysine carbonate, arginine carbonate, and combinations thereof. In some embodiments, the alkaline effervescing compound is sodium bicarbonate, potassium bicarbonate, sodium carbonate, or mixtures thereof.
[0015] The acid component of the effervescent couple can be any suitable acid for effervescent compositions. Typically, the acid is an organic or mineral acid that is safe for consumption and which provides effective and rapid effervescent disintegration upon contact with water and the alkaline effervescent compound. The acid may be selected from the group consisting of citric acid, tartaric acid, malic acid, fumaric acid, adipic acid, succinic acid, acid anhydrides, related organic acids, and their mixtures. In some embodiments, the acid is citric acid, and especially useful is anhydrous citric acid or tartaric acid.
[0016] The acid salt of the composition can be any suitable acid salt or any mixture of suitable salts. Examples of such a suitable acid salt include disodium dihydrogen pyrophosphate, acid citrate salts including mono sodium citrate, and other salts of related organic acids. Combinations thereof are possible. In some embodiments, the acid salt is a salt of citric acid or tartaric acid, and especially useful is monosodium citrate or monosodium tartarate.
EXAMPLE 1
[0017] Initial development studies were conducted using placebo blends. Based on information found in the literature, an effervescent dosage form was manufactured to evaluate tablet physical properties such as hardness, thickness, friability and disintegration time. These blend/compress experiments exhibited marginal compressibility with a maximum hardness of 3.5 kp, resulting in a tablet friability of greater than 1% for these formulations. Additionally, sticking was observed during the compression process. The spray dried mannitol exhibited slightly better compressibility and less sticking than the granular grade of mannitol. These experiments are summarized in the Table 1.
[0000]
TABLE 1
Placebo Effervescent Dosage Form Experiments
Experiment number
X08-036
1A1
1A2
AB1
2B2
Part I
mg/unit
%
mg/unit
%
mg/unit
%
mg/unit
%
Mannitol (spray-dried)
102
51
255
51
255
51.0
Mannitol (granular)
255
510
Sodium bicarbonate
42
21
105
21
105
21
105
210
Sodium carbonate
16
8
40
8
40
8
40
8.0
Sodium starch
8
4
20
4
20
4
20
4.0
glycolate (explotab/
Citric Acid,
30
15
75
15
75
15
75
15.0
Anhydrous
Magnesium Stearate
2
1
5
1
5
1
5
1.0
(Veg)
Total Core Weight
200
100
500
100
500
100
500
100
Process
Screen/Blend
Screen/Bag Blend
Screen/Blend
Screen/Blend
(8 quart)
(4 quart)
(4 quart)
Compression/Tablet
properties
Notes
All of Part II
Material was
Repeat of 1A2
Repeat of 1B1
including Mag
blended, a sample
using a 4 quart
using Granular
was blended in
was pulled for
blender. Material
Mannitol.
an 8 quart
carver testing.
blended for 10
Maximum hardness
blender for 15
The mag was
minutes, mag
1.2 kp. Filming
minutes.
added and
added blended
occurred on
Tablets
continue to blend.
additional 5
punches during the
capping off the
Samples were
minutes.
short compression
press.
pulled at several
Maximum
time (1700 tablet
Maximumhard
bland time
hardness 3.5 kp.
batch size)
ness 2.5 kp.
intervals. Carver
No sticking
Sticking on
Test demonstrated
occurred during
punches (8000
a lubricant blend
the short
tablet batch
time
compression time
size).
compressibility
(1700 tablet batch
correlation.
size)
EXAMPLE 2
[0018] In an effort to minimize the observed sticking, a series of experiments were conducted to improve processing characteristics for the effervescent dosage form utilizing a series of blending and milling steps prior to compression. The experiments are summarized in Table 2. It was observed that the citric acid in the presence of the sodium carbonate/sodium bicarbonate resulted in the filming/sticking of the material to the punch faces during compression. By pre-blending the sodium carbonate/sodium bicarbonate with silicon dioxide (Syloid) and passing it through a mill as well as pre-blending the citric acid with silicon dioxide prior to milling, the sticking was eliminated during the compression process.
[0000]
TABLE 2
Effervescent Dosage Form Blending/Milling Experiments containing Citric Acid
Experiment Number X08-36
97A2
97B1
97C1
97D1
mg/unit
%
mg/unit
%
mg/unit
%
mg/unit
%
Part I
Mannitol (mannogem EZ spray
98.00
49.0
98.00
49.0
98.00
49.0
98.00
49.0
dried)
Syloid 244FP
2.00
1.0
2.00
1.0
1.00
0.5
1.40
0.7
Sodium Starch Glycolate
8.0
4.0
8.0
4.0
8.0
4.0
8.0
4.0
Sodium Bicarbonate
42.0
21.0
42.0
21.0
42.0
21.0
42.0
21.0
Sodium Carbonate
18.0
9.0
18.0
9.0
18.0
9.0
18.0
9.0
Part II
Citric Acid granular
30.0
15.0
30.0
15.0
30.0
15.0
30.0
15.0
Syloid 244FP
1.00
0.5
0.60
0.3
Part III
Magnesium Stearate
2.0
1.0
2.0
1.00
2.0
1.00
2.0
1.00
Total Core Weight
200.0
100.0
200.0
100.0
200.0
100.0
200.0
100.0
Processing Comments:
Premix
Premix
Premix
Premix
carbonates with
carbonates
carbonates
carbonates
syloid. Clean
with syloid
with syloid
with syloid
mill with Part II.
increase
pass through
pass through
Compressed on
mixing time.
mill. Premix
mill. Premix
Hata. Upper
Clean mill
citric acid with
citric acid with
punch faces light
with Part II.
syloid then
syloid then
film lead to
Compressed
clean mill with
clean mill with
picking.
on Hata. After
part II. Some
part II. After
60 min run
haze on upper
60 min run
punch faces
punch only.
time punch
had film
faces clean.
present but
Soft sample
improved from
punch faces
97A2.
clean.
EXAMPLE 3
[0019] Additionally an alternative acid was evaluated, summarized in Table 3. It was determined that tartaric acid which is slightly less water soluble than citric acid exhibited less filming/sticking characteristics. It was possible to eliminate the sticking by screening only the sodium carbonate/sodium bicarbonate/silicon dioxide (SYLOID) premix. It was not required to blend the tartaric acid with silicon dioxide.
[0000]
TABLE 3
Effervescent Dosage Form Blending/Milling Experiments containing Tartaric Acid
Experiment Number
93A1
93B1
93C1
mg/unit
%
mg/unit
%
mg/unit
%
Part I
Mannitol (mannogem EZ spray
98.00
49.0
98.00
49.0
98.00
49.0
dried)
Syloid 244FP
2.00
1.0
2.00
1.0
2.00
1.0
Sodium Starch Glycolate
8.0
4.0
8.0
4.0
8.0
4.0
Tartaric Acid
30.0
15.0
Sodium Bicarbonate
42.0
21.0
42.0
21.0
Sodium Carbonate
18.0
9.0
18.0
9.0
Part II
Tartaric Acid
30.0
15.0
30.0
15.0
Sodium Bicarbonate
42.0
21.0
Sodium Carbonate
18.0
9.0
Part III
Magnesium Stearate
2.0
1.00
2.0
1.00
2.0
1.00
Total Core Weight
200.0
100.0
200.0
100.0
200.0
100.0
Premix mannitol
Premix mannitol
Premix carbonates
with syloid.
and carbonates
with syloid then
Clean mill with
with syloid then
screen. Clean mill
Part II. Lower
screen. Clean
with part II.
punch faces
mill with Part II.
Punch faces clean
shiny. Upper
Upper punch
the entire run.
punch faces film
face filming
present. Need to
significantly
blend carbonates
improved.
with syloid then
Remove
screen.
mannitol out of
premix.
EXAMPLE 4
[0020] Studies were conducted to evaluate sorbitol in place of mannitol. It was determined that the sorbitol formulations exhibited increase tablet hardness. Table 4 is a summary of the experiments.
[0000]
TABLE 4
Effervescent Dosage Form Experiments containing Sorbitol or Mannitol
Experiment Number X08-36
95A1
96A1
103A1
100A1
mg/unit
%
mg/unit
%
mg/unit
%
mg/unit
%
Part I
Fentanyl Citrate
0.628
0.3
0.628
0.3
0.628
0.3
0.628
0.3
Mannitol (mannogem EZ
94.372
46.3
97.372
48.7
spray dried)
Sorbitol
94.372
47.2
97.372
48.7
Syloid 244FP
2.00
1.0
2.00
1.0
1.40
0.7
1.40
0.7
Sodium Starch Glycolate
8.0
3.9
8.0
4.0
8.0
4.0
8.0
4.0
Sodium Bicarbondate
42.0
20.6
42.0
21.0
42.0
21.0
42.0
21.0
Sodium Carbonate
21.0
10.3
21.0
10.5
18.0
9.0
18.0
9.0
Part II
Tartaric Acid
34.0
16.7
30.0
15.0
Citric Acid granular
30.0
15.0
30.0
15.0
Syloid 244FP
0.60
0.3
0.60
0.3
Part III
Magnesium Stearate
2.0
0.98
2.0
1.00
2.0
1.00
2.0
1.00
Total Core Weight
204.0
100.0
200.0
100.0
200.0
100.0
200.0
100.0
Tablet Properties
Max hardness
Max hardness
Max hardness
Max hardness
1.4 kp.
4.2 kp.
1.5 kp.
4.5 kp.
[0021] Formulations 103A1 and 100A1 exhibited acceptable potency, content uniformity, and dissolution assays, and were chosen for further development.
[0022] Table 5 discloses a % range of excipients that could be used in Formulations 103A1 and 100A1 m (Table 4):
[0000]
TABLE 5
Target
% range
mg/unit
%
Low
High
Mannitol or Sorbitol
93.372
46.686
25
75
Syloid 244FP
4
2
1
5
Sodium Starch Glycolate
8
4
1
10
Sodium Bicarbonate
42
21
5
30
Sodium Carbonate
20
10
3
15
Citric Acid granular
30
15
5
25
Magnesium Stearate
2
1
0.5
5
Total Core Weight
200
100
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Methods of manufacturing effervescent dosage forms. Methods of manufacturing an effervescent tablet using a dry, direct compression process are disclosed. The methods do not result in the sticking of the mixture to be tableted to the punches during production.
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BACKGROUND
Various functions in motor vehicles today are regulated or controlled by control units. For example, the ignition, fuel injection times and also the electrical power windows or the electrical sunroof are controlled or regulated by such control units. In automotive engineering today, there is an observable trend toward concentrating on a few control units with which numerous functions may be controlled. This concentration on a few control units is associated with a greater number of electrical contacts with which more actuators are controlled or regulated, and also more parameters are detected by sensors. Furthermore, the number of sensors installed is increasing steadily and these in turn require additional electrical contacts on the control units. Control units manufactured in the 1990s had far fewer than 100 contacts, but today it is standard for a control unit to have slightly less than 200 contacts. Efforts are presently underway to furnish control units with approximately 300 contacts.
Already today multiple contacts are combined to form one plug-in module having a plug housing, so that one control unit includes multiple plug-in modules. Accordingly, multiple electrical connectors which are compatible with the plug-in modules or the plug housings and are connected to a wiring harness are also required for detecting the parameters supplied by the sensors and/or for triggering the actuators.
The plug-in modules which are integrated into the control unit and connect the control unit to the sensors and actuators are designed in a plug connector assembly in which the plug connector assembly, which includes the plug-in modules, is manufactured in one piece, monolithically, so to speak, by the plastic injection molding method.
The electrically conductive contacts connecting the printed circuits present in the control unit to the plug connectors of the wiring harnesses are designed as pin contacts made of metal. To manufacture the finished plug connector assembly, the pin contacts are inserted into the injection mold and are sheathed with plastic during the injection molding process. The pin contact protrudes approximately 8 mm out of the plastic surrounding it in the direction of the plug connector. The opposite side of the pin contact is usually bent at an angle for reasons of space and is contacted directly to the printed circuit. Each plug connector assembly is therefore manufactured in accordance with the layout of the printed circuits encompassed by the control units.
On the part of automobile manufacturers, there are strict requirements on the plug connector assembly to be met by the control unit manufacturers. The individual contacts which extend in the direction of the plug connector and are combined to form a plug-in module must provide a position tolerance of 0.4 mm at their contact tips. On the other side, there is an effort on the part of the control unit manufacturers who want to ensure that the contact tips of the contact elements facing the printed circuits are precisely positioned, so that there is no problem with the tips finding the receptacles provided for them on the printed circuits.
Unforeseeable warpage may occur with the plug connector assembly because of the large amount of metal due to the electrical contacts and the irregular distribution within the plug connector assembly as well as the associated possibility of differences in cooling of individual areas inside the plug connector assembly. To be able to meet the tolerances as stipulated above and nevertheless be able to manufacture the plug connector assemblies in a fully automated manner, extensive reworking on an injection molding tool is required after it has been manufactured, thus causing substantial costs.
SUMMARY
There may thus be a need for manufacturing such plug connector assemblies less expensively and with greater flexibility in making changes in plug-in modules.
According to an example embodiment of the present invention, a modular electrical plug connector assembly for control units in a motor vehicle includes a module rack and at least one first and second plug-in module, the first and second plug-in modules being situated side by side and/or in series in the module rack. The first plug-in module includes a first plug housing that is shaped to accommodate a first electrical plug connector. The second plug-in module includes a second plug housing that is shaped to accommodate a second electrical plug connector. The first plug housing includes an electrically conductive first contact element, and the second plug housing includes an electrically conductive second contact element. According to an example embodiment, the modular electrical plug connector assembly is structured for the first plug-in module and the second plug-in module to be positioned in a predetermined position relative to one another in the module rack. In addition, according to an example embodiment, the first and second plug-in modules are each inseparably connected to the module rack by a joining process.
The first and second plug connectors are designed to be complementary to the first and second plug housings and both are connected to a cable, whereby the plug connector includes an electrically conductive contact. The shape of one area of the contact element, provided for contacting with the contact of the plug connector, is complementary to that of the contact of the plug connector. Thus, an electrically conductive connection between the contacts and the contact elements is established by plugging the plug connector into the corresponding plug-in modules. The area of the contact element connected to the plug-in module can be designed as a male contact or as a female contact. It is also possible to include both male and female contacts in one plug-in module. Both the module rack and the plug-in modules are usually made of nonconductive plastic.
According to an example embodiment, the contact elements are introduced into the corresponding plug housing of the plug-in module during the plug housing manufacturing process. For example, according to an example embodiment, the contact elements are inserted into a plastic injection mold and are inseparably connected to the plug housing during the injection molding process. Alternatively, according to another example embodiment, the contact elements are introduced into the corresponding plug housing of the plug-in module and inseparably connected to it after the plug housing has already been manufactured, for example, by shooting the contact elements into the finished plug housing. After the first plug-in module and the second plug-in module or the first and second contact elements have been positioned in relation to one another, the plug-in modules are connected inseparably to the module rack by a joining process, for example by welding or gluing. The individual plug-in modules need not necessarily be situated in one plane; they may also be situated at a predetermined angle to one another.
In another example embodiment of the present invention, the module rack of the modular electrical plug connector assembly is delimited by a front side and a rear side opposite the front side, the module rack including a first passage for the first plug-in module, extending between the front side and the rear side in the direction from the front side to the rear side and a second passage for the second plug-in module, extending between the front side and the rear side in the direction from the front side to the rear side. The first passage is designed in such a way that the first plug-in module which is insertable into the first passage is displaceable across a first plug-in direction and is rotatable about a first axis extending in parallel to the first plug-in direction. The second passage is designed in such a way that the second plug-in module which is insertable into the second passage is displaceable across a second plug-in direction and is rotatable about a second axis extending in parallel to the second plug-in direction.
The plug-in module may be inserted into the module rack from the front side to the rear side of the module rack or from the rear side to the front side of the module rack. The heights of the respective plug-in modules, beyond the front side and beyond the rear side, can be respectively set as needed. The contact elements of the second plug-in module can be positioned accurately in relation to the contact elements of the first plug-in module due to the two or three translational degrees of freedom and the one rotational degree of freedom.
In another example embodiment of the present invention, the first plug housing of the modular electrical plug connector assembly includes first protrusions, these first protrusions being designed in such a way that the first plug-in module cannot be pushed through the first passage. In addition, the second plug housing includes second protrusions, these second protrusions being designed in such a way that the second plug-in module cannot be pushed through the second passage.
The plug-in modules may thus be inserted so far into their corresponding passages that the protrusions belonging to the corresponding housing are in contact with the front side or the rear side of the module rack. The front side or rear side of the module rack in combination with the protrusions thus determine the plane in which the individual plug-in modules are positioned.
In another example embodiment of the present invention, the first protrusions are connected to form a first flange, the first flange being designed in such a way that the first passage is covered by the first flange. The second protrusions are connected to form a second flange, the second flange being designed in such a way that the second passage is covered by the second flange.
This ensures that, regardless of the position of the plug-in module, the flange will reliably cover the corresponding passage. Thus the flange can at the same time also function as the adhesive surface for connecting the plug-in module to the module rack with the aid of a suitable adhesive. The flange can also be inseparably connected to the module rack at the periphery by welding. The adhesive connection as well as the welded connection ensures that the plug-in module is connected to the module rack in a dustproof, splash water-protected and possibly also waterproof and vibration-proof manner.
In another example embodiment of the present invention, a seal is inserted between the first and/or second flange and the module rack.
In another example embodiment of the present invention, the first plug-in module includes first locking elements which are situated on the first plug housing and are inseparably connected to the first plug housing for locking the first plug connector. The second plug-in module includes second locking elements which are situated on the second plug housing and are inseparably connected to the second plug housing for locking the second plug connector.
The plug connectors are locked in this position to the corresponding plug housing with the aid of the locking elements after attachment to the plug-in module. The locking here is designed to be unlockable. The locking ensures that the plug connector may be connected to the plug-in module in a vibration-proof manner. In the case of plug connectors including a small number of contacts in particular, it is possible to omit locking if the holding forces of the contact elements of the plug-in module, which are designed to be complementary to one another, and the contacts of the plug connector are strong enough so that the plug connector is not able to be detached from the plug-in module due to vibrations.
In another example embodiment of the present invention, the first contact element and the second contact element each includes a respective first subelement. The first subelement of the first contact element extends beyond the first plug housing. The first subelement of the second contact element extends beyond the second plug housing. The first subelement of the first contact element and the first subelement of the second contact element are positioned in relation to one another.
The first subelement can also extend in the plug-in direction of the corresponding plug-in module into the module rack as well as against the plug-in direction. The first subelement can also extend across the plug-in direction. The first subelement of the first contact element and the first subelement of the second contact element also need not necessarily extend in the same direction.
The contact elements situated inside the plug-in module are generally positioned accurately in relation to one another due to the manufacturing process of the individual plug-in module. The first subelements will generally extend against the plug-in direction of the plug-in modules, the first subelements being configured to be connected in an electrically conductive manner to the printed circuit of the control unit. There is also a positioning of the individual plug-in modules in relation to one another through a positioning based on the first subelements. Through the accurate positioning of the first subelements of all plug-in modules in relation to one another, it is possible for an electrically conductive connection of the contact elements to the at least one printed circuit of the control unit to be established with no problem even when there is fully automated manufacturing. The accurate positioning may be created, for example, in that the areas of all subelements of the individual plug-in modules, which are accommodated by the at least one printed circuit of the control unit, are provided with a position tolerance of 0.4 mm in relation to one another. These areas may be accommodated, for example, through openings, such as, for example, boreholes in the at least one printed circuit, these areas being connected to the printed circuit in an electrically conductive manner, for example, by soldering after being inserted into the openings.
In another example embodiment of the present invention, the first contact element of the modular electrical plug connection and the second contact element each includes one respective second subelement, the second subelements being situated at an angle to the first subelements, the respective first and second subelements being connected to one another in an electrically conductive manner.
The second subelements are generally connected directly to the printed circuits. The connection may be a soldered connection. The second subelements may also be pressed into the printed circuit. There is also the possibility of connecting the second subelements to plug connectors situated on the printed circuits. Since, for reasons of space, the plug-in modules are generally situated in such a way that the plug-in direction is in parallel to the direction of extension of the circuit board assembled with electrical components, the second subelements generally form a 90° angle to the first subelements, but they may also form any other angle. Depending on the design of the contact points of the printed circuits, the first and/or second subelements may also be designed to be of different lengths within a plug-in module.
In another example embodiment of the present invention, at least one contact element from the group of the first contact element and the second contact element is formed as an electrically conductive pin.
Electrically conductive contacts in pin form may be manufactured in a particularly inexpensive manner. The contacts may be manufactured in one piece. Such pins may include a circular, square or rectangular cross section, for example. The cross-sectional area may be determined on the basis of the electrical currents to be transmitted. The cross-sectional areas for triggering actuators, for example, of the ignition, are generally designed to be larger than the cross-sectional areas for the test of sensors.
In another example embodiment of the present invention, the first plug-in module is different from the second plug-in module. For example, according to an example embodiment, the number of contact elements within the first plug-in module is different than the number of contact elements of the second plug-in module. According to an example embodiment, the plug housings of the particular plug-in modules are also designed differently.
In another example embodiment of the present invention, a control unit for a motor vehicle is equipped with a modular electrical plug connector assembly.
Some advantages of the present invention include the following. The modular configuration of the electrical plug connector assembly with the aid of a module rack and plug-in modules provides the possibility of an inexpensive and space-saving integration of the plug-in modules. The shape of the plug-in modules can be designed individually. In addition, the plug-in modules can be situated individually. The warpage and shrinkage problems mentioned at the outset, which are the result of using plastic with regard to shape and load tolerances, have largely no effect, thereby reducing or completely eliminating any tool correction costs with regard to the plug-in module position tolerances. A layout of the contact elements which ensure transmission of signals from the interior of the control unit or from the printed circuits to the plug connectors and the cables connected to them on the outside offers a new freedom of design. In addition, the injection molding tools may have a simpler design and may thus be less expensive. Due to the fact that the plug-in modules are manufactured individually, they can be manufactured with a higher precision and allow the plug forces for the plug connectors to remain within narrower limits. In addition, the modular configuration permits a greater freedom in the design of plug connectors connected to a cable.
Example embodiments of the present invention are described herein in conjunction with a modular electrical plug connector assembly including a module rack and plug-in modules as well as with a control unit. It will be clear to those skilled in the art that the individual features described herein can be combined in various ways to arrive at different embodiments of the present invention.
Specific example embodiments of the present invention are described below with reference to the accompanying figures. The figures are only schematic and are not drawn to scale.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a modular electrical plug connector assembly including a module rack and plug-in modules in a perspective view, according to an example embodiment of the present invention.
FIG. 2 shows a cross section of the module rack including two plug-in modules, according to an example embodiment of the present invention.
FIG. 3 shows a cross section of the module rack including one plug-in module and a seal, according to an example embodiment of the present invention.
FIG. 4 shows a rear side of the module rack assembled with plug-in modules in a top view, according to an example embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 1 shows a perspective view of a modular electrical plug connector assembly 2 including a module rack 4 , a first plug-in module 6 , a second plug-in module 8 , and a third plug-in module 10 . First plug-in module 6 , second plug-in module 8 , and third plug-in module 10 are situated either side by side or in series. First plug-in module 6 includes a first plug housing 12 , second plug-in module 8 includes a second plug housing 14 , and third plug-in module 10 includes a third plug housing 16 . All plug housings 12 , 14 , 16 are shaped to accommodate one electrical plug connector (not shown here) in a plug-in direction S marked with an arrow. In addition, a first contact element 18 is situated in first plug-in module 6 , a second contact element 20 is situated in second plug-in module 8 , and a third contact element 22 is situated in third plug-in module 10 . Contact elements 18 , 20 , and 22 are designed to be electrically conductive. All contact elements 18 , 20 , and 22 extend in plug-in direction S beyond corresponding plug housing 12 , 14 , and 16 . Plug-in modules 6 , 8 , and 10 are situated in module rack 4 , in such a way that corresponding plug housings 12 , 14 , and 16 extend from a front side 24 of module rack 4 against plug-in direction S. A rear side 26 opposite front side 24 of module rack 4 faces an interior of a control unit (not shown here). All contact elements 18 , 20 , and 22 are designed as one-piece pin contacts in the example embodiment described here. The portion beyond plug housing 12 , 14 , and 16 with respect to plug-in direction S is divided into a first subelement 50 and a second subelement 52 . First subelement 50 extends in plug-in direction S. Second subelement 52 is at an angle to the first subelement, first subelement 50 and second subelement 52 forming an angle α. In the illustrated example embodiment, the angle α is 90°. First subelement 50 and second subelement 52 may also be of different lengths within a plug-in module 6 , 8 , 10 . The at least one second subelement 52 is provided for being accommodated in and/or on a printed circuit (not shown here). In the present example embodiment, the at least one second subelement 52 is shaped for insertion into boreholes in a circuit board of the printed circuit and soldered there. Second subelements 52 are aligned in parallel to one another and extend all in the same direction. Second subelements 52 are positioned in relation to one another in such a way that the position tolerance at all ends provided for soldering to the circuit board is 0.4 mm. In addition, the position tolerance of second subelements 52 to rear side 26 of module rack 4 may also be 0.4 mm.
First plug housing 12 delimits a first interior space 13 , second plug housing 14 delimits a second interior space 15 , and third plug housing 16 delimits a third interior space 17 . Third subelements 54 (shown in FIG. 2 with respect to plug-in module 6 ), designed as pins, protrude approximately 8 mm into interior spaces 13 , 15 , and 17 of plug housings 12 , 14 , and 16 . First locking element 46 and second locking element 48 are formed on the narrow sides of plug-in modules 6 , 8 , and 10 . Locking elements 46 and 48 lock the plug connectors inserted into plug housings 12 , 14 , and 16 (not shown here). To remove the plug connectors from plug housings 12 , 14 , and 16 , locking elements 46 are 48 are unlockable, the release mechanism mostly being formed on the plug connectors. Locking elements 46 and 48 prevent the plug connectors from being unlockable automatically from plug-in modules 6 , 8 , and 10 due to vibrations, for example. Plug-in modules 6 , 8 , and 10 are inseparably connected to module rack 4 .
FIG. 2 shows a cross section through module rack 4 including first plug-in module 6 and third plug-in module 10 , according to an example embodiment of the present invention. A first passage 28 , a second passage 30 and a third passage 32 are formed in module rack 4 . First passage 28 is designed to accommodate first plug-in module 6 , second passage 30 is designed to accommodate third plug-in module 10 , and third passage 32 is designed to accommodate second plug-in module 8 (not shown here). Passages 28 , 30 , and 32 extend between front side 24 and rear side 26 of module rack 4 in the direction from front side 24 to rear side 26 . It is clearly apparent that first plug-in module 6 is different from third plug-in module 10 . In the present example embodiment, first plug-in module 6 and third plug-in module 10 are inserted from rear side 26 of module rack 4 along a plug-in direction E to front side 24 of module rack 4 . Plug-in direction E extends in parallel to passages 28 , 30 , and 32 . Plug-in direction E of plug-in modules 6 and 10 is against plug-in direction S of the plug connectors (not shown here). It is clearly apparent that passages 28 and 30 are larger than corresponding plug-in modules 6 and 10 . Plug-in modules 6 and 10 here may be displaced across plug-in direction E for more accurate positioning. In addition, a first axis 34 extends in parallel to plug-in direction E, about which first plug-in module 6 is rotatable at a predetermined angle. A second axis 36 also extends in parallel to plug-in direction E about which third plug-in module 10 is also rotatable at a predetermined angle. The rotatability of plug-in modules 6 and 10 is indicated by curved double arrows 56 . To prevent plug-in modules 6 and 10 from being insertable through passages 28 and 30 , respectively, first plug housing 12 includes a first peripheral flange 38 and third plug housing 16 includes a second peripheral flange 40 . According to an example embodiment, the flanges 38 and 40 are designed like disks, and in such a way that they cover passages 28 and 30 , regardless of the position within passages 28 and 30 assumed by plug-in modules 6 and 10 .
Plug-in modules 6 and 10 are positioned by the fact that first subelements 50 protruding beyond plug housings 12 and 16 are set at a predetermined distance from one another. In this condition, individually manufactured plug-in modules 6 and 10 are inseparably connected to module rack 4 , which is designed in one piece with the aid of a joining process. In the example embodiment shown here, third plug-in module 10 has been welded to module rack 4 , the weld seam being represented by a welding bead 42 . The peripheral weld seams ensure that plug-in modules 6 and 10 are connected to module rack 4 in such a way that neither dust nor splashed water is able to migrate between (a) plug-in modules 6 and 10 and (b) passages 28 and 30 from front side 24 to rear side 26 and thus possibly be able to penetrate into an interior unit at rear side 26 .
FIG. 3 shows a cross section through module rack 4 including first plug-in module 6 , according to an example embodiment of the present invention. In this example embodiment, a seal 44 covering first passage 28 is situated between first flange 38 and rear side 26 of module rack 4 .
FIG. 4 shows rear side 26 of module rack 4 including plug-in modules 6 , 8 and 10 in a top view. Rear side 26 faces the printed circuit (not shown here). Contact elements 18 , 20 , and 22 of corresponding plug-in modules 6 , 8 and 10 are shown to be of different thicknesses. This is also continued in a cross-sectional area of individual contact elements 18 , 20 and 22 , so that a cross-sectional area of second contact element 20 is larger than a cross-sectional area of first contact element 18 , for example. Thus, second contact element 20 is able to transmit higher currents than first contact element 18 , for example to control or regulate actuators such as, for example, the ignition or the fuel injection, while, for example, parameters detected by sensors are transmitted with the aid of contact elements 18 and 22 including the smaller cross section(s). In the example embodiment shown here, all second subelements 52 end at the same height. All contact elements 18 , 20 , and 22 of corresponding plug-in modules 6 , 8 , and 10 are electrically conductively connected to the printed circuit. The electrical conductivity in the example shown here is ensured, for example, by a soldering process. For this purpose, the second subelements are therefore inserted into boreholes located in a circuit board of the printed circuit.
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A modular electrical plug connector assembly for control units in a motor vehicle includes a module rack and at least first and second plug-in modules that are situated in the module rack and that each includes respective housings shaped to accommodate respective electrical plug connectors. The housings are provided with respective electrically conductive contact elements. The first and second plug-in modules are positioned relative to one each other in a predetermined manner in the module rack, and are inseparably connected to the module rack by a joining process.
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RELATED APPLICATIONS
This application claims priority from U.S. patent application Ser. No. 09/724,160 filed on Nov. 28, 2000 and PCT Patent Application Serial No. PCT/US01/44299 filed on Nov. 27, 2001.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an insect repellent composition. More particularly, the present invention relates to an insect repellent exhibiting extended duration of repellency on the skin. Further, the present invention relates to such a composition exhibiting water, sweat, and wear resistance. As used herein, the term “insect” is intended to mean any insect or arachnid.
2. Description of the Prior Art
Insect repellent compositions are available commercially in a variety of product forms, such as aerosol and pump sprays, creams, lotions and gels. Depending upon the product form, the compositions may be administered to both the skin and to clothing. The compositions may be administered in preparation for a variety of outdoor situations, such as picnicking, hiking, fishing, swimming and exercise.
A common problem associated with insect repellent compositions is a lack of duration of repellency. This translates into insufficient repellency and the need to re-apply often. Insect repellent compositions may wash off from exposure to water, sweating and/or physical contact with the skin.
It would be desirable to increase the duration of repellency of insect repellent compositions on the skin. It would further be desirable to have insect repellent compositions that resist removal by exposure to water, sweating and physical contact.
U.S. Pat. No. 4,913,897 to Chvapil et al. is directed to hydrogel compositions that form films on the surface of the skin to protect it against exposure to toxic substances and infections. This patent provides that such films may also contain an insect repellent. The urethane polymers of the present invention are not hydrogels nor do they form hydrogels in the present invention.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an insect repellent composition exhibiting extended duration and enhanced degree of repellency on the skin.
It is another object of the present invention to provide such a composition that provides even application and is water, sweat, and wear resistant.
It is a further object of the present invention to provide such a composition that is aesthetically acceptable.
These and other objects of the present invention are achieved by an insect repellent composition having an amount of an insect repellent active sufficient to repel insects when the composition is applied to the skin. The composition also has an amount of urethane polymer sufficient to form a thin, substantially continuous film on the skin. The composition also has a cosmetically acceptable vehicle.
Further according to the present invention, there is provided a method of repelling insects from the skin. The composition described above is applied to the skin. A thin urethane film, that is different from a hydrogel film, remains on the skin to enhance the function and effectiveness of the insect repellent. This urethane film is substantially uniform and provides superior coverage over the peaks and valleys of the skin surface, allowing for reduction of unprotected skin areas.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a bar graph illustrating the duration of insect repellency with varying levels of urethane polymers.
FIG. 2 is a view of a photograph of showing the topography of an artificial skin substrate without the application of the present invention.
FIG. 3 is a view of a photograph showing the topography of a skin substrate with and without the application of an acrylic polymer not of the present invention.
FIG. 4 is a view of a photograph showing the appearance of a skin substrate with and without the application of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention surprisingly found that an insect repellent composition can be produced that exhibits extended duration of repellency on the skin, and also enhanced insect repellency. In addition, the composition has superior spread characteristics on the skin. The composition may also exhibit water, sweat and wear resistance.
The composition can be formulated to be substantially transparent or otherwise aesthetically acceptable to impart a pleasant feel or sensation to the skin.
When applied to the skin, the present composition leaves a uniform film on the surface of the skin. The composition, which exhibits superior spread characteristics, provides more uniform and consistent coverage on the skin. The film has been found to maintain the duration of the insect repellent active(s) for a longer period of time than it would otherwise remain without the urethane polymer. The film also affords sustained release of the active. Additionally, enhanced resistance to water, sweat, and wear may be observed. In view of the foregoing advantages, the film has an enhanced degree of insect repellency for a given amount of insect repellent active employed. Thus, the amount of insect repellent active applied to the skin can be minimized.
The film-forming component of the present composition is a urethane polymer resin. Urethane polymers are formed by reactions of diisocyanate and glycol monomers. Preferred urethane polymer resins for use in the present invention are of the following formula:
wherein R and R′ are, independently, any linear or branched alkyl, alkylene, aliphatic or aromatic group having from 1 to about 30 carbon atoms, preferably about 6 to about 24 carbon atoms, and n is an integer from 2 to about 1000. When R′ is cyclic, it preferably contains 6 or more carbon atoms. Urethane polymer resins useful in the present invention can be either hydrophobic or hydrophilic.
The most preferred urethane polymer resins are those referred to in the art as Polyurethane-1, Polyurethane-2, Polyurethane-4, Polyurethane-5 or mixtures thereof. These urethane polymer resins are described in the International Cosmetic Ingredient Dictionary and Handbook, 8 th edition, Printed Edition Pages 1152–1153, which is incorporated herein by reference.
The urethane polymer is present in an amount about 0.1 wt. % to about 20 wt. % based on the total weight of the composition. The amount of the urethane polymer is preferably about 0.5 wt. % to about 10 wt. %, and, most preferably, about 1 wt. % to about 5 wt. %, based on the total weight of the composition.
The insect repellent or insect repellent active employed in the present composition may be any known in the art. Such actives that can be used in the present invention include, but are not limited to, N,N diethyl-m-toluamide (DEET), ethyl butylacetylaminopropionate (IR3535 by Merck Co.), hydroxy-ethyl isobutyl piperidine carboxylate (1-piperidinecarboxylic acid) (Bayer KBR 3023), oil of citronella, soy bean oil, lemon grass oil, geranium/geraniol oil, p-menthane-3,8-diol, or mixtures thereof. Other actives that can be used in the present invention are disclosed in U.S. Pat. Nos. 5,130,136 and 5,698,209, which are incorporated herein by reference.
The amount of insect repellent active is about 0.1 wt. % to about 70 wt. % based on the total weight of the composition. The amount of insect repellent active is preferably about 0.1 wt. % to about 25 wt. %, and, most preferably, about 5 wt. % to about 25 wt. %, based on the total weight of the composition.
The present composition may take any form known in the art. Such forms include, but are not limited to, a cream, lotion, gel, solution, ointment, towelette, mousse, stick, or pump spray or aerosol. If an aerosol spray, the composition may contain propellents, such as hydrocarbons, hydrofluorocarbons, chlorofluorocarbons and ethers. The composition may be aqueous or anhydrous. The composition may further be in an emulsion form.
The present composition preferably has a vehicle. Such vehicles may be any known in the art including, for example, water; vegetable oils; esters such as octyl palmitate, isopropyl myristate and isopropyl palmitate; ethers such as dicapryl ether and dimethyl isosorbide; alcohols such as ethanol and isopropanol; fatty alcohols such as cetyl alcohol, stearyl alcohol and behenyl alcohol; isoparaffins such as isooctane, isododecane and isohexadecane; silicone oils such as cyclomethicone, dimethicone, dimethicone cross-polymers, polysiloxanes and their derivatives, preferably organomodified derivatives; hydrocarbon oils such as mineral oil, petrolatum, isoeicosane and polyisobutene; polyols such as propylene glycol, glycerin, butylene glycol, pentylene glycol and hexylene glycol; waxes such as beeswax and botanical waxes; and mixtures of the foregoing.
The vehicle is about 0.1 wt. % to about 99.8 wt. % of the total weight of the composition. Preferably, the vehicle is about 10 wt. % to about 93 wt. % of the total weight of the composition.
Optionally, the present composition may further include a sunscreen. The sunscreen may be any sunscreen know in the art. Such sunscreens include, but are not limited to, oxybenzone, sulisobenzone, dioxybenzone, menthyl antranilate, para aminobenzoic acid (PABA), dea methoxycinnamate, octyl methoxycinnamate, octocrylene, drometrizole trisiloxane, octyl salicylate, homomenthyl salicylate, octyl dimethyl PABA, TEA (triethanolamine) salicylate, titanium dioxide, zinc oxide, butylmethoxy dibenzoylmethane, methyl benzilidene camphor, octyl triazone, terephthalydiene, dicamphor sulfonic acid, ethyl PABA, hydroxy methylphenyl benzotriazole, methylene bis-benzotriazoyltetramethylbutylphenol (MBBT), bis-ethylhexyl oxyphenol) methoxyphenol triazine (BEMT), and mixtures thereof. Other sunscreens include those disclosed in U.S. Pat. No. 5,000,937, which is incorporated herein.
The sunscreen is preferably about 1 wt. % to about 45 wt. % of the total weight of the composition. Preferably, the sunscreen is about 2 wt. % to about 35 wt. % of the total weight of the composition. Most preferably, the sunscreen protects against both UVA and UVB radiation, and provides a SPF factor of at least about 2 and more preferably at least about 4. The preferred range of SPF protection is about 10 to about 50 and most preferably about 15 to about 30.
Further optionally, the present composition may have one or more of the following additional ingredients: anesthetics, anti-allergenics, antifungals, anti-inflammatories, antiseptics, chelating agents, colorants, depigmenting agents, emollients, emulsifiers, exfollients, fragrances, humectants, lubricants, moisturizers, pharmaceutical agents, preservatives, skin penetration enhancers, stabilizers, surfactants, thickeners, viscosity modifiers, vitamins or any combinations of these ingredients.
EXAMPLES 1 AND 2 AND CONTROL
Two compositions of the present invention were tested for duration of insect repellency. A control composition (“the Control”) was likewise tested.
The compositions of Examples 1 and 2 had polyurethane concentrations of 1.0 wt. % and 2.0 wt. %, respectively, based upon the total weight of the compositions. The Control did not have any polyurethane (zero wt. %). The polyurethane resin employed was Polyurethane-1. All the compositions had 20 wt. % of IR3535 (Merck) as an insect repellent active, and q.s. with a mixture of alcohol and water.
The duration of insect repellency was tested on five subjects in a cage test utilizing a 1 cubic meter cage containing 200 mosquitoes.
The results are set forth in FIG. 1 . The inclusion of polyurethane significantly increased the duration of repellency at both the 1.0 wt. % and 2.0 wt. % levels.
Optical Profilometry of Polymer Films
To determine the attributes of the present invention, an optical profilometry study of the present invention was performed on samples of an artificial skin substrate. FIG. 2 shows a 3-dimensional interactive display of the bare substrate as viewed under an optical profiler microscope. The peaks and valleys of the skin surface are clearly pronounced. As a comparison, tape was placed over the left side of a substrate sample. An insect repellent composition containing a conventional acrylic film forming polymer was applied to the right side of the substrate, allowed to dry and the tape was removed. A digital image was taken of this substrate surface using a Wyko NT1000 Optical Profiler made by Vecco. As is evident in FIG. 3 , there was bleeding of the insect repellent composition under the tape, as well as non-uniform coverage of the peaks and valleys over which it was applied. As a further comparison, similar insect repellent composition having the urethane polymer film former of the present invention was prepared. Tape was placed over the left side of a substrate sample, and the inventive composition was applied to the right side and allowed to dry. The tape was removed and a digital image was taken of the substrate surface. As is evident from FIG. 4 , this composition stayed where applied and did not run under the tape. Moreover, there was maximum, substantially uniform coverage of the peaks and valleys over which it was applied.
It should be understood that the foregoing description is only illustrative of the present invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances that fall within the scope of the appended claims.
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Disclosed is an insect repellent composition. The composition has an amount of an insect repellent active effective to repel insects when the composition is applied to the skin, and an amount of a urethane polymer sufficient to form a film on the surface of the skin. The composition also has a cosmetically-acceptable vehicle. Also disclosed is a method of repelling insects from the skin by applying the composition to the skin.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. application Ser. No. 13/071,942 filed Mar. 25, 2011, which claims priority to U.S. Provisional Application No. 61/407,808 filed Oct. 28, 2010, the entire contents of each of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] A lit door handle for a vehicle is provided. More particularly, a door handle is provided that includes a light source, such as an LED inside a door handle body of a vehicle, and a light-transmitting member, such as clear resin, positioned between the light source and the door handle body, and partially exposed to the door handle body.
BACKGROUND OF THE INVENTION
[0003] Discussion of Background
[0004] It is known to include at least one LED in a door handle. Conventional door handle lighting systems, such as those described in U.S. Patent Application Publication No. 2010/0117381, light a back side of a door handle, so as to illuminate a car body side of the door handle. Other conventional door handles, such as those described in U.S. Patent Application Publication No. 2006/0282987, include LEDs that are located on a face of the door handle.
SUMMARY OF EXEMPLARY ASPECTS OF THE ADVANCEMENTS
[0005] In one aspect, a door handle apparatus for a vehicle is provided. The door handle includes a door handle body that is configured to be disposed at a door of the vehicle. A light source is mounted inside the door handle body. A light-transmitting member is located between the light source and the door handle body. The light-transmitting member is partially exposed to an exterior of the door handle body.
[0006] A door handle for a vehicle that includes an intelligent lighting system that provides continuous lighting is provided. The door handle includes a door handle body. The door handle body includes a first body member and a second body member. The first body member and a second body member are assembled together so as to define an interior space within the door handle. A light source is disposed within the interior space of the door handle body. At least one light transmission member extends from the interior space of the door handle to an exterior surface of the door handle body so as to provide a continuous band of light along each of an upper and lower surface of the door handle.
[0007] In another aspect, a method for providing door lock status information via an intelligent lighting system that provides continuous lighting from a door handle is provided. The method includes transmitting a first light signal having a first color from a door handle when a user approaches a vehicle and comes within a predetermined area such that a key fob carried by the vehicle owner is detected by a smart antenna in the handle. When the user touches a smart sensor, a second light signal having a second color is transmitted from the door handle and all of the vehicle doors are unlocked. If the user does not get into the vehicle after a predetermined period of time, a third light signal having a third color is transmitted from the door handle and all of the doors are locked.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
[0009] FIGS. 1A-1C illustrate various views of a door handle in accordance with an exemplary aspect of the disclosure;
[0010] FIGS. 2A and 2B illustrate exploded views the door handle in accordance with an exemplary aspect of the disclosure;
[0011] FIG. 3A illustrates a side cut-away view of the door handle in accordance with an exemplary aspect of the disclosure
[0012] FIG. 3B illustrates a top cut-away view of a door handle in accordance with an exemplary aspect of the disclosure;
[0013] FIGS. 4A-4F illustrate cross sectional views along a cross-section of the door handle in accordance with several exemplary aspects of the disclosure; and
[0014] FIGS. 5A-5D illustrate cross sectional views along the cross-section of the door handle in accordance with several further exemplary aspects of the disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] Various kinds of key-less entry systems exist in the market. Some keyless entry systems require activation (such as by pushing a button) by a user in order to unlock a door lock. Other types are able to unlock a door lock without an activation by a user since a wireless key detector (“key fob”) recognizes an approaching user with the key fob within a predetermined area.
[0016] A smart entry system, as referred to herein may be one of the key-less entry system which has a wireless key fob detector, a touch sensor, a user hand or grip detector and so on. The concept of this present disclosure can be applied to all kinds of key-less entry systems including smart entry system for vehicles.
I. Hardware.
[0017] FIGS. 1A-1C illustrate various views of a door handle in accordance with an exemplary aspect of the disclosure. In particular, a door handle 100 includes a first body member 110 , which faces away from a vehicle body, and a second body member 120 , which faces a vehicle body. The second body member 120 can also be understood as being located on the “working” side of the door handle, as the second body member 120 is typically grasped by a vehicle passenger to actuate the handle.
[0018] FIGS. 2A and 2B illustrate exploded views the door handle in accordance with an exemplary aspect of the disclosure. As shown in FIGS. 2A and 2B , the door handle 100 includes a smart antenna 200 , which is used as part of a smart entry system. The door handle 100 further includes an LED board 310 that includes a plurality of LEDs 320 . The LEDs may all transmit the same color, or each may transmit different colors from each other. The light emitted from the LEDs 320 is transmitted through the top and bottom surfaces the first body member 110 via the transmission elements 130 and 140 . The transmission elements 130 and 140 can be clear resin elements that are made of for example, acrylic or polycarbonate. As shown in FIGS. 2A and 2B , the transmission elements 130 and 140 are each long, continuous members that extend lengthwise along the door handle 100 . Thus, unlike a configuration in which single LEDs are provided to provide single points of light, the transmission elements 130 and 140 are able to provide an uninterrupted, continuous band of light along the length of both the upper and lower portions of the door handle 100 .
[0019] FIG. 3A illustrates a side cut-away view of the door handle 100 , and FIG. 3B illustrates a top cut-away view of the door handle 100 . As shown in FIG. 3B , the door handle 110 is able to accommodate a wire harness 330 and an electronic circuit board 340 . As discussed in greater detail below, the inclusion of the wire harness 330 and the electronic circuit board 340 in a single package with the smart antenna 200 allows the door handle to perform various lighting operations.
[0020] FIGS. 4A-4F illustrate cross sectional views along a cross-section of the door handle in accordance with several exemplary aspects of the disclosure. The door handles illustrated in FIGS. 4A-4F are designed such that the first and second transmission elements and the first and second body members of the door handle can be assembled in a watertight manner without any gaps.
[0021] FIG. 4A shows a cross-sectional view of the door handle 100 taken along the line A-A in FIG. 1A . The transmission element 130 is exposed to a top surface of the door handle 100 , and the transmission element 140 is exposed to a bottom surface of the door handle 140 . Each of the transmission elements 130 and 140 are in direct contact with both the first body member 110 and the second body member 120 . As shown in FIG. 4A , the LED board 310 acts as a locater that locates the transmission elements 130 and 140 within the door handle 100 . In particular, the transmission member 130 is pushed up into place within the first body member 110 by a top portion of the LED board 310 . Likewise, the transmission member 140 is pushed down into the first body member 110 by a bottom portion of the LED board 310 . In this manner, the LED Board 310 causes the transmission elements 130 and 140 as well as the first and second body members 110 and 120 to fit together in a snug fashion without gaps. Thus, in this example, the LED Board 130 has the dual functions of supporting the LEDs 320 and also locating the transmission members 130 and 140 in the door handle 100 .
[0022] FIG. 4B shows a cross-section of a door handle 100 a that includes a first body member 110 a, a second body member 120 a, a smart antenna 200 a, an LED board 310 a, at least one LED 320 a, a transmission element 130 a and a transmission element 140 a. The embodiment in FIG. 4B differs from the embodiment in FIG. 4A in that the transmission elements 130 a and 140 a do not make direct contact with the second body member 120 a. In this configuration, the location of the transmission elements 130 a and 140 a is handled by the location and size of the LED board 310 , and is not affected by the location of the second body member 120 a. Therefore, existing manufacturing techniques, which do not incorporate the transmission elements 130 a and 140 a, can be used so as to locate the first and second body members 110 and 120 relative to each other in a gap-free manner. In other words, the incorporation of the transmission elements 130 a and 140 a does not become a source of error in the manufacturing process with respect to the location of the first and second body members 110 and 120 . Thus, the number of parts that must be manufactured with tight tolerances can be reduced. As a result, it is easier to control the overall tolerances during manufacture of the 100 a, which can reduce the appearance of a gap between the first body member 110 a and the second body member 120 a.
[0023] FIG. 4C shows a cross-section of a door handle 100 b that includes a first body member 110 b, a second body member 120 b, a smart antenna 200 b, an LED board 310 b, at least one LED 320 b, a transmission element 130 b and a transmission element 140 b. The embodiment in FIG. 4C differs from the previous embodiments in that the transmission elements 130 b and 140 b are secured to the first body member 110 b by ultrasonic welding at locations 132 b and 142 b. This configuration further reduces the need for tight tolerances in manufacturing, as neither of the second body member or the LED board 310 b are used to locate the transmission elements 130 b and 140 b.
[0024] FIG. 4D shows a cross-section of a door handle 100 c that includes a first body member 110 c, a second body member 120 c, a smart antenna 200 c, an LED board 310 c, at least one LED 320 c, a transmission element 130 c and a transmission element 140 c. The embodiment in FIG. 4D differs from the previous embodiments in that the transmission elements 130 b and 140 b are secured to each of the first body member 110 c, the second body member 120 c, and the a circuit board 210 c of the smart antenna 200 c, but are not in direct contact with the LED board 310 c. In particular, the circuit board 210 c includes stops 212 c that locate the transmission elements 130 b and 140 b within the door handle 100 c. This configuration allows for more flexibility in the placement of the LED board 310 c within the door handle 100 c.
[0025] FIG. 4E shows a cross-section of a door handle 100 d that includes a first body member 110 d, a second body member 120 d, a smart antenna 200 d, an LED board 310 d, at least one LED 320 d, a transmission element 130 d and a transmission element 140 d. The embodiment in FIG. 4E differs from the previous embodiments in that the transmission elements 130 d and 140 d are secured to the first body member 110 d by snap-fit at locations 132 d and 142 d. This configuration further reduces the need for tight tolerances in manufacturing, as neither of the second body member 102 d or the LED board 310 d are used to locate the transmission elements 130 d and 140 d.
[0026] FIG. 4F shows a cross-section of a door handle 100 e that includes a first body member 110 e, a second body member 120 e, a smart antenna 200 e, an LED board 310 e, at least one LED 320 e, a transmission element 130 e and a transmission element 140 e. The embodiment in FIG. 4F differs from the previous embodiments in that the transmission elements 130 e and 140 e are secured to the second body member 120 e by a slant stopper at locations 132 e and 142 e. The slant angle of the slant stoppers creates stabilizing forces in both two directions, and thereby reduces the need for tight tolerances in manufacturing, as the LED board 310 e is not used to locate the transmission elements 130 e and 140 e.
[0027] FIGS. 5A-5D illustrate cross sectional views of further embodiments of the present disclosure. The examples shown in FIGS. 5A-5D include waterproof configurations, in which the smart antenna 200 is encased in a cover so as to become a waterproof antenna assembly 200 ′. Likewise, the LEDs and LED boards depicted in FIGS. 5A-5D are configured to be waterproof in a manner that will be readily apparent to those having skill in the art. FIG. 5A shows a cross-section of a door handle 100 g that includes a first body member 110 g, a second body member 120 g, a waterproof smart antenna assembly 200 ′, an LED board 310 g, at least one LED 320 g, and a single transmission element 150 g. The embodiment in FIG. 5A differs from the previous embodiments in that plural transmission elements are replaced by a single transmission element 150 g that is sandwiched between the first body member 110 g and the second body member 120 g.
[0028] FIG. 5B shows a cross-section of a door handle 100 h that includes a first body member 110 h, a second body member 120 h, a waterproof smart antenna assembly 200 ′, an LED board 310 h, at least one LED 320 h, a transmission element 130 h and a transmission element 140 h. The example in FIG. 5B is the same as that shown in FIG. 4A , with the exception that the smart antenna 200 is replaced with a waterproof smart antenna assembly 200 ′. In particular, the LED Board 310 h has the dual functions of supporting the LEDs 320 h and also locating the transmission members 130 h and 140 h in the door handle 100 h.
[0029] FIG. 5C shows a cross-section of a door handle 100 j that includes a first body member 110 j, a second body member 120 j, a smart antenna 200 , an LED board 310 j, at least one LED 320 j, a transmission element 130 j and a transmission element 140 j. The embodiment in FIG. 5C differs from the previous embodiments in that the LED board 10 j and the LED 320 j are integrated with the waterproof smart antenna assembly 200 ′. In this example, the waterproof smart antenna assembly 200 ′ includes stops 212 ′j that locate the transmission elements 130 j and 140 j within the door handle 100 j.
[0030] FIG. 5D shows a cross-section of a door handle 100 i that includes a first body member 110 i, a second body member 120 i, an LED board 310 i, at least one LED 320 i, a transmission element 130 i and a transmission element 140 i. The embodiment in FIG. 5D differs from the previous embodiments in that the door handle 100 i does not include a smart antenna 200 .
II. System Operation.
[0031] As noted above, the door handle described herein can include LEDs that transmit several different colors. This configuration allows a vehicle passenger to gain valuable information as they approach a vehicle with a key fob that communicates with a smart antenna 200 . For example a door handle can show a welcome status with a white light, a lock status with a red light, and unlock status with a green light. When all of the doors include the handles disclosed herein passengers easily understand which door is locked or unlocked.
[0032] Basically, lighting control is achieved based on a “smart entry system” such as lighting duration. For example, in an initial state, there is no lighting. As a vehicle owner approaches a vehicle, and comes within a predetermined area such that a key fob carried by the vehicle owner is detected by a smart antenna in the handle, a white light is transmitted from the handle. Once the vehicle owner touches a smart sensor, all of the vehicle doors unlock, and the handle lights up green. Once the vehicle owner and the vehicle passengers get into the vehicle, the handle lighting turns off.
[0033] In another example, as a vehicle owner approaches a vehicle, and comes within a predetermined area such that a key fob carried by the vehicle owner is detected by a smart antenna in the handle, a white light is transmitted from the handle. Once the vehicle owner touches a smart sensor, all of the vehicle doors unlock, and the handle lights up green. In this example, if the owner does not get into the vehicle after a predetermined period of time, all of the doors lock, and the vehicle handle lights red.
[0034] In another example, when the vehicle owner exits the vehicle, the vehicle handle lights up white. Once all of the doors are locked, the door handle lights up red. When the vehicle owner passes a predetermined distance away from the vehicle, such that the smart antenna no longer detects a key fob carried by the vehicle owner, the handle light turns off.
[0035] In another example, in an initial state, there is no lighting. As a vehicle owner approaches a vehicle, and comes within a predetermined area such that a key fob carried by the vehicle owner is detected by a smart antenna in the handle, a white light is transmitted from the handle. Once the vehicle owner touches a smart sensor, all of the vehicle doors unlock, and the handle lights up green. After a predetermined period of time (i.e. five seconds) the handle light turns white. Once the vehicle owner and the vehicle passengers get into the vehicle, the handle lighting turns off
[0036] In another example, in an initial state, there is no lighting. As a vehicle owner approaches a vehicle, and comes within a predetermined area such that a key fob carried by the vehicle owner is detected by a smart antenna in the handle, a white light is transmitted from the handle. Once the vehicle owner touches a smart sensor, only the driver's door is unlocked, the driver's handle lights up green, and all of the other vehicle doors light up with a white light. Once the vehicle owner gets into the vehicle, the handle lighting turns off
[0037] Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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A door handle apparatus for a vehicle is provided. The door handle includes a door handle body that is configured to be disposed at a door of the vehicle. A light source is mounted inside the door handle body. A light-transmitting member is located between the light source and the door handle body. The light-transmitting member is partially exposed to an exterior of the door handle body.
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FIELD OF THE INVENTION
The invention relates to copiers and printers, and more particularly, to an improved apparatus and method for use in the clearance of jammed media sheets.
BACKGROUND OF THE INVENTION
Paper jams have long been a burden to users of copiers and printers. When a paper jam occurs, the user is required to take some action to restore the system to working order and to recover the integrity of the particular job. Various strategies and features have been developed to reduce the occurrence of jams and to minimize the burden on the user to recover from the jam. However, there is still a need for an improved and efficient jam clearance system.
Reference is made to systems relating to jam clearance including U.S. Pat. Nos.; 3,819,266; 3,944,794; 4,231,567; 5,623,720; 5,732,620; 5,840,003; 6,003,864 and 6,010,127.
All documents cited herein, including the foregoing, are incorporated herein by reference in their entireties.
SUMMARY OF THE INVENTION
In an embodiment, there is provided a media clearance apparatus including a member having a length, a thickness, and a width, and a first end and a second end. The member is securable along a portion of the member to a secondary member and is functionally operational such that a portion of the member is movable from a first position out of contact with a media path into a second position in contact with the media path.
In another embodiment, there is provided a media clearing member in an electrophotographic apparatus including a member functionally associated with a media path having at least one curve. The member includes a length, a thickness, and a width, and a first end and a second end. The member is securable to a part of the electrophotographic apparatus. The member functionally operates such that one of the first end and the second end of the member is movable from a first position to a second position causing the other of the first end and the second end to move from a first position out of contact with the media path into a second position in contact with the media path. The member is not straight between the first end and the second end.
In yet another embodiment, there is provided an electrophotographic apparatus including at least one media path and a member. The member is functionally associated with the at least one media path. The member has a length, a thickness, and a width, and a first end and a second end. The member is securable to a part of the electrophotographic apparatus and adapted such that one of the first end and the second end of the member is movable from a first position to a second position causing the other of the first end and the second end to move from a first position out of contact with the media path into a second position in contact with the media path.
In another embodiment, there is provided a method of clearing media from a media path in an electrophotographic apparatus comprising: moving a first member functionally associated with a second member in the electrophotographic apparatus such that a free end of the second member intersects a portion of a media path and contacts the media causing movement of a portion of the media out of the media path; and removing the media from the media path.
Still other aspects and advantages of the present invention and methods of construction of the same will become readily apparent to those skilled in the art from the following detailed description, wherein embodiments are shown and described, simply by way of illustration. As will be realized, the invention is capable of other and different embodiments and methods of construction, and its several details are capable of modification and interchangeability in various respects, all without departing from the invention. Accordingly, the drawing and description are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic elevation view of an embodiment of an electrophotographic apparatus incorporating the media clearance member;
FIG. 2 is a side view of an assembly including an embodiment of the media clearance member in a first position; and
FIG. 3 is a side view of an embodiment of media clearance member in a second position.
DETAILED DESCRIPTION OF THE INVENTION
While the principles and embodiments of the present invention will be described in connection with a printer or copying device such as an analog or digital electrophotographic apparatus, it should be understood that the present invention is not limited to that embodiment or to that application. Therefore, it should be understood that the principles of the present invention and embodiments extend to all alternatives, modifications, and equivalents thereof.
Referring to FIG. 1 of the drawings, schematically illustrated is an original document is positioned in a document handler 27 on a raster input scanner (RIS) indicated generally by reference numeral 28 . The RIS contains document illumination lamps, optics, a mechanical scanning drive and a charge coupled device (CCD) array. The RIS captures the entire original document and converts it to a series of raster scan lines. This information is transmitted to an electronic subsystem (ESS) which controls a raster output scanner (ROS) described below.
An electrophotographic printing or copying machine may generally include a photoconductive belt 10 . The photoconductive belt 10 may be made from a photoconductive material coated on a ground layer, which, in turn, is coated on an anti-curl backing layer. Belt 10 moves in the direction of arrow 13 to advance successive portions sequentially through the various processing stations disposed about the path of movement thereof. Belt 10 is entrained about stripping roller 14 , tensioning roller 20 and drive roller 16 . As roller 16 rotates, it advances belt 10 in the direction of arrow 13 .
Initially, a portion of the photoconductive surface passes through charging station A. At charging station A, a corona generating device indicated generally by the reference numeral 22 charges the photoconductive belt 10 to a relatively high, substantially uniform potential.
At an exposure station, B, a controller or electronic subsystem (ESS), indicated generally by reference numeral 29 , receives the image signals representing the desired output image and processes these signals to convert them to a continuous tone or greyscale rendition of the image which is transmitted to a modulated output generator, for example the raster output scanner (ROS), indicated generally by reference numeral 30 . Preferably, ESS 29 is a self-contained, dedicated minicomputer. The image signals transmitted to ESS 29 may originate from a RIS as described above or from a computer, thereby enabling the electrophotographic printing machine to serve as a remotely located printer for one or more computers. Alternatively, the printer may serve as a dedicated printer for a high-speed computer. The signals from ESS 29 , corresponding to the continuous tone image desired to be reproduced by the printing machine, are transmitted to ROS 30 . ROS 30 includes a laser with rotating polygon mirror blocks. The ROS will expose the photoconductive belt to record an electrostatic latent image thereon corresponding to the continuous tone image received from ESS 29 . As an alternative, ROS 30 may employ a linear array of light emitting diodes (LEDs) arranged to illuminate the charged portion of photoconductive belt 10 on a raster-by-raster basis.
After the electrostatic latent image has been recorded on photoconductive surface 12 , belt 10 advances the latent image to a development station, C, where toner, in the form of liquid or dry particles, is electrostatically attracted to the latent image using commonly known techniques. The latent image attracts toner particles from the carrier granules forming a toner powder image thereon. As successive electrostatic latent images are developed, toner particles are depleted from the developer material. A toner particle dispenser, indicated generally by the reference numeral 44 , dispenses toner particles into developer housing 46 of developer unit 38 .
After the electrostatic latent image is developed, the toner powder image present on belt 10 advances to transfer station D. A print sheet 48 is advanced to the transfer station, D, by a sheet feeding apparatus, 50 . Preferably, sheet feeding apparatus 50 includes a nudger roll 51 which feeds the uppermost sheet of stack 54 to nip 55 formed by feed roll 52 and retard roll 53 . Feed roll 52 rotates to advance the sheet from stack 54 into vertical transport 56 . Vertical transport 56 directs the advancing sheet 48 of support material into the registration transport 120 of the invention herein, described in detail below, past image transfer station D to receive an image from photoreceptor belt 10 in a timed sequence so that the toner powder image formed thereon contacts the advancing sheet 48 at transfer station D. Transfer station D includes a corona generating device 58 which sprays ions onto the back side of sheet 48 . This attracts the toner powder image from photoconductive surface 12 to sheet 48 . The sheet is then detacked from the photoreceptor by corona generating device 59 which sprays oppositely charged ions onto the back side of sheet 48 to assist in removing the sheet from the photoreceptor. After transfer, sheet 48 continues to move in the direction of arrow 60 by way of belt transport 62 which advances sheet 48 to fusing station F of the invention herein, described in detail below.
Fusing station includes a fuser assembly 200 which permanently affixes the transferred toner powder image to the copy sheet. Fuser assembly 200 may include a heated fuser roller 240 and a pressure roller 230 with the powder image on the copy sheet contacting fuser roller 240 . The pressure roller is loaded against the fuser roller to provide the necessary pressure to fix the toner powder image to the copy sheet. The fuser roll is internally heated by a quartz lamp (not shown). Release agent, stored in a reservoir (not shown), is pumped to a metering roll (not shown). A trim blade (not shown) trims off the excess release agent. The release agent transfers to a donor roll (not shown) and then to the fuser roll 240 . Or alternatively, release agent is stored in a presoaked web (not shown) and applied to the fuser roll 240 by pressing the web against fuser roll 240 and advancing the web at a slow speed.
The sheet then passes through fuser 200 where the image is permanently fixed or fused to the sheet. After passing through fuser 200 , a gate 80 either allows the sheet to move directly via output 84 to a finisher or stacker, or deflects the sheet into the duplex path 100 , specifically, first into single sheet inverter 82 here. That is, if the sheet is either a simplex sheet, or a completed duplex sheet having both side one and side two images formed thereon, the sheet will be conveyed via gate 80 directly to output 84 . However, if the sheet is being duplexed and is then only printed with a side one image, the gate 80 will be positioned to deflect that sheet into the inverter 82 and into the duplex loop path 100 , where that sheet will be inverted and then fed to acceleration nip 102 and belt transports 110 , for recirculation back through transfer station D and fuser assembly 200 for receiving and permanently fixing the side two image to the backside of that duplex sheet, before it exits via exit path 84 .
After the print sheet is separated from photoconductive surface 12 of belt 10 , the residual toner/developer and paper fiber particles adhering to photoconductive surface 12 are removed therefrom at cleaning station E. Cleaning station E includes a rotatably mounted fibrous brush in contact with photoconductive surface 12 to disturb and remove paper fibers and a cleaning blade to remove the nontransferred toner particles. The blade may be configured in either a wiper or doctor position depending on the application. Subsequent to cleaning, a discharge lamp (not shown) floods photoconductive surface 12 with light to dissipate any residual electrostatic charge remaining thereon prior to the charging thereof for the next successive imaging cycle.
The various machine functions are regulated by controller 29 . The controller is preferably a programmable microprocessor which controls all of the machine functions hereinbefore described. The controller provides a comparison count of the copy sheets, the number of documents being recirculated, the number of copy sheets selected by the operator, time delays, jam corrections, etc. The control of all of the exemplary systems heretofore described may be accomplished by conventional control switch inputs from the printing machine consoles selected by the operator. Conventional sheet path sensors or switches may be utilized to keep track of the position of the document and the copy sheets.
Referring to FIGS. 2-3, a media clearance member 310 is illustrated in a portion of a media transport assembly 83 of an electrophotographic apparatus. The media clearance member 310 is used to improve both visual and physical access to the sheets in the event of a jam. The media clearance member 310 addresses two important aspects of jam clearance: (1) moving the media to a position where it can be seen by an operator; and (2) providing improved access to the media for easy removal of the media. Jammed sheets in curved paper path regions can be particularly difficult to clear and/or detect due to the media hugging the inside radius of a media path and transport baffle, for example, when the media sheet is in a nip region before and after the media path turn. In embodiments, the media clearance member 310 provides efficient media jam clearance.
FIG. 2 illustrates a media sheet 240 which has stopped and become jammed in the media path 250 . The media clearance member 310 is attached to a baffle assembly 300 . A baffle assembly 400 is shown on the opposite side of the media path. The baffle assemblies 300 , 400 are both shown in a closed position in FIG. 2 and in an open position in FIG. 3 . In use, the baffle assembly 400 is first moved to an open position as shown in FIG. 3 and then the baffle assembly 300 is then moved to a maximum open position indicated by imaginary line 315 from closed position indicated by imaginary line 305 . The baffle assembly 400 may pivot about a pivot point 410 . In the process of opening the baffle assembly 300 away from the closed position 305 , the attached media clearance member 310 also moves and an end 314 of the media clearance member 310 enters the media path 250 and contacts the media 240 . As the baffle assembly 300 is further moved toward its most open position 315 , the end 314 is further moved and extends further into the media path 250 and then may extend out of the media path 250 onto the opposite side of the media path 250 into an open region where a portion of the baffle assembly 400 was once positioned when in a closed position (See FIG. 2 ). With movement, the end 314 pushes on the media sheet 240 , causing and forming a bulge 260 out of the normal media path region, which allows for improved visibility and accessibility of the media 240 for jam clearance. The baffle assembly 300 and media clearance member 310 may angularly rotate an angle θ in a range up to 120 degrees from position 305 up to position 315 .
In embodiments, the media clearance member 310 may include an offset portion or a curved portion and form a finger-like portion 312 . The media clearance member 310 may be secured to a secondary member such as an aluminum extrusion or a rail of a baffle assembly 300 using a fastener such as a plastic or metal screws, adhesives, welding, or other chemical or thermal attachment methods or systems. The baffle assembly 300 may pivot from the closed position 305 to an open position 315 about a pivot point 330 . The media clearance member 310 may be made from a metal or a plastic, for example, the media clearance member 310 may be made of a molded ABS plastic or a sheet metal having a length and a width and a shape sufficient to extend into the media path 250 when moved a selected angular distance. The media clearance member 310 may be straight, jogged, or offset, and the cross-section thereof may be round, square, or non-circular. The media clearance member 310 may include a diameter along a portion of its length. The media clearance member 310 may have an overall length up to 12 inches and a diameter up to 1 inch; in an embodiment, the finger portion 312 may be about 2½ inches and have a diameter of about 0.2362 inches. The media 240 may include paper or a transparency. The media path 250 may be curved including an S shaped curve. The media clearance member 310 may be associated with a media path 250 at a location thereof where there is a radius or curve, for example, an inside radius at a nip region located before and after the turn in the media path 250 or at an inverter portion of the media path 250 . The media clearance member 310 may function as a mechanism for pushing and moving the media 240 away from a surface and creating a bulge 260 in the media 240 to allow greater visibility and access of the media 240 to an operator. The bulge 260 may be formed such that a concave surface of the media 240 is closest to the media clearance member 310 .
In summary, the media clearance member 310 is adapted to aid in the movement of the media 240 out of a media path 250 and position the media 240 for easier retrieval by an operator. Removal of the media 240 from the electrophotographic apparatus may be a manual hand operation performed by the operator.
Other modifications may occur to those skilled in the art subsequent to a review of the present application, and these modifications, including equivalents thereof, are intended to be included within the scope of the present invention. Moreover, it is evident that many alternatives and variations thereof will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications, and variations and their equivalents.
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A media clearance apparatus including a member having a length, a thickness, and a width, and a first end and a second end. The member is securable along a portion of the member to a secondary member and is functionally operational such that one end of the member is movable from a first position out of contact with a media path into a second position in contact with the media path.
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PREFERRED EMBODIMENT OF THE INVENTION
In one preferred embodiment of this invention is provided a lock assembly for a trailer hitch which can be mounted on a vehicle in a conventional manner. More particularly, a pickup truck is illustrated as having a rear bumper assembly with a vertically mounted hitch ball member operable to receive a trailer hitch assembly thereon.
The lock assembly includes a trailer hitch assembly having a hitch lock assembly of this invention mounted thereon. The trailer hitch assembly includes 1) a trailer tongue member which is mounted on a trailer member (not shown); 2) a main hitch housing assembly connected to the trailer tongue member as by welding or the like; and 3) a hitch ball latch assembly mounted within the main hitch housing assembly.
The main hitch housing assembly is of generally U-shape in transverse cross section having a top wall integral with parallel spaced side walls, all of which are integral with a common front wall. The spaced parallel side walls are provided with axially aligned respective latch receiving openings therein.
The hitch ball latch assembly is provided with a forward ball receiver member mounted within the main hitch housing assembly which operably cooperates with a latch actuator assembly.
The forward ball receiver member is provided with an arcuate ball receiving surface of a spherical shape similar to the hitch ball member which is integral with an anchor housing secured to an inside forward surface of the main hitch housing assembly.
The latch actuator assembly includes 1) a latch handle member pivotally connected to the parallel side walls of the main hitch actuator assembly; 2) an intermediate link member having one end pivotally connected to the latch handle member and 3) a ball contact member pivotally connected to an opposite end of the intermediate link member and to the spaced parallel side walls of the main hitch housing assembly.
The latch handle member includes a handle section having holes therethrough to receive a handle support shaft therein for pivotal movement thereof upwardly from a latched condition and downwardly to a latched condition as will be explained.
The intermediate link member includes a handle connector section and an actuator ball connector section. The handle connector section is mounted through a pivot shaft or pin to the latch handle member.
The actuator ball connector section is provided with a pivot shaft or pin for pivotal connection to the ball contact member for subsequent movement thereof between the latched to the unlatched conditions.
The ball contact member includes a pair of spaced, parallel main actuator bodies which are pivotally connected to a support shaft member for movement from the latched to the unlatched conditions.
More particularly, each main actuator body is of irregular shape and provided with 1) a shaft connector hole to receive the support shaft member therethrough; 2) a lock anchor hole is operable to receive a portion of the hitch lock assembly therein in the locked anchored condition as will be noted; and 3) an arcuate ball contact section operable to engage a portion of an outer surface of the hitch ball member while cooperating with the arcuate ball receiving surface of the forward ball receiver member when in the locked clamped condition as will be explained.
The trailer hitch assembly is operable in a substantially conventional manner whereupon the hitch ball member is placed interiorly of the main hitch housing assembly and having an upper, outer surface nested within the arcuate ball receiving surface of the forward ball receiver member which is part of the hitch ball latch assembly as noted in FIG. 5.
On pivotal movement of the latch handle member forwardly and downwardly from the position of FIG. 5 to the position of FIG. 6, it is seen that the hitch ball member is enclosed in a confining relationship between the arcuate ball receiving surface of the forward ball receiver member and the arcuate ball contact section of the ball contact member to hold in the enclosed latched condition. However, this latched condition is further enhanced and made secure from dislodgment and further from one stealing the trailer hitch assembly and a trailer member connected thereto through use of the hitch lock assembly of this invention.
The hitch lock assembly includes a pair of lock pin members used in conjunction with a conventional padlock member.
The lock pin members are identical, each having a padlock section integral with a horizontal spacer section which, in turn, is integral with a vertical intermediate section which is integral with a second horizontal spacer section having at an outer end thereof an integral vertical hitch lock section.
Each lock pin member is of a bent rod construction, circular shape in transverse cross section and preferably constructed of a high strength steel material.
The padlock section is provided with a circular ring portion having an outer bent end thereof secured as by welding to an adjacent portion of the horizontal spacer section. The ring portion is operable to receive a portion of the padlock member therethrough as will be explained.
The vertical intermediate section is extended perpendicular to both the horizontal spacer section and the second horizontal spacer section which are extended parallel to each other in a same direction from the vertical intermediate section.
The vertical hitch lock section is extended perpendicular to the second horizontal spacer section and extended downwardly therefrom. The cross sectional size of the lock pin members is of a size to fit snugly within respective latch receiving openings in the parallel side walls of the main hitch housing assembly and, additionally, the lock anchor holes in the main actuator bodies of the ball contact member when in the latched, locked conditions as noted in FIGS. 2 and 4.
The padlock member can be of a conventional key lock or combination dial lock configuration. The padlock member includes a padlock body section having a shackle member having a portion releasably connected to the padlock body section to move from the locked condition of FIG. 2 to an unlatched condition in a manner to be explained.
OBJECTS OF THE INVENTION
One object of this invention is to provide a lock assembly for a trailer hitch mounted on a vehicle including 1) a trailer hitch assembly secured to a hitch ball member on the vehicle; and 2) a hitch lock assembly releasably connected to the trailer hitch assembly to secure in the connected latched condition to prevent unauthorized removal of the trailer hitch assembly from the hitch ball member.
Another object of this invention is to provide a hitch lock assembly which can be readily attached and removed from a trailer hitch assembly connected to a hitch ball member on a vehicle to hold in a latched and securely locked condition to prevent unauthorized removal of the trailer hitch assembly from the hitch ball member.
One other object of this invention is to provide a hitch lock assembly mountable on a trailer hitch assembly connected to a hitch ball member including a pair of irregular shaped lock pin members operable in combination with a padlock member with the lock pin members engagable through openings in the trailer hitch assembly to achieve an enclosed locked condition when the padlock member is secured to adjacent portions of the lock pin members to secure in a locked, latched condition.
One further object of this invention is to provide a hitch lock assembly having a pair of irregular shaped lock pin members cooperating with a padlock member, and the lock pin members are engagable with parallel side walls of a main hitch housing assembly and a latch actuator assembly when in the latched condition so as to be unable to move the latch actuator assembly to an unlatched condition due to the padlock member interconnecting adjacent circular portions of the lock pin members.
Still, one other object of this invention is to provide a hitch lock assembly comprising a pair of lock pin members used in combination with a padlock member which is economical to manufacture; simple to use; sturdy in construction; providing economical means for anchoring a hitch ball assembly to a hitch ball member in the latched condition; and substantially maintenance free.
Various other objects, advantages, and features of the invention will become apparent to those skilled in the art from the following discussion, taken in conjunction with the accompanying drawings, in which:
FIGURES OF THE INVENTION
FIG. 1 is a perspective view of a rear end of a pickup truck having a trailer hitch assembly connected thereto utilizing the hitch lock assembly of this invention;
FIG. 2 is a fragmentary perspective view of a trailer hitch assembly having the hitch lock assembly of this invention mounted thereon;
FIG. 3 is a perspective view of one of a pair of lock pin members of the hitch lock assembly of this invention;
FIG. 4 is a sectional view taken along line 4--4 in FIG. 2; and
FIG. 5 is a view similar to FIG. 4 having the hitch lock assembly removed and illustrating the trailer hitch assembly in an unlatched condition about a hitch ball member illustrated in dotted lines.
The following is a discussion and description of preferred specific embodiments of the lock assembly for a trailer hitch of this invention, such being made with reference to the drawings, whereupon the same reference numerals are used to indicate the same or similar parts and/or structure. It is to be understood that such discussion and description is not to unduly limit the scope of the invention.
DESCRIPTION OF THE INVENTION
Referring to the drawings in detail, and in particular to FIG. 1, a lock assembly for a trailer hitch, indicated generally at 12, is shown as being mounted on a trailer hitch assembly 20 connected to a hitch ball member 18 anchored to a rear bumper of a pickup truck 14. The hitch ball member 18 and the trailer hitch assembly 20 are of a conventional nature as will be noted herein.
The lock assembly for a trailer hitch 12 is releasably connectable to the trailer hitch assembly 20 which may be connected to a stock trailer, U-Haul trailer, or the like for trailering same.
The trailer hitch assembly 20 includes 1) a trailer tongue member 21 of rectangular, tubular shape in transverse cross section having one end secured to a trailer member (not shown); 2) a main hitch housing assembly 24 connected to another outer end of the trailer tongue member 21; and 3) a hitch ball latch assembly 26 connected to the main hitch housing assembly 24 and engagable with an outer surface of the hitch ball member 18 in a latched, locked condition.
The main hitch housing assembly 24 is secured as by welding to the trailer tongue member 21 and includes a top wall 28 integral with downwardly depending spaced parallel side walls 29, all of which are integral with a front wall 31.
Each parallel side wall 29 is provided with a latch receiving opening 33 therein to receive a portion of the hitch lock assembly 22 therein when in the locked, latched condition as will be explained.
As noted in FIG. 4, the hitch ball latch assembly 26 includes a forward ball receiver member 28 acting in cooperation with a latch actuator assembly 30 to releasably secure the hitch ball member 18 within the main hitch housing assembly 24 in the latched or unlatched conditions as shown in FIGS. 4 and 5, respectively.
The forward ball receiver member 28 is provided with an arcuate ball receiving surface 32 and an anchor housing 34 which is secured as by welding to inner adjacent surfaces of the main hitch housing assembly 24 or, more specifically, secured to the top wall 28, parallel side walls 29, and front wall 31.
The arcuate ball receiving surface 32 is of a spherical shape similar in size to the hitch ball member 18 which is mounted thereagainst in a clamping action while allowing pivotal movement of the trailer tongue member 21 and interconnected main hitch housing assembly 24 thereabout during normal turning and driving operations of the pickup truck 14.
The latch actuator assembly 30 includes 1) a latch handle member 36 which is pivotally connected to the parallel side walls 29 of the main hitch housing assembly 24; 2) an intermediate link member 38 having one end pivotally connected to the latch handle member 36; and 3) a ball contact member 40 pivotally connected to another end of the intermediate link member 38 and pivotally connected to the main hitch housing assembly 24.
The latch handle member 36 includes a grasp handle section 42 and being pivotally connected to a handle support shaft 44 which extends through and is mounted within aligned openings in the parallel side walls 29 for movement from the released condition of FIG. 5 to the latched condition as noted in FIGS. 2 and 4.
The intermediate link member 38 has a handle connector section 46 and an actuator ball connector section 48. The handle connector section 46 is pivotally connected through a pivot shaft or pin 50 within a hole in the latch handle member 36.
The actuator ball connector section 48 is provided with the pivot pin or shaft 50 which is mounted in a hole in the ball contact member 40.
As noted in FIG. 5, the ball contact member 40 is provided with a pair of spaced, parallel main actuator bodies 52 of irregular shape which are pivotally mounted on a support shaft member 54.
Each main actuator body 52 is provided with 1) a shaft connector hole 56 operable to receive the support shaft member 54 therethrough; 2) lock anchor holes 60 on each side of the identical ones of the main actuator bodies 52 to receive a portion of the hitch lock assembly 22 therein as will be explained; and 3) an arcuate ball contact section 58 interconnecting the main arcuate bodies 52 which is of a spherical shape and is operable to engage in an adjacent, conforming spaced relationship with the hitch ball member 18 when in the latched condition as noted in FIG. 4.
The arcuate ball contact section 58 being of spherical shape cooperates with the arcuate ball receiving surface 32 of the forward ball receiver member 28 of the hitch ball latch assembly 26 as noted in FIG. 4. This firmly holds the hitch ball member 18 in an enclosed latched condition while spaced to allow relative rotational movement therebetween necessary for pulling of a trailer hitch and attached trailer during turning operations.
In FIG. 5, the latch actuator assembly 30 is operable through a linkage type connection from the unlatched condition of FIG. 1 having the handle support shaft 44 and the support shaft member 54 providing fixed pivot points.
The intermediate link member 38 is pivotal about movable pivot points being the pivot shaft or pin 50 from the position in FIG. 5 to the rear pivoted position in the enclosed locked or latched condition as shown in FIG. 4.
This linkage condition allows the intermediate link member 38 to be passed over a center position so that any downward force by the hitch ball member 18 on the arcuate ball contact surface 58 operates in an "over dead center" manner. Any force from the hitch ball member 18 would tend to further enclose and secure the hitch ball latch assembly 26 against the outer spherical surface of the hitch ball member 18.
The hitch lock assembly 22 includes a pair of identical lock pin members 62 utilized with a padlock member 64 so as to engage and lock the hitch ball latch assembly 26 in a latched, locked condition as shown in FIG. 2.
Each lock pin member 62 is constructed preferably of a bent, high strength steel rod construction being of circular shape in transverse cross section.
Each lock pin member 62 includes a padlock section 66 integral with a horizontal spacer section 68 which is connected to a vertical intermediate section 70 which, in turn, is integral with a second horizontal spacer section 72 having connected thereto a vertical hitch lock section 74. All of the sections 66, 68, 70, 72, and 74 are aligned in a common plane.
The horizontal spacer section 68 and the second horizontal spacer section 72 are located in spaced horizontal and parallel common planes having the vertical intermediate section 70 extended to one side thereof so as to be operable to be placed laterally to extend outwardly of the main hitch housing assembly 24 in the assembled, locked condition.
The vertical hitch lock section 74 is extended perpendicular to the horizontal spacer section 68 and the second horizontal spacer section 72. The vertical hitch lock section is operable to be mounted through, and locked within, the latch receiving opening 33 in one of the side walls 29 of the main hitch housing assembly 24 and the lock anchor hole 60 in the ball contact member 40 in a manner to be described.
The padlock member 64 is of a conventional nature and could be a key lock, padlock, or combination padlock as desired. The main function thereof is to secure the lock pin members 62 in a locked condition as noted in FIG. 2.
More particularly, the padlock member 64 is provided with a padlock body section 80 having a shackle member 82 having a portion which is releasably connected to the padlock body section 80.
Use and Operation of the Invention
In the use and operation of the invention, the hitch ball latch assembly 26 is mounted about the hitch ball member 18 as noted in FIG. 5.
The hitch actuator assembly 30 and, more particularly, the latch handle member 36 has been actuated to a closed condition as noted in FIG. 4 whereupon the hitch ball member 18 is connected to, and enclosed by, the forward ball receiver member 28 and the arcuate ball contact section 58.
Next, the trailer/vehicle operator would take independently and respectively, each of the lock pin members 62 and insert the vertical hitch lock section 74 through the respective aligned latch receiving openings 33 in the side walls 29 of the main hitch housing assembly 24 and, concurrently, through an adjacent lock anchor hole 60 in the ball contact member 40 as noted in FIG. 4.
After inserting the vertical hitch lock section 74 therethrough, the entire lock pin member 62 would then be rotated upwardly to place the vertical intermediate section 70 in contact with outer respective surfaces of the side walls 29.
On achieving this movement by both of the lock pin members 62, this places the padlock section 66 and, more particularly, the circular ring portions 76, in adjacent parallel planes.
Next, the operator would open the shackle member 82 of the padlock member 64 and insert the shackle member 82 through the aligned central receiving openings of the circular ring portion 76 of the lock pin members 62.
The shackle member 82 would then be pushed inwardly into the padlock body section 80 to achieve the latched, locked condition as shown in FIGS. 2 and 4.
In this locked condition, it is noted that the respective lock pin members 62 thereupon secure the hitch ball latch assembly 26 to the main hitch housing assembly 24 so that the entire assembly cannot move from this latched, locked condition to a released condition without removing the padlock member 64 from its connection to the circular ring portions 76. Therefore, this achieves the secured, locked condition of the trailer hitch assembly 20 to the hitch ball member 18 which can only be released by removal of the padlock member 64 in a conventional manner.
The locked condition, as noted in FIG. 2, is unlocked by opening of the padlock member 64 to remove the shackle member 82 from its insertion through the adjacent circular ring portions 76 of the lock pin members 62.
Then, the respective lock pin members 62, on outward and downward movement, operate to remove the vertical hitch lock section 74 and the second horizontal spacer section 72 laterally of the respective latch receiving openings 33 and the lock anchor holes 60 to achieve the unlatched condition. Thereupon, the latch handle member 36 can be moved upwardly to the position as shown in FIG. 5 and the entire hitch ball latch assembly 26 can be removed from its latched condition about the hitch ball member 18.
The hitch lock assembly of this invention is economical to manufacture; rigid in construction to prevent unauthorized removal thereof from a trailer latch assembly; easy to use; and substantially maintenance free.
While the invention has been described in conjunction with preferred specific embodiments thereof, it will be understood that this description is intended to illustrate and not to limit the scope of the invention, which is defined by the following claims:
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A hitch lock assembly which is readily attachable to a trailer hitch assembly to provide a means for securing a hitch ball latch assembly from unauthorized removal from a hitch ball member. The hitch lock assembly includes a pair of lock pin members operable with a padlock member to provide means for securing the hitch ball latch assembly about the hitch ball member. Each lock pin member is of a high strength steel rod construction having a vertical hitch lock section mountable within aligned holes through a main hitch housing assembly and a ball contact member to insure that these elements are not movable relative to each other to an unlatched condition. The padlock member is removed from the interconnected lock pin members and the hitck lock sections are removed from the aligned holes to achieve an unlatched condition.
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FIELD OF THE INVENTION
The present invention relates to the dryer section of a papermaking machine in general, and to apparatus for separating the felts in the draw between dryer sections in particular.
BACKGROUND OF THE INVENTION
Paper is made by forming a mat of fibers, normally wood fibers, on a moving wire screen. The fibers are in a dilution with water constituting usually above 95 percent of the mix. As the paper web leaves the forming screen, it may be still over eighty percent water. The paper web travels from the forming or wet end of the papermaking machine and enters a pressing section where, with the web supported on a felt, the moisture content of the paper is reduced by pressing the web to a fiber content of about forty-two percent. After the pressing section, the paper web is dried on a large number of steam heated dryer rolls, so the moisture content of the paper is reduced to about five percent.
One type of dryer is the apparatus manufactured by Beloit Corporation of Beloit, Wis. and sold under the trade name "Bel-Champ." The Bel-Champ dryer has a single tier of dryer upper rolls with vacuum reversing rolls disposed therebetween. As the web, supported by a felt, progresses through a single dryer section, typically composed of five or more dryer rolls, the same face of the web is repeatedly placed in contact with the heated dryer roll surfaces. To effectively dry both faces of the web, the first felt is directed away from the web and a second felt is brought into contact with the opposite face. Once supported on the second felt the web is led through a succeeding dryer section where the alternate face is placed in contact with the heated dryer rolls. The transfer of the web between dryer sections takes place in a fully supported draw between two vacuum rolls. Each felt extends from a vacuum roll to a felt roll which is spaced either above or below the vacuum rolls.
On occasion it becomes necessary to separate the felts on the order of one half inch. In the past this separation has been achieved by using air or hydraulic cylinders to move the felt rolls horizontally. However, in order to retain the felts on the rollers as they are moved, it is essential that the roll be advanced evenly. As a felt is typically wrapped in the range of 90 degrees around the felt roll, angling of the roll in motion may cause the felt to run off the machine. Even movement is effectively obtained by employing a large cross-shaft. Such shafts, however, are costly.
Furthermore, because the felt rolls must be spaced several feet from the vacuum rolls, the felt roll must be moved up to ten inches or more in order to achieve the desired separation of the felts of about one half inch. Additionally, this significant displacement of the felt rolls changes the lengths of the felt runs, requiring a stretcher assembly to take up the additional felt length. In order to accommodate the stretcher, the felt rolls must be moved slowly to insure that the stretcher has enough time to respond and maintain felt tension. As the felt rolls are spaced above and below the web, the separation operation is also difficult to observe.
What is needed is an economical mechanism for separating the felts in a dryer section break which is rapid and effective.
SUMMARY OF THE INVENTION
The single tier dryer of this invention has a first dryer roll mounted to a frame in a first dryer section, and a pivot arm mounted to the frame for pivoting about a cross-machine axis. A first vacuum roll is positioned downstream of the first dryer roll. The first vacuum roll is rotatably mounted to the pivot arm. A first felt is guided about the first dryer roll such that the web is disposed between the first dryer roll and the first felt for drying a first side of the web. The first felt then extends over the first vacuum roll. A second vacuum roll is mounted to the frame downstream of the first vacuum roll in a subsequent dryer section. A second dryer roll is mounted downstream of the second vacuum roll. A second felt is guided about the second dryer roll such that the web is disposed between the second dryer roll and the second felt for drying a second side of the web The second felt extends from the second vacuum roll to the second dryer roll, and the web is transferred from the first felt to the second felt between the first dryer roll and the second dryer roll. Inflatable air rides provide means for pivoting the pivot arm to pivot the first vacuum roll from a first position in which the first felt, the web, and the second felt are engaged, and a second position in which the first felt, the web, and the second felt are not simultaneously engaged.
It is a feature of the present invention to provide a dryer section with felts which may be rapidly separated at the section break.
It is also a feature of the present invention to provide a papermaking dryer with a mechanism for separating the felts at a section break which is easily visible to the machine operator.
It is a further feature of the present invention to provide a papermaking dryer which spaces the felts at a section break with minimal increase in the felt run length.
It is an additional feature of the present invention to provide a papermaking dryer with a mechanism for spacing the felt runs at the section break which is economical.
Further objects, features and advantages of the invention will be apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of two sequential dryer sections in the papermaking dryer of this invention.
FIG. 2 is an enlarged side elevational view of the section break of the dryer of FIG. 1 taken at line 2--2.
FIG. 3 is an enlarged side elevational view of the vacuum roll pivoting mechanism at the section break of FIG. 2 taken at line 3--3.
FIG. 4 is a fragmentary isometric view of the apparatus of FIG. 3.
FIG. 5 is a fragmentary cross-sectional view of the apparatus of FIG. 2 taken along section line 5--5.
FIG. 6 is a side elevational view of a section break of the dryer run of FIG. 1 showing the web transfer arrangement from a top-felted dryer section to a bottom-felted dryer section.
FIG. 7 is a side elevational view of an alternative embodiment vacuum roll pivot arrangement for a papermaking dryer of this invention.
FIG. 8 is a schematic view of an alternative embodiment section break of this invention employing two pivoting vacuum rolls.
FIG. 9 is a schematic view of another alternative embodiment section break of this invention also employing two pivoting vacuum rolls.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring more particularly to FIGS. 1-9, wherein like numbers refer to similar parts, two sequential dryer sections 20, 21 of the dryer run 22 of a papermaking machine are shown in FIG. 2. The dryer run 22 is of the single tier type of the general type disclosed in U.S. Pat. No. 5,065,529, the disclosure of which is incorporated by reference herein. The dryer run 22 may have five or more dryer sections. Each dyer section 20, 21 has a plurality of larger diameter heated dryer rolls 24 about which a paper web 26 is guided to reduce the moisture content of the web. The dryer rolls are cylinders up to 400 or more inches wide in the cross machine direction which are rotatably mounted to a frame 29, as shown in FIG. 2. Throughout the dryer run 22, the web 26 is supported by alternating top felts 28 and bottom felts 30.
The web 26 is supported by a felt as it wraps partially around a dryer roll 24, preferably for more than 180 degrees. A vacuum roll 32 is mounted to the frame 29 between each pair of dryer rolls 24. The vacuum roll engages the supportive felt, and turns the web to guide it to the downstream dryer roll 24 within a particular dryer section.
To best achieve consistent drying of the web, and to prevent warping or distortion of the paper, the dryer run 22 alternately drys first one side and then the other of the web 26. In order to dry an alternate side of the web 26, the web must be transferred from the felt which is supporting the first side, to a second felt which will support the opposite side so that the first side may be placed in direct contact with subsequent dryer rolls 24. This transfer takes place at the section breaks 34, 36, where the upstream felt is directed away from the web, and the web is handed off or transferred to the downstream felt for drying of the alternate side of the web.
A section break 34 is shown in FIGS. 2 and 3 at which the web 26 supported by a bottom felt 30 in a bottom-felted dryer section 20 is transferred to a top felt 28 to be conveyed through a top-felted dryer section 21. The path of the web 26 is from the dryer roll 24 of the bottom-felted dryer section 20, to a pivoting vacuum roll 38, to a fixed vacuum roll 40 and then to a dryer roll 24 in the top-felted dryer section 21.
The bottom felt 30 extends from pivoting vacuum roll 38 to a bottom felt roll 42 beneath the dryer rolls 24 of the dryer section 20. The bottom felt 30 is a continuous loop which extends through a stretcher assembly 44, indicated schematically in FIG. 1, and returns to engage the web at the inlet to that same dryer section 20. The stretcher assembly 44 comprises a number of felt rolls 42 which are mounted to allow slack to be removed from the bottom felt 30 as the length of the felt run and the felt itself change with conditions and time. The top felt 28 moves in to receive the advancing web 26 from an overhead felt roll 46 which is part of a top stretcher assembly 48.
The transfer arrangement of this invention will be discussed in the context of a transfer from a bottom-felted dryer section to a top-felted dryer section. However, it should be emphasized that the invention also encompasses similar arrangements for transferring the web from a top-felted dryer section to a bottom-felted dryer section.
As best shown in FIG. 3, under ordinary conditions, the bottom felt 30, the web 26, and the top felt 28 are engaged at the section break 34. However, under certain conditions it is desirable to space the two felts such that both are not in simultaneous contact with the web. For example, on start up of the dryer run, each section 20, 21 may be brought up to speed sequentially. Contact of the moving felt of an activated dryer section with the non-moving felt on subsequent section may cause wear and deterioration of both felts and is to be avoided. By spacing the top and bottom felts at the section breaks, it is possible to bring up all the dryer sections in a run and only bring the felts together once a web is introduced. At times the dryer operator will wish to visually inspect the web as it traverses the dryer run, the section break is an optimal position for this inspection, and by spacing the felts the web is made visible. Furthermore, in certain papermaking applications, one dryer section is allowed to run faster than the previous section, the thereby stretch the web. Binding of the paper between felts moving at different speeds is eliminated by spacing the two felts at the section break. In addition, when it comes time to replace a felt, the old felt is cut, and a new felt is attached thereto at a temporary seam and drawn through the dryer section. By spacing the felts at the section break, destructive pressure contact between the temporary seam and adjacent felts is avoided.
The dryer run 22 separates and engages the felts 28, 30 and the web 26 at the section break 34 by pivoting the pivoting vacuum roll 38 about an axis which extends in a cross-machine direction. As shown in FIG. 2, the vacuum roll 38 is mounted to two pivot arms 50 which are spaced on either side of the vacuum roll 38. The pivot arms 50 are mounted to the frame 29 at bearings 52. The bearings 52 define the cross-machine direction axis about which the pivot arms 50 pivot. The pivot axis is positioned downstream of the rotational axis of the vacuum roll 38. As the vacuum roll is substantially axisymmetric, the center of mass of the vacuum roll 38 is upstream of the pivot axis throughout the approximately six degrees of pivot travel of the pivot arm 50. There is thus a tendency for the vacuum roll 38 to assume an inclination away from the downstream dryer section. The means for pivoting the vacuum roll may include pneumatic or hydraulic actuators, mechanical linkages or cams, or other mechanical motion transmitters. In a preferred embodiment a first air ride 54 extends downstream from the frame 29 to the pivot arm 50, beneath the bearing 52. A second, smaller, air ride 56 extends upstream from the frame to the pivot arm 50. Each air ride is an inflatable elastic member, generally in the form of two connected flattened spheroids. By introducing air into the air ride through an air inlet 58, an air ride may be inflated. By venting air through the air inlet 58, an air ride may be deflated.
As shown in FIG. 3, the vacuum roll 38 is pivoted downstream by inflating the larger first air ride 54 to displace the pivot arm 50 upstream. The smaller second air ride 56 may be simultaneously deflated, or, preferably, the larger first air ride 54 may be allowed to simply overpower the second air ride 56 and compress the air therein. The two air rides 54, 56 thus work together to cushion any sudden impact or sharp vibrations as a result of pivoting the vacuum roll 38.
As shown in FIG. 5, the vacuum roll 38 is mounted to the two pivot arms 50 on roller bearings 60 for rotation as felt and web pass thereover. Air is withdrawn through perforations 62 in the vacuum roll surface and then through an air duct 64 which has wiping seals (not shown) which insure that vacuum is drawn only on the fraction of the vacuum roll over which the felt is wrapped. The air duct 64 is connected to a hollow shaft 66 which is fixed to the pivot arm 50 and which is connected by a flexible elastic hose or boot 68 to a source of vacuum.
When the vacuum roll 38 is pivoted downstream, the roll surface engages the web 26, which is supported on the bottom felt 30, against the top felt 28 which is advancing through the downstream dryer section 21 at is the same velocity.
When it is desired to separate the felts 28, 30, for any reason, the larger air rides 54 are inflated to pivot the two pivot arms 50 upstream and disengage the bottom felt and web from the top felt. Approximately six degrees of pivot will space the felts about one half of an inch. A spacing of up to two inches may be desirable for certain applications.
Because of the location of the pivot arm-vacuum roll assembly center of mass with respect to the pivot axis of the assembly, should the large air rides 54 fail, the position of the vacuum roll 28 will failsafe to a nonengaged condition. Should the smaller air ride 56 fail, the force of gravity alone should retain the vacuum roll in a nonengaged condition.
Because the bottom felt 30 and the web 26 are wrapped approximately 180 degrees around the pivoting vacuum roll 28, there is not a need for precise positioning in advancing and retracting the roll 28. Because of this significant wrap, tilting of the vacuum roll 28 about a z-axis because of variations in inflation of air rides will not readily cause the felt to run off the roll.
Because the vacuum roll 28 is pivoted only a small amount to open up the desired spacing between the felts, the length of the bottom felt path is only slightly changed, hence a standard stretcher is sufficient to maintain proper tension in the felt. Furthermore, because there is such a small change in felt length when the vacuum roll moves in a direction generally perpendicular to the felt transfer sandwich area, the rolls can be moved quickly to achieve the optimum geometry sought, without delay while the stretcher adjusts the felt run.
An additional advantage of the arrangement of this invention is that the pivoting vacuum roll is in a location easily viewed by the machine operator, which provides for better visual control of the separation operation.
As shown in FIG. 6, the transfer arrangement at the section break 36 from a top-felted dryer section 21 to a bottom-felted dryer section 20 is similar to the arrangement described above. A pivoting vacuum roll 70 is mounted on pivot arms 72 which are connected to the frame 29 to pivot about a cross-machine direction axis. Air rides 74 provide a means for pivoting the vacuum roll to alternately dispose the vacuum roll 70 with the top felt 28 and web 26 against the bottom felt 30. It should be noted that the pivot arm arrangement may be varied to suit particular machine geometry, for example as shown in the alternative embodiment arrangement 76 shown in FIG. 7. The apparatus 76 has a vacuum roll 78 which is connected to pivot arms 80 which are actuated by air rides 82. The pivot arms 80 have members 84 which extend upstream to which air rides are connected.
A section transfer with a single pivoting vacuum roll is a low cost approach to separating the felts at the transfer break. An alternative arrangement is shown in FIGS. 8 and 9, in which both vacuum rolls at the section transfer are pivotable.
A transfer from a lower-felted dryer section 86 to an upper-felted dryer section 88 is shown in FIG. 8. The web 90 travels over a first dryer roll 92 backed by the lower felt 94 and then passes over a lower felt vacuum roll 96. The lower felt 94 is turned by the vacuum roll 96 to pass over the lower felt roll 98. The lower felt vacuum roll 96 is supported on pivot arms 98, and is driven to pivot upstream or downstream by air rides 100. The web passes from the lower felt to an upper felt 102 which moves from an upper felt roll 104 over an upper felt vacuum roll 106 which is pivotably mounted on pivot arms 108 to pivot toward and away from the lower felt vacuum roll 96. At least one set of air rides 110 are connected to the upper felt vacuum roll pivot arms to pivot the vacuum roll 106. The web 90 is backed by the upper felt 102. The two vacuum rolls 96, 106 may be pivoted together to form a sandwich of the two felts 94, 102 and the web 90, or pivoted apart to open up the sandwich.
A transfer from an upper-felted dryer section 88 to a lower-felted dryer section 88 is shown in FIG. 9.
Although the means for pivoting the vacuum rolls has been disclosed as inflatable air rides in conjunction with pivoting arms, it should be understood that alternative mechanisms for pivoting a vacuum roll may be employed, for example a linkage or cam arrangement.
It is understood that the invention is not limited to the particular construction and arrangement of parts herein illustrated and described, but embraces such modified forms thereof as come within the scope of the following claims.
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The top and bottom felts at the web transfer between two dryer sections in a single tier papermaking dryer are spaced by pivoting the vacuum roll over which the felt and web move. The vacuum roll is mounted to two pivot arms which are driven by inflatable air rides to alternately incline the roll toward the downstream felt, forming a sandwich of the two felts and the web, and to a spaced position. The short motion of the vacuum roll allows standard felt stretchers to be used, and permits rapid adjustment of the felt spacing.
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FIELD OF TECHNOLOGY
The following relates to a washing machine, and more particularly, to a method for warning of a residual amount of liquid detergent by determining the residual amount of liquid detergent based on a value calculated by adding up amounts of liquid detergent used for washing processes.
BACKGROUND
In general, a washing machine refers to a product that removes pollutants of clothes and bedclothes through emulsification of a detergent, friction of water flow caused by rotations of a pulsator, and impact applied by the pulsator.
The washing machine is divided into a top-loading type in which a washing tub is erected and a drum type in which a washing tub is laid, depending on the shape of the washing tub in which laundry is housed.
When a container of a washing machine is filled up with a liquid detergent easy to dilute and having an excellent emulsification function and a washing command is inputted, the washing machine supplies a preset amount of liquid detergent, and then automatically performs a series of processes including a washing process, a rinsing process, and a spin-drying process.
As a related art of the present invention, Korean Patent Laid-open Publication No. 10-2010-0081214 published on Jul. 14, 2010, has disclosed a washing machine and a sensing method for liquid detergent supply.
Since the conventional washing machine automatically supplies a liquid detergent during a washing process, a user must previously store the liquid detergent in the container before the washing process such that the washing machine does not lack the liquid detergent.
Therefore, the user must frequently check the residual amount of liquid detergent stored in the container, whenever using the washing machine.
Furthermore, since the conventional washing machine includes a plurality of sensors for sensing the residual amount of liquid detergent, the manufacturing cost increases, and a current flowing through the sensors may leak to the container. In this case, the user may get an electric shock.
SUMMARY
The present disclosure is conceived to solve such problems of the related art, and an aspect is to provide a method for warning of a residual amount of liquid detergent, which calculates a total use amount by adding up amounts of liquid detergent used for washing processes, determines a residual amount of liquid detergent based on the calculated total use amount, and warns of the residual amount depending on the determination result.
Another aspect is to provide a method for warning of a residual amount of liquid detergent, which automatically warns a residual amount of liquid detergent stored in a container such that a user does not need to frequently check the residual amount of liquid detergent and easily supplies liquid detergent.
According to another aspect, a method for warning of a residual amount of liquid detergent includes: calculating a total use amount of liquid detergent by adding up a use amount of liquid detergent whenever a washing process is performed; and comparing the total use amount of liquid detergent to a reference amount, and warning of a residual amount of liquid detergent according to the comparison result.
The warning of the residual amount of liquid detergent may include warning of the residual amount of liquid detergent when the total use amount of liquid detergent is equal to or more than the reference amount.
The use amount of liquid detergent may be set according to one or more of a washing course, a laundry amount, a liquid detergent control command, and a washing water amount.
The method may further include displaying the number of additional washing processes to be performed, after the warning of the residual amount of liquid detergent.
The number of additional washing processes to be performed is calculated by dividing the residual amount of liquid detergent by an average use amount of liquid detergent.
The average use amount of liquid detergent may be calculated by dividing the total use amount of liquid detergent by the number of performed washing processes.
The reference amount may be set according to an initial amount of liquid detergent when a container is filled up with the liquid detergent.
According to the embodiment of the invention, since a warning for a residual amount of liquid detergent is automatically issued, a user does not need to frequently check the residual amount of liquid detergent, and may easily fill up a container with the liquid detergent.
Furthermore, since a sensor for sensing the residual amount of liquid detergent is not installed, it is possible to reduce the manufacturing cost of the washing machine and to prevent a user from getting an electric shock from a current leaking to the container.
BRIEF DESCRIPTION
The above and other aspects, features and advantages of the invention will become apparent from the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 is a block configuration diagram of a washing machine in accordance with an embodiment of the present invention;
FIG. 2 is a flowchart showing a method for warning of a residual amount of liquid detergent in accordance with the embodiment of the present invention;
FIG. 3 is a flowchart showing a process of controlling a use amount of liquid detergent in FIG. 2 ; and
FIG. 4 is a graph illustrating a reference amount and a warning time point in accordance with the embodiment of the present invention.
DETAILED DESCRIPTION
Embodiments of the invention will hereinafter be described in detail with reference to the accompanying drawings. It should be noted that the drawings are not to precise scale and may be exaggerated in thickness of lines or sizes of components for descriptive convenience and clarity only. Furthermore, the terms as used herein are defined by taking functions of the invention into account and can be changed according to the custom or intention of users or operators. Therefore, definition of the terms should be made according to the overall disclosures set forth herein.
A method for warning of a residual amount of liquid detergent is performed as follows: amounts of liquid detergent used for washing processes are added up to calculate a total use amount, the calculated total use amount is compared to a reference amount, and a warning for the residual amount of liquid detergent is issued according to the comparison result.
Here, the total use amount of liquid detergent is calculated by adding up the amount of liquid detergent used whenever a washing process is performed.
An amount of liquid detergent to be used (hereafter, referred to as use amount of liquid detergent) is preset according to the amount of laundry. However, the use amount of liquid detergent may be additionally set for each washing course selected by a user, directly set by the user, or set according to a washing water amount selected by the user.
After a warning for the residual amount of liquid detergent is issued, an average use amount of liquid detergent is calculated. Then, based on the calculated average use amount, the number of washing processes which can be additionally performed by the residual amount of liquid detergent is calculated and displayed.
FIG. 1 is a block configuration diagram of a washing machine in accordance with an embodiment of the present invention.
The washing machine in accordance with the embodiment of the present invention includes a key input unit 10 , a liquid detergent supply unit 30 , a laundry amount detection unit 40 , a washing device 50 , a warning unit 60 , a display unit 70 , and a control unit 80 .
The key input unit 10 is configured to receive various control commands from a user. The key input unit 10 includes a washing command input key 11 , a washing course select key 12 , a washing water control key 13 , a liquid detergent control key 14 , and an initial amount setting key 15 .
The washing command input key 11 is configured to input a washing command. The washing command selectively performs one or more of a washing process, a rinsing process, a spin-drying process, and a drying process or continuously performs a preset series of washing courses.
In this specification, a case in which a washing process using liquid detergent is performed when the washing command input key 11 is inputted will be taken as an example for description.
The washing course select key 12 is configured to input a washing course select command for selecting a washing course. The washing course may include a standard washing course in which a series of processes including a washing process, a rinsing process, and a spin-drying process are automatically performed. In addition, the washing course may include a lingerie washing course, a wool washing course, a sports shoes washing course and the like, depending on the type and material of the laundry.
The washing course is not limited to the above-described examples, but may be further subdivided into various washing courses. Therefore, the scope of the present invention may include all washing courses provided by the washing machine.
Meanwhile, the use amount of liquid detergent is set in various manners depending on the washing courses. Therefore, when a user inputs a washing course select command through the washing course select key 12 , the liquid detergent is supplied according to the use amount of liquid detergent, which is set in the selected washing course.
For reference, a washing water amount is preset for each of the washing courses. Therefore, the washing water amount set for the selected washing course is supplied to perform a washing process. However, the washing water amount may be separately controlled.
The washing water control key 13 is configured to input a washing water control command for controlling the washing water amount. Through the washing water control key 13 , a user may arbitrarily control the washing water amount. Furthermore, although a washing course is selected to set a washing water amount, the washing water amount may be additionally controlled.
Here, the washing water amount may be set is various manners such as large amount, medium amount, and small amount.
The liquid detergent control key 14 is configured to input a liquid detergent control command for controlling the amount of liquid detergent used in the washing process. Through the liquid detergent control key 14 , the user may arbitrarily control the use amount of liquid detergent. Furthermore, although a washing course is selected to set the use amount of liquid detergent, the use amount of liquid detergent may be additionally controlled.
In this case, whenever the liquid detergent control key 14 is inputted once, the use amount of liquid detergent may be increased or decreased by a predetermined amount, or any one of a plurality of preset liquid detergent supply amounts may be selected, and the liquid detergent may be supplied by the selected amount.
The initial amount setting key 15 is configured to set an initial amount of liquid detergent supplied to a container (not illustrated), when the container is filled up with the liquid detergent.
The initial amount refers to an initial amount of liquid detergent supplied to the container by a user when the container is filled up with the liquid detergent, and is set by the user. The initial amount may include a plurality of initial amounts, and the user sets an initial amount corresponding to the amount of liquid detergent supplied by the user.
For example, when the container is filled up with liquid detergent, the initial amount is set to the highest amount, and when the container is filled with a smaller amount of liquid detergent than the highest amount, the initial amount may be set to the second highest amount.
Therefore, a separate sensor for sensing liquid detergent does not need to be provided.
The liquid detergent supply unit 30 opens or closes a valve (not illustrated) installed in the container, and supplies the liquid detergent stored in the container to a washing tub. In this case, the liquid detergent supply unit 30 supplies liquid detergent by a use amount set according to a laundry amount, or additionally supplies liquid detergent by a use amount set according to a washing course select command, a washing water control command, or a liquid detergent control command.
The washing device 50 includes a water supply device 51 , a drain device 52 , and a washing motor 53 .
The water supply device 51 supplies washing water to the washing tub (not illustrated). The water supply device 51 includes a water supply tube (not illustrated) and a water supply valve (not illustrated). The water supply tube has one side to a water supply unit (not illustrated) to supply cold water and hot water and the other end connected to the washing tub, thereby forming a flow path through which washing water supplied from the water supply unit is transferred to the washing tub. The water supply valve is installed in the water supply tube so as to control the washing water.
The drain device 52 includes a drain tube (not illustrated), a drain valve (not illustrated), and a drain pump (not illustrated). The drain tube has one side connected to the washing tub and the other side connected to communicate with the outside of the washing machine, thereby forming a flow path through which the washing water of the washing tub is drained to the outside of the washing machine. The drain valve is installed in the drain tube so as to control washing water. The drain pump forces washing water to be drained to the outside of the washing machine through the washing tube.
The washing motor 53 rotates the washing tub in a forward or backward direction to wash the laundry. Typically, a driving force generated by the washing motor 53 is transmitted to the washing tub through a power transmission device (not illustrated) including a gear or transmission belt.
The above-described washing device 50 is not limited to the washing device 51 , the drain device 52 , and the washing motor 53 , but may further include various devices such as a heater to heat washing water.
The warning unit 60 warns of the residual amount of liquid detergent. The warning unit 60 warns of the residual amount through a buzzer sound or a display (not illustrated) provided on a front panel of the washing machine.
The display unit 70 displays the number of additional washing processes to be performed. The display unit 70 is installed on the front panel of the washing machine such that a user may easily recognize the number of additional washing processes to be performed. The display unit 70 may include a light emitting diode (LED) or liquid crystal display (LCD).
Here, the number of additional washing processes to be performed indicates an expected number of washing processes which can be performed by the residual amount of liquid detergent, after the warning unit 60 warns of the residual amount of liquid detergent.
The control unit 80 calculates a total use amount by adding up the amounts of liquid detergent used for washing processes in a state where the initial amount is set, compares the calculated total use amount to the reference amount, and warns of the residual amount depending on the comparison result.
Here, the reference amount refers to an amount serving as a reference value for warning that the residual amount of liquid detergent is insufficient. The reference amount is set in such a manner that the amount of liquid detergent remaining in the container based on the initial amount is equal to or more than the amount of liquid detergent used for at least one washing process. That is, even after a warning is issued because the total use amount of liquid detergent is equal to or larger than the reference amount, a washing process may be additionally performed.
Therefore, when a user performs the next washing process, the user may not lack the liquid detergent. At this time, the user may be induced to fill up the container with the liquid detergent.
Hereafter, the method for warning of a residual amount of liquid detergent in accordance with the embodiment of the present invention will be described with reference to FIGS. 2 to 6 .
FIG. 2 is a flowchart showing the method for warning of a residual amount of liquid detergent in accordance with the embodiment of the present invention. FIG. 3 is a flowchart showing a process of controlling the use amount of liquid detergent in FIG. 2 . FIG. 4 is a graph illustrating the reference amount and a warning time point in accordance with the embodiment of the present invention.
Referring to FIG. 2 , an initial amount corresponding to the amount of liquid detergent supplied to the container is set through the initial amount setting key 15 , and a reference amount is set according to the initial amount, at step S 10 .
At this time, the reference amount is set in such a manner that the amount of liquid detergent remaining in the container based on the initial amount is equal to or more than the amount of liquid detergent used for at least one washing process.
In such a state where the reference amount is set, the amount of liquid detergent to be used during the washing process may be set at step S 100 .
The process of setting the use amount of liquid detergent will be described with reference to FIG. 3 .
First, when the washing course select key 12 is inputted at step S 101 , the use amount of liquid detergent is set according to the input washing course select command at step S 102 .
In this case, the use amount of liquid detergent is preset for each washing course. When a specific washing course is selected, the amount of liquid detergent to be used for the corresponding washing process is set to the preset amount of liquid detergent to be used for the corresponding washing course.
Meanwhile, when the liquid detergent control key 14 is inputted at step S 103 , the use amount of liquid detergent is set according to the input liquid detergent control command at step S 104 . In this case, the use amount of liquid detergent is increased or decreased according to the liquid detergent control command. The use amount of liquid detergent may be increased or decreased by a predetermined amount whenever the liquid detergent control key is inputted once, or may be set to any one of a large amount, a medium amount, and a small amount.
On the other hand, when the washing water amount control key is inputted at step S 105 , the use amount of liquid detergent is set according to the input washing water amount control key at step S 106 . In this case, the use amount of liquid detergent is increased or decreased depending on the washing water amount. As the washing water amount is increased, the use amount of liquid detergent is increased, and as the washing water amount is decreased, the use amount of liquid detergent is decreased.
Furthermore, although a washing course is selected, the use amount of liquid detergent which is set for the washing course may be additionally changed according to a liquid detergent control command, when the liquid detergent control command is inputted.
Furthermore, although a washing course is selected, the use amount of liquid detergent which is set for the washing course may be additionally changed according to a washing water control command, when a washing water control command is inputted.
Furthermore, although a washing course is selected, the use amount of liquid detergent which is set for the washing course may be additionally changed according to a liquid detergent control command and a washing water control command, when a liquid detergent control command and a washing water control command are inputted.
Therefore, a user may select a washing course, and then input the liquid detergent control key 14 and/or the washing water control key, thereby performing a washing process according to the washing course, a washing water amount, and the use amount of liquid detergent which are suitable for the user's taste.
As described above, after the use amount of liquid detergent is set, whether or not a washing command is inputted through the washing command input key 11 is checked at step S 140 .
When the washing command is inputted, the laundry amount is detected through the laundry amount detection unit 40 at step S 150 .
Here, when the laundry amount is detected, various data required for performing the selected washing course are set.
Then, according to the use amount of liquid detergent which was set at the use amount setting process S 100 , the liquid detergent is supplied at step S 160 .
Then, a washing process is performed by the washing device 50 . Here, since the process of performing a washing process using the washing device 50 may be easily understood by those skilled in the art, the detailed descriptions thereof are omitted herein.
Meanwhile, the control unit 80 calculates a total use amount of liquid detergent by adding up the supplied amounts of liquid detergent, at step S 170 .
When the total use amount of liquid detergent is calculated, the total use amount of liquid detergent is compared to the preset reference amount so as to determine whether the total use amount of liquid detergent is equal to or more than the reference amount, at step S 180 .
As a determination result, when the total use amount of liquid detergent is equal to or more than the reference amount, the control unit 80 controls the warning unit 60 to issue a warning for the residual amount of liquid detergent at step S 190 .
Meanwhile, when the total use amount of liquid detergent is less than the reference amount, whether or not to perform the next washing process is checked.
When the use amount of liquid detergent is not set at the use amount setting process S 100 , whether or not a washing command is inputted through the washing command input key 11 is checked at step S 110 .
When the washing command input key 11 is inputted, a laundry amount is detected through the laundry amount detection unit 40 at step S 120 , a washing water amount and a use amount of liquid detergent are set according to the detected laundry amount, and the set amount of liquid detergent is supplied by the liquid detergent supply unit 30 .
Then, the washing device 50 is controlled to perform a washing process.
Meanwhile, after the liquid detergent is supplied, the total use amount of supplied liquid detergent is calculated at step S 170 , and whether the total use amount of liquid detergent is equal to or more than the reference amount is determined at step S 180 . As a determination result, when the total use amount of liquid detergent is equal to or more than the reference amount, a warning for the residual amount of liquid detergent is issued by the warning unit 60 at step S 190 .
As such, after the warning is issued, the average use amount of liquid detergent is calculated by dividing the total use amount of liquid detergent by the number of performed washing processes at step S 200 .
When the average use amount of liquid detergent is calculated, the number of additional washing processes to be performed is calculated by dividing the residual amount of liquid detergent by the average use amount, and then displayed through the display unit 70 at step S 210 .
At this time, the residual amount of liquid detergent is set based on the initial amount when the reference amount is set.
Therefore, the number of washing process which can be performed by the amount of liquid detergent remaining in the container may be expected.
That is, as illustrated in FIG. 4 , when the total use amount is equal to or more than the reference amount lower than the initial amount, a warning is issued. However, it can be seen that the amount of liquid detergent remaining in the container corresponds to an amount of liquid detergent by which three additional washing processes can be performed.
Meanwhile, when and the user fills up the container with liquid detergent and inputs the initial amount setting key 15 after a warning for the residual amount of liquid detergent is issued by the warning unit 60 , the total use amount of liquid detergent and the average use amount which have been calculated so far are initialized, and a reference amount is reset according to the set initial amount.
Although some embodiments have been provided to illustrate the invention in conjunction with the drawings, it will be apparent to those skilled in the art that the embodiments are given by way of illustration only, and that various modifications and equivalent embodiments can be made without departing from the spirit and scope of the invention. The scope of the invention should be limited only by the accompanying claims.
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A method for warning of a residual amount of liquid detergent includes: calculating a total use amount of liquid detergent by adding up a use amount of liquid detergent whenever a washing process is performed; and comparing the total use amount of liquid detergent to a reference amount, and warning of a residual amount of liquid detergent according to the comparison result. Accordingly, a user does not need to frequently check the residual amount of liquid detergent, and may easily fill up a container with the liquid detergent. Furthermore, since a sensor for sensing the residual amount of liquid detergent is not installed, it is possible to reduce the manufacturing cost of the washing machine and to prevent a user from getting an electric shock from a current leaking to the container.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. Ser. No. 13/201,206, which is the US national phase entry of International Patent Application No. PCT/CA2009/000172 filed Feb. 12, 2009, the entire contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to a method and apparatus to recover purified methanol stripped from a foul gas stream.
BACKGROUND OF THE INVENTION
[0003] Methanol is formed as a by-product of the kraft pulping process, when the hydroxyl on reacts with a lignin methoxyl group:
[0000] lignin.OCH 3 +OH − →CH 3 OH+lignin.O −
[0004] Depending on the mill configuration, up to 90% of the methanol generated in the digester can be captured in the foul condensate from the digester and evaporator areas. The foul condensate is typically treated in a steam stripping system, where up to 95% of the methanol can be removed from the foul condensate and captured in the overhead vapours from the stripping process. The concentrated gas stream is often referred to as stripper off gas (SOG).
[0005] The SOG is then usually disposed of through thermal oxidation in a lime kiln, power boiler, recovery boiler, or dedicated incinerator. The SOG typically consists of about 40 to 70 wt % methanol, 5 to 10 wt % non-condensable materials, including sulphur compounds, and the balance water vapour.
[0006] Waste SOG can be burned as a replacement for fossil fuels. However, the value of SOG as a fuel depends on the amount of water vapour that it contains. Natural gas provides 50.5 MJ/kg (37.2 MJ/m 3 ) heat of combustion, pure methanol provides 22.7 MJ/kg, and SOG containing 70 wt % methanol provides the equivalent of about 21.9 MJ/kg. The SOG provides less heat because the entrained water vapour must first be heated up to combustion temperature.
[0007] Chlorine dioxide is used in the pulp bleaching process; grade AA methanol (99.85 wt %) is used to manufacture ClO.sub.2. In a well-run mill, a methanol purification system would preferably be able to produce sufficient amounts of purified methanol for the demands of the ClO.sub.2 process, as well as some purified methanol for external sale. If a substantial portion of the methanol in the SOG can be recovered and purified to an industrial grade AA product, the methanol produced in a typical kraft pulping process could be worth as much as four and a half times more as a commodity than as a fuel.
[0008] There are numerous methanol purification systems in operation. Most such systems use some form of distillation to separate methanol from other compounds. See for example, U.S. Pat. No. 5,718,810 to Robbins and U.S. Pat. No. 6,217,711 to Ryham et al. Canadian Patent No. 1,0888,957 to Suokas et al., uses a combination of distillation steps and acid or alkaline oxidating treatments to separate the various fractions. Distillation separates the components of a solution by partial vapourization of the mixture and separate recovery of vapour and residual liquid. The more volatile constituents of the original mixture are obtained in increased concentration in the vapour, while less volatile components remain in greater concentration in the liquid residue. Distillation columns may be designed using trays, structured packing, or random dumped packing. Due to restricted access, for small columns below about 750 mm diameter, random dumped packing is preferred.
[0009] However, methanol recovered from a kraft pulping process has several unique characteristics that inhibit separation by distillation.
[0010] Typically, significant quantities of dimethyl disulphide are present in the crude methanol produced during the kraft pulping process. The presence of an azeotrope between methanol and dimethyl disulphide requires that the methanol content in the SOG be no higher than approximately 40 wt % to ensure separation. Control of the foul condensate steam stripping system, in terms of both the quantity and quality of SOG produced, can reduce the impact of azeotropes of dimethyl disulphide. Many existing stripping systems include a reflux condenser integrated with the multiple effect evaporators; see for example U.S. Pat. No. 4,137,134 to Suominen et al., U.S. Pat. No. 3,807,479 to Brannland et al., and U.S. Pat. No. 5,830,314 to Mattsson. Unfortunately, in this arrangement, control of the stripping system may be compromised because any fluctuations in evaporator operation will ripple through the stripping system, unpredictably affecting SOG quantity and quality.
[0011] Further, contaminants including ionizable sulphur compounds such as hydrogen sulphide and methyl mercaptan are produced during the pulping process. These compounds can dissociate under certain conditions, making them all but impossible to remove from SOG by simple distillation. As can be seen in FIG. 1 , hydrogen sulphide (H.sub.2S) begins to dissociate at a pH above about 6, while methyl mercaptan (MM) begins to dissociate at a pH above about 9. In their dissociated form, these compounds do not exert a vapour pressure and therefore can not be removed by distillation. Controlling the pH of the liquid phase in the distillation column is therefore an effective way to remove these compounds in a distillation process.
[0012] As condensed SOG typically has a pH of about 9 to 10, an acid, such as sulphuric acid, may be metered to the appropriate distillation column to lower the pH in the system. However, the acid cannot simply be added to the liquid feed to the column as it will react with any ammonia present in the system, producing ammonium sulphate. This is known as fouling the column and is to be avoided. U.S. Pat. No. 5,989,394 to Johansson et al. describes a process in which an acidifier is introduced to a stripping column above the admission point of the liquid being purified, or alternatively is added to the liquid feed directly. However, Johansson is concerned with producing a relatively purified condensate stream, rather than removal and high level purification of methanol from the liquid feed stream and does not seem to be concerned with fouling the column.
[0013] It is therefore an object of the invention to provide a method and apparatus to recover and purify methanol stripped from a foul gas stream that overcomes the foregoing deficiencies.
[0014] In particular, it is an object of the invention to provide a method and apparatus to recover and purify methanol to a high degree, allowing methanol to be used within a kraft pulping process and to allow excess methanol to be sold, rather than destroyed.
[0015] These and other objects of the invention will be appreciated by reference to the summary of the invention and to the detailed description of the preferred embodiment that follow.
SUMMARY OF THE INVENTION
[0016] The invention relates to a method and apparatus to recover and purify methanol from gases produced in the digester during the kraft pulping process. The gas is typically recovered as a foul gas (called stripper off gas or SOG) comprising methanol, water and various other contaminants.
[0017] Stripper off gas is stripped from the digester and evaporator areas of the pulping process; the SOG then passes, at a controllable flow rate to a dedicated condensing means, where volatile components are boiled off and vented to an incineration system, while the condensate drains to a topping red oils removal means, such as a decanter. Heavy contaminants that are immiscible in the solution are decanted and recovered separately. The underflow is moved to a first distillation means, such as a topping column and heated. Acid is added to the mid-point of the topping column to lower the pH of the solution without allowing the acid to react with ammonia in the feed. Volatile components are returned to the condensing means, while the underflow moves to a surge tank, which may be used to stabilize the flow and concentration of the feed to the rectification section.
[0018] The rectification section may comprise one or two columns. The feed is introduced near the top of the bottoms section of the column, and moves down through the packing in the column, countercurrent to the stripping steam flow. Vaporized methanol moves up through the top section of the column, and any impurities are removed as the overhead vapor flow. Water and other less volatile components form the underflow, while fusel oils are drawn off in a side stream. Purified methanol is drawn off and passed to a methanol cooler for condensation and storage. The methanol is at least 99.85 wt % pure.
[0019] Alternatively, the bottoms section and the top section may each be a separate column. The feed is introduced near the top of the bottoms column, and moves down through the packing in the column, countercurrent to the stripping steam flow. Vaporized methanol is removed as the overhead vapor flow. Water and other less volatile components form the underflow, while fusel oils are drawn off in a side stream. The methanol vapor is passed to the rectification top column, where it is distilled again. Condensate from the rectification top column is returned to the rectification bottoms column, while vapors are collected and condensed before being vented to the incineration system. Purified methanol is drawn off and passed to a methanol cooler for condensation and storage. The methanol is at least 99.85 wt % pure.
[0020] In one aspect, the invention comprises a method to recover and purify methanol from a stripped off gas stream, comprising the steps of: obtaining, at a controlled rate, a foul gas feed comprising no more than approximately 40 wt % methanol; condensing the foul gas feed; removing immiscible contaminants from the condensed foul gas feed; heating the condensed foul gas feed in the presence of an acid to evaporate volatile components, leaving a contaminated methanol feed, the acid being supplied at an entry point below an input point of the condensed foul gas feed; refining the contaminated methanol feed by heating to evaporate methanol from the contaminated methanol feed; and further refining the evaporated methanol by heating to evaporate remaining volatile components and to produce purified methanol and impure condensate. The purified methanol may be cooled and collected for storage. The condensate may be recycled to the step of refining the contaminated methanol feed.
[0021] In a further aspect, excess foul gas may be diverted to a disposal system prior to the condensing step.
[0022] In yet a further aspect, fusel oils may be stripped from the contaminated methanol feed during the refining step.
[0023] In further aspect, the invention may comprise the further step of storing the contaminated methanol feed prior to refining the contaminated methanol feed.
[0024] In a further aspect, the immiscible contaminants may be removed by decanting the immiscible contaminants.
[0025] In another aspect, the invention comprises an apparatus to recover and purify methanol from a stripped off gas stream, comprising: condensing means to receive and condense a controlled amount of stripped off gas comprising no more than approximately 40 wt % methanol; decanting means to remove immiscible contaminants from the condensed gas; first distillation means comprising upper and lower sections, to receive the condensed gas in the upper section, and to heat the condensed gas in the presence of acid received in the lower section, to evaporate volatile components, leaving contaminated methanol; a first refining section to evaporate methanol from the contaminated methanol; and a second refining section to evaporate and condense impurities from the evaporated methanol, producing purified methanol. Means may also be provided to capture and condense the purified methanol for storage
[0026] In a further aspect, the apparatus of the invention may comprise storage means to store the contaminated methanol prior to entering the first refining section.
[0027] In a further aspect, the apparatus of the invention may comprise means to remove fusel oils from the contaminated methanol.
[0028] In another aspect, the first distillation means of the apparatus of the invention may comprise a topping column. The topping column may further comprise a reboiler to recycle part of the contaminated methanol.
[0029] In yet another aspect, the first and second refining sections of the apparatus of the invention may comprise a second distillation means. The second distillation means may comprise a rectification column, or first and second rectification columns.
[0030] In a further aspect, the apparatus of the invention may comprise means to divert excess gas to a disposal system prior to entering the condensing means.
[0031] The foregoing was intended as a broad summary only and of only some of the aspects of the invention. It was not intended to define the limits or requirements of the invention. Other aspects of the invention will be appreciated by reference to the detailed description of the preferred embodiment and to the claims.
[0032] The inventors thank Alberta-Pacific Forest Industries Inc. for its continued interest in this work and for its assistance in testing the system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The preferred embodiment of the invention will be described by reference to the drawings in which:
[0034] FIG. 1 is a graph showing the dissociation fractions for hydrogen sulphide and methyl mercaptan at various pH levels;
[0035] FIG. 2 is a schematic of the topping section of the invention;
[0036] FIG. 3 is a schematic of the rectification section of the invention; and
[0037] FIG. 4 is a schematic of an alternative layout of the rectification section of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0038] Stripper off gas (SOG), typically containing about 40 to 70 wt % methanol, is produced in an existing foul condensate steam stripping column. The SOG is directed to a methanol purification system 10 , being diverted from a kiln, boiler, incinerator or other incineration system 12 , as shown in FIG. 2 .
[0039] Vapour 14 from the existing stripping column is introduced to a dedicated reflux condenser 16 ; this vessel may be of any suitable type, such as a falling film type shell and tube evaporator effect. The heat from the stripping system may be utilized in the evaporator system, but use of a dedicated vessel allows sufficient control over the system to ensure stable qualities and quantities of SOG are produced under all evaporator operating conditions. Pressure is maintained by throttling the flash vapour from the system.
[0040] SOG is introduced to the methanol purification system 10 at a controlled flow rate, with any excess gas being diverted to the incineration system 12 . This helps to maintain the methanol entering the purification system 10 at an optimal content of approximately 40 wt % or less.
[0041] The topping column system 18 strips out low boilers and non-condensables from the SOG, including malodorous sulphur compounds, ammonia, and some ethers, ketones and aldehydes. When SOG is introduced to the topping reflux condenser 20 , the low boilers and non-condensables are vented 22 back to the incineration system 12 while the condensate is drained 24 to the topping red oils decanter 26 .
[0042] Topping red oils pump 28 moves the decanted red oils to a turpentine recovery system (not shown), if available. The underflow 32 from the decanter 26 is moved to the topping column 34 by any suitable means, such as topping reflux pump 36 . A topping reboiler 38 may be used to provide heat to the topping column 34 , evaporating the volatile contaminants in a stream 42 , which can be returned to the topping reflux condenser 20 or otherwise disposed of.
[0043] Sulphuric acid may be added to topping column 34 by any suitable means, such as feed pump 44 . Preferably the acid is added about the mid-point of the column, or at any rate at an entry point 46 below the input point 48 of the condensed underflow feed from the topping reflux pump 36 . The separation between the feed input point 48 and the acid entry point 46 allows any highly volatile ammonia present in the underflow feed to be stripped out in the upper section of the topping column 34 before it has a chance to react with the acid, thereby avoiding the formation of ammonium sulphate precipitates. The acid reduces the pH in the lower section of the topping column 34 , releasing dissociated hydrogen sulphide and methyl mercaptan, which will rise to the upper section of topping column 34 , where it can be removed as part of volatile contaminant stream 42 .
[0044] The underflow 50 from the topping column 34 flows to the surge tank 52 , with some being recycled to topping reboiler 38 . As the flow and concentration of SOG can vary significantly depending on the operation of the existing stripping system, the surge tank can smooth out the flow and concentration of the feed to the methanol rectification column system 54 .
[0045] The feed enters rectification system 54 from surge tank 52 , such as by rectification feed pump 56 . The rectification column system 54 comprises two sections, namely a bottoms stripping section 97 and a top rectification section 99 , as shown in FIG. 3 . The feed is introduced to the stripping section 97 of column 55 and flows down through the packing, countercurrent to the stripping steam 57 , which may be supplied by a rectification reboiler 59 . The volatile component, including methanol, moves upward to the top rectification section 99 , while the less volatile component, which is mainly water along with other high boilers, is removed as the underflow 63 .
[0046] The feed may also comprise intermediate boilers, such as some higher alcohols (primarily ethanol), higher ketones, etc. These components, often referred to as fusel oils, are drawn off from the bottoms column 55 , preferably at a point 65 located below the feed introduction point 67 . The fusel oils can be recovered separately, or may be combined with the underflow 63 from the column 55 , passing to effluent treatment through rectification bottoms pump 69 .
[0047] The overhead vapour flow 61 , comprising methanol and other volatiles, from upper rectification section 99 is condensed in a rectification reflux condenser 71 , located above column 55 . Any low boilers and non-condensables 73 may be vented to the incineration system 12 .
[0048] The remaining product, which is approximately 99.85 wt % methanol, is drawn off in a stream 75 , preferably located slightly below the top of the packing in top rectification section 99 , and moved to a methanol cooler 77 by suitable means such as by methanol pump 79 , where it can be moved to storage. The methanol product is preferably drawn off in sufficient quantities to maintain the methanol profile in the column.
[0049] Alternatively, the two sections of rectification column system 54 may be supplied in two separate columns, the rectification bottoms column 60 and the rectification top column 62 , as shown in FIG. 4 . The feed is introduced 64 to the stripping section of the bottoms column 60 and flows down through the packing, countercurrent to the stripping steam 66 , which may be supplied by a rectification reboiler 68 . The volatile component, including methanol, is removed into the overhead vapour flow 70 , while the less volatile component, which is mainly water along with other high boilers, is removed as the underflow 72 .
[0050] In this embodiment, the fusel oils are drawn off from the bottoms column 60 , preferably at a point 74 located below the feed introduction point 64 . Again, the fusel oils can be recovered separately, or may be combined with the underflow 72 from the column 60 , passing to effluent treatment through rectification bottoms pump 76 .
[0051] The overhead vapour flow 70 from rectification bottoms column 60 is directed to the lower section of the rectification top column 62 . Any condensate 80 collected in the bottom of the top column 62 may be returned by an intermediate rectification pump 82 to introduction point 84 of the bottoms column 60 . Vapour 86 from the top column 62 is condensed in a rectification reflux condenser 88 , located above top column 62 . Any low boilers and non-condensables 78 may be vented to the incineration system 12 .
[0052] The remaining product, which is approximately 99.85 wt % methanol, is drawn off in a stream 90 , preferably located slightly below the top of the packing in top column 62 . Again, the methanol product is preferably drawn off in sufficient quantities to maintain the methanol profile in the column and moved to the methanol cooler 94 by suitable means such as by methanol pump 92 , where it can be moved to storage.
[0053] It will be appreciated by those skilled in the art that other variations to the preferred embodiment described herein may be practised without departing from the scope of the invention, such scope being properly defined by the following claims.
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The invention relates to a method and apparatus to recover and purify methanol from gases produced in the digester during the kraft pulping process. The gas is typically recovered as a foul gas (called stripper off gas or SOG) comprising methanol, water and various other contaminants. The gas is then treated with successive decanting and distillation steps to remove impurities, thereby producing highly purified methanol.
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